STILL STED forklift EGU 30 EGV 20 EGP 14-20 Electric Pallet Truck workshop Manual

EGU 30 EGV 20 EGP 14-20 Electric Pallet Truck Pedestrian stacker Pedestrian stradle stacker

Workshop manual

Ident-Nr. 4494857 STILL WAGNER STILL

33 0136 3 00001 EGU 30 33 0223 3 00001 EGV 20 33 0233 3 00001 EGV 20 LB 33 0227 3 00001 EGP 14 33 0228 3 00001 EGP 20

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Instructions on Use of Manual The user will in future receive Workshop 3.

Manuals for every specific type of truck (in this case EGU30, EGV20, EGP14/20 models).

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

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.

Version : April 2003 (Replaces version : )

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.

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

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

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 (*).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.

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

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

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Serial number of the trucks

Example :

33 0136

3

00001 => for computers

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Version : April 2003 (Replaces version : )

Chronological number Variant Typeës of truck number Factory Factory : 33 : STILL Truck type : 0136 : EGU 30 0223 : EGV 20 0233 : EGV 20 LB 0227 : EGP 14 0228 : EGP 20 LB : Initial fork lift Variant : year of manufacture 3 : for 2003 4 : for 2004 5 : for 2005 Chronological number : 00001 : Increasing number since the begin of the production.

Part 1 - EGU 30 Electric Pallet Truck

STILL WAGNER STILL

33 0136 3 00001 EGU 30

Workshop manual EGU 30 / EGV 20 / EGP 14-20

00 Generality 01 Chassis 02 Runing axle 03 Gear-Box 04 Wheels

Version : Septembre 2003 (En remplacement de la version :

)

05 Driving controls 07 Brake 08 Electrical system 09 Accessories 10 Hydraulics 11

Motors

28 Built-in charger

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32 Special tools

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Generality

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Version : Septembre 2003 (En remplacement de la version :

)

Contents

Page

Description ............................................................................................................. 01 Fork Arm Tolerance Table ..................................................................................... 01 Speed Tolerance Table........................................................................................... 01 Specifications ......................................................................................................... 02 Standards and certifications .................................................................................. 04 Driving Position ...................................................................................................... 05 Working Environmental Conditions........................................................................ 06 Inspection and Maintenance Table ........................................................................ 08 Tightening Torques Table....................................................................................... 09 Motor Brush Wear Table ........................................................................................ 09

Workshop manual EGU 30 / EGV 20 / EGP 14-20

00 Generality

Introduction

Description ÅIt is a wheeled transport vehicle ÅIts energy source is an accumulator battery ÅIt has a tiller steering gear ÅIt is equipped with a platform to carry the driver ÅIt is a non-stacker truck that is equipped with fork arms to lift pallets from the ground and to carry them. ÅIt is used to transport loads whose weight and size are well-determined, because of its construction.

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Version : April 2003 (Replaces version : )

This new range of tiller trucks has been planned in order to offer the operator a high degree of safety and comfort.

Model EGU 30 has rated capacity 3,300g

Fork Arm Tolerance Table These tolerances refer to the values in the technical datasheet h3 h13 s/e/l b5

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

Speed Tolerance Table The tolerances refer to the values in the technical datasheet

Traction speed with no load Traction speed with 3,000 kg Lifting speed Lowering speed

+0 / -5% km/h +0 / -5% km/h ±5% m/sec +0 / -10% m/sec

Note: The times relative to the speeds were measured after allowing the gear reducer oil to warm up (approximately 1 hour of continuous traction).

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Generality

Specifications

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Version : April 2003 (Replaces version : )

1 = RUNNING 2 = BRAKING

fork arms l c mm mm 800 400 980 500 1150 600 1450 715 1600 800 1980 1000 1980pc 1000 2160 1072,5 2160 pc 1072,5 2400 1200 2400 pc 1200

x mm 522 702 872 1172 1322 1702 1354 1882 1534 2122 1774

Standard DIN battery platfor.up y l1 Wa* mm mm mm 997 1469 1234 1177 1649 1414 1347 1819 1584 1647 2119 1884 1797 2269 2034 2177 2649 2414 1829 2649 2066 2357 2829 2594 2009 2829 2246 2597 3069 2834 2249 3069 2486

Large DIN battery plat. down y l1 Wa* mm mm mm 1100 1541 1306 1280 1721 1486 1450 1891 1656 1750 2191 1956 1900 2341 2106 2280 2721 2486 1932 2721 2138 2460 2901 2666 2112 2901 2318 2700 3141 2906 2352 3141 2558

* using the ìtiller active in vertical positionî function the truck can also be used with the tiller in vertical position 1

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

00 Generality

DIMENSIONS PERFORMANCE EL.MOTOR AOB

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WHEELS, CHASSIS WEIGHTS

FEATURES

EGU 30 AS TO STANDARD VDI 2198 Electric tiller (eased/standing) 1.5 Capacity / Load Q (t) 3 1.6 Barycentre c (mm) 600(1) 1.8 Load distance from load gear axle with lifted fork arms x (mm) 872 1.9 Wheelbase y (mm) 1347 1419 2.1 Net weight (without battery) kg 354 363 2.2 Load with loaded axle (front/rear) kg 1037 / 2529 (1043 / 2531)(2) 1065 / 2586 (1077 / 2591)(3) 2.3 Load with empty axle (front/rear) kg 432 / 134 (438 / 136)(2) 490 / 161 (503 / 165)(3) 3.1 Solid, super-resilient, pneumatic, polyurethane tyres Polyurethane 3.2 Front wheel dimensions mm 250 / 100 3.3 Rear wheel dimensions mm 85 X 70 3.5 Wheels: front/rear quantity (x = driving wheel) 1x-2 / 4 3.6 Front wheel track b10 (mm) 358 / 398 / 488 3.7 Rear wheel track b11 (mm) / 4.4 Lifting h3 (mm) 135 4.9 Tiller height in running mode (min/max) h14 (mm) 1183 /1380 4.15 Lowered fork arm height h13 (mm) 85 4.19 Total length l1 (mm) 1819 1891 4.20 Length included fork arm shoulder l2 (mm) 671 743 4.21 Total width b1 (mm) 710 4.22 Fork arm dimensions s/e/l (mm) 50 / 162 / 1150 (4) 4.25 External fork arm gauge b5 (mm) 520 / 560 / 650 4.32 Clear span in the middle when loaded m2 (mm) 168 4.33 Pallet working path 1,000x1,200 forking 1,200 Ast3 (mm) 1912 (5) 1984 (5) 4.34 Pallet working path 800x1,200 forking 800 Ast3 (mm) 2112 2184 4.35 Bending radiuses Wa (mm) 1584 1656 5.1 Translation speed (loaded/empty) km/h 6/6 5.2 Lifting speed (loaded/empty) m/s 0,03 / 0,076 5.3 Lowering speed (loaded/empty) m/s 0,045 5.7 Surmountable gradient KB30' (loaded/empty) (1) % *,* / *,* 5.8 Max surmountable gradient KB5' (loaded/empty) (1) % *,* / *,* 5.10 Service brake Electric 6.1 Traction motor performance KB 60' kW 2,5 6.2 Lifting motor performance 15% ED W 1,8 6.3 Battery as to British Standard / DIN 43531/35/36 A, B, C DIN 43535 B 6.4 Voltage / Rated capacity V / Ah 24 / 220 (250) 24 / 330 (375) 6.5 Battery weight (± 5%) kg 212 (220) 288 (305) 8.1 Type of control Electronic 8.4 Noise to the truck operator’s ear dB (A) < 70

(1) unless otherwise reported, the table figures refer to fork arm length l = 1,150 mm (2) with standard 24 V / 220 Ah (250 Ah) DIN battery (3) with large 24 V / 330 Ah (375 Ah) DIN battery (4) for other lengths, see the table below the figure 5) fork arm length l = 980 mm

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Generality

Standards and Certifications The EGU 30 complies with the Machinery Directive 98/37/EC, adapted to cover materials handling trucks with harmonised standards EN 1726 (For trucks with capacity of 10,000 kg or less and tractors with towing capacity of 20,000 N or less), EN 1551 (For trucks with capacity greater than 10,000 kg), prEN 1757 (For manual and semi-manual trucks with pedestrian operator). It also complies with the Electromagnetic Compatibility Directive 89/336/EEC and subsequent amendments, adapted for materials handling trucks by harmonised draft standard EN 12895.

Finally, it meets the requirements of standard prEN12053 concerning noise emissions (<70 db).

Version : April 2003 (Replaces version : )

As for the definition of Forward Running Direction, the ISO3691 standard states :

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Backward

Forward

In order to be more clear, let us determine a single way to intend the running direction, by identifying it with the traction direction towards the fork arms or towards the operator, avoiding the forward and backward instruction, as shown in the figure below :

Running towards the fork arms

Running towards the operator

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

00 Generality

Driving position Operator position (Pedestrian steering with use of the “tiller active in vertical position”function)

The ìTiller active in vertical positionî function allows the operator to activate truck drive (Low speed) also when the tiller is positioned vertically, with the following advantages :

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Version : April 2003 (Replaces version : )

Å Reduced steering radius Wa Å Capacity to work in smaller spaces Å Greater manoeuvring precision Å Greater visibility of forks

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Generality

Working Environmental Conditions According to the working environment, the following two versions are available : • Standard • Cold-Storage Room

Version : April 2003 (Replaces version : )

Working Environment for the “Standard” Version The standard version truck, special requirements excepted, has been manufactured in order to work in standard environmental conditions save outdoors with temperatures not higher than +40°C and not lower than +5°C. Its use in environmental conditions other than the standard ones implies the execution of special workmanships; the user, who intends to use the truck in an environment having peculiar features, should previously inform the manufacturer.

Beyond temperature, relative humidity is important: actually it is not possible to work with the standard version truck where humidity reaches levels so high as to produce condensate on protected parts (equipments, switches, contacts, etc.), which may prevent the perfect operation of the truck.

A high condensate also damages static parts, provoking a weakening of bearing frames.

Brackish air and/or water or any other corrosive substance in the working area are borderline conditions for the use of the truck and are regarded as dangerous.

WARNING: it is forbidden to use the standard version truck with environment temperatures higher than +40°C and lower than +5°C. Working Environment for the “Cold-Storage Room” Version The truck is designed to operate in cold stores observing categories 1-2.

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Class 1 2

Working Temperature Min. Max.

- 5°C - 10°C (For a short time) - 32°C

40° C

Working Conditions Switching off outside the cold-storage room

+ 25°C Alternate use inside and outside the + 40°C (For a Ccoldstorage room. Permanence outside short time) at least until there is no longer any condensate (usually at least 30 minutes) or for such a short time so as to prevent the formation of condensate (usually max 10 minutes).

Switching off outside the cold-storage room.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

00 Generality

WARNING : it is strictly FORBIDDEN to use standard and cold-storage room trucks in areas where there are explosion-hazardous atmospheres, if the trucks either have not been designed or have not been properly modified so as to be used in such cases. Similar instructions should be complied with in the event of trucks working in dusty areas or where atmospheres are full of suspended fine dust particles.

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Version : April 2003 (Replaces version : )

Explosion-proof trucks have been particularly manufactured in order to work avoiding explosion and fire hazards, in places where there are gases, fumes and inflammable and explosive dusts.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

00 Generality

Inspection and Maintenance Table

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Version : April 2003 (Replaces version : )

MAINTENANCE OPERATIONS Description As Daily Work Hours required Check 1000 2000 3000

Battery Electrolyte level and density inspection Load Intake Greasing of pull rods and levers Replacement of lever bushes Brake Check of the emergency stopping brake operation Replacement of the brake disk Adjustment of the emergency stopping brake Electric System Cleaning of electric motors Check of motor manifolds Replacement of traction motor brushes Replacement of lifting motor brushes (1.8kW only) Hydraulic System Check of pipe conditions Check of the hydraulic system oil level Topping up of the hydraulic system oil Replacement of the hydraulic system oil Reduction Unit Check of oil level Replacement of the oil Wheels and Gears Check of wheel conditions and wear Replacement of load gears Replacement of the driving gear Replacement of pivoting wheels

Warning: for the cold-storage room version, the greasing and lubrication interventions should be doubled, by halving the interval hours.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Generality

Table of Main Screws and their Relevant Tightening Torques DESCRIPTION Traction wheel securing screws Tiller head to the arm securing screws Pivoting wheels to the body securing screws Reduction unit to the body securing screws Traction motor to the reduction unit securing screws EGU 30 Ring to reduction gear fixing screws Tiller arm support to ring fixing screws Cylinder securing screws Tolerance

Nm 140 2 20 85 10 11 10 17 ± 5%

Note: the figures of tightening torques are relevant to class 8.8 screws.

The replacement of the brush should be carried out when the brush length reaches: Traction Motor 1,2 kW 2,5 kW Pump Motors 1,8 kW Tolerance

Residual Length (mm) 15 18 - 0 / + 20%

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Motor Brush Wear Table

09

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Chassis

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Contents

Page

Dashboard-Controls-Instrument System................................................................01 Mushroom-Head Emergency Button .....................................................................01 Start-up Switch.......................................................................................................01 I.B.S. + Hour Counter Instrument ..........................................................................02 Access Compartment to the Battery Charger Cable .............................................03 Fairings ..................................................................................................................04 Standard enlarded DIN battery compartment hood ...............................................04 Standard narrow DIN battery compartment hood ..................................................04 Motor compartment hood.......................................................................................04 Motor compartment Bonnet removal .....................................................................05 Battery Cover removal ...........................................................................................07 Separation of frames .............................................................................................08 Position of the identification plates and stickers....................................................10 View From operator Side .......................................................................................10 View From Forks Side ...........................................................................................11 Lateral view............................................................................................................12 View From above ...................................................................................................13

Workshop manual EGU 30 / EGV 20 / EGP 14-20

01 Chassis

Dashboard – Controls – Instrument System

1 Mushroom-head emergency button 2 Start-up key-operated switch 3 I.B.S. + Hour Counter Instrument Battery charge level indicator, indi cator of work hours, truck ìON/OFFî state indicator Access compartment to the power supply 4 cable of the built-in battery charger (Optional)

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Version : April 2003 (Replaces version : )

Mushroom-Head Emergency Button The red mushroom-head emergency button is clearly visible and easy to reach. Once pushed, it cuts the current off both to power circuits and to ancillary circuits, so as to cause the prompt tripping of the electromagnetic brake. It is a ìjointî-type pushbutton, that is to say that the disconnection of the current occurs in one of the following two ways: - 1) by means of a mechanical pressure control by the operator; or - 2) by means of a control operated through an electric signal by the Combi system.

This feature enabled the use of a single component instead of using the traditional diagram push button + contactor, therefore reducing used spaces and wirings.

Warning: This button must only be used in conditions of emergency.

Uses other than the type of use described are considered to be improper.

ON / OFF selector switch When the start-up switch is on ìlî setting, it energizes the control circuits and starts up the safety diagnostic controls of the electronic panelboard. Whereas on the ìOî setting, no circuit is energized.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Chassis

I.B.S. + Hour Counter Instrument The Indicator ñ Hour Counter instrument: Å Shows the truck operation time (running or lifting/lowering), which is expressed in hours (Running). Otherwise, it is possible to pair off the count cut-in with one setting of the start-up switch only, that is to say with the ìlî setting (Key on). Å Shows the battery charge level, by displaying it on a coloured 10-led row. Å Shows that the start-up switch is on ìlî setting, by switching the led row on. Å Stops the lifting operation when the battery is by 80% down.

A) Hour Counter Display:

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When the hour counter is working, the hourglass on the left side of the display blinks (15 times per minute approximately).

Five digits and one place of decimals are displayed. Starting from zero, the numbering progressively increases.

B) Led-row indicator relevant to the battery charge state:

1-2 Red leds 3-4-5 Yellow-orange leds 6-7-8-9-10 Green Leds

Å When the battery is 100% charged, only the led 10 is on.

Whereas, while the battery is running down, the leds switch on one at a time, from right to left. Å When the battery is by 70% down, both leds 1 and 2 blink at the same time, which means that the battery should be recharged (low). Å When the battery is by 80% down, both leds 1 and 2 alternately blink, which means that the lifting stop threshold has been reached. Å This instrument has a fixed recovery voltage threshold, therefore, the shift from the totally or partially low battery indication to the 100% charged battery indication occurs only if the voltage applied is >25.1 V (Figure supplied by the manufacturer).

Thus, you need to keep in mind that when you replace a otally low battery with a partially low battery (having a voltage < 25.1 V), the instrument does not show the change of charge but keeps on displaying the previous charge level.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Chassis Table of the instrument reference voltages, when the battery is by 80% down, with regard to the trimmer letters: Trimmer Figure

K 1.57 V for each cell (factory setting) L 1.65 V for each cell M 1.68 V for each cell N 1.73 V for each cell (lead battery setting) O 1.78 V for each cell P 1.82 V for each cell Q 1.84 V for each cell R 1.86 V for each cell S 1.89 V for each cell (gel battery setting) T 1.91 V for each cell U 1.93 V for each cell

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Version : April 2003 (Replaces version : )

The discharge trimmer should be set on the K setting.

Recovery CURTIS 803 has a fixed recovery threshold that is set by the manufacturer.

The following two kinds of recovery are possible: Å When the battery is disconnected during its charge, CURTIS 803 will recover if the battery voltage is equal or higher than 2.09 V for each cell. Å When the battery keeps being connected to the equipment during its charge (for example: battery charger installed on the equipment), CURTIS 803 will recover when the battery vol tage reaches 2.35V for each cell.

Access Compartment to the Battery Charger Power Supply Cable (Optional) An access compartment to reach the built-in battery charger power supply cable may be provided on the bonnet.

In order to reach the power supply cable plug of the builtin battery charger, you should lift the suitable opening cut in the bonnet on one side (As shown in the Figure beside).

The plug lies within a special housing that is able to keep it fastened to the opening. In order to remove the plug, you should push it towards the opening and, at the same time,pull it upwards.

This procedure is easy and handy.

This compartment is not provided on the bonnet of the production truck.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

01 Chassis

Fairings The fairings are made of polyethylene. This material is flexible, impact resistant and is deformed permanently only when subjected to intensive stress, in which case it does not break, therefore eliminating a source of potential hazards for the operator (e.g. injury caused by sharp edges of broken fairings, etc.).

Standard hood for enlarged DIN battery compartment

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Version : April 2003 (Replaces version : )

The battery compartment hood features: Å A spacious courtesy compartment "B". Å A practical pen holder "C".

Clipboard and documents tray "D"

Standard hood for narrow DIN battery compartment The battery compartment hood features: A courtesy compartment "A".

As an optional the hood can be supplied with clipboard and pen holder of exactly the same design as the hood for the enlarged DIN battery compartment.

Motor compartment hood 1

2

3

The motor compartment hood features a series of recesses accommodating: Å The emergency stop button 1 Å The keyswitch 2 Å Instrument IBS 3 This solution means that the above com ponents are protected from impact damage and unintentional activation.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

01 Chassis

Motor Compartment Bonnet Removal

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Version : April 2003 (Replaces version : )

Lift the mushroom emergency button.

Turn the (red) mushroom until the side hole of the screw lines up with the side hole of the insulating casing of the emergency button unit.

Into the aligned holes insert a 2 mm pin going through them.

The pin makes the screw integral with the fixed insulating casing.

Turn the mushroom button in an anticlockwise direction till it is completely unscrewed.

Remove all the hood fixing screws.

Remove the motor compartment hood by lifting upwards to clear the emergency contact.

Remove the keys from the keyswitch unit.

Unscrew the key contact block locking ring, immobilising the unit on the side internal to the hood. Extract the key swich unit and reassemble.

Disconnect the CURTIS 803 indicator connector.

Remove the fixing screws of the indicators supporting bracket.

Remove the CURTIS indicator and, once it is free of the hood, reassemble the component and refit the relative connector.

This operation is required to be able to use all the truck functions.

Fix the cable harnesses of the indica ñ tor and keyswitch unit to the cables on board the truck.

Do not leave the cables loose in the motor compartment.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

01 Chassis

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Version : April 2003 (Replaces version : )

Turn the tiller counter-clockwise.

Lift the left-hand edge of the lower hood.

Pull it outwards, ensuring you clear the truck chassis profile.

Release the hood, placing it on the chassis profile, and turn the tiller clockwise.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

01 Chassis

Lift the right-hand edge of the lower hood. Pull it outwards, ensuring you clear the truck chassis profile. The hood can now be freed from the fixed structure.

Version : April 2003 (Replaces version : )

Battery Cover Removal By means of a pin-bar, remove the lockpin of the battery cover.

Warning: elastic pins could fall inside the motor compartment.

Recover the fallen pins by means of a recovery magnetic tool.

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Spring pin

Remove the battery compartment hood, paying attention to the three rubber grommets.

N°1 grommet RH side

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Chassis

The rubber washers have a vibrationdampin function for the battery cover.

N°2 grommets SX side

Cable inlet opening

Separation of Frames

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Version : April 2003 (Replaces version : )

Before starting to disassemble the fixed and mobile chassis, with the truck switched on, lift the forks to their maximum height, insert woode chocks under the truck chassis, and remove the linkage pin fixing screws.

Remove the male contacts of the battery connectors and remove the guide collars of the battery leads on the mobile chassis.

Extract the power cables from the battery compartment to the motor compartment. These cables are the sole electrical connection between the two sections.

1

2

Screw the truck lifting eyebolt (1) into the relative hole as shown by the symbol (2) next to the battery compartment. Using the overhead travelling crane take the strain of the truckís weight without causing the wheels to lift from the ground.

Mind the symbol

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

01 Chassis

You can now extract the lower pins from the linkages.

Lower pins Warning: ensure you position wooden chocks for anti-tipping protection under the fixed structure.

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Version : April 2003 (Replaces version : )

Remove the elastic safety seal washers of the upper pins that are placed at the end of the lifting cylinders and pull the pins out.

The frames are separated.

Pin with spring washer Rod

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Chassis

Position of the identification plates and stickers Follow these instructions in case the identification plates or stickers need to be replaced.

Sticker kits: replace the stickers when missing or after the painting following a complete overhaul.

Identification plates: replace the plates if missing, worn out or damaged. When ordering the plates, please specify the truckís serial number (plain plates are not available).

Replacing the original plates with different ones showing different features from the original ones is NOT PERMITTED. In order to modify the truckís data, the truck itself must be tried and tested at the manufacturerís factory, then a new compliance certificate will be issued and the truckís technical specifications will be modified.

Version : April 2003 (Replaces version : )

View from operator side DO NOT PLATE WHEEL TORQUE SPECIFICATIONS CARD TIE TO THE TILLER WITH A STRAP

IDENTIFICATION PLATE

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OIL FILLING DECAL

MANUFACTURER’S LOGO

10

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

01

Chassis

View from forks side

11

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Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Chassis

Lateral view

12

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Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20

01

Chassis

View from above

13

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Runing axle

Contents

Page

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Version : Septembre 2003 (En remplacement de la version :

)

Load Rollers and Pallets intake Rollers.................................................................01 Lever Removing.....................................................................................................02 Lever Bush Removal and Replacement ................................................................09 Greasing ................................................................................................................15

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Runing axle

Load Rollers and Pallet Intake Rollers Pull rod side 3

Pull rod side 1 2

4

Fork arm tip side

1 Single Load Roller 2 Pallet intake rollers on fork arm tip side (To fork the pallet on the non-preferential side) 3 Pallet intake rollers on pull rod side (To leave the pallet on the non-preferential side) 4 Double Load Rollers The tandem load roller is standard for the 3,000 kg version.

The pallet lead-in rollers are supplied as optional equipment.

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Version : April 2003 (Replaces version : )

Fork arm tip side

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Lever Removing

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Version : April 2003 (Replaces version : )

Lift the fork arms and place a wood beam under their tips.

Lower the fork arms till the lower limit stop so as to enlighten the levers. By means of a suitable pinbar, remove the elastic pin from the main pivot. Recover the elastic pin.

Using a soft metal drawn tube, hit the main pivot and pull it out.

The round bar will fill the place of the pivot.il posto del perno.

By pulling the round bar out, the lever will fall.

Mind the hand fingers!

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Place the lever on a wood beam and pull out the elastic pin of the second pivot using a pin-rod and making it cross the hole, which was created on the fork plane.del perno secondario.

Using a soft metal drawn tube, hit the second pivot and pull it out.

The fork unit will separate from the pull rod.

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Version : April 2003 (Replaces version : )

Access hole

03

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Version : April 2003 (Replaces version : )

Place the fork unit on a wood beam, so that the roller pivots do not touch the ground.

By means of a pin-rod of suitable diameter, pull out the elastic pins of both pivots.

Hit the roller pivots in order to remove them from the bearings.

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In the event that the pivots are blocked, pull them out by means of an hydraulic press.

04

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Hit the roller pivots in order to remove them from the bearings.

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Version : April 2003 (Replaces version : )

In the event that the pivots are blocked, pull them out by means of an hydraulic press.

Once the rollers have been removed, pull the equalizers out.

Check that the equalizer pin is not worn out. If it is worn out, replace it. The wear appears like a convex lens.

Unscrew the main pivot-retaining screw of the rear fork.

The screw is placed under the motor compartment.

Warning: remove the battery before going on disassembling the rear forks.

05

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Using a sufficiently long 5 mm punch or a T-Allen wrench, hit through the extraction hole of the elastic pin retaining the second pivot of the rear fork.

Perform this operation inside the battery compartment.

Version : April 2003 (Replaces version : )

Extraction hole

The elastic pin of the second pivot, will get out on the lower side of the truck.

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Elastic pin

Using a soft metal drawn tube, hit the main pivot of the rear fork through the extraction hole.

Extraction hole of the main pivot

06

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Using a soft metal drawn tube, hit the second pivot of the rear fork in order to pull it out. The round bar will fill the place of the pivot.

By pulling the round bar out, the lever will fall.

Once the lever unit has been removed, by means of the pin-bar, hit in order to extract the elastic pin of the pull rod pivot of the rear fork.

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Version : April 2003 (Replaces version : )

Mind the hand fingers!

07

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Runing axle

Version : April 2003 (Replaces version : )

Now, the lever unit is ready to be overhauled.

Check the wear of the pivots, equalizers, bushes, rollers and rings (wire-covers).

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Front fork

Check the wear of the pivots and of the bushes.

Rear fork

08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Lever Bush Removal and Replacement

Version : April 2003 (Replaces version : )

Clamp the fork in a vice and using a punch having a diameter slightly lower than the bush diameter, pull the bushes out by hitting them.

It is possible to previously make the suitable punches for each kind of bush.

It is also possible to use countersunk-headed screws of suitable diameter.

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Warning: when you use very short tools, like screws, it is advisable to hold them with a pair of pliers and not with your hand fingers.

09

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Once all the bushes have been removed, replace them with new ones.

As regards the front fork, the equalizer bushes have no grease inlet hole, thus they have no right position.

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Version : April 2003 (Replaces version : )

The introduction of the bushes is performed by hitting with the flat surface of the hammer or by interposing a cylinder filled with metal between the hammer and the bush.

As for both forks, the bushes with a grease inlet hole have a right position.

The hole of the bush should be placed next to the grease inlet hole of the fork.

In order to locate it, pay attention to the position of the lubricating nipple.

Grease Hole

Lubricating Warning: replace all the bushes. It is not advisable to replace only one of them or only the ones of a single lever.

Once all the bushes have been replaced, re-assemble the whole lever unit including all pull rods and rollers.

10

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Runing axle

Before beginning the assembling step of the lever unit, check the surface of the pivots. If they are grooved, they need to be replaced.

Do not polish pivots with rubbing paper, as they have been ground with roughness index numbers of 0.8-0.4 and their surface is burnished, which prevents rusting.

Pay attention to the impression

Before inserting the pivot, lubricate it with grease or oil.

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Version : April 2003 (Replaces version : )

Impressio

11

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Place the elastic pin on the hole and hit it until it is completely inserted.

Hold the elastic pin by means of a pair of pliers.

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Version : April 2003 (Replaces version : )

After having centered the pivot to the fork holes, hit the pivot by means of a soft-surface hammer till the head of the pivot protrudes by 1 cm, then, using a pair of pliers, turn the pivot so as to align the impression with the pin hole. Hit again till it is completely inserted.

12

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Place the elastic pin on the hole and hit it until it is completely inserted.

Hold the elastic pin by means of a pair of pliers.

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Version : April 2003 (Replaces version : )

Lift the rear fork, align the holes and insert the pivot aligning the undercut with the pin hole.

13

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

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Version : April 2003 (Replaces version : )

Align the fork holes with the holes of the main pivot. Insert the pivot.

Turn the pivot in order to align the hole of the plate, which is integral with the pivot, with the threaded hole on the framing.

Hit the pivot until its head protrudes by 1 cm.

Apply the retaining screw, bring the pivot to a stop and tighten the screw.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

Greasing

The operation of lever greasing is to be performed while the truck is switched on.

The lubricating nipples of front levers may be seen through the slits.

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Version : April 2003 (Replaces version : )

Lubricating Nipples

Lift the fork arms 10cm above the ground level.

By means of a manual or pneumatic greasing pump, insert the lubricating nipple in the grease nozzle. Pump the grease until it comes out of the bushes.

Repeat the operation for all the four lubricating nipples of front levers.

15

Workshop manual EGU 30 / EGV 20 / EGP 14-20

02 Runing axle

The lubricating nipples of rear levers may be seen when watching under the truck.

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Version : April 2003 (Replaces version : )

Lubricating Nipples

Lift the fork arms up to the lifting limit stop.

By means of a manual or pneumatic greasing pump, insert the lubricating nipple in the grease nozzle. Pump the grease until it comes out of the bushes.

Repeat the operation for all the six lubricating nipples of rear levers.

Adjust the diameter of the grease nozzle according to the kind of lubricating nipple.

Pump the grease until it comes out of the bushes.

16

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Gear Box

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Version : Septembre 2003 (En remplacement de la version :

)

Contents

Page

Traction Speed .......................................................................................................01 Traction Stoppage ..................................................................................................01 Reduction Unit Overhauling...................................................................................02 3,000 Kg Ttaction Unit Assembly...........................................................................07 Reduction Unit Oil Topping Up ..............................................................................08

03

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Gear Box

Traction Speed Legend: LF = Running towards the fork arms LO = Running towards the operator Type of Driving Pedestrian operation (LF and LO) with tiller active in vertical position Tolerance

Speed 2000 kg (km/h) <2

3000 kg (km/h) <2

+0/-35% +0/-35%

+0/-35%

0 kg (km/h) <2

Version : April 2003 (Replaces version : )

Note: Speed times have been detected after having heated the reduction unit oil (After 1 hour approximately of continuous traction)

Traction Stoppage Traction is always blocked, when the following conditions occur:

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Stopped Traction

Manoeuvre made by the operator The tiller butterfly is set in the neutral rest position The emergency stop button is pressed The start-up switch is turned in the ìOî setting (Switched off truck) The tiller is set in the braking position In the event of electric guide alarm and COMBI alarm tripping

01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03 Gear Box

Reduction Unit Overhauling

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Version : April 2003 (Replaces version : )

Place the reduction unit on the floor or on a workbench.

By means of an Allen wrench, remove all the screws of the cover.

Lift the cover from the reducer casing, by means of a hammer and of a chisel.

The putty sticks the cover to the reducer casing.

Warning: do not heavily groove the cover supporting surface.

Heat the ring nut by means of a small patent blowpipe. It is better to use an electric air heater.

This operation aims at softening the thread-locking adhesive.

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03 Gear Box

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Version : April 2003 (Replaces version : )

By means of a pin wrench of suitable diametre, completely unscrew the ring nut retaining the M25x1.5 gear.

In order to keep the bevel gear pair rotation jammed, insert a soft metal wedge between the teeth of the gears or clamp the wheel securing flange in a vice.

Hit the reducer shaft with a softsurfac hammer till the gear.

Place a wood board or any soft surface on the wheel coupling flange side.

By means of a soft metal drawn tube, hit the reducer shaft until it gets completely out.

03

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03 Gear Box

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Version : April 2003 (Replaces version : )

By means of an Allen wrench, remove all the securing screws of the fifth wheel-holder.

Hit with a soft-surface hammer the edge of the reducer.

Warning: if you remove the tracks of crankshaft bearings, you will find the shims for the calibration of the pinion-gear coupling under them. Do not forget from which of the two bearings they have been removed. Tie the one to the other by means of a string.

04

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03 Gear Box

Insert an Allen wrench in the hole of the cylindrical couple gear in order to stop the shaft rotation during the unscrewing operation.sviamento.

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Version : April 2003 (Replaces version : )

Gear Hole Using a wrench, unscrew the ring nut retaining the M16x1.5 cylindrical gear by means of a morbida.

By means of a soft-surface hammer, hit the end of the pinion shaft in order to pull it out of its housing. A cone-shaped bearing will remain fastened to the shaft.

05

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03 Gear Box

List of the parts forming the reducer. Now, you can go on washing the different parts and replacing, for instance, the bearings or the shaft outlet oil splash guard.

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Version : April 2003 (Replaces version : )

In order to assembly the reducer, reversely follow the whole disassembling procedure. Do not forget to use the thread-locking adhesive where it had been previously used and to bend the ring nut anti-screwing tongues.

Strictly comply with the driving torques recommended by the manufacturer.

See reduction unit drawing.

06

03

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Gear Box

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Version : April 2003 (Replaces version : )

3,000 Kg traction unit assembly diagram

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

Description Braket Motor nut M14 1.4 Screw M8x70 8.8 Washer Gear Box Electromagnetic Brake Drive Motor Circlip Hub Drive Gear Oíring Drive Wheel Wheel screw M14x30 Washer Screw M6x50 Key

Qty 1 1 3 3 1 1 1 2 1 1 1 1 5 8 8 1

Note 25 Nm 11 Nm

2.5 Kw

Z26 Tractothan 140 Nm 11 Nm

Drawing 452670005 07

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03 Gear Box

Reduction Unit Oil Topping up Remove the fairing when the truck is switched off.

Turn the tiller until the filler plug is visible through opening A in the structure.

The opening will be visible on the righthand side of the fixed chassis.

After having aligned the plug with opening A, use a socket wrench with swivel extension to unscrew and remove the plug.

Version : April 2003 (Replaces version : )

Fill the gear reducer oil syringe and insert the nozzle into the filler hole.

Inject oil up to the rim of the hole.

Refit the filler plug and torque to 15 Nm. Dry any spilled oil from the area around the plug using a clean rag.

Important: it is good practice to renew the seal washer each time the gear unit is filled with oil.

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Gear Oil Standard

SAE 80W 90EP

Cold Store

SAE 75W 90EP

Grease pour the truck

Standard

Grease with lithium

Cold Store

Special cold store

08

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Wheels

Contents

Page

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)

Driving Wheel.........................................................................................................01 Traction Wheel Replacement.................................................................................01 Pivoting Wheel Unit ...............................................................................................03 Complete pivoting wheel assembly (latÈral view)..................................................03 Complete pivoting wheel assembly (front view) ....................................................04 Wheel assembly.....................................................................................................05 Removing the pivoting wheel.................................................................................06

Workshop manual EGU 30 / EGV 20 / EGP 14-20

04 Wheels

Driving Wheel It is a wheel made of a material named TRACTOTHAN, that is to say a special compound of polyurethane and rubber that is able to achieve a higher adhesive force than the previous vulkolan type. The steering is easy even when the truck is not running thanks to the electric steering system.

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Version : April 2003 (Replaces version : )

Traction Wheel Replacement Warning: before starting the traction wheel replacement, place a wood beam under the end of the fork arms. Then, lower the fork arms making them rest on the wood beam.

Switch the truck on and turn the tiller (in a full clockwise direction) so that the securing screws of the traction wheel are turned towards the fork arms.

Switch the truck off.

Disconnect the battery plug.

Safety Wood Beam

Using the hydraulic lifting jack, lift the truck on platform side by means of the platform support.

01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

04 Wheels

Lift the truck 17-18 cm between the edge of the frame and the floor.

Place some safety wood beams under the edge of the fixed frame.

For reasons of safety, it is advisable to leave the jack in position where it is applying slight force on the underside of the chassis.

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Version : April 2003 (Replaces version : )

Safety Wood

By means of a socket ratched wrench, unscrew and remove the securing screws of the traction wheel.

Remove the traction wheel from the flange.

In the event that it is not possible to remove it manually, hit the edge of the wheel by means of a soft-surface hammer.

Let the wheel fall on the floor.

Mind your hands!

Replace the traction wheel with a reverse procedure.

Tighten the screws with a torque of 140Nm

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

04 Wheels

Pivoting wheel unit The unit comprises a polyurethane wheel mounted on a height-adjustable support. This system makes it possible to adjust the trim of the truck in the event of significant wear of the drive wheel with consequent reduction in diameter. This procedure must be performed exclusively by skilled personnel.

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Version : April 2003 (Replaces version : )

Complete pivoting wheel assembly (lateral view)

Floor

03

04

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Wheels

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Version : April 2003 (Replaces version : )

Complete pivoting wheel assembly (front view)

Floor

Floor

04

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Wheels

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Version : April 2003 (Replaces version : )

Wheel assembly

Wheel assembly table Pos. 1 2 3

Wheel assembly WHEEL INTERNALDISTANCE WHEEL 120X60 BEARING

Qty 1 1 2

Note

05

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Wheels Removal of pivoting wheel

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

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Version : April 2003 (Replaces version : )

Use a hydraulic jack to lift the truck on the tiller side. Insert a block of wood under the chassis.

Warning: keep the forks lowered. Lift the truck approximately 15 cm from the ground.

Remove snap ring 1 using circlip pliers Insert a short 12 mm flat head screw in hole 2 to protect the thread.

Interpose a soft metal bar (aluminium) and then strike the head of the screw.

Extract the wheel from under the truck.

Working from underneath remove bearing retainer snap ring 3.

Remove bearing 4.

Using 2 hex wrenches unscrew wheel retaining screws 1. Extract spindle 2 and remove the wheel complete with bearings.

06

Workshop manual EGU 30 / EGV 20 / EGP 14-20

04

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Version : April 2003 (Replaces version : )

Wheels

At this point you can renew the entire wheel, or wheel bearing 1, or support bearing 2.

Before starting the reassembly procedure, grease all moving parts, spindle 3, the shoulders of the support, etc.

To reassemble the pivoting wheel remove the Ø 12 screw, refit bearing 2 and fit ring 4: Align the wheel in the housing of bearing 2.

To assemble the pivoting wheel, remove the M12 screw located on the fork pin.

Insert the pivoting wheel slew bearing (2) and press it fully home until it locates against the spot facing.

Fit the bearing retainer snap ring (4) into its groove.

From the underside of the bearing align the fork pin with the bore and then use a percussion extractor to drive in the pin until it locates against the bearing.

Fit the second snap ring (5) on the top of the pin.

Ensure that snap ring (5) locates fully inside its groove.

07

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Driving Controls

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Contents

Page

Tiller Head..............................................................................................................01 Tiller Casing ...........................................................................................................01 Connection Diagram between Tiller Card and COMBI System.............................02 Traction Control Butterfly .......................................................................................03 Traction Accelerator Potentiometer........................................................................03 The redundant potentiometer ................................................................................04 Tiller Safety Device Button ....................................................................................04 Tiller Head Buttons ................................................................................................05 Tiller Positions........................................................................................................06 Traction Potentiometer Replacement ....................................................................07 Traction Control Diagram.......................................................................................13 Tiller Board Diagram ..............................................................................................14 Tiller Cable Harness Diagram................................................................................15

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05 Driving Controls

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Version : April 2003 (Replaces version : )

Tiller Head

1 2 3 4 5 6 7 8

Fork Arm Lowering Button Fork Arm Lifting Button Acoustic Alarm Button Tiller Safety Device Button Tiller Safety Device Button Tiller Casing Fork Arm Lifting Button Fork Arm Lowering Button

Tiller Casing The tiller casing is a plastic enbloc (PA6 polyamide), which is produced through an injection system followed by an emptying operation by means of gas, in order to obtain some inner lightening hollows.

The angle handles of suitable dimensions make the hand position comfortable, thus they provoke no aching also when they are used for long periods. Plenty of space is available inside the handle also when one uses work gloves.

The mechanical stress and breaking tests confirmed their excellent resistance to shocks.

An electronic card, which has the function to collect the electric signals from the pushbuttons as well as from the accelerator potentiometer, is housed inside the tiller casing. This logics elaborates the data received and sends them through a serial digital transmission to the lectronic control.

01

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Driving Controls Connection Diagram between Tiller Card and COMBI System

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Version : April 2003 (Replaces version : )

It is rather important to highlight the connection between the COMBI system and the tiller card occurring through the serial transmission by means of the TX RS232-type current-loop wire. This connection enables a remarkable sparing of the quantity of cables used and, therefore, the decrease of sheath failure probabilities. The signals from the BELLY SWITCH, from the CPOT.T2 (traction potentiometer 2 unit) and from the CPOT.S2 (lifting/lowering potentiometer 2 unit) directly enter the COMBI for safety reasons.

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05 Driving Controls

Traction Control Butterfly

Running towards operator

Running towards fork arms

The Traction Control Butterfly has the following functions : - Running direction and electromagnetic brake return selector - Accelerator - Service brake (electric braking at running reversal) - Electric braking return when releasing the butterfly

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The system is equipped with a helical spring automatically switching to the neutral position, thus it is not very tiring. The butterfly has a working rotation stroke of 42° approximately and the truck speed is proportional to the angular motion of the valve.

When the butterfly is released, the electric braking is enabled till the equipment stopping and, then, till the brake locking.

Traction Accelerator Potentiometer The functions of accelerator and running selector are performed by means of a double (Redundant) potentiometer that is suitably coupled to the butterfly shaft.

The potentiometer has a "double crossed signals" system: when one signal is at its ceiling level, the other one reaches its floor level (see diagram beside). It has two separate tracks controlling two different voltages. It is produced by means of a carbon-film technology and this system ensures a redundant-type safety feature.

03

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Driving Controls The Redundant Potentiometer

Version : April 2003 (Replaces version : )

Practically, it is a double potentiometer where the cursors of the two potentiometers are hooked to the same shaft, which produces the rotatory motion. The two signals from the potentiometer 1 and from the potentiometer 2 are continuously compared by the COMBI system according to a mathematical formula: POT.1 + POT.2 . 5V. Any defect of one of the two potentiometers is detected at once and the truck is blocked through an alarm.

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Tiller Safety Device Button The safety device button casing winds around most of the head surface so that its enabling is optimum also when the tiller is at peak angles.

The pressure of this button enables a particular functioning, according to the operation condition: Functioning

Operation Condition Tiller

Brake

Truck running towards the operator

In working position

Open (Nonbraking)

Truck running towards the fork arms

In working position

Open (Nonbraking)

Butterfly In rest Truck stop and sudden position or running restarting towards the turned fork arms according to what is towards the provided for by EN1175-1 operator standard.

In rest position

Sudden running restarting towards the fork arms according to what is provided for

by EN1175-1 standard.

The release of the button provokes the truck stop: the electric braking is enabled till the equipment stopping and, then, till the brake locking.

04

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05 Driving Controls

Tiller Head Buttons

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Version : April 2003 (Replaces version : )

The operator does not need to leave the handle in order to press the acoustic alarm button, he simply needs to stretch his fingers to reach it. This button is housed inside a raised-edge niche in order to avoid accidental operation. It is an ìON-OFFî button, with silver oxide membrane, without contact and with mechanical motion. It is covered with a polyester film, which is oil-, grease- and acid-proof. It is "sensitive" also when wearing work gloves.

05

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Driving Controls Tiller position Position of tiller without using the “tiller active in vertical position” function

The positions of the tiller are: Pos.”1”: Working Position Å Possibility to start the running by means of the butterfly Pos.”2”: Braking Position Å Locked traction Å Parking and emergency brake (Jammed brake and nonpowered traction motor) This kind of braking should not be used as service braking.

Position of tiller using "tiller active in vertical position” function

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Version : April 2003 (Replaces version : )

The tiller position is: Pos.”1”: Operating position Å Facility to select travel direction by means of the butterfly control while holding down one of the two low speed travel request buttons.

To activate parking and emergency brakes release one of the low speed travel request buttons regardless of the position of the tiller.

This type of braking must not be used in place of the service brake.

When released, the tiller will automatically assume position "A".

Automatic return of the tiller arm is obtained by a helical spring strut inside the tubular section. This system ensures slight and even pressure throughout the entire stroke. When released, the tiller arm stops without rebounding thanks to a special retaining mechanismformed of rubber bumpers.

Traction enable without using the “tiller active in vertical position” function Sequence 1 2

Operator manoeuvre Bring the tiller to its operating position Turn the tiller butterfly control until reaching the required speed

Traction enable in low speed with the “tiller active in vertical position” function Sequence 1 2

Operator manoeuvre Press and hold down one of the two low speed travel enable buttons Turn the tiller butterfly control until reaching the required speed value

06

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Driving Controls Traction Potentiometer Replacement

By means of a rod-pin of suitable diameter, move the notched pin retaining the emergency button.

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Version : April 2003 (Replaces version : )

Notched Pin

Clamp the pin with a pair of pliers and pull it out of the emergency button.

Unscrew and remove the TCCE M4X6 securing screw of the emergency button.

Remove the emergency button.

07

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Driving Controls

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Version : April 2003 (Replaces version : )

Remove the angle bar, by pulling it out of the potentiometer support as well as its pin and its compression spring.

Unscrew and remove the securing screws of the potentiometer support.

Remove the two upper shutters.

Upper Shutter

08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05 Driving Controls

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Version : April 2003 (Replaces version : )

Lift the potentiometer unit by pulling it out if the tiller head casing.

Unscrew and remove the securing screws of the upper butterfly on potentiometer side.

Remove the butterfly, by pulling it out of the potentiometer square shaft.

09

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05 Driving Controls

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Version : April 2003 (Replaces version : )

Unscrew and remove the securing screws of the potentiometer.

Remove the potentiometer connector from the card.

Remove the potentiometer, by pulling it out of the square shaft.

10

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Driving Controls

The potentiometer assembly stage should be performed by following the same procedure but in a reverse manner. Mind the reference notch that may be seen on the movable part (cursor): it should be turned towards the connector.

Potentiometer

Version : April 2003 (Replaces version : )

Connector

Cursor Notch

Enlargement of the potentiometer cursor. The reference notch, which is useful in order to assembly the potentiometer to the square shaft, may be clearly seen.

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Cursor Notch

11

5

4

1

3

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1 1

Machanical lever complete with microswitch Tiller serial card Potentiometer

3 4 5

452249551

1

Complete drive control assembly 2

1

1

Qty

Square shaft

Desription

2

1

Pos

Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05

Driving Controls

12

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05 Driving Controls

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Version : April 2003 (Replaces version : )

Traction Control Diagram

Drive potentiometer Diagram Electric angle Mechanical angle Protection Rating Power Nominal Resistance Potentiometer type Operating temperature

2x42° 2x50° IP65 1w/70°C 8 khom Redudant - 30°C / ë+80°C

452249552 13

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Driving Controls

XO

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Version : April 2003 (Replaces version : )

Pin 1 2 3 4

XJ

description BPOT 2 + 5V DC POT 1

Pin 1 2 3 4 5 6

XN ET XO Description + 24V DC - BATT CPOTT 2 DRFT Belly switch CPOTS2

Pin 1 2 3 4

XN ET XO Description POT1 +5V DC POT2 B-

XA XB XC XD XE XF XG XJ XK XL XM XN

description slow lift button lift button lowering button slow lift button lift potentiometer LH drive button/slow drive button lowering button drive potentiometer lift button horn button RH drive button/overbooster button cable-card connections

14

Version : April 2003 (Replaces version : )

Pos A B C D E

Contact female Rubber cap for SAAB and J.P timer Rubber seal for QSAAB 10 pole

Contact male

Description

Pos Description a Contact male b c Contact female d Rubber cap for SAAB and J.P timer e Rubber seal for QSAAB 10 pole

Cables n°11 and yellow-green wire of the sheath must be not cut, but clamped to the sheath itself Connectors X3 and X4 be supplied pre-wired Connector X8 and seal E must be supplied in a separate pack

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

05

Driving Controls

15

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)

Brake

Contents

Page

Electromagnetic Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electromagnetic Brake Calibration Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of the electromagnetic brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of E.M.B. dataplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Po wer ; Voltage, Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools required for E.M.B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of clutch disk for sizes 06-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of brake flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly phases of E.M.B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the rubber guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electro Hydraulic Brake (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Braking (regenerative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E.M.B. Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01 01 02 03 04 05 06 06 07 09 10 10 11

Workshop manual EGU 30 / EGV 20 / EGP 14-20

07 Brake

The truck is equipped with two independent braking systems : Å Electromagnetic brake (Electrically driven friction brake) Å Energy-regenerating electromagnetic brake (Dynamic braking on the traction motor)

Electromagnetic Brake

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Due to its use features, it is considered like: Å A parking brake Å An emergency brake It is a current-controlled device. Its powering will produce a magnetic field enabling the release of the brake: no dynamic braking.

On the contrary, when it is no longer energized, it is jammed: dynamic braking.

The braking occurs through a helical spring system pushing the braking disks on the flange of the traction motor.

The braking couple remains fixed, both with and without load and may be, anyhow, calibrated during the maintenance stage by means of the suitable brake adjusters.

This kind of braking occurs with the following operation conditions : Å With the tiller in braking position Å With the platform in stand-by position Å With vertical platform and closed side panels Å By operating the emergency button Å When releasing the motor butterfly after the truck stopping (once the release braking has ended) Å In the event of electric drive alarm and COMBI chopper alarm tripping Å With the start-up switch turned in ìOî setting (Switched off truck)

Electromagnetic Brake Calibration Table Capacity (kg)

S1 (mm)

S2 (mm)

toll.S1 toll.S2 (mm) (mm)

2,000

3

0,25

+/-0,2 ±0,05

S1 = air space between the adjustment ring nut and the electromagnetic brake casing; the lower is this figure the higher is the braking force.

S2 = air space between the electromagnetic brake casing and the flange. Wrong adjustments may compromise the proper operation of the same electromagnetic brake: uneven wear of the brake lining surface, braked traction motor and overheating with consequent breaking of the motor crankshaft bearings and loss of the properties of the electromagnetic brake coil.

Warning : Replace the brake disk when S2 0.6 mm 01

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07 Brake

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Description of the Electromagnetic Brake

Type - E

Type - N

1. Electric brake disk 2. Compression spring 3. Brake disk 4. Hub 5. Motor shaft 6. Flange 7. Electric brake body 8. Adjustment ring 9. Air gap adjuster nuts S2

1. Compression spring 2. Compression spring 3. Brake disk 4. Hub 7. Electric brake body 9. S2 adjustement nuts

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

02

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07 Brake

Description of E.M.B. Plates

B

FK

458

-

PRODUCT GROUP

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PRODUCT FAMILY TYPE MEASURE DRAWING

Measures 06,08,10,12,14,16,18,20,25 Electromagnetic brake drawing E ñ adjustable (the brake force may be decreased bymeans of the adjustment ring nut) N ñ non-adjustable Under the code: power supply voltage, hub diameter, optionals These figures are valid only for type 458.

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Brake Power, Voltage, Coil Resistance

TYPE

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BFK458-10

BFK458-12

ELECTRIC POWER

VOLTAGE

COIL RESISTANCE 20° C +-8%

W 30 21 32 30 32 30 33

V 24 96 103 170 180 190 205 24 96 102 170 180 190 205

 19. 2 297.3 331.5 963. 3 101.3 1203 1273 14.4 230.4 265.2 722.5 810 902.5 1051

40

Refer to the calibration procedure in the specification.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Brake Tools to use for E.M.B.

Type

Torque wrench

[Nm]

Feeler gauge

Wrench Wrench size [mm]

Hook wrench DIN1810 Design A for outside Diameter [mm]

Wrench size [mm]

Box spanner for flange installation Wrench size [mm]

Manual release 3x1/4 îsquare 4x1/4 îsquare 5x1/4 îsquare

Cap screws 8 9 12

6x1/4 îsquare

15

8x1/2 îsquare

17

Nuts / bolts 7/5.5

2kt lever

10/7

7

12/8

9

-/10

10 12 14

Caliper gauge

42-55 52/55 68/75 80-90 95-100 110-115 135-145 155-165

7x1/4 îsquare 8x1/4 îsquare 10x1/4 îsquare 13x1/2 îsquare 17x1/2 îsquare

Multimeter

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Version : April 2003 (Replaces version : )

BKFK458-06 BKFK458-08 BKFK458-10 1 to 12 BKFK458-12 BKFK458-14 BKFK458-16 BKFK458-18 20 to 100 BKFK458-20 BKFK458-25

Insertion for hexagon socket screws

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07 Brake

Assembly of the Clutch Disk for Measures 06-16

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Place the clutch disk on the motor flange on the trucks where it is contemplated.

Check that the internal hole of the clutch disk is larger than the hub diameter and that he clutch disk lip contains the brake disk.

12. Clutch disk 15. Motor flanges

Brake Flange Assembling The flange (6) may be screwed on the motor flange (15) by means of the suitable cheeseheaded screws on the trucks where it is contemplated.

Make sure that the head of the screw is embedded in the brake flange thickness.

6. Brake flanges 10.1 Securing screws 15 Motor flange

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07 Brake

E.M.B. Assembling Steps

Version : April 2003 (Replaces version : )

First step : press the Hub on the shaft and lock it by means of the safety elastic washer. (make sure that there is the spline)

4. Hub 4.1 Safety elastic washer 15. Motor flange Second step : press the brake disk on the hub, as shown in the figure below.

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(check the surface of the motor flange, there should be neither oil nor grease ......traces)

3. Brake disk 15. Motor flange 4. Hub

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07 Brake

7.Electromagnetic brake casing 10. Securing screws 11. Clip 15. Motor flange Fourth step : Secure the screws (10) by means of a dynamometric wrench that is calibrated on the value in Nm as reported in the plate, check the air space between the electromagnetic brake casing and the electromagnetic brake disk by means of a thickness gauge (1). This figure should be equal to the S1 value reported in the table.

Otherwise, first unloose the securing screws and then repeat the operation by means of an Allen wrench.

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Third step : place the electromagnetic brake casing on the motor flange, align the holes between the electromagnetic brake (7) and the motor flange (15) to fasten the screws (10).

Before tightening, remove the clips (11).

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

07 Brake

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Version : April 2003 (Replaces version : )

Once the securing screws are unloosened (10), by means of the Allen wrench, adjust the adjustment nuts (9) more or less in order to increase or decrease the air space. Tighten again with the dynamometric wrench and repeat the operation till the achievement of the correct value.

Rubber Protection Assembling If it is contemplated or if it is deemed necessary, it is possible to place a rubber protection all around the electromagnetic brake, close to the brake disk. This rubber protection aims at protecting the brake lining against any abrasive dust, etc.

1. Electromagnetic brake disk 7. Electromagnetic brake casing 10. Securing screws 12. Clutch disk 13. Rubber protection 15. Motor flange 09

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07

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Brake

1. Electromagnetic brake disk 6. Flange 7. Electromagnetic brake casing 10. Securing screws 12. Clutch disk 13. Rubber protection 15. Motor flange

Electrohydraulic Brake (Optional) It electrically works like the electromagnetic brake, but moreover it automatically adjusts the braking couple according to the load, through an hydrostatic system connected to the hydraulic lifting circuit. It has the following advantages : Å Decreased wear of the brake disk Å Invariable braking spaces Å Softer loadless braking vs. the braking by means of the traditional electromagnetic brake

Electric (Regenerating) Braking This braking is achieved through a suitable control of the traction motor current by the combi chopper. During the braking stage, this system enables to use the motor also as a generator and to transmit this energy (current) to the battery (energy regeneration).

This type of braking occurs in the following operation conditions : Å When the traction control butterfly is completely released while the truck is running Å At the reversion controlled by the traction control butterfly The regenerated energy (non-dissipated by the motor) decreases the motor heating and the wear of the electromagnetic brake disks.

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07 Brake

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E.M.B. Assembling diagram

Fit the brake, keeping the cable in correspondence with the mid point of the distance between the motor power terminals.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

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)

Contents

Page

COMBI Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 COMBI System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 Armature Pilot System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 Field Pilot System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Pump Motor Pilot System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 Energy Regenaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 COMBI Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Parameter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Signal Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Accelerator Voltage Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Stored Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Additional Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Special Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Parametter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 COMBI System EPROM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 COMBI System Input/Output Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Cable and Sheath positining Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Legend to wiring Diagramand connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Tiller card Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Tiller cable harness Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

COMBI Specifications The traction and lifting motors are managed by the COMBI (COMBI stands for "combined") control, which may work with max temperatures of 300 A. The logic and power units are assembled inside the COMBI casing that is equipped with gaskets in order to ensure a perfect protection against sprinklings (water, acid, etc.), as well as against dust, shavings or small particles.

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Å Rated power supply voltage: 24V DC Å Max current for the traction motor: 300A DC Å Max current for the pump motor: 300A DC Å High frequency MOS technology (Static) Å Real-time control of the external and internal parts that may affect the truck behaviour with self-diagnosis by the same control circuits. Å Several functioning configurations that may be selected on the console in order to comply with the different requirements of the user. Å Speed control: the motor speed follows the accelerator by automatically tripping a regenerative braking when the motor speed exceeds the preset speed; therefore the truck has a perfect functioning on slopes. Å Good working order of the traction and lifting motors due to the high switching frequency of the MOSFET power transistors. Å Communication of tiller serial signals with reduction of wirings. Å Microcontroller supervisor controlling the functions of the main microcontroller (Safety features in redundancy) Å Automatic system of energy regeneration during traction (energy sent to the battery) in the following working conditions: - Lowering Truck with released accelerator - Braking truck when the accelerator is released - Braking truck when reversing the running The control is assembled to a 30 mm-thick aluminium dissipator to further improve the heat exchange.

The chopper, which is the same for different types of machines, detects the kind of truck it was assembled to and automatically selects the management program for the inputs and outputs, including the relevant configurations and parameters.

It is an encoding, which is different for each truck and which is executed through the wiring. It consists in the negative polarization or non-polarization of one or both X1:34 and X1:35 inputs, SEL.1 and SEL.2 respectively.

Name SEL.1 SEL.2

Ident. Pin. X1:34 X1:35

Polarization Connected to -B Connected not -B

Type EGU 30 EGU 30 01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

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The following table shows which are the inputs and outputs of the COMBI system and which are their functions in a detailed manner : Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Name Input NHO +AUX < PMC NMC NEVP I4 < I5 < TS < 2Å ãTS < MAINS < NCLRXD < CPOT.T2 < CPOT.S2 < KEY < +AUX NEB NEV1 NEV3 NEV5 I2 < I3 < BELLY < SR1 < LIFT < -BATT +12 PCLTXD -BATT +AUX PEB NEV2 NEV4 NEV6 SEL1 < SEL2 < I1 < DRFT < SR2 < TOP MAST < GND NCLTXD KEY OUT

output < < < <

< < < < <

< < < < < < < < <

< < <

Functions 0V +24 V aucillary equipment +24 V emergency button coil 0V emergency button coil 0V lowering coil valve not connected not connected Tiller sensor 1S1 7S3,7S4 Tiller always ON (slow when tiller vertical) Battery charger microswitch U.C.B. Console Traction potentiometer 2 Lift potentiometer +24 V after Key switch +24 V Horn 0V electromagnetic brake Not used Not used Not used Not used To battery discharge Indicator relay Tiller safety device button (belly switch signal) Not connected Not connected 0V tiller card +12 V U.C.B. console U.C.B. console 0V Battery +24 V Lowing coil valve +24 V electromagnetic brake Not used Not used (-) Curtis hour counter 0V Not connected Not used Tiller card serial signal Not connected Lifting end sensor 2S1 0V U.C.B. console U.C.B. Console +24 V tiller card 02

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System

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COMBI System Assembly

SPECIFICATIONS PROTECTION DEGREE IP54 WORKING TEMPERATURE -30°/+70° C POWER SUPPLY VOLTAGE +24V DC WORKING FREQUENCY 16 KHz MAIN MICROPROCESSOR SIEMENS 80C517 CONTROL MICROPROCESSOR ST62T30 TYPE OF MEMORY EPROM 27256 POWER CARD TECHNOLOGY IMS LOGIC CARD TECHNOLOGY SMD KIND OF TRACTION MOTOR EXCITATION SEPARATE KIND OF PUMP MOTOR EXCITATION PRODUCTION TRACTION POWER 200A-300A LIFTING POWER 250A-300A MANUFACTURER ZAPI SINGLE PACKAGE FOR ALL TYPES

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

Armature Pilot System Diagram

Version : April 2003 (Replaces version : )

The adjustment of the VMN armature voltage is achieved through a set of power MOSFETs.

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Qi: Qj: C:

set of 6 IRF3205S-type MOSFETs with integrated diode and channel no. set of 6 IRF3205S-type MOSFETs with integrated diode and channel no. 300 A set of 14 1000µF 35V condensers connected in parallel

The power MOS (PWM and FRE) are controlled by two inverted signals: when one is ON, the other is OFF and viceversa.

At peak conduction, the MOS PWM is always ON (MOS FRE always OFF).

At rest, the MOS FRE as well as the MOS PWM are always OFF.

04

08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Field Pilot System Diagram

Version : April 2003 (Replaces version : )

Field regulation occurs, on the contrary, by the connection of 2+2 mosfets.

Fiield Adjustment Diagram.

Q26-Q29: serie di 4 mosfet tipo IRF3205S con diodo integrato, a canale n.

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Forward travel Mosfet Q27 is activated for the full duration of the travel request.

Mosfet Q28 is activated with PWM (f=800Hz) for the duration of the travel request Mosfets Q26 and Q29 are maintained disconnected Reverse travel Mosfet Q29 is activated for the full duration of the travel request.

Mosfet Q26 is activated with PWM (f=800Hz) for the duration of the travel request Mosfets Q27 and Q28 are maintained disconnected

05

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Field regulation method.

06

08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Pump Motor Pilot System Diagram

Q: series of 6 mosfets type IRF3205S with integral diodes, channel n. 300A D: series of 6 diodes type IR 20ETF04S

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Version : April 2003 (Replaces version : )

The adjustment of the VMN power supply voltage of the pump is achieved through a MOSFET bank.

07

08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Energy Regeneration The energy regeneration occurs in the following conditions: a) lowering truck with released accelerator b) braking truck when the accelerator is released c) braking truck when the running is reversed

1) Functioning like a motor Å When PWM is ON, the battery current circulates within the motor first and then within the MOS. Å When FRE is ON, the current stored within the motor circulates again (in the same direction as before) through the integrated diode within the MOS fre, which acts as a flywheel. In this case the MOS fre could also be OFF (at the same time as the MOSpwm).

2) Functioning like a generator Å When PWM is ON, the current stored within the motor circulates through the MOS PWM and recharges the battery. The current does not circulate within the PWMfre diode. Å When FRE is ON, the current stored within the motor circulates again within the MOSfre, which acts as a flywheel. In this case, the MOS fre cannot be replaced by the diodes. The current does not circulate within the PWM diode.

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Now, let us examine what happens within the COMBI in the following conditions :

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08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System COMBI Diagnostic The COMBI control interfaces with an external diagnostic unit that is called U.C.B. 97 (the previous U.C.B. versions are not compatible).

This equipment communicates with the chopper through a serial digital communication with a protocol (definition and interpretation of digitized information), which functions as a software key to enable said transmission (COMBI-console recognition).

The console is a device for the displaying and adjustment of the parameters and configurations contained within the COMBI.

In order to access the diagnostic, it is necessary : Å to connect the console to the 6-poles black saab ìX7î connector within the motor compartment (when the truck is switched off); Å to switch the truck on. Å Automatically also the console displaying the main menu is enabled.

HEADER:

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WARNING: The diagnostic unit should be used only by suitably trained personnel. The change of some parameters or configurations may cause dangerous situations for the operator (For instance, traction speed increase).

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08 Electrical System

Press the Enter key to access the following submenus : - PARAMETER CHANGE - TESTER - PROGRAM VACC - MOTOR DATA (Not available) - ALARMS - SAVE PARAMETER (Not to use) - RESTORE PARAMETER (Not to use) - SET OPTIONS - HARDWARE SETTINGS

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The menu structure is as follows:

The console is equipped with 6 keys: Å ENTER: confirm your selection Å ROLL UP: select the next option Å ROLL DOWN: select the previous option Å OUT: quit the selected function Å SET UP: increase the parameter setting SET DOWN: decrease the parameter setting

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Electrical System Parameter Change : When you open the PARAMETER CHANGE menu, the list of the items that may be modified in order to achieve the implementation of the truck operation is displayed.

(The "curve braking" parameter has been removed) Name ACCELER. DELAY

Meaning Traction motor acceleration delay

DECELER. DELAY

INVERS. BRAKING

Traction motor deceleration delay when the accelerator is partially released Braking when running is released (total release of the accelerator) Braking when running is reversed

CUTBACK SPEED 1

Speed decrease 1 (connected to the SR1input state)

CUTBACK SPEED 2

Speed reduction 2 : (Dependant on the status of input SR2) Speed reduction 3 : Not used

RELEASE BRAKING

CUTBACK SPEED 3

Version : April 2003 (Replaces version : )

CREEP SPEED TR. SOFT WORKING MAX SPEED FORW MAX SPEED BACK MAX. I TRACTION ARMA NOM CURR.

FIELD CURR. MAX

Rated minimum armature current, below which the fieldmay be weakened Armature current value which is the threshold of field weakening Max current of the traction motor field

FIELD NOM CURR.

Rated current of the traction motor field

PU. ACCELER. DEL

Pump motor acceleration delay

PU. DECELER. DEL

LIFT SPEED

Pump motor deceleration delay when the second tiller butterfly is partially released Lifting speed by the second tiller butterfly or by the distributor Lifting speed by the tiller button

DOWN SPEED

Lowering speed by the tiller button (Non used)

WEAK DROPOUT Copyrighted. Reproduction in any form forbidden Copyright reserved.

Power supply voltage applied to the traction motor when the accelerator is slightly rotated Slow running speed with the "tiller always ON" functioning (2TS inlet) Maximum drive speed with travel direction towards operator Maximum drive speed with travel direction towards forks Min = 0 Max armature current on the traction motor

LEVER LIFT SPEED

SLOW LIFT SPEED

Low speed lifting speed controlled by tiller button (Not used) CREEP SPEED PUMP Voltage applied to the pump at a minimum lifting request by the tiller second butterfly

Ref. Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System

Name EV. ACCELER. DEL

Meaning Acceleration delay of the proportional opening valve

EV. DECELER. DEL

Deceleration delay of the proportional closing valve when the second tiller butterfly is released MIN DESC. EVP Minimum voltage (current) on the coil of the proportional valve that corresponds to the beginning of the opening MAX DESC.EVP Max voltage (current) on the coil of the proportional valve that corresponds to the maximum opening MIN DESC. EVP FINE Fine adjustment of the MIN DESC.EVP parameter MAX DESC.EVP FINE Fine adjustment of the MAX DESC.EVP parameter AUXILIARY TIME

Not used

Ref. Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Signal Monitoring The TESTER menu displays the items that are monitored in real time. The displayed values depend on the state of the battery and on the functions that the truck is performing at that moment, therefore we will show a nominal value (##) plus the relevant unit of measure in the table. Whereas, the meaning of ON and OFF is as follows : Å ON: the corresponding function is enabled Å OFF: the corresponding function is disabled.

Name BATTERY VOLTAGE MOTOR VOLTAGE MOTOR CURRENT FIELD CURRENT DESC. EVP VOLT. TEMPERATURE TR. ACCELERATOR

Description

Reference of the battery voltage value Armature voltage value Armature current value Field current value Voltage value on the coil of the lowering valve COMBI internal temperature Voltage value relevant to the traction potentiometer 1 and percentage compared to the value at rest LIFT Voltage value relevant to the lifting/lowering ACCELERATOR potentiometer 1 and % compared to the value at rest 2 ND TR. ACCELER. Voltage value relevant to the traction potentiometer 2 and percentage compared to the value at rest 2 ND LIFT ACCEL Voltage value relevant to the lifting/lowering pot. 2 and % compared to the value at rest 1 ST TILLER SW. State of the tiller sensor 1 input 2 ST TILLER SW State of the slow running buttons with "tiller always ON" input FORWARD SWITCH State of the running-to-the-operator triggering signal BACKWARD SWITCH State of the running-to-the-fork-arms triggering signal CUTBACK SWITCH 1 State of the speed decrease 1 input (SR1) TRACTION STOP State of the traction-stop-from-electric-drive input

Displayed Value

##V ##V ##A ##A ##V ##c° ##V-##% ##V-##%

##V-##% ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Name

Description

State of the tiller safety device button input State of the lifting microswitch (Distributor) input or of the lifting tripping from second tiller butterfly LEVER DESC. SW State of the lowering tripping signal from second tiller butterfly LIFT SW. 1 State of the lifting button input from tiller DESC. SW. 1 State of the lowering button input from tiller LIFT SW. 2 State of the lifting button input from tiller DESC. SW. 2 State of the lowering button input from tiller LIFT BLOCK State of the lifting limit stop sensor input PLUG INPUT Status of the rectifier mains presence relay contacts input HORN SWITCH State of the horn button input SPRING RGT SW. State of the hydraulic-unit-opposite-side sensor input, paired off with the hydraulic pivoting wheel management SPRING LFT SW. State of the sensor input on hydraulic unit side, paired off with the hydr. pivoting wheel management FLOOR PLATE UP State of the vertical platform sensor input ON/OFF FLOOR PLATE DW State of the horizontal platform sensor input ON/OFF SIDE GATES State of the side panel position sensor input ON/OFF OIL LEVEL LOW State of the pivoting wheel circuit oil level sensor input SELECTOR #1 State of the SEL.1 input (Program encoding) ON/OFF SELECTOR #2 State of the SEL.2 input (Program encoding) ON/OFF SLOW LIFT SP SW1 State of the slow lifting button 1 input ON/OFF SLOW LIFT SP SW2 State of the slow lifting button 2 input ON/OFF EXT. LIFT BLOCK State of the lifting stop input of the indicator - hour counter instrument EV. SPRING RGT State of the valve managing the right pivoting wheel on hydraulic unit side EV. SPRING LFT State of the valve managing the left pivoting wheel on hydraulic unit opposite side BATTERY CHARGE State of the battery charge (percentage)

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

BELLY SWITCH LEVER LIFT SW.

Displayed value ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF

ON/OFF ON/OFF

ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ##%

Accelerator Voltage Programming Access the PROGRAM VACC menu, where you can program the accelerator voltages values that the COMBI recognizes as ceiling and floor values. The operation should be performed for both running directions.

Now letís look at travel in the forks direction: press ENTER to display.

VACC 0.6

SETTINGS 4.8

The voltage values corresponding to the peak conduction for the running towards the fork arms or towards the operator are displayed.

If the values are correct, press OUT to exit without making any change.

Press ENTER to change the preset values. MIN VACC MAX 0.6

----

0.0

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System The traction is disabled: perform a running operation towards the fork arms and slowly turn the accelerator at full speed and then slowly release it.

N.B. Sudden accelerations may provoke errors.

After the adjustment, press OUT to confirm. The display shows : ARE YOU SURE? YES=ENTER NO=OUT Press ENTER to confirm the change or OUT to exit without saving.

In any case, you will go back to the starting page.

N.B. The whole operation is to be repeated also for the running towards the operator.

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Stored Alarms Access the ALARMS menu, where the last four stored alarms of the equipment are displayed. Next to the alarm message, the number of times that this alarm occured is shown, as well as the working hours of the system and the system temperature at that time (the O°C message means that this alarm occured when the truck was switched on). (the indication 0°C shows that the alarm in question appeared when the truck was switched on).

Configurations Access the CONFIG menu, the following sub-menus are displayed: 1. SET MODEL (not available) 2. SET OPTIONS 3. ADJUSTMENTS Adjustments Access the ADJUSTMENTS menu, the following presettings may be adjusted : ADJUST. BATTERY : It enables to set the battery voltage value. Press ENTER to select the function, the 0.2V step value may be changed by pressing the SET and RESET keys. Once the correct value has been reached, it may be confirmed by pressing OUT and then ENTER. MIN.ACC.LIFT: (0V) It enables to set the minimum voltage value of the lifting potentiometer. Press ENTER to select the function, then, leaving the lever at rest, the value may be confirmed by pressing OUT and then ENTER. MAX.ACC.LIFT : (5V) It enables to set the maximum voltage value of the lifting potentiometer. Press ENTER to select the function, then, holding the lever at full lifting, the value may be confirmed by pressing OUT and then ENTER. MIN.ACC.DESC.: (0V) It enables to set the minimum voltage value of the lowering potentiometer. Press ENTER to select the function, then, leaving the lever at rest, the value may be confirmed by pressing OUT and then ENTER. 14

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Additional Functions It is a set of available functions, which are additional or alternative to standard functions.

Access the SET OPTION menu : HOUR COUNTER: Å RUNNING (The calculation of the hours by the indicator - hour counter instrument starts, when a pump or traction function is requested) Å KEY ON (The calculation of the hours by the indicator - hour counter instrument starts, when the truck is switched on) LIFT BLOCK : Å ABSENT = The lifting limit stop sensor is considered absent by COMBI Å PRESENT = The lifting limit stop sensor is considered present by COMBI QUICK INVERSION: Å BELLY = When the tiller safety device button is pressed, the inversion is continuous Å TIMED = When the tiller safety device button is pressed, the inversion is timed (it lasts only for a given delay) PROPORTION LIFT: Å PRESENT = The lifting/lowering potentiometer that is paired off with second tiller butterfly is considered present by COMBI Å ABSENT = The lifting/lowering potentiometer that is paired off with second tiller butterfly is considered absent by COMBI BRAKE IN QCK. INV: Å ON = When the tiller safety device button is pressed, the quick braking by the electromagnetic brake occurs Å OFF = When the tiller safety device button is pressed, the quick inversion occurs BRAKE IN RELEASE: Å ON = The braking by the electromagnetic brake starts, when the accelerator is fully released Å OFF = The braking by the electromagnetic brake is disabled, when the accelerator is fully released EV TYPE : Å NONE = The controlling of any valve on the COMBI X1:5 output is disabled Å OPTION #1 = The controlling of the lowering proportional valve is enabled Å OPTION #2 = The ON/OFF-type controlling of the lowering valve is enabled Special Adjustments Access the menu, the following sub-menus are displayed : Å SPECIAL ADJUST. Å HARDWARE SETTING Å READ RAM Å READ EEPROM Å CLEAR EEPROM Å CLEAR CONSOLE NOTE: Read RAM and EEPROM enable to read the contents of certain memory cells; Clear EEPROM and Clear Console enable to cancel the memories of the system (the first control) and of the console (the second control) that it is better not to execute.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

Special adjust.

The following presettings are available : SET TEMPERATURE SET TEMPERATURE: It enables to set the temperature value of the system power board at a 1°C step. Once the function has been selected, the actual value may be changed by means of the SET UP or SET DOWN keys on the console.

Hardware Setting The following presettings are available:

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

SET CURRENT : It enables to set the maximum armature current delivered by COMBI. Once the function has been selected, the actual value may be changed by means of the SET UP or SET DOWN keys on the console.

SET FIELD CURRENT: It enables to set the maximum field current delivered by COMBI. Once the function has been selected, the actual value may be changed by means of the SET UP or SET DOWN keys on the console.

Alarms NOTE: the letter ìBî next to the alarm means that this alarm stops the truck.

Therefore, if this alarm appears when the truck is switched on, it does not enable to close the power contacts of the emergency button, whereas if this alarm occurs when the truck is running, it opens the power contacts of the emergency button.

Legend: P.E.=Emergency Button

ALARM EVP NOT OK (B) Anomalous absorption of the lowering proportional valve coil EB DRIVER KO (B) The voltage of the brake coil control driver is not correct VFIELD NOT OK (B) The field voltage is not correct SERIAL ERROR #1 (B) Lack of message transmission from the tiller card to the COMBI

PROBABLE CAUSES Å The valve is not connected Å The coil is not consistent with the project specifications Å Coil resistance is too high Å Brake not connected

CORRECTIVE ACTION Å Check the proper supply of the coil Å Replace the valve Å Check brake connection Å Renew brake

Å The field cables are disconnected Å Check the field connection Å The serial cables are cut off Å The battery voltage is very low Å The tiller card is ko Å The system is ko

Å Check the cables Å Check the battery voltage Å Replace the tiller card Å Replace the system

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Electrical System ALARM PROBALBLE CAUSES CORRECTIVE ACTION • Possible cancellation of • Replace the system EEPROM KO the EEPROM • Perform a CLEAR (B) Communication problems with EEPROM or • Defective EEPROM EEPROM in the parameter reading during the startup stage • When it occurs when • Check that the PUMP ACC. NOT OK switching the truck on potentiometer value at (B) Incorrect voltage of the lifting potentiometer when so that the P.E. does rest not close, probably the • Replace the potentiomelifting/lowering requests are lacking startup sequence is ter incorrect • Incorrect operation of • Replace the system MICRO CONTROL KO (B) the control microswitch • VMN value at rest • Replace the system VMN NOT OK (B) Incorrect armature different from the • Check the proper opera battery voltage tion of the motor voltage value • Non-decreasing VMN value when the motor PWM increases during running • Broken P.E. • Check the proper opera CONTACTOR CLOSED • Broken system tion of the P.E. (B) At startup, the P.E. contacts are already stuck in • Replace the system the closing position OPEN CONTACTOR • The P.E is not • Check the connection of the P.E. (B) Emergency button power connected • The microcontroller opens the • Check current absorpcontacts opened by the microcontroller P.E. contacts because of tions detected anomalies I TR.=0 (EVER) • Disconnected motor • Check the connections • Broken current sensor • Replace the system (B) Null traction current during running or braking HIGH I TR. ST. BY • Wrong reading of the • Replace the system current sensors (B) High rotor current (running or braking) at • Anomalous current flow towards the traction motor startup or during the traction rest state • Wrong reading of the • Replace the system current sensors HIGH FIELD CURRENT (B) High field current at • Anomalous current flow towards the traction motor startup or at rest NO FIELD CUR. • The P.E. coil is not connected (B) Lack of field current when the traction function is • The motor field is not connected claimed or during the monitoring stage of the traction rest state

• Check the connection of the P.E. Coil • Check the proper connection of the field power cables

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

ALARM CAPACITOR CHARGE (B) Impossibility to charge the battery condensers of the COMBI power unit

. The chopper temperature is ?7¡ÆC (when a performance drop is observed) or over 90¡ÆC (if the truck is stopped) . Low battery BATTERY LOW The lifting is stopped as the . Regular operation . Broken P.E. control battery is low circuit CHARGING BATTERY . The traction accelerator (B) The battery is being voltage value is higher recharged by the built-in than the preset minimum rectifier at rest CONTACTOR DRIVER . The oil level in the (B) The closing of the P.E. pivoting wheel circuit is power contacts during the too low synchronization stage is .

Broken oil level indicator not detected . When it occurs as a TR. ACC NOT OK function is requested, (B) The accelerator voltage probably the sequence is value is incorrect incorrect NO OIL . When it occurs as the (B) truck is switched on, the INCORRECT START P.E. contacts are not Incorrect sequence when opened the truck is switched on or Short circuit on valves when some function is Short circuit on TG. started up Short circuit on EVP. POWER FAILURE 1 Short circuit on F.E.M. 1) Short circuit on outputs Short circuit on main SHORT CIR.DRIVER contactor driver (B) drive request phase FORW + BACK Double drive request (B) Incorrect sequence during drive request phase

Version : April 2003 (Replaces version : )

TH. PROTECTION Thermic protection on the chopper

Copyrighted. Reproduction in any form forbidden Copyright reserved.

PROBALBLE CAUSES . Possible short-circuit on the outlets . Disconnected traction motor armature

CORRECTIVE ACTION • Check the lack of short circuits on the outlets • Check the proper connection of the trac tion • Switch the truck off and let it rest till the temperature lowers under the limit • Recharge the battery • No corrective action • Check the proper opera tion • Replace the potentiome ter • Replace the system • Perform the program VACC • Check the lack of lea kages • Replace the oil level • Check that one or more of the following devices are not B. Traction or lifting/lowering • Check wiring and Double drive request • Check wiring and • Renew tiller board.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Parameter setting (standard) MODEL

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

PARAMETER CHANGE

MODEL

EGU 30

ACCELER DELAY

2

DECELER DELAY

7

RELEASE BRAKING

0

INVER. BRAKING

9

!

CUTBACK SPEED 1

9

!

CUTBACK SPEED 2

9

!

CUTBACK SPEED 3

9

CREEP SPEED TR

0

SOFT WORKING

5

!

MAX SPEED FORW

5

!

MAX SPEED BACK

4

!

MAXI TRACTION

9

!

ARMA NOM CURR

9

!

WEAK DROPOUT

9

!

FIELD CURR MAX

9

!

FIELD NOM CURR

8

PU ACCELER DEL

0

PU ACCELER DEL

0

LEVER LIFT SPEED

9

LIFT SPEED

9

DOWN SPEED

5

SLOW LIFT SPEED

5

CREEP SPEED PUMP

0

EV. ECCELER DEL

5

EV. DECELER DEL

5

MIN DESC EVP

5

MAX DESC EVP

5

MIN DESC EVP FINE

5

MAX DESC EVP FINE

5

AUXILARY TIME

5

value of field nom curr with parameter at 0 and parameter field curr max at 0

6,5 A

value of field nom curr with parameter at 9 and parameter field curr max at 9

18 A

ADJUSTEMENTS

EGU 30

ADJUST. BATTERY enables entry of battery voltage value

X

MIN. ACC. LIFT (0V) enables entry of minimum lift potentiometer voltage value MAX. ACC. LIFT (5V) enables entry of maximum lift potentiometer voltage value MIN. ACC. DESC. (0V) enables entry of minimum descent potentiometer voltage value MAX. ACC. DESC. (5V) enables entry of maximum descent potentiometer voltage value SET STEER MIN (0V) enables entry of minimum voltage value related to position of drive wheel.

SET STEER max (5V) enables entry of maximum voltage value related to position of drive wheel.

SET STEER o-pos (2,5V)

maximum voltage value related to position of drive wheel when it is parallel to fork arms

parameter not effective

parameter to adjust during test phase

Version eprom zapi : picox 036

!

warning : modification to this parameter may impair safe use of the machine

CODE : 452206030 19

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Parameter setting (standard) MODEL

SET OPTIONS

EGU 30 4526

HOUR COUNTER RUNNER

MODEL

HARDWARE SETTING

EGU 30 4526

SET CURRENT x

300 A

KEY ON

x

200 A

LIFT BLOCK

SET FIELD CURRENT

PRESENT

x

A

28

ABSENT !

QUICK INVERSION BELLY

x

Version : April 2003 (Replaces version : )

TIMED PROPORTION LIFT PRESENT ABSENT !

X

BRAKE IN QCK INV ON OFF

!

X

BRAKE IN RELEASE

Copyrighted. Reproduction in any form forbidden Copyright reserved.

ON OFF EV. TYPE NONE OPTION #1 OPTION #2

X

ALWAYS CHECK EPROM VERSIONS

CODE : 452206030

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

COMBI System EPROM Replacement

Version : April 2003 (Replaces version : )

Using a cross screwdriver, unscrew the securing screws of the inspection cover.

Remove the inspection cover.

Remember that the seal gasket should be placed in the same position during closing.

Gasket

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Inspection Cover

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

In order to remove the EPROM, use the suitable extractor for integrated circuits.

Put the extractor hooks under the narrower sides of the EPROM. Slightly press the extractor arms and slowly pull outwards.

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

From the inspection hole, it is possible to see the COMBI system EPROM.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

It is possible to self-manufacture the integrated circuit extractor, using a metal strap stripe having the following dimensions:18X1 cm.

Bend the ends of the stripe at 90° for 5 mm, then insert it into a piece of thermoshrinking 16cm-long sheath.

Heat the thermo-shrinking sheath so that it sticks to the metal stripe surface.

Finally, U-bend the central part of the metal stripe.

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

The EPROM will remain trapped by the extractor arms.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

During the assembling stage of the new EPROM, carefully place the reference notch that is carved on the EPROM casing so as to fit in the notch that is carved in the visible serigraph of the printed circuit.

Begin the assembling by inserting first the lower row of EPROM pins into the base. Then, slightly pushing downwards, align the upper row of pins with the base pins and fully insert them.

Warning: check that all the EPROM pins have been perfectly inserted into the base.

Reference Notch

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Version : April 2003 (Replaces version : )

Reference Notch

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Version : April 2003 (Replaces version : )

COMBI System Input/Output Diagram

2Y1 1Y1

151 753

Copyrighted. Reproduction in any form forbidden Copyright reserved.

754

charger switch

251

Drawing n° 45 260 6008

25

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08 Electrical System

Electric System Sheathes and Connectors

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Drive Controller

26

QS1

Copyrighted. Reproduction in any form forbidden Copyright reserved.

1S1

1Y1

2Y1

Version : April 2003 (Replaces version : )

2S1

4H1

6P1

S1

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

27

FU3

7K1

G2

A3

FU2

2M1

S1

6P1

A3

4H1

7K1

1Y1

1S1 2S2

2Y1

Version : April 2003 (Replaces version : )

7S4

7S3

4S1

1R1

A4

7S1

2S5 2S4

2S2 2S3

Wiring Diagram

Drawing 452606010 B

QS1

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

28

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Legend to wiring diagram A1/A2 A3 A4 F1/F2 FU1 FU2 FU3 G1 G2 4H1 1M1 2M1 6P1 QS1 S1 1S1 2S1 2S2 2S3 2S4 2S5 4S1 7S1 7S2 7S3 7S4 1R1 1Y1 2Y1

Drive Motot Armature Electronic Control (COMBI) Tiller head Drive Motor Field Power fuse (300A) Electronic fuse (5A) Auxiliary fuse (10A) Battery Built in charger Horn Drive Motor Lift pump motor Battery low indicator + hour counter (BDI) Emergency switch pushbutton Key switch Tiller Sensor Lift end sensor Upper RH lift pushbutton Upper LH lowering pushbutton Lower LH lowering pushbutton Lower RH lift pushbutton Horn pushbutton Tiller safety pushbutton (Belly switch) Battery Door Switch (optional) Lower RH slow speed drive pushbutton (optional) Lower LH slow speed drive pushbutton (optional) Tiller drive potentiometer Electromagnetic Brake Lowering electrovalve

Legend to Connector X1 X2 X3 X4 X5 X6 X8 X9 X10 X11 X12 X13 X14 X15

42-pole SAAB connector 8-pole SAAB connector 8-pole MOLEX connector 4-pole MOLEX connector (optional) 8-pole MOLEX connector 10-pole SAAB connector 10-pole SAAB connector Terminal BBatt. Terminal +24V Terminal B+ Terminal - l Terminal - P Terminal F1 Terminal F2

X16 X17 X18 X19 X20 X21 X22 X23 X24 X25 X26 X27 X30 X32 X34 X35 X41 X42 X43 X44 X45 X46 X47 X48 X49 X50 X51 XA XB XBS XC XD XE XF XG XJ XK XL XM XN

Plug-socket DIN 43 650-PG9 Connector QS1 Terminal QS1 Terminal QS1 Contact : -BOB Terminal QS1 Contact : +BOB Termina QS1 Contact : Microswitch QS1 Contact : Microswitch S1 Contact : direct S1 Contact : ritorno 4H1 Contact : (-) 4H1 Contact : (+) FU3 Contact FU2 Contact Contact 7S2 : MAINS Contact 7S2 : BTerminal 1M1: +24V Terminal 1M1: -B Terminal F1Drive motor Terminal F2Drive motor Terminal 2M1: +24V Terminal 2M1: -B Battery Terminal : + Battery Terminal : 3- way Female Contact (rectifier) Cables without connector (rectifier) Schuko Plug 2-pole Connector 2-pole Connector Sodered terminals 2-pole Connector 2-pole Connector 4-pole Dupont Dubox Connector 2-pole Connector 2-pole Connector 4-pole Dupont Dubox Connector 2-pole Connector 2-pole Connector 2-pole Connector Soldered Cables without Connector

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Tiller card diagram

View from potentiometer side

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

XO

XA XB XC XD XE XF XG XJ XK XL XM XN

desciption slow lift button lift button lowering button slow lift button lift potentiometer LH drive button :slow drive button lowering button drive potentiometer lift button horn button RH drive button/overbooster button cable-card connections

PIN 1 2 3 4

XJ Description BPOT 2 +5V DC POT 1

PIN 1 2 3 4 5 6

XN et XO Description +24V DC - BATT CPOTT 2 DRFT Belly switch CPOTS2

PIN 1 2 3 4

XE Description POT1 + 5V DC POT2 B-

Drawing 452249553 30

Pos a b c d e

Tiller cable harness diagram

Version : April 2003 (Replaces version : )

description Contact male grommet Contact female Rubber cap for SAAB and JP timer Rubber seal for SAAB 10 pole

Drawing 452649101

Pos a b c d e

description connector SAAB 10 pole connector MOLEX 6 pole connector MOLEX 4 pole Cable 12 x 0.5 cable clamp

Cables n°11 and yellow-green wire of the sheath must not be cut, but clamped to the sheath itself Connectors X3 and X4 be supplied pre-wired.

Connector X8 and seal E must be supplied in a separate pack.

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System

Batteries The battery compartment was designed to house batteries complying with DIN 43535 standard, as well as batteries with oversize cells complying with EN 60254-2 standard.

These liquid-electrolyte lead-acid storage batteries are (all) available in two versions : standard (with manual topping up) and with automatic topping up.

They are contained in ìboxî containers that are lined inside with an acid corrosion-proofing material, which constitutes an electrical insulation coating. These containers are externally coated with special antiacid coverings. As the battery compartment is closed by the cover, no speficic colour was required (RAL), therefore, the containers are painted with the supplierís standard colour.

Battery Dimensions and Weights Battery General Specifications

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Version : April 2003 (Replaces version : )

Battery

Code

Voltage Capacity

V

Ah

Dimensions

mm

Length x Width

DIN 43535 References Weight

kg ±5%

EN 60254-2 References

Element Element

Element

Diagram Abbreviation

Version

Terminals

and Type

x Height

Small DIN Small DIN Large DIN Large DIN

89428013

24

220 624x212x627

212

B

2 PzS 220 L LF

screw

89428019

24

250 624x212x627

220

B

-

LF

screw

452228011

24

330

624x284x627

288

B

3 PzS 330 L LF

screw

452228014

24

375 624x284x627

305

B

-

screw

LF

Battery Connectors (Socket and Plug) The connectors used comply with the DIN 43568 and FEM 4007a and 4007b standards, and they withstand a rated current of 160A. They are housed under the cover closing the battery compartment and they are placed on the battery (for all the versions).

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Battery Replacement The battery can be replaced in the following ways: Å Vertical Extraction/Introduction (Standard) Å Side Extraction/Introduction (Optional) Å Battery vertical extraction : The side extraction of the battery is available as an optional : (The bottom of the battery compartment is equipped with rolls, the side panel 1should be removed in order to reach them)

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Version : April 2003 (Replaces version : )

1

Battery Fixed / Movable Rack (Optional) Fixed rack : It is a metal frame equipped with rolls and with an adjustable safety stop to lock the battery in the right position. This rack was designed to carry a single battery.

No. 2 fixed racks are required in order to perform the battery change.

Movable rack : Its frame is similar to the fixed rack. It is mounted on a suitable transpallet and is equipped with an adjustable safety stop to lock the battery in the right position. The transpallet lifting device is used in order to make the height adjustment of the rolls easy. This rack was designed to carry a single battery.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System Vertical battery removal Extract the battery vertically using an overhead travelling crane. The battery must be attached to lifting ropes.

Check that the breaking strength of the ropes is greater than the total weight of the battery.

Check that the connection bars between the battery elements are fitted with the insulating cover.

Take care not to short circuit the battery terminals.

After removing the battery, position it well clear of the work area.

Installing the battery

Version : April 2003 (Replaces version : )

While installing the battery pay attention to cables and connectors ; these parts must be positioned outside the battery compartment to eliminate the risk of them being severed by shearing action during the insertion of the battery.

After inserting the battery into the compartment, position the retaining pads between the case and the compartment, arranged in a triangular formation.

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Battery retaining

Battery terminals located on LH side facing the forks side

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Accessories

Contents

Page

Battery Descharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

09 Accessories

Battery Descharge Indicator (B.D.I) The Indicator ñ Hour Counter instrument : Å Shows the truck operation time (running or lifting/lowering), which is expressed in hours (Running). Otherwise, it is possible to pair off the count cut-in with one setting of the start-up switch only, that is to say with the ìlî setting (Key on). Å Shows the battery charge level, by displaying it on a coloured 10-led row. Å Shows that the start-up switch is on ìlî setting, by switching the led row on. Å Stops the lifting operation when the battery is by 80% down.

Version : April 2003 (Replaces version : )

A)Hour Counter Display : When the hour counter is working, the hourglass on the left side of the display blinks (15 times per minute approximately).

Five digits and one place of decimals are displayed. Starting from zero, the numbering progressively increases.

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1-2 Red leds 3-4-5 Yellow-orange leds 6-7-8-9-10 Green leds

B) Led-row indicator relevant to the battery charge state : Å When the battery is 100% charged, only the led 10 is on.

Whereas, while the battery is running down, the leds switch on one at a time, from right to left. Å When the battery is by 70% down, both leds 1 and 2 blink at the same time, which means that the battery should be recharged (low). Å When the battery is by 80% down, both leds 1 and 2 alternately blink, which means that the lifting stop threshold has been reached. Å This instrument has a fixed recovery voltage threshold, therefore, the shift from the totally or partially low battery indication to the 100% charged battery indication occurs only if the voltage applied is >25.1 V (Figure supplied by the manufacturer).

Thus, you need to keep in mind that when you replace a totally low battery with a partially low battery (having a voltage < 25.1 V), the instrument does not show the change of charge, but keeps on displaying the previous charge level.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

09 Accessories

Trimmer figure

Table of the instrument reference voltages, when the battery is by 80% down, with regard to the trimmer letters : K 1.57 V for each cell (factory setting) L 1.65 V for each cell M 1.68 V for each cell N 1.73 V for each cell (lead battery setting) O 1.78 V for each cell P 1.82 V for each cell Q 1.84 V for each cell R 1.86 V for each cell S 1.89 V for each cell (gel battery setting) T 1.91 V for each cell U 1.93 V for each cell

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Version : April 2003 (Replaces version : )

The discharge trimmer should be set on the K setting.

Recovery CURTIS 803 has a fixed recovery threshold that is set by the manufacturer.

The following two kinds of recovery are possible: Å When the battery is disconnected during its charge, CURTIS 803 will recover if the battery voltage is equal or higher than 2.09 V for each cell. Å When the battery keeps being connected to the equipment during its charge (for example: battery charger installed on the equipment), CURTIS 803 will recover when the battery voltage reaches 2.35V for each cell.

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Hydraulics

Contents

Page

Lifting Lowering and Interlock Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Unit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3,000 Kg Hydraulic Lifting Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor-Driven Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor-Driven Pump Unit Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Cylinder Overhauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Cylinder Assembly Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Cylinder Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Unit Topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01 01 02 03 05 06 09 13 13 14 15

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

Lifting, Lowering and Interlock Devices As for the lowering function, there is no interlock (Only in the event of a COMBI defect).

The lifting and lowering enabling occurs by pressing the relevant tiller pushbuttons.

In the following operating conditions, lifting is blocked : Operator Actual Manoeuvre Blocked Lifting

Continuous use of the battery till the limit fixed by the manufacturer that is equal to an 80% down battery. (Low-battery lifting block) Lifting return when fork arms already reach the electric limit stop height Disconnected connector of the indicator - hour counter COMBI blocking alarm

As to lifting and lowering speeds, please refer to the specifications sheet.

The hydraulic unit motors have the following features : Å Power supply voltage: 24 V DC Å Power: 1.8 kW for the 3,000 kg type (Compound excitation)

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Version : April 2003 (Replaces version : )

Hydraulic Unit Motor

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

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Version : April 2003 (Replaces version : )

3,000 Kg hydraulic lifting diagram

Fonction

Pump Motor 2M1

Electrovalve 2Y1

Lifting

ON

OFF

Lowering

OFF

ON

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Hydraulics

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Version : April 2003 (Replaces version : )

Motor-driven Pump Removal

By means of a screwdriver, unscrew the retaining screw of the nipple of the 2Y1 lowering solenoid valve.

By means of a wrench, unscrew the hydraulic fittings of the unit.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

Using a bridge crane and strictly complying with the instructions reported in the ìBatteryî Section, remove the battery from the compartment.

By means of a ratched wrench, unloose the securing screws of the unit that may be reached through the battery compartment. The motor pump unit will remain hanging on its support.

Lift the hydraulic unit by holding it firmly with your hands, so as to release the screws from the support. Then, lower it towards the pivoting wheel, rotate the upper part outwards and pull it out of the motor compartment. Once the hydraulic unit has been removed, it will be possible to perform all required operations.

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Version : April 2003 (Replaces version : )

Screw Inlet Holes

04

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

Motor-driven Pump Unit Assembling

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Version : April 2003 (Replaces version : )

First insert the upper part of the hydraulic unit by passing under the bonnet support. Hold the hydraulic unit firmly with your hands.

Once the hydraulic unit has been inserted into the motor compartment, lift it so as to hook the securing screws of the support.

Warning: the screws should be rather unloosen so that the support may be inserted between the washers and the unit casing.

Tighten the securing screws with a torque of 12Nm. Perform the assembly of the pipes, the electric cables and the L.E.S. system by following the previously described procedure but in a reverse manner.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Hydraulics Lifting Cylinder Removal Remove the battery and place it on the plug side, close to the battery compartment. Connect the plug, switch the truck on and lift the fork arms at such a height so as to be able to insert the hydraulic lifting jack under the battery compartment. Switch the truck off, disconnect the plug and range the battery in a safe place.

Remove the bonnets.

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Version : April 2003 (Replaces version : )

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

Battery Hydraulic Lifting

By means of the hydraulic lifting jack, lift the movable frame. Insert some safety wood beams under the battery compartment.

Discharge the hydraulic lifting jack by making the movable frame rest on the wood beams. The lifting cylinder pins are lightened. For safety reasons, it is advisable to leave the hydraulic lifting jack slightly pushed under the battery compartment.

Safety Wood Beams

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

Remove the safety elastic washers that are placed on the external side of the lifting cylinder pins.

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Version : April 2003 (Replaces version : )

Remove the hydraulic unit by following the ìMotor-driven Pump Unit Removalî procedure above.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

Place some rugs to drop the oil under the fittings of the lifting cylinders.

By means of the suitable wrench, passing through the inlet hole that is cut in the battery compartment, unscrew and remove the fittings of stiff pipes.

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Version : April 2003 (Replaces version : )

Inlet Hole

Using an articulated Allen wrench, unscrew and remove the securing screws of the lifting cylinders.

In the event that it is not possible to reach the screws, especially the lower ones, by means of the articulated wrench, rather use an Lwrench.

By means of the hydraulic lifting jack, lift the movable frame till the upper lifting limit stop.

Warning: Add some more wood beams in order to reduce to a minimum the shift of the movable frame in case of lowering due to a wear of the inner gaskets of the hydraulic lifting jack.

Remove the lifting cylinders by shifting them from their support seat.

First remove the upper part through the holes of the fixed frame.

Now, the cylinders may be overhauled.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

Lifting Cylinder Overhauling

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Version : April 2003 (Replaces version : )

Clamp the lifting cylinder in a vice that is suitable for its supports.

By using a patent blowpipe ñ it is better to use an electric hot-air device -, heat the plug in order to soften the thread-locking adhesive.

By means of a caliper wrench, unscrew and remove the plug from the cylinder barrel.

In the event that the thread-locking adhesive is too strong, use a pipe wrench in order to unscrew the plug by clamping it on its edge.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

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Version : April 2003 (Replaces version : )

The cylinder plug is equipped with an O-ring.

When the O-ring is broken, excessively squashed or too rigid, replace it.

Take the suitable extraction tool and screw it inside the threaded hole at the foot of the stem. By pulling, seizing the handle and pushing the stem head, pull it out of the barrel. The tool will also be useful in order to keep the stem inside its slide, avoiding any friction of the chromium-plated surface with the internal part of the barrel.

See the “Notes for the Technician” Section as for the manufacturing of the tool.

During the extraction of the stem, hold it with one hand.

Once the stem has been pulled out of the barrel, place it on a soft surface or on some V-grooved wood beams.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

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Version : April 2003 (Replaces version : )

Clamp the stem in a vice, by interposing between the stem and the jaws two aluminium angular elements.

By means of a spring collet - for instance, the one used for safety elastic washers - widen the stop ring by making it slide along the stem edge.

In the event that tools are worse, using cutting nippers, clamp the stop ring and remove it from its housing, making it slide along the stem edge.

By means of a flat-end screwdriver, lift the scraper by pulling it out of the barrel.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

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Version : April 2003 (Replaces version : )

By means of a punch, lift and remove the O-ring that is placed over the gasket.

Using a flat-end screwdriver, lift and remove the gasket from its own housing.

Once all the different components of the lifting cylinder have been degreased, check their working order and replace the worn out ones.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

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Version : April 2003 (Replaces version : )

Lifting Cylinder Assembly

Lifting Cylinder Assembly Table

7 6 5 4 3 2 1 ITEM

Cap O-Ring Retainer ring Tube stem Gasket Scraper DESCRIPTION

1 1 1 1 1 1 1 Q.TY

REMARKS

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Hydraulics Lifting Cylinder Assembling

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Version : April 2003 (Replaces version : )

Before starting the lifting cylinder assembling, check the internal surface of the barrel.

There should be neither cracks in the material, nor grooves in the support seats of gaskets.

Start inserting the gasket, by pressing it on its external edge. If it is too stiff, soften it with hot water.

Warning: before the assembling, check that the groove of the gasket is turned towards the scraper.

Insert the O-ring over the gasket.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

Insert the scraper by pressing it on its external edge. If it is too stiff, soften it with hot water.

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Version : April 2003 (Replaces version : )

Warning: the scraper lip should protrude outside the barrel.

Using the file in order to restore the threads, which should have a pitch equal to the plug, remove the rest of the thread-locking adhesive.

Blow with compressed air.

Apply a grease film on the cylinder barrel gaskets.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

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Version : April 2003 (Replaces version : )

Using the file in order to restore the threads, which should have a pitch equal to the threading of the plug, remove the rest of the threadlocking adhesive.

Blow with compressed air.

Apply a grease film on the O-ring housing that is built in the plug.

Place the O-ring on its seat, making it adhere with the surface.

The grease serves as an adhesive for the O-ring during the assembling.

By means of very fine grain rubbing paper, grind the surface of the stop ring if it has been grooved during its extraction from the stem.

Warning: never grind the chromiumplated surface of the stem for any reason.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

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Version : April 2003 (Replaces version : )

Screw the stem introduction tool in the threaded hole.

Insert the stem into the barrel, being careful not to cause heavy frictions with the barrel.

When the stem reaches the gaskets, hit the tool handle with your hand palm with small strokes.

During this operation, hold the stem aligned with the barrel.

The stem will be introduced in the gasket block.

Apply some medium thread-locking adhesive on the threading of the plug.

Screw the plug to the barrel. Screw and unscrew it several times in order to make the thread-locking adhesive uniform.

By means of the caliper wrench, screw the plug to the barrel until its stop.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

10 Hydraulics

Version : April 2003 (Replaces version : )

Hit the caliper wrench by means of a soft-surface hammer in order to tighten the plug.

During the assembling stage of the lifting cylinder unit, once the stiff pipe has been placed and the fittings have been screwed, interpose a screwdriver between the bending of the stiff pipe and the cylinder support, by passing through the inspection hole. The screwdriver serves as a spacer.

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Warning: every time that the lifting cylinder fittings are removed, replace the sealing washers.

By holding the screwdriver in this position, tighten the fittings by means of a wrench.

Warning: if you forget to perform this operation, the stiff pipe will remain propping against the fixed frame and, during the lifting operation, the vibrations of the motor-driven pump will be transferred to the frame and a peculiar noise will be heard.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Hydraulics Hydraulic Unit Topping up Remove the bonnet, when the truck is switched off.

Switch the truck on.

Completely lower the fork arms and unscrew the filling plug of the hydraulic unit tank.

The level is equivalent to the lowest point of the oil filling elbow pipe. Repeat the operation, if required.

Oil required

Standard

46 HM

Cold Store

DIN 51 524 HVLP 32

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Version : April 2003 (Replaces version : )

The plug is self-bleeding.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

11

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Motors

Contents

Page

Motor Brush Wear Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Minimum Diameter table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01 01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

11 Motors

Motor Brush Wear Table The replacement of the brush should be carried out when the brush length reaches : Traction Motor 2,5 kW Pump Motors 1,8 kW Tolerance

Residual Length (mm) 18 - 0 / + 20%

Manifold Minimum Diameter Table

Traction Motor 2,5 kW Pump Motors 1,8 kW Tolerance

Residual Diameter (mm)

- 0 / + 20%

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The replacement of the rotor should be carried out when the manifold diameter reaches :

01

28

Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Built-in Charger

Contents

Page

Built-in charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access comportment to the battery charges power supply cable . . . . . . . . . . .

01 01

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Built-in Charger Built-in Charger (Optional) The charger is mounted on the body, inside the motor compartment, and its socket can be reached through the suitable window cut in the cover.

Warning: Before charging the battery always switch off the truck.

The charger is equipped with an internal relay designed to detect the presence of the power supply and connected electrically to the COMBI system. The system provides the following operation :

Version : April 2003 (Replaces version : )

Operational condition Truck ON and rectifier powered

Operation Immediate interruption of power circuits by opening of the emergency button contacts

It is a battery charger having the following specifications: Å Power supply voltage: 230V +10/-15% AC Å Frequency: 50-60 Hz +/-1% Å Output rated current: 50A +/-2% Å Output rated voltage: 24V DC Å The plug is schuko type 2P+T 16A 250V Å The recharge time depends on the battery capacity: 7÷16 hours Å Inclusive of inner mains voltage pilot relay Data supplied by the manufacturer

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N.B. The built-in rectifier is not available for the cold-storage room version.

Access Compartment to the Battery Charger Power Supply Cable An access compartment to reach the built-in battery charger power supply cable may be provided on the bonnet.

In order to reach the power supply cable plug of the built-in battery charger, you should lift the suitable opening cut in the bonnet on one side (As shown in the Figure beside).

The plug lies within a special housing that is able to keep it fastened to the opening. In order to remove the plug, you should push it towards the opening and, at the same time, pull it upwards.

This procedure is easy and handy.

This compartment is not provided on the bonnet of the production truck.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Special tools

Contents

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Percussion Extrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Threaded Pins For Percussion Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tiller Spring Pre-reloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Cylinder Ectraction and Introduction Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EPROM Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Console for drive-hydraulic controller and interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 01 02 03 03 04 05

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Percussion Extractor

32

Special tools

01

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

32

Special tools

Threaded Pins for Percussion Extractor

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

32 Special tools

Lifting Cylinder Extraction and Introduction Tool

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Version : April 2003 (Replaces version : )

Tiller Spring Pre-reloading Tool

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

32 Special tools

EPROM Extractor

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Version : April 2003 (Replaces version : )

It is possible to self-manufacture the integrated circuit extractor, using a metal strap stripe having the following dimensions:18X1 cm.

Bend the ends of the stripe at 90° for 5 mm, then insert it into a piece of thermo-shrinking 16cm-long sheath.

Heat the thermo-shrinking sheath so that it sticks to the metal stripe surface.

Finally, U-bend the central part of the metal stripe.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

32 Special tools

Interface Console/truck for drive/ hydraulic controller part number : 0157205

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Version : April 2003 (Replaces version : )

Console for drive/hydraulic contoller part number : 4494118

05

Part 2 - EGV 20 EGP 14-20 Pedestrian stacker Pedestrian stradle stacker

STILL WAGNER STILL

33 0223 3 00001 EGV 20 33 0233 3 00001 EGV 20 LB 33 0227 3 00001 EGP 14 33 0228 3 00001 EGP 20

Workshop manual EGU 30 / EGV 20 / EGP 14-20

00 Generality

Version : Septembre 2003 (En remplacement de la version :

)

01 Chassis 03 Gear-Box 04 Wheels 05 Driving controls 07 Brake 08 Electrical system 09 Accessories

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10 Hydraulics 11 Motors 28 Built-in charger 32 Special tools

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Contents

Page

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forklift and Fork Arm Tolerance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forklift Vertically Tolerance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Tolerance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standards and Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator position (Pedestrian steering with use of the . . . . . . . . . . . . . . . . . . “tiller active in vertical position” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening Torques Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01 02 04 04 04 05 06 06 07 08 09

Workshop manual EGU 30 / EGV 20 / EGP 14-20

00

Generality

Description

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Version : April 2003 (Replaces version : )

• It is a wheeled transport vehicle • Its energy source is an accumulator battery • It has a tiller steering gear • It is a stacker truck with load bearing side members and is equipped with forks whose arms cover the side members.

• It is used to lift, to stack or to place in shelves loads whose weight and size are well determined, because of its construction.

This new range of tiller trucks has been planned in order to offer the operator a high degree of safety and comfort

01

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Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20 Generality

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Generality

DIMENSIONS PERFORMANCE EL.MOTOR AOB

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Version : April 2003 (Replaces version : )

WHEELS, CHASSIS WEIGHTS

FEATURES

EGV 20 DPX PAL

1.2 Model 1.3 Propulsor unit: electric, diesel, petrol, gas, electric mains 1.4 Drive: tiller, eased, standing, sitting, ordered 1.5 Capacity Load 1.6 Barycentre 1.8 Load distance from load gear axle with lifted fork arms 1.9 Wheelbase 2.1 Net weight (without battery) 2.2 Load with loaded axle (front/rear) 2.3 Load with empty axle (front/rear) 3.1 Solyd, super-resilient, tyre, polyurethane tyres 3.2 Front wheel dimensions 3.3 Rear wheel dimensions 3.5 Wheels: front/rear quantity (x=driving wheel) 1x-1 / 4 3.6 3.7 4.2 4.3 4.4 4.5 4.6 4.9 Tiller height in running mode (min/max) h14 (mm) 762 / 1232 4.15 Lowered fork arm height 4.19 Total lenght (platform up/down) 4.20 Length included fork arm shoulder (platform up/down) 4.21 Total width 4.22 Fork armsdimensions 4.24 Front width 4.25 External fork arm gauge 4.31 Clear span under the loaded mast 4.32 Clear span in the middle when loaded 4.33 Pallet working path 1000x1200 forking 1200 (platform up/down) 4.34 Pallet working path 800x1200 forking 800 (platform up/down) 4.35 Bending radiuses (platform up/down) 5.1 Translation speed (loaded/empty) 5.2 Lifting speed (loaded/empty) 5.3 Lowering speed (loaded/empty) 5.7 Surmountable gradient KB30' (loaded/empty) 5.8 Max surmountable gradient KB5' (loaded/empty) 5.10 Service Brake 6.1 Traction motor, performance KB 60' kW 1 6.2 Lifting motor, performance 15% ED kW 3 6.3 Battery according to British Standard / DIN 43531/35/36 A , B, C 6.4 Voltage /TRated capacity 6.5 Battery weight (+/- 5%) 8.1 Type of control 8.4 Noise of the truck operator’s ear

Q (t) c (mm) x (mm) y (mm) kg kg kg mm mm b10 (mm) b11 (mm) h1 (mm) h2 (mm) h3 (mm) h4 (mm) h5 (mm) h14 (mm) h13 (mm) l1 (mm) l2 (mm) b1 (mm) s/e/l (mm) b3 (mm) 680 b5 (mm) 570 m1 (mm) / m2 (mm) Ast3 (mm) Ast3 (mm) Wa (mm) km/h m/s m/s % % kW kW V / Ah kg dB (A)

ACCORDING TO VDI 2198 STANDARD EGV 20 Electric tiller (eased/standing) 2 600 706 1323 965 (2) 1018 / 2242 (4) 864 / 396 (4) polyurethane 230 / 120 85 × 70 1x-1 / 4 574 380 1977 - 2327 90 2900 - 3580 3407 - 4087 (5) / 762 / 1232 85 1956 (5) 794 (6) 860 61 / 200 / 1150 (1000) 680 570 / 29 2454 (6) 2421 (6) 1585 5/6 0,10 (2) / 0,17 (2) 0,30 (2) / 0,23 (2) 0.5%(2) (4) / 6,5% (2) (4) 2,8%(2) (4) / 9,0% (2) (4) (7) Electric 1 3 DIN cells 24 / 315 ( 375 ) 295 (302) Electronic <70

(1) data relative to mast with h3 = 4480 mm (2) data relative to mast with h3 = 3580 mm (3) with 240 Ah battery (4) with 315 Ah battery (5) with load backrest + 490 mm (6) with tiller active in vertical position - 45 mm (7) maximum gradeability unladen due to geometrical limitations of the truck (8) for masts with height up to h3=3600 mm inclusive

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Generality Fork Arm and Forklift Tolerance Table Reference to the data in the Specifications h1 h3 h13 s/e/l b5

0 / +10 mm ±15 mm 0 / +7 mm +3 / -3 mm +2 / -2 mm

Forklift Verticality Tolerance Table

Version : April 2003 (Replaces version : )

The forklift control should be performed with closed masts :

Forklift Longitudinal Verticality (towards the operator)

Forklift Transversality Verticality

Degrees (°)

Tolerance

1°

± 0,1°

Degrees (°) 0°

Tolerance ± 0,1°

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Speed Tolerance Table

(Reference to the data in the Specifications) Traction speed with no load 14 Traction speed with 1,400 kg Traction speed with no load 20 Traction speed with 2,000 kg Lifting speed Lowering speed

Tolerance +0 / -5% km/h +4 / -5% km/h +0 / -18% km/h +0% / -5% km/h ±5% m/sec.

0 /-10% m/sec.

Note : The times relative to the speeds were measured after allowing the gear reducer oil to warm up (approximately 1 hour of continuous traction).

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Generality Standards and certifications The EGV 20 truck complies with the Machinery Directive 98/37/EC, adapted to cover materials handling trucks with harmonised standards EN 1726 (For trucks with capacity of 10,000 kg or less and tractors with towing capacity of 20,000 N or less), EN 1551 (For trucks with capacity greater than 10,000 kg), prEN 1757 (For manual and semi-manual trucks with pedestrian operator). It also complies with the Electromagnetic Compatibility Directive 89/336/EEC and subsequent amendments, adapted for materials handling trucks by harmonised draft standard EN 12895.

Finally, it meets the requirements of standard prEN12053 concerning noise emissions (<70dB)

Version : April 2003 (Replaces version : )

As for the definition of Forward Running Direction, the ISO3691 standard states :

• By on-the-ground driving, forward running means the traction towards the operator Backward

Forward

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In order to be more clear, let us determine a single way to intend the running direction, by identifying it with the traction direction towards the fork arms or towards the operator, avoiding the forward and backward instruction, as shown in the figure below :

Running towards the fork arms

Running towards the operator

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Generality

Driving position

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Version : April 2003 (Replaces version : )

The "Tiller active in vertical position” function allows the operator to select travel (low speed) also with the tiller positioned vertically, with the following advantages : • Reduction of steering radius Wa • Capacity to work in smaller spaces Greater manoeuvring precision

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Generality

Working Environmental Conditions According to the working environment, the following two versions are available : • Standard • Cold-Storage Room (This version requires the use of special oils and greases)

Version : April 2003 (Replaces version : )

Working Environment for the “Standard” Version The standard version truck, special requirements excepted, has been manufactured in order to work in standard environmental conditions save outdoors with temperatures not higher than +40°C and not lower than +5°C. Its use in environmental conditions other than the standard ones implies the execution of special workmanships; the user, who intends to use the truck in an environment having peculiar features, should previously inform the manufacturer.

Beyond temperature, relative humidity is important: actually it is not possible to work with the standard version truck where humidity reaches levels so high as to produce condensate on protected parts (equipments, switches, contacts, etc.), which may prevent the perfect operation of the truck.

A high condensate also damages static parts, provoking a weakening of bearing frames.

Brackish air and/or water or any other corrosive substance in the working area are borderline conditions for the use of the truck and are regarded as dangerous.

WARNING : it is forbidden to use the standard version truck with environment temperatures higher than +40°C and lower than +5°C. Working Environment for the “Cold-Storage Room” Version

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Class 1 2

Use Temperature Min. Max. -5°C -10°C (For a 40°C short time) -32°C + 25°C + 40°C (For a short time)

Working Conditions Switching off outside the cold-storage room Alternate use inside and outside the cold storage room. Permanence outside at least until there is no longer any indensate (usually at least 30 minutes) or for such a short time so as to prevent the formation of condensate (usually max10 minutes).

Switching off outside the cold-storage room.

WARNING : it is strictly FORBIDDEN to use standard and cold-storage room trucks in areas where there are explosion-hazardous atmospheres, if the trucks either have not been designed or have not been properly modified so as to be used in such cases. Similar instructions should be complied with in the event of trucks working in dusty areas or where atmospheres are full of suspended fine dust particles.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Generality

MAINTENANCE OPERATIONS Description

As required

Battery

•

Electrolyte level and density inspection Load Intake Greasing of pull rods and levers Replacement of lever bushes Brake Check of the emergency stopping brake operation Replacement of the brake disk

Version : April 2003 (Replaces version : )

Adjustment of the emergency stopping brake Electric System

•

• • •

•

• •

Cleaning of electric motors Check of motor manifolds Replacement of traction motor brushes Replacement of lifting motor brushes (1.8kW only) Hydraulic System

• •

• •

Check of pipe conditions Check of the hydraulic system oil level Topping up of the hydraulic system oil

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Daily Work Hours Check 1000 2000 3000

•

•

Replacement of the hydraulic system oil Reduction Unit

•

Check of oil level Replacement of the oil Wheels and Gears Check of wheel conditions and wear Replacement of load gears Replacement of the driving gear Replacement of pivoting wheels

• • •

•

•

Note 1 : every hour 1000 / 3 month or alternatively Note 2 : every hour 1000 / 12 month or alternatively Warning: As for the cold-storage room version, the greasing and lubrication interventions should be doubled, by halving the interval hours.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Generality

Table of Main Screws and their Relevant Tightening Torques DESCRIPTION Traction wheel securing screws Tiller head to the arm securing screws Pivoting wheels to the body securing screws Side panel support to the body securing screws Reduction unit to the body securing screws Traction motor flange to reduction unit fixig screws Electromagnetic brake fixing screws Column Securing Screws Hydraulic pipe fittings Tolerance

Nm 75 2 18 60 22 2

± 5%

Motor Brush Wear Table The replacement of the brush should be carried out when the brush length reaches : Traction Motor 1 kW Pump Motors 2.2 kW Tolerance

Residual Length (mm) 15 - 0/ + 20%

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Version : April 2003 (Replaces version : )

Note : the figures of tightening torques are relevant to class 8.8 screws.

09

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Relève de la protection du droit d'auteur.

Toute forme de reproduction interdite.

Copyright reserved.

Version : Septembre 2003 (En remplacement de la version :

)

Contents

01

Chassis

Page

Dashboard Controls e Instruments System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Mushroom-Head Emergency Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Start-up Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 I.B.S + Hour Counter Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 Access Compartment to the Battery Charger Cable (Optional) . . . . . . . . . . . . . . 04 Motor Compartment Bonnet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Battery Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 Bonnet and Cover Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 Position if the indentification plates and stickers . . . . . . . . . . . . . . . . . . . . . . . . . 08 View from the operator side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 View from forks side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Lateral view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 View from above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Workshop manual EGU 30 / EGV 20 / EGP 14-20

01

Chassis

Dashboard – Controls – Instrument System

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Version : April 2003 (Replaces version : )

1 Mushroom-head emergency button 2 Start-up key-operated switch 3 I.B.S. + Hour Counter Instrument Battery charge level indicator, indicator of work hours, truck “ON/OFF” state indicator 4 Access compartment to the power supply cable of the built-in battery charger (Optional)

Mushroom-Head Emergency Button The red mushroom-head emergency button is clearly visible and easy to reach.

Once pushed, it cuts the current off both to power circuits and to ancillary circuits, so as to cause the prompt tripping of the electromagnetic brake. It is a “joint”-type pushbutton, that is to say that the disconnection of the current occurs in one of the following two ways : - 1) by means of a mechanical pressure control by the operator ; or - 2) by means of a control operated through an electric signal by the Combi system.

This feature enabled the use of a single component instead of using the traditional diagram pushbutton + contactor, therefore reducing used spaces and wirings.

Warning: This button must only be used in conditions of emergency.

Uses other than the type of use described are considered to be improper.

Start-up Switch

When the start-up switch is on “l” setting, it energizes the control circuits and starts up the safety diagnostic controls of the electronic panelboard.

Whereas on the “O” setting, no circuit is energized.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Chassis

I.B.S. + Hour Counter Instrument The Indicator – Hour Counter instrument : • Shows the truck operation time (running or lifting/lowering), which is expressed in hours (Running). Otherwise, it is possible to pair off the count cut-in with one setting of the start-up switch only, that is to say with the “l” setting (Key on).

• Shows the battery charge level, by displaying it on a coloured 10-led row.

• Shows that the start-up switch is on “l” setting, by switching the led row on.

• Stops the lifting operation when the battery is by 80% down.

Version : April 2003 (Replaces version : )

A) Hour Counter Display: When the hour counter is working, the hourglass on the left side of the display blinks (15 times per minute approximately).

Five digits and one place of decimals are displayed. Starting from zero, the numbering progressively increases.

3 – 4 – 5 Yellow-orange leds 6 – 7 – 8 – 9 – 10 Green leds

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1-2 Red leds 3-4-5 Yellow-orange leds 6-7-8-9-10 Green leds

B) Led-row indicator relevant to the battery charge state: • When the battery is 100% charged, only the led 10 is on.

Whereas, while the battery is running down, the leds switch on one at a time, from right to left.

• When the battery is by 70% down, both leds 1 and 2 blink at the same time, which means that the battery should be recharged (low).

• When the battery is by 80% down, both leds 1 and 2 alternately blink, which means that the lifting stop threshold has been reached.

• This instrument has a fixed recovery voltage threshold, therefore, the shift from the totally or partially low battery indication to the 100% charged battery indication occurs only if the voltage applied is >25.1 V (Figure supplied by the manufacturer).

Thus, you need to keep in mind that when you replace a totally low battery with a partially low battery (having a voltage < 25.1 V), the instrument does not show the change of charge, but keeps on displaying the previous charge level.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Trimmer figure

01

Chassis

Table of the instrument reference voltages, when the battery is by 80% down, with regard to the trimmer letters : K 1.57 V for each cell (factory setting) L 1.65 V for each cell M 1.68 V for each cell N 1.73 V for each cell (Standard setting) O 1.78 V for each cell P 1.82 V for each cell Q 1.84 V for each cell R 1.86 V for each cell S 1.89 V for each cell (gel battery setting) T 1.91 V for each cell U 1.93 V for each cell

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Version : April 2003 (Replaces version : )

The discharge trimmer should be set on the K setting.

Recovery CURTIS 803 has a fixed recovery threshold that is set by the manufacturer.

The following two kinds of recovery are possible : • When the battery is disconnected during its charge, CURTIS 803 will recover if the battery voltage is equal or higher than 2.09 V for each cell.

• When the battery keeps being connected to the equipment during its charge (for example: battery charger installed on the equipment), CURTIS 803 will recover when the battery voltage reaches 2.35V for each cell.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Chassis

Access Compartment to the Battery Charger Power Supply Cable (Optional) An access compartment to reach the built-in battery charger power supply cable may be provided on the bonnet.

In order to reach the power supply cable plug of the built-in battery charger, you should lift the suitable opening cut in the bonnet on one side (As shown in the Figure beside).

The plug lies within a special housing that is able to keep it fastened to the opening. In order to remove the plug, you should push it towards the opening and, at the same time, pull it upwards.

This procedure is easy and handy.

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

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Version : April 2003 (Replaces version : )

This compartment is not provided on the bonnet of the production truck.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

01

Chassis

Bonnets Motor Compartment Bonnet Removal

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Version : April 2003 (Replaces version : )

Lift the mushroom emergency button.

Turn the (red) mushroom until the side hole of the screw lines up with the side hole of the insulating casing of the emergency button unit.

Into the aligned holes insert a 2 mm pin going through them.

The pin makes the screw integral with the fixed insulating casing.

Turn the mushroom button in an anti-clockwise direction till it is completely unscrewed.

A 2 mm Allen wrench may be used.

Remove the wrench after having unscrewed the mushroom button.

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

Remove all the securing screws of the bonnet.

Remove the motor compartment bonnet, lift it in order to get over the emergency contact.

After removing, set aside in the vicinity of the truck.

Do not pull too hard: the cables of the hour counter and of the key-operated switch are still connected.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Chassis

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Version : April 2003 (Replaces version : )

Remove the key from the key block.

Unscrew the securing ring nut of the key block, by keeping the key block firm from the inner part of the bonnet.

Remove the key block and reassemble it.

Insert the key.

Disconnect the connector of the CURTIS 803 indicator.

Remove the securing screws of the indicator support bracket.

Pull out the CURTIS indicator, then re-assemble it once it has been removed from the bonnet.

Insert again its connector.

This operation is required, as it is not possible to start up the truck when the indicator is disconnected.

Secure the gaiters of the indicator and of the key block to the wiring of the truck.

Do not leave them hanging inside and outside the truck.

06

01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Chassis

Battery Cover Removal Once the motor compartment bonnet has been removed, the hinges of the battery cover will be visible.

Hinge

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

Version : April 2003 (Replaces version : )

By means of a pin-bar, remove the lockpin of the battery cover.

Warning: elastic pins could fall inside the motor compartment.

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Recover the fallen pins by means of a recovery magnetic tool.

Bonnet and Cover Assembling In the assembling step of bonnets and covers carry out the same operations performed during the removal operations but in the opposite way. Remember that the longest securing screws are the upper ones.

Check that all the bonnets and covers are perfectly housed in their standard positions.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Chassis

Position of the identification plates and stickers Follow these instructions in case the identification plates or stickers need to be replaced.

Sticker kits: replace the stickers when missing or after the painting following a complete overhaul.

Identification plates: replace the plates if missing, worn out or damaged. When ordering the plates, please specify the truck’s serial number (plain plates are not available).

Replacing the original plates with different ones showing different features from the original ones is NOT PERMITTED. In order to modify the truck’s data, the truck itself must be tried and tested at the manufacturer’s factory, then a new compliance certificate will be issued and the truck’s technical specifications will be modified.

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Version : April 2003 (Replaces version : )

View from operator side

08

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Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20 Chassis

01

View from forks side

09

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Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20 Chassis

01

Lateral view

10

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Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20 Chassis

01

View from above

11

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Relève de la protection du droit d'auteur.

Toute forme de reproduction interdite.

Copyright reserved.

Version : Septembre 2003 (En remplacement de la version :

)

Contents

03

Gear Box

Page

Traction Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 Traction Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 Overhaul of rreduction gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 TractionUnit Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08

03

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Gear Box

Traction Speed Legend: LF = Running towards the fork arms LO = Running towards the operator Traction speeds These speeds are not described in the technical datasheet : Key: LF = Forks side travel; LO = Operator side travel

Type of Driving

Version : April 2003 (Replaces version : )

Steering with tiller active in vertical position LF and LO) Tolerance

0 kg (km/h)

Speed 1,400 kg (km/h)

2,000 kg (km/h)

2

2

2

0/-30%

0/-30%

0/-30%

Note: Speed times have been detected after having heated the reduction unit oil (After 1 hour approximately of continuous traction).

Traction Stoppage

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Traction is always blocked, when the following conditions occur :

Stopped Traction

Manoeuvre made by the operator The tiller butterfly is set in the neutral rest position The emergency stop button is pressed The start-up switch is turned in the “O” setting (Switched off truck) The tiller is set in the braking position In the event of Combi alarms

Traction Motor It is a separately excited motor having the following specifications : • Power supply voltage 24 V DC • Rated power 1 kW Because of the use of a separately excited motor and through a specific software within the COMBI, we succeeded in producing a motor that has the advantages both of separately excited motors and of production excited motors. Below are its main advantages: • Speed control with loaded truck, empty truck and loading ramp truck • Energy-regeneration with decrease of energy consumption.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

03

Gear Box

Overhaul of reduction gear unit Place the reduction unit on the floor or on a workbench.

By means of an Allen wrench, remove all the screws of the cover.

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug

Version : April 2003 (Replaces version : )

- Remove the FU4 fuse

Lift the cover from the reducer casing, by means of a hammer and of a chisel.

The putty sticks the cover to the reducer casing.

Warning: do not heavily groove the cover supporting surface.

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*

Heat the ring nut by means of a small patent blowpipe. It is better to use an electric air heater.

This operation aims at softening the thread-locking adhesive.

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03

Gear Box

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Heat the ring nut by means of a small patent blowpipe. It is better to use an electric air heater.

This operation aims at softening the thread-locking adhesive.

Hit the reducer shaft with a softsurface hammer till the gear plane.

Place a wood board or any soft surface on the wheel coupling flange side.

By means of a soft metal drawn tube, hit the reducer shaft until it gets completely out.

03

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03

Gear Box

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Place a wood board or any soft surface on the wheel coupling flange side.

By means of a soft metal drawn tube, hit the reducer shaft until it gets completely out.

Hit with a soft-surface hammer the edge of the reducer cover.

Warning: if you remove the tracks of crankshaft bearings, you will find the shims for the calibration of the pinion-gear coupling under them. Do not forget from which of the two bearings they have been removed. Tie the one to the other by means of a string.

04

Workshop manual EGU 30 / EGV 20 / EGP 14-20

03

Gear Box

Insert an Allen wrench in the hole of the cylindrical couple gear in order to stop the shaft rotation during the unscrewing operation.

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Version : April 2003 (Replaces version : )

Gear Hole Using a wrench, unscrew the ring nut retaining the M16x1.5 cylindrical gear by means of a soft-surface hammer.

By means of a soft-surface hammer, hit the end of the pinion shaft in order to pull it out of its housing. A cone-shaped bearing will remain fastened to the shaft.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

03

Gear Box

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Version : April 2003 (Replaces version : )

List of the parts forming the reducer.

Now, you can go on washing the different parts and replacing, for instance, the bearings or the shaft outlet oil splash guard.

In order to assembly the reducer, reversely follow the whole disassembling procedure. Do not forget to use the thread-locking adhesive where it had been previously used and to bend the ring nut anti-screwing tongues.

Strictly comply with the driving torques recommended by the manufacturer.

See reduction unit drawing.

06

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

Description Ring nut M14X1.4 Pinion = 1/23 Gasket 20x35x6 DIN 376 Roller 6004 2Rs July motor 1 Kw Elastic pin 6x20 TTCE M6x20 8.8 DIN 7984 Washer din 7980 - 6 MACHINED MOTOR FLANGE O-RING 3300 A+P BRAKE FMPR 125 Roller 6004 2rS

Version : April 2003 (Replaces version : )

Qty 1 1 1 1 1 1 3 3 1 1 1 1

Workshop manual EGU 30 / EGV 20 / EGP 14-20 Gear Box

03

Traction unit assembly diagram

Drawing 452070004

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Gear Box

Lubrication Oil and Grease Supply for the Standard Version With regard to the quantity and type of oils and greases for the standard version, refer to the table of lubricants in the user and maintenance manual. (SAE 80w 90EP)

Oil and Grease Supply for the Cold-Storage Room Version With regard to the quantity and type of oils and greases for the cold store version, refer to the table of lubricants in the user and maintenance manual. (SAE 75w 90EP)

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

General Lubrication Remove the fairings with the truck switched off.

Turn the tiller until you can see the filler plug through opening A in the structure. The opening will be visible on the right-hand side of the fixed chassis.

After having aligned the plug with opening A, use a socket wrench with swivel extension to unscrew and remove the plug.

Fill the gear reducer oil syringe and insert the nozzle into the filler hole.

Inject oil up to the rim of the hole.

Refit the filler plug and torque to 15 Nm. Dry any spilled oil from the area around the plug using a clean rag.

Important: it is good practice to renew the seal washer each time the gear unit is filled with oil.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Gear Box

Greasing of the fifth wheel of the reducer unit

Standard

grease with lithium

Cold Store

special cold store grease

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Version : April 2003 (Replaces version : )

Remove the fairings with the truck switched off.

Working through opening B fit the grease nozzle on the grease nipple below and inject grease while varying the position of the rack by turning the tiller to the right and the left.

09

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04

Wheels

Contents

Page

Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pivoting wheel unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete pivoting wheel assembly (lateral view) . . . . . . . . . . . . . . . . . . . . . .

Complete pivoting wheel assembly (front view) . . . . . . . . . . . . . . . . . . . . . . .

Wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the pivoting wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Roller Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Roller Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01 01 03 03 04 05 06 09 10 12

Workshop manual EGU 30 / EGV 20 / EGP 14-20

04

Wheels

Driving Wheel The drive wheel is made of polyurethane.

Traction Wheel Replacement

Version : April 2003 (Replaces version : )

Warning: before starting the traction wheel replacement, place a wood beam under the end of the fork arms.

Then, lower the fork arms making them rest on the wood beam.

Switch the truck on and place the tiller parallel to the fork arms.

Switch the truck off.

Disconnect the battery plug.

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Safety Wood Bean

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Wheels

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Using the hydraulic lifting jack, lift the truck on platform side by means of the platform support.

For safety reasons, it is advisable to leave the lifting jack slightly pushing under the platform support.

Place some safety wood beams under the edge of the fixed frame.

By means of a wrench, unscrew and remove the securing screws of the traction wheel.

Remove the traction wheel from the flange. In the event that it is not possible to remove it manually, hit the edge of the wheel by means of a soft-surface hammer.

Let the wheel fall on the floor.

Mind your hands!

Replace the traction wheel with a reverse procedure.

Tighten the screws with a torque of 75Nm.

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Wheels

Pivoting wheel unit The unit comprises a polyurethane wheel mounted on a height-adjustable support. This system makes it possible to adjust the trim of the truck in the event of significant wear of the drive wheel with consequent reduction in diameter. This procedure must be performed exclusively by skilled personnel.

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Version : April 2003 (Replaces version : )

Complete pivoting wheel assembly (lateral view)

A Bearing play adjustment procedure 1-Assemble parts as shown and tighten screw to torque of 45 Nm 2-Bend one edge of the safety washer over the head of the screw B C D E

Adjustment 164.5 mm mini 168.5 mm OK 172.5 mm factory adjustment 176.5 mm maxi 03

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Wheels

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Complete pivoting wheel assembly (front view)

Pivoting Wheel Assembly Table 12 11 10 9 8 7 6 5 4 3 2 1 ITEM

Hexagonal headed screw M12x100 8.8 ISO 401 Hexagonal headed screw M14x35 8.8 ISO 4 Nut M12 UNI EN 240033 Washer UNI 1751-A 12 Washer D15 UNI 6599 Wheel assembly 12x60 Retainer plate PIVOTING (CASTOR) WHEEL BODY Wheel spacer Bearing 68x39x37 Pivoting (castor) wheel flange Side plate DESCRIPTION

3 1 3 3 1 1 1 1 2 1 1 2 Q.TY

REMARKS 04

Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Wheels

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Wheel Assembly

Wheel Assembly Table 1 2 3 ITEM

Wheel inner spacer WHELL 12x60 Bearing 6205 2RS DESCRIPTION

1 1 3 QTY

REMARKS

05

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Wheels

Pivoting Wheel Removal

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

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Version : April 2003 (Replaces version : )

Use a hydraulic jack to lift the truck from the mast support on the righthand side.

Insert a wooden chock for safety under the chassis.

Warning: keep the forks in their fully lowered position.

Lift the truck about 15 cm from the ground.

Use a punch to unclench the locking tab on the screw head.

Use the relevant hex wrench to unscrew and remove the retaining screw from the body of the pivoting wheel.

Now remove the pivoting wheel retaining plate.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Wheels

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Interposing a soft metal bar (aluminium) strike the body of the pivoting wheel and remove it fromthe flange.

The wheel complete with fork will be equipped with a taper roller bearing; the other bearing will remain in theflange.

Using two hex wrenches unscrew the wheel retaining nut.

Extract the screw, utilised as a spindle, and remove the wheel complete with bearings.

To renew both taper roller bearings you must also remove the supporting flange.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Wheels

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

You can now proceed to renew the entire wheel or only the bearings

Grease the conical bearings before starting mounting the fork. Tighten the fork’s nuts to 53 Nm of torque.

Assemble the body of the pivoting wheel by performing the removal steps in reverse order.

Torque the screw to 45 Nm, this being the necessary force to assure a secure fit without overloading the taper roller bearings. Re-clench the locking tab.

Check inclination of the truck.

If necessary, adjust the height regulation system.

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Wheels

Load Rollers

The production single load roller is available only for the 1,400 kg version.

The production double load rollers are available for the 2,000 kg version.

For a detailed description of the different standard and optional combinations, see the “Optionals” Section.

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Version : April 2003 (Replaces version : )

1 Single Load Roller 2 Double Load Rollers

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Wheels

Load Roller Removing Lift the fork arms up to the heigth of 1.5m.

Place the hydraulic lifting jack under the column support and lift the load roller to be replaced 2-3cm above the ground.

By means of a pin-bar of suitable diameter, hit the pivot-retaining elastic pin, until the it is fully pulled out.

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Version : April 2003 (Replaces version : )

Place a safety beam under the forkholder plate in order to support it.

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Wheels

After having removed the roller, the bearings or the nylon rings (wirecover) may be likely to be replaced.

Replace the roller if it is planed or split off.

When the replacement of one roller is required, replace also the other one if it is excessively worn out.

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Version : April 2003 (Replaces version : )

Using a soft metal bar, hit the pivot in order to push it out of the roller

11

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Wheels

Load Roller Assembling

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Insert the roller together with its rings in the fork.

Check the surface of the pivot. If it is grooved, it needs to be replaced. Do not polish pivots with rubbing paper, as they have been ground with roughness index numbers of 0.8-0.4 and their surface is burnished, which prevents rusting.

Make sure that the pivot hole is aligned with the hole of the elastic pin, before fully inserting the pivot.

After having fully inserted the pivot, insert the pin-bar in the hole so as to align the holes on the same axis.

Place the elastic pin at the inlet of the hole, holding it in the proper position by means of a pair of pliers. Hit the pin with a hammer until it is completely inserted.

12

Workshop manual EGU 30 / EGV 20 / EGP 14-20

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)

Contents

05

Driving Controls

Page

Tiller Head Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Tiller casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Connection Diagram between Tiller Card and COMBI SYSTEM . . . . . . . . . . . . . 02 Traction Control Butterfly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 Traction Accelerator Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 The Redundant Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 Lifting/Lowering Control Butterfly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Lift and lower speed Control potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Tiller Safety Device Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Tiller Head Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Tiller Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 Tiller Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 Tiller Head Assembly Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 Lift/lower potentiometer diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Tiller functions diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tiller Card Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05

Driving Controls

Version : April 2003 (Replaces version : )

Tiller Head Controls

1 2 3 4 5 6

Traction Control Butterfly Tiller Safety Device Button Fork Arm Lifting/Lowering Control Butterfly Tiller Casing Acoustic Alarm Button Low speed travel enable "Tiller active in vertical position" (Optional)

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Tiller Casing The tiller casing is a plastic enbloc (PA6 polyamide), which is produced through an injection system followed by an emptying operation by means of gas, in order to obtain some inner lightening hollows.

The angle handles of suitable dimensions make the hand position comfortable, thus they provoke no aching also when they are used for long periods. Plenty of space is available inside the handle also when one uses work gloves.

The mechanical stress and breaking tests confirmed their excellent resistance to shocks.

An electronic card, which has the function to collect the electric signals from the pushbuttons, from the traction accelerator potentiometer as well as from the lifting/lowering potentiometer, is housed inside the tiller casing. This logics elaborates the data received and sends them through a serial digital transmission to the electronic control.

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Driving Controls

Connection Diagram between Tiller Card and COMBI System

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Version : April 2003 (Replaces version : )

It is rather important to highlight the connection between the COMBI system and the tiller card occurring through the serial transmission by means of the TX RS232-type current-loop wire. This connection enables a remarkable sparing of the quantity of cables used and, therefore, the decrease of sheath failure probabilities. The signals from the BELLY SWITCH, from the CPOT.T2 (traction potentiometer 2 unit) and from the CPOT.S2 (lifting/lowering potentiometer 2 unit) directly enter the COMBI for safety reasons.

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Driving Controls

Traction Control Butterfly

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Version : April 2003 (Replaces version : )

Running towards the operator

Running towards fork arms

The Traction Control Butterfly has the following functions : • Running direction and electromagnetic brake return selector • Accelerator • Service brake (electric braking at running reversal) • Electric braking return when releasing the butterfly

The system is equipped with a helical spring automatically switching to the neutral position, thus it is not very tiring. The butterfly has a working rotation stroke of ±42° and the truck speed is proportional to the angular motion of the valve.

When the butterfly is released, the electric braking is enabled till the equipment stopping and, then, till the brake locking.

Traction Accelerator Potentiometer The functions of accelerator and running selector are performed by means of a double (Redundant) potentiometer that is suitably coupled to the butterfly shaft.

The potentiometer has a "double crossed signals" system: when one signal is at its ceiling level, the other one reaches its floor level (see diagram beside). It has two separate tracks controlling two different voltages. It is produced by means of a carbon-film technology and this system ensures a redundant-type safety feature.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Driving Controls

The Redundant Potentiometer

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Version : April 2003 (Replaces version : )

Practically, it is a double potentiometer where the cursors of the two potentiometers are hooked to the same shaft, which produces the rotatory motion. The two signals from the potentiometer 1 and from the potentiometer 2 are continuously compared by the COMBI system according to a mathematical formula: POT.1 + POT.2 5V. Any defect of one of the two potentiometers is detected at once and the truck is blocked through an alarm.

Lifting and Lowering Control Butterfly functions : The lifting/lowering control butterfly has the following functions : - Lifting or lowering function selector - "Accelerator" (lifting or lowering speed adjuster).

The lifting speed adjustment is performed by selecting the number of revolutions of the pump motor.

The lowering speed adjustment is performed by operating the coil current of the proportional valve.

The system is equipped with a helical spring automatically switching to the neutral position, thus it is not very tiring. The butterfly has a working rotation stroke of ±25° approximately and the fork arm lifting and lowering speed is proportional to the angular motion of the valve.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Driving Controls

Lifting/Lowering "Accelerator" Potentiometer The functions of "accelerator" and of lifting and lowering control return are performed by means of a double (Redundant) potentiometer that is suitably coupled to the butterfly shaft.

The potentiometer has a "double crossed signals" system: when one signal is at its ceiling level, the other one reaches its floor level (see diagram beside).

It has two separate tracks controlling two different voltages. It is produced by means of a carbon-film technology and this system ensures a redundant-type safety feature.

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Version : April 2003 (Replaces version : )

Tiller Safety Device Button The safety device button casing winds around most of the head surface so that its enabling is optimum also when the tiller is at peak angles.

The pressure of this button enables a particular functioning, according to the operation condition : Operation Condition Functioning Tiller Brake Butterfly Truckr unning In working Open In rest Truck stop and sudden running towards the position (Nonbraking) position or restarting towards the fork operator turned arms according to what is towards provided for by EN1175-1 the standard. operator Truck running towards the fork arms

In working Open position (Nonbraking)

In rest position

Sudden running restarting towards the fork arms according to what is provided for by EN1175-1 standard.

Tiller Head Buttons The operator does not need to leave the handle in order to press the acoustic alarm button, he simply needs to stretch his fingers to reach it. This button is housed inside a raised-edge niche in order to avoid accidental operation. It is an “ON-OFF” button, with silver oxide membrane, without contact and with mechanical motion. It is covered with a polyester film, which is oil-, grease- and acid-proof. It is "sensitive" also when wearing work gloves.

All tiller controls are tested for 2 million operations.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Driving Controls

Tiller Positions 6.1 Tiller position 6.1.1 Tiller position (Standard version) The positions of the tiller are : Pos.”1”: Working Position • Possibility to start the running by means of the butterfly Pos.”2”: Braking Position • Locked traction • Parking and emergency brake (Jammed brake and nonpowered traction motor) This kind of braking should not be used as service braking.

Version : April 2003 (Replaces version : )

6.1.2 Tiller position during use of the “tiller active in vertical position” option Pos.”1”: Operating position • Possibility to activate travel by means of the butterfly control, keeping pressed one of the two low speed travel buttons.

To activate parking and emergency brakes release one of the low speed travel request buttons regardless of the position of the tiller.

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This type of braking must not be used in place of the service brake.

When released, the tiller will automatically assume position "A".

Automatic return of the tiller arm is obtained by a helical spring strut inside the tubular section. This system ensures slight and even pressure throughout the entire stroke.

When released, the tiller arm stops without rebounding thanks to a special retaining mechanism formed of rubber bumpers.

06

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Workshop manual EGU 30 / EGV 20 / EGP 14-20 Driving Controls

05

Tiller head assembly

A

07

Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Driving Controls

Tiller head assembly table

Item 1

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Version : April 2003 (Replaces version : )

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Description Hexagonal split headed screw M5x12 8.8 UNI 5933 Washer UNI 1751-A 4 Washer UNI 6592 – 4.3x9 Plastic sheath D.6 SCREW PH AB-3.5X9.5 UNI69 Cheese hexagonal headed screw M4x6 8.8 UNI 5931 Self-blocking screw ph-AB 3.5x6.5 U Compression spring Split pin d.3 x 40 UPPER BUTTERFLY Emergency button Upper potentiometer bearing Push button control angle bar Push button control pin upper lock-up electronics system Membrane push button Lifting/lowering reduction unit potentiometer Tiller head body Lower butterfly Bush for lower butterfly Lower potentiometer bearing PUSH BUTTON DUMMY

Qty 2 4 4 1 1 5 1 1 1 2 1 1 1 1 2 1 1 1 1 2 2 1 4

A The Stud should be adjusted carefully in order to prevent the emergency button locking

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Driving Controls

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Version : April 2003 (Replaces version : )

Lifting / Lowering potentiometer diagram

Potentiometer type Mechanical angle Rated resistance Tolerance Electric angle Power 1w/70°C Working temperature Protection rating

Redundant 2x50° 8 KΩ ± 35 % 2x50° - 30°C / ‘+80°C IP 65

452149162 09

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Workshop manual EGU 30 / EGV 20 / EGP 14-20 Driving Controls

05

Tiller function diagram

452349101

10

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2B1

Version : April 2003 (Replaces version : )

1B1 2B1

1B1

452349102

Drive potentiometer Lift potentiometer

Workshop manual EGU 30 / EGV 20 / EGP 14-20

05

Driving Controls

Tiller card connection diagram

11

Workshop manual EGU 30 / EGV 20 / EGP 14-20

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)

Contents

07

Brake

Page

Electromagnetic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Electromagnetic Brake Calibration Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Description of electromagnetic brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 Description of E.M.B. dataplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 Power ; Voltage, Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 Tools required for E.M.B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Installation of clutch disk for sizes 06-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 Installation of brake flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 Assembly phases of E.M.B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 Fitting the rubber guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Electro Hydraulic Brake (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electric Braking (regenerative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 E.M.B. Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Workshop manual EGU 30 / EGV 20 / EGP 14-20

07

Brake

The truck is equipped with two independent braking systems : • Electromagnetic brake (Electrically driven friction brake) • Energy-regenerating electromagnetic brake (Dynamic braking on the traction motor)

Electromagnetic Brake

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Version : April 2003 (Replaces version : )

Due to its use features, it is considered like: • A parking brake • An emergency brake It is a current-controlled device. Its powering will produce a magnetic field enabling the release of the brake: no dynamic braking.

On the contrary, when it is no longer energized, it is jammed: dynamic braking.

The braking occurs through a helical spring system pushing the braking disks on the flange of the traction motor.

The braking couple remains fixed, both with and without load and may be, anyhow, calibrated during the maintenance stage by means of the suitable brake adjusters.

This kind of braking occurs with the following operation conditions : • With the tiller in braking position • With the platform in stand-by position • With vertical platform and closed side panels • By operating the emergency button • When releasing the motor butterfly after the truck stopping (once the release braking has ended) • In the event of electric drive alarm and COMBI chopper alarm tripping • With the start-up switch turned in “O” setting (Switched off truck)

Electromagnetic Brake Calibration Table Capacity (kg)

S1 (mm)

S2 (mm)

toll.S1 toll.S2 (mm) (mm)

2,000

3

0,25

+/-0,2 ±0,05

S1 = air space between the adjustment ring nut and the electromagnetic brake casing; the lower is this figure the higher is the braking force.

S2 = air space between the electromagnetic brake casing and the flange. Wrong adjustments may compromise the proper operation of the same electromagnetic brake: uneven wear of the brake lining surface, braked traction motor and overheating with consequent breaking of the motor crankshaft bearings and loss of the properties of the electromagnetic brake coil.

Warning : Replace the brake disk when S2 0.6 mm 01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

07

Brake

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Version : April 2003 (Replaces version : )

Description of the Electromagnetic Brake

Type - E

Type - N

1. Electric brake disk 2. Compression spring 3. Brake disk 4. Hub 5. Motor shaft 6. Flange 7. Electric brake body 8. Adjustment ring 9. Air gap adjuster nuts S2

1. Compression spring 2. Compression spring 3. Brake disk 4. Hub 7. Electric brake body 9. S2 adjustement nuts

Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

07

Brake

Description of E.M.B. Plates

B

FK

458

-

PRODUCT GROUP

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Version : April 2003 (Replaces version : )

PRODUCT FAMILY TYPE MEASURE DRAWING

Measures 06,08,10,12,14,16,18,20,25 Electromagnetic brake drawing E – adjustable (the brake force may be decreased bymeans of the adjustment ring nut) N – non-adjustable Under the code: power supply voltage, hub diameter, optionals These figures are valid only for type 458.

03

07

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Brake

Power, Voltage, Coil Resistance

TYPE

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BFK458-10

BFK458-12

ELECTRIC POWER

VOLTAGE

COIL RESISTANCE 20° C +-8%

W 30 21 32 30 32 30 33

V 24 96 103 170 180 190 205 24 96 102 170 180 190 205

Ω 19. 2 297.3 331.5 963. 3 101.3 1203 1273 14.4 230.4 265.2 722.5 810 902.5 1051

40

Refer to the calibration procedure in the specification.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Brake

Tools to use for E.M.B. Type

Torque wrench

[Nm]

Feeler gauge

Wrench Wrench size [mm]

Hook wrench DIN1810 Design A for outside Diameter [mm]

Wrench size [mm]

Box spanner for flange installation Wrench size [mm]

Manual release 3x1/4”square 4x1/4”square 5x1/4”square

Cap screws 8 9 12

6x1/4”square

15

8x1/2”square

17

Nuts / bolts 7/5.5

2kt lever

10/7

7

12/8

9

-/10

10 12 14

Caliper gauge

42-55 52/55 68/75 80-90 95-100 110-115 135-145 155-165

7x1/4”square 8x1/4”square 10x1/4”square 13x1/2”square 17x1/2”square

Multimeter

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Version : April 2003 (Replaces version : )

BKFK458-06 BKFK458-08 BKFK458-10 1 to 12 BKFK458-12 BKFK458-14 BKFK458-16 BKFK458-18 20 to 100 BKFK458-20 BKFK458-25

Insertion for hexagon socket screws

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Brake

Assembly of the Clutch Disk for Measures 06-16

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Place the clutch disk on the motor flange on the trucks where it is contemplated.

Check that the internal hole of the clutch disk is larger than the hub diameter and that he clutch disk lip contains the brake disk.

12. Clutch disk 15. Motor flanges

Brake Flange Assembling The flange (6) may be screwed on the motor flange (15) by means of the suitable cheeseheaded screws on the trucks where it is contemplated.

Make sure that the head of the screw is embedded in the brake flange thickness.

6. Brake flanges 10.1 Securing screws 15 Motor flange

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Brake

E.M.B. Assembling Steps

Version : April 2003 (Replaces version : )

First step : press the Hub on the shaft and lock it by means of the safety elastic washer. (make sure that there is the spline)

4. Hub 4.1 Safety elastic washer 15. Motor flange Second step : press the brake disk on the hub, as shown in the figure below.

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(check the surface of the motor flange, there should be neither oil nor grease ......traces)

3. Brake disk 15. Motor flange 4. Hub

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07

Brake

7.Electromagnetic brake casing 10. Securing screws 11. Clip 15. Motor flange Fourth step : Secure the screws (10) by means of a dynamometric wrench that is calibrated on the value in Nm as reported in the plate, check the air space between the electromagnetic brake casing and the electromagnetic brake disk by means of a thickness gauge (1). This figure should be equal to the S1 value reported in the table.

Otherwise, first unloose the securing screws and then repeat the operation by means of an Allen wrench.

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Third step : place the electromagnetic brake casing on the motor flange, align the holes between the electromagnetic brake (7) and the motor flange (15) to fasten the screws (10).

Before tightening, remove the clips (11).

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Brake

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Version : April 2003 (Replaces version : )

Once the securing screws are unloosened (10), by means of the Allen wrench, adjust the adjustment nuts (9) more or less in order to increase or decrease the air space. Tighten again with the dynamometric wrench and repeat the operation till the achievement of the correct value.

Rubber Protection Assembling If it is contemplated or if it is deemed necessary, it is possible to place a rubber protection all around the electromagnetic brake, close to the brake disk. This rubber protection aims at protecting the brake lining against any abrasive dust, etc.

1. Electromagnetic brake disk 7. Electromagnetic brake casing 10. Securing screws 12. Clutch disk 13. Rubber protection 15. Motor flange

09

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

07

Brake

1. Electromagnetic brake disk 6. Flange 7. Electromagnetic brake casing 10. Securing screws 12. Clutch disk 13. Rubber protection 15. Motor flange

Electrohydraulic Brake (Optional) It electrically works like the electromagnetic brake, but moreover it automatically adjusts the braking couple according to the load, through an hydrostatic system connected to the hydraulic lifting circuit. It has the following advantages : • Decreased wear of the brake disk • Invariable braking spaces • Softer loadless braking vs. the braking by means of the traditional electromagnetic brake

Electric (Regenerating) Braking This braking is achieved through a suitable control of the traction motor current by the combi chopper. During the braking stage, this system enables to use the motor also as a generator and to transmit this energy (current) to the battery (energy regeneration).

This type of braking occurs in the following operation conditions : • When the traction control butterfly is completely released while the truck is running • At the reversion controlled by the traction control butterfly The regenerated energy (non-dissipated by the motor) decreases the motor heating and the wear of the electromagnetic brake disks.

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Brake

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E.M.B. Assembling diagram

Fit the brake, keeping the cable in correspondence with the mid point of the distance between the motor power terminals.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Relève de la protection du droit d'auteur.

Toute forme de reproduction interdite.

Copyright reserved.

Version : Septembre 2003 (En remplacement de la version :

)

Contents

08

Electrical System

Page

COMBI Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 COMBI System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 Armature Pilot System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 Field Pilot System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Pump Motor Pilot System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 Energy Regenaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 COMBI Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Parameter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Signal Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Accelerator Voltage Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Stored Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Additional Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Special Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Parametter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 COMBI System EPROM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 COMBI System Input/Output Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Cable and Sheath positining Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Legend to wiring Diagramand connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Tiller card Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

COMBI Specifications

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Version : April 2003 (Replaces version : )

The traction and lifting motors are managed by the COMBI (COMBI stands for "combined") control, which may work with max temperatures of 300 A. The logic and power units are assembled inside the COMBI casing that is equipped with gaskets in order to ensure a perfect protection against sprinklings (water, acid, etc.), as well as against dust, shavings or small particles.

• Rated power supply voltage: 24V DC • Max current for the traction motor: 300A DC • Max current for the pump motor: 300A DC • High frequency MOS technology (Static) • Real-time control of the external and internal parts that may affect the truck behaviour with self-diagnosis by the same control circuits.

• Several functioning configurations that may be selected on the console in order to comply with the different requirements of the user.

• Speed control: the motor speed follows the accelerator by automatically tripping a regenerative braking when the motor speed exceeds the preset speed; therefore the truck has a perfect functioning on slopes.

• Good working order of the traction and lifting motors due to the high switching frequency of the MOSFET power transistors.

• Communication of tiller serial signals with reduction of wirings.

• Microcontroller supervisor controlling the functions of the main microcontroller (Safety features in redundancy) • Automatic system of energy regeneration during traction (energy sent to the battery) in the following working conditions: - Lowering Truck with released accelerator - Braking truck when the accelerator is released - Braking truck when reversing the running

The control is assembled to a 30 mm-thick aluminium dissipator to further improve the heat exchange.

The chopper, which is the same for different types of machines, detects the kind of truck it was assembled to and automatically selects the management program for the inputs and outputs, including the relevant configurations and parameters.

It is an encoding, which is different for each truck and which is executed through the wiring. It consists in the negative polarization or non-polarization of one or both X1:34 and X1:35 inputs, SEL.1 and SEL.2 respectively.

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Electrical System

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Version : April 2003 (Replaces version : )

The following table shows which are the inputs and outputs of the COMBI system and which are their functions in a detailed manner : Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Name Input NHO +AUX

PMC NMC NEVP I4

I5

TS

2• ‹TS

MAINS

NCLRXD

CPOT.T2

CPOT.S2

KEY

+AUX NEB NEV1 NEV3 NEV5 I2

I3

BELLY

SR1

LIFT

-BATT +12 PCLTXD -BATT +AUX PEB NEV2 NEV4 NEV6 SEL1

SEL2

I1

DRFT

SR2

TOP MAST

GND NCLTXD KEY OUT

output

Functions oV +24 V after emergency button +24 V emergency button coil 0V emergency button coil 0V lowering coil valve Oil level sensor For speed reduction not connected Tiller sensor 1S1 1S4,1S5 Tiller always ON (slow when tiller vertical) Battery charger microswitch U.C.B. Console Traction potentiometer 2 Lift potentiometer 2 +24 V after Key switch +24 V Horn 0V electromagnetic brake Not used Not used Not used Not used To battery discharge Indicator relay Tiller safety device button (belly switch signal) Not connected Not connected 0V tiller card +12 V U.C.B. console U.C.B. console 0V Battery +24 V Lowing coil valve +24 V electromagnetic brake Not used Not used 0V For hourmeter compting 0V battery 0V battery Not used Tiller card serial signal Not connected Not connected 0V U.C.B. console U.C.B. Console +24 V tiller card 02

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Electrical System

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COMBI System Assembly

SPECIFICATIONS PROTECTION DEGREE IP54 WORKING TEMPERATURE -30°/+70° C POWER SUPPLY VOLTAGE +24V DC WORKING FREQUENCY 16 KHz MAIN MICROPROCESSOR SIEMENS 80C517 CONTROL MICROPROCESSOR ST62T30 TYPE OF MEMORY EPROM 27256 POWER CARD TECHNOLOGY IMS LOGIC CARD TECHNOLOGY SMD KIND OF TRACTION MOTOR EXCITATION SEPARATE KIND OF PUMP MOTOR EXCITATION PRODUCTION TRACTION POWER 200A-300A LIFTING POWER 250A-300A MANUFACTURER ZAPI SINGLE PACKAGE FOR ALL TYPES

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Electrical System

Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20

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Qi: Qj: C:

set of 6 IRF3205S-type MOSFETs with integrated diode and channel no. set of 6 IRF3205S-type MOSFETs with integrated diode and channel no. 300 A set of 14 1000µF 35V condensers connected in parallel

The power MOS (PWM and FRE) are controlled by two inverted signals: when one is ON, the other is OFF and viceversa.

At peak conduction, the MOS PWM is always ON (MOS FRE always OFF).

At rest, the MOS FRE as well as the MOS PWM are always OFF.

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Electrical System

Field Pilot System Diagram

Version : April 2003 (Replaces version : )

Field regulation occurs, on the contrary, by the connection of 2+2 mosfets.

.

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Fiield Adjustment Diagram.

Q26-Q29: serie di 4 mosfet tipo IRF3205S con diodo integrato, a canale n.

Forward travel Mosfet Q27 is activated for the full duration of the travel request.

Mosfet Q28 is activated with PWM (f=800Hz) for the duration of the travel request Mosfets Q26 and Q29 are maintained disconnected Reverse travel Mosfet Q29 is activated for the full duration of the travel request.

Mosfet Q26 is activated with PWM (f=800Hz) for the duration of the travel request Mosfets Q27 and Q28 are maintained disconnected

05

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Workshop manual EGU 30 / EGV 20 / EGP 14-20 Electrical System

08

Field regulation method.

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08

Electrical System

Pump Motor Pilot System Diagram

Q: series of 6 mosfets type IRF3205S with integral diodes, channel n. 300A D: series of 6 diodes type IR 20ETF04S

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The adjustment of the VMN power supply voltage of the pump is achieved through a MOSFET bank.

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Electrical System

Energy Regeneration The energy regeneration occurs in the following conditions: a) lowering truck with released accelerator b) braking truck when the accelerator is released c) braking truck when the running is reversed

1) Functioning like a motor • When PWM is ON, the battery current circulates within the motor first and then within the MOS. • When FRE is ON, the current stored within the motor circulates again (in the same direction as before) through the integrated diode within the MOS fre, which acts as a flywheel. In this case the MOS fre could also be OFF (at the same time as the MOSpwm).

2) Functioning like a generator • When PWM is ON, the current stored within the motor circulates through the MOS PWM and recharges the battery. The current does not circulate within the PWMfre diode.

• When FRE is ON, the current stored within the motor circulates again within the MOSfre, which acts as a flywheel. In this case, the MOS fre cannot be replaced by the diodes. The current does not circulate within the PWM diode.

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Version : April 2003 (Replaces version : )

Now, let us examine what happens within the COMBI in the following conditions :

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Electrical System

COMBI Diagnostic The COMBI control interfaces with an external diagnostic unit that is called U.C.B. 97 (the previous U.C.B. versions are not compatible).

This equipment communicates with the chopper through a serial digital communication with a protocol (definition and interpretation of digitized information), which functions as a software key to enable said transmission (COMBI-console recognition).

The console is a device for the displaying and adjustment of the parameters and configurations contained within the COMBI.

In order to access the diagnostic, it is necessary : • to connect the console to the 6-poles black saab “X7” connector within the motor compartment (when the truck is switched off); • to switch the truck on.

• Automatically also the console displaying the main menu is enabled.

HEADER:

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Version : April 2003 (Replaces version : )

WARNING: The diagnostic unit should be used only by suita bly trained personnel. The change of some parameters or configurations may cause dangerous situations for the opera tor (For instance, traction speed increase).

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Electrical System

Press the Enter key to access the following submenus : - PARAMETER CHANGE - TESTER - PROGRAM VACC - MOTOR DATA (Not available) - ALARMS - SAVE PARAMETER (Not to use) - RESTORE PARAMETER (Not to use) - SET OPTIONS - HARDWARE SETTINGS

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Version : April 2003 (Replaces version : )

The menu structure is as follows:

The console is equipped with 6 keys: • ENTER: confirm your selection • ROLL UP: select the next option • ROLL DOWN: select the previous option • OUT: quit the selected function • SET UP: increase the parameter setting • SET DOWN: decrease the parameter setting 10

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08

Electrical System

Parameter Change : When you open the PARAMETER CHANGE menu, the list of the items that may be modified in order to achieve the implementation of the truck operation is displayed.

(The "curve braking" parameter has been removed) Name ACCELER. DELAY

Meaning Traction motor acceleration delay

DECELER. DELAY

INVERS. BRAKING

Traction motor deceleration delay when the accelerator is partially released Braking when running is released (total release of the accelerator) Braking when running is reversed

CUTBACK SPEED 1

Speed decrease 1 (connected to the SR1input state)

CUTBACK SPEED 2

Speed reduction 2 : (Dependant on the status of input SR2) Speed reduction 3 : Not used

RELEASE BRAKING

Version : April 2003 (Replaces version : )

CUTBACK SPEED 3 CREEP SPEED TR. SOFT WORKING MAX SPEED FORW MAX SPEED BACK MAX. I TRACTION ARMA NOM CURR.

FIELD CURR. MAX

Rated minimum armature current, below which the fieldmay be weakened Armature current value which is the threshold of field weakening Max current of the traction motor field

FIELD NOM CURR.

Rated current of the traction motor field

PU. ACCELER. DEL

Pump motor acceleration delay

PU. DECELER. DEL

LIFT SPEED

Pump motor deceleration delay when the second tiller butterfly is partially released Lifting speed by the second tiller butterfly or by the distributor Lifting speed by the tiller button

DOWN SPEED

Lowering speed by the tiller button (Non used)

WEAK DROPOUT Copyrighted. Reproduction in any form forbidden Copyright reserved.

Power supply voltage applied to the traction motor when the accelerator is slightly rotated Slow running speed with the "tiller always ON" functioning (2TS inlet) Maximum drive speed with travel direction towards operator Maximum drive speed with travel direction towards forks Min = 0 Max armature current on the traction motor

LEVER LIFT SPEED

SLOW LIFT SPEED

Low speed lifting speed controlled by tiller button (Not used) CREEP SPEED PUMP Voltage applied to the pump at a minimum lifting request by the tiller second butterfly

Ref. Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

Name EV. ACCELER. DEL

Electrical System

Meaning Acceleration delay of the proportional opening valve

EV. DECELER. DEL

Deceleration delay of the proportional closing valve when the second tiller butterfly is released MIN DESC. EVP Minimum voltage (current) on the coil of the proportional valve that corresponds to the beginning of the opening MAX DESC.EVP Max voltage (current) on the coil of the proportional valve that corresponds to the maximum opening MIN DESC. EVP FINE Fine adjustment of the MIN DESC.EVP parameter MAX DESC.EVP FINE Fine adjustment of the MAX DESC.EVP parameter AUXILIARY TIME

08

Not used

Ref. Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9

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Signal Monitoring The TESTER menu displays the items that are monitored in real time. The displayed values depend on the state of the battery and on the functions that the truck is performing at that moment, therefore we will show a nominal value (##) plus the relevant unit of measure in the table. Whereas, the meaning of ON and OFF is as follows : • ON: the corresponding function is enabled • OFF: the corresponding function is disabled.

Name BATTERY VOLTAGE MOTOR VOLTAGE MOTOR CURRENT FIELD CURRENT DESC. EVP VOLT. TEMPERATURE TR. ACCELERATOR

Description

Reference of the battery voltage value Armature voltage value Armature current value Field current value Voltage value on the coil of the lowering valve COMBI internal temperature Voltage value relevant to the traction potentiometer 1 and percentage compared to the value at rest LIFT Voltage value relevant to the lifting/lowering ACCELERATOR potentiometer 1 and % compared to the value at rest 2 ND TR. ACCELER. Voltage value relevant to the traction potentiometer 2 and percentage compared to the value at rest 2 ND LIFT ACCEL Voltage value relevant to the lifting/lowering pot. 2 and % compared to the value at rest 1 ST TILLER SW. State of the tiller sensor 1 input 2 ST TILLER SW State of the slow running buttons with "tiller always ON" input FORWARD SWITCH State of the running-to-the-operator triggering signal BACKWARD SWITCH State of the running-to-the-fork-arms triggering signal CUTBACK SWITCH 1 State of the speed decrease 1 input (SR1) TRACTION STOP State of the traction-stop-from-electric-drive input

Displayed Value

##V ##V ##A ##A ##V ##c° ##V-##% ##V-##%

##V-##% ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF

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Version : April 2003 (Replaces version : ) Copyrighted. Reproduction in any form forbidden Copyright reserved.

Electrical System

Description

BELLY SWITCH LEVER LIFT SW.

08

State of the tiller safety device button input State of the lifting microswitch (Distributor) input or of the lifting tripping from second tiller butterfly LEVER DESC. SW State of the lowering tripping signal from second tiller butterfly LIFT SW. 1 State of the lifting button input from tiller DESC. SW. 1 State of the lowering button input from tiller LIFT SW. 2 State of the lifting button input from tiller DESC. SW. 2 State of the lowering button input from tiller LIFT BLOCK State of the lifting limit stop sensor input PLUG INPUT Status of the rectifier mains presence relay contacts input HORN SWITCH State of the horn button input SPRING RGT SW. State of the hydraulic-unit-opposite-side sensor input, paired off with the hydraulic pivoting wheel management SPRING LFT SW. State of the sensor input on hydraulic unit side, paired off with the hydr. pivoting wheel management FLOOR PLATE UP State of the vertical platform sensor input ON/OFF FLOOR PLATE DW State of the horizontal platform sensor input ON/OFF SIDE GATES State of the side panel position sensor input ON/OFF OIL LEVEL LOW State of the pivoting wheel circuit oil level sensor input SELECTOR #1 State of the SEL.1 input (Program encoding) ON/OFF SELECTOR #2 State of the SEL.2 input (Program encoding) ON/OFF SLOW LIFT SP SW1 State of the slow lifting button 1 input ON/OFF SLOW LIFT SP SW2 State of the slow lifting button 2 input ON/OFF EXT. LIFT BLOCK State of the lifting stop input of the indicator - hour counter instrument EV. SPRING RGT State of the valve managing the right pivoting wheel on hydraulic unit side EV. SPRING LFT State of the valve managing the left pivoting wheel on hydraulic unit opposite side BATTERY CHARGE State of the battery charge (percentage)

Displayed value ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ##%

Accelerator Voltage Programming Access the PROGRAM VACC menu, where you can program the accelerator voltages values that the COMBI recognizes as ceiling and floor values. The operation should be performed for both running directions.

Now let’s look at travel in the forks direction: press ENTER to display.

VACC 0.6

SETTINGS 4.8

The voltage values corresponding to the peak conduction for the running towards the fork arms or towards the operator are displayed.

If the values are correct, press OUT to exit without making any change.

Press ENTER to change the preset values.

MIN VACC MAX 0.6 ---0.0 13

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Electrical System

The traction is disabled: perform a running operation towards the fork arms and slowly turn the accelerator at full speed and then slowly release it.

N.B. Sudden accelerations may provoke errors.

After the adjustment, press OUT to confirm. The display shows : ARE YOU SURE? YES=ENTER NO=OUT Press ENTER to confirm the change or OUT to exit without saving.

In any case, you will go back to the starting page.

N.B. The whole operation is to be repeated also for the running towards the operator.

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Version : April 2003 (Replaces version : )

Stored Alarms Access the ALARMS menu, where the last four stored alarms of the equipment are displayed. Next to the alarm message, the number of times that this alarm occured is shown, as well as the working hours of the system and the system temperature at that time (the O°C message means that this alarm occured when the truck was switched on). (the indication 0°C shows that the alarm in question appeared when the truck was switched on).

Configurations Access the CONFIG menu, the following sub-menus are displayed: 1. SET MODEL (not available) 2. SET OPTIONS 3. ADJUSTMENTS Adjustments Access the ADJUSTMENTS menu, the following presettings may be adjusted : ADJUST. BATTERY : It enables to set the battery voltage value. Press ENTER to select the function, the 0.2V step value may be changed by pressing the SET and RESET keys. Once the correct value has been reached, it may be confirmed by pressing OUT and then ENTER. MIN.ACC.LIFT: (0V) It enables to set the minimum voltage value of the lifting potentiometer. Press ENTER to select the function, then, leaving the lever at rest, the value may be confirmed by pressing OUT and then ENTER. MAX.ACC.LIFT : (5V) It enables to set the maximum voltage value of the lifting potentiometer. Press ENTER to select the function, then, holding the lever at full lifting, the value may be confirmed by pressing OUT and then ENTER. MIN.ACC.DESC.: (0V) It enables to set the minimum voltage value of the lowering potentiometer. Press ENTER to select the function, then, leaving the lever at rest, the value may be confirmed by pressing OUT and then ENTER. 14

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Additional Functions It is a set of available functions, which are additional or alternative to standard functions.

Access the SET OPTION menu : HOUR COUNTER: • RUNNING (The calculation of the hours by the indicator - hour counter instrument starts, when a pump or traction function is requested) • KEY ON (The calculation of the hours by the indicator - hour counter instrument starts, when the truck is switched on) LIFT BLOCK : • ABSENT = The lifting limit stop sensor is considered absent by COMBI • PRESENT = The lifting limit stop sensor is considered present by COMBI QUICK INVERSION: • BELLY = When the tiller safety device button is pressed, the inversion is continuous • TIMED = When the tiller safety device button is pressed, the inversion is timed (it lasts only for a given delay) PROPORTION LIFT: • PRESENT = The lifting/lowering potentiometer that is paired off with second tiller butterfly is considered present by COMBI • ABSENT = The lifting/lowering potentiometer that is paired off with second tiller butterfly is considered absent by COMBI BRAKE IN QCK. INV: • ON = When the tiller safety device button is pressed, the quick braking by the electromagnetic brake occurs • OFF = When the tiller safety device button is pressed, the quick inversion occurs BRAKE IN RELEASE: • ON = The braking by the electromagnetic brake starts, when the accelerator is fully released • OFF = The braking by the electromagnetic brake is disabled, when the accelerator is fully released EV TYPE : • NONE = The controlling of any valve on the COMBI X1:5 output is disabled • OPTION #1 = The controlling of the lowering proportional valve is enabled • OPTION #2 = The ON/OFF-type controlling of the lowering valve is enabled Special Adjustments Access the menu, the following sub-menus are displayed : • SPECIAL ADJUST. • HARDWARE SETTING • READ RAM • READ EEPROM • CLEAR EEPROM • CLEAR CONSOLE NOTE: Read RAM and EEPROM enable to read the contents of certain memory cells; Clear EEPROM and Clear Console enable to cancel the memories of the system (the first control) and of the console (the second control) that it is better not to execute.

15

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Special adjust.

The following presettings are available : SET TEMPERATURE SET TEMPERATURE: It enables to set the temperature value of the system power board at a 1°C step. Once the function has been selected, the actual value may be changed by means of the SET UP or SET DOWN keys on the console.

Hardware Setting The following presettings are available:

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Version : April 2003 (Replaces version : )

SET CURRENT : It enables to set the maximum armature current delivered by COMBI. Once the function has been selected, the actual value may be changed by means of the SET UP or SET DOWN keys on the console.

SET FIELD CURRENT: It enables to set the maximum field current delivered by COMBI. Once the function has been selected, the actual value may be changed by means of the SET UP or SET DOWN keys on the console.

Alarms NOTE: the letter “B” next to the alarm means that this alarm stops the truck.

Therefore, if this alarm appears when the truck is switched on, it does not enable to close the power contacts of the emergency button, whereas if this alarm occurs when the truck is running, it opens the power contacts of the emergency button.

Legend: P.E.=Emergency Button

ALARM EVP NOT OK (B) Anomalous absorption of the lowering proportional valve coil EB DRIVER KO (B) The voltage of the brake coil control driver is not correct VFIELD NOT OK (B) The field voltage is not correct SERIAL ERROR #1 (B) Lack of message transmission from the tiller card to the COMBI

PROBABLE CAUSES • The valve is not connected • The coil is not consistent with the project specifications • Coil resistance is too high • Brake not connected

CORRECTIVE ACTION • Check the proper supply of the coil • Replace the valve • Check brake connection • Renew brake

• The field cables are disconnected • Check the field connection • The serial cables are cut off • The battery voltage is very low • The tiller card is ko • The system is ko

• Check the cables • Check the battery voltage • Replace the tiller card • Replace the system

16

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

PROBALBLE CAUSES CORRECTIVE ACTION ALARM • Possible cancellation of • Replace the system EEPROM KO the EEPROM • Perform a CLEAR (B) Communication EEPROM problems with EEPROM or • Defective EEPROM in the parameter reading during the startup stage • When it occurs when • Check that the PUMP ACC. NOT OK switching the truck on potentiometer value at (B) Incorrect voltage of the so that the P.E. does rest lifting potentiometer when not close, probably the • Replace the potentiomelifting/lowering requests are startup sequence is ter lacking incorrect MICRO CONTROL KO • Incorrect operation of • Replace the system (B) the control microswitch VMN NOT OK • VMN value at rest • Replace the system different from the • Check the proper opera (B) Incorrect armature battery voltage tion of the motor voltage value • Non-decreasing VMN value when the motor PWM increases during running • Broken P.E. • Check the proper opera CONTACTOR CLOSED • Broken system tion of the P.E. (B) At startup, the P.E. • Replace the system contacts are already stuck in the closing position • The P.E is not • Check the connection of OPEN CONTACTOR the P.E. (B) Emergency button power connected • The microcontroller opens the • Check current absorpcontacts opened by the P.E. contacts because of tions microcontroller detected anomalies • Disconnected motor • Check the connections I TR.=0 (EVER) • Broken current sensor • Replace the system (B) Null traction current during running or braking • Wrong reading of the • Replace the system HIGH I TR. ST. BY current sensors (B) High rotor current • Anomalous current flow (running or braking) at towards the traction motor startup or during the traction • Wrong reading of the • Replace the system rest state current sensors HIGH FIELD CURRENT • Anomalous current flow (B) High field current at towards the traction motor startup or at rest • The P.E. coil is not NO FIELD CUR. connected (B) Lack of field current when the traction function is • The motor field is not claimed or during the connected monitoring stage of the traction rest state

• Check the connection of the P.E. Coil • Check the proper connection of the field power cables

17

Workshop manual EGU 30 / EGV 20 / EGP 14-20

ALARM CAPACITOR CHARGE (B) Impossibility to charge the battery condensers of the COMBI power unit

. The chopper temperature is ?7¡ÆC (when a performance drop is observed) or over 90¡ÆC (if the truck is stopped) .

Low battery BATTERY LOW .

Regular operation The lifting is stopped as the .

Broken P.E. control battery is low circuit CHARGING BATTERY . The traction accelerator (B) The battery is being voltage value is higher recharged by the built-in than the preset minimum rectifier at rest CONTACTOR DRIVER . The oil level in the (B) The closing of the P.E. pivoting wheel circuit is power contacts during the too low synchronization stage is . Broken oil level indicator not detected . When it occurs as a TR. ACC NOT OK function is requested, (B) The accelerator voltage probably the sequence is value is incorrect incorrect NO OIL . When it occurs as the (B) truck is switched on, the INCORRECT START P.E. contacts are not Incorrect sequence when opened the truck is switched on or Short circuit on valves when some function is Short circuit on TG. started up Short circuit on EVP. POWER FAILURE 1 Short circuit on F.E.M. 1) Short circuit on outputs Short circuit on main SHORT CIR.DRIVER contactor driver (B) drive request phase FORW + BACK Double drive request (B) Incorrect sequence during drive request phase

Version : April 2003 (Replaces version : )

TH. PROTECTION Thermic protection on the chopper

Copyrighted. Reproduction in any form forbidden Copyright reserved.

PROBALBLE CAUSES . Possible short-circuit on the outlets . Disconnected traction motor armature

08

Electrical System CORRECTIVE ACTION • Check the lack of short circuits on the outlets • Check the proper connection of the trac tion • Switch the truck off and let it rest till the temperature lowers under the limit • Recharge the battery • No corrective action • Check the proper opera tion • Replace the potentiome ter • Replace the system • Perform the program VACC • Check the lack of lea kages • Replace the oil level • Check that one or more of the following devices are not B. Traction or lifting/lowering • Check wiring and Double drive request • Check wiring and • Renew tiller board.

18

08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System MODEL

MODEL

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

PARAMETER CHANGE

EGV 20 EGP 14/20

ACCELER DELAY

9

DECELER DELAY

5

RELEASE BRAKING

5

INVER. BRAKING

5

!

CUTBACK SPEED 1

9

!

CUTBACK SPEED 2

9

CREEP SPEED TR

0

SOFT WORKING

5

!

MAX SPEED FORW

4

!

MAX SPEED BACK

4

MAXI TRACTION

5

ARMA NOM CURR

0

WEAK DROPOUT

5

!

FIELD CURR MAX

9

!

FIELD NOM CURR

9

PU ACCELER DEL

5

PU DECELER DEL

5

LEVER LIFT SPEED

9

LIFT SPEED

9

DOWN SPEED

5

R-SHIFT SPEED

5

L-SHIFT SPEED SLOW LIFT SPEED

5 6

CREEP SPEED PUMP

0

EV. ACCELER DEL

2

EV. DECELER DEL

2

MIN DESC EVP

5

MAX DESC EVP

5

MIN DESC EVP FINE

5

MAX DESC EVP FINE

2

ADJUSTEMENTS

EGV 20 EGP 14/20

ADJUST. BATTERY enables entry of battery voltage value

X

MIN. ACC. LIFT (0V) enables entry of minimum lift potentiometer voltage value

X

MAX. ACC. LIFT (5V) enables entry of maximum lift potentiometer voltage value

X

MIN. ACC. DESC. (0V) enables entry of minimum descent potentiometer voltage value

X

MAX. ACC. DESC. (5V) enables entry of maximum descent potentiometer voltage value

X

value of field nom curr with parameter at 0 and parameter field curr max at 0 value of field nom curr with parameter at 9 and parameter field curr max at 9

value of field nom curr with parameter at 0 and parameter field curr max at 9

11,3

value of field nom curr with parameter at 9 and parameter field curr max at 9

15 parameter not effective

parameter to adjust during test phase

!

warning : modification to this parameter may impair safe use of the machine

EPROM : PICON 041/0375

19

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Parameter setting (standard) MODEL

MODEL SET OPTIONS

EGV 20 EGP 14-20

HARDWARE SETTING

EGV 20 EGP 14/20

HOUR COUNTER

SET CURRENT

RUNNER

x

300 A

KEY ON BATTERY CHECK

!

ON OFF

!

x

SET FIELD CURRENT A

x

PRESENT

Version : April 2003 (Replaces version : )

3

0-9

2

LOAD HOURS MDI

LIFT BLOCK ABSENT

ON x

QUICK INVERSION BELLY

OFF

x

PROPORTION LIFT PRESENT

x

CHECK UP DONE ON

TIMED !

0-9 ADJUSTMENT 02

ON

!

28

ADJUSTMENT 01

SHIFT FUNCTION OF

x

200A

OFF

x

NONE

x

CHECK UP TYPE x

ABSENT

OPTION #1

BRAKE IN QCK. INV.

OPTION #2 ON

x

OFF BRAKE IN RELEASE ON OFF

x

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EV.TYPE NONE OPTION #1

x

OPTION #2 CUTBACK SP. TUPE NONE

x

OPTION #1 OPTION #2 SOFT WORK NONE

x

OPTION #1 OPTION #2

ALWAYS CHECK EPROM VERSIONS

CODE : 452506030 20

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

COMBI System EPROM Replacement

Version : April 2003 (Replaces version : )

Using a cross screwdriver, unscrew the securing screws of the inspection cover.

Remove the inspection cover.

Remember that the seal gasket should be placed in the same position during closing.

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Gasket

Inspection Cover

21

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

In order to remove the EPROM, use the suitable extractor for integrated circuits.

Put the extractor hooks under the narrower sides of the EPROM. Slightly press the extractor arms and slowly pull outwards.

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

From the inspection hole, it is possible to see the COMBI system EPROM.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

It is possible to self-manufacture the inte grated circuit extractor, using a meta strap stripe having the following dimen sions:18X1 cm.

Bend the ends of the stripe at 90° for 5 mm, then insert it into a piece of thermoshrinking 16cm-long sheath.

Heat the thermo-shrinking sheath so that it sticks to the metal stripe surface.

Finally, U-bend the central part of the metal stripe.

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Version : April 2003 (Replaces version : )

The EPROM will remain trapped by the extractor arms.

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Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

During the assembling stage of the new EPROM, carefully place the reference notch that is carved on the EPROM casing so ved in the visible serigraph of the printed circuit.

Begin the assembling by inserting first the lower row of EPROM pins into the base.

Then, slightly pushing downwards, align the upper row of pins with the base pins and fully insert them.

Warning: check that all the EPROM pins have been perfectly inserted into the base.

asar

Reference Notch

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Version : April 2003 (Replaces version : )

Reference Notch

24

08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Electrical System

COMBI System Input/Output Diagram

Version : April 2003 (Replaces version : )

6P1

2Y2 Y1

1S1 1S4

Copyrighted. Reproduction in any form forbidden Copyright reserved.

1S5

Charger Switch (option)

trac. 2

TILLER

lift. 2

Drawing n° 452506003

25

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Electric System Sheathes and Connectors

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Drivend lift Controller

Console

26

4H1

1S1

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Y1

Version : April 2003 (Replaces version : )

S1

Drawing : 452506001

2Y2

6P1

Workshop manual EGU 30 / EGV 20 / EGP 14-20 Electrical System

08

27

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20/ EGP 14- 20 Electrical System

08

Wiring Diagram

28

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

A1/A2 A1 A2 F1/F2 FU1 FU2 FU3 G1 G2 4H1 1M1 2M1 6P1 QS1 S1 1S4 1S5 2S1 2S4 2S5 2S6 2S7 2S6 4S1 7S1 7S2 7K1 7B1 1R1 1R2 Y1 2Y2

Drive Motot Armature Electronic Control (COMBI) Tiller Card Drive Motor Field Power fuse (300A) Electronic fuse (5A) Auxiliary fuse (10A) Battery Built in charger Horn Drive Motor Lift Pump Motor Battery Low indicator + Hour Counter (BDI) Emergency switch pushbutton Key switch RH Slow Speed Drive Pushbutton (optional) LH Slow Speed Drive Pushbutton (optional) Oil level sensor Upper RH Lift Lever Upper LH Lowering Lever Lower RH Lowering Lever Lower LH Lift Lever List Microdistributor Horn pushbutton Tiller safety Pushbutton = Q1 + S2 Tiller safety pushbutton (Belly switch) Built in charger relay Tiller lever sensor Tiller Drive Potentiometer Tiller Lowering/Lifting Potentiometer Electromagnetic Brake Lowering electrovalve

XA XB XBS XC XD XE XF XG XJ XK XL XM XN

2-pole Connector 2-pole Connector (2S4) 4-pole Connector (7S2) 2-pole Connector (2S5) 2-pole Connector 4-pole Dupont Connector (2R1) 2-pole Connector 2-pole Connector (2S6) 4-pole Connector (1R1) 2-pole Connector (2S7) 2-pole Connector (4S1) 2-pole Connector Soldered Cables without Connector (X0)

X1-1 X1-2 X2 X3 X4 X5 1X1 2X1 6X1 6X2 +B -T F1 F2 -P

+ Battery plug - Battery plug 3-pole connector (G2) 42 pole connector (A1) 10-pole connector (A2 + 1X1) 10-pole connector (7K1, Y1, 7B1) 4-pole SAAB connector (optional 1S4, 1S5) 4 pole connector (2Y2) 6 pole connector (for hand set console) 8 pole connector (6P1) A1 (1M1) and D1E1 (2M1) A2 (1M1) F1 (1M1) F2 (1M1) D2E2 (2M1)

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Version : April 2003 (Replaces version : )

Legend to wiring diagram

29

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Tiller card Diagram

View from potentiometer side

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

XO

XA XB XC XD XE XF XG XJ XK XL XM XN

description lift button lowering button lift potentiometer lowering button drive potentiometer lift button horn button cable-card connections

PIN 1 2 3 4

XJ Description BPOT 2 +5V DC POT 1

PIN 1 2 3 4 5 6

XN et XO Description +24V DC - BATT CPOTT 2 DRFT Belly switch CPOTS2

PIN 1 2 3 4

XE Description POT1 + 5V DC POT2 B-

Driwing 452249553 30

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Batteries The battery compartment was designed to house batteries complying with DIN 43535 standard, as well as batteries with oversize cells complying with EN 60254-2 standard.

These liquid-electrolyte lead-acid storage batteries are (all) available in two versions : standard (with manual topping up) and with automatic topping up.

They are contained in “box” containers that are lined inside with an acid corrosion-proofing material, which constitutes an electrical insulation coating. These containers are externally coated with special antiacid coverings. As the battery compartment is closed by the cover, no speficic colour was required (RAL), therefore, the containers are painted with the supplier’s standard colour.

Battery Dimensions and Weights Battery General Specifications Battery

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Version : April 2003 (Replaces version : )

Code

Voltage Capacity

V

Ah

Dimensions

mm

Length x Width

DIN 43535 References Weight

kg ±5%

EN 60254-2 References

Element Element

Element

Diagram Abbreviation

Version

Terminals

and Type

x Height

Small 89428013 DIN Small 89428019 DIN Large 452228011 DIN Large 452228014 DIN

24

220 624x212x627

212

B

2 PzS 220 L LF

screw

24

250 624x212x627

220

B

-

LF

screw

24

330

624x284x627

288

B

3 PzS 330 L LF

screw

24

375 624x284x627

305

B

-

screw

LF

Battery Connectors (Socket and Plug)

The connectors used comply with the DIN 43568 and FEM 4007a and 4007b standards, and they withstand a rated current of 160A. They are housed under the cover closing the battery compartment and they are placed on the battery (for all the versions).

31

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Battery Replacement The battery can be replaced in the following ways: • Vertical Extraction/Introduction (Standard) • Side Extraction/Introduction (Optional) • Battery vertical extraction :

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

The side extraction of the battery is available as an optional : (The bottom of the battery compartment is equipped with rolls, the side panel 1should be removed in order to reach them)

Battery Fixed / Movable Rack (Optional) Fixed rack : It is a metal frame equipped with rolls and with an adjustable safety stop to lock the battery in the right position. This rack was designed to carry a single battery.

No. 2 fixed racks are required in order to perform the battery change.

Movable rack : Its frame is similar to the fixed rack. It is mounted on a suitable transpallet and is equipped with an adjustable safety stop to lock the battery in the right position. The transpallet lifting device is used in order to make the height adjustment of the rolls easy. This rack was designed to carry a single battery.

32

Workshop manual EGU 30 / EGV 20 / EGP 14-20

08

Electrical System

Vertical battery removal Extract the battery vertically using an overhead travelling crane. The battery must be attached to lifting ropes.

Check that the breaking strength of the ropes is greater than the total weight of the battery.

Check that the connection bars between the battery elements are fitted with the insulating cover.

Take care not to short circuit the battery terminals.

After removing the battery, position it well clear of the work area.

Installing the battery

Version : April 2003 (Replaces version : )

While installing the battery pay attention to cables and connectors ; these parts must be positioned outside the battery compartment to eliminate the risk of them being severed by shearing action during the insertion of the battery.

After inserting the battery into the compartment, position the retaining pads between the case and the compartment, arranged in a triangular formation.

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Battery retaining

Battery terminals located on LH side facing the forks side

33

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Contents

09

Accessories

Page

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Toute forme de reproduction interdite.

Copyright reserved.

Version : Septembre 2003 (En remplacement de la version :

)

Battery Descharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

09

Accessories

Battery Descharge Indicator (B.D.I) The Indicator – Hour Counter instrument : • Shows the truck operation time (running or lifting/lowering), which is expressed in hours (Running). Otherwise, it is possible to pair off the count cut-in with one setting of the start-up switch only, that is to say with the “l” setting (Key on).

• Shows the battery charge level, by displaying it on a coloured 10-led row.

• Shows that the start-up switch is on “l” setting, by switching the led row on.

• Stops the lifting operation when the battery is by 80% down.

Version : April 2003 (Replaces version : )

A)Hour Counter Display : When the hour counter is working, the hourglass on the left side of the display blinks (15 times per minute approximately).

Five digits and one place of decimals are displayed. Starting from zero, the numbering progressively increases.

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1-2 Red leds 3-4-5 Yellow-orange leds 6-7-8-9-10 Green leds

B) Led-row indicator relevant to the battery charge state : • When the battery is 100% charged, only the led 10 is on.

Whereas, while the battery is running down, the leds switch on one at a time, from right to left.

• When the battery is by 70% down, both leds 1 and 2 blink at the same time, which means that the battery should be recharged (low).

• When the battery is by 80% down, both leds 1 and 2 alternately blink, which means that the lifting stop threshold has been reached.

• This instrument has a fixed recovery voltage threshold, therefore, the shift from the totally or partially low battery indication to the 100% charged battery indication occurs only if the voltage applied is >25.1 V (Figure supplied by the manufacturer).

Thus, you need to keep in mind that when you replace a totally low battery with a partially low battery (having a voltage < 25.1 V), the instrument does not show the change of charge, but keeps on displaying the previous charge level.

01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Trimmer figure

09

Accessories

Table of the instrument reference voltages, when the battery is by 80% down, with regard to the trimmer letters : K 1.57 V for each cell L 1.65 V for each cell M 1.68 V for each cell N 1.73 V for each cell (Standard setting) O 1.78 V for each cell P 1.82 V for each cell Q 1.84 V for each cell R 1.86 V for each cell S 1.89 V for each cell T 1.91 V for each cell U 1.93 V for each cell

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

The discharge trimmer should be set on the K setting.

Recovery CURTIS 803 has a fixed recovery threshold that is set by the manufacturer.

The following two kinds of recovery are possible: • When the battery is disconnected during its charge, CURTIS 803 will recover if the battery voltage is equal or higher than 2.09 V for each cell.

• When the battery keeps being connected to the equipment during its charge (for example: battery charger installed on the equipment), CURTIS 803 will recover when the battery voltage reaches 2.35V for each cell.

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Relève de la protection du droit d'auteur.

Toute forme de reproduction interdite.

Copyright reserved.

Version : Septembre 2003 (En remplacement de la version :

)

Contents

10

Hydraulics

Page

Lifting, Lowering and Interlock Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Hydraulic Unit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Hoister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Duplex PAL Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 3 KW Hydraulic Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 Hydraulic Unit and Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 Proportional Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Proportional Valve Overhauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lifting Cylinder Overhauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Topping up of the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Lifting System Lifting , Lowering and Interlock Devices As for the lowering function, there is no interlock (Only in the event of a COMBI defect).

The lifting and lowering enabling occurs by pressing the relevant tiller pushbuttons.

In the following operating conditions, lifting is blocked : Blocked Lifting

Operator Actual Manoeuvre Continuous use of the battery till the limit fixed by the manufacturer that is equal to an 80% down battery. (Low-battery lifting block) Disconnected connector of the indicator - hour counter COMBI blocking alarm

As to lifting and lowering speeds, please refer to the specifications sheet.

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Version : April 2003 (Replaces version : )

Hydraulic Unit Motor The hydraulic unit motors have the following features: • Power supply voltage: 24 V DC • Power 3 kW (compound excitation) for the 2,000 kg version with all masts.

Hoister

Their main features are : • Use of cushion advance and retract cylinders to avoid the irritating "bang" during the free elevation getting out and getting in (Simplex, Duplex GAL, Triplex GAL) • Production pulley protection laminations • Production column net protection • Newly manufactured higher-visibility front • Production stiffened front for 2,000 kg capacity • Front with fixed forks as standard and adjustable angle forks in option only for the 1,400 kg capacity version • Simplex, duplex PAL and GAL, triplex GAL column • A load-bearing grate on the front is available as an optional.

01

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Fork Lifting Fork Lowering

Fonction

Version : April 2003 (Replaces version : )

Activation sequence Motor-pump 2Y1 on off off on

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Duplex PAL Hydraulic Diagram (Small Free Elevation)

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Proportional Valve

Proportional valve Proportional solenoid valve complete with block and G3/8 connections 452105060

03

3

2

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Version : April 2003 (Replaces version : )

Item 1 2 3 *

1

Description Part n° 2,2 Kw control unit Plug Tank Kit supplied with control unit

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

2.2 KW Hydraulic Unit Assembly

04

3

2

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1

Version : April 2003 (Replaces version : )

Item 1 2 3 *

452305100

Description Part n° 3 Kw control unit Plug Tank Kit supplied with control unit

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

KW Hydraulic Unit Assembly

05

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Hydraulic Unit and Tank Removal Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

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Version : April 2003 (Replaces version : )

Unscrew the clamp securing the pump casing to the support.

Lift the clamp by removing it from the support.

Unscrew the fitting of the draining pipe on the hydraulic unit.

Place some absorbing material under the pipes to drop the oil.

06

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Unscrew and remove the securing nuts of the power cable terminals of the pump motor.

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Version : April 2003 (Replaces version : )

Unscrew the fitting of the delivery pipe on the hydraulic unit.

07

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Version : April 2003 (Replaces version : )

Move the tank equipped with the pump away from the battery compartment wall.

Unscrew the closing screw of the clamp that fastens the hydraulic unit to the tank.

Widen the clamp as much as it is necessary, hold the pump motor with your hands and strongly lift it till the tank is fully pulled out.

Now, it will be possible to perform the overhauling of the motor, of the hydraulic unit, of the gear pump as well as the cleaning of the filters that are placed at the ends of the pipes.

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Oil level marks

In order to replace the hydraulic oil, remove the tank and empty its contents in the suitable disposal container, according to the regulations in force.

Carefully clean the bottom of the tank to remove any settled waste.

Fill the tank with AP31 hydraulic oil, referring to the marks shown on the tank body.

08

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Proportional Valve Removal Danger!

During all the operations inside the motor compartment : - Disconnect the battery plug - Remove the FU4 fuse

Warning: this operation must be performed after having made sure that the forks are in their fully lowered position.

Unscrew retaining screw 1 of the coil connector.

Use the relevant wrench to unscrew union 3 connecting the return line to the proportional valve outlet.

Unscrew the 4 screws responsible for fixing the proportional valve to its support.

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Version : April 2003 (Replaces version : )

Use the relevant wrench to unscrew union 2 connecting the supply line to the proportional valve inlet.

09

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Proportional Valve Overhauling

By means of a wrench, unscrew the valve and remove it from the body.

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Version : April 2003 (Replaces version : )

Clamp the proportional valve body in a vice, interposing two aluminium angle bars between the proportional valve and the jaws.

Using a screwdriver, remove the safety ring that holds the coil.

10

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

In order to overhaul the proportional valve, it is necessary to disassemble it in all its components.

This operation is useful in order to troubleshoot any malfunction, such as, for instance, whether there are foreign bodies inside the mechanism that may prevent its proper movement.

During the overhauling operation, it is possible to replace the valve or the seal O-rings.

As for the assembling stage, the same operations should be performed but in a reverse manner.

Once the assembling has been executed, check the proper functioning of the valve.

11

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

As for the lifting cylinders removal, strictly comply with the safety rules.

The upper plug of the cylinder should be removed by means of the pin wrench.

Warning: there is some thread-locking adhesive.

Remember to use the threadlocking adhesive during the assembling operation.

Version : April 2003 (Replaces version : )

Upper plug

Hole

Gaskets

All the cylinders are self-braking.

The pistons look like double-effect pistons, but actually they are plungers.

The seal gasket is used for achieving a slowdown arriving to and departing from the end of stroke, when the stem is completely out. The hole on the stem functions as a valve, as it closed by the upper plug.

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spacer

12

Workshop manual EGU 30 / EGV 20 / EGP 14-20

10

Hydraulics

Topping up of the hydraulic oil Remove the fairings with the truck switched off.

Fit the keyswitch and the battery charge indicator / hour meter.

Switch on the truck.

Activate the fork lifting control until the forks reach the maximum lift height.

If this proves impossible due to lack of oil in the tank, pour in oil through the filler hole T until reaching the maximum lifting height.

In this condition the oil level must reach 20 mm with respect to the raised part of the bottom of the tank (i.e. the part in correspondence with the pivoting wheel).

Version : April 2003 (Replaces version : )

Warning: to prevent possible leakage from the filler plug breather hole due to splashing of the oil inside the tank when the truck is travelling, it is advisable not to exceed the 20 mm mark as described above.

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Oil Type

Standard

46 HM

Cold Store

HVLP 32

13

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Contents

28

Built-in Charger

Page

Relève de la protection du droit d'auteur.

Toute forme de reproduction interdite.

Copyright reserved.

Version : Septembre 2003 (En remplacement de la version :

)

Built-in charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 Access comportment to the battery charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01

Workshop manual EGU 30 / EGV 20 / EGP 14-20

28

Built-in Charger

Built-in Charger (Optional) The charger is mounted on the body, inside the motor compartment, and its socket can be reached through the suitable window cut in the cover.

Warning: Before charging the battery always switch off the truck.

The charger is equipped with an internal relay designed to detect the presence of the power supply and connected electrically to the COMBI system. The system provides the following operation :

Version : April 2003 (Replaces version : )

Operational condition Truck ON and rectifier powered

Operation Immediate interruption of power circuits by opening of the emergency button contacts

It is a battery charger having the following specifications: • Power supply voltage: 230V +10/-15% AC • Frequency: 50-60 Hz +/-1% • Output rated current: 50A +/-2% • Output rated voltage: 24V DC • The plug is schuko type 2P+T 16A 250V • The recharge time depends on the battery capacity: 7÷16 hours • Inclusive of inner mains voltage pilot relay Data supplied by the manufacturer

Copyrighted. Reproduction in any form forbidden Copyright reserved.

N.B. The built-in rectifier is not available for the cold-storage room version.

Access Compartment to the Battery Charger Power Supply Cable An access compartment to reach the built-in battery charger power supply cable may be provided on the bonnet.

In order to reach the power supply cable plug of the built-in battery charger, you should lift the suitable opening cut in the bonnet on one side (As shown in the Figure beside).

The plug lies within a special housing that is able to keep it fastened to the opening. In order to remove the plug, you should push it towards the opening and, at the same time, pull it upwards.

This procedure is easy and handy.

This compartment is not provided on the bonnet of the production truck.

01

32

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Special tools

Contents

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Percussion Extrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Threaded Pins For Percussion Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tiller Spring Pre-reloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Cylinder Ectraction and Introduction Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EPROM Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Console for drive-hydraulic controller and interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 01 02 03 03 04 05

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Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20

32

Special tools

Percussion Extractor

01

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Threaded Pins for Percussion Extractor

32

Special tools

02

Workshop manual EGU 30 / EGV 20 / EGP 14-20

Special tools

Lifting Cylinder Extraction and Introduction Tool

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

Tiller Spring Pre-reloading Tool

32

03

Workshop manual EGU 30 / EGV 20 / EGP 14-20

32 Special tools

EPROM Extractor

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Version : April 2003 (Replaces version : )

It is possible to self-manufacture the integrated circuit extractor, using a metal strap stripe having the following dimensions:18X1 cm.

Bend the ends of the stripe at 90° for 5 mm, then insert it into a piece of thermo-shrinking 16cm-long sheath.

Heat the thermo-shrinking sheath so that it sticks to the metal stripe surface.

Finally, U-bend the central part of the metal stripe.

04

Workshop manual EGU 30 / EGV 20 / EGP 14-20

32 Special tools

Interface Console/truck for drive/ hydraulic controller part number : 0157205

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Version : April 2003 (Replaces version : )

Console for drive/hydraulic contoller part number : 4494118

05