STILL STED forklift Pallet truck ECU14 ECU 14 Full Lead ECU16 ECU18 ECU20 Workshop Manual

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STILL

Workshop literature

Pallet truck ECU14 ECU 14 Full Lead ECU16 ECU18 ECU20

0164 0165 0166 0167 0176 45588042311 EN - 4/2020

first in intralogistics

CE

First edition.

Various improvements and corrections: "Electrical isolation measurement (added)" "Full Lead version (added)"

"New temperature sensor (PT1000)" Various improvements and corrections:

45588042311 EN - 4/2020

I

The precautions , , , und in this manual are provided to indicate special hazards or unusual information requiring special identification:

Identifies technical information requiring special attention because the connection may not even be obvious to skilled personnel.

The information contained herein must be observed, otherwise environmental damage may occur. indicates hazards that may result in personal injury and/or substantial damage to the product.

For your safety other symbols are also used.

Please note the different symbols.

indicates hazards that may result in damage to or destruction of the product.

45588042311 EN - 4/2020

III

Do the following before performing maintenance operations: Position the truck on a flat surface and make sure that it cannot move accidentally Fully lower the forks Switch off the truck

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

dence, paying attention to possible causes of accident and their consequences, scrupulously following the safety rules.

For this reason, accidents can be avoided in most cases by the necessary care and pru-

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

IV

45588042311 EN - 4/2020

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

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

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

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

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

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

Do not disperse oils or other operating liquids!

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

Do not inhale the vapour: it is poisonous.

Wear appropriate personal protective equipment to prevent contact with the skin.

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

Explosive gas mixtures can form when charging the battery; therefore, the rooms in which the battery is charged must be in compliance with the specific regulations on the subject (e.g. EN 62485-3 etc.).

DO NOT smoke or use open flames and lights within a 2-m radius of the charged battery or in the battery charging area.

Always comply with anti-pollution regulations!

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

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

Avoid contact with skin.

Do not inhale oil vapours.

Wear appropriate personal protective equipment during truck maintenance operations (gloves, goggles etc.) to prevent the oil from coming into contact with your skin.

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

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

The used oils and relative filters contain substances that are hazardous to the environment and they must be disposed of according to current regulations. We advise you to contact the authorised service network.

45588042311 EN - 4/2020

V

A truck specifically equipped for cold-storage rooms must be used when working at .

A truck equipped for working in cold climates and cold-storage rooms may be used: Up to -5°C for From -5°C to -32°C for

If the truck has been working in environments at temperatures below -5°C and it is taken outside the coldstorage room, let it stand either for a sufficiently long time to allow any condensation to evaporate (at least 30 minutes) or a sufficiently short time to prevent the formation of any condensation (less than 10 minutes).

The truck must always be switched off and parked outside the cold area/cold-storage room.

VI

45588042311 EN - 4/2020

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45588042311 EN - 4/2020

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45588042311 EN - 4/2020

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45588042311 EN - 4/2020

IX

Example: Complete serial number.

= plant in Luzzara (Italy).

ECU 14 ECU 16 ECU 18 ECU 20 ECU 14 Full Lead

= 2020 201x 202x

0 A X

1 B Y

2 C K

3 D L

4 E M

5 F N

6 G P

7 H R

8 J S

9 V T

Start of series production = 2012

= Number increasing from start of production. This is reset at the beginning of each calendar year.

45588042311 EN - 4/2020

-1

1

2

3

4

11

12

5

6

Please indicate the serial number for all technical enquiries.

*

7

8 9

10

13 2327

The truck's serial number is marked on the chassis frame (1).

The serial number is not visible when the truck forks are lowered.

To view the serial number, raise the forks, as the truck serial number (1) is positioned in the lower part of the fixed chassis in an area specifically protected from damage during use.

1 2337

-2

45588042311 EN - 4/2020

In case of emergency, take hold of the battery plug (1) and, pulling upwards, remove it from the battery socket.

1

This blocks all of the forklift functions; the forklift will brake and stop.

OM1774

45588042311 EN - 4/2020

-3

Checks and tests before use Check wheel tightness Grease the reducer fifth wheel Check the condition of the piping Check hydraulic system oil level Check reducer oil level Check bushes and levers Check pivot wheels Check the condition of battery and truck wiring Check insulation between chassis and any electric motors Check insulation between chassis and electronic control Grease micro tiller (1) Check air gap, carry out any adjustment or disc replacement Grease the rods and levers Change hydraulic system oil = to be carried out every 1000 hours or 6 months, whichever comes first.

To be repeated every 1000 hours. For example at 1000, 2000, 3000, 4000, 5000. . .

To be repeated every 2000 hours. For example at 2000, 4000, 6000, 8000, 10,000. . .

To be repeated every 3000 hours. For example at 3000, 6000 and 9000. . .

During maintenance operations, follow the instructions provided in the section "Safety regulations relative to operating materials" in "Chapter 2".

-4

45588042311 EN - 4/2020

Hydraulic system Reduction gear unit General lubrication

HLF 32 Tutela MATRIX Tutela MP02

Hydraulic system Reduction gear unit General lubrication

Tutela GI/M Tutela MATRIX Tutela Jota

45588042311 EN - 4/2020

-5

These tolerances refer to the data in the datasheet. h3 h13 s/e/l b5

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

These tolerances refer to the technical sheet data.

Drive speed when unloaded Drive speed with 1400 kg Drive speed with 1600 kg Drive speed with 1800 kg Drive speed with 2000 kg Speed lifting Speed lowering

-6

+0 / -5% +0 / -5% +0 / -5% +0 / -5% +0 / -5% ± 5% +0 / -10%

45588042311 EN - 4/2020

The truck insulation must have sufficient resistance, which must be evaluated according to DIN 57117 and DIN 43539, VDE 0117 and VDE 0510 at least once a year.

The truck's electrical system and the battery must be tested separately.

Nominal battery voltage < test voltage < 500 [V].

– Measure the insulation resistance using a suitable instrument.

The insulation resistance is sufficient when it has a nominal value of against the chassis.

Please contact the service department.

Nominal battery voltage < test voltage < 500 [V].

– Make sure that there is no voltage in the truck's electrical system.

– Measure the insulation resistance using a suitable instrument.

The insulation resistance is sufficient when it has a nominal value of against the chassis.

Please contact the service department.

45588042311 EN - 4/2020

-7

-8

45588042311 EN - 4/2020

The diagnostic connector on the electronics panel is marked with an arrow in the diagram.

45588042311 EN - 4/2020

-1

The diagnostics unit must be used by trained personnel only. The variation of some parameters or configurations may create hazardous situations for the operator (e.g. an increase in traction speed). .

Before accessing the "PC programming station" software, check the connections between the PC and the truck. See section "Connections prior to truck diagnostics".

The connections between the PC and truck must be performed with the truck turned off.

– Start the " software by double clicking.

"

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



– Enter the "



-2

" menu, and click on .

45588042311 EN - 4/2020

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

Ɣ Ɣ



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

– Enter the menu, choose " " and then " ".



– Wait until the main page, shown at the side, appears.



–

: The program " " contains numerous menus and functions. It is not possible to explain all the functions; the most important will be dealt with here. However, those who wish to study the matter in more depth can refer to the on-line program.

– For access to the main menus, click with the left mouse key on the icon indicated by the arrow in the figure at the side . The code at the side of the icon represents the electronic control model (code in the figure: 1236-4403)



45588042311 EN - 4/2020

-3

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



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

The menus available are the following:

– " " = This menu allows for the display of information regarding the traction controller.



– " " = This menu allows for adjustment of the traction controller parameters.



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



-4

45588042311 EN - 4/2020

–

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

– " present.

" = This menu is empty at





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

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



– " " = This menu allows the display of the history of previous device alarms.



45588042311 EN - 4/2020

-5

– Right clicking on the alarm displays further information.



= For deleting the fault history after having read it. For this purpose, select (in the drop-down menu), which appears when the right mouse button is clicked on the menu. The program will ask for confirmation before cancelling the alarms history.



–

-6

45588042311 EN - 4/2020

Legend: M1 = MODE1 = Standard operation.

M2 = MODE2 = Operation with tiller always active (slow speed).

Time taken by the electronic system to increase the motor output from 0 to 100% in Mode 1 2.

Time taken by the electronic system to reduce the motor output to zero when the accelerator is totally released in Mode 1 2.

Time taken by the electronic system to increase braking current from 0 to 100% when changing direction in Mode 1 2.

Time taken by the electronic system to reduce the motor output to zero on releasing the tiller microswitch or pressing the anticrush emergency button.

Deceleration on partial release of the accelerator.

No effect on the truck.

No effect on the truck.

How fast the electronic system reduces the speed after the throttle is released.

Accelerator dead zone: the zone of the potentiometer which the electronic system interprets as a neutral zone before the adjustment zone. Percentage of the nominal voltage value of the drive potentiometer.

Drive potentiometer voltage required for the electronic system output to reach 100%. Percentage of the nominal voltage value of the drive potentiometer.

Traction motor output with the accelerator at 50%. It determines the acceleration curve.

Time after which the electromagnetic brake is released. It is measured from the instant in which the accelerator reaches 0%.

Truck speed when the Belly button is pressed.

Maximum traction duration with Belly button pressed.

Voltage for each battery cell which indicates a discharged battery.

Set to ON, it activates speed reduction after "Total Service Hours" have elapsed.

Set to ON, it activates speed reduction after "Drive Service Hours" have elapsed.

45588042311 EN - 4/2020

-7

For setting the hours meter (e.g. after replacing the electronic control system).

Set to ON, it adds "Adjust Hours" to the total hour meter count.

Set to ON, it adds "Adjust Hours" to the drive hour meter count.

For selecting the number of hours before the next servicing deadline.

For selecting the number of hours before the next traction motor servicing deadline.

Speed reduction is activated after this time has elapsed.

Speed reduction is activated after this time has elapsed.

Slow speed (both M1 and M2) applied to traction after the servicing deadline has elapsed.

The electronic system sets this parameter to ON after the total service time has elapsed. It must be reset to OFF when the appropriate service has been performed.

The electronic system sets this parameter to ON after the drive service time has elapsed. It must be reset to OFF when the appropriate service has been performed.

If set to ON, the battery charge status check is activated.

If set to ON, the block on lifting with residual battery capacity below 20% is activated.

Maximum operating time of lifting contactor.

-8

Battery voltage.

Battery charge percentage.

Motor speed.

Motor voltage.

Motor frequency.

Motor slip.

v % rpm v Hz Hz

Drive potentiometer as percentage.

%

Tiller microswitch.

Forward microswitch.

Reverse microswitch.

Operating mode selection.

Anti-crush emergency function microswitch.

Lifting microswitch.

ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF

45588042311 EN - 4/2020

Not used Not used Not used Not used Not used

Pin 23 output status (pump contactor control) Pin 24 output status (lowering solenoid valve control) Not used

ON/OFF

Electronic system internal temperature.

Main contactor status Period of time before next service (drive and lifting).

Period of time before next service (drive).

Not used

°C ON/OFF

ON/OFF

Hr Hr

Current alarms

List of stored alarms

Delete list of stored alarms

Shows the features of the electronic control system (e.g. serial number, type, software version, etc.).

45588042311 EN - 4/2020

-9

(from table of parameters code 45588089009 Version 00 - 05/2012)

-10

M1 Accel Rate M2 Accel Rate M1 Decel Rate M2 Decel Rate M1 Brake Rate M2 Brake Rate Fast Stop Rate Accel Release Rate M1 Min Speed M2 Min Speed M1 Max Speed Coast Decel Rate Throttle Deadband Throttle Max Throttle Map Brake Delay

4.5 5.0 1.4 0.7 0.5 1.0 0.1 0.0 10.0 10.0 100.0 2.0 3.0 85.0 15.0 0.2

0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.0 0.0 0.0 10.0 0.1 0.0 40.0 5.0 0.0

5.0 5.0 10.0 10.0 3.0 3.0 5.0 1.0 50.0 41.0 100.0 20.0 30.0 100.0 90.0 2.0

Seconds Seconds Seconds Seconds Seconds Seconds Seconds Seconds % % % Seconds % % % Seconds

Speed

17.0

0.0

25.0

%

Time Limit

6.0

0.0

6.0

Seconds

Empty Battery Voltage Enable Total Service Hours Enable Drive Service Hours Adjust Hours Set Total Hours Set Drive Hours Total Service Hours Drive Service Hours Total Disable Hours Drive Disable Hours Drive Disable Speed Service Total Expired Service Drive Expired Pump Lockout Check Enable Pump BDI Lockout Max Pump Run Time

1.90

0.90

3.00

Volts

0.0

0.0

1.0

0.0

0.0

1.0

0.0 0.0 0.0 5000.0 5000.0 10.0 10.0 80.0 0.0 0.0

0.0 0.0 0.0 100.0 100.0 0.0 0.0 0.0 0.0 0.0

999999.0 1.0 1.0 5000.0 5000.0 500.0 500.0 100.0 1.0 1.0

0.0

0.0

1.0

0.0 3.5

0.0 0.0

1.0 60.0

45588042311 EN - 4/2020

Hours

Hours Hours Hours Hours %

Seconds

(from table of parameters, code 45588089010 Version 00 - 05/2012)

M1 Accel Rate M2 Accel Rate M1 Decel Rate M2 Decel Rate M1 Brake Rate M2 Brake Rate Fast Stop Rate Accel Release Rate M1 Min Speed M2 Min Speed M1 Max Speed Coast Decel Rate Throttle Deadband Throttle Max Throttle Map Brake Delay Speed Time Limit

2.6 5.0 1.4 0.7 0.5 1.0 0.1 0.0 10.0 10.0 100.0 2.0 3.0 85.0 15.0 0.2 17.0 6.0

0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.0 0.0 0.0 10.0 0.1 0.0 40.0 5.0 0.0 0.0 0.0

5.0 5.0 10.0 10.0 3.0 3.0 5.0 1.0 50.0 41.0 100.0 20.0 30.0 100.0 90.0 2.0 25.0 6.0

Seconds Seconds Seconds Seconds Seconds Seconds Seconds Seconds % % % Seconds % % % Seconds % Seconds

Empty Battery Voltage Enable Total Service Hours Enable Drive Service Hours Adjust Hours Set Total Hours Set Drive Hours Total Service Hours Drive Service Hours Total Disable Hours Drive Disable Hours Drive Disable Speed Service Total Expired Service Drive Expired Pump Lockout Check Enable Pump BDI Lockout Max Pump Run Time

1.73

0.90

3.00

Volts

0.0

0.0

1.0

0.0

0.0

1.0

0.0 0.0 0.0 5000.0 5000.0 10.0 10.0 80.0 0.0 0.0

0.0 0.0 0.0 100.0 100.0 0.0 0.0 0.0 0.0 0.0

999999.0 1.0 1.0 5000.0 5000.0 500.0 500.0 100.0 1.0 1.0

0.0

0.0

1.0

0.0 3.5

0.0 0.0

1.0 60.0

45588042311 EN - 4/2020

Hours

Hours Hours Hours Hours %

Seconds

-11

(from table of parameters, code 45588089011 Version 00 - 05/2012)

-12

M1 Accel Rate M2 Accel Rate M1 Decel Rate M2 Decel Rate M1 Brake Rate M2 Brake Rate Fast Stop Rate Accel Release Rate M1 Min Speed M2 Min Speed M1 Max Speed Coast Decel Rate Throttle Deadband Throttle Max Throttle Map Brake Delay Speed Time Limit

2.6 5.0 1.4 0.7 0.5 1.0 0.1 0.0 10.0 10.0 100.0 2.0 3.0 85.0 15.0 0.2 17.0 6.0

0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.0 0.0 0.0 10.0 0.1 0.0 40.0 5.0 0.0 0.0 0.0

5.0 5.0 10.0 10.0 3.0 3.0 5.0 1.0 50.0 41.0 100.0 20.0 30.0 100.0 90.0 2.0 25.0 6.0

Seconds Seconds Seconds Seconds Seconds Seconds Seconds Seconds % % % Seconds % % % Seconds % Seconds

Empty Battery Voltage Enable Total Service Hours Enable Drive Service Hours Adjust Hours Set Total Hours Set Drive Hours Total Service Hours Drive Service Hours Total Disable Hours Drive Disable Hours Drive Disable Speed Service Total Expired Service Drive Expired Pump Lockout Check Enable Pump BDI Lockout Max Pump Run Time

1.73

0.90

3.00

Volts

0.0

0.0

1.0

0.0

0.0

1.0

0.0 0.0 0.0 5000.0 5000.0 10.0 10.0 80.0 0.0 0.0

0.0 0.0 0.0 100.0 100.0 0.0 0.0 0.0 0.0 0.0

999999.0 1.0 1.0 5000.0 5000.0 500.0 500.0 100.0 1.0 1.0

0.0

0.0

1.0

0.0 3.5

0.0 0.0

1.0 60.0

45588042311 EN - 4/2020

Hours

Hours Hours Hours Hours %

Seconds

Incorrect motor speed

Encoder wiring problem.

Faulty electronic system.

The motor is stalling or running faster than expected.

Encoder wiring problem.

Motor seized.

Low braking torque.

1.2

1.3

1.4

1.5

2.1

2.2

2.3

2.4

Check encoder wiring.

Replace encoder or electronic control system.

Check the encoder wiring.

Replace the encoder.

Check or replace the motor.

Check the encoder wiring.

Current in the drive motor too Replace the encoder. high.

Replace electronic control system.

Motor wiring problems.

Check motor wiring.

Replace the electronic conFaulty electronic system. trol or the drive motor.

Perform the correct ignition sequence: Ignition sequence error (non- Incorrect sequence in truck 1. Key. blocking, but traction is inhibi- ignition phase.

2. Tiller sensor. ted) 3. Direction microswitches and accelerator.

Tiller sensor or "Tiller always active" button active without any other function being requested.

Place the tiller in the vertical After "Min. 0 min./Max. 5 min" position and check the micro has elapsed, the main contiller. tactor opens and the green LED flashes, signalling the alarm condition.

Check whether the potentiometer output is short circuitTraction potentiometer volted on the positive battery terTraction potentiometer voltage is too high. minal. age is too high.

Check operation of traction potentiometer.

Excess current in the motor

Anti-crush safety alarm button

Signal problems on pins 15-16, regarding the anticrush emergency function.

Incorrect sequence in truck Ignition sequence error (nonignition phase. blocking, but drive is disabled).

Traction potentiometer voltage is too low.

Traction potentiometer voltage is too low.

45588042311 EN - 4/2020

Check wiring of pins 15-16.

Replace the electronic card inside the tiller head.

Perform the correct ignition sequence: 1. Key 2. Tiller sensor 3. Direction microswitches and accelerator Check whether the potentiometer output is short circuited on the negative battery terminal.

Check operation of traction potentiometer.

-13

3.1

3.2

Multiplexer function error.

Problem concerning main contactor (blocking).

Capacitor preload error.

3.3

Tiller multiplexer error (not applicable) Main contactor coil short circuited.

Main contactor coil is open circuit or stuck.

Incorrect main contactor wiring.

Capacitor preload error.

Electromagnetic brake coil Electromagnetic brake wiring open. problems.

Brake wiring problems.

Replace electronic control system.

Check the state of the main contactor and replace if it is defective.

Replace electronic control system.

Battery charge too low.

Replace electronic control system.

Check electromagnetic braking.

Replace electronic control system.

The TOTAL DISABLED time has expired.

The DRIVE DISABLED time has expired.

The SERVICE TOTAL time has expired.

4.1

The SERVICE DRIVE time has expired.

4.2

Battery voltage is too high.

Battery voltage is too low.

4.3 4.4

Temperature problems.

Mode selector microswitch tripped during ignition.

Battery voltage higher than permitted limit.

Battery voltage lower than permitted limit.

Electronic system temperature too high (>85°C) or too low (<-25°C).

Mode selector microswitch short circuited on the positive battery terminal.

5.1

Hardware problems.

5.2

Software problems.

5.3

Corrupt parameters.

-14

45588042311 EN - 4/2020

When maintenance has been carried out set the SERVICE TOTAL EXPIRED parameter to OFF. When maintenance has been carried out set the SERVICE DRIVE EXPIRED parameter to OFF. Check the battery voltage.

Replace electronic control system.

Check the battery voltage.

Replace electronic control system.

Check the electronic system temperature.

Check mode selector microswitch.

Replace electronic control system.

Replace electronic control system.

Replace electronic control system.

This is a three-phase AC traction motor with an internal triangular connection with the following characteristics: Supply voltage 14 V AC Power rating 1 Kw

Drive is always disabled under the following conditions: Throttle/tiller placed in rest position.

With the tiller in position 1, after the time interval set for the INTERLOCK TIMEOUT parameter.

Ignition switch turned to position "O" (truck off).

Tiller placed in braking position.

– Using an Allen key, remove the plastic casing unscrewing the three screws.



– Disconnect the encoder connector and remove the wiring (the encoder cable has a black reference mark to adjust the length of the wiring).



45588042311 EN - 4/2020

-1

– Disconnect the electromechanical brake connector and remove it, disconnect the thermal sensor connector and remove the smallest tiller cable, and finally disconnect the control wiring cable coming from the tiller.



– Remove the cable tie on the fixed motor using an Allen key.



– Using an Allen key, disconnect the motor power cables.



– Still using the Allen key, remove the ring holding the cables from the chassis.



-2

45588042311 EN - 4/2020

– Unscrew the three screws on the body of the brake (use a wrench with a narrow shank).



– Lift the brake block out upwards.



– Remove the Seeger ring which locks the brake pinion coupled to the drive shaft.



– Remove the traction motor shaft pinion.



45588042311 EN - 4/2020

-3

– Remove the Seeger ring which locks the bearing to the motor bearing shield and the Seeger ring which locks the bearing to the shaft (as in the adjacent illustrations).



–



– Using an Allen key, unscrew the five screws securing the motor bearing shield.



-4

45588042311 EN - 4/2020

–



– Using an Allen key, remove the encoder pickup.



– Raise the bearing shield / support with the entire drive shaft.



45588042311 EN - 4/2020

-5

– Rest the drive shaft carefully paying attention not to damage the pinion.



– Using an Allen key, unscrew the six screws at the base of the motor.



– Raise the stator.



– To reassemble the traction motor, proceed as described for the disassembly in reverse order, applying the tightening torques (see the relevant section).

-6

45588042311 EN - 4/2020

Ɣ

Following a technical product improvement, the temperature sensor has been replaced with a sensor.

Truck production date ( ) Until 2019 From 2019 (up to serial numbers ... / G / H / (from serial numbers V / X / V) Y / ...)

Example F2 xxxx 00001 Example F2 xxxx 00001 Sensor type X7:1 cable colour X7:2 cable colour Resistance at 20°C Part number of the motor Part number of the tiller head PCB

Ɣ

45588042311 EN - 4/2020

-7

– The temperature sensor signal is processed by the tiller head PCB:



Refer to the circuit diagram for a better understanding.

-8

45588042311 EN - 4/2020

– The resistance of the temperature sensor can be measured using a multimeter. Take the measurement between pins 1 and 2 of the connector X7.

45588042311 EN - 4/2020

-9

-10

-40 -30 -20 -10 0 10

359 391 424 460 498 538

30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

626 672 722 773 826 882 940 1000 1062 1127 1194 1262 1334 1407 1482 1560 1640 1722

45588042311 EN - 4/2020

-40 -30 -20 -10 0 10

843 882 922 961 1000 1039

30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

1117 1155 1194 1232 1271 1309 1347 1385 1423 1461 1498 1536 1573 1610 1648 1685 1722 1758

45588042311 EN - 4/2020

-11

-12

45588042311 EN - 4/2020

2 3 4 5 6 7 8 9 10 11 12 13

14

Joining plate Crown wheel Joining plate Thread guard Motor pinion gear Body Pinion gear Top cover Bottom cover Crown wheel Wheel shaft Special nut with dowel; (apply green Loctite 648. Fully tighten to a torque of 80/90 Nm; loosen; retighten to 30 Nm; use a torque meter to check that the total rolling torque of the shaft and Gleason bearings is between 1.4 and 1.8 Nm. Tighten the dowel to 15 Nm. Caulk the nut near to the dowel.)

Special nut; (apply green Loctite 648. Fully tighten to a torque of 35/40 Nm; loosen; retighten to 15 Nm; use a torque meter to check that the rolling torque of the shaft and

15 16 17 18 19 20 21 22 23 25 27 28 29 (*B) (*C) (*D)

45588042311 EN - 4/2020

Gleason bearings is between 0.8 and 1.2 Nm. Caulk the screw seating.)

Complete fifth wheel Bearing (tightening torque: ) Bearing Tapered roller bearing with crown wheel Gasket Screws (tightening torque: ) Screws (tightening torque: ) Blind plug; (apply red Loctite 542) Shimming ring M8x8 dowel with socket head and conical end Shimming ring Gasket 90° lubrication nipple Assemble covers "9" and "10", placing a silicone gasket between the parts.

Fit joining plate "2" into crown wheel "3" following the arrow.

Caulk near dowel "13".

-1

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



Ring with incorporated bearing Helicoidal pinion

-2

45588042311 EN - 4/2020

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

The reducer is supplied without drive motor.

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

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

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

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

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

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

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

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

The technical service interventions on the reducer include the following points: The helicoidal pinion is installed directly on the drive shaft.

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

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

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

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

The guide bearing is supplied full of grease.

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

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

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

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

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

If the reducer is reassembled after the replacement of any component, it is very important that the position of the taper roller bearings is set

45588042311 EN - 4/2020

-3

correctly and that the form of the contact impressions on the profile of the bevel gears is correct.

This can only be obtained with a perfect shimming of the taper roller bearings.

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

– Use a hoist to raise the truck and rest it safely on trestles.

– To disassemble the reducer gearbox unit, unscrew the 6 screws that fix the reducer gearbox unit to the chassis frame (after having disassembled the traction motor and the tiller flange from the truck).



During reassembly of the complete reducer gearbox, tighten the screws with a torque setting of 45Nm.

– Once the reducer gearbox unit has been disassembled, replace the fifth wheel of the same by unscrewing the 8 hexagon sockethead screws that secure the fifth wheel on to the reducer gearbox.



During reassembly of the fifth wheel onto the reducer gearbox, tighten the screws with a torque setting of 30Nm.

-4

45588042311 EN - 4/2020

– Position the reducer gearbox group on the floor or on a work bench.



– Use an Allen key to remove all the screws of the cover.

Disconnect the battery plug.

– Using a hammer and chisel, lift the cover from the rest of the reducer gearbox.



– The sealing agent keeps the cover attached to the body of the reducer gearbox.

Do not force the cover with the chisel.

Avoid heavy scoring of the support surface of the cover severely.

– Heat the ring nut using a small gas torch, or preferably an electric air heater. This operation is performed in order to soften the thread locking.



– Using an appropriate hook spanner, completely unscrew the retaining ring nut of the crown. In order to block the rotation of the crown wheel and pinion, insert a soft metal wedge between the teeth of the gears, or block the wheel fixing flange in a vice.



45588042311 EN - 4/2020

-5

– Use a soft hammer to strike the shaft of the reducer gearbox, up to the crown surface.



– Position a wooden board or any other soft surface next to the wheel attachment flange.

Using a soft metal drawn tube, strike on the shaft of the reducer gearbox until it is completely extracted.



– Use an Allen key to remove all the clamping screws of the fifth wheel base plate.



– Strike with a soft hammer on the edge of the reducer gearbox cover.



-6

45588042311 EN - 4/2020

– If you remove the races of the main bearings, you will find shims underneath for the calibration of the pinion-crown wheel coupling.



Remember from which of the two bearings the shims were taken.

Tie them together with a cord.

– Insert a hexagon wrench into the hole of the crown wheel. This is in order to block rotation of the shaft during disassembly.



– Using an open-end spanner, unscrew the retaining ring nut of the cylindrical crown with the help of a soft hammer.



– Using the soft hammer, strike on the end of the pinion shaft in order to extract it from its seat. A cone bearing will remain attached to the shaft.



45588042311 EN - 4/2020

-7

– Detail of the parts forming the reducer gearbox. At this point it is possible to clean the various parts and replace, for example, the bearings or the shaft outlet oil seal.

–



: To assemble the reducer gearbox, follow the disassembly instructions in the reverse order, remembering to use the threadlocks where applicable and to clinch the locking tabs of the ring nuts.

Pay special attention to the tightening torques indicated by the manufacturer.

See the reducer gearbox group drawing.

-8

45588042311 EN - 4/2020

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

ting the reducer in motion, after a few revolutions, dots of colour will appear along the profiles, shiny areas that represent the contact zones of the gear teeth.

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

In order to perform this check, oil paint must be applied to the teeth of the gears. Then, by set-

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

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

45588042311 EN - 4/2020

-9

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

-10

Impression towards the external side on the lower part of the crown tooth When the contact impressions of the teeth appear as shown in the figure, the pinion must be advanced towards the crown by adding shims behind the pinion itself.

45588042311 EN - 4/2020

Insufficient clearance

For the reducer oil, see "Supply table".

Impression towards the external side, towards the crest of the pinion tooth

To change the oil, see "Synoptic table of maintenance operations".

Impression towards the internal side, towards the crest of the pinion tooth

Pour the oil into the upper part of the reducer.

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

Impression towards the internal side, towards the lower part of the crown tooth Impression towards the external side, towards the lower part of the crown tooth When the contact impressions of the teeth appear as shown in the figure, the pinion must be moved back by removing shims.

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

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

The reducer is supplied without oil. Ensure it is filled with oil before using the reducer for the first time.

45588042311 EN - 4/2020

-11

-12

45588042311 EN - 4/2020

The following covers are present on the truck: battery compartment cover (A). motor compartment covers (B). tiller cover (C).

45588042311 EN - 4/2020

-1

– Insert a pin punch of the correct dimensions in the hole shown in the illustration, remove the pin and this will release the cover restraint cord; this operation is then performed at the other end point of the cord.



– Using a screwdriver, remove the two screws with their respective washers.



– Remove the two pins to release the cover, position the screwdriver in the pin groove and using a hammer force the pin out.



-2

45588042311 EN - 4/2020

– Loosen the two lateral Allen screws by 2 or 3 turns without removing them.



– Turn the tiller as far as it will go and remove the cover. Remove it noting that there is a centring hole in the back part in which a dowel, found on the internal plastic mask, is inserted.



– Using the screwdriver, remove the lower cover from its seating (the cover is fitted flush).



– Now, the motor cover can be completely removed.



45588042311 EN - 4/2020

-3

– Using an Allen key, remove the screws from the two front mounting points.



– Continue, still using the Allen key, by removing the two side screws.



– Turn the tiller to allow the casing to be removed.



– Lift the cover out from the top.



-4

45588042311 EN - 4/2020

– To remove the tiller closure casing, use an Allen key in the bottom part of the tiller shank.



– Lifting the tiller closure casing in the bottom part of the tiller shank, two new attachment points become visible in the top part of the tiller. Remove the casing.



45588042311 EN - 4/2020

-5

-6

45588042311 EN - 4/2020

The following braking devices are present:

The following braking methods are used: (see section: Stopping the truck in an emergency.)

Braking by battery socket removal: Uncontrolled emergency stop.

Service braking is obtained by releasing the tiller; controlled stop. The negative electromagnetic brake ensures the truck is parked.

Inversion braking is carried out on the moving truck, by inverting the direction using the butterfly lever controlling the drive. Controlled stopping via electrical braking and eventual cut in of electromagnetic brake.

Service and inversion braking recover energy through the efficient management of the drive motor current by the electronic system. This system allows for use of the motor as a generator during braking, and to send the energy (current) to the battery (energy recovery). The energy recovered (and not dissipated by the motor) reduces motor heating and wear of the electromagnetic brake disc.

– Remove the hoods of the truck as described in "31 Chassis"

– 5-mm hexagon socket wrench

45588042311 EN - 4/2020

-1

– Disconnect the plug from the battery socket.



Do not perform maintenance without first disconnecting the plug from the battery socket.

– Unscrew the three mounting screws for the brake using a 5-mm hexagon socket wrench.



– Manually remove the brake by sliding it out from above.



– To reassemble the brake, proceed in the reverse order. Follow the removal instructions in reverse order, taking into account the following.

– Using a 5-mm hexagon socket wrench, tighten the three mounting screws for the brake to a tightening torque of .

-2

45588042311 EN - 4/2020

To improve the functionality of the brake, in May 2016, the brake will be supplied with three additional components: a cap ( ), a seal ( ) and a flange ( ): The cap ( ) is installed under pressure; it is removed using a flathead screwdriver The seal ( ) is fitted to the flange ( ) on one side and to the body of the brake on the other The flange ( ) must be fitted between the motor and the electromagnetic brake If there are problems with brake functionality before modification (usually due to the humidity of the work environment, which tends to jam the brake in the braking position), it is possible to resolve the problem by ordering the three parts individually. For the order codes, consult the parts catalogue.

45588042311 EN - 4/2020

-3

– Remove the hoods of the truck as described in "31 Chassis"

– Feeler gauge

– The electromagnetic brake is

adjustable.

– Switch off the truck and electrically isolate it.

– Using a feeler gauge, check that the value of the air gap is correct as per the following table. (mm) 0.2



(mm) ±0.1

– If the value of the air gap is outside the set tolerances, replace the brake lining disc.

-4

45588042311 EN - 4/2020

The drive wheel is heavy, proceed with care when changing it. The wearing of gloves is recommended.

– Use a hoist to raise the truck and rest it safely on trestles.

– Remove the drive wheel unscrewing the 6 tightening screws.



– To reassemble the drive wheel, proceed as for the disassembly in reverse order.

The tightening torque of the 6 screws is 100 Nm.

45588042311 EN - 4/2020

-5

– Use a hoist to raise the truck and rest it safely on trestles.



– Remove the Seeger ring.



– Loosen the 4 nuts fastening the pivoting wheel.



-6

45588042311 EN - 4/2020

– Completely unscrew the 4 nuts, holding the pivoting wheel from below the hood with the other hand.



Danger of crushing feet.

– To reassemble the pivoting wheel, perform the disassembly operations in reverse order.

The tightening torque of the four nuts is 30 Nm.

Shimming discs are available if necessary to fit between the pivoting wheel and the chassis. For the order codes, consult the parts catalogue.

– Completely unscrew the 4 nuts, holding the pivoting wheel from below the hood with the other hand.



Danger of crushing feet.

– To reassemble the pivoting wheel, perform the disassembly operations in reverse order.

The tightening torque of the four nuts is 30 Nm.

Shimming discs are available if necessary to fit between the pivoting wheel and the chassis. For the order codes, consult the parts catalogue.

45588042311 EN - 4/2020

-7

– If you wish to adjust the height of the wheel according to its wear, unscrew the wheel clamping screw and move the pin inside the ring nut.

-8



45588042311 EN - 4/2020

45588042311 EN - 4/2020

-1

– The tiller head buttons are equipped with special holes to make it easy to remove them.



– To remove the buttons, lever them out, through the special slots, using the levers securing the buttons (for example, using paper clips as can be seen in the photo).



– When the buttons have been released, make sure not to lose the springs.



– It is better to remove and keep the springs with the buttons.



-2

45588042311 EN - 4/2020

1 2 3

Anti-crush button Pin Flat spiral spring

4 5 6

– To extract the anti-crush button retaining pin, use a pin punch. Alternatively, you can use a rivet, as shown in the photo.



– Disconnect and remove the button manually as shown in the photo.



45588042311 EN - 4/2020

Plug Washer Screw

-3

–



-4

45588042311 EN - 4/2020

– Before removing the top cover, remove the tiller closure casing; see the "Disassembling tiller closure casing "section.

– To remove the cover, unscrew the 4 screws placed where the buttons were.



– Remove the cover.



– If the 2 LED display is fitted: disconnect the connector coming from the internal PCB, which goes to the LEDs on the top cover. If necessary, the two retainers can be unscrewed with a screwdriver and the display removed.



45588042311 EN - 4/2020

-5

– If the 10 LED display is fitted: disconnect the connector (A) coming from the internal PCB, which goes to the LEDs on the top cover. If necessary, the four retainers can be unscrewed with a screwdriver and the display removed.



– Remove the tiller card with potentiometer.



– Remove the potentiometer and unscrew the card from the plastic section which contains it.



– Remove the Tortoise button (previously removed) microswitch using the toggle lever.



-6

45588042311 EN - 4/2020

– To remove the lower tiller cover (operator side), unscrew the three Allen screws; see illustration.



– To unscrew the screws, the corresponding nut must be locked with a spanner.



–



– You then have to unscrew the retainer, disconnect the connector and remove the ignition switch from behind.



45588042311 EN - 4/2020

-7

– You can now access the nut that lets you unscrew the lower screw securing the tiller cover.



– Remove the screw.



– Disconnect the electric wiring.



– Remove the lower tiller cover.



-8

45588042311 EN - 4/2020

1 2 3

Lever Flat spiral spring Shaft

4 5 6

– Remove the connector to disconnect the potentiometer from the tiller card.



– Once removed, the potentiometer remains attached to the drive operating levers as shown in the figure.



45588042311 EN - 4/2020

Potentiometer Bush Screw

-9

– To remove the levers from the tiller, unscrew the appropriate screws and take off the levers.



–



– Remember that the flat spiral spring can be detached but must be repositioned in the same way during reassembly.



-10

45588042311 EN - 4/2020

*

Angle of rotation / Wiring

Rotation of the lever in one direction or the other generates two types of signals in the potentiometer: a digital drive signal an analogue potentiometer signal The digital drive signal is active (ON) when the lever is rotated more than 7°.

The digital drive signal is inactive (OFF) when the lever is rotated between 0° and 7°.

Analogue potentiometer signal (S1) 0÷5 V as shown in Figure 1.

Truck stopped.

In working position or rest position.

In neutral position.

Truck travelling in the diIn working position. rection of the operator.

Turned in the direction of the operator.

Truck travelling in the diIn working position. rection of the forks.

Turned in the direction of the forks.

No effect, no alarm.

The truck reverses the direction of travel and, after six seconds, stops.

No effect: the truck continues to travel.

: Depending on the current operating conditions, pressing this button causes the truck to reverse, and subsequently stop after six seconds, if the button is held down.

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-11

– To install the tiller gas spring, use the special tool shown here (can be ordered from the spare parts service with code F191665).



– Position the tool, referring to the dowels inside the holes on the heads of the fixing screws on the motor flange.



– Position the end of the gas spring on the ground part of the bar.

– Gripping the equipment by the tube, push it upwards until the spring slides into position.

-12



45588042311 EN - 4/2020

– To disassemble, remove the head of the spring from the housing, using an appropriately sized flat-head screwdriver.



– Remove the caps on the tiller arm.



– Position the cylindrical fixing bolt of the gas spring in line with the holes and remove it.



– Remove the gas spring.



Once you have disassembled the gas spring, you can then disassemble the tiller arm; see relevant section.

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-13

Before disassembling the tiller arm, you need to first have disassembled the gas spring (see section "Disassembling the gas spring").

– Position the tiller arm in a horizontal position to access the pin on the tiller joint and, using an appropriate pin punch, remove the elastic pin.



– Take out the elastic safety pin from the tiller arm.



– Then remove the pin from the tiller arm.



-14

45588042311 EN - 4/2020

– By doing this, you can access the screws to remove the wiring and the tiller position microswitch.



– Remove and replace the Teflon "bushings" on the joint if they are worn.



45588042311 EN - 4/2020

-15

A

Protective frame

B

Tiller card

Inside the tiller head is an electronic card equipped with a self-heating system for when the truck is used in cold stores.

On the card are four microswitches for the lifting, lowering, horn and rapid reversing controls, activated directly from the buttons.

A special frame (A) protects them from any extra pressure on the buttons, which might break them.

-16

45588042311 EN - 4/2020

Lifting the fork arms is timed by the controller.

The lifting time can be set from the console using the MAX PUMP RUN TIME parameter, from 0 to 60 sec.

The fork arm lifting function is activated by putting, in sequence, the tiller or the tiller always active button (if this option is fitted) in the working position and only then pressing the lifting button on the tiller head.

In the following operating conditions, lifting is blocked: Continuous use of battery up to limit set by manufacturer, i.e. 80% discharged.

(Lifting blocked due to low battery charge using optional instruments on the tiller head or using electronic control) Lack of compliance with function activation sequence, leading to triggering of the HYDRAULIC HPD alarm.

Ignition switch turned to "O" (Machine off) Tiller in braking position.

There is no interlock for the lowering function.

For lifting and lowering speeds, refer to the "Technical Data" in the instruction and maintenance manual.

A numerical keypad is available as an alternative to the ignition key: numerical keys (1 -2 -3 -4) confirmation key (OK) cancellation key (C), used to enter the machine start-up code When the forklift is turned off, the green LED (A) remains lit.

When the forklift is turned on, the green LED flashes.

D

A

B OM1782

The forklift is turned on by entering the fournumber user password and then pressing the key (OK): if the password (Pin Code) entered is correct, the green LED (A) begins to flash. if the password (Pin Code)entered is incorrect, the red LED (B) lights up and the numerical keypad emits an acoustic warning signal, after which the green LED (A) lights up and remains lit.

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The forklift is turned off by pressing key (C).

The four-digit user password for the first start-up is factory-set and is:

The person responsible for operators has a password(Master Code) that makes it possible to: memorise several personal operator passwords (Pin Code) for turning on the forklift. cancel one or more personal operator (Pin Code) passwords change the password of the person responsible for operators (Master Code) Enter the password of the person responsible for operators (Master Code) (for the first time memorised, the password is the one set by the factory: ) and press the key (OK).

The green LED (A) turns off and the yellow LED turns on(D).

Using the keyboard, enter the control code ' and press the key (OK). The yellow LED (D) will begin to flash.

Enter a new six-number password (Master Code) and press the key (OK).

The new password (Master Code) will overwrite the previous password.

We recommend that the person responsible for operators change the password (Master Code) when the forklift is delivered.

The four-digit user password for the first startup is factory-set and is: We recommend that the person responsible for operators change this password and personalise it as follows: Enter the password of the person responsible for operators (Master Code) (for the first time memorised, the password is the one set by the factory: ) and press the key (OK).

The green LED (A) turns off and the yellow LED turns on(D).

Using the keyboard, enter the control code ' and press the key (OK). The yellow LED (D) will begin to flash.

Enter a new four-digit password for the operator (Pin Code) and press the key (OK).

-18

At the end of the procedure, the green LED (A) comes on and remains lit.

In the case of an error in the procedure, the red LED (B) comes on and the numerical keypad emits an acoustic warning signal, after which the green LED (A) comes on and remains lit. Repeat the procedure Enter the password of the person responsible for operators (Master Code) (for the first time memorised, the password is the one set by the factory: ) and press the key (OK).

The green LED (A) turns off and the yellow LED turns on(D).

Using the keyboard, enter the control code ' ' and press the key (OK). The yellow LED (D) will begin to flash.

Enter the operator's password to be cancelled (Pin Code) and press the key (OK).

At the end of the procedure, the green LED (A) comes on and remains lit.

In the case of an error in the procedure, the red LED (B) comes on and the numerical keypad emits an acoustic warning signal, after which the green LED (A) comes on and remains lit. Repeat the procedure

Enter the password of the person responsible for operators (Master Code) (for the first time memorised, the password is the one set by the factory: ) and press the key (OK).

The green LED (A) turns off and the yellow LED turns on(D).

Using the keyboard, enter the control code ' ' and press the key (OK). The yellow LED (D) will begin to flash.

Enter the password of the person responsible for the operators (Master Code) and press the key (OK).

At the end of the procedure, the green LED (A) comes on and remains lit.

In the case of an error in the procedure, the red LED (B) comes on and the numerical keypad emits an acoustic warning signal, after which the green LED (A) comes on and remains lit. Repeat the procedure

This procedure cancels all of the operator passwords (Pin code) memorised, including the factory-set password (1234).

45588042311 EN - 4/2020

Before disassembling the numerical keypad, remove both covers from the tiller head; see section "Removing tiller head covers".

– Disconnect the 3 cables attached to the keypad.

– Unscrew both screws shown in Figure 1 and remove them.

– To reassemble the numerical keypad, reverse the procedure.

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-19

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1 2 3 4 5 6 7 8 9

24V battery Emergency battery warning light Pump fuse Pump contactor Main contactor Electronic system Fork lowering solenoid valve Heat sensor Electromagnetic brake

10 11 12 13 14 15 16

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Motor encoder Tiller head Signal horn Main contactor coil (K1) Pump contactor coil (2K1) Micro tiller Auxiliary circuit protection fuse and key

-1

17

Diagnostic tool

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

Nominal power supply voltage 24V d.c.

Maximum current for drive motor 120 A DC (1400 / 1600 kg version) or 150 A (1800 / 2000 kg) version.

Various functional configurations, which can be selected from the console to respond to the user's needs.

Good traction motor efficiency thanks to the high frequency MOSFET power transistor switching.

Runs silently at high frequencies.

Full diagnostics on console and via internal status LED. Regenerative braking that allows for shorter stopping distances, increases available energy from the battery and reduces motor and brake overheating Fully protected inputs and output drivers protected from short circuits.

Internal reversed polarity protection.

-2

45588042311 EN - 4/2020

KSI Interlock M1/M2 mode Lift / Throttle pot_wiper / / / Lower / / FWD REV Belly Belly check Status_led Batt_led +12V supply device Ground device / K1 2K1 2Y1

/

/

/ / /

/ / /

/ /

/ /

Key Interlock M1/M2 mode Fork lifting Not Used Traction potentiometer Not Used Not Used Not Used Fork arms lowering Not Used Not Used Forward direction of travel Reverse travel Belly Belly check Not Used Status LED Not Used Battery status Tiller sensor positive supply feed

/

ENC+ ENC_A BRAKE return ENC_B ENCBRAKE

/

Tiller sensor negative supply feed Not Used Traction contactor negative Pump contactor negative Lowering solenoid valve negative

Encoder positive supply feed Encoder A Lowering solenoid valve positive Encoder B Encoder negative supply feed Electromagnetic brake negative

45588042311 EN - 4/2020

-3

Turn off the truck and perform the preliminary maintenance operations.

2

1

Before carrying out any operations on the electrical system, turn off the truck power supply by disconnecting the battery connector.

4

Before replacing the fuse, eliminate the cause that led to its blowing. The blown fuse must only be replaced with a fuse of the same amperage. Do not tamper with the truck's electrical system.

Access the fuses as indicated in the " " section.

3

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

Loosen the screws, replace the fuses and retighten the screws.

Fuse = 5A Fuse = 5A Lifting motor protection fuse = 80A Traction motor protection fuse = 100A

-4

45588042311 EN - 4/2020

OM1779

Use two 12 V sealed batteries in series. These must be sealed batteries (not gel, but AGM technology) with the electrolyte contained in maintenance-free (no top-up needed) and fume-free airtight cells.

Requires a special battery charger that is supplied as standard on the truck (located in the battery compartment).

The batteries are 12 V/44 Ah and are secured in the correct position by a belt; the battery charger supplied is 24 V/6 A. Use two 12-V sealed batteries in series. These must be sealed batteries with "Full Lead" technology.

Requires a special battery charger that is supplied as standard on the truck (located in the battery compartment).

The batteries are 12 V/58 Ah and are secured in the correct position by a belt; the battery charger supplied is 24 V/30 A. Uses standard batteries for trucks in 2 possible formats: Standard metal housing (DIN or British Standard); Plastic housing (MBS block): in this case, there are caps or top-up systems as for the standard housing model, but it is NOT possible to replace the single cell in the event of a partial fault in the battery.

2PZS-B 110 2PZS-B 150 2PZV 200 2PZV 220 2PZV 230 2PZV 250

73

110

123

73

150

152

112 112 112 112

200 220 230 250

212 212 212 212

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-5

<250 Ah = 250 Ah

-6

24 V/30 A high frequency 24 V/35A high frequency

45588042311 EN - 4/2020

1

Ignition indicator

2

Battery charging status indicator

The ignition/operating and battery charging status indicators are located on the tiller arm.

The ignition indicator is included in the standard set-up for all versions.

Red LED (A) (for battery charging status) Green LED (B) (for machine status)

LED "off" LED "flashing".

LED "continuous light".

LED "flashing regularly".

LED "flashing irregularly".

Battery charged.

Battery 30% charged.

Battery low. Lifting is blocked and traction speed reduced to 20% of max.

No alarms.

Alarm condition.

The battery charging status indicator is included in the optional set-up for 1600 - 1800 - 2000 kg versions (not available for the 1400 kg version).

LED (C) "on" LED (D) "on" LED (E, F) "flashing" Multicolour LED bar.

LED (E, F) "flashing alternately"

45588042311 EN - 4/2020

Battery 100% charged.

Battery 50% charged.

Battery 30% charged.

Battery low (20%).

Lifting blocked.

Discharge curve: - 2.04 V/cell@full_battery - 1.73 V/cell@empty_batt - 2.09 V/cell reset_level.

-7

The charge curves refer to standards DIN 41774 and DIN 41772.

Please note: = Charge with decreasing current = Charge with constant voltage = Charge with constant current = Charge with automatic stop = Charge with different currents

= The maximum current of 35 A is maintained until the voltage is lower than 29.2 V (2.43 V/cell). This stage is completed when the battery reaches this voltage level. = The voltage U1 is kept constant at 29.2 V with progressively decreasing current until the end of charging current I2 is reached. = The voltage U1 is kept constant at 29.2 V with progressively decreasing current until the end of charging current I2 is reached. = The current I2 is kept constant until charging is completed. During this phase, the voltage is limited to 32 V max

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45588042311 EN - 4/2020

(2.67 V/cell). The current could therefore decrease in accordance with the U2 phase. = this is carried out only every 7 full charging cycles (more than 4 hours). In this phase, the current is I2/2 for a maximum of 4 hours. = when the charger remains connected to the mains, even when charging is finished, a new cycle starts after 48 hours, to offset the battery self-discharge.

= The maximum current of 30A is maintained until the voltage is lower than 29.2 V (2.43 V/cell). This stage is completed when the battery reaches this voltage level. = The voltage U1 is kept constant at 29.2 V with progressively decreasing current until the end of charging current I2 is reached. = The current I2 is kept constant until charging is completed. During this phase, the voltage is limited to 32 V max (2.67 V/cell). The current could therefore decrease in accordance with the U2 phase. = this is carried out only every 7 full charging cycles (more than 4 hours). In this phase the current is I2/2. = when the charger remains connected to the mains, even when charging is finished, a new cycle starts after 48 hours, to offset the battery self-discharge.

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-9

= The maximum current of 6.1A is maintained until the voltage is lower than 28.8V (2.4 V/cell). This stage is completed when the battery reaches this voltage level. = The voltage U1 is kept constant at 28.8V with progressively decreasing current until the end of charging current I2 = 1A is reached. = The voltage U2 is kept constant at 27 V. The current absorbed by the battery decreases progressively. This phase lasts until the battery is charged.

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45588042311 EN - 4/2020

The main functions are identified by the lights on the single three-colour LED. – Features of the "three-colour LED":



(A): LED off (B): LED flashing slowly (C): LED flashing quickly (D): LED continuously lit

-

(A), OFF

LED not on

- output fuse inside the CB is blown - battery plug/socket is damaged - at least one cable is disconnected - battery voltage less than 7 V - the battery is connected but not the mains

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-11

- you haven't switched off the main system switch - input fuse inside the CB is blown (B), GREEN End of charge condition (Phase )

-

-

-

(B), RED

Error - no battery voltage

-

(B), RED

Vini1 threshold error

-

(B), RED

Vini2 threshold error

(C), YELLOW Charge with constant voltage condition (Phase )

-

-

(C), RED

(D), YELLOW Condition of charge with constant voltage (Phase )

-

-

-12

(D), RED

Battery high -

Internal error (watchdog)

45588042311 EN - 4/2020

Batt. not connected or with voltage < 25% Vnom Battery voltage at the start < 30% Vnom Battery voltage < 33% Vnom after 1 minute.

The battery could be sulphated, faulty, disconnected or connected to an external charge.

Battery voltage exceeding 145% of Vnom Curve selected not present; error - current less than permissible value > CB not working

Charge the battery with the truck turned off and the battery hood open.

You can only remove the plug from the socket when the truck is switched off.

Access the upper part of the battery, open the battery hood and hold the hood open.

Connect the battery outlet to the battery charger to begin charging Turn on the external battery charger After the battery charging operation is completed, switch off the battery charger Unplug the battery charger Plug the battery in again Close the battery hood

Refer to the battery operating instructions for more information.

The on-board battery charger is attached to the load chassis inside the motor compartment and the plug, suitably supported, is accessible in the battery compartment, together with the charging status LEDs.

In case the truck is not turned off, there is a protection circuit that prevents the operator from moving the truck during recharging.

The on-board battery charger is fitted with an internal mains presence relay that is electrically connected in series to the main contactor coil.

This system controls the following operations:

Rectifier powered

Opening of the internal relay contacts and immediate cut-out of power circuits by opening the power contactor contacts. In this way, the machine remains powered but it is impossible to move it.

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-13

The on-board battery charger plug must only be connected to an electrical distribution system that is fitted with a circuit breaker, in accordance with standard EN 60204-1 clause 6.3 "Protection against indirect contacts".

Supply voltage: 230 ± 10% AC Frequency: 50-60 Hz +/-1% Nominal output current: 35 A, 30 A, 6 A +/-2% Nominal output voltage: 24 V DC The plug is Schuko type 2P+T 16 A 250 V Charging time depends on battery capacity.

Internal mains presence relay

The on-board battery charger is not available for the cold-storage room version.

Charge the battery with the truck turned off and the start key removed.

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45588042311 EN - 4/2020

Follow the instructions below: Lift the battery cover (1) Take the plug (2) of the on-board battery charger and connect it to the power outlet.

The green LED (3) begins to flash When charging is completed, the green LED (3) remains lit.

Replace the plug in its housing.

Close the battery compartment cover.

3 2

4

The red LED (4) indicates that the battery has been left too long with insufficient charge.

Do not leave the battery with insufficient charge for longer than 24 hours.

1

1843

Two LEDs are connected to the battery charger: a and a located in the battery compartment indicate the charging status.

Battery charger plug not connecOFF ted to the mains Phase I1, P U1, I2, U2 FLASH Stop ON Equalisation phase ON Maintenance phase OFF Charge time too long OFF Polarity inversion of the battery ON charger cables Polarity inversion of the battery OFF Selector in neutral position FLASH

45588042311 EN - 4/2020

OFF OFF OFF OFF OFF ON ON OFF FLASH

-15

Before removing the battery charger, you must "remove the battery plug mounting bracket"; see relevant section.

– Disconnect the earth cable shown in the photo.



– Remove the electronic system connecting cables.



– Using an appropriate wrench, remove the three battery charger mounting screws.



-16

45588042311 EN - 4/2020

– Battery charger compartment.



– To reassemble the battery charger, proceed in the reverse order.

– Using an appropriate screwdriver, unscrew the four screws that attach the mains plug mounting bracket (2) to the battery plug handle (1).



– Detail.



45588042311 EN - 4/2020

-17

– Behind the mains plug mounting bracket are two LED holders.



– Unscrew the two ring nuts on the LED holders using a suitable wrench.



– Push the LED holders (A) and (B) downwards until you reach the connecting cables, then move the two LED holders into the larger hole (C) and remove the LED holders from the seat (C).



– Using an Allen key, remove the two screws from the battery plug handle.



-18

45588042311 EN - 4/2020

– Remove the hoods of the truck as described in "31 Chassis"

– Two 13-mm open-ended spanners – 17-mm open-ended spanner – Socket wrench with extension and 13-mm socket

– Protective gloves – Protective goggles

To avoid short circuits when replacing batteries, DO NOT under any circumstances connect poles (+) and (-) of the battery. Pay particular attention when using open-ended spanners.

– Fully lift the forks.



45588042311 EN - 4/2020

-19

– Fully lifting the forks facilitates access to the batteries from the interior of the motor compartment.



– Disconnect the plug from the battery socket.



Do not perform maintenance without first disconnecting the plug from the battery socket.

– Before removing the batteries, mark the cable connections for the poles of the batteries.

This helps to avoid connection errors during refitting.

– Unscrew the four mounting screws for the cables using the socket wrench with extension and 13-mm socket.



–



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45588042311 EN - 4/2020

– Manually remove the four screws that you just unscrewed and the four washers.



– Move aside the battery cables for easy access to the battery compartment.



– Unscrew the screw and the nut in the illustration using two 13-mm open-ended spanners.

Then manually remove the self-locking nut and the relative screw, sliding it horizontally.



– Manually remove the bar and battery mounting buffer assembly.



45588042311 EN - 4/2020

-21

– Remove the battery: Tilt it slightly towards the interior of the motor compartment. Then slide and lift it from the motor compartment side.



–



Each battery weighs approximately 19 kg Lift the battery carefully using the correct lifting technique to avoid straining the back and limbs of the technical staff involved. Be careful to avoid crushing hands and dropping the battery.

– To reassemble the batteries, proceed in the reverse order. Follow the removal instructions in reverse order, taking into account the following.

– When inserting the battery into the battery compartment, be particularly careful.

Each battery weighs approximately 19 kg Lift the battery carefully using the correct lifting technique to avoid straining the back and limbs of the technical staff involved. Be careful to avoid crushing hands and dropping the battery.

– If necessary, adjust the height of the battery mounting buffer using a 17-mm open-ended spanner.

-22



45588042311 EN - 4/2020

– Tighten the four mounting screws for the battery cables to a tightening torque of .



–



When tightening the mounting screws for the battery cables, you may generate sparks.

Wear protective goggles.

45588042311 EN - 4/2020

-23

– 6-mm open-ended spanner

– Open the battery compartment hood.

– Disconnect the plug from the battery socket.



Do not perform maintenance without first disconnecting the plug from the battery socket.

– Unscrew the two mounting screws 6-mm open-ended spanner.

– Remove the wiring harnesses

with a



.

– Remove the on-board battery charger including the mounting bracket.

– To reassemble the batteries, proceed in the reverse order.

-24

45588042311 EN - 4/2020

205 Bar: for the 1400 kg and 1600 kg versions 240 Bar: for the 1800 kg and 2000 kg versions

This is a motor with the following features in all versions: Supply voltage 24 V DC Power rating 1 kW The capacity difference is obtained from different calibration of the maximum-pressure valve:

Before replacing the hydraulic control unit, make sure that the fork arms have been completely lowered and that the battery has been removed.

– Using a cross-head screwdriver, unscrew the clamping screw of the solenoid valves connector and then detach the connector manually.



45588042311 EN - 4/2020

-1

– Detach the hydraulic line by removing the clamping screw.



– Disconnect the two electric cables of the pump. The black cable is connected to the -B terminal of the electronic system(1) while the red cable is connected to the pump contactor.

(2)



– Access the battery compartment and using a hexagonal "T" wrench, unscrew the 2 fixing screws for the hydraulic control unit from the bodywork.



Before performing this last operation, position a support below the hydraulic control unit or support it with your other hand so that it does not fall.

-2

45588042311 EN - 4/2020

– Disassembly of the non-return valve: Unscrew the valve using a n.7 Allen key.



– Detail of the non-return valve. To reassemble the valve again, proceed in the reverse order.



– Disassembly of the tank and pump: Unscrew the 4 clamping screws using a TX/30 screwdriver. Manually remove the tank and the pump.



45588042311 EN - 4/2020

-3

– Replacement of the Oldham joint: in case of breakage, replace the joint shown in the figure.



– Replacement of the on/off valve coil: Unscrew the screw shown in the figure using a n.10 Allen key.



-4

45588042311 EN - 4/2020

– Disassembly of the coil body: Use a n.24 key.



– Replacement of the maximum-pressure valve: Unscrew the maximum-pressure valve using a n.14 key, and replace it by proceeding in the reverse order.



– Adjustment of the maximum-pressure valve: Using 2 spanners, loosen the lock nut at the head of the valve.



45588042311 EN - 4/2020

-5

– Use a screwdriver to adjust the adjusting screw at the head of the maximum pressure valve, thus adjusting the operating pressure of the valve.



– After the adjustment, tighten the lock nut again.



-6

45588042311 EN - 4/2020

– Lower the forks to the ground.

– Secure the battery compartment by attaching appropriate slings, as if you were lifting the truck. Keep the sling taut.

– Using appropriate pliers, remove the Seeger ring and the washer below, as shown in the photo.



– Detail of pin to be removed.



– Using a hammer and pin, strike the retaining pin.



45588042311 EN - 4/2020

-7

– Remove the pin and release the cylinder head, watching out for any unintended movement of the battery compartment.



– Using an appropriate wrench, loosen the end of the hydraulic line from the cylinder.



– Manually unscrew and release the hydraulic line from the cylinder.



Before carrying out this procedure, place a cloth near the hole as shown in the next photo.

-8

45588042311 EN - 4/2020

–



– Using an appropriate wrench, unscrew the two screws that attach the cylinder to the bodywork.



– Release the cylinder by striking the points shown in the photo with small hammer blows.



45588042311 EN - 4/2020

-9

– Finally, remove the cylinder.



– To reassemble the lift cylinder, proceed in the reverse order.

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(1*)

Common

(2*) (3*) (4*)

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Traction chassis only Connection only Three different load chassis

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A B C D

b5=520 b5=560 b5=650 View from above of the connection/orientation of the load lever between the fixed and mobile chassis

From a combination of fork gauge solutions A, B and C on the load chassis, the truck can be configured in one of two solutions, E or F. Solutions E and F differ in the type of actuation exerted on the actuation rod by the load lever.

The rod can be moved in two ways: : versions are fitted with strut

systems as standard. : versions with are fitted with rod systems as standard.

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E F

Configurable lifting system with the new lever system provided by a combination of solutions A, B and C Configurable lifting system with the new lever system provided by a combination of solutions A, B and C

The dual solution of following advantages:

and

has the

Free and easy lifting of one or more pallets with the forks inserted on the closed side of the pallet, even with tandem rollers, on all versions with strut systems.

Option of increasing the fork length to 2400 mm or more without structural problems on all rod versions.

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Before removing the lever system, raise the fork arms and position a wooden shim under the tips.

Then lower the fork arms, resting them on the shims, to the lower stop in order to release the lever system.

– Using an appropriate pin punch, remove the elastic pin from the primary pivot and retrieve the elastic pin.



– Using a soft metal cylinder pin, strike the primary pivot and extract it.



– The cylinder pin will take the place of the primary pivot.

Remove the pivot and the lever will fall.

– Rest the lever system on a wooden shim.

– Using an appropriate pin punch, extract the elastic pin from the secondary pivot.



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– Using a hammer, strike the secondary pivot and extract it.



– The fork group will separate from the tie rod.

– Before extracting the rollers, rest the 2 groups on a piece of wood.

– Using a pin punch with an appropriate diameter, strike to extract the elastic pin from the roller pivot.



– At the point indicated in the illustration, use a metal cylinder pin and strike the roller pivot with a hammer. Extract the roller.



Before disassembling the rear forks, remove the battery.

– Access the battery compartment and, using a pin punch with an appropriate diameter, extract the pins from both the forks. Retrieve the pins.

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

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– At the point indicated in the illustration, use a soft metal cylinder pin and strike the fork pivot with a hammer and extract it.



– The cylinder pin will take the place of the fork pivot.

Remove the cylinder pin and the fork will fall.

Be careful not to crush your hands.

– Now the lever system has been removed.

– Using a pin punch with an appropriate diameter, strike to remove the elastic pin from the rear fork tie-rod pivot.



– At this point, the lever system is ready to be overhauled.

– Check the wear of the pivots, pins and rollers.

– To assemble the lever system, follow these instructions in reverse order.

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– Tighten the fork in the vice and extract the bushings using a punch with a diameter slightly smaller than that of the bushings.

Punches can be made beforehand for each type of bushing.



– Countersunk screws with an appropriate diameter can also be used.



Risk of crushing hands.

If very short tools, like screws, are used, hold them with pliers and not your fingers.

– After having removed all the bushings, replace them with new ones.



– With regard to the front fork, the bushings of the rocker levers have no hole for the passage of grease, and thus have no particular orientation. The bushings should be inserted by striking them with the flat surface of a hammer, or by placing a solid metal cylinder between the hammer and the bushing.

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– Ensure correct orientation of the bushings.



– The hole of the bushing should be lined up with the fork grease supply hole. To identify the supply hole, observe the position of the grease nipple.

Replace all the bushings.

It is unadvisable to replace only one bushing, or only those of a single lever. After having replaced all the bushings, reassemble the entire lever system including rods and rollers.

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STILL GmbH 45588042311 EN - 4/2020