Still STED forklift Pallet truck ECU25 ECU 30 ECU 30 Special Workshop manual

0168 0169 45628042104 EN - 4/2020

First edition.

Removed electrical and hydraulic schematic views.

Corrected tightening torque for pivot wheels.

Updated alarms list.

Updated synoptic table of maintenance.

Added paragraphs relating to lifting the truck safely both from the fork side and from the operator side.

Added paragraphs relating to lifting the truck safely both from the fork side and from the operator side.

Added cable image for diagnostics.

"New temperature sensor (PT1000)"

45628042104 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.

45628042104 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

45628042104 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.

45628042104 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

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45628042104 EN - 4/2020

IX

Example: Complete serial number.

= plant in Luzzara (Italy).

ECU 25 ECU 30 / 30 Special

= 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.

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-1

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

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

-2

45628042104 EN - 4/2020

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.

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– Before performing any maintenance on the truck, you must disconnect the battery.



: Wooden blocks Hydraulic jack

– Position the truck against a suitably robust and stable wall, with the forks fully lowered.

The wall prevents the truck from sliding forwards when lifting the truck.



Only use walls that are sufficiently robust and stable.

We recommend the use of load-bearing walls made of reinforced concrete. The use of walls that do not ensure sufficient resistance, such as plasterboard walls, doors, partition walls etc., is prohibited.

Park the truck on a flat surface and then turn off the truck.

-4

45628042104 EN - 4/2020

– Place the hydraulic jack in a central position, as shown in the illustration.



The hydraulic jack must be in good condition.

Use a jack with a maximum capacity greater than the weight of the truck to be lifted (battery included).

– Raise the truck using the hydraulic jack.



Keep hands and feet away from the edge of the truck.

– Insert a block of wood on the right-hand side of the truck.



– Insert a block of wood on the left-hand side of the truck.



45628042104 EN - 4/2020

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– Lower the truck. Rest it securely and safely on the wooden blocks.



Make sure that only the truck chassis is supported by the wooden blocks. Only use wooden blocks that are in good condition and that are able to bear the weight of the truck.

Resting parts of the truck that are not as stable and safe, such as rollers, wheels etc., on the wooden blocks is forbidden.

– When maintenance has been completed, follow the process in the reverse order to remove the truck from the wooden blocks.

Keep hands and feet away from the edge of the truck.

-6

45628042104 EN - 4/2020

– Wooden blocks – Hydraulic jack

The following instructions are necessary if any straddle maintenance operations are required, for example: replacement of load rollers, bushings, load roller pins etc.

Do not perform this procedure with the electromagnetic brake disconnected and/or undergoing maintenance.

– Position the hydraulic jack securely and safely under the fork tips.

The hydraulic jack must be in good condition.

Use a jack with a maximum capacity greater than the weight of the truck to be raised (battery included).

– Carefully raise the truck, making sure that the truck is stable and does not slip backwards.

– Insert wooden blocks under both straddles.

Keep hands and feet away from the edge of the truck.

– Lower the truck, resting it securely and safely on the wooden blocks.



45628042104 EN - 4/2020

-7

–



Only use wooden blocks that are in good condition and that are able to withstand the weight of the truck.

– Once the maintenance operation has been completed, follow the process in reverse order to remove the truck from the wooden blocks.

Keep hands and feet away from the edge of the truck.

Tutela Matrix Quantity (l) Quantity (l)

0.85 HLF32 1 Tutela MP 02

Tutela Matrix Quantity (l)

0.85 Tutela GI/M

Quantity (l)

1 Tutela JOTA1

-8

45628042104 EN - 4/2020

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 Check wear on the lifting motor brushes Grease micro tiller (1) Grease the rods and levers Change hydraulic system oil (1) Every 1000 hours or 6 months, whichever

comes first

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

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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 data in the datasheet.

Drive speed when unloaded Drive speed with 2500 kg Drive speed with 3000 kg Lifting speed Lowering speed

-10

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

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



45628042104 EN - 4/2020

-1

A

Connector.

B

Cable for electronic system diagnostics.

– The truck diagnostics software is called and is installed on the diagnostics PC. – The diagnostics PC and the electronic system cable (B) are connected using the connector (A).



Connection should ONLY be carried out when the truck is switched off.

The software must only be used by trained personnel.

Variation of some parameters or configurations may create hazardous situations for the operator (e.g. an increase in drive speed).

– Open on

-2

on the diagnostics PC. Click and run a search for . Double-click on it.

45628042104 EN - 4/2020

– Click

.



– Check that the connection speed is . Then press .

– When the program opens, a dialogue box containing two messages is displayed.

– 1st message: tells the operator to connect the CAN terminals of the interface to the truck cable and then turn the start key.

– 2nd message: shows the initialisation status of the PEAK interface (USB to CAN).

45628042104 EN - 4/2020

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– There is an LED in the lower bar that shows the " ": GREEN LED " "; RED LED " ".

-4

45628042104 EN - 4/2020

– Open the menu and select . Then type next to the heading and press .



– – Press in the close the connection.

menu to

45628042104 EN - 4/2020

-5

In the "

" menu, you can select:

. : allows you to view and acquire variable values over time. : lists the alarms raised by various modules. : deletes data saved in the EEPROM and restores default data. : displays the chart showing data saved by the tester function in a .csv file.

– Detail: file with .csv extension.

-6



45628042104 EN - 4/2020

Selecting the function will display an empty window with a series of buttons.

In the top part of the window, you can select the required parameter category: Machine, Acceleration, Speed, Braking, Joystick, Safety, Calibration, Drive settings, Pump settings, Display.

In the lower part of the window, there are three buttons: –

: receives all truck parameters displayed in the window.

–

: stores any changes made to the parameters.

–

: closes the Parameter window.

Loading starts when you click . Two bars are displayed in the lower part of the window indicating the loading status for the parameters and for each node. Once loading is complete, the parameters and their current value are displayed in the table. At this point, the value or status of each parameter can be modified using the and buttons and then stored by selecting the button.

Clicking on the parameter row opens a document containing a description of the parameter.

The menu is also at the top of the window and contains the following functions:

45628042104 EN - 4/2020

-7

: opens a set of parameters previously saved in a .csv file. : saves a set of truck parameters in a .csv file. : sends the truck parameters to print.

Selecting the function opens a window, the left part of which contains a list of the variable values for the connected node. It is possible to monitor up to four values at the same time.

These values are displayed in real time in rows at the top of the window and as a trend on a graph on a white background. It is possible to save the long-term development of the values using the buttons in the section:

file.

starts data recording. stops data recording. saves the recorded data in a .csv

allows you to determine the sampling frequency and the number of samples saved.

In the buttons:

-8

section, there are two additional

45628042104 EN - 4/2020

clears the graph and starts a new one. opens a new window that shows a larger version of the graph, with additional options to change the scale of the axis for each value and to change the colours for the values and the background. sends the graph to print. closes the

window.

Current battery voltage value measured after switch on.

This value is not measured directly by the electronic system, but is calculated by the software based on the current value of the battery voltage and the load percentage of the battery.

This is the voltage generated by the electronic control expressed as a percentage of the current value of the battery voltage.

Additional voltage supplied to the motor expressed as a percentage in relation to its nominal value.

Displays the frequency of the sinusoid and the electronic control supplying the motor.

This is the motor speed as measured by the encoder.

The difference between the frequency and the motor speed measured by the encoder.

(SLIP VALUE = FREQUENCY - ENCODER) Effective value of the motor current.

Shows the residual charge of the battery expressed as a percentage of the full charge.

The electronic control base temperature.

This value is used to generate the HIGH TEMPERATURE alarm.

Temperature of the motor windings, measured by an analogue sensor inside the motor. This temperature is only used to generate a "warning".

Analogue value of the drive potentiometer.

Shows the status of the tiller microswitch.

Shows the status of the microswitch in relation to the "Tiller always active" or slow speed button.

Shows the status of the microswitch in relation to the fork lowering button.

Shows the status of the operator-side drive signal.

Shows the status of the fork-side drive signal.

Shows the status of the microswitch in relation to the fork lifting button.

Activation of the fork lowering valve.

Volts Amperes

% % Hz Hz Hz Amperes % °C °C From 0.0 to 5.0 V. ON = +Vbatt OFF = GND ON = +Vbatt OFF = GND ON = +Vbatt OFF = GND ON = +Vbatt OFF = GND ON = +Vbatt OFF = GND ON = +Vbatt OFF = GND ON / OFF

Not active

45628042104 EN - 4/2020

-9

Not active Not active Shows the output status for operation of the fork lowering solenoid valve.

Shows the output status for operation of the lifting contactor coil.

When reopening the menu, the values previously selected will remain selected, but to see them on the graph, you will need to deselect and then reselect them.

button in the

function.

– In the section, you can select or deselect one of the monitored values by clicking on the name in the drop-down menu and selecting the flag on the right. You can then change the colour of the line using the function.

– In the section, you can choose the maximum and minimum values of the two axes by selecting the or axis and changing the limits using the button, or by selecting the flag to enable automatic recalculation.

-10

45628042104 EN - 4/2020

ON / OFF ON / OFF

Buttons: allows you to choose the colours of the values. resets the graph back to standard view. clears the graph and starts a new one (by selecting the flag, the graph is cleared each time it reaches the end of the axis). saves the graph as a .bmp image file. automatically updates the bottom scale of the graph based on the data. sends the graph to print. allows you to choose the background colour of the graph. closes the window.

Selecting the function opens a window that displays all the alarms raised in various modules and saved in the respective EEPROM. The current alarm raised by the connected node is displayed at the top of the window.

The table in the centre of the window lists the following in every row: node alarm refers to; name of alarm; number of repetitions;

45628042104 EN - 4/2020

-11

module temperature at the time of the alarm; module hour meter at the time of the alarm.

In the lower section, there are four buttons: updates the list of alarms shown in the table. sends the alarm table to print. clears all the alarms in each node. closes the window.

– In the menu, select and press OK.



– The factory settings will be restored (shown in paragraph "Table of parameters").

-12

45628042104 EN - 4/2020

(from parameter table code 45628089001 - vers.

01 - 18/01/2011)

Acceleration ramp with the throttle in maximum position.

1.7

0.3

10

Seconds

0.8

0.3

10

Seconds

0.4

0.3

10

Seconds

1.5

0.3

10

Seconds

Maximum speed in the direction of the operator.

100

0

100

%

Maximum speed in the direction of the forks.

100

0

100

%

30

0

30

%

Deceleration ramp when the throttle is fully released (linear).

Deceleration ramp when reverse is requested.

Deceleration ramp when the traction throttle is partially released.

Defines the quick inversion mode from the Belly pushbutton.

- Brake: if this push-button is pressed during traction in the direction of the operator, the truck will stop immediately.

- Belly: if this push-button is pressed during traction in the direction of the operator, quick inversion will be activated while the pushbutton is pressed.

- Timed: if this push-button is pressed during traction in the direction of the operator, quick inversion will be activated for a maximum of 6 seconds while the pushbutton is pressed. When the push-button is released, the truck will stop.

45628042104 EN - 4/2020

-13

Speed reduction with tiller always active.

Gives the acceleration ramp a parabolic shape rather than a linear shape.

Gives the acceleration ramp a parabolic shape rather than a linear shape (after reversing).

Defines the first "X" Hz at which the parabolic degree of the acceleration curve can be changed starting from a standstill or reversing.

Gives the deceleration ramp a parabolic shape rather than a linear shape.

Frequency (= speed) at which the effects of the parabolic acceleration ramp stop.

The battery discharge algorithm acquires the values with the truck at rest. A 5% decrease of the battery charge is forced after each period indicated by this parameter (very intensive use without pauses).

Defines the length of time the TILLER / TILLER2 can remain ON without any functions activated. After this time, the main contactor opens and the INTERLOCK TIME alarm is triggered.

Main contactor opening delay when the tiller is released.

31

10

40

1.5

1

5

1

1

5

10

3

20

3

1

5

10

3

20

Hz

4

0

60

Seconds

60

5

300

Seconds

10

1

10

Seconds

Running

-14

45628042104 EN - 4/2020

%

Running / Key on

Defines the hour counter mode: RUNNING (counter is active when the micro tiller is active) or KEY ON (counter is active when the key is turned).

ON: when the residual battery capacity reaches 10%, the hydraulic functions, except for the hydraulically assisted steering, drop to a minimum (useful only to terminate the manoeuvre in progress).

OFF: No limitation.

BELLY = when the tiller safety push-button is pressed, the truck reverses continuously TIMED = when the tiller safety push-button is pressed, the truck reverses for a timed period (continuously for a certain period only).

Activates the optional output for the buzzer or flashing beacon: Level = 0 output not active.

Level = 1 output active when travelling in the direction of the forks.

Level = 2 output active with TILLER / TILLER 2.

Level = 0

Level = 0 / 1 / 2 / 3

Timed

Timed / Belly / Brake

Level = 0

Level = 0 / 1 / 2

6%

0 - 100 %

40%

0 - 100 %

25%

0 - 100 %

Defines the voltage range relating to the traction potentiometer, which the controller interprets as neutral position.

The parameter modifies the vehicle's response according to the rotation of the throttle: - By setting "X" to 50%, a linear response is achieved; - Lower values give the truck greater manoeuvrability; - "X" represents the Cartesian coordinate of the "knee" of the potentiometer curve.

The parameter modifies the vehicle's response according to the rotation of the throttle: - By setting "Y" to 50%, a linear response is achieved; - Lower values give the truck greater manoeuvrability; - "Y" represents the Cartesian coordinate of the "knee" of the potentiometer curve.

45628042104 EN - 4/2020

-15

If set to ON, the last maintenance counter value and the "CHECK UP NEEDED" warning can be reset by carrying out the relevant specified actions.

Specifies how the "CHECK UP NEEDED" warning is managed: - NONE: no warning; - OPTION #1: the warning appears on the console after 300 hours; - OPTION #2: in the same way as OPTION #1, but after 340 hours there is a reduction in speed; - OPTION #3: in the same way as OPTION #2, but after 380 hours the truck stops.

off

off / on

none

none / opt. # 1, # 2, # 3

21°C

Used to acquire the controller temperature.

-16

45628042104 EN - 4/2020

8

8

17

26

31

40

41

42

53

At start-up, the Watch- Fault in the electronic control - Replace the electronic control dog signal is already acsystem. system. tive before the software activates it.

- Programming error in the "flash" - Correctly reprogram the "flash" memory. memory.

Checksum error detec- Fault in the electronic control - Replace the electronic control ted in the flash memory. system. system if the problem persists.

Fault in excess current protection circuits.

- Fault in the electronic control system.

Problem detected at the - Fault in the electronic control current sensor in the system. electronic control system.

Phase voltage of the traction motor higher than expected.

- Incorrect connections on the motor.

- Traction motor no longer isolated.

- Fault in the electronic control system.

Fault detected on the - Electromagnetic brake connecdriver (X2:4) that contions X2:4 and X2:2 incorrect. trols the electromagnetic - Fault in the electronic control brake coil. Driver closed system. even when not enabled via software.

- Replace the electronic control system.

- Replace the electronic control system.

- Check that the motor wiring is correct.

- Check that the isolation between the motor and the chassis is correct.

- Replace the electronic control system if the problem persists.

- Check that inputs X2:4 and X2:2 are connected correctly.

- Replace the electronic control system if the problem persists.

- Check that the battery's nominal - Battery with incorrect nominal voltage value is correct.

Battery voltage (meas- voltage.

- Bring the ADJUST BATTERY ured at input X2:10 Key) - The ADJUST BATTERY paramvalue to the correct value (measis too low or too high eter has an incorrect value. ured with the tester). (<0.8 Vbatt or >1.2 - Fault in the electronic control - Replace the electronic control Vbatt). system. system if the problem persists.

Fault detected on the - The electromagnetic brake coil driver (X2:2) that concontrol is faulty. trols the electromagnetic - Fault in the electronic control brake coil. Driver open system. even when enabled via software.

- Fault in the electronic control system.

45628042104 EN - 4/2020

- Replace the electronic control system.

- Replace the electronic control system.

-17

In standby conditions, a higher current than expected has been detected on the traction motor.

53

54

55

60

68

Feedback voltage for the - Internal voltage values incorrect.

- Replace the electronic control traction motor phase - Fault in the electronic control system. outside of expected system. range.

- Check that the key connection is correct.

- Check that the battery status is - Incorrect voltage values on correct.

X2:10 input.

- Check that the connections on - Battery charge too low.

Excess voltage on powthe battery and on the power line - Incorrect battery connections. er capacitors or voltage are correct.

- False contact on power line. drops on key input.

- Check that the screws that se- Fault in the electronic control cure the power contacts are tightsystem. ened correctly.

- Replace the electronic control system if the problem persists.

The internal circuit of the - The motor voltage control cirelectronic control system cuits are faulty. that manages feedback - Fault in the electronic control of motor phase voltage system. is damaged.

- Lowering valve already controlled at start-up.

- Possible load connected in parThe voltage on the powallel at the capacitor group (+ er capacitors is lower AUX) than expected.

- Fault in the electronic control system.

Problem detected at out- - Connector 1X1 not connected. put X2:2 (missing posi- - Fault in the electronic control tive from electromagnet- system. ic brake 1Y1).

72

- Motor cables disconnected.

- Incorrect connections on the motor.

Phase voltage of traction - Traction motor no longer isolamotor lower than expec- ted. ted.

- TG K1 open.

- Fault in the electronic control system.

74

- Input X2:12 already at B- at Fault in control circuit of start-up. driver that controls the - Fault in the electronic control main contactor coil. system (MOS short circuited).

75

-18

Fault in control circuit of - Fault in the electronic control driver that controls the system (MOS open). main contactor coil.

45628042104 EN - 4/2020

- Replace the electronic traction control.

- Check that the connections of the lowering valve are correct.

- Check that there are no loads connected in parallel at the capacitor group (+ AUX).

- Replace the electronic control system if the problem persists.

- Check that connector 1X1 is correctly connected.

- Replace the electronic control system.

- Check that the motor wiring is correct.

- Check that the isolation between the motor and the chassis is correct.

- Check that the main contactor is working correctly.

- Replace the electronic control system if the problem persists.

- Check that input X2:12 is connected correctly.

- Replace the electronic control system if the problem persists.

- Replace the electronic control system.

75

76

76

77

80

82

- Check that the main contactor is - Main contactor faulty. working correctly and replace if - Connection of main contactor in- necessary.

The main contactor con- correct.

- Check that the coil connection is tact is jammed close.

- Fault in the electronic control correct. system.

- Replace the electronic control system if the problem persists.

- Check that the contactor is working correctly and is not using more current than necessary.

- Contactor K1 faulty.

- Check that the electromagnetic - Contactor connections (X2:12, brake is working correctly and is Current too high on driv- +24 V) incorrect. not using more current than necer (X2:12) that controls - Electromagnetic brake faulty. essary. the main contactor coil - Electromagnetic brake connec- Check that inputs X2:12, +24 V K1 or on driver (X2:2) tions (X2: 2, X2:4) incorrect. are connected correctly. that controls the electro- - Fault in the electronic control - Check that inputs X2:2, X2:4 are magnetic brake coil 1Y1. system. connected correctly.

- Replace the electronic control system if the problem persists.

At start-up, a fault is detected in the internal circuit of the electronic - Fault in the electronic control control system that man- system. ages "under/over voltage" signals. Output always active.

- Replace the electronic control system.

- Check that the main contactor is - Main contactor faulty. working correctly and replace if The main contactor coil - Connection of main contactor in- necessary. driver is controlled but correct.

- Check that the coil connection is the contact did not - Fault in the electronic control correct. close. system.

- Replace the electronic control system if the problem persists.

- Check that the status of fuse F3 - Fuse F3 open. is correct.

- Pin X2:3 connections incorrect. - Check that pin X2:3 is connected Voltage level too low on - Fault in the electronic control correctly. pin X2:3 (+ AUX). system.

- Replace the electronic control system if the problem persists.

- Check that connector 1X2 is cor- Connector 1X2 is not correctly rectly connected to the motor. connected to the motor.

- Check that the wires are correctly - One or more wires not correctly connected to connector 1X2. connected on connector 1X2.

- Check that inputs X4:1, X4:2, - One or more wires not correctly X4:3 and X4:4 are connected corProblems reading the connected on connector X4 rectly. signals of the traction (X4:1, X4:2, X4:3, X4:4).

- Check that inputs X2:5, X2:13, motor encoder during - One or more wires not correctly X2:14 and X2:25 are connected travel. connected on connector X2 correctly.

(X2:5, X2:13, X2:14, X2:25).

- Check that the encoder power - Motor encoder damaged. supply is correct.

- Fault in the electronic control - If the problem persists, replace system. the traction motor encoder.

45628042104 EN - 4/2020

-19

- If the problem still persists, replace the electronic traction control.

86

89

96

- Incorrect connections on pin High voltage level detecX2:2. ted (+Batt) on pin X2:2 - Fault in the electronic control (electromagnetic brake system (smart driver short circuitpositive) with tiller in rest ed). position.

Short circuit on power MOSFETs.

- Fault in the electronic control system.

Error detected in reading of analogue inputs by - Fault in the electronic control the microprocessor in system. the electronic control system.

The tiller is in the working position for a period of > 5 minutes without requests for operations (traction or hydraulic movements).

- The tiller does not automatically return to the rest position.

- Tiller microswitch 7S3 faulty (contacts jammed).

- Check that input X2:2 is connected correctly.

- Replace the electronic control system if the problem persists.

- Replace the electronic control system.

- Replace the electronic control system.

- Check that the tiller automatically returns to the rest position.

- Check that tiller microswitch 7S3 works correctly.

- Values incorrect in EEPROM. - Carry out CLEAR EEPROM. Error detected in the EE- Fault in the electronic control - Replace the electronic control PROM of the electronic system. system if the problem persists. control system.

- Identify the potential causes for the overheating of the electronic control system (over-intensive - Eliminate the causes of the overThe internal control sys- use, ambient temperature too heating. tem temperature is high- high, reducer partially jammed - Replace the electronic traction er than 85°C. etc.). control if the problem persists.

- Fault in the electronic control system.

- Identify the potential causes for the overheating of the traction - Eliminate the causes of the overmotor (over-intensive use, ambiheating.

The traction motor tem- ent temperature too high, reducer - Replace the electronic control perature is too high partially jammed etc.). system if the problem persists. (>150°C).

- Fault in the electronic control system.

- Recharge the battery correctly.

- Battery needs recharging.

- Check that the battery status is The battery discharge - Battery status incorrect. correct. level has reached the - BATTERY CHECK parameter - Check that the BATTERY set threshold of 80%. not set to the correct value.

CHECK parameter is set to the correct value.

Check that potentiometer input - Input X2:15 has a voltage value X2:15 is connected correctly. of > 1 V + VACC MIN at rest.

- Recalibrate the accelerator corAccelerator potentiome- - Incorrect calibration of accelerarectly using the diagnostic softter voltage is too high at tor. ware. rest.

- Fault in the electronic control - Replace the potentiometer unit if system. the problem persists.

-20

45628042104 EN - 4/2020

- If the problem still persists, replace the electronic control system.

- Check that the alarm disappears with the correct sequence.

- Check that input X2:1 (Tiller) is - Incorrect traction activation seconnected correctly. quence.

- Check that input X2:32 (FWD) is - Input X2:1 (Tiller) already closed connected correctly. at start-up.

- Check that input X2:31 (RWD) is - Input X2:32 (FWD) already Incorrect traction activaconnected correctly. closed at start-up. tion sequence detected - Check that the Belly microswitch - Input X2:31 (RWD) already (tiller + gear + acceleraworks correctly. closed at start-up. tor potentiometer).

- Check that tiller microswitch 7S3 - Belly microswitch already pressworks correctly. ed at start-up.

- Check that the accelerator poten- Fault in the electronic control tiometer works correctly. system.

- If the problem still persists, replace the electronic traction control.

- Check that the potentiometer - Accelerator potentiometer faulty generates the correct signals for Both directions of move- (gear outputs short circuited). the gears. ment active simultane- - Fault in the electronic control - Replace the electronic control ously. system. system if the problem persists.

- Check that connector 1X2 is correctly connected to the motor.

- Connector 1X2 is not correctly - Check that the wires are correctly connected to the motor. connected to connector 1X2.

- One or more wires not correctly - Check that inputs X4:1, X4:2, connected on connector 1X2.

X4:3 and X4:4 are connected cor- One or more wires not correctly rectly.

Problems reading the connected on connector X4 - Check that inputs X2:5, X2:13, signals of the traction (X4:1, X4:2, X4:3, X4:4).

X2:14 and X2:25 are connected motor encoder when be- - One or more wires not correctly correctly. ginning travel. connected on connector X2 - Check that the encoder power (X2:5, X2:13, X2:14, X2:25). supply is correct.

- Motor encoder damaged.

- If the problem persists, replace - Fault in the electronic control the traction motor encoder. system.

- If the problem still persists, replace the electronic traction control.

- Input X2:6 (Belly microswitch normally closed) already open at Conflict detected beCheck that inputs X2:6 and X2:7 start-up. tween the status of input are connected correctly.

- Input X2:7 (Belly microswitch X2:6 (Belly microswitch - Check that the Belly microswitch normally open) already closed at normally closed) and the is working correctly. start-up. status of input X2:7 (Bel- Replace the electronic control - Belly microswitch damaged. ly microswitch normally system if the problem persists.

- Fault in the electronic control open). system.

Error detected in reading - Fault in the electronic control of some data contained system. in the RAM registries (RAM corrupt).

45628042104 EN - 4/2020

- Replace the electronic control system.

-21

- Wire disconnected on input X2:22.

- Wire disconnected on inputs X7:1 and X7:2.

Out-of-range voltage - Wire disconnected on inputs level detected on inputs X4:7 and X4:8.

X2:22 and B- (1B1 trac- - Short circuit between X7:1 and tion motor temperature X7:2 or between X4:7 and X4:8. sensor).

- Motor temperature sensor faulty.

- Fault in the electronic control system.

- Check that the connections on inputs X2:22, X7:1, X7:2, X4:7 and X4:8 are correct.

- Check that the sensor works correctly.

- Replace the electronic control system if the problem persists.

Out-of-range voltage - Carry out PROGRAMM VACC - PROGRAMM VACC calibration level detected on accelcalibration correctly. not carried out correctly. erator potentiometer in- Check that the accelerator poten- Accelerator potentiometer faulty. put (X2:15). The permittiometer works correctly.

- Accelerator potentiometer input ted range is a value be- Check that input X2:15 is con(X2:15) connections incorrect. tween VACC MIN and nected correctly.

- Fault in the electronic control VACC MAX saved with - Replace the electronic control system.

PROGRAMM VACC calsystem if the problem persists. ibration.

The truck is in standby - No fault: just an indication that with the tiller in rest posiTG K1 has opened. tion for more than 30 seconds.

At start-up, the Watchdog 2 signal is already active before the software activates it.

- Fault in the electronic control system.

Fault in control circuit of driver that controls the - Fault in the electronic control coil of lowering valve system (MOS open even if con2Y1 or fault in control trolled by software). circuit of driver that controls the coil of lifting contactor 2K1.

- Pin X2:33 already at B- at startFault in control circuit of up. driver that controls the - Pin X2:33 not connected. coil of lowering valve - Pin X2:34 already at B- at start2Y1 or fault in control up. circuit of driver that con- - Pin X2:34 not connected. trols the coil of lifting - Fault in the electronic control contactor 2K1. system (MOS short circuited).

- 2Y1 valve faulty.

Current too high on driv- - 2K1 contactor faulty. er (X2:33) that controls - Valve 2Y1 connections (X2:33, the coil of the lowering 2X2:1, 2X2:2) incorrect. valve 2Y1 or on driver - Contactor 2K1 connections (X2:34) that controls the (X2:34, 2X2:1, 2X2:2) incorrect. coil of the lifting contac- - Fault in the electronic control tor 2K1. system.

-22

45628042104 EN - 4/2020

- The alarm disappears with the closure of TG K1 when the tiller microswitch is closed.

- Replace the electronic control system.

- Replace the electronic control system.

- Check that input X2:33 is connected correctly.

- Check that input X2:34 is connected correctly.

- Replace the electronic control system if the problem persists.

- Check that valve 2Y1 is working correctly and is not using more current than necessary.

Check that pins X2:33, 2X2:1 and 2X2:2 are connected correctly.

- Replace the electronic control system if the problem persists.

Error detected in MAX. current calibration.

- Fault in the electronic control system.

- Replace the electronic control system.

- Check that the lifting/lowering buttons on the tiller head work cor- Lifting/lowering buttons on the rectly. tiller head damaged or do not re- Check that pins X01:5 and turn to rest position.

X01:13 on the tiller PCB are not - Tiller PCB faulty.

Simultaneous activation short circuited to +24 V. - Connections on pins X01:5, of lifting and lowering re- Check that pins X01:5, X01:13, X01:13, X5:5, X5:13, X2:17 and quests detected.

X5:5, X5:13, X2:17 and X2:20 are X2:20 incorrect. connected correctly.

- Fault in the electronic control - If the problem still persists, resystem. place the electronic control system.

- Incorrect activation sequence - Check that the alarm disappears for hydraulic movements. with the correct sequence.

- Input X2:17 (LIFT) already ac- Check that pin X2:17 (LIFT) is Incorrect activation se- tive at start-up or before tiller mi- connected correctly. quence for hydraulic croswitch is activated.

- Check that input X2:20 (DEmovements detected - Input X2:20 (DESCEND) alSCEND) is connected correctly. (tiller + lifting/lowering ready active at start-up or before - Check that the lifting/lowering button). tiller microswitch is activated. buttons work correctly.

- Fault in the electronic control - Replace the electronic control system. system if the problem persists.

Calibration process of maximum traction cur- Fault in the electronic control rent under way (this calisystem. bration procedure can only be carried out by ZAPI).

- Replace the electronic control system.

- Check that the CAN connection - Fault on CAN line (wire broken).

The CAN line of the line is correctly connected.

- Fault in the electronic control electronic control system - Replace the electronic control system. is not working. system if the problem persists.

The number of working hours set after which - No fault. servicing by a technician is required has been reached.

Out-of-range voltage level detected for internal temperature sensor in the electronic control system.

- Fault in the electronic control system.

Error detected in param- Fault in the electronic control eters for the managesystem. ment of traction motor SLIP.

45628042104 EN - 4/2020

- Reset the alarm through the CHECK UP DONE parameter.

- Replace the electronic control system.

- Replace the electronic control system.

-23

CHECKUP NEEDED

Maintenance due.

DATA ACQUISITION

Data is being updated.

LIFT+LOWER

Lifting and lowering requests simulta- Always neously active.

Pump motor blocked.

51

TILLER OPEN

The truck is in stand-by with the tiller at rest position for at least 60 sec- Stand-by onds, (INTERLOCK TIME OUT) parameter.

Main contactor open.

61

THERMIC SENS KO

The system's thermal sensor output Always is out of range.

49

62

TH. PROTECTION

65

BATTERY LOW

65

-24

MOTOR TEMPERATURE

/

Stand-by

The system has reached a temperature of 85°C and Always thermal protection has been activated.

If the BATT.CHECK>0 parameter is set, the warning will apAlways pear when the battery has a residual charge that is less than 20%.

The drive motor temperature sensor has exceeded the 150°C threshold.

Always

/

Drive blocked.

The max. current and max. speed are reduced by half.

The controller reduces the max. drive current linearly from Imax [85°C] to 0 A [105°C].

Carry out scheduled maintenance and set the CHECK UP DONE parameter to ON. The warning disappears when the data acquisition procedure has finished.

- Check the lifting and lowering buttons are working properly; - Check the lifting/ lowering signals output from the tiller PCB; - Replace the system The warning disappears when the tiller is activated.

- Internal system problem; change.

- Look for possible causes of overheating.

- If the problem persists, change the system.

Depends on the Charge the batBATTERY CHECK tery. parameter setting.

The max. current and max. speed are reduced by half.

45628042104 EN - 4/2020

- Check that the drive motor thermal sensor is connected properly.

- Look for possible causes of motor overheating.

67

Traction motor SENS. MOT. temperature senTEMP. sor is damaged.

Always

Significantly reduced performance.

71

EEPROM KO

EEPROM memory Always error.

The controller uses the default parameters.

74

Short circuit on the EV4 DRIVER Ignition; "lifting contactor" SHORTED stand-by coil driver.

Function not active.

74

Short circuit on the EV1/5 DRIVdriver of the "status Ignition; ER SHORLED" ON/OFF stand-by.

TED valves and EV5

Function not active.

74

Short circuit on the EV2 DRIVER "battery status out- Ignition; SHORTED put" LED output stand-by. driver.

Function not active.

74

Short circuit on the EV3 DRIVER "lowering solenoid Ignition; SHORTED valve" LED output stand-by. driver.

Function not active.

75

CONT. DRIV. EV1

Control unable to control "status LED" output.

75

CONT. DRIV. EV2

Control unable to When the "battery Function not accontrol "battery sta- status output LED" tive. tus output". is operating.

75

CONT. DRIV. EV3

Control unable to control "lowering solenoid valve".

When "status Function not acLED" is operating. tive.

When "lowering solenoid valve" is operating.

45628042104 EN - 4/2020

Function not active.

- Internal system problem; change.

- Check that the drive motor thermal sensor is connected properly.

- Change the motor thermal sensor - If the problem persists, change the controller.

Carry out a CLEAR EEPROM. - If the problem persists, change the controller.

- Check that there is no short circuit between the coil negative and the battery negative.

- Internal system problem; change.

- Check that there is no short circuit between the coil negative and the battery negative.

- Internal system problem; change.

- Check that there is no short circuit between the coil negative and the battery negative.

- Internal system problem; change.

- Check that there is no short circuit between the coil negative and the battery negative.

- Internal system problem; change.

- Internal system problem; change (default parameter programming error).

- Internal system problem; change (default parameter programming error).

- Internal system problem; change.

-25

75

CONT. DRIV. EV4

Control unable to When "lifting concontrol "lifting con- tactor" is operattactor". ing.

75

CONT. DRIV. EV5

76

Short circuit on COIL SHOR. ON/OFF valves EV coil.

Function not active.

EV5 output not enabled.

Ignition; stand-by; when valve is operating.

The accelerator analogue value is Ignition, above the acceptastand-by, ble minimum and drive. the direction signal is not active.

Function not active.

- Internal system problem; change.

- Internal system problem; change (default parameter programming error).

- Check the solenoid valve coil is intact; - Check the coil connections.

Check the calibration and operation of the drive potentiometer.

78

VACC NOT OK

79

Activation seINCORRECT quence of any inSTART correct function.

Ignition, stand-by, drive.

Drive blocked.

80

FORWARD +BACKWARD

Both directions of movement active simultaneously.

Ignition, stand-by, drive.

Drive blocked.

92

CURRENT GAIN

Internal error.

Ignition, stand-by.

The controller operates but with low - Internal system max. current val- problem; change. ues.

99

SLIP PROFILE

Ignition, Error in slip paramstand-by, eter settings. drive.

-26

Drive blocked.

Drive blocked.

45628042104 EN - 4/2020

Check correct execution of activation sequence for a function.

- Check the drive control throttle is working properly in relation to the direction signals; - Check the direction signals output from the tiller PCB; - Change the system.

- Internal system problem; change.

1

Electromagnetic brake.

2 45628042104 EN - 4/2020

Screw;

.

-1

3 4 5

Pinion gear.

Transmission gear.

Electric motor.

6 7 8

Screw; Screw; Screw;

. .

.

This is a three-phase AC drive motor with an internal triangular connection with the following characteristics: Supply voltage Nominal power

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

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

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

Tiller placed in braking position.

-2

45628042104 EN - 4/2020

Preparations: Remove the covers to access the motor compartment Remove the tiller – Unplug the encoder connector



Next, unplug: the electromechanical brake connector and remove it; the thermal sensor and remove it; the smallest tiller cable and remove it; the control wiring cable from the tiller.

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



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

45628042104 EN - 4/2020

-3

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



– Using an Allen key with a narrow shank, unscrew the screws on the brake body.



-4

45628042104 EN - 4/2020

– Lift the brake block out upwards.



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



– Use an extraction tool to remove the pinion from the drive shaft.



During this phase, it is essential to avoid blows to the teeth of the pinion.

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-5

– 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 photos).



–



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



-6

45628042104 EN - 4/2020

–



– Using an Allen key, remove the encoder pickup.



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



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-7

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



– Unscrew the six drive motor mounting screws using an Allen key



– Raise the stator.



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

-8

45628042104 EN - 4/2020

Before removing the bearing, follow the drive motor removal procedure described above.

– Remove the Seeger ring from the drive motor pinion.



– Use an extraction tool to remove the pinion from the drive shaft.



– Manually slip off the flange (A).



– Remove the bearing (B) using an extraction tool.

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-9

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 traction/lift controller ( ) Part number of the traction/lift controller ( )

Ɣ

-10

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– The temperature sensor signal is processed by the traction/lift electronic controller.



Refer to the circuit diagram for a better understanding.

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-11

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

-12

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-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

45628042104 EN - 4/2020

-13

-14

-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

45628042104 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)

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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

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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

45628042104 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.

-4

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.

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Before removing the transmission gear, you need to have removed the drive motor and the tiller flange from the truck; see relevant sections.

– Lift the truck using an appropriate tool and rest it safely on some support blocks.



– Support the truck on blocks of the same height.



– You can remove the fifth wheel of the transmission gear unit by unscrewing the socket head screws that attach the fifth wheel to the transmission gear.



During reassembly of the fifth wheel onto the transmission gear, tighten the screws with a torque setting of .

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-5

– Unscrew the six screws that fix the transmission gear unit to the chassis. The transmission gear unit must be supported from beneath the bodywork.



Be careful not to crush your hands or feet!

During reassembly of the transmission gear unit, tighten the screws with a torque setting of .

– Remove the transmission gear unit from beneath the bodywork.



– You can now overhaul the transmission gear unit.



– To reassemble the transmission gear, proceed in the reverse order.

-6

45628042104 EN - 4/2020

Remove the oil from the reducer.

– Using the appropriate wrench remove the 5 screws that secure the fifth-wheel to the reducer housing.



– Use a T-wrench to unscrew the screws on the cover.



– The silicone gasket keeps the cover sealed to the reducer housing; use a chisel and mallet to separate the two parts.



45628042104 EN - 4/2020

-7

– Remove the dowel from the nut using the appropriate T-wrench.



– Unscrew the nut with a wrench.



– Tap the drive shaft with a mallet to remove it from the reducer, stopping when you reach the ring gear. Be careful not to let it fall by supporting it with the other hand.



– Detail of removing the drive wheel shaft from its seat.



-8

45628042104 EN - 4/2020

– Slide out the drive shaft bearing using a twoarm extractor.



– Tap the thread guard with a mallet and remove it.



– Remove the oil seal with a screwdriver.



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-9

– Detail of the items removed.



– To take the cover off, remove the screws with a T-wrench.



– The silicone gasket keeps the cover sealed to the reducer housing; use a screwdriver to separate the cover from the reducer housing.



– Detail



-10

45628042104 EN - 4/2020

– Before unscrewing the nut with the appropriate wrench, block the ring gear by putting a screwdriver into the appropriate hole.



– Tap the pinion gear with a mallet to remove it from the reducer housing and support the pinion gear with the other hand to prevent it from falling.



45628042104 EN - 4/2020

-11

– Once you have slipped the pinion gear out of its seat, remove the ring gear.



– Detail of some parts that make up the reducer. At this point, it is possible to clean the different parts and replace any that are damaged (for example, the bearings or the drive shaft oil outlet seal).



To reassemble, follow the operations described in this section in reverse order. information on screw tightening torques can be found in the "Reducer design" section; to caulk the special nuts, see the "Reducer design" section; when refitting the covers, insert the silicone gasket; use thread lock where used before; reposition shim rings where used.

-12

45628042104 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.

45628042104 EN - 4/2020

-13

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

-14

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.

45628042104 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.

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-15

-16

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

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-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

45628042104 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.



45628042104 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

45628042104 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.



45628042104 EN - 4/2020

-5

-6

45628042104 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.

Braking by "throttle release": controlled stopping via electrical braking and eventual cut in of electromagnetic brake.

"Inversion braking" is carried out on the moving truck by inverting the direction using the traction control throttle. Controlled stopping via electrical braking and eventual cut in of electromagnetic brake.

Braking by "total throttle release" and "inversion" " " 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

45628042104 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

45628042104 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.

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-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

45628042104 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.

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-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

45628042104 EN - 4/2020

– Completely unscrew the 4 nuts, holding the pivoting wheel from below the cover 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.

– 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.



45628042104 EN - 4/2020

-7

-8

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45628042104 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

45628042104 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.



45628042104 EN - 4/2020

Plug Washer Screw

-3

–



-4

45628042104 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.



45628042104 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

45628042104 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.



45628042104 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

45628042104 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.



45628042104 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

45628042104 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



45628042104 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

45628042104 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.



45628042104 EN - 4/2020

-15

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

-16

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.

45628042104 EN - 4/2020

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).

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).

45628042104 EN - 4/2020

-17

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.

-18

45628042104 EN - 4/2020

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.

45628042104 EN - 4/2020

-19

-20

45628042104 EN - 4/2020

1 2 3

24V battery Emergency battery plug Main contactor

4 5 6

45628042104 EN - 4/2020

Pump fuse Pump contactor Electronic system

-1

7 8 9 10 11 12

Fork lowering solenoid valve Tiller head Horn Main contactor coil (K1) Pump contactor coil (2K1) Micro tiller

13 14 15 16 17 18

Auxiliary circuit protection fuses and key Diagnostic tool Lowering solenoid valve Electromagnetic brake Thermal sensor Motor encoder

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

Nominal supply voltage 24 V DC Maximum current for the drive motor 220 A DC for the 2500 - 3000 kg version.

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

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

Runs silently at high frequencies.

Full diagnostics via PC. Regenerative braking that allows for shorter stopping distances, increases available energy from the battery and reduces motor and brake overheating.

Internal reversed polarity protection.

-2

45628042104 EN - 4/2020

1 2 3

TILLER P_EB +AUX

4

N_EB

5

N_ENC

6

BELLY_N.C.

7

BELLY N.O.

8 9 10 11 12 13 14

/ STATUS LED + KEY BATTERY LED N_M.C. CH_A CH_B

15

THROTTLE

16 17 18 19 20 21 22 23 24 25

/ LIFT / / DESCENT TH_MOTOR / / PENC

26

HORN

27 28 29 30 31 32 33 34 35

CAN_L CAN_H / / REV FWD LOWER EV 2K1 TILLER2

/

/

Micro tiller Positive to electromagnetic brake coil Positive from solenoid valves Negative to electromagnetic brake coil

/

/

/

/

/

/

/ /

/ / /

/ / /

/ / /

/ /

/ /

45628042104 EN - 4/2020

Drive motor encoder negative Contact normally closed from rapid reversing micro switch Contact normally open from rapid reversing micro switch Free Status LED negative (ignition/alarms) +24 V from key Battery status LED negative (flat) Negative from main contactor coil Drive motor encoder channel A Drive motor encoder channel B Analogue signal from drive potentiometer Free Fork lift control Free Free Fork lowering control Free Drive motor thermal sensor Free Free Encoder positive (+5 V) Output for options (flashing beacon, reverse buzzer) CAN BUS communication line CAN BUS communication line Free Free Fork-side drive actuation Operator-side drive actuation Lowering solenoid valve coil negative Pump contactor coil negative Tiller always active

-3

Turn off the truck and perform the preliminary maintenance operations.

1

-B

M

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.

2

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

2

4 1837

Fuse = 7.5 A Fuse = 5 A Traction motor protection fuse = 200 A Lifting motor protection fuse = 150 A

-4

U

V

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

3

45628042104 EN - 4/2020

Voltage Capacity ±5% 24

200

24

220

24

230

24

250

24

300

24

330

24

345

24

375

Dimensions

624 x 212 x 627 624 x 212 x 627 624 x 212 x 627 624 x 212 x 627 624 x 284 x 627 624 x 284 x 627 624 x 284 x 627 624 x 284 x 627

Weight ±5%

TROG

Component series and type

212

112

LF

47

212

112

LF

47

212

112

LF

47

212

112

LF

47

288

113

LF

65

288

113

LF

65

288

113

LF

65

288

113

LF

65

3

Component length

screw type screw type screw type screw type screw type screw type screw type screw type

2

1

4 Indicates the battery charge level; it is subdivided into ten sectors with respective coloured LEDs. When the battery is 100% charged, LED remains lit up.

As the battery discharges, the LEDs light up one at a time from right to left, starting from LED , which indicates the completely charged battery status.

At 50% charged, LED lights up When the battery is 20% charged, LEDs flash alternately.

Terminals

N

?

12345.6

5

OM1766

Charge the battery to at least 30% charged; below this level the truck will not lift.

45628042104 EN - 4/2020

-5

Indicates the actual forklift operation time, expressed in hours.

When the hour meter is working, the hourglass flashes; five numbers plus one decimal digit are displayed. The hour meter is progressive and starts at zero.

-6

45628042104 EN - 4/2020

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.

45628042104 EN - 4/2020

-7

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: 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.

Rectifier powered

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 Frequency Rated output current Rated output voltage Plug Charging time depends on battery capacity Internal mains presence relay

230 ±10% AC 50-60 Hz +/-1% 35 A +/-2% 24 V DC Schuko type 2P+T 16 A 250 V 14 hours per 200 Ah

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

-8

45628042104 EN - 4/2020

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

3

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.

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

45628042104 EN - 4/2020

1843

-9

= 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. = Current I2 is kept constant, supplying the required charging increase and agitating the electrolyte (I2 = boost current).

Current I2 depends on the Ah charged during phases I1 and P. During this phase, the voltage is limited to 32 V max (2.67 V/cell). The current could therefore decrease (phase U2 is shown in the graphic above). Note: phase I2 ends when the battery has been supplied with 17% of the Ah of phases I1-P-U1. = In this phase the current is I2/2. This phase ends when the battery voltage has been increased by 120 mV/h or when 4 hours have elapsed. = 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.

-10

45628042104 EN - 4/2020

The charge curves refer to standards DIN 41774 and DIN 41772, and we mention again that: = Charge with decreasing current = Charge with constant voltage = Charge with constant current = Charge with automatic stop = Charge with different currents

45628042104 EN - 4/2020

-11

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.



-12

45628042104 EN - 4/2020

– Battery charger compartment.



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

45628042104 EN - 4/2020

-13

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



– Detail.



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



-14

45628042104 EN - 4/2020

– 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.



45628042104 EN - 4/2020

-15

-16

45628042104 EN - 4/2020

1

Central manifold.

2 45628042104 EN - 4/2020

Solenoid valve.

-1

3 4 5 6 7 8

Coil with connector.

Pump.

Direct current electric motor.

Tank.

Connecting piece.

Tank mounting support on KS manifold.

-2

9 10 11 12 13 14

Intake pipe.

Suction filter.

Return pipe.

Adjustment valve.

Maximum-pressure valve.

Non-return valve.

45628042104 EN - 4/2020

This is a motor with the following features in all versions: Supply voltage: 24 V DC Nominal power: 2.2 kW The capacity difference is obtained from different calibration of the maximum-pressure valve:

2500 kg 2500 kg

l </= 1600 l > 1600

45628042104 EN - 4/2020

165 bar 200 bar

-3

3000 kg 3000 kg

-4

l </= 1600 l > 1600

45628042104 EN - 4/2020

190 bar 230 bar

Before removal, follow the instructions given in the "Preliminary maintenance operations" section.

Remove the battery.

Lower the forks fully.

– Disconnect the two wires from the control unit using an appropriate wrench.



– Disconnect the hydraulic line by removing the mounting screw.



45628042104 EN - 4/2020

-5

– Using an appropriate articulated wrench, disconnect the hydraulic line that is attached to the lift cylinder.



– Next, using a cross-head screwdriver, unscrew the coil connector mounting screw and then detach the connector manually.



– Using an appropriate wrench, unscrew the horn mounting screw from the fixing bracket on the control unit.



-6

45628042104 EN - 4/2020

– Access the battery compartment and using a hexagonal "T" wrench, unscrew the 2 mounting 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.

– To reassemble the control unit, proceed in the reverse order.

45628042104 EN - 4/2020

-7

– Select an appropriate wrench.



– Unscrew the valve closure nut.



– Adjust the maximum-pressure valve with a pin punch.



-8

45628042104 EN - 4/2020

– Unscrew the cap and remove the small seal.



– Unscrew the coil upwards.



– Unscrew the solenoid valve using an appropriate wrench.



– Remove the solenoid valve.



45628042104 EN - 4/2020

-9

– Grip the O-ring using a pair of pliers.



– Next, remove the adjustment valve and the spring.



– To reassemble the solenoid valve unit, proceed in the reverse order.

– Unscrew the valve using an Allen key and remove it.

-10



45628042104 EN - 4/2020

– Replace the valve.



– Unscrew the 4 mounting screws using an appropriate key.



– Manually remove the tank and the pump.



– Before changing the filter, remove the tank as described above.

– Manually unscrew the filter as shown in the photo and replace it.



45628042104 EN - 4/2020

-11

– Unscrew the 2 mounting screws using an appropriate key.



– Remove the cover to check the brushes; replace them if necessary.



– Remove the tank and pump as described above.



-12

45628042104 EN - 4/2020

– Using a wrench, unscrew the 2 screws, as shown in the photo.



–



– Use a pair of pliers to remove the connecting piece and replace it.



– To reassemble the connecting piece, proceed in the reverse order.

45628042104 EN - 4/2020

-13

– 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.



-14

45628042104 EN - 4/2020

– 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.

45628042104 EN - 4/2020

-15

–



– 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.



-16

45628042104 EN - 4/2020

– Finally, remove the cylinder.



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

45628042104 EN - 4/2020

-17

1 2 3

Threaded port plate.

Rod. Snap ring.

-18

4 5 6

O-ring.

Tube.

Ring.

45628042104 EN - 4/2020

7

Gasket.

8

45628042104 EN - 4/2020

Scraper.

-19

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



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



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



– The cylinder cap is equipped with an O-ring. If it is broken, by excessive squeezing or because it is too rigid, replace the O-ring.



-20

45628042104 EN - 4/2020

– Using the special extraction tool, screw it into the threaded hole at the base of the rod. Pulling, applying pressure on the handle, and pushing the head of the rod, extract it from the tube. The tool is also useful to keep the rod in the runner, avoiding friction between the chromed surface and the inside of the tube.



– When extracting the rod, support it with your hand. After extracting the rod from the tube, place it on a soft surface or on a wooden surface with a "V" depression.



– Tighten the rod in a clamp, placing two aluminium corners between the rod and the jaws.

Using a pair of expander pliers, such as those used for the safety spring washers, widen the stop ring and slide it onto the edge of the rod.



– If suitable equipment is not available, grip the stop ring with a pair of clippers and slide it on the edge of the rod, removing it from its seat.



45628042104 EN - 4/2020

-21

– Using a flat-head screwdriver, raise the scraper and extract it from the tube.



– Using a pin or brawl, raise and extract the Oring placed on top of the gasket.



– Using a flat-head screwdriver, raise and extract the gasket from its seat.



– After greasing the various components of the lift cylinder: check the efficiency and replace those that are worn.



-22

45628042104 EN - 4/2020

– Before starting to assemble the lift cylinder, check the internal surface of the tube. There must be no residues of material, or scoring in the gasket support seats.



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



Before assembling, check that the opening of the gasket is facing the scraper.

– Insert the O-ring on top of the gasket.



– Insert the scraper, pressing it on its outer edge. In the case of excess rigidity, soften it in hot water.



The scraper lip must protrude outside the tube.

45628042104 EN - 4/2020

-23

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



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



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



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



-24

45628042104 EN - 4/2020

– Using fine grain sandpaper, file the surface of the stop ring if it has been scored during extraction from the rod.



Do not file the chromed surface of the rod for any reason whatsoever.

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

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

The rod must slide into the gasket pack.



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



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



45628042104 EN - 4/2020

-25

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



– You can now assemble the fork lift cylinder by following the instructions in the "Removing the fork lift cylinder" section in reverse.

-26

45628042104 EN - 4/2020

(1*)

Common

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

45628042104 EN - 4/2020

Traction chassis only Connection only Three different load chassis

-1

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.

-2

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.

45628042104 EN - 4/2020

Before removal, follow the instructions given in the "Preliminary maintenance operations" section.

Remove the battery.

Raise the fork arms and position the end of a wooden support block underneath.

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

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



– Use a soft metal cylinder pin and strike the primary pin and extract it.



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



When you remove the pin, the lever will fall: be careful not to crush your hands.

45628042104 EN - 4/2020

-3

– Access the battery compartment and, using a pin punch with an appropriate diameter, extract the 2 pins from both the forks. Retrieve the pins.



– Seat from which the fork pins are removed.



– Use a soft metal cylinder pin and strike the fork pin with a hammer and extract it.



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



-4

45628042104 EN - 4/2020

– Detail



When you remove the pin, the fork will fall: be careful not to crush your hands.

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



– Use a soft metal cylinder pin and strike the fork pin with a hammer and extract it.



Note the position of the pin to ensure it is correctly positioned during reassembly.

– The lever system has now been removed and can be overhauled.



– Check and replace the pins and plugs of parts and of the fork.



45628042104 EN - 4/2020

-5

– Position a wooden support block under rear fork and, using an appropriate pin punch, remove the elastic pin. Next, using a hammer, strike the fork pin in the direction shown in the photo and remove it.



– Position a wooden support block under front fork and, using an appropriate pin punch, remove the elastic pin.



-6

45628042104 EN - 4/2020

– Next, using a hammer, strike the fork pin in the direction shown in the photo and remove it.



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



– Using a metal cylinder pin, strike the roller pin with a hammer and remove the roller, as shown in the photo.



– At this point, check the wear of the pivots, pins and rollers.



To reassemble the lever system, proceed in the reverse order.

45628042104 EN - 4/2020

-7

– 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.

-8

45628042104 EN - 4/2020

– 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.

45628042104 EN - 4/2020

-9

The following information is specific to the ECU 30 SPECIAL Tightening torque for the mast bolts: 85 N/m The mast tilt is adjusted using the forks as a reference. Adjust the chain so that the height of the fork plane on the heel side is approximately 64 mm. Shim the mast so that the fork tips measure between 65 and 70 mm.

Quantity of hydraulic system oil: 2 litres type HLF32

The following table is specific to the ECU 30 Special model. The table includes the maintenance operations already in use for the ECU 25/30 model. The following are therefore additional maintenance operations and do not replace those already in use.

Pump unit: check mounting Hydraulic system: check the oil level Hydraulic system: check for any leaks Hydraulic system: check the condition of the pipe lines Mast: lubricate the sliding tracks of the mast and forks Mast: check the mounting Lift cylinders, chains, rollers and end stops: check the condition, mounting and operation Lifting chain: clean, check, adjust and grease the chains Forks: check the forks for wear and ensure that they are in good condition = Every 1000 hours or at least every 12 months (whichever comes first), unless local regulations require more frequent intervention.

-10

45628042104 EN - 4/2020

STILL GmbH 45628042104 EN - 4/2020