Yale D857 MO 20 20S 20F Service Manual P.No524237829 - PDF DOWNLOAD

PART. N° 524237829

Technical information for Yale customer care centres

MO20F

MO20

MO20S

This manual is addressed to the skilled technicians of Yale service network.

D857......

D857.......

A943.......

MO20 MO20S MO20F

SERVICE

PREFACE

IMPORTANT This manual contains detailed information about the routine and preventive maintenance, troubleshooting, disassembly/assembly of components, adjustment procedures for the following Yale models: MP20X, MO20F, MS12-15X, MP20XD. These procedures require specific technical knwoledge and they must be carried out only by qualified and trained staff. Please read this manual carefully in order to prevent damage or accidents to people; it must be kept in good conditions so that it is always readable and complete in all its parts.

This manual is an integral part of the use and maintenance manual and it does not replace it.

Product support group

NOTES:

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PREFACE

HOW TO USE THE MANUAL ENCLOSED MANUALS AC drive motor control DDI Display Steering motor control Motors Reduction gears ETACC “AC Controls Program”-

Part No. 524238693 Part No. 524238698 Part No. 524238703 Part No. 272490600 Part No. 2200 YRM 1058

SECTIONS This manual is divided into the following sections: Section 1: Section 2: Section 3: Section 4: Section 5: Section 6: Section 7: Section 8: Section 9: Section 10:

Preface Introduction Installation and settings Electric system Diagnostics and measures Hydraulic system Frame mechanics Mast-fork mechanics Reduction gear Braking system

Always refer to the index with the numbered black bands in order to go to the desired section.

WORDS AND SYMBOLS It indicates the presence of a danger that can cause accidents to people or damage to the truck.

It indicates notes or important information to be taken into consideration.

It indicates that, in the electronic version of the manual, by clicking on this symbol it is possible to display a filmed sequence.

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SERVICE

PREFACE

GENERAL SAFETY STANDARDS PERSONAL SAFETY n

Always use the personal protective equipment when it is required.

n

Pay attention to the squashing risks due to moving parts, oscillations, not correctly fastened materials when lifting operations are carried out or when the loads are moved.

n

Do not wear rings, watches, jewels, unbuttoned or hanging clothes such as scarves, unbuttoned jackets or smocks with open zips that can get entangled in the moving parts.

n

Never carry out cleaning, lubrication or maintenance operations when the battery is connected.

n

If you use compressed air to clean the parts, wear glasses with lateral guards.

SAFETY IN THE WORKPLACE n

Make sure that all working tools are perfectly efficient and ready to use. Keep the working surfaces clean and free from the deposits that settle on the truck parts and cause damage.

n

Keep sparks, free flames and cigarettes at a distance from fuels or flammable materials such as the gas of the batteries.

n

Make sure that the working area is well ventilated, illuminated, dry and clean. Remove any water puddles or oil spots.

n

Make sure that the lifting equipment, devices or machines can bear the load.

n

Never use petrol, gas oil or other flammable liquids as detergents: use commercial non-toxic and non-flammable solvents.

n

In case the interventions are carried out of the workshop, lay the truck flat and block it. If it is necessary to carry out the work on slopes, block the truck and bring it in a flat area as soon as possible within a certain safety limit.

n

Disconnect the batteries and label all controls in order to indicate that an intervention is in progress.

Block the truck and any equipment to be lifted.

n

Do not carry out any intervention on the truck when the operators are controlling it, except that they are qualified operators and help to carry out the intervention.

n

During towing operations use only the prescribed attachment points and make sure that the pins and/or bolts are tightly secured. Lift and move all heavy components by means of a lifting device of proper carrying capacity. Use the proper eyebolts. Make sure that nobody stays near the load to be lifted.

n

Do not twist chains or metal ropes.

n

Do not use damaged or bent chains or ropes: do not use them during lifting or towing operations.

While handling them always wear safety gloves.

n

Do not accumulate cloths soaked with grease or oil: they represent a risk of fire. Always put them in a closed metal container.

n

The oil must be collected and not be let off in the drain pipes; the industrial oils must be disposed of by specialized companies under the protection of the law in force in every Country.

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n

n n n n n n n n n

PREFACE

When welding operations are carried out, it is necessary to use proper accident-prevention protections: protective glasses, helmet, overalls, shoes. The protective glasses must be worn also by the people who do not carry out the works if they stay near a welding area.

Before using the batteries, make sure that the cables are connected to the terminals as described: (+) with (+) and (-) with (-).

Do not short-circuit the terminals.

The gas emanated during a recharge is higly flammable. During the recharge of the battery leave the battery compartment uncovered in order to use a more efficient ventilation and remove the plugs.

Do not check the condition of the battery charge by means of “jumpers” obtained by placing metal objects on the terminals.

Before any intervention check if there are no short-circuit elements.

Disconnect the batteries before acting on the electric system.

For the battery chargers and similar equipment, use only auxiliary electric power supply sources in order to avoid any electric shocks.

A fluid passing through a very small hole can be almost invisible but strong enough to penetrate into the skin; in these cases check the fluid by means of a card or a piece of wood.

To check the pressure of the plant use the proper devices.

BANDS, ROPES AND HANGING ROPES: SUGGESTIONS FOR THE USE n n n n n n n n n n n

Register all used hanging ropes, whose features and data are shown on the identification plate.

Do not use bands, ropes or hanging ropes, whose identification plate has been lost.

Always use bands, ropes or hanging ropes of proper dimensions. As far as the hanging ropes are concerned, take into consideration the lifting angle and the unbalance of the load.

The hooks of the hanging ropes must have a proper size according to the hook of the bridge crane and they must move freely.

Position the load in the hook mouth.

Do not place the load on the point of the hook.

During lifting, do not carry out sudden operations that could tear the ropes and the bands.

Do not carry out lifting operations with twisted ropes and bands.

Knots are forbidden.

Always protect the ropes and the bands when they are near sharp edges.

During the movements without load in order to avoid unintentional collisions or hooking, fasten the hooks to the proper seats and lock them.

Use of hanging ropes with unbalanced load If unbalanced loads must be lifted it is advisable to reduce the carrying capacity of the hanging ropes: n Slings with 2 arms, consider them as the slings with 1 arm. n Slings with 3 and 4 arms, consider them as the slings with 2 arms.

Suggestions for maintenance Check the bands, the ropes and the hanging ropes according to the law in force in order to determine their working conditions.

Carry out the replacement in the following cases: n When the components are deformed, cut or when there are cracks, hollows, notches or abrasions on them. n When the wear of the components is higher than 10% of the initial dimensions. n When the sling is overloaded.

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SERVICE

PREFACE

Band capacity table

Colour

Working capacity (kg.)

violet green yellow grey red brown blue orange orange orange orange orange orange

Coefficient

1000

2000

1400

800

2000

4000

2800

1600

3000

6000

4200

2400

4000

8000

5600

3200

5000

10000

7000

4000

6000

12000

8400

4800

8000

16000

11200

6400

10000

20000

14000

8000

12000

24000

16800

9600

15000

30000

21000

12000

20000

40000

28000

16000

25000 30000

50000 60000

35000 42000

20000 24000

1

2

1.4

0.8

Rope capacity table

Width (mm.)

C olour

Working capacity (kg.)

black violet black green yellow grey red brown blue orange

35

500

1000

700

400

50

1000

2000

1400

800

50

1500

3000

2100

1200

60

2000

4000

2800

1600

75

3000

6000

4200

2400

120

4000

8000

5600

3200

150

5000

10000

7000

4000

180

6000

12000

8400

4800

240

8000 10000

16000 20000

11200 14000

6400 8000

1

2

1.4

0.8

300

Coefficient

Hanging rope capacity table

Colour

Working capacity (kg.)

Coefficient

violet green yellow grey red

1000

1400

2100

2100

2000

2800

4200

4200

3000

3800

6300

6300

4000 5000

5600 6600

8400 9800

8400 10500

1

1.4

2.1

2.1

W orking ca pa city: the w orking ca pa city is ca lcula te d w ith a n a ngle of 90° in the ce ntre

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PREFACE

Hanging rope capacity table

Colour

Working capacity (kg.)

violet green yellow grey red

Coefficient

1000

1400

2100

2100

2000

2800

4200

4200

3000

3800

6300

6300

4000 5000

5600 6600

8400 9800

8400 10500

1

1.4

2.1

2.1

W orking ca pacity: the working capacity is caluculated with an angle of 90° in the centre

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PREFACE

DRIVING TORQUE OF SCREWS, NUTS AND CONNECTORS Before the disassembly of the various parts and of the bolts and screws, read carefully the instructions below.

To tighten the screws use the product LOCTITE 270 in order to ensure the safety of the threaded couplings.

DRIVING TORQUE Nm

Nominal diameter

If it is not possible to loosen the screws because this product is used, do not add extensions to the tools, but heat the area (maximum 50° - XXX farehnheit degrees) in oder to eliminate the effect of LOCTITE 270.

Class 8

Class 10

4

5.02

M3 M4

7

9,15

M5

12.14

14.8

M6

17.2

20.9

In the above-mentioned cases use a small quantity of LOCTITE 270 in the assembly phase (30% of the connection surface).

M8

31.8

38.1

M 10

50.5

60.3

M 12

74.2

88.5

The driving torque with which the threaded couplings are tightened is very important to ensure the safety of the truck connection.

M 14

101.2

120.8

M 16

138.2

164.9

M 18

176.6

203.5

M 20

225.4

259.7

M 22

278.8

321.2

M 24

324.8

374.2

M 27

422.3

486.5

M 30

516.1

594.7

The bolts and nuts and the corresponding driving torques are shown in the tables on this page.

DRIVING TORQUE Nm Preloading N

Class 5.8

Class 8.8

Class 10.9

M4

0.07

7

3

2400

1.92

1.44

3.07

2.3

4.17

3.13

M5

0.08

8

4

3880

3.88

2.91

6.2

4.65

8.43

6.33

M6

1

10

5

5490

6.58

4.94

10.5

7.9

14.3

10.8

M8

1.25

13

6

9990

16

12

25.6

19.2

34.8

26.1

M8

1

13

6

10700

17.1

12.8

27.4

20.5

37.3

27.9

M 10

1.05

16

8

15825

31.7

23.8

51

38

69

52

M 10

1.25

16

8

16700

33.4

25.1

53

40.1

73

55

M 12

0,09375

18

10

23025

55

44.1

88

66

120

90

M 12

1.25

18

10

25150

60

45.3

96

72

130

98

M 14

2

21

12

31400

88

66

140

105

190

145

M 14

1.05

21

12

34125

96

72

155

115

210

155

M 16

2

24

14

42850

135

105

220

165

300

225

M 16

1.05

24

14

45600

145

110

235

175

320

240

M 20

2.05

30

17

66875

270

200

430

320

580

435

M 20

1.05

30

17

74250

295

225

475

355

650

485

= with lubricant

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SERVICE

PREFACE

CORRECT METHOD TO APPLY THE FEMALE CONNECTORS To ensure an optimum connection between the female connectors and the adapters mentioned in this manual, it is necessary to carry out the following procedure, which is different from the one for the assembly of the rigid pipes.

Female connectors without gasket (metal/metal connection) Screw the nut manually and then tigthen 1/4 turn by means of a spanner.

Female connectors with O-RING Screw the nut manually and then tighten 1/4 turn by means of a spanner.

In any case make sure that the pipe is correctly aligned before tightening the nut to the adapter.

DRIVING TORQUES ROTARY FEMALE CONNECTOR jic 37°

ROTARY METRIC FEMALE CONNECTOR

Driving torque Nm

Driving torque Nm

Thread UNF

Pipe outside Nominal torque diameter

min. / max.

Thread UNF

Dimension

Nominal torque

min. / max.

M 12x1.5

6

20

15 -25

7/16-20

-4

15

9 - 21

M 14x1.5

8

38

30 - 45

1/2-20

-5

20

13 - 27

45

38 - 52

18 - 42

M 16x1.5

M 18x1.5

8

9/16-18

-6

30

10

3/4-16

-8

50

30 - 70

10

7/8-14

-10

69

44 - 94

1.1/16-12

-12

98

63 - 133

1.3/16-12

-14

118

73 - 163

1.5/16-12

-16

140

90 - 190

1.5/8-12

-20

210

135 - 285

51

43 - 85

58

50 - 65

12 M 20x1.5 M 22x1.5

12 14

74

15

60 - 88

M 24x1.5

16

74

60 - 88

1.7/8-12

-24

290

200 - 380

M 26x1.5

18

105

85 - 125

2.1/2-12

-32

450

300 - 600

135

115 - 155

166

140 - 192

M 30x2

M 36x2

20 22 25 28

M 42x2

30

240

210 - 270

M 45x2

35

290

255 - 325

330

280 - 380

M 52x2

38 42

ROTARY FEMALE CONNECTOR ORFS ROTARY FEMALE CONNECTOR BSP Driving torque Nm Thread UNF G1/4

Nominal torque 20

Driving torque Nm Thread UNF

Dimension

Nominal torque

max.

max.

15 - 25

9/16-18

-4

14

16

11/16-16

-6

24

27

13/16-16

-8

43

47

G3/8

34

27 - 41

G1/2

60

42 - 76

1-14

-10

60

68

G5/8

69

44 - 94

1.3/16-12

-12

90

95

G3/4

115

95 - 135

1.3/16-12

-14

90

95

G1

140

115 - 165

1.7/16-12

-16

125

135

G1.1/4

210

140 - 280

1.11/16-12

-20

170

190

G1.1/2

290

215 - 365

2-12

-24

200

225

G2

400

300 - 500

2-1/2-20

-32

460

490

The values shown in the tables refer to galvanized steel connectors. Different values correspond to connectors of different materials.

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SERVICE

PREFACE

INSTRUCTIONS FOR THE INSTALLATION OF HOSES AND CONNECTORS Visual check of hoses and connectors: if one of the following conditions occurs, the hose must be immediately disconnected and replaced:

• • • • • • •

movement of the connector on the hose; there are damage, cuts or abrasions on the surface; hardening or stiffness of the hose, burned parts or cracks due to heat; cracks, damage or corroded parts on the connector; leakages from the hose or connector; the hose has permanent folds, squashed or twisted parts; presence of bubbles, softening and wear of the external surface.

Pre-installation inspection: before installing a hose it is necessary to check the conditions of the pipes.

First of all check if the type, the size, the reference code and the length are correct and then make sure that there are no impurities, obstructions, bubbles, external layer peeling-off or other visible defects.

Installation: Do not twist the hose, otherwise it could break due to pressure.

Consider a proper radius of curvature in order to avoid the bending or breaking. If the radius of curvature is lower than the minimum radius of curvature allowed, the life of the hose is considerably reduced.

The pressure can change the length of the hose, up to + 2%. Therefore it is advisable to consider a length which is higher than the required one in order to compensate for such changes.

SPECIAL EQUIPMENT

Interface cable kit Part No. 580039670

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INTRODUCTION

INTR ODUCTION INTRODUCTION 1.00 PRESENTATION OF THE VARIOUS MODELS....................................................................................2 2.00 TRUCK IDENTIFICATION DATA ..........................................................................................3 3.00 PLATE POSITIONING MOD. ALL MODELS.........................................................................................4 4.00 STAMPING OF THE TRUCK SERIAL NUMBER MOD. MO20F - MP20X..............................................4 5.00 CONFIGURATION MOD. MO20 - MO20S........................................................................................6 5.01 CONFIGURATION

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MO20F................................................................................................8

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INTRODUCTION

1.00

PRESENTATION OF THE VARIOUS MODELS

VIEWS OF THE TRUCKS

MO20

MO20F

MO20S

MO20SLF

MO20LF

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SERVICE 2.00

INTRODUCTION

TRUCK IDENTIFICATION DATA

TRUCK IDENTIFICATION DATA PLATE

The identification plate provides the following data:

• • • • • • • • • •

Manufacturer’s trade name Model Serial number Weight without battery Year of manufacture Max battery weight Min battery weight Battery voltage Nominal capacity Persons on board Always refer to the carrying capacity plate to ensure to load the allowed load.

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INTRODUCTION

3.00 PLATE POSITIONING MODEL ALL MODELS

MO20 MO20S MO20LF MO20SLF MO20F 4.00 STAMPING OF THE TRUCK SERIAL NUMBER MOD. MO20F - MP20X

serial number stamped on the truck

serial number stamped on the truck

MO20 MO20S MO20LF MO20SLF

MO20F

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INTRODUCTION

5.00 CONFIGURATION MODEL M20-M20S

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MOTORS

PERFORMANCE

DIMENSIONS

WHEELS AND TYRES

WEIGHT

CHARACTERISTICS

SERVICE

1.1 1.2 1.3 1.4 1.5 1.6 1.8 1.9 2.1 2.2 2.3 3.1

INTRODUCTION

Manufacturer Model designation Power: battery.diesel, LPG, electric mains Operation: manual, pedestrian, stand-on, seated, orderpicker Load capacity Load centre Load distance Wheelbase Unladen weight Axle loading with load, front/rear Axle loading without load, front/rear Tyres: rubber, polyurethane front/rear

3.2

Tyre size, front

3.3

Tyre size, rear

3.4 3.5 3.6 3.7 4.2 4.4 4.5 4.8 4.9 4.14 4.15 4.19 4.20 4.21 4.22 4.25 4.32 4.33 4.34 4.35 5.1 5.2 5.3 5.8 5.9 5.10 6.1 6.2 6.3 6.4 6.5 6.6 8.1 84

Additional wheels (dimensions) Wheels, number front/rear ( x = driven) Track width, front Track width, rear height of mast, lowered Lift height height of mast, extended Height of seat/platform Height of tiller arm in working position min./max. height of platform Lowered height Overall length Length to face of forks Overall width Fork dimensions Outside fork width Ground clearance centre of wheelbase Aisle width with pallets 1000 x 1200 crossways Aisle width with pallets 800 x 1200 lengthwise Turning radius Travel speed with/without load Lift speed with/without load Lowering speed with/without load Max. gradeability, with/without load Acceleration time ( over 10 mt ) , with / without load Service brake Drive motor,S2 60 minute rating Lifting motor, S3 10% rating Battery DIN 43531/35/36 A,B,C, no Battery voltage/capacity at 5 hour rate Battery weight +/- 5% ( depending on manifacturer ) Energy consumption according to VDI cycle Drive control Noise peack at operator's ears Vibrations

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Yale

Q (t) c (mm) x (mm) y (mm) kg kg kg

b10 (mm) b11 (mm) h1(mm) h3 (mm) h4(mm) h7 (mm) h14(mm) h12(mm) h13 (mm) l1 (mm) l2 (mm) b1/b2 (mm) s/e/l b5 (mm) m2 (mm) Ast (mm) Ast (mm) Wa (mm) km/h m/s m/s %

kW kW 43535 V/Ah kg Kwh/h dB(A) m/sec

Yale D857_MO20 Battery Orderpicker 2 2 600 965 2191 820 1085 / 1735 580 / 240 Vulkollan ø 254 x 90

Yale D858_MO20S Battery Orderpicker 2 2 600 965 2191 910 1120 / 1790 610 / 300 Vulkollan ø 254 x 90

ø 85 x 94 ø 150 x 75

ø 85 x 94 ø 150 x 75

1x+1/4 495 340 1384 120 150 1230/1495 85 2584 1 1428 1 780/770 55/180/1156 520 60 1 2650 1 2850 1 2415 4 10.5/11 0.03/0.04 0.05/0.045 8/85 4 6/5 el.magnetic 4.0 2 B 24/480 410 0,81 AC - MOSFET < 70 0,5

1x+1/4 495 340 1384/1604 120 2214/2434 150 1230/1495 980 / 1200 85 2584 1 1428 1 780/770 55/180/1156 520 60 1 2650 1 2850 1 2415 4 10.5/11 0.03/0.04 0.05/0.045 8/85 4 6/5 el.magnetic 4.0 2 B 24/480 410 0,81 AC - MOSFET < 70 0,5

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INTRODUCTION

5.01 CONFIGURATION MODEL MO20F

MO20F

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INTRODUCTION

RUOTE E GOMME

WEIGHTS

CHARACTERISICS

GENERAL SPECIFICATION

Yale

1.1

Manufacturer

1.2

Model

1.3

Power: battery, diesel, LPG, electric mains

MO20F Battery

Operation: manual, pedestrian, stand on, seated

1.5

Load capacity

Q (t)

2.0

1.6

Load centre

c (mm)

600

1.8

Load distance

x (mm)

1002

1.9

W heelbase

y (mm)

2046

(1)

970

kg

1130 / 1840

kg

730 / 240

Unladen weight (battery included) Axle loading laden, front/rear

2.3

Axle loading, front/rear (1)

3.1

Tyres: rubber, polyurethane, vulkollan, front/rear

3.2

Tyre size - front

3.3

Tyre size - rear

3.4

Additional wheels (dimensions)

3.5

W heels - number, front/rear (x = driven)

3.6

Track width front

b 10 (mm)

484

3.7

Track width rear

b 11 (mm)

390

4.4

Lift height

4.9

Height of the tiller arm in working position min/max.

(1)

Vulkollan / Vulkollan

ø 254 x 90 ø 85 x 94 ø 125 x 50 1x + 1 / 4

4.20 Lenght to front face of forks 4.21 Overall width

h3 (mm)

130

h14 (mm)

1220 / 1460

h13 (mm)

85

l1 (mm)

2426

l2 (mm)

1245

b1/b2 (mm)

780

s/e/l (mm)

55 / 170 / 1181

4.25 Ouside fork width

b5 (mm)

560

4.32 Ground clearance, centre of wheelbase

m2 (mm)

30

4.33 Aisle width for pallets 1000x1200 wide

Ast (mm)

2464

4.34 Aisle width for pallets 1000x1200 long 4.35 Turning radius 5.1 Travel speed, laden/unladen

Ast (mm) W a (mm) km/h

2664 2266 8 / 8,5 - (10 / 10,5)(2)

4.22 Fork dimensions

PERFORMANCE

kg

2.1 2.2

4.19 Overall length

POWER UNIT

pedestrian (stand on)

1.4

4.15 Lowered height

ALTRO

MO20F

5.2

Lift speed laden/unladen

m/s

0.03 / 0.04

5.3

Lowering speed laden/unladen

m/s

0.05 / 0.04

5.7

Gradeability, laden/unladen

%

10 / 20

5.8

Max gradeability, laden/unladen

%

10 / 20 electromagnetic

5.10 Service brake 6.1

Drive motor rating (S2 60 min.)

kW

6.2

Lift motor rating (S3 15%)

kW

6.3

Battery to DIN 43531/35/36 A,B,C, no

6.4

Battery voltage/capacity (5 hour rate)

6.5

Battery weight

6.6

Consumption according to VDI cycle

8.1

Drive control

8.4

Average noise level at the operator's ear

2.2 - 4.0

(3)

2.0 no

V/Ah

24/400

kg

330

kW h/h

/ Mosfet ~ AC

dB (A)

< 70

(1)

The values refer to a truck with power steering and battery as described in line 6.4, with fork dimension b5=560 L=1181

(2)

The values refer to a truck with power steering and 4 kw drive motor

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INTRODUCTION

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INST ALLA TION AND SETTINGS INSTALLA ALLATION 1.00 TRUCK ASSEMBLY................................................................................................................................2 2.00 WEIGHT TABLE...................................................................................................................................4 3.00 UNLOADING FROM THE LORRY WITH TRUCK ON THE PALLET.......................................5 4.00 TRUCK LIFTING ........................................................................................................................5 5.00 CABLE CONNECTION TO THE BATTERY MOD.ALL MODELS........................................................6 6.00 BATTERY INSTALLATION MOD.

MO20F...........................................................................7

6.01 BATTERY INSTALLATION MOD. MO20 - MO20S - MO20LF - MO20SLF...........................................8

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1.00 TRUCK ASSEMBLY LIST OF THE MATERIALS RECEIVED BY THE DEALER TRUCK SUPPLIED WITHOUT BATTERY

2 1

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Ref. 1 2 4 4 5

Description Lift truck Battery charger connector Battery connector Roller track for battery side extraction (on request) Battery plug extension (for trucks with battery side extraction)

The materials received by the dealer can vary according to the presence or absence of optional equipment.

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TRUCK SUPPLIED WITH BATTERY

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7

Ref. 1 2 3 4 5 6 7

Description Lift truck Battery Battery plug Roller track for battery side extraction (on request) Can for electrolyte level topping up in the batteries Battery charger Battery plug extension (for trucks with battery side extraction)

The materials received by the dealer can vary according to the presence or absence of optional equipment.

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INSTALLATION AND SETTINGS

2.00 WEIGHT TABLE

TYPE OF TRUCK

MO20

MO20S

MO20F

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WEIGHT (without battery) kg

BATTERY VOLTAGE/CAPACITY

BATTERY WEIGHT

TOTAL WEIGHT

V/Ah

kg

kg

24/400

330

970

24/375

285

1225

24/435

395

1435

24/480

410

1510

24/560

530

1590

640

1040

1060

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INSTALLATION AND SETTINGS

3.00 UNLOADING FROM THE LORRY WITH TRUCK ON THE PALLET Necessary special tools

A lift truck with 3 t carrying capacity

Procedure Position the truck forks under the pallet, lift it and place it in a safe area supplied with hoist with a carrying capacity of 3t and far from the transit of other motor vehicles and from the passage of pedestrians.

Fig. 1

4.00 TRUCK LIFTING Necessary special tools

hoist with 3000 kg carrying capacity

hanging rope with hanging rope with two arms two arms 2100 kg carrying 2100 kg carrying

Procedure Remove the packing.

Hook the hanging rope to two arms of the hoist.

Fasten the two hooks of the hanging rope to the two frame side holes suitable for lifting (ref.A fig.2).

Fig. 2

Make sure the hoist is perpendicular to the truck to be lifted.

Lift slowly and position the truck on the floor with care.

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INSTALLATION AND SETTINGS

5.00 CABLE CONNECTION TO THE BATTERY MOD. ALL MODELS The battery poles are marked with a red colour or with the symbol “+” to identify the positive pole, and with a blue colour or with the symbol “-” to identify the negative pole.

The battery plug cables are marked as well: the first one with a red clamp for the connection to the positive pole and the second one with a blue clamp for the connection to the negative pole.

After connecting the cable terminals to the battery poles, lubricate with some vaseline grease to prevent oxidation.

Before assembling the battery on the truck recharge it by means of a suitable charger.

RED clamp for cable connection to the positive pole

BLUE clamp for cable connection to the negative pole

Negative pole BLUE

_

Positive pole RED

+

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INSTALLATION AND SETTINGS

6.00 BATTERY INSTALLATION MOD. MO20F Necessary special tools

hoist with 1000 kg carrying capacity

Necessary tools

hanging rope with two arms carrying capacity 1400 kg

A

13mm open ended spanner

Fig. 1 Procedure Before starting to work wear the proper accident prevention clothes.

Park the truck in a safe area, far from the transit of other motor vehicles and from the passage of pedestrians.

Step 1 HOIST - HANGING ROPE WITH TWO ARMS Open the upper bonnet of the battery compartment (ref.A fig.1). Remove the two battery retainers located in the battery compartment (ref.B fig.3).

Hook the hanging rope to two arms of the hoist.

Fasten the two hooks of the hanging rope to the two battery side holes suitable for lifting.

Make sure the hoist is perpendicular to the battery.

Fig. 2

Lift the battery, position it over the battery compartment and insert it with care (fig.2).

Step 2 13mm OPEN ENDED SPANNER Position the two battery retainers and screw the check nuts by means of the open ended spanner (ref.C fig.3).

C B

Fig. 3

Step 3 Connect the battery plug cables supplied to the positive and negative pole of the battery (see “CABLE CONNECTION TO THE BATTERY” on page 7).

Connect the battery plug (ref.D fig.4) and lower the bonne he battery compartment.

D Fig. 4

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6.01 BATTERY INSTALLATION MOD. MO20 - MO20S - MO20LF - MO20SLF Necessary special tools

Necessary tools

A hoist with 1000 kg carrying capacity

hanging rope with 4 arms 4200 kg carrying capacity

13 mm open ended spanner

Procedure

Fig. 1

Before starting to work wear the proper accident prevention clothes.

Park the truck in a safe area, far from the transit of other motor vehicles and from the passage of pedestrians.

Step 1 Open the upper bonnet of the battery compartment (ref.A fig.1).

Lift and remove the battery retainers located in the battery compartment ref. B fig.3).

Step 2 HOIST - HANGING ROPE WITH FOUR ARMS Hook the hanging rope to the hoist.

Hook the hanging rope hooks to the battery side holes pre-arranegd for the lifting.

Fig. 2 Make sure the hoist is perpendicular to the battery.

B C

Lift the battery, position it over the battery compartment and insert in carefully (fig.2).

Step 3 13 mm OPEN ENDED SPANNER Position the two battery retainers and by using the open ended spanner tighten the nuts (ref.C fig.3).

Fig. 3

Step 4 Connect the battery plug cables supplied to the positie and negative pole of the battery (see “CONNECTION OF THE BATTERY CABLES” on page XX).

Connect the battery plug (ref.D fig.4) and lower the plug on the battery compartment.

D

D Fig. 4

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1.00 WIRING DIAGRAM KEY TO SYMBOLS MOD. MO20 -MO20LF......................................................................4 1.01 WIRING DIAGRAM KEY TO SYMBOLS MOD. MO20S - MO20SLF...............................................................6 1.02 WIRING DIAGRAM KEY TO SYMBOL MOD. MO20F.................................................................................8 1.03 WIRING DIAGRAM KEY TO SYMBOL MOD. MO20F MECHANICAL STEERING.............................................10 2.00 REFERENCE TABLE FOR THE DESCRIPTION OF THE ELECTRIC COMPONENTS MOD. MO20 - MO20LF.....12 2.01 REFERENCE TABLE FOR THE DESCRIPTION OF THE ELECTRIC COMPONENTS MOD. MO20S - MO20SSR. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .14 2.02 REFERENCE TABLE FOR THE DESCRIPTION OF THE ELECTRIC COMPONENTS MOD MO20F.................16 2.03 ELECTRIC COMPONENTS MOD. MO20F....................................................................................17 2.04 REFERENCE TABLE FOR THE DESCRIPTION OF THE ELECTRIC COMPONENTS MOD. MO20F MECHANICAL STEERING......................................................................................................................................18 2.05 ELECTRIC COMPONENTS MOD MO20F MECHANICAL STEERING...................................................19 2.06 REF ERENCE TABLE FO R THE TILLER BOX... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... .20 2.07 TILLER BOX ELECTRIC COMPONENTS...............................................................................21 2.08 REFERENCE TABLE FOR THE TILLER BOARD........................................................................22 2.09 TILLER BOARD COMPONENTS...............................................................................................23 2.10 ELECTRIC COMPONENTS OF THE STEERING SYSTEM......................................................................24 2.11

REFERENCE TABLE FOR THE ELECTRIC COMPONENTS OF THE STEERING SYSTEM..........................24

2.12 CONNECTION OF THE POWER CABLES TO THE “AC COMBI” CONTROL......................................................25 2.13 REFERENCE TABLE FOR THE POWER CABLES CONNECTING THE CONTROL TO THE MOTORS...........25 3.00 DESCRIPTION OF THE FUNCTIONS OF “DDI”...................................................................................26 3.01 REFERENCE TABLE FOR THE DISPLAY SYMBOL ......................................................................26 3.02 BATTERY CHARGE INDICATOR........................................................................................27 3.03 SEQ UENCE 3.04 ALARM

OF

IMAGES

DI SPLAY

DI SPLAYED

ON

“DDI”

AT

“START”. ..... ..... .... ..... ..... .... .28

... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... .... ..... ..... .29

3.05 TESTER MENU .........................................................................................................................30 3.06 MOT OR

CO NTROL

TESTER

MENU.. ..... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... .30

3.07 TESTER MENU OF CONTROL INPUT: “COMBI INPUT” - “TILLER INPUT” - “VERSION EPROM” - “DISPLAYING OF THE LAST 10 ALARMS”..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... .31 3.08 “COMBI INPUT”.........................................................................................................................31 3.09 “TILLER INPUT”..........................................................................................................................33 3.10 “EPROM VERSION”................................................................................................................34 3.11

“ALARM PAGE” DISPLAY................................................................................................35

4.00 FUNCTIONS OF THE TRUCK.....................................................................................................36 4.01 FORWARD/BACKWARD DRIVE...............................................................................................................37 4.02 SPEED REDUCTION...........................................................................................................38 4.03 DECELERATION WITH STEERED DRIVE W HEEL ...................................................................39 4.04 DECELERATION W ITH FLAT BATTERY.............................................................................39 4.05 BRAKING.....................................................................................................................................40

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4.06 BACKING FUNCTION...................................................................................................................41 4.07 TABLE OF DRIVE SPEEDS ................................................................................................41 4.08 CONNECTOR JUMPERS ACCORDING TO THE TRUCK CONFIGURATION......................................41 4.09 SETTING.........................................................................................................................................42 4.10 POTENTIOMETER ACQUISITION........................................................................................................42 4.11

STEERING..........................................................................................................................43

4.12 SELF-CENETERING SYSTEM WITH “BACKING” FUNCTION......................................................................45 4.13 POTENTIOMETER ACQUISITION..........................................................................................45 5.00 OUTRIGGER LIFTING/LOW ERING...................................................................................46 5.01 LIFTING AND LOWERING SPEED OF THE OUTRIGGERS AND OF THE PLATFORM MOD. MO20 - MO20LFMO20F-MO20S-MO20SLF.....................................................................................................................47 5.02 PLATFORM

LIFT ING

END

OF

STROKE

DECELERATIO N.... ..... ..... ..... .... ..... ..... ..... .47

5.03 OUTRIGGER ACCELERATION/DECELERATION RAMPS.....................................................48 5.04 PLATFORM ACCELERATION/DECELERATION RAMP..............................................................49 6.00 REFERENCE TABLE FOR THE CONFIGURATION PARAMETERS OF THE DRIVE CONTROL....................50 6.01 REFERENCE TABLE FOR THE CONFIGURATION PARAMETERS OF THE EPAS CONTROL.................................53 6.02 PARAMET ER STANDARD CO NFIGURATI ON... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... .54 7.00 “AC COMBI” MODULE REPLACEMENT.............................................................................56 7.01 CONFIGURATION OF THE WORKING HOURS FROM DISPLAY “DDI” TO “COMBI” CONTROL....................57 7.02 REPLACEMENT OF THE STEERING MOTOR “EPAS” MODUL................................................................58 7.03 STEERING POTENTIOMETER SENSOR...................................................................................59 7.04 REPLACEMENT OF THE STEERING POTENTIOMETER SENSOR.......................................................60 7.05 ASSEMBLY...............................................................................................................................62 7.06 COLD-STORAGE ROOM POTENTIOMETER..................................................................................63 7.07 ACQUISITION OF THE STEERING POTENTIOMETER SENSOR....................................................................64 7.08 REPLACEMENT O F “T ILLER” BOARD .. ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ..... .65 7.09 REPLACEMENT OF PUSH BUTTONS “P1-P2-P3-P4”......................................................................66 7.10 TILLER HEAD POTENTIOMETER ACQUISITION .................................................................67 7.11

FORWARD/REVERSE POTENTIOMETER ACQUISITION.............................................................67

8.00 REPLACEMENT OF THE MAIN EMERGENCY PUSH BUTTON..............................................................69 8.01 REPLACEMENT OF DISPLAY “DDI”...................................................................................70 8.02 REPLACEMENT OF THE START KEY SW ITCH ..................................................................71 8.03 REPLACEMENT OF THE DEADMAN AND BOARD LIFTING/LOWERING SENSORS......................................72 8.04 REPLACEMENT OF STEERING CENTERING SENSOR WITH “BACKING” FUNCTION...........................73 8.05 REPLACING OF THE “BACKING” PUSH BUTTONS................................................................................74 8.07 REPLACEMENT OF THE PLATFORM LIMIT SWITCH SENSORS SW7, AND OF THE SENSOR SW6 FOR STOPPING THE PLATFORM AT 1200MM........................................................................................75 8.08 REPLACEMENT OF THE SENSOR STOPPING THE PLATFORM 200mm LIFTED..............................76 9.00 ASSEMBLY OF THE COMBI CONTROL COOLING FAN ( OPTIO N).. ..... ..... .... ..... ..... .... .77 9.01 REMOVAL OF THE FAN FOR THE REPLACEMENT.........................................................77

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ELECTRIC SYSTEM 1.00

WIRING DIAGRAM KEY TO SYMBOLS MODELS MO20 - MO20LF

Ref

Description of the component functions

S T1 T2 T3 FU1 FU2 FU3 Key Switch PM MTR MTS Torque Sensor TH T. MT T. MS DDI Display M. Fan HORN EMB P1 P2 P3 P4 P5 P6 P7 SW1 SW2 SW5 SW9 SW12 EV1 Speed Control Horn Push Button Oveerride Brake

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Outlet and plug connecting the truck system to the battery Remote control switch Emergency push button on the left side of the platform back Emergency push button on the right side of the platform back 415 A power fuse on Combi control 30 A powe fuse on "Power Epas" steering control 10A fuse for the auxiliary functions Key switch 2.00 Kw DC-DC pump motor 4.5 Kw AC drive motor 0.15 Kw AC steering motor Steering sensor connecting the tiller and the EPAS board Drive motor cable heating thermal cut-out Drive motor themal cut-out Steering motor thermal cut out Test and diagnostics display (Driver Diagnostic Interface) Cooling fan for the motor compartment systems Horn Electromagnetic brake Push button for the quick lifting of the forks Push button for the quick lowering of the forks Snail push button for the inching with tiller in vertical position Push button for the slow lifting of the forks Push button for the slow lowering of the forks Push button for the forward drive with operator on the ground (BACKING) Push button for the backward drive with operator on the ground (BACKING) Sensor enabling the tiller Push button for the quick reverse (Belly Switch) Sensor for the centring of the steering Push button for the calibration of the steering Push button/sensor for man on board Proportional solenoid valve for the fork and the platform lowering Potentiometer adjusting the forward/backward drive Push button enabling the horn Connector of the electromagnetic brake coil in case the control is not supplied with current

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ELECTRIC SYSTEM OPERATING WIRING DIAGRAM MODEL MO20

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SERVICE Ref CPS1 CPS2 CPS3 CPS4 CPS6 CPS7 CPS12 CPS13 CPS14 CPS18 CPS19 CPS20 CPS21 CPS22 CPS24 CPS28 CPS29 CPS30 CPS31 CPS32 CPS33 CPS34 CPSK CPSTS T6, T7, T8

ELECTRIC SYSTEM DIAGRAM FOR THE SHEATH CONNECTION MOD.MO20

Description of the connector Connector connecting the plants to the Comb control Connector connecting the main contactor Connector connecting the tiller sheath Connector connecting the encoder Connector connecting the thermal sensor of the drive motor Connector connecting the electromagnetic brake coils Connector connecting the motor compartment cooling fan Connector connecting the electromagnetic brake when no voltage is supplied Connector connecting the lowering proportional solenoid valve (EV1) Connector connecting the solenoid valves (EV2, EV3, EV4) Connector connectiond the sensors (SW6 - SW7 - SW8) Connector connecting "EPAS" control and "COMBI" control Connector connecting the "COMPUTER" to adjust the parameters Connector connecting the "DDI" diagnostics display Connector connecting the steering cenetering sensor (SW5) Connector connecting the sensors (SW3 - SW4 - SW10 - SW11 - SW12) Connector connecting push buttons P6, P7 for forward and reverse operated on the ground Connector connecting "ETAC" interface Connector connecting the serial interface (for Technicians Iskra only) Connector connecting emergency push buttons T2, T3 Connector connecting the auxiliary solenoid valves (EV5, EV6) Connector connecting the safety switch for the power cable temperature (TH) Connector connecting the key switch (KEY) Connector connecting the steering potentiometer Horm connecting Faston

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ELECTRIC SYSTEM DIAGRAM FOR THE CONNECTION OF THE POWER CABLES MOD. MO20

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ELECTRIC SYSTEM 1.01

WIRING DIAGRAM KEY TO SYMBOLS MODELS MO20S- MO20SLF

Ref

Description of the component functions

S T1 T2 T3 FU1 FU2 FU3 Key Switch PM MTR MTS Torque Sensor TH T. MT T. MS DDI Display M. Fan HORN EMB P1 P2 P3 P4 P5 P6 P7 SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 SW12 EV1 EV2 EV3 EV4 Speed Control Horn Push Button Oveerride Brake

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Outlet and plug connecting the truck system to the battery Remote control switch Emergency push button on the left side of the platform back Emergency push button on the right side of the platform back 415 A power fuse on Combi control 30 A powe fuse on "Power Epas" steering control 10A fuse for the auxiliary functions Key switch 2.00 Kw DC-DC pump motor 4.5 Kw AC drive motor 0.15 Kw AC steering motor Steering sensor connecting the tiller and the EPAS board Drive motor cable heating thermal cut-out Drive motor themal cut-out Steering motor thermal cut out Test and diagnostics display (Driver Diagnostic Interface) Cooling fan for the motor compartment systems Horn Electromagnetic brake Push button for the quick lifting of the forks Push button for the quick lowering of the forks Snail push button for the inching with tiller in vertical position Push button for the slow lifting of the forks Push button for the slow lowering of the forks Push button for the forward drive with operator on the ground (BACKING) Push button for the backward drive with operator on the ground (BACKING) Sensor enabling the tiller Push button for the quick reverse (Belly Switch) Sensor of the platform left side gate (only with platform at 1500mm) Sensor of the platform right side gate (only with platform at 1500mm) Sensor for the centring of the steering Sensor for platform stop at 1200mm (only with platform at 1500mm) Platform lifting limit switch sensor Sensor of drive stop with platform 200mm lifted Push button for the calibration of the steering Push button/sensor for platform lifting Push button/sensor for platform lowering Push button/sensor for man on board Proportional solenoid valve for the fork and the platform lowering Platform lowering solenoid valve Fork lifting solenoid valve Platform lifting solenoid valve Potentiometer adjusting the forward/backward drive Push button enabling the horn Connector of the electromagnetic brake coil in case the control is not supplied with current

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SERVICE CPS1 CPS2 CPS3 CPS4 CPS6 CPS7 CPS12 CPS13 CPS14 CPS18

CPS20 CPS21 CPS22 CPS24

CPS28

CPS29 CPS30 CPS31 CPS32 CPS33 CPS34 CPSK CPSTS T6, T7, T8

DIAGRAM FOR THE SHEATH CONNECTION MOD. MO20S

Description of the connector

Ref.

CPS19

ELECTRIC SYSTEM

CPS25 CPS26 CPS27

CPS8 CPS9 CPS10 CPS16 CPS17

Connector connecting the plants to the Comb control Connector connecting the main contactor Connector connecting the tiller sheath Connector connecting the encoder Connector connecting the thermal sensor of the drive motor Connector connecting the electromagnetic brake coils Connector connecting the motor compartment cooling fan Connector connecting the electromagnetic brake when no voltage is supplied Connector connecting the lowering proportional solenoid valve (EV1) Connector connecting the solenoid valves (EV2, EV3, EV4) Connector connecting the sensor stopping the platform at 1200mm "SW6" Connector connecting the lifting limit switch sensor "SW7" Connector connecting the sensor for the drive stop with platform at 200mm "SW8" Connector connecting "EPAS" control and "COMBI" control Connector connecting the "COMPUTER" to adjust the parameters Connector connecting the "DDI" diagnostics display Connector connecting the steering cenetering sensor (SW5) Connector connecting the platform lowering sensor (SW11) Connector connecting the sensor (SW4) of the platform right side gate (only h 1500mm) Connector connecting the deadman sensor (SW12) Connector connecting the platform lifting sensor (SW10) Connector connecting the sensor (SW3) of the platform left side gate (only h 1500) Connector connecting push buttons P6, P7 for forward and reverse operated on the ground Connector connecting "ETAC" interface Connector connecting the serial interface Connector connecting emergency push buttons T2, T3 (back red push button) Connector connecting the auxiliary solenoid valves (EV5, EV6) Connector connecting the safety switch for the power cable temperature (TH) Connector connecting the key switch (KEY) Connector connecting the steering potentiometer (torque sensor) Horm connecting Faston

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ELECTRIC SYSTEM 1.02

WIRING DIAGRAM KEY TO SYMBOLS MODEL MO20F

Re f

De scription of the com pone nt functions

S T1 FU1 FU2 FU3 Ke y Sw itch PM MTR MTS Torque Se nsor TH T. MT T. MS DDI Displa y M. Fa n HORN EMB P1 P2 P3 P4 P5 P6 P7 SW 1 SW 2 SW 5 SW 9 SW 12 EV1 Spe e d Control Horn Push Button Ove e rride Bra ke

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Outlet and plug connecting the truck system to the battery Remote control switch 415 A power fuse on Combi control 30 A powe fuse on "Power Epas" steering control 10A fuse for the auxiliary functions Key switch 2.00 Kw DC-DC pump motor 4.5 Kw AC drive motor 0.15 Kw AC steering motor Steering sensor connecting the tiller and the EPAS board Drive motor cable heating thermal cut-out Drive motor themal cut-out Steering motor thermal cut out Test and diagnostics display (Driver Diagnostic Interface) Cooling fan for the motor compartment systems Horn Electromagnetic brake Push button for the quick lifting of the forks Push button for the quick lowering of the forks Snail push button for the inching with tiller in vertical position Push button for the slow lifting of the forks Push button for the slow lowering of the forks Push button for the forward drive with operator on the ground (BACKING) Push button for the backward drive with operator on the ground (BACKING) Sensor enabling the tiller Push button for the quick reverse (Belly Switch) Sensor for the centring of the steering Push button for the calibration of the steering Push button/sensor for man on board Proportional solenoid valve for the fork and the platform lowering Potentiometer adjusting the forward/backward drive Push button enabling the horn Connector of the electromagnetic brake coil in case the control is not supplied with current

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SERVICE CPS1 CPS2 CPS3 CPS4 CPS6 CPS7 CPS12 CPS13 CPS14 CPS18

CPS20 CPS21 CPS22 CPS24

CPS28

CPS29 CPS30 CPS31 CPS32 CPS33 CPS34 CPSK CPSTS T6, T7, T8

DIAGRAM FOR THE SHEATH CONNECTION MOD. MO20F

Description of the connector

Ref.

CPS19

ELECTRIC SYSTEM

CPS25 CPS26 CPS27

CPS8 CPS9 CPS10 CPS16 CPS17

Connector connecting the plants to the Comb control Connector connecting the main contactor (T1) Connector connecting the tiller sheath Connector connecting the encoder Connector connecting the thermal sensor of the drive motor (T.MT) Connector connecting the electromagnetic brake coils (EMB) Connector connecting the motor compartment cooling fan (FAN) Connector connecting the electromagnetic brake when no voltage is supplied (override brake) Connector connecting the lowering proportional solenoid valve (EV1) Connector connecting the solenoid valves (EV2, EV3, EV4) Connector connecting the sensor stopping the platform at 1200mm "SW6" Connector connecting the lifting limit switch sensor "SW7" Connector connecting the sensor for the drive stop with platform at 200mm "SW8" Connector connecting "EPAS" control and "COMBI" control Connector connecting the "COMPUTER" to adjust the parameters Connector connecting the "DDI" diagnostics display Connector connecting the steering cenetering sensor (SW5) Connector connecting the platform lowering sensor (SW11) Connector connecting the sensor (SW4) of the platform right side gate Connector connecting the deadman sensor (SW12) Connector connecting the platform lifting sensor (SW10) Connector connecting the sensor (SW3) of the platform left side gate Connector connecting push buttons P6, P7 for forward and reverse operated on the ground Connector connecting "ETAC" interface Connector connecting the serial interface Connector connecting emergency push buttons T2, T3 Connector connecting the auxiliary solenoid valves (EV5, EV6) Connector connecting the safety switch for the power cable temperature (TH) Connector connecting the key switch (KEY) Connector connecting the steering potentiometer (TORQUE SENSOR) Horm connecting Faston

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ELECTRIC SYSTEM 1.03 WIRING DIAGRAM KEY TO SYMBOLS MODEL MO20F Mechanical Steering Ref

Description of the component functions

S T1 FU1 FU3 Key Switch PM MTR TH T. MT DDI Display M. Fan HORN EMB P1 P2 P3 P4 P5 SW1 SW2 SW12 EV1 Speed Control Horn Push Button Oveerride Brake

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Outlet and plug connecting the truck system to the battery Remote control switch 415 A power fuse on Combi control 10A fuse for the auxiliary functions Key switch 2.00 Kw DC-DC pump motor 4.5 Kw AC drive motor Drive motor cable heating thermal cut-out Drive motor themal cut-out Test and diagnostics display (Driver Diagnostic Interface) Cooling fan for the motor compartment systems Horn Electromagnetic brake Push button for the quick lifting of the forks Push button for the quick lowering of the forks Snail push button for the inching with tiller in vertical position Push button for the slow lifting of the forks Push button for the slow lowering of the forks Sensor enabling the tiller Push button for the quick reverse (Belly Switch) Push button/sensor for man on board Proportional solenoid valve for the fork and the platform lowering Potentiometer adjusting the forward/backward drive Push button enabling the horn Connector of the electromagnetic brake coil in case the control is not supplied with current

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ELECTRIC SYSTEM OPERATING WIRING DIAGRAM MOD. MO20F Mechanical Steering

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SERVICE CPS1 CPS2 CPS3 CPS4 CPS6 CPS7 CPS12 CPS13 CPS14 CPS18

CPS20 CPS21 CPS22 CPS24

CPS28

CPS29 CPS30 CPS31 CPS32 CPS33 CPS34 CPS36 CPSK CPSTS T6, T7, T8

DIAGRAM FOR THE SHEATH CONNECTION MOD. MO20F Mechanical Steering

Description of the connector

Ref.

CPS19

ELECTRIC SYSTEM

CPS25 CPS26 CPS27

CPS8 CPS9 CPS10 CPS16 CPS17

Connector connecting the plants to the Comb control Connector connecting the main contactor (T1) Connector connecting the tiller sheath Connector connecting the encoder Connector connecting the thermal sensor of the drive motor (T.MT) Connector connecting the electromagnetic brake coils (EMB) Connector connecting the motor compartment cooling fan (FAN) Connector connecting the electromagnetic brake when no voltage is supplied (override brake) Connector connecting the lowering proportional solenoid valve (EV1) Connector connecting the solenoid valves (EV2, EV3, EV4) Connector connecting the sensor stopping the platform at 1200mm "SW6" Connector connecting the lifting limit switch sensor "SW7" Connector connecting the sensor for the drive stop with platform at 200mm "SW8" Connector connecting "EPAS" control and "COMBI" control Connector connecting the "COMPUTER" to adjust the parameters Connector connecting the "DDI" diagnostics display Connector connecting the steering cenetering sensor (SW5) Connector connecting the platform lowering sensor (SW11) Connector connecting the sensor (SW4) of the platform right side gate Connector connecting the deadman sensor (SW12) Connector connecting the platform lifting sensor (SW10) Connector connecting the sensor (SW3) of the platform left side gate Connector connecting push buttons P6, P7 for forward and reverse operated on the ground Connector connecting "ETAC" interface Connector connecting the serial interface Connector connecting emergency push buttons T2, T3 Connector connecting the auxiliary solenoid valves (EV5, EV6) Connector connecting the safety switch for the power cable temperature (TH) Connector connecting the sensor for cornering deceleration of the mechanical steering (SW13) Connector connecting the key switch (KEY) Connector connecting the steering potentiometer (TORQUE SENSOR) Horm connecting Faston

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ELECTRIC SYSTEM DIAGRAM FOR THE CONNECTION OF THE POWER CABLES MOD. MO20F Mechanical Steering

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NOTES:

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SERVICE

ELECTRIC SYSTEM 2.00

REFERENCE TABLE FOR THE DESCRIPTION OF THE ELECTRIC COMPONENTS MODELS MO20 - MO20LF

The table below indicates the functions of the components shown in the following page.

Key to symbols Ref. Wiring diagram ref.

Description of the component Ref

Wiring diagram ref.

1 2 3

MTR PM MTS ELECTRONIC POWER EPAS ELECTRONIC CONTROL CAMBI EMB EV1 T1 DDI KEY SWITCH HORN FU3 FU2 FU1 SW9 P7 P6 T2 T3 SW12 TILLER CONTROL BOX SW5 TORQUE SENSOR SW1

4 5 6 7 8 9 10 11 12 13 14 15 16-19 17-20 18 21 22 23 24 25 26

Reference of the component on the exploded view Reference of the component on the wiring diagram Description of the component function Description of the component 4.00 Kw AC drive motor 2.00 Kw DC-DC pump motor 1.5 Kw AC steering motor Steering motor electronic control Electronic control of AC drive motor and DC-DC pump motor Electromagnetic brake Proportional solenoid valve for ON-OFF controlled lowering Main contactor "Driver Diagnostic Interface" test and diagnostics display Key switch Horn 10A fuse for the auxiliary functions 30 A powe fuse on "Power Epas" steering control 415 A power fuse on Combi control Push button for the calibration of the steering Push button for the backward drive with operator on the ground (BACKING) Push button for the forward drive with operator on the ground (BACKING) Emergency push button on the left side of the platform Emergency push button on the right side of the platform Push button/sensor for man on board Tiller control box Sensor for the centring of the steering (during backing) Steering position sensor Sensor enabling the tiller

NOTE: All Yale codes are contained in the spare part list.

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ELECTRIC SYSTEM ELECTRICAL COMPONENTS MOD. MO20

22 24

23

19

20

21

18 17

16

26

9

10

8

14 5 25

2 6 24

7

1 4 3

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ELECTRIC SYSTEM

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ELECTRIC SYSTEM 2.01

REFERENCE TABLE FOR THE DESCRIPTION OF THE ELECTRIC COMPONENTS MODELS MO20S - MO20SLF

The table below indicates the functions of the components shown in the following page.

Key to symbols Ref. Wiring diagram ref.

Description of the component

Ref

Wiring diagram ref.

1 2 3

29 30 31

MTR PM MTS ELECTRONIC POWER EPAS ELECTRONIC CONTROL CAMBI EMB EV1 EV2 EV3 EV4 T1 DDI KEY SWITCH HORN FU3 FU2 FU1 SW9 P7 P6 T2 T3 SW12 SW10 SW11 TILLER CONTROL BOX SW5 TORQUE SENSOR SW1

32

SW6

33 34

SW7 SW8

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19-22 20-23 21 24 25 26 27 28

Reference of the component on the exploded view Reference of the component on the wiring diagram Description of the component function

Description of the component 4.00 Kw AC drive motor 2.00 Kw DC-DC pump motor 1.5 Kw AC steering motor Steering motor electronic control Electronic control of AC drive motor and DC-DC pump motor Electromagnetic brake Proportional solenoid valve for fork and platform lowering Platform lowering solenoid valve Fork lifting/lowering solenoid valve Platform lifting solenoid valve Main contactor "Driver Diagnostic Interface" test and diagnostics display Key switch Horn 10A fuse for the auxiliary functions 30 A powe fuse on "Power Epas" steering control 415 A power fuse on Combi control Push button for the calibration of the steering Push button for the backward drive with operator on the ground (BACKING) Push button for the forward drive with operator on the ground (BACKING) Emergency push button on the left side of the platform Emergency push button on the right side of the platform Push button/sensor for man on board Push button/sensor for platform lifting Push button/sensor for platform lowering Tiller control box Sensor for the centring of the steering (during backing) Steering position sensor Sensor enabling the tiller Sensor for platform stop at 1200mm (only with platform at 1500mm copleted with side gates) Platform lifting limit switch sensor Sensor of drive stop with platform 200mm lifted

NOTE: All Yale codes are contained in the spare part list.

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ELECTRIC SYSTEM ELECTRICAL COMPONENTS MOD. MO20S

34

26

27

25

32

33

28

22

23

24

21 20

19

31

30

6 1

2 9 17 5 8 10 7

12

13

11

4 3

29

16

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ELECTRIC SYSTEM 2.02

REFERENCE TABLE FOR THE DESCRIPTION OF THE ELECTRIC COMPONENTS MODEL MO20F

The table below indicates the functions of the components shown in the following page.

Key to symbols Ref. Wiring diagram ref.

Description of the component

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Reference of the component on the exploded view Reference of the component on the wiring diagram Description of the component function

Wiring diagram ref.

MTR PM MTS ELECTRONIC POWER EPAS ECTRONIC CONTROL COMBI P6 P7 EMB EV1 DDI KEY SWITCH TILLER CONTROL BOX SW1 T1 TORQUE SENSOR PUSH BUTTON CALIBRATION FU2 FU3 HORN SW12

Description of the component 4.00 Kw AC drive motor 2.00 Kw DC-DC pump motor 1.5 Kw AC steering motor Steering motor electronic control Electronic control of AC drive motor and DC-DC pump motor Forward Backing push button Reverse Backing push button Electromagnetic brake Proportional solenoid valve for ON-OFF controlled lowering "Driver Diagnostic Interface" test and diagnostics display Key switch Tiller control box Sensor enabling the tiller Main emergency switch Steering position sensor Steering calibration push button 30 A powe fuse on "Power Epas" steering control 10A fuse for the auxiliary functions Horn Push button/sensor for man on board

NOTE: All Yale codes are contained in the spare part list.

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SERVICE 2.03

ELECTRIC SYSTEM

ELECTRIC COMPONENTS MODEL MO20F

6

7 12

10

11

14 13

8 1 5

4

2

19

16

3

9

18

17

20

15

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SERVICE

ELECTRIC SYSTEM 2.04

REFERENCE TABLE FOR THE DESCRIPTION OF THE ELECTRIC COMPONENTS MODEL MO20F Mechanical Steering

The table below indicates the functions of the components shown in the following page.

Key to symbols Ref. Wiring diagram ref.

Description of the component

Ref 1 2 3 4 5 6 7 8 9 10 12 13 14

Wiring diagram ref.

MTR PM ECTRONIC CONTROL COMBI EMB EV1 DDI KEY SWITCH TILLER CONTROL BOX SW1 T1 FU3 HORN SW12

Reference of the component on the exploded view Reference of the component on the wiring diagram Description of the component function

Description of the component 4.00 Kw AC drive motor 2.00 Kw DC-DC pump motor Electronic control of AC drive motor and DC-DC pump motor Electromagnetic brake Proportional solenoid valve for ON-OFF controlled lowering "Driver Diagnostic Interface" test and diagnostics display Key switch Tiller control box Sensor enabling the tiller Main emergency switch 10A fuse for the auxiliary functions Horn Push button/sensor for man on board

NOTE: All Yale codes are contained in the spare part list.

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SERVICE 2.05

ELECTRIC SYSTEM

ELECTRIC COMPONENTS MODEL MO20F Mechanical Steering

8

6

7

10

10

9

12

4

3

1

2 11 13

5

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ELECTRIC SYSTEM 2.06

REFERENCE TABLE FOR THE TILLER BOX MODEL ALL MODELS

The table below indicates the functions of the components shown in the following page.

Key to symbols Ref. Wiring diagram ref.

Description of the component

Reference of the component on the exploded view Reference of the component on the wiring diagram Description of the component function

4 5 6 7 8

W iring dia gra m re f.

TILLER CONTROL BOX SPEED CONTROL "POT1" HORN PUSH BUTTON P4 P5 P1 P2 BELLY SW ITCH

9

P3

10

TILLER BOARD

11

TILLER BOARD

Re f.

1 2 3

De scription of the com pone nt Control tiller head Butterfly control of the potentiometer for forward/backward drive Push button enabling the horn Push button enabling the fork slow lifting f Push button enabling the fork slow lowering ON/OFF push button for the quick fork lifting ON/OFF push button for the quick fork lowering Quick reverse push button SNAIL push button enabling the inching with tiller in upright position Connection of the lifting push buttons on the ON/OFF tiller board Connection of the proportional push buttons on the tiller box

NOTE: All Yale codes are contained in the spare part list.

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ELECTRIC SYSTEM

ELECTRIC COMPONENTS OF THE TILLER BOX MODEL ALL MODELS 2

3

1

7

6

4

5

UPPER BOX BODY

9

8

LOWER BOX BODY

10

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ELECTRIC SYSTEM 2.08

REFERENCE TABLE FOR THE TILLER BOARD COMPONENTS MOD. ALL MODELS

The table below indicates the functions of the components shown in the following page.

Key to symbols Ref. Wiring diagram ref.

Description of the component Ref.

Wiring diagram ref.

1 2 3 4 5 6

TILLER CONTROL POT1 BELLY SWITCH P3 SNAIL HORN PUSH BUTTON

7 8

K5 K5 K4 K4

9

K7

10

K6

11 12 13 14 15

K9 K8 K2 K3 K1

Reference of the component on the exploded view Reference of the component on the wiring diagram Description of the component function Description of the component Tiller control board Potentiometer for forward/reverse travel speed control Microswitch for the quick forward reversal SNAIL microswitch for inching with tiller in upright position Microswitch for the horn enabling Microswitch for forward/reverse travel start Connector of the fork lowering ON/OFF push button Connector of the fork lowering proportional push button Connector of the fork lifting ON/OFF push button Connector of the fork lifting proportional push button Connector of the ON/OFF push button for the slow lowering or for the lowering of the outriggers Connector of the ON/OFF push button for the slow lifting or for the lifting of the outriggers Connector of ON/OFF push button for auxiliary devices Connector of ON/OFF push button for auxiliary devices Connector of the tiller control cable CAN BUS connector Connector of the tiller enabling sensor

NOTE: All Yale codes are contained in the spare part list.

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SERVICE 2.09

ELECTRIC SYSTEM

TILLER BOARD COMPONENTS MOD. ALL MODELS

2

3

4 5 6

12 11

1

10 9 8 14

7

15

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SERVICE

ELECTRIC SYSTEM 2.10

ELECTRIC COMPONENTS OF THE STEERING SYSTEM MODEL ALL MODELS

6

5

7

3

4

1

2

2.11

REFERENCE TABLE FOR THE STEERING SYSTEM COMPONENTS MOD. ALL MODELS

The table below indicates the functions of the components shown above.

Key to symbols Ref. Wiring diagram ref.

Description of the component

Ref.

Wiring diagram ref.

1 2 3 4 5 6 7

MTS

Reference of the component on the exploded view Reference of the component on the wiring diagram Description of the component function

Description of the component

Steering DC motor without brushes Steering control reduction gear POWER EPAS Steering motor control board TORQUE SENSOR Sensor for the steering position B+ Battery B+ cable terminal BBattery B- cable terminal CPS20 Power Epas connector to Combi control and tiller board

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2.12 CONNECTION OF THE POWER CABLE TO THE “AC COMBI” CONTROL MODEL ALL MODELS

2

1

3

4

9

6

5

2.13

7

8

REFERENCE TABLE FOR THE POWER CABLES CONNECTING THE CONTROL TO THE MOTORS MOD. ALL MODELS

The table below shows the description of the power cables connecting the control to the drive, pump and steering motors.

Ref.

Cable No.

Cable section

Battery terminal

1

5 4 12

25mm 25mm 6mm

B+ B-

9 13 10 7 8 6

25mm 6mm 25mm 25mm 25mm 25mm

2 3 4 5 6 7 8 9

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Control terminal B+ fuse B- negative B- negative 425A fuse B+ after fuse B+ after fuse B- negative V terminal W terminal U terminal Auxiliary device connector

3 4

Drive motor terminal

Pump motor terminal

Steering motor terminal

BD1

B+

A2 V W U

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SERVICE

ELECTRIC SYSTEM 3.00

DESCRIPTION OF THE FUNCTIONS OF “DDI” MODEL ALL MODELS 1

9 3 4

2

5

8

7

6 Fig. 1

3.01

REFERENCE TABLE FOR THE DISPLAY SYMBOLS

Ref 1 2 3 4 5 6 7 8 9

Page: 26

Description of the function Diagnostics tool "Driver Diagnostic Interface" Display Battery charge status indicator Battery charge status indication Battery charge status partial indication Drive mode indicator Scheduled maintenance operation indication Diagnostics alarm indication Hour counter Speed reduction indication Green led signalling a correct operation Red led signalling a faulty operation (alarm)

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ELECTRIC SYSTEM

BATTERY CHARGE INDICATOR

The battery charge status is indicated on the display by 10 notches, each of which corresponds to 10% of the whole charge.

When all the notches are displayed the battery is 100% charged.

By the use of battery the notches start turning off progressively. The number in the centre indicates the real battery charge status (90%, 80%, 70%, etc).

When the battery charge status reaches 30% the three notches starts flashing. We recommend charging the battery.

When the battery charge status reaches 20% the horn beeps three times to warn the operator that the battery is flat. The forks can not be lifted and the maximum current on drive motor is reduced in order to allow the operator to reach the charge area.

SPEED REDUCTION INDICATOR The symbol indicates that the speed reduction function is enabled (for speed reduction functions see “TRUCK FUNCTIONS” on page 36)

HOUR COUNTER When the symbol

flashes, a function is enabled. The symbol shows that “DDI” is storing the work hour.

DRIVE MODE INDICATION It shows the operation mode of the selected drive. This function allows the operator to personalize the truck drive functions without the help of a technician.

The four different functions “SOFT, SLOW, STD (standard), HARD” (see “TRUCK FUNCTIONS on page 36) can be programmed and displayed.

Fig. 2

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ELECTRIC SYSTEM 3.03

SEQUENCE OF IMAGES DISPLAYED ON “DDI” AT “START” MODEL ALL MODELS

When the truck is enabled the “DDI” display carries out some tests concerning the work hours of the different motors.

The images are displayed by following the sequence below: 1) 2) 3) 4) 5) 6) 7) 8)

Drive mode selected Drive motor work hours Pump motor work hours Steering motor work hours Total work hours of the truck Kilometres covered by the truck (forward and backward direction) Hours to go before the scheduled maintenance Drive mode selected

Fig. 3

If no alarm has been activated at the end of the tests the green LED remains on.

Before using the truck, wait 3 seconds from the start.

Fig. 4 1

2

5

6

3

4

8

7

Fig. 5

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SERVICE 3.04

ELECTRIC SYSTEM

ALARM DISPLAY MODEL ALL MODELS

The “DDI” gives information about the alarms of the modules to which it is connected by displaying a numerical code corresponding to the current alarm preceded by two letters identifying the alarm module.

In case an alarm is on, the led becomes red and it blinks to warn the operator.

The “DDI” can store up to ten alarms and can give information about the number of times they have been activated, the time, and the temperature of the module involved (see procedure “Alarm Display” on page 35 of this section).

- “Co” followed by the alarm number corresponds to “COMBI” drive control

Fig. 6

- “Ep” followed by the alarm number corresponds to “EPAS” steering motor control.

Fig. 7

- “Ti”followed by the alarm number corresponds to “TILLER” box board.

Fig. 8

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ELECTRIC SYSTEM 3.05

TESTER MENU MODELLO. ALL MODELS

By displaying the TESTER MENU some information concerning the parameters of the drive control inputs, the tiller board outputs and the motor absorption control are displayed.

3.06

MOTOR CONTROL TESTER MENU

The access to tester menu for the motor absorption control can be always carried out. This allows always checking the supply Volt, the absorption Ampere and above all the motor temperature.

To display the test control menu, turn on the truck when the corresponding page is displayed (Fig. 1) press the fork push buttons for the lifting/lowering located on the left side of the tiller box (Fig. 2) and keep them pressed 5 seconds.

Fig. 2

Fig. 1

After 5 seconds the “VARIABLES GROUP 1” page is displayed (Fig. 3).

During the work the values change according to the stress and to the steer angle.

KEY TO "VARS GROUP 1" PAGE EPS TS EPS POT BATTERY BATTERY

0008 Nm 0022* 0023V 0000A

Resistance to the steering stress measured in Nm Steer angle in degrees of the tiller head Steering supply battery Volt Battery absorbtion current

Fig. 3

To display the second tester page, press the two push buttons for the fork lifting/lowering located on the left side of the tiller box (Fig. 2) at the same time, keep pressed 5 seconds.

The “VARIABLES GROUP 2” page is displayed. (Fig. 4). This page refers to the drive motor. During the work the values change according to the truck speed.

KEY TO "VARS GROUP 1" PAGE TRM VOLT TRM CURR TRM TEMP ENCODER

0008 V 0015A 0030° 1750rpm

Motor supply Volt Motor absorption current Motor temperature Number of revolutions on the motor per minute

Fig. 4

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ELECTRIC SYSTEM

To display the third tester page press the two push buttons for the fork lifting/lowering on the left side of the tiller box at the same time (Fig. 2), keep pressed 5 seconds.

The “VARIABLES GROUP 3” page (Fig. 5) is displayed. This page refers to the pump motor. During the work the values change according to the number of revolutions of the pump motor.

KEY TO "VARS GROUP 3" PAGE PMT VOLT PMT CURR ACC TEMP EVP CURR

0023 V 0028A 0019°C 0000A

Motor supply Volt Motor absorption current Total temperature of the motor Absorption current of the solenoid valves currently enabled

Fig. 5

To come back to the main menu, press the two push buttons for the fork lifting/lowering located on the left side of the tiller box (Fig. 2) at the same time, keep pressed 5 seconds.

The page of the selected drive mode is displayed. (Fig. 6)

FIG. 6

3.07

TESTER MENU OF INPUTS OF CONTROLS: “COMBI INPUT” - “TILLER INPUT” - “VERSION EPROM” “DISPLAYING OF THE LAST 10 ALARMS”

3.08

“COMBI INPUT”

The “COMBI INPUT” menu page allows displaying the input status.

When the input is active, a luminous square next to the number corresponding to the input lights up.

The sensor is enabled when it is reading and the rear led is on.

The tables in the following page show the inputs of each truck model.

Fig. 7

PROCEDURE TO DISPLAY THE TESTER MENU To display the “COMBI INPUT” page (Fig.8) press the two push buttons for the lifting and the lowering located on the left side of the tiller box at the same time and turn the key switch ON (“KEY ON” )(Fig. 7). Keep the bush buttons pressed 5 seconds and release.

Fig. 8

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SERVICE

ELECTRIC SYSTEM CONTROL INPUTS FOR MODEL “MO20 - MO20F - MO20LF” Display ref.

Wiring Number diagram ref.

1 2 3 4 5 6

SW2 SW12 SW1

7

P6

8 9 10 11 12

P7

Description of the signal output

Display

Belly Switch pressed (non-operating travel reverse) Sensor of man on board Sensor of lowered tiller (active) Push button for the forward drive with operator on the ground (BACKING) Push button for the backward drive with operator on the ground (BACKING) "EPAS" steering control safety input

Fig. 9

CONTROL INPUTS FOR MODEL “MO20S - MO20SLF” Display ref.

Wiring Number diagram ref.

Description of the signal output

Display

1 2 3 4 5 6

SW10 SW11

Platform lifting sensor Platform lowering sensor

SW2 SW12 SW1

7

P6

8 9 10 11 12

P7

Micro Belly Switch pressed (non-operating travel reversal) Sensor of man on board Sensor for lowered tiller (active) Push button for the forward drive with operator on the ground (BACKING) Push button for the backward drive with operator on the ground (BACKING) "EPAS" steering control safety input Sensor of drive stop with platform at 200mm Sensor of drive stop with platform at 1200mm Sensor of platform lifting limit switch

SW8 SW6 SW7

Fig. 10

Once the “COMBI INPUT” page test has been completed, press the two push buttons for lifting/lowering located on the left side of the tiller box at the same time (Fig. 11). Keep the push buttons pressed 5 seconds to display the selected drive mode page (Fig. 12).

Fig. 11

Fig. 12

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SERVICE 3.09

ELECTRIC SYSTEM

“TILLER INPUT”

The “TILLER INPUT” menu page allows checking if the tiller box control outputs are enabled.

When the ouput is active, a luminous square next to the number corresponding to the function lights up.

The table below shows the outputs of each function.

PROCEDURE Carry out the PROCEDURE TO DISPLAY THE “TESTER MENU” (see on page 31) To display the “TILLER INPUT” page (Fig.14) press the push button for the fork lifting located on the left side of the tiller box (Fig. 13); keep it pressed 5 seconds and release.

Display reference

Wiring diagram ref.

1 2 3

P4 P5 Pot1 Horn Push Button Belly Switch P3 P1-Pot2 P2-Pot3 SW1

4 5 6 7 8 9 10 11

Fig. 13

Description of the signal output Slow lifting push button or Initial Lift Slow lowering push button or Initial Lift Forward/reverse Horn push button Belly switch, emergency reverse Push button for inching with tiller in upright position Fork quick lifting push button or proportional push Fork quick lifting push button or proportional push Tiller sensor Optional Optional

Fig. 14

Once the “TILLER INPUT” page test has been completed, press the push buttons for lifting and lowering located on the left side of the tiller box (Fig. 15); keep them pressed 5 seconds to come back to the selected drive mode page (Fig. 16).

Fig. 16

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Fig. 15

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SERVICE

ELECTRIC SYSTEM 3.10

“EPROM VERSION”

The “VERSIONS” menu page allows checking the version of the “EPROM” assembled on each control (Combi, Tiller, Epas, DDI).

The page displays the type of control and a series of nine numbers subdivided into three groups. The serial number corresponds to the three central numbers.

The table below makes the reading of the page easier.

Fig. 17

PROCEDURE Carry out the PROCEDURE TO DISPLAY THE “TESTER MENU” (see on page 30) To display the “VERSIONS” page (Fig.18), press the push button for the fork lifting located on the left side of the tiller box (Fig. 17) two times; keep it pressed 5 seconds.

KEY TO EEPROM VERSIONS EEPROM Display reference version No. TILLER - Ver 070 000 COMBI - Ver 407 000 EPAS - Ver 985 000 DDI - Ver 069 000

Fig. 18 001 006 002 001

Once the “TILLER INPUT” page test has been completed, press the push buttons for lifting/lowering located on the left side of the tiller box (Fig. 19); keep them pressed 5 seconds to display the selected drive mode page.

Fig. 19

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ELECTRIC SYSTEM

“ALARM DISPLAY” PAGE

The menu page “ALARM DISPLAY” allows checking how many alarms have been activated and which modules have been involved.

The page displays the current alarm, the alarm code, the hours worked and the module temperature when the alarm has been activated and how many times it has been enabled.

The table below explains how to read the display.

Fig. 20

PROCEDURE Carry out the procedure MENU” see page 31)

(“PROCEDURE TO ENTER THE TESTER

To display another page press three times the fork lifting push button located on the left side of the tiller box (Fig. 20) and keep pressed 5 seconds each time to display the page “ALARM DISPLAY”. (Fig. 2122).

Page description "Alarm display" FAULT LOG Log 001 Device

Fig. 21

Combi

Indication of the alarmed module

Tiller

Indication of the alarmed module

Device

Epas

Indication of the alarmed module

Error Time Occ. Temp.

21376 00025 005 0018

Alarm code Hours worked when the alarm has been activated Number of times the alarm has been activated Module temperature when the alarm has been activated

Device

FAULT LOG Log 002 FAULT LOG Log 003

The alarms are displayed automatically according to the order they have been activated.

After displaying the alarms stored, press the push buttons “HORN and BELLY SWITCH” (fig. 23) at the same time to reset the list. When the alarms are reset, the writing “LOG IS EMPTY” (fig. 24) is displayed.

To quit the tester function press the lifting/lowering push buttons located on the left side of the tiller box at the same time (fig. 25), keep pressed 5 to display the page of the drive mode selected (fig.26).

Fig. 26

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Fig. 23

Fig. 24

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SERVICE

ELECTRIC SYSTEM 4.00

FUNCTIONS OF THE TRUCK MODEL ALL MODELS

INTRODUCTION For each function there is a sheet containing: • • • • • • •

enabling controls configuration parameters description of the functions control inputs control outputs setting potentiometer acquisition

Each truck can be provided with some functions according to the model.

To change the parameters, use a computer with “ETACC” program (SEE MANUAL “FAILURE DIAGNOSIS AND ADJUSTMENTS THROUGH “AC CONTROL PROGRAM (ETACC)”. Ref. 2200R SRM 1058). The parameters can be changed only when the machine is in “STD” (standard) mode.

To enable each function, the controls above mentioned must be activated and the sensor of man on board must be enabled.

MAN ON BOARD The max. drive speed can be obtained with man on board, outriggers lifted and platform lowered (Fig. 1)

Fig. 1 The drive is stopped when lifting the platform beyond 200mm up to the maximum height (Fig. 2)

Fig. 2

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ELECTRIC SYSTEM

FORWARD/BACKWARD DRIVE

ENABLING CONTROLS

To carry out the forward drive turn forward the potentiometer butterfly control.

To carry out the backward drive turn backward the potentiometer butterfly control.

Forward

Backward Actuators used

Emergency push button Key switch Platform sensor, man on board Sensor of tiller 45° tilted in travel position

Status ON ON ON ON Forward / backward rotation

Drive potentiometer (Butterfly control)

Symbol on wiring diagram T1 Key Switch SW12 SW1 Sensor Control

CONFIGURATION PARAMETERS

ETACC PARAMETERS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

EMERGENCY BUTTON AT REST HIGH SPEED EMERGENCY BUTTON DRIVE MODES BRAKE PLATFORM ON RABBIT MODE FASTER THEN STANDARD FLASH BEACON BACKUP ALARM LIFT LOCK OUT SET POINT % TILLER ANGLE TO REDUCE SPEED BACKING FUNTION RPM* BACKING FUNCTION TIME RPM WITH 90° DEGREE TILLER MAXIMUM ACCELERATION DEC REGENERATIVE BRAKING NEUTRAL BRAKING ACC ON ANGLE DEC ON ANGLE COMBI SAVE PARAMETERS

For the adjusting value of each parameter refer to “PARAMET ER STANDARD CONFIGURATION” on page 50.

For the description of each parameter refer to “REFERENCE TABLE FOR T HE CONFIGURATION PARAMETER” on page 54.

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The maximum drive speed can be set by means of programming device only in “HARD” mode.

Setting of the max. drive speed in “HARD” mode Parameter: “rabbit mode faster than standard” 12.5%: +12.5% as to “STD” mode 25%: +25% as to “STD” mode The acceleration can be set by means of programming device.

Setting of the acceleration Parameter: “maximum acceleration%”

4.02

SPEED REDUCTION

REDUCTION OF PRESET SPEED The machine is equipped with a device reducing the preset speed level (“turtle speed” - 5 km/h), which can not be set by means of programming device.

CONDITIONS FOR THE ENABLING OF THE REDUCTION SPEED PRESET (5Km/h) The battery charge level is lower tha the value set through parameter “lift lock out set point%” (default 20%).

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ELECTRIC SYSTEM

DECELERATION WITH DRIVE WHEEL STEERED

This function reduces proportionally the max. drive speed when the steer angle increases.

Besides the value of the steer angle set by means of parameter “tiller angle to reduce speed” (default 15°) a deceleration settable through programming device is enabled and the drive speed is reduced proportionally when the steer angle is increased.

With the wheel 90° steered a reduction of speed that can be set by means of programming device is enabled.

Setting of the steer angle, after which the speed is reduced proportionally Parameter: “tiller angle to reduce speed” Setting of the deceleration with the steer angle value set by means of the parameter “tiller angle to reduce speed” Parameter: “dec on angle%” Setting of the speed with the wheel 90°steered Parameter: “rpm with 90° degree tiller”

with straight tiller max. speed

4.04

wit h st eer angle set through parameter “tiller angle to reduce speed” (def aul t 15°) a deceleration settable through parameter “dec on angle%” is enabled. With steer angle between the value set through parameter “tiller angle to reduce speed” (default 15°) and 90°, deceleration proportional to the steer angle.

with 90°steered angle deceleration settable through parameter “rpm with 90° degree tiller”

DECELERATION WITH FLAT BATTERY

When the battery charge level is lower than the value set through the parameter “lift lock out set point%” (default 20%) the preset speed reduction is enabled (“turtle speed” - 5km/h).

When the battery is nearly flat, the truck stops and all its functions are disabled.

In both cases the battery must be recharged to restore the initial operation condition of the truck.

The functions of deceleration and stop when the battery is flat can be disabled by deactivating the battery charge level test.

Cutting out of the battery charge level test Parameter: “batt volt watch” DISABLE

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ELECTRIC SYSTEM 4.05

BRAKING

The trucks are equipped with five braking systems: • Release braking (regenerative braking) • Partial release braking (regenerative braking) • Reverse braking (regenerative braking) • Emergency braking • Parking braking The truck brakes differently according to the type of braking systems enabled.

For further details on the the braking systems refer to “BRAKING SYSTEMS” on page 3 of the section “BRAKING SYSTEM” BRAKING SYSTEM

WHEN IS IT ENABLED?

Release braking

Release of the drive control (potentiometer butterfly button )

Partial release braking

Partial release of the drive control (potentiometer butterfly button )

Reverse braking

Reversal of the travel direction by means of the drive control (potentiometer butterfly button) Release of the tiller in vertical position (rest position)

Emergency braking An alarm requiring the immediate stop of the truck drive is activated Parking braking

The truck is at rest and the operator is not on board

The deceleration ramp for the release braking, the partial release braking and the reverse braking can be set through the programming device.

Setting of the release braking deceleration ramp: Parameter: “neutral braking” Setting of the partial release braking deceleration ramp: Parameter: “dec” Setting of the reverse braking deceleration ramp: Parameter: “regenerative braking”

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ELECTRIC SYSTEM

BACKING FUNCTION (function installed on models “LO2.0M” equipped with EPAS”)

The “backing” function is enabled only when the tiller is at rest and one of the two push buttons enabling the backing function (P6 - backing: forward / P7 - backing: reverse ) is pressed.

By enabling the “backing” function the truck carries out the self-centering of the wheel (see “Self-centering system” with “backing function” on page 45) and then it starts travelling in the direction required and it stops when the enabling push button is released or the “backing” function limit time is spent.

This function can have a limited or unlimited length of time that can be set through programming device.

The “backing” function truck speed can be set through programming device.

Setting of the “backing” function length of time Parameter: “backingfunction time” 0: 10: 20: 30: ....: ....: 100:

unlimited length of time 1 second 2 seconds 3 seconds ................ ................

100 seconds

“backing” function push button for forward travel

Setting of “backing” function speed Parameter: “backing function rpm” “backing” function push button for reverse travel

4.07

TABLE OF THE DRIVE SPEEDS OPERATION MODE OF THE VARIOUS DRIVE SPEEDS

Type of ste e ring Drive m otor "KW " Mode l Ma x . spe e d of the drive m otor Hard(+25% ) Hard Sta nda rd Soft Slow

4.8

Pow e r ste e ring 4 MO20 D857

Pow e r ste e ring 4 MO20S D857

Pow e r ste e ring 4 MO20F A949

3200 rpm

3200 rpm

3200 rpm

3200 rpm

11.93 km/h 10.74 km/h 9.55 km /h 8.3 km/h 6.83 km/h

11.93 km/h 10.74 km/h 9.55 km /h 8.3 km/h 6.83 km/h

11.93 km/h 10.74 km/h 9.55 km /h 8.3 km/h 6.83 km/h

11.93 km/h 10.74 km/h 9.55 km /h 8.3 km/h 6.83 km/h

Me cha nica l

Me cha nica l

4 ( Spe d ) MO20F A949

2,2 MO20F A949

8.5 Km/h 7.65 Km/h 6.8 Km /h 5.95 Km/h 5.1 Km/h

CONNECTOR JUMPERS ACCORDING TO THE TRUCK CONFIGURATION CONNECTORS ASSEMBLED ON THE COMPLETE SYSTEM

Model MO20F MO20F

Description of the option Model with power steering Model with mechanical steering

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Jumper on Jumper on connector connector CPS19 CPS19 (SW7-SW8-SW9) (SW7-SW8-SW9) X X

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Five Pin Connector with Jumper (Pin 1-2-3-4)

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SERVICE

ELECTRIC SYSTEM 4.9

SETTING

SELECTION OF THE DRIVE OPERATION MODE This function allows the operator to personalise the drive functions without the help of a technician.

Four different predefined performance levels are displayed on the DDI: “Slow“, “Soft“, “Std“, “Hard“. Each of them corresponds to a specific setting concerning:

• maximum speed • acceleration • braking

Fig. 1

Procedure Step 1 By keeping the tiller in vertical position press the horn and at the same time turn the key to position “1” (fig. 1). At the start the symbol of the standard drive mode “STD” is displayed (fig. 2).

Fig. 2 Step 2 To change the drive mode, press the left push button for the lifting by keeping the tiller always in vertical position (fig. 3): the different possible drive modes are displayed. Choose the mode desired.

Step 3 To confirm the setting desired, lower the tiller in drive position (fig. 4).

Fig. 3

Fig. 4

4.10

POTENTIOMETER ACQUISITION

FORWARD/REVERSE POTENTIOMETER ACQUISITION. Refer to “FORWARD/BACKWARD POTENTIOMETER ACQUISITION” on page 67 of this section.

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ELECTRIC SYSTEM

STEERING

ENABLING CONTROLS

Actuators used Emergency push button Key switch Side gate sensors Sensor of lowered board, man on board Sensor of tiller 45° tilted in travel position Tiller rotation to the right and to the left

Status ON ON ON ON ON Tiller rotation

Symbol on wiring diagram T1 Key Switch SW5 - SW6 SW3 SW1 Torque Sensor

To steer to the right or to the left, rotate the tiller to the right or to the left according to the arrow direction

CONFIGURATION PARAMETERS ETACC PARAMETERS 1 2 3 4 5 6 7 8 9 10 11 12 13

EPAS NO PRESENT A_MAX STEER ASSIST REDUCTION WITH FORWARD SPEED STEER ASSIST REDUCTION WITH REVERSE SPEED MINIMUM FORWARD STEER ASSIST MINIMUM REVERSE STEER ASSIST STEER ASSIST REDUCTION WITH ANGLE ANGLE_MAX STEER GEAR RATIO EPAS OPTION 0 EPAS OPTION 1 EPAS OPTION 2 EPAS SAVE PARAMETERS

For the adjusting value of each parameter refer to “PARAMET ER STANDARD CONFIGURATION” on page 50.

For the description of each parameter refer to “REFERENCE TABLE FOR T HE CONFIGURATION PARAMETER” on page 54.

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The truck can be equipped with a steering system provided with mechanical steering or power steering (EPAS).

Configuration of the steering system Parameter: “epas no present” false: power steering (EPAS) true: mechanical steering STEERING SYSTEM PROVIDED WITH POWER STEERING (EPAS)

The assistance supplied to the steering by the EPAS system depends on:

• speed and direction of travel - when the speed is increased, the assistance supplied to the steering is

reduced.

The minimum assistance (at maximum speed) and the reduction of the assistance when the speed is increased can be set according to the direction of travel of the truck (forward/reverse) • steer angle - when the steer angle is increased, the assistance supplied to the steering is reduced.

SETTING ACCORDING TO THE SPEED AND TO THE DIRECTION OF TRAVEL (forward/reverse) Setting of assistance when the speed is zero or low (maximum assistance) Parameter: “a_max” Setting of the assistance at the maximum forward speed (minimum assistance-forward) Parameter: “minimum forward steer assist” Setting of the assistance at the maximum reverse speed (minimum assistance-reverse) Parameter: “minimum reverse steer assist” Setting of the assistance reduction according to the increasing of the forward speed Parameter: “steer assist reduction with forward speed” Setting of the assistance reduction according to the increasing of the reverse speed Parametro: “steer assist reduction with reverse speed” SETTING ACCORDING TO THE STEER ANGLE Setting of the assistance reduction according to the increasing of the steer angle Parameter: “steer assist reduction with angle”

Setting of the steer angle (absolute value) near which the assistance is minimum (up to the end of stroke) Parameter: “angle max”

90° end of stroke

stan ce minim um assi max” r“ ang le pa ram ete = 85 °) 6 7 lt (d ef au

to al eer n t e e ti o s th por the h th s t f o pro of ug si s ” o n tio nc e ing thr r a gl e c e s e u l a a e an t d re s is c re ttab “ st t h n s e i a e s er w i t h g le m e t o n an ra c ti pa d u re

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maximum assistance

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ELECTRIC SYSTEM

SELF-CENTERING SYSTEM WITH “BACKING” FUNCTION

A steering self-centering sensor is installed on models MO20 equipped with “backing” function (SW5).

The “backing” function is enabled when the tiller is at rest and one of the two push buttons enabling the backing function (P6 - backing forward / P7 - backing reverse) is pressed.

By pressing one of the two “backing” push buttons (P6 or P7), EPAS carries out the self-centering of the steering and keeps the centring for the whole “backing” function.

The “backing” function with steering self-centering system can be enabled or disabled by means of the programming device.

“backing” function push button for forward travel

“backing” function push button for freverse travel

Enabling/disabling of the backing function with steering self-centering system Parameter: “epas option 0”

4.13

enable: enabling of “backing” function disable: disabling of “backing” function

POTENTIOMETER ACQUISITION

ACQUISITION OF THE STEERING POTENTIOMETER SENSOR Refer to “ACQUISITION OF THE STEERING POTENTIOMETER SENSOR” on page 64 of this section.

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ELECTRIC SYSTEM 5.00

OUTRIGGER LIFTING AND LOWERING

ENABLING CONTROLS

D

C

A

HYDRAULIC CONTROLS MO20 - MO2.0F - MO20LF

B

To carry out the quick lifting of the outriggers press the ON/OFF push button “A”.

To carry out the quick lowering of the outriggers press ON/OFF push button “B” To carry out the slow lifting of the outriggers press ON/OFF push button “C”.

To carry out the slow lowering of the outriggers press ON/OFF push button “D”

Actuators used

Symbol on wiring diagram T1 Key Switch SW5 - SW6 SW3 P1 P4 P2 P3

Status

Emergency push button Key switch Side gate sensors Sensor of man on board Outrigger quick lifting; press on/off push button (A) Outrigger slow lifting; press the on/off push button (C) Outrigger quick lowering; press the on/off push button (B) Outrigger slow lowering; press the on/off push button (D)

ON ON ON ON ON ON ON ON

HYDRAULIC CONTROLS MO20S - MO2.0S-SR

“F”

To carry out the quick lifting of the outriggers press the ON/OFF push button “A”.

To carry out the quick lowering of the outriggers press ON/OFF push button “B” To carry out the slow lifting of the outriggers press ON/OFF push button “C”.

To carry out the slow lowering of the outriggers press ON/OFF push button “D” To carry out the quick lifting of the platform press the right push button “E” located on the board.

To carry out the quick lifting of the platform press the left push button “F” located on the board.

Actuators used

Status

Emergency push button Key switch Side gate sensors Sensor of man on board Outrigger quick lifting; press on/off push button (A) Outrigger slow lifting; press the on/off push button (C) Outrigger quick lowering; press the on/off push button (B) Outrigger slow lowering; press the on/off push button (D) Platform quick lifting Platform quick lowering

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“E”

ON ON ON ON ON ON ON ON ON ON

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Symbol on wiring diagram T1 Key Switch SW5 - SW6 SW3 P1 P4 P2 P3 SW10 SW11

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ELECTRIC SYSTEM

CONFIGURATION PARAMETERS

ETACC PARAMETERS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

LOWERING VALVE AUTO LOWER BASE ARMS LOW BATTERY BIP EV2,3,4 PRESENT DOUBLE CLICK MINIMUM PROPORTIONAL VALVE CURRENT MAXIMUM PROPORTIONAL VALVE CURRENT PROPORTIONAL VALVE RAMP UP PROPORTIONAL VALVE RAMP DOWN PUMP RAMP FAST LIFT SPEED% FAST LOWER SPEED% SLOW LIFT SPEED% SLOW LOWER SPEED% MINIMUM PUMP SPEED% MAXIMUM PUMP CURRENT MAXIMUM LIFT TIME

For the adjusting value of each parameter refer to “PARAMET ER STANDARD CONFIGURATION” on page 50.

For the description of each parameter refer to “REFERENCE TABLE FOR T HE CONFIGURATION PARAMETER” on page 54.

5.01

LIFTING/LOWERING SPEED OF THE OUTRIGGERS AND OF THE PLATFORM MODELS: MO20 - MO20LF - MO20F - MO20S - MO20SLF

The maximum speed of the lifting/lowering of the outriggers can be set through programming device.

Setting of the maximum speed of the outrigger lifting with push button (A) pressed Parameter: “fast lift speed%” Setting of the maximum speed of the outrigger lowering with push button (B) pressed Parameter: “fast lower speed%” Setting of the minimum speed of the outrigger lifting with push button (C) pressed Parameter: “slow lift speed%” Setting of the minimum speed of the outrigger lowering with push button (D) pressed Parameter: “slow lower speed%”

5.02

PLATFORM LIFTING END OF STROKE DECELERATION MODELS MO20S - MO20SLF

During the lifting, the platform reaches the maximum height without any deceleration. The platform stops at the end of its stroke thanks to the reading of sensor “SW7”, which stops the pump motor.

During the lowering, the platform reaches the lowering stop without any deceleration. The lowering of the platform stops when the platform reaches the mechanical stop.

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5.03

OUTRIGGER ACCELERATION/DECELERATION RAMPS

By enabling the on/off push button for the lifting (P1) the outriggers start lifting with an acceleration ramp depending on the acceleration ramp of the pump motor. By releasing the on/off push button for the lifting the outriggers start stopping with a deceleration ramp depending on the deceleration ramp of the pump motor.

Both the acceleration and the deceleration of the pump motor depend on a configuration parameter only.

Setting of the acceleration ramp for the lifting of the outriggers and setting of the deceleration ramp with release of the push button Parameter: “pump ramp” By enabling the on/off push button for the lowering (P2), the outriggers start lowering with an acceleration ramp depending on the opening ramp of the solenoid valve EV1.

Setting of the acceleration ramp of the outrigger lowering Parameter: “proportional valve ramp up” Release the on/off push button for the lowering (P2), le forks start stopping with a deceleration ramp depending on the closing valve of the solenoid valve EV1.

Setting of the deceleration ramp of the outrigger lowering Parameter: “proportional valve ramp down” By enabling the on/off push button for lifting (P4) and lowering (P5) the acceleration and deceleration ramps are the same.

OUTRIGGER LIFTING AND PUSH BUTTON RELEASE (MO20 - MO20LF - MO20S - MO20SLF) stop

deceleration ramp for the outrigger lifting settable by means of parameter: “pump ramp”

P4

P1

push button release

maximum lifting speed settable by means of parameters: “fast lift speed%” - on/off push button P1 “slow lift speed%” - on/off push button P4 acceleration ramp for the outrigger lifting settable by means of parameter: “pump ramp”

OUTRIGGER LOWERING AND PUSH BUTTON RELEASE (MO20 - MO20LF - MO20S - MO20SLF) acceleration ramp settable by means of parameter: “proportional valve ramp up”

P5

P2

maximum lowering speed settable by means of parameters: “fast lower speed%” - pulsante on/off P2 “slow lower speed%” - pulsante on/off P5 push button release

deceleration ramp settable by means of parameter: “proportional valve ramp down” stop

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ELECTRIC SYSTEM

PLATFORM ACCELERATION/DECELERATION RAMPS

By enabling the push button for the lifting (SW10) the platform starts lifting with an acceleration ramp depending on the acceleration ramp of the pump motor. By releasing the push button for the lifting the platform starts stopping with a deceleration ramp depending on the deceleration ramp of the pump motor. Both the acceleration and the deceleration of the pump motor depend on a configuration parameter only.

Setting of the acceleration ramp for the lifting of the platform and setting of the deceleration ramp with release of the push button Parameter: “pump ramp” By enabling the push button for the lowering (SW11), the platform starts lowering with an acceleration ramp depending on the opening ramp of the solenoid valve EV1.

Setting of the acceleration ramp of the platform lowering Parameter: “proportional valve ramp up” Release the push button for the lowering (SW11), the platform starts stopping with a deceleration ramp depending on the closing valve of the solenoid valve EV1.

Setting of the deceleration ramp of the platform lowering Parameter: “proportional valve ramp down”

PLATFORM LIFTING AND PUSH BUTTON RELEASE (MO20S - MO20SLF) stop

deceleration ramp for the platform lifting settable by means of parameter: “pump ramp” push button release

maximum lifting speed settable by means of parameters: “fast lift speed%” - push button SW10 acceleration ramp for the platform lifting settable by means of parameter: “pump ramp”

SW10 PLATFORM LOWERING AND PUSH BUTTON RELEASE(MO20S - MO20SLF) acceleration ramp settable by means of parameter: “proportional valve ramp up”

SW11

maximum lifting speed settable by means of parameters: “fast lower speed%” - push button SW11 push button release

deceleration ramp settable by means of parameter: “proportional valve ramp down” stop

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ELECTRIC SYSTEM 6.00

Ref. 1 2 3

4

REFERENCE TABLE FOR THE CONFIGURATION PARAMETERS OF THE DRIVE CONTROL MODEL ALL MODELS ETACC Parameter name T WARNING ODO RATIO EMERGENCY BUTTON AT REST HIGH SPEED EMERGENCY BUTTON

5

LOWERING VALVE

6

AUTO LOWER BASE ARMS

7

DRIVE MODES

8

LOW BATTERY BEEP

Measure range 40…100 2000…15000 Active at rest No active at rest Active at high speed Disable at high speed Digital Proportional Disable Enable Disable Enable Disable Enable

9

BATT VOLT WATCH

10

EV2, 3, 4, 5, 6 PRESENT

11

BRAKE PLATFORM ON

12

RABBIT MODE FASTER THEN STANDARD

13

SHIFT FUNCTION

Disable Enable Disable Enable Disable Enable 12,5% 25% Disable Enable

14

15

FLASH BEACON

BACKUP ALARM

Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Lowering solenoid valve controlled by ON/OFF push button Lowering solenoid valve controlled by proportional push button The automatic lowering of the outriggers is disabled when the forks are over 1500mm The automatic lowering of the outriggers is enabled when the forks are over 1500mm The selection of the drive mode is disabled The selection of the drive mode is enabled When the battery charge level reaches 30% and when the fork lifting is enabled the three horn beeps are disabled.

When the battery charge level reaches 30% and when the fork lifting is required, the horn beeps three times Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" It disables the function of the EV2,3,4 solenoid valves.

It enables the function of the EV2,3,4 solenoid valves.

Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" The truck speed in "HARD" mode is 12. 5% higher than the speed set in standard mode.

The truck speed in "HARD" mode is 25% higher than the speed set in standard mode The digital outputs 6 and 8 of the control are used for the flash beacon (Flash Beacon) or for the alarm buzzer (Backup Alarm).

The digital outputs 6 and 8 of the control are used for the auxiliary solenoid valves EV5 and EV6.

The flash beacon function during the backward movement is enabled if parameter "SHIFT FUNCTION" is set to "DISABLE"

Active with tiller down

The flash beacon function (Flash Beacon) is enabled with any function of the truck.

The alarm buzzer function (Backup Alarm) during the forward movement is enabled if the parameter "SHIFT FUNCTION" is set to "ENABLE" The alarm buzzer function (Backup Alarm) during the backward movement is enabled if the parameter "SHIFT FUNCTION" is set to "DISABLE" The double-click function of the push buttons for the lifting and lowering of the forks and of the footboard is disabled. Only on models MO20 - MO20F -MO20S The double-click function of the push buttons for the lifting and lowering of the forks and of the footboard is enabled. Only on models MO20 - MO20F -MO20S

Active going forward

Disable DOUBLE CLICK Enable

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Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE"

Active on any function

Active going in reverse

16

Description of the parameter

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ELECTRIC SYSTEM

Ref.

ETACC Parameter name

17

EPAS NO PRESENT

Measure range False True

The truck is enabled with mechanical steering The truck is enabled with power steering After 500 working hours, the symbol of the adjustable wrench appears on the "DDI" and it indicates that the maintenance is required; the truck keeps the set speed After 500 working hours, the symbol of the adjustable wrench apppears on the "DDI" and during the following 250 working hours, the truck starts a progressive deceleration until 750 working hours are reached and the speed is reduced to the minimum (5 km/hour)

False 18

BIT 15 True

19 20 21 23 23 24 25 26

27 28

MAIN CONTACTOR ENGAGED TIME MAIN CONTACTOR PWM ELECTROMAGNETIC BRAKE PWM FULL BATTERY VOLTAGE (mV) EMTY BATTERY VOLTAGE (Mv)

10…100

Read-only parameter "NON-CHANGEABLE"

50…100

Read-only parameter "NON-CHANGEABLE"

50…100

Read-only parameter "NON-CHANGEABLE"

20000…27000 20000…25000

LIFT LOCK OUT SET POINT %

0…50

BDI ADJUSTMENT MINIMUM PROPORTIONAL VALVE CURRENT MAXIMUM PROPORTIONAL VALVE CURRENT PROPORTIONAL VALVE HYSTERESIS

Description of the parameter

-20…20 0…20

20…100 0…10

Value in m/Volt near which the battery is considered 100% charged Value in m/Volt near which the battery is considered 20% charged When the DDI reaches the value of parameter "LIFT LOCK OUT SET POINT %" (Example 20%), the lifting is stopped and the maximum drive current is reduced by 50%.

Read-only parameter "NON-CHANGEABLE" Minimum value of the pulse modulation applied to open the proportional valve for the lowering. Minimum value of the valve current near which the valve starts to open.

Minimum value of the pulse modulation to open the proportional valve for the lowering. Maximum value of the valve current near which the valve starts to open.

Read-only parameter "NON-CHANGEABLE" Opening ramp of the proportional valve. Every 50mS the pulse modulation is increased by the value corresponding to the above-mentioned parameter, until the set reference is reached

29

PROPORTIONAL VALVE RAMP UP

30

PROPORTIONAL VALVE RAMP DOWN

10…100

31

PUMP RAMP

10…100

32

FAST LIFT SPEED %

20…100

33

FAST LOWER SPEED %

20…100

34

SLOW LIFT SPEED %

10…100

35

SLOW LOWER SPEED %

10…100

36

MINIMUM PUMP SPEED %

5…20

Minimum value of pulse modulation applied to the pump near the minimum value of the lifting required (minimum speed of the pump at start)

37

MAXIMUM PUMP CURRENT

100…350

Maximum current allowed by the control in the pump motor for 2 seconds

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2

3 4

Closing ramp of the proportional valve. Every 50mS the pulse modulation is decreased by the value corresponding to the above-mentioned parameter, until the set reference value is reached Start and stop ramp of the pump motor: Every 50mS the pulse modulation is increased or decreased by a value corresponding to the above-mentioned parameter, until the set reference value is reached Maximum lifting speed when the right push button for the lifting is pressed Maximum lowering speed when the right push button for the lowering is pressed Maximum lifting speed when the left push button for the lifting (or initial lifting) is pressed Maximum lowering speed when the left push button for the lowering (or initial low) is pressed

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SERVICE

ELECTRIC SYSTEM 38

PUMP DELAY

0…1000

Read-only parameter "NON-CHANGEABLE"

39

MAXIMUN LIFT TIME

6…100

Maximum lifting time allowed when the right proportional push button for the lifting is pressed. This time is cumulative and it is reset by pressing the proportional push button for the lowering.

40 41

THROTTLE X THROTTLE Y EMERGENCY BRAKE DELAY MINIMUM HYDRAULIC THROTTLE %

10…90 10…90

Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE"

0…100

Read-only parameter "NON-CHANGEABLE"

0…20

Read-only parameter "NON-CHANGEABLE"

44

MAXIMUM HYDRAULIC THROTTLE %

80…100

Read-only parameter "NON-CHANGEABLE"

45

HYDRAULIC THROTTLE MAPPING

20…80

Read-only parameter "NON-CHANGEABLE"

46

TILLER ANGLE TO REDUCE SPEED

10…90

47

BACKING FUNTION RPM

500…2000

42 43

48

49 50 51 52 53 54 55 56 57 58

BACKING FUNCTION TIME

EMERGENCY REVERSE RPM EMERGENCY REVERSE TIME OUT EMERGENCY REVERSE ACCELERATION EMERGENCY REVERSE JERK RELEASE SPEED TURTLE RPM (standard mode) RABBIT RPM (standard mode) RPM WITH 90° DEGREE TILLER SNAIL RPM SPEED REDUCTION

0…100

This time is settable and it corresponds to the duration of the "BACKING" function. By setting the parameter to "0" the backing function will have no stop limits. By setting the parameter to "50" the backing function stops after 5 seconds.

By setting the parameter to "100" the backing function stops after 10 seconds. Only for models MO20 -MO20S - MO20F.

500…4000

Read-only parameter "NON-CHANGEABLE"

0…100

Read-only parameter "NON-CHANGEABLE"

10…100

Read-only parameter "NON-CHANGEABLE"

20…100

Read-only parameter "NON-CHANGEABLE"

0…4200

Read-only parameter "NON-CHANGEABLE"

700…1794

Read-only parameter "NON-CHANGEABLE"

700…8000

Read-only parameter "NON-CHANGEABLE"

700…2500 400…1000 600…3000

59

MAXIMUM ACCELERATION %

7…100

60

ACC 0

7…100

61

DEC

4…50

62

REGENERATIVE BRAKING

20…100

63

NEUTRAL BRAKING

4…80

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Value of the steer angle according to which the truck speed is proportionally reduced from the maximum value to the minimum value of TminSpeed parameter with +90° and -90° steered wheel (RPM with 90°Degree Tiller) Parameter for the speed of the backing function.Only for models MO20 -MO20S - MO20F.

Maximum speed of the truck with the tiller completely turned by +90° or -90° Read-only parameter "NON-CHANGEABLE" Speed of the truck with the forks lifted more than 500mm Maximum acceleration of the truck during the start after an acceleration request. Higher values produce higher acceleration.

Read-only parameter "NON-CHANGEABLE" Release braking during the partial return of the butterfly control.Higher values produce stronger braking. Lower values produce less strong braking.(the butterfly control is in "0" position).

The reverse braking is used when the butterfly control is inverted. Higher values produce stronger braking. Lower values produce less strong braking.

The release braking is used when the butterfly control is completely released. Higher values produce stronger braking.

Lower values produce less strong braking.

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Ref.

ETACC Parameter name

Measure range

Description of the parameter

64

ACC ON ANGLE

7…100

Acceleration during the start with the tiller completely turned by an angle higher than the value of the "Tiller Angle Offset To Reduce Speed" parameter that has been set.

This deceleration occurs when the steering is carried out when the steer angle is higher than the "Tiller Angle Offset To Reduce Speed" parameter. The truck decelerates until the speed corresponding to the angle set for the curve is reached.

65

DEC ON ANGLE %

4…80

66 67 68 69 70

ACC STOP JERK ACC (%) JERK ACC 0 JERK DEC JERK REV (%) NEUTRAL BRAKING JERK % JERK REL 0 LIMIT UBAT

30…100 10…100 5…100 20…100 20…100

Read-only Read-only Read-only Read-only Read-only

5…100

Read-only parameter "NON-CHANGEABLE"

71 72 73 74

6.01

COMBI SAVE PARAMETER

10…100 10…30 Write to ram only Read eeprom Write to eeprom Default to eeprom

parameter parameter parameter parameter parameter

"NON-CHANGEABLE" "NON-CHANGEABLE" "NON-CHANGEABLE" "NON-CHANGEABLE" "NON-CHANGEABLE"

Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Memory Eeprom of "NON-CHANGEABLE" parameters Memory Eeprom of "NON-CHANGEABLE" parameters Memory Eeprom of "NON-CHANGEABLE" parameters Memory Eeprom of "NON-CHANGEABLE" parameters

REFERENCE TABLE FOR THE CONFIGURATION PARAMETERS OF THE EPAS CONTROL MODEL ALL MODELS "EPAS" (STEERING) BOARD PARAMETERS

Ref. 1 2

3 4 5

ETACC Parameter name

Measure range

A-MAX STEER ASSIST REDUCTION WITH FORWARD SPEED STEER ASSIST REDUCTION WITH REVERSE SPEED MINIMUM FORWARD STEER ASSIST MINIMUM REVERSE STEER ASSIST

1..20

Maximum assistance when the speed is zero or very low.

1..10

Reduction of the assistance according to the truck forward speed (fork direction). The higher the value is, the more the assistance is reduced.

1..10

Reduction of the assistance according to the truck backward speed (drive wheel direction). The higher the value is, the more the assistance is reduced.

1..A_max

Minimum assistance at high forward speed of the truck (fork direction)

1..A_max

Minimum assistance at high backward speed of the truck (drive wheel direction)

High

6

High reduction of the speed when the steer angle is increased.

Medium High

STEER ASSIST REDUCTION WITH ANGLE

Medium

ANGLE MAX STEER GEAR RATIO

EPAS OPTION 0 9

EPAS OPTION 1 EPAS OPTION 2

10

EPAS SAVE PARAMETERS

UPDATE

0 1

Medium high reduction of the speed when the steer angle is increased.

Medium reduction of the speed when the steer angle is increased.

Low reduction of the speed when the steer angle is increased ("DEFAULT" setting)

Low 7 8

Description of the parameter

Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Read-only parameter "NON-CHANGEABLE" Memory Eeprom of "NON-CHANGEABLE" parameters Memory Eeprom of "NON-CHANGEABLE" parameters Memory Eeprom of "NON-CHANGEABLE" parameters Default to eeprom Memory Eeprom of "NON-CHANGEABLE" parameters 0..100 1..500 Disable Enable Disable Enable Disable Enable Write to ram only Read eeprom Write to eeprom

2

3 4

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SERVICE

ELECTRIC SYSTEM 6.02

STANDARD CONFIGURATION OF THE PARAMETERS "DEFAULT" PARAMETERS APPLIED BY THE MANUFACTURER Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74

Page: 54

ETACC Parameter Name

MO20 - MO20S - MO20F MO20LF - MO20SLF 60 5950 Active at rest Active at high speed Digital Disable Enable Enable Enable Disable Disable 12.5% Disable Active on any function Active going forward Disable False False 20 80 80 24700 23000 20 20 10 80 3 45 60 50 100 100 50 80 5 200 0 6 50 50 0 0 100 50 15 1000 50 1100 50 100 100 0 1600 3200 2200 680 1000 25 20 12 40 18 10 40 30 30 30 30 50 50 60 19 Write to EEPROM

T WARNING ODO RATIO EMERGENCY BUTTON AT REST HIGH SPEED EMERGENCY BUTTON LOWERING VALVE AUTO LOWER BASE ARMS DRIVE MODES LOW BATTERY BEEP BATT VOLT WATCH EV2, 3, 4 PRESENT BRAKE PLATFORM UP RABBIT MODE FASTER THEN STANDARD SHIFT FUNCTION FLASH BEACON BACKUP ALARM DOUBLE CLICK EPAS NO PRESENT BIT 15 MAIN CONTACTOR ENGAGED TIME MAIN CONTACTOR PWM ELECTROMAGNETIC BRAKE PWM FULL BATTERY VOLTAGE (mV) EMTY BATTERY VOLTAGE (Mv) LIFT LOCK OUT SET POINT % BDI ADJUSTMENT MINIMUM PROPORTIONAL VALVE CURRENT MAXIMUM PROPORTIONAL VALVE CURRENT PROPORTIONAL VALVE HYSTERESIS PROPORTIONAL VALVE RAMP UP PROPORTIONAL VALVE RAMP DOWN PUMP RAMP FAST LIFT SPEED % FAST LOWER SPEED % SLOW LIFT SPEED % SLOW LOWER SPEED % MINIMUM PUMP SPEED % MAXIMUM PUMP CURRENT PUMP DELAY MAXIMUN LIFT TIME THROTTLE X THROTTLE Y EMERGENCY BRAKE DELAY MINIMUM HYDRAULIC THROTTLE % MAXIMUM HYDRAULIC THROTTLE % HYDRAULIC THROTTLE MAPPING TILLER ANGLE TO REDUCE SPEED BACKING FUNTION RPM BACKING FUNCTION TIME EMERGENCY REVERSE RPM EMERGENCY REVERSE TIME OUT EMERGENCY REVERSE ACCELERATION EMERGENCY REVERSE JERK RELEASE SPEED TURTLE RPM (standard mode) RABBIT RPM (standard mode) RPM WITH 90° DEGREE TILLER SNAIL RPM SPEED REDUCTION MAXIMUM ACCELERATION % ACC 0 DEC REGERATIVE BRAKING NEUTRAL BRAKING ACC ON ANGLE DEC ON ANGLE % ACC STOP JERK ACC (%) JERK ACC 0 JERK DEC JERK REV (%) NEUTRAL BRAKING JERK % JERK REL 0 LIMIT UBAT COMBI SAVE PARAMETER Read only parameters - NOT CHANGEABLE Parameters changeable only in "STD" (Standard) mode

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MO20F Mechanic Steering 4 Kw 60 5950 Active at rest Active at high speed Digital Disable Enable Enable Enable Disable Disable 12.5% Disable Active on any function Active going forward Disable True False 20 80 80 24700 23000 20 20 10 45 3 45 60 50 100 100 50 80 5 300 0 6 50 50 0 0 100 50 15 1000 50 1100 50 100 100 0 1600 3200 1200 680 1000 13 13 12 25 12 10 40 30 30 30 30 30 25 60 19 Write to EEPROM

3 4

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"DEFAULT" PARAMETERS APPLIED BY THE MANUFACTURER Ref.

ETACC Parameter Name

1 2 3 4 5 6 7 8

A-MAX STEER ASSIST REDUCTION WITH FORWARD SPEED STEER ASSIST REDUCTION WITH REVERSE SPEED MINIMUM FORWARD STEER ASSIST MINIMUM FORWARD STEER ASSIST STEER ASSIST REDUCTION WITH ANGLE ANGLE MAX STEER GEAR RATIO

9

EPAS OPTION - 0 EPAS OPTION - 1 EPAS OPTION - 2

10

EPAS SAVE PARAMETERS

UPDATE

0 1

2

3 4

MO20 - MO20S - MO20F MO20LF - MO20SLF

15 7 7 5 5 Low 76 81 Disable Enable Enable Write to EEPROM

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SERVICE

ELECTRIC SYSTEM 7.00

REPLACEMENT OF THE “AC MODULE” COMBI MODEL ALL MODELS

Necessary tools

large slotted screwdriver

4-6mm Allen wrench

10mm articulated socket wrench

100 Ohm 10W insulated resistance

Special tools

adapter code 580039670

software “ETACC”

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles ans from the passage of pedestrians. Lower the forks to the ground, turn the key switch OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Fig. 1

A

B

Step 2 100 Ohm 10W RESISTANCE - 6mm ALLEN WRENCH Loosen the screws fastening the power cables (ref.A-B fig.2) and insert a 100 Ohm 10W resistance between tra il B+ positive pole and B- negative pole of module (fig.2).

Wait about 8 seconds so that the internal capacitors discharge and then disconnect the resistance.

Fig. 2

To avoid short circuits, the resistance must be insulated.

If you do not have an external resistance to discharge the capacitors, you must wait at least 90 seconds before disconnecting any power cable.

C

Step 3 6mm ALLEN WRENCH Disconnect the main connector (ref.C fig.3) and using the Allen wrench loosen the seven screws fastening the power cables.

Disconnect the power cables (fig.3).

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Step 4 ARTICULATED SOCKET WRENCH Loosen the four fixing screws (ref.D fig.4,5) and remove the module complete with dissipator.

Position on a clean workbench.

D

Step 5 4mm ALLEN WRENCH Loosen the four screws (ref.E fig.6) fastening the module to the dissipator and replace it.

Install the new module by carrying out the procedure in the reverse order.

Step 6 ADAPTER - SOFTWARE “ETACC” - Connect the adapter to connector CPS30 of COMBI control - Connect the USB connector of the interface cable to USB port on PC - Connect the battery, activate the emergency push button and turn the key switch ON - Start program “ETACC”, - Select the truck model and set the parameter configuration applied by the manufacturer or a personalised configuration. (Key OFF to sore the data) (see manual “FAILURE DIAGNOSIS AND ADJUSTMENT THROUGH AC CONTROLS PROGRAM” - ref. 2200 YRM 1058)

Fig. 4

D

Fig. 5

E

The working hours stored on the broken COMBI control are stored on DDI. If the configuration procedure is not carried out within 10 minutes from the truck start, the working hours will be deleted and both controls will start from “0” hours.

7.01

E

Fig. 6

CONFIGURATION OF THE WORKING HOURS FROM DISPLAY “DDI” TO “COMBI” CONTROL MODEL ALL MODELS

ADAPTER - SOFTWARE “ETACC” Procedure to transfer the working hours from DDI to new COMBI control.

-

Connect the adapter to COMBI control connector CPS30 Connect the USB connector of interface cable to USB port on PC Connect the battery, activate the emergency push button and turn the key switch ON Start software “ETACC” and select the truck model Select “INSTRUMENTS” Select ”INDIVIDUAL SETUP” “RESET DDI ERROR” Enable (type in “DISABLE”) is displayed Type in DOWNLOAD The hours stored on “DDI” are transferred to COMBI control This operation must be carried out within 10 minutes from the truck start.

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SERVICE 7.03

ELECTRIC SYSTEM

STEERING POTENTIOMETER SENSOR

DESCRIPTION The steering potentiometer sensor is made up of five potentiometer sensors held in a case containing two coupled rotors. The two rotors (a position rotor and a torsion rotor) follow the movements of the steer shaft and the torsion shaft. The torsion rotor moves ± 11°with respect to the position rotor and can move 0.5mm.

The five potentiometer sensors have five outputs:

• • •

T1-T2 P1-P2 P3 The first couple of output signals (T1-T2) detects the movement of the torsion shaft and give indications of the steer torsion couple.

The second couple of output signals (P1-P2) detects the movement of the main steering shaft and give a continuous indication of the absolute position of this latter for the whole tiller stroke.

The fifth output signal (P3) is not used.

When the operator exerts strength on the tiller to steer, the steering potentiometer sensor detects a torsion torque, thanks to which “Epas” module makes an assistance torque correspond to the steering applied by means the steering motor.

According to the steer angle the “Epas” module manages the speed reductions and the intensity of the steering assistance.

FEATURES Supply: Resistance: Working temperature:

12 Volt max 350 Ohms ± 30% from -40° to 125°

centring spring

rotor

case

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SERVICE

ELECTRIC SYSTEM 7.04

REPLACEMENT OF THE STEERING POTENTIOMETER A SENSOR MODEL ALL MODELS

Necessary tools

15mm socket wrench

ratchet

external circlip pliers

bearing puller

hammer

large slotted screwdriver

pin extractor with 5mm diam.

Fig. 1 Fig. 2

17mm open ended spanner

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key switch OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the fastening screws of the motor bonnet and of the upper bonnet.

Disconnect the “DDI” and the key switch. Remove the bonnet (fig. 2).

B

Step 2 15 mm SOCKET WRENCH - RATCHET Loosen and remove the fastening screws of the cardanic shaft upper unit (ref. A fig. 1). Remove the cardanic shaft fom the tiller crown to make the removal easier.

Fig. 3

C Step 3 15 mm SOCKET WRENCH - RATCHET - 17mm OPEN ENDED SPANNER Loosen and remove the fastening screws of the motor compartment bonnet (ref. B fig 3), remove the bracket from the chassis (ref. C fig 4).

Fig. 4

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Step 4 15 mm SOCKET WRENCH - RATCHET Disconnect the connectors of the tiller sheath and the steering sensor sheath. Loosen and remove the screws fastening the tiller unit to the chassis (ref. C fig. 5). Remove the complete tiller and position it on a workbench.

Step 5 15 mm SOCKET WRENCH - RATCHET Loosen the fastening screws of the lower protection support (ref. E fig.

8) and remove the lower support (ref. F fig. 8).

D

Fig. 5

If there are some distance washers (ref. G fig. 8) they must be reassembled.

Step 6 EXTERNAL CIRCLIP PLIERS - PULLER By using the pliers remove the bearing snap ring (ref. H fig. 9) and by means of the puller extract the bearing (ref. I fig. 9).

Step 7 HAMMER - PIN EXTRACTOR By using the hammer and the pin extractor remove the hinge pin of crown gear (ref. L fig. 10), move the crown gear downward (ref. M fig. 11) and extract the potentiometer sensor (ref. N fig. 11). Replace it.

Fig. 6 The hinge pin must not be used again.

Assemble a new pin.

I

H

Fig. 9

Fig. 7

G

G

N M

E

Fig. 11

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Fig. 10

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F

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Fig. 8

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SERVICE

ELECTRIC SYSTEM 7.05

ASSEMBLY

During the assembly insert the steering potentiometer sensor into the torsion bar (ref.O) up to the bushing so that the rotor notch (ref.N1) fits together with the slot (ref.N). Insert the flange into the torsion bar, rotate it till the centring hole (ref.Q) corresponds with the centring spring (ref.R). Insert the flange into the sensor so that the slot (rif.P) is by the rotor notch (ref.P1).

Position the new hinge pin, the bearing and the snap ring.

To assemble the other components follow the procedure in the reverse order.

After the assembly of the potentiometer extract the potentiometer centring spring (ref.R).

After the assembly of the complete tiller on the truck, carry out the procedure for the acquisition of the potentiometer with “EPAS” steering control (see procedure 64).

steering potentiometer sensor

N1 N

O

P1 R

P

Q flange Fig.12

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ELECTRIC SYSTEM

COLD-STORAGE ROOM POTENTIOMETER MODEL ALL MODELS

To arrange the truck to work in the cold-storage room (-25/30°), replace the potentiometer provided with a 10 Watt resistance.

The potentiometer is equipped complete with resistance (fig. 11-12).

After assembling connect the resistance to plant connector “CPS 12”.

Fig.14

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Fig.13

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SERVICE

ELECTRIC SYSTEM 7.07

ACQUISITION OF THE STEERING POTENTIOMETER SENSOR MODEL ALL MODELS

B

When must this procedure be carried out?

- When the steering potentiometer sensor must be replaced.

- When the steering motor must be replaced.

Necessary tools

large slotted screwdriver

Fig. 1

Procedure Before starting to work wear suitable safety clothes.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the fastening screws of the motor bonnet. Remove the bonnet.

Step 2 Press the push button located under module “AC Combi” (ref.A fig.3) downward or upward and at the same time start the truck (key ON) (ref.B fig.1).

During this operation, do not touch the tiller at all

Wait 5/6 seconds after the tiller stop, then “Release the push button”.

In models provided with “BAKING” push button, the tiller moves until it reads the centring sensor, then it stops.

Fig. 2

Step 3 Position the tiller centrally in travel direction.

Turn off the truck (key OFF).

Wait at least six seconds.

Step 4 (“REPEAT STEP” 1) Press the push button located under module “AC Combi” (ref.A fig.3) downward or upward and at the same time start the truck (key ON) (ref.B fig.1).

A

During this operation do not touch the tiller at all.

Fig. 3 Wait 5/6 seconds after the tiller stop, then “Release the push button”.

In models provided with “BAKING” push button, the tiller moves until it reads the centring sensor, then it stops. Wait 5/6 seconds then “Release the push button” Now the truck can be used.

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ELECTRIC SYSTEM

REPLACEMENT OF THE TILLER BOARD MODEL ALL MODELS

If the various controls do not have any function such as forward/reverse, horn, fork liftings and lowerings, the complete board must be replaced.

Necessary tools

2.5-4mm Allen wrench

A

Procedure

Fig. 1

Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key switch OFF and disconnect the battery.

Step 1 4mm ALLEN WRENCH Loosen the 3 bolts fastening the upper box body (ref.A fig.1).

B

Fig. 2

Step 2 Lift the upper box body and remove it from the lower box body (ref.B fig.2). Disconnect the serial cable connector, position the cover on a clean workbench.

Step 3 2.5mm ALLEN WRENCH Loosen the screw fastening the butterfly control (right or left), (ref.C fig.3).

Extract the butterfly control from the pin (ref.D fig.4), remove the other butterfly control complete with guide pin (ref.E fig.4).

C

Fig. 3

E

D

Step 4 Extract the board from its seat, disconnect the connectors of the various control microswitches.

Before disconnecting the connectors mark their position to make the connection on the new board easier and replace it (fig.4).

Reassemble the board by carrying out the procedure in the reverse order.

We recommend inserting the board into their seats.

After the assembly carry out the potentiometer acquisition (see “LIFTING/LOWERING POTENTIOMETER ACQUISITION”on page 67).

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SERVICE

ELECTRIC SYSTEM 7.09

REPLACEMENT OF PUSH BUTTONS “P1 - P2 - P3 - P4”” MODEL ALL MODELS

Necessary tools

small slotted screwdriver

4mm Allen wrench

A

Procedure

Fig. 1

Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key switch OFF and disconnect the battery.

Step 1 4mm ALLEN WRENCH Loosen the 3 bolts fastening the upper box body (ref.A fig.1).

Fig. 2 Step 2 Open the tiller box (fig.2).

B

Step 3 SMALL SLOTTED SCREWDRIVER By using the screwdriver act on the retainers of the ON/OFF push button (ref.B fig.3), press the push button (ref.C fig.3), remove it and replace it.

B

Reassemble the push button by carrying out the procedure in the reverse order.

C

After the assembly no adjustment is required.

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ELECTRIC SYSTEM

TILLER HEAD POTENTIOMETER ACQUISITION MODEL ALL MODELS

When must this procedure be carried out?

- When the tiller board must be replaced - When the “AC Combi” module must be replaced - When the tiller head potentiometer push buttons must be replaced The acquisition procedure of all the tiller head potentiometers must be carried out even if only a potentiometer is replaced.

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground.

Fig. 1

7.11

FORWARD/REVERSE POTENTIOMETER ACQUISITION

Step 1

Press the two lifting push buttons located on the left side of the tiller box and turn the key switch ON (KEY ON) (Fig. 1).

Keep the push button pressed 5 seconds and release them. Page “COMBI INPUT” is displayed (Fig. 2)

Fig. 2

Press the left lowering push button (fig.3) and keep it pressed 5 seconds.

The page “tiller head calibration” (TILLER ANALOG INPUT - fig.4) is displayed on DDI.

Fig. 3

Fig. 4

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Step 2 Move slowly the butterfly control forward up to the end of stroke. The cursor shifts left on the analog input screen (fig.5) then return to the centre.

Move slowly the butterfly control backward up to the end of stroke. The cursor shifts right on the analog input screen (fig.6) then return to the centre.

Repeat the operation three times.

Step 3 Press the left lifting/lowering push buttons at the same time and release them after 5 seconds to save the data and quit the “calibration” function (fig.7).

Fig. 7

Fig. 5

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SERVICE 8.00

ELECTRIC SYSTEM

REPLACEMENT OF THE EMERGENCY PUSH BUTTON MODEL ALL MODELS

D

Necessary tools

Ø 3 mm pin extractor

13 mm open ended spanner

large slotted screwdriver

medium crosshead screwdriver

E Fig. 1

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key switch OFF and disconnect the battery.

Step 1 LARGE SCREWDRIVER Loosen and remove the fastening screws of the motor bonnet. remove the bonnet (fig.2).

Step 2 13 mm OPEN ENDED WRENCH By using the open ended spanner loosen the fastening screw of the electric cables connected to the contactor (ref.A fig.3). Disconnect the contactor coil supply cable (ref. B fig. 3). Disconnect the cables to the auxiliary device microswitch (ref. C fig. 3).

Step 3 PIN EXTRACTOR Insert the pin extractor tip in the hole located under the red knob of the emergecy push button (ref. D fig. 1).

Rotate the knob, until the pin extractor enters the hole of the pin inside the knob. Then loosen and remove the knob.

Step 4 CROSS-HEAD SCREWDRIVER Loosen the fastening screws of the main emergency push button (ref.E fig.1), remove the contactor and replace it.

Fig. 2

C

B

A

Fig. 3

Reassemble the main emergency push button by carrying out the procedure in the reverse order.

After the assembly no maintenance is required.

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SERVICE

ELECTRIC SYSTEM 8.01

REPLACEMENT OF “DDI” DISPLAY MODEL ALL MODELS

Necessary tools

Fig. 1

D

large slotted screwdriver

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key switch OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen and remove the fastening screws of the motor bonnet. Remove the bonnet (fig.2).

Step 2 Disconnect the connector (ref. A fig. 3). Loosen and remove the “DDI” fastening screws by your hands (ref. B fig. 3), extract the supports (ref.

C fig. 3).

Extract the “DDI” by moving it upwards (ref. D fig. 1) and replace it.

Fig. 2

C

A

Reassemble the new DDI by carrying out the procedure in the reverse order.

After the assembly of the new “DDI”, the acquisition of the working hours stored in controllo “COMBI” are carried out by the truck start.

B

Fig. 3

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SERVICE 8.02

ELECTRIC SYSTEM

REPLACEMENT OF THE START KEY SWITCH MODEL ALL MODELS

B

C

Necessary tools

large slotted screwdriver

medium adjustable pliers

Fig. 1 Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key switch OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen and remove the fastening screws of the motor compartment bonnet. Remove the bonnet (fig. 2).

Step 2 ADJUSTABLE PLIERS Disconnect the fastons (rif. A fig. 3). Extract the key (ref. B fig.1) and by using the pliers loosen and remove the ring nut of the key switch (ref. C fig. 3). Remove the key switch by moving it downward (ref. D fig. 4) and replace it.

Reassemble the new key switch by carrying out the procedure in the reverse order.

Fig. 2

D

A

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SERVICE

ELECTRIC SYSTEM 8.03

REPLACEMENT OF THE DEADMAN AND BOARD LIFTING/LOWERING SENSORS MODEL ALL MODELS

The deadmen sensor SW12, the platform lifting sensor SW10, the lowering platform sensor SW11 are located under the platform and are enabled by the operator’s feet through some push buttons located on the board. The three sensors are replaced by following the procedure below.

Necessary tools

24mm open ended spanner

Fig. 1

scissors

Procedure SW12

Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians. Lift the board at the maximum height (fig.1). Turn the key switch OFF and disconnect the battery.

B A SW11

Step 1 SCISSORS - 24mm OPEN ENDED SPANNER By using the scissors, cut the cable clamp of the sensor supply cable, release the cable (ref. A fig. 2). Disconnect the supply connector (ref. B fig. 2).

By using the open ended spanner loosen and remove the sensor locknut (rif. C fig. 3). Extract the sensor from its support and replace it.

SW10

Fig. 2

C

D

Reassemble the new sensor by carrying out the procedure in the reverse order.

Adjust the sensor, until a distance of 0.5mm from the reading cam is reached (ref. D fig. 3).

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SERVICE 8.04

ELECTRIC SYSTEM

REPLACEMENT OF STEERING CENTERING SENSOR WITH “BACKING” FUNCTION MODEL ALL MODELS

Necessary tools

19mm open ended spanner

scissors

large slotted screwdriver

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground. Turn the key switch OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen and remove the fastening screws of the motor compartment bonnet. Remove the bonnet (fig. 1).

Step 2 SCISSORS - 19mm OPEN ENDED SPANNER By using the scissors cut the clamp of the sensor cable, release the cable. Disconnect the supply cable.

By using the open ended spanner loosen the sensor locknut (ref. A fig.

2). Remove the sensor from the seat (ref. B fig. 2) and replace it.

Fig. 1

B

Reassemble the new sensor by carrying out the procedure in the reverse order.

A

Fig. 2

Adjust the sensor, until a maximum distance of 0.5mm from the reading cam is reached.

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ELECTRIC SYSTEM 8.05

REPLACEMENT OF THE “BACKING” PUSH BUTTONS MODEL ALL MODELS

A

Necessary tools

large slotted screwdriver

small slotted screwdriver

medium crosshead screwdriver

Fig. 1

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground. Turn the key switch OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen and remove the upper and lower screws fastening the bonnet to the back platform (ref. A-b fig. 1-3).

Remove the bonnet and tilt toward the battery to reach the push button (fig. 4).

Fig. 2

B

Step 2 From the internal part of the platform bonnet disconnect the push button fastons (ref. C fig. 5). Press the push button on tha faston part and push them outward (direction of the arrow), remove the push bottons and replace them.

Fig. 3

Reassemble the new push buttons by carrying out the procedure in the reverse order.

8.06

REPLACEMENT OF THE MICROSWITCH OF THE EMERGENCY PUSH BUTTON LOCATED ON THE BACK

MEDIUM CROSS-HEAD SCREWDRIVER - SMALL SLOTTED SCREWDRIVER From the internal part of the platform bonnet loosen and remove the screws fastening the cables to the microswitch by means of cross-head screwdriver (ref. C fig. 6), remove the cables. By using the slotted screwdriver act on the clips locking the microswitch to the push button ( ref. D fig. 6 ), remove the microswitch and replace it.

Reassemble the new microswitch by carrying out the procedure in the reverse order.

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C

C

Fig. 5

Fig. 6

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SERVICE 8.07

ELECTRIC SYSTEM

REPLACEMENT OF THE PLATFORM LIMIT SWITCH SENSORS SW7, AND OF THE SENSOR SW6 FOR STOPPING THE PLATFORM AT 1200MM MODELS MO20S -MO20SLF

The procedure to remove both sensors “SW6 and SW7” is the same.

Necessary tools

medium crosshead screwdriver

scissors

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground. Turn the key switch OFF and disconnect the battery.

Step 1 SCISSORS - MEDIUM CROSS-HEAD SCREWDRIVER By using the scissors, cut the sensor cable clamp up to the connector and disconnect the connector.

By using the screwdriver, loosen the sensor fastening screw (ref. A fig.

2). Remove the sensor from the clamp and replace it.

Fig. 1

A

Reassemble the new sensor by carrying out the procedure in the reverse order.

Adjust so that the distance of the sensor reading is not higher than 0.5mm.

Fig. 2

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ELECTRIC SYSTEM 8.08

REPLACEMENT OF THE SENSOR STOPPING THE PLATFORM 200mm LIFTED MODEL MO20S -MO20SLF

Necessary tools

medium crosshead screwdriver

scissors

5mm Allen wrench

8mm open ended spanner

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground.

Step 1 SCISSORS - ALLEN WRENCH - OPEN ENDED SPANNER Press the platform lifting push button and lift at the maximum height to reach the sensor. Turn the key switch OFF and disconnect the battery.

By using the scissors, cut the sensor cable clamps up to the connector (ref. A fig. 2), disconnect the connector.

Fig. 1 Step 2 ALLEN WRENCH - OPEN ENDED SPANNER - SCREWDRIVER By using the two wrenches loosen and remove the fastening screws of the clamp to the support (ref. B fig. 2), remove the clamp complete with sensor.

By using the screwdriver loosen the sensor fastening screw (ref C fig.

2), remove the sensor and replace it.

A

C

Reassemble the new sensor by carrying out the procedure in the reverse order.

B

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SERVICE 9.00

ELECTRIC SYSTEM

ASSEMBLY OF THE COMBI CONTROL COOLING FAN (OPTION) MODEL ALL MODELS

If the truck works in very warm and little ventilated rooms, the control can reach too high temperature thus causing the drive stop. To avoid this trouble a fan limiting the increasing of the control temperature can be installed. The fan kit is supplied complete with fastening screws.

Standard tools

Small cross-head screwdriver

Large slotted screwdriver

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key switch OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen and remove the fastening screws of the motor compartment bonnet. Remove the bonnet to reach the Combi control (fig. 1).

Step 2 SMALL CROSS-HEAD SCREWDRIVER To fasten the fan, it is important to tighten at least three fixing screws.

By using the screwdriver tighten the screws on the fan (ref. A fig. 4).

Insert the fan under the control into its seat (fig. 3). Insert the screw head in the slots of the support (ref. B-C fig. 2-3), lift upward and push the fan forward (direction of the arrow). By using the screwdriver tighten the screws and fasten the fan.

Connect the fan connector to connector “CPS12”

Fig. 1

B

Fig. 2

C

After the assembly no adjustment is required.

9.01

REMOVAL OF THE FAN FOR THE REPLACEMENT MODEL ALL MODELS

Step 1 To remove the fan for the replacement, carry out the procedure in the reverse order.

After the assembly no adjustment is required.

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SERVICE

ELECTRIC SYSTEM

NOTES:

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SERVICE

ELECTRIC SYSTEM DESCRIPTION OF THE COMBI CONTROL INPUTS/OUTPUTS MOD. ALL MODELS

Combi control connector No. of connector pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Connecting wire

Connectors and Pins

Digital input/output

No. of wire

No. of connector

Key-in Digital input 1 Digital input 2 Digital input 3 Digital input 4 Digital input 5 Digital input 6 Digital input 7 Digital input 8 Digital input 9 Digital input 10 Digital input 11 Digital input 12 Digital output 1 Digital output 2 Digital output 3 Digital output 4 Digital output 5

10E 519 510 511 541 512 540 544 545 841 515 513 514 840 802 803 804 843

19

Digital output 6

780

20

Digital output 7

721

21 22 23 24

Digital output 8 Output B+ proportional valve Output B - proportional valve Main accelerator 0:+4.7V Analogue input of drive motor thermal switch sensor Analogue input +4.7V Can High Can Low GND +5 V Encoder Phase A Phase B Tx Rx Boot In

805 800 801 362

CPSK CPS16 CPS8 CPS9 CPS3 CPS10 CPS3 CPS29 CPS29 CPS20 CPS27 CPS25 CPS26 CPS7 CPS18 CPS18 CPS18 CPS2 T8 CPS33 T7 T11 CPS33 CPS14 CPS14 CPS34

367 901 900 103A 280 578 577 723 724 725

25 26 27 28 29 30 31 32 33 34 35

No. of connector pin 2 2 2 2 4 2 3 2 3 4 2 2 2 2 2 3 4 5 .

2

Functions assigned

MO20 - MO20S

3 2 1 2

Key-in Platform"Up" sensor SW10 - Active input B+ (only MO20S) Platform"Down" sensor SW11 - Active input B+ (only MO20S) Closed side gate sensor SW4 - Active input B+ (only MO20S) Belly Switch enabling push button - Emergency reverse - Active input (B+) Operator on board sensor SW12 - Active input B+ Tiller enabling sensor (Tiller Sensor) -High active input (B+) Backing Forward push button - Active input B+ Backing Reverse push button - Active input B+ "EPAS" safety input - steering board Platform >200mm sensor SW9 - Active input B+ (only MO20S) Platform >1200mm sensor SW6 - Active input B+ (only MO20S) Platform completely lifted sensor "SW7" - Active input B+ Electromagnetic brake control output Output for fork lowering solenoid valve "EV2" supply (only MO20S) Output for board lifting and lowering solenoid valve "EV3" supply (only MO20S) Output for fork lifting solenoid valve "EV4" supply (only MO20S) Main contactor coil control output Backup Alarm Opt. valve EV6 output Horn Backup Alarm Opt. valve EV5 output Positive pole output (B+) for proportional valve "EV1" (EV1 ON-OFF) supply Positive pole output (B1-) for proportional valve "EV1" (EV1 ON-OFF) supply Themal switch on the power cables

CPS6

1

Signal deriving from the drive motor thermal switch

CPS20 CPS20 CPS4 CPS4 CPS4 CPS4 CPS31 CPS31 CPS31

1 2 4 1 2 3

. .

Negative pole of drive motor encoder supply Positive pole of drive motor encoder supply

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SERVICE

DIAGNOSTICS

DIA GNOSTICS DIAGNOSTICS 1.00

ALARMS OF “COMBI”CONTROL............................................................................................2

2.00

ALARMS OF “EPAS” CONTROL..............................................................................................................3

3.00

ALARMS OF “TILLER” CONTROL ............................................................................................................... . 3

4.00

ALARMS OF “DDI” CONTROL................................................................................................................4

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DIAGNOSTICS

1.00

ALARMS OF “COMBI” CONTROL MOD. ALL MODELS

The alarms stopping the truck are displayed on “DDI” with a numerical alarm code preceded by two letters identifying the alarm module and the LED becomes red.

“Co” followed by the alarm code corresponds to “COMBI”control.

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SERVICE

DIAGNOSTICS LIST OF THE ALARM CONCERNING THE "COMBI" CONTROL MOD. ALL MODELS

WHEN IS THE TEST CARRIED OUT? CODE

DESCRIPTION start/travelling

Co 8976 Co 9009 Co 9010 Co 9011 Co 9012 Co 9013 Co 9014 Co 9015 Co 9016 Co 9017

Too high drive motor current Motor phase U short-circuited with battery negative pole Motor phase V short-circuited with battery negative pole Motor phase W short-circuited with battery negative pole Open motor phase U Open motor phase V Open motor phase W Motor phase U short-circuited with battery positive pole Motor phase V short-circuited with battery positive pole Motor phase W short-circuited with battery positive pole

Start Start Start

WHERE IS THE PROBLEM? inside outside AC Combi

TRUCK BEHAVIOUR

EFFECTS ON THE ELECTRIC CIRCUIT

COMPONENT FAILURES

CHECKS - SOLUTIONS

outside outside outside

DISAB drive, ENABLED hydraulics DISAB drive, ENABLED hydraulics DISAB drive, ENABLED hydraulics

Phase U not connected to AC motor Phase V not connected to AC motor Phase W not connected to AC motor

AC Motor AC Motor AC Motor

Check the phase U connection Check the phase V connection Check the phase W connection

AC Motor

Check all the outputs of the power connections; if there are no errors, there might be an internal error in Combi logic or in the power stage

Start, travelling

inside,outside

DISAB drive, ENABLED hydraulics

Jumper on the power outputs shortcircuited with other outputs or with positive or negative battery pole; the main contactor enables immediately

Short-circuited pump motor

Start, travelling

inside

ENABLED drive, DISAB hydraulics

The pump motor output on the Combi is connected to the battery positive pole

None

Check if there is a short-circuit between the battery positive pole and the pump motor output on the Combi

Co 9089

Pump motor connection enabled

Start, travelling

inside,outside

ENABLED drive, DISAB hydraulics

The pump motor output on the Combi is not connected. The pump motor is not connected to the battery negative pole

Pump motor

Check the pump motor and the connection of the pump motor

Co 9090

Current on pump motor higher than "maximum pump current"

Start, travelling

inside,outside

ENABLED drive, DISAB hydraulics

The current on the pump motor is higher than the maximum current set by means of parameter:"maximum pump current"

Co 12816

Battery voltage higher than 36V

Start, travelling

inside,outside

DISAB drive, ENABLED hydraulics

Co 12832

Battery voltage higher than 16V

Start, travelling

inside,outside

DISAB drive, ENABLED hydraulics

Co 12848

Damaged electrolytic condensers (one or more)

Co 9024

Short-circuited jumper on the power outputs (U,W,V or P)

Co 9025 Co 9026 Co 9027

Motor phase U short-circuited with phase V Motor phase V short-circuited with phase W Motor phase W short-circuited with phase U

Co 9088

Pump motor

The Combi detects a too high battery voltage The Combi detects a too low battery voltage

Battery Battery

Check the pump motor and the connection of the pump motor; check the value of the pump parameters, press the lowering push button to delete the error message.

Check the battery voltage; if it is OK, there might be an internal error in Combi logic Check the battery voltage; if it is OK, there might be an internal error in Combi logic

inside,outside

Co 16912

Too high temperature of the power stage

Start, travelling

inside,outside

Co 16928

Too low temperature of the power stage

Start, travelling

inside,outside

DISAB drive, ENABLED hydraulics

The Combi detects a temperature of the power stage equal to or higher than the temperature set through parameter "Twarning" + 25 degrees

None

Check the temperature of the power stage; if it is normal, there might be an internal error in Combi logic

None

Check the temperature of the power stage; if it is normal, there might be an internal error in Combi logic

Co 16944

Temperature of the power stage near the maximum value

Start, travelling

inside,outside

REDUCED drive, DISAB. hydraulics

The Combi detects a temperature of the power stage between the temperature set through parameter "Twarning" and the same temperature plus 25 degrees

Co 17168

Too high temperature of the drive motor

Start, travelling

inside,outside

REDUCED drive, DISAB. hydraulics

The Combi detects an AC motor temperature equal to or higher than 150°

AC Motor

Check the AC motor, the motor temperature and the measurement unit connection; if everything is OK, there might be an internal error in Combi logic

Co 17169

Temperature of the drive motor near the maximum temperature allowed

Start, travelling

inside,outside

ENABLED drive, ENABLED hydraulics

The AC Combi detects a temperaure of the AC Motor between 105° and 150°; reduced drive speed

AC Motor

Check the AC motor, the motor temperature and the measurement unit connection; if everything is OK, there might be an internal error in Combi logic

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SERVICE

DIAGNOSTICS LIST OF THE ALARM CONCERNING THE "COMBI" CONTROL MOD. ALL MODELS

CODE

DESCRIPTION

WHEN IS THE TEST CARRIED OUT? start/travelling

WHERE IS THE PROBLEM? inside outside AC Combi

EFFECTS ON THE ELECTRIC CIRCUIT

Main contactor

Tiller

Co 20756

Overvoltage when starting

Start, travelling

inside, outside

DISAB. Drive, DISABLED Hydraulics

When starting the voltage (pin1 of K1) is too high (higher than 36V)

Co 21376

Belly switch pressed when starting

Start, travelling

inside, outside

DISAB. Drive, ENABLED Hydraulics

The Combi detects the belly switch status (ON,OFF), but the status is not confirmed through communication CANopen.

Co 21378

Incorrect start. Throttle pressed without tiller presence

Co 21379

Inconsistency between the tiller sensor presence and what indicated on tiller board through can bus

Co 21392

Throttle failure

Start, travelling

inside, outside

COMPONENT FAILURES

TRUCK BEHAVIOUR

DISAB. Drive, DISABLED Hydraulics

The Combi does not detect the tiller thorugh CANopen.

Start, travelling

inside, outside

DISAB. Drive, ENABLED Hydraulics

The Combi detects the status of the tiller switch (ON,OFF), but the status is not confirmed thorugh comminication CANopen.

Travelling

outside

DISAB. Drive, ENABLED Hydraulics

The tiller is in vertical position with throttle pressed.

CHECKS - SOLUTIONS

Check the pin1 of the main contactor connection; check the connection of the main contactor; if everything is OK, there might be an internal error in Combi logic Check the Tiller, check the connections on DIGIN4,CANH, CANL (pins 5,27,28 of T1 on Combi), check the communication CANopen with the Combi; if everything is OK, there might be an internal error on Combi logic

Tiller

Check the tiller, check the connections CANH, CANL (pins 27,28 of T1 on Combi), check the communication CANopen with the Combi; if everything is OK, there might be an internal error on Combi logic

Tiller

Check the tiller, check the connections DIGIN6,CANH, CANL (pins 7,27,28 of K1 on Combi), check the communication CANopen with the Combi; if everything is OK, there might be an internal error on Combi logic

Tiller

Release the throttle (put in neutral position)

Check the connection of the proprtional solenoid The Combi volatge for the proprtional Proportional solenoid valves and the connections on pins 22,23; if valve output (pin 22 of T1 on Combi), but valve everything is OK, there might be an internal error on 23 of K1 on Combi remains zero Combi logic The Combi detects the voltage on pin 23 Check if there is a short circuit between Ubat+ and pin of T1, when the voltage is not set for the 22 of k1 proportional solenoid valve output on the None proprtional valve output (pin 22 of K1 on Combi Combi) The Combi detects a voltage too high on Check if there are a short circuit between Ubat+ and EV2 pin 15 of T1 EV2 output (pin 15 of K1 on Combi) Valve EV2 is not connected on Combi Check the connection of valve 2 EM; if everything is EV2 output (pin 15 of T1) to the battery OK there might be an internal error on Combi logic negative pole

Co 21409

Proportional valve enabled

Start, travelling

inside, outside

ENABLED Drive, DISAB.Hydraulics

Co 21410

Short-circuited proportional valve

Start, travelling

inside

ENABLED Drive, DISAB.Hydraulics

Co 21521

Valve EV2 short-circuited with the battery positive pole

Start, travelling

inside, outside

ENABLED Drive, DISAB.Hydraulics

Co 21522

Valve EV2 enabled

Start, travelling

inside, outside

ENABLED Drive, DISAB.Hydraulics

Co 21523

Valve EV2 short-circuited with the battery negative pole

Start, travelling

inside

ENABLED Drive, DISAB.Hydraulics

Co 21524

Valve EV3 short-circuited with the battery positive pole

Start, travelling

inside, outside

ENABLED Drive, DISAB.Hydraulics

Co 21525

Valve EV3 enabled

Start, travelling

inside, outside

ENABLED Drive, DISAB.Hydraulics

Co 21526

Valve EV3 short-circuited with the battery negative pole

Start, travelling

inside

ENABLED Drive, DISAB.Hydraulics

The Combi output (pin 16 of T1) connected to the battery negative pole

None

Co 21527

Valve EV4 short-circuited with the battery positive pole

Start, travelling

inside, outside

ENABLED Drive, DISAB.Hydraulics

The Combi detects a too high voltage on pin 17 of T1

EV4

The Combi output (pin 15 of T1) is connected to the battery negative pole The Combi detects a too high voltage on pin 16 of T1 Valve EV3 is not connected on the Combi output (pin 16 of K1) to the battery negative pole

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None

Check if there is a short circuit between EV2 output (pin 15 of K1 on Combi) and the battery negative pole

EV3

Check if there is a short circuit between Ubat+ and EV3 output (pin 16 of T1 on Combi)

EV3

Check the connection of valve EV3; if everything is OK, there might be an internal error on Combi logic Check if there is a short circuit between the EV3 output (pin 16 of T1 on Combi) and the battery negative pole Check if there is a short circuit between Ubat+ and the EV4 output (pin 17 of T1 on Combi)

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SERVICE

DIAGNOSTICS LIST OF THE ALARM CONCERNING THE "COMBI" CONTROL MOD. ALL MODELS

CODE

DESCRIPTION

WHEN IS THE TEST CARRIED OUT? start/travelling

WHERE IS THE PROBLEM? inside outside AC Combi

TRUCK BEHAVIOUR

EFFECTS ON THE ELECTRIC CIRCUIT

COMPONENT FAILURES

CHECKS - SOLUTIONS

Co 21528

Valve EV4 enabled

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

Valve EV4 is not connected on the Combi output (pin 17 of T1) to battery negative pole

EV4

Check the connection of valve EV4; if everything is OK, there might be an internal error on Combi logic

Co 21529

Valve EV4 short-circuited with the battery negative pole

Start, travelling

inside

ENABLED drive, DISAB. Hydraulics

The Combi output (pin 17 of T1) is connected to the battery negative pole

None

Check, if there is a short circuit between EV4 output (pin 17 of T1 on Combi) and the battery negative pole

Co 21530

Forward/reverse buzzer short-circuited with the battery positive pole

Start, travelling

inside, outside

DISABLED drive, DISAB. Hydraulics

The Combi detects a too high voltage on pin 19 of T1

Buzzer

Check, if there is a short ciruit between the battery positive pole and the back alarm output (pin 19 of T1 on Combi)

Co 21531

Backup alarm enabled

Start, travelling

inside, outside

DISABLED drive, DISAB. Hydraulics

The buzzer is not connected on the Combi output (pin 19 of T1) to the battery negative pole

Buzzer

Check the buzzer connection; if everything is OK, thre might be an internal error on Combi logic

Co 21532

Backup alarm short-circuited with the battery negative pole

Start, travelling

inside

DISABLED drive, DISAB. Hydraulics

The Combi output (pin 19 of T1) is connected to the battery negative pole

None

Co 21533

Horn short-circuited with the battery positive pole

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

The Combi detects a too high voltage on pin 20 of T1

Horn

Co 21534

Horn enabled

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

The horn is not connected on Combi output (pin 20 of T1) to the battery negative pole

Horn

Co 21535

Horn short-circuited with the battery negative pole

Start, travelling

inside

ENABLED drive, DISAB. Hydraulics

The Combi output (pin 20 of T1) is connected to the battery negative pole

None

Co 21536

Flash beacon short-circuited with the battery positive pole

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

The Combi detects a too high voltage on pin 21 of T1

Flash beacon

Co 21537

Flash beacon enabled

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

The flash beacon is not connected on Combi output (pin 21 di T1) to the battery negative pole

Flash beacon

Check the flash beacon connection; if everything is OK there might be an internal error on Combi logic

Co 21538

Flash beacon short-circuited with the battery negative pole

Start, travelling

inside

ENABLED drive, DISAB. Hydraulics

The Combi output (pin 21 of T1) is connected to the battery negative pole

None

Check if there is a short circuit between the flash beacon output (pin 21 of T1 on Combi) and the battery negative pole

Co 21539

Failure of digital output driver

Start, travelling

inside

ENABLED drive, DISAB. Hydraulics

Non-operating driver of the digital output on Combi logic

None

Internal error on Combi logic

Co 21540

Valve EV5 short-circuited with the battery positive pole

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

The Combi detects a too high voltage on pin 19 of T1

EV5

Check if there are a short circuit between the battery positive pole and valve EV5 output (pin 19 of T1 on Combi)

Co 21541

Valve EV5 enabled

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

Valve EV5 is not connected on Combi output (pin 19 of T1) to the battery negative pole

EV5

Check valve EV5 connection; if everything is OK, there might be an internal error on Combi logic

Co 21542

Valve EV5 short-circuited with the battery negative pole

Start, travelling

inside

ENABLED drive, DISAB. Hydraulics

The Combi output (pin 19 of T1) is connected to the battery negative pole

None

Co 21543

Valve EV6 short-circuited with the battery positive pole

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

Co 21544

Valve EV6 enabled

Start, travelling

inside, outside

ENABLED drive, DISAB. Hydraulics

Co 21545

Valve EV6 short-circuited with the battery negative pole

Start, travelling

inside

ENABLED drive, DISAB. Hydraulics

UPDATE

The Combi detects a too high voltage on pin 21 of K1 Valve 6 EM is not connected on Combi output (pin 21 of K1) to the battery negative pole The Combi output (pin 21 of T1) is connected to battery negative pole

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2

3

4

5 6

EV6

Check if there is a short circuit between the back alarm output (pin 19 of T1 on Combi) and the battery negative pole Check if there is a short circuit between the battery positive pole and the horn output (pin 20 of T1 on Combi) Check the horn connection; if everything is OK, there might be an internal error on Combi logic Check, if there is a short circuit between the horn output (pin 20 of T1 on Combi) and the battery negative pole Check if there is a short circuit between the battery positive pole and the flash beacon output (pin 21 of T1 on Combi)

Check if there is a short circuit between valve EV5 output (pin 19 of K1 on Combi) and battery negative pole Check, if there is a short circuit between Ubat+ and valve EV6 output (pin 21 of K1 on Combi)

EV6

Check the valve EV6 connection; if everything is OK, there might be an internal error on Combi logic

None

Check if there is a short circuit between EV6 output (pin 21 of T1 on Combi) and battery negative pole

March 2006 Part No.: 524237829 Page: 2c

SERVICE

DIAGNOSTICS

LIST OF THE ALARM CONCERNING THE "COMBI" CONTROL MOD. ALL MODELS

CODE

DESCRIPTION

WHEN IS THE TEST CARRIED OUT? start/travelling

WHERE IS THE PROBLEM? inside outside AC Combi

TRUCK BEHAVIOUR

EFFECTS ON THE ELECTRIC CIRCUIT

Main contactor switch on Combi output (pin 18 of T1) set to ON, but the contact does not activate The Combi detects a too high value on pin 18 of T1 The main contactor is not connected on the Combi output (pin 18 of T1) to the battery negative pole

Co 21568

The main contactor is not enabled

Start, travelling

inside, outside

DISAB. drive, DISABLED hydraulics

Co 21569

The main contactor is short-circuited with the battery positive pole

Start, travelling

inside, outside

DISAB. drive, DISABLED hydraulics

Co 21570

The main contactor is enabled, the main contactor does not activate

Start, travelling

inside, outside

DISAB. drive, DISABLED hydraulics

Co 21571

The main contactor is short-circuited with the battery negative pole

Start, travelling

inside

DISAB. drive, DISABLED hydraulics

The Combi output (pin 18 of T1) is connected to the battery negative pole

Co 21572 Co 25360

Main contactor with stuck power contacts Error in storage containing the parameters (EEPROM)

Co 28945

The electromagnetic brake is short-circuited with the battery positive pole

Start, travelling

inside, outside

DISAB. drive, DISABLED hydraulics

The Combi detects a too high voltage on pin 14 of T1

Co 28946

Electromagnetic brake enabled

Start, travelling

inside, outside

DISAB. drive, DISABLED hydraulics

Brake EM is not connected to Combi output (pin 14 of T1) to Ubat-

Co 28947

The electromagnetic brake is short-circuited with the battery negative pole

Start, travelling

inside

DISAB. drive, DISABLED hydraulics

The Combi output (pin 14 of T1) is connected to the battery negative pole

Co 29445

No signal from the encoder or encoder not connected

Travelling

inside, outside

DISAB. drive, DISABLED hydraulics

No encoder signal on pin 31 and/or pin 32 of T1, but AC motor must rotate; the main contactor opens immediately

DISAB. drive, DISABLED hydraulics

No communication CANopen between Tiller and Combi

Co 33056

Interrupted communication via Can bus with tiller board

Travelling

inside, outside

COMPONENT FAILURES

CHECKS - SOLUTIONS

Main contactor

Check the main contactor connection

Main contactor

Check if there is a short circuit between Ubat+ and the contactor output (pin 18 of K1 on Combi)

Main contactor

Check the main contactor connection; if everything is OK, there might be an internal error on Combi logic

None

Check if there is a short circuit between the main contactor output (pin 18 of T1 on Combi) and the battery negative pole

Check if there is a short circuit between the battery positive pole and the electromagnetic brake output (pin 14 of T1 on Combi) Check the electromagnetic brake connection; if Electromagnetic everything is OK there might be an internal error on brake Combi logic Check if there is a short circuit between the None electromagnetic brake (pin 14 of T1 on Combi) and battery negative pole Check the encoder connection: pin 29 (GND), pin 30 (+15V), pin 31 (ENC A), pin 32 (ENC B); check the AC motor connection; check the AC motor, the pulses Encoder, AC Motor of the encoder A and B;check if there is a short circuit between the power output and the battery terminals (+ o -); if everything is OK there might be an internal error on Electromagnetic brake

Tiller

Check the Tiller, check the connections on CANH, CANL (pins 27,28 of T1 on Combi), check the communication CANopen with Combi; if everything is OK there might be an internal error on Combi logic

EPAS

Check EPAS, check the connections on CANH, CANL (pins 27,28 of T1 on Combi), check the communication CANopen with Combi; if everything is OK there might be an internal error on Combi logic

Travelling

inside, outside

DISAB. drive, DISABLED hydraulics

No communication CANopen between EPAS and Combi

Low Epas safety digital output

Start, travelling

inside, outside

DISAB. drive, DISABLED hydraulics

Combi detects a low voltage on pin 10 of K1

EPAS

The truck maintenance hours have been reached

Start, travelling

inside

REDUCED drive, ENABLED hydraulics

None

None

Co 33057

Interrupted communication via Can bus with Epas

Co 36864 Co 65281

UPDATE

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2

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Check EPAS, check the connections between pin 10 of T1 and EPAS; if everything is OK there might be an internal error on Combi logic Update the Service Time by means of interface CANopen

March 2006 Part No.: 524237829

Page: 2d

SERVICE 2.00

DIAGNOSTICS

ALARM OF “EPAS” CONTROL MOD. ALL MODELS

The alarms stopping the trucks are displayed on “DDI” with a numerical alarm code preceded by two letters identifying the module in alarm, moreover the LED becomes red.

“Ep” followed by the alarm code corresponds to steering motor control “EPAS”.

CODE

DESCRIPTION

Ep 21588 Co 36864

PROBLEM

POSSIBLE CAUSES

TEST PROCEDURE Check if +24V is present on motor terminal B+. If not present, check the fuse and the power connection. If the power supply is OK, there might be a motor failure - replace the motor

The truck stops

No power supply, error on power MOSFET, fuse burnt-out

Straight wheel inductive sensor

The truck stops

Check. If the signal of the inductive sensor changes Electric connection not installed correctly status (from 0 to +24V or vice versa). When the wheel (too small or too large distance between passes the neutral position. Check the assembly the sensor and the metal surface) distance and the connections.

Ep 65281 Co 36864

Torsion sensor

The truck stops

Ep 65282 Co 36864

Mechanical connection

The truck stops

Power stage, fuse

Ep 29472 Co 36864

3.00

Damaged sensor, features of the sensor not specified, bad electric connection on one of the six sensors Damaged torsion bar, damaged reduction gear, no mechanical connection, bad electric connection on sensor P1

Check the connections and that there are no short circuits on the sensor connectors. If everything is OK, replace the sensor.

Check the transmission between the tiller and the EPAS motor, check the torsion bar, check the connection of the torsion sensor on pin 5

ALARMS OF THE “TILLER” CONTROL MOD. ALL MODELS

The alarm stopping the truck are displayed on “DDI” with a numeric alarm code preceded by two letters identifying the modul in alarm. Moreover the LED becomes red.

“Ti” followed by the alarm code corresponds to the tiller box board “TILLER”.

CODE

DESCRIPTION

PROBLEM

Ti 21552

Start the truck input control procedure.

Ti 29456

Error of the throttle sensor

Ti 29457 Ti 33072 Ti 33073 Ti 21024

Error of the proportional switches The Combi is not connected or does not reply The Epas is not connected or does not reply The permanent storage does not work

UPDATE

POSSIBLE CAUSES

TEST PROCEDURE

Turn off all the switches and put the throttle in neutral One or more tiller inputs are not set to 0. position. Do not press the porportional switches. If an The truck in Problem caused by an operator or by a alarm is still activated, check the outputs and replace standby malfunction of an input (or more inputs). them in case they are broken or if they do not operate.

Repeat the procedure for the acquisition of the Procedure for the acquisition of the potentiometer. Try to move the throttle. If the error Proportional potensiometer not carried out, or nonappears again, the neutral sensor or the throttle switches disabled operating throttle sensor or neutral sensor do not operate correctly. Check if the neutral switch. switch changes its status correctly. If the sensor does not operate correctly, replace it.

One or both the proportional switches do Replace the damaged switch. not operate correctly.

Bad operation of Faulty CAN connection or malfunction Check the CAN connection between the Combi and Combi control of Combi control Tiller, check the Combi.

Bad operation of Interrupted CAN connection or Check the CAN connection between the Epas and Epas control malfunction of Epas control the Tiller, check the Epas.

The eeprom does The truck does not work Replace the tiller board not communicate

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SERVICE

DIAGNOSTICS

4.00 ALARMS OF THE “DDI” CONTROL MOD. TUTTI I MODELLI

The alarms stopping the truck are displayed on the “DDI” with a numerical alarm code preceded by two letters identifying the module in alarm.

Moreover, the LED becomes red.

“DD” followed by the alarm code corresponds to display control “DDI”.

CODE

DDI 21008

DDI 21024

DESCRIPTION

PROBLEM

POSSIBLE CAUSES

TEST PROCEDURE

Carry out the procedure to transfer the working hours The working hours stored in The COMBI control The alarm disappears automatically after from the DDI to the COMBI (see paragraph 7 DDI do not correspond to the has been replaced 10 minutes from the machine start "TRANSFER OFTHE WORKING HOURS" on page working hours stored in the 57, electric system section) The permanent storage does The eeprom does The truck does not work Replace the DDI display not work not communicate

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SERVICE

FRAME MECHANICS

1.00 MECHANICAL COMPONENTS OF THE REAR FRAME MOD. MO20 - MO20LF - MO20F...............2 1.01 MECHANICAL COMPONENTS OF THE REAR FRAME MOD. MO20S - MO20SLF............................3 2.00 REPLACEMENT OF THE DRIVE WHEEL MOD. ALL MODELS..........................................................4 2.01 REPLACEMENT OF THE STABILIZING WHEEL UNIT MOD. ALL MODELS........................................5 2.02 REPLACEMENT OF THE STABILIZING WHEEL MOD. ALL MODELS..........................................6 3.00 COMPONENTS OF THE STEERING MOTOR MOD. ALL MODELS ..................................................7 3.01 REMOVAL OF THE STEERING MOTOR MOD. ALL MODELS............................................................8 4.00 COMPONENTS OF THE DRIVE WHEEL MOD. ALL MODELS..............................................................9 4.01 REMOVAL OF THE DRIVE MOTOR MOD. ALL MODELS......................................................................10 4.02 MOTOR ASSEMBLY............................................................................................................................11 4.03 REPLACEMENT OF THE ENCODER BEARING MOD. ALL MODELS..........................................12 5.00 REMOVAL OF THE HYDRAULIC POWER UNIT MOD. MO20 - MO20LF - MO20F..........................14 5.01 PUMP REPLACEMENT MOD. MO20 - MO20LF - MO20F...................................................................16 5.02 REMOVAL AND REPLACEMENT OF THE PUMP MOTOR MOD. MO20 - MO20LF - MO20F .......17 5.03 REPLACEMENT OF THE PUMP MOTOR BRUSHES MOD. MO20 - MO20LF - MO20F.................18 5.04 DRIVING TORQUE OF THE HYDRAULIC POWER UNIT NUTS AND BOLTS MOD. ALL MODELS....19 6.00 REMOVAL OF THE HYDRAULIC POWER UNIT MOD. MO20S - MO20SLF.....................................20 6.01 REMOVAL OF THE PUMP BODY MOD. MO20S - MO20SLF............................................................22 6.02 7.00 7.01 7.02

REMOVAL AND REPLACEMENT OF THE PUMP MOTOR MOD. MO20S - MO20SLF......................23 COMPONENTS OF THE STEERING CARDANIC JOINT MOD. ALL MODELS................................24 REFERENCE TABLE FOR THE COMPONENTS OF THE STEERING CARDANIC JOINT.............24 REMOVAL OF THE STEERING CARDANIC JOINT MOD. ALL MODELS...............................................25

7.03 CENTERING OF THE WHEEL WITH THE STEERING TILLER........................................................26 8.00 COMPONENTS OF THE STEERING TILLER MOD. ALL MODELS...................................................28 8.01 REFERENCE TABLE OF THE COMPONENTS FOR THE STEERING TILLER MOD. ALL MODELS..29 8.02 REPLACEMENT OF THE TILLER GAS SPRING MOD. ALL MODELS..............................................30 8.03 REPLACEMENT OF THE TILLER MOD. ALL MODELS........................................................................31 8.04 REPLACEMENT OF THE STEERING TILLER TORSION BAR MOD. ALL MODELS.......................32 8.05 REPLACEMENT OF THE TILLER BASE BEARINGS MOD. ALL MODELS.......................................35 9.00 REPLACEMENT OF THE PLATFORM BEARINGS MOD. ALL MODELS...........................................36 10.00 CHAIN GREASING MOD. MO20LF - MO20SLF.................................................................................38 10.01 CHAIN ELONGATION.............................................................................................................................38 10.02 CHAIN MEASURE....................................................................................................................................38 10.03 CHECK OF LINKS, PINS AND CHAIN TIGHTENERS...............................................................................38 11.00 REMOVAL AND REPLACEMENT OF THE LIFTING CHAINS MOD. MO20S - MO20SLF.......................39 11.01 ADJUSTMENT OF THE LIFTING CHAINS...........................................................................................40 11.02 REMOVAL AND REPLACEMENT PF THE CHAIN PULLEYS...................................................................41 11.03 FORK REMOVAL FOR BEARING REPLACEMENT MOD. MO20S - MO20SLF................................42

UPDATE

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SERVICE

FRAME MECHANICS 1.00

MECHANICAL COMPONENTS OF THE REAR FRAME MOD. MO20 - MO20LF - MO20F

8

7

6

4

5

3

1 Reference 1 2 3 4 5 6 7 8

Page: 2

2 Description of the component Drive wheel unit Pivoting wheel unit Steering motor unit Drive motor unit Hydraulic power unit Pump motor unit Steering cardanic joint unit Tiller unit

Part No.: 524237829 March 2006

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SERVICE 1.01

FRAME MECHANICS

MECHANICAL COMPONENTS OF THE REAR FRAME MOD. MO20S - MO20SLF

9

8

6 5

7

4

3

1 Riferimento 1 2 3 4 5 6 7 8 9

UPDATE

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2 Descrizione Componente Drive wheel unit Pivoting wheel unit Steering motor unit Drive motor unit Hydraulic power unit Pump motor unit Steering cardanic joint unit Tiller unit Platform unit

5 6 March 2006 Part No.: 524237829

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SERVICE

FRAME MECHANICS 2.00

REPLACEMENT OF THE DRIVE WHEEL MOD. ALL MODELS

Necessary tools

large slotted screwdriver

Special tools

22 mm socket wrench

ratchet with extension

hanging ropes with two hooks

bridge crane

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Step 2 BRIDGE CRANE - HANGING ROPE WITH TWO HOOKS Hook the hooks of the hanging ropes to the holes prearranged for the lifting located on the chassis and the hanging rope ring to the bridge crane hook. Enable the bridge crane and lift about 200 mm (fig. 1).

Step 3 22 mm SOCKET WRENCH - RATCHET WITH EXTENSION From the left side of the chassis, through the proper hole, loosen and remove the fastening screws securing the wheel to the reduction gear (ref. A-C fig. 2-3), remove the washers (ref.B fig.3), remove the wheel and replace it (ref. D fig. 4).

Fig. 1

A

B

Fig. 2

Reassemble the new wheel by carrying out the procedure in the reverse order.

Tighten the wheel fastening screws with 200 Nm driving torque. Use Loctite of average texture.

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D

Fig. 3

UPDATE

SERVICE 2.01

FRAME MECHANICS

REPLACEMENT OF THE STABILIZING WHEELS MOD. ALL MODELS

Necessary tools

large slotted screwdriver

15 mm socket wrench

ratchet with extension

No. 2 24 mm open ended spanner

Special tools

Fig. 1 bridge crane

hanging ropes with two hooks

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

A

Fig. 2

C

Fig. 3

Step 1 LARGE SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Step 2 BRIDGE CRANE - HANGING ROPE WITH TWO HOOKS Hook the hooks of the hanging ropes to the holes prearranged for the lifting located on the chassis and the hanging rope ring to the bridge crane hook. Enable the bridge crane and lift about 200 mm (fig. 1).

Step 3 15 mm SOCKET WRENCH WITH EXTENSION - RATCHET Loosen the fastening screws of the frame stabilizing wheel (ref. A-B fig.

2-3), remove the unit (ref. C fig. 3) and replace it.

Reassemble the new unit by carrying out the procedure in the reverse order.

Tighten the wheel fastening screws with 40 Nm driving torque.

Use Loctite of average texture.

UPDATE

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B

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SERVICE

FRAME MECHANICS 2.02

REPLACEMENT OF THE STABILIZING WHEEL MOD. ALL MODELS

Special tools

bridge crane

Utensili necessari

hanging rope with two hooks

No. 2 24mm open ended spanners

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Fig. 1

A

Step 1 LARGE SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Step 2 BRIDGE CRANE - HANGING ROPE WITH TWO HOOKS Hook the hanging rope hooks to the holes prearranged for the lifting of the chassis and the hanging rope ring to the bridge crane. Enable the bridge crane and lift about 500 mm (fig. 1).

Fig. 2

C

Step 3 No. 2 24 mm OPEN ENDED SPANNERS By using a spanner keep the wheel hinge pin blocked (ref. A fig. 2) and by using the other spanner loosen the check nut (ref. B fig. 2).

Extract the screw (ref. C fig. 3), remove the wheel (ref. D fig. 3) and replace it.

Reassemble the new wheel by carrying out the procedure in the reverse order

D Fig. 3

Tighten the wheel fastening screws with 40 Nm driving torque.

Use Loctite of average texture.

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B

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UPDATE

SERVICE 3.00

FRAME MECHANICS

COMPONENTS OF THE STEERING MOTOR MODEL ALL MODELS

6 7

1 4

3

2

5 Reference 1 2 3 4 5 6 7

UPDATE

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Description of the component Complete steering motor Steering motor Reduction gear O-Ring Screws fastening motor/reduction gear Connector connecting the steering potentiometer Connector controlling the Combi control

2

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SERVICE

FRAME MECHANICS 3.01

REMOVAL OF THE STEERING MOTOR MOD. ALL MODELS

Necessary tools

A large slotted screwdriver

10-13 mm open ended spanner

10 mm socket wrench

ratchet with extension

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SCREWDRIVER Loosen and remove the screws fastening the motor compartment bonnet.

Remove the bonnet.

Step 2 10 mm SOCKET WRENCH - RATCHET Remove the caps from the steering motor terminals (ref. A fig. 1). By using the wrench loosen and remove the fastening nuts of the steering motor supply cables (ref. A fig. 1), extract the cables from the terminals.

By using the same spanner loosen and remove the fastening screw securing the pinion to the steering motor(ref. B fig. 3). Remove the washer and remove the pinion by extracting it from the motor shaft.

Fig. 1

C

B

Fig. 2

Step 3 13 mm OPEN ENDED SPANNER Loosen and remove the fastening screws securing the steering motor to the support (ref. C fig. 3). Remove the complete motor by extracting it from the support (fig. 4) and replace it.

Reassemble the new motor by carrying out the procedure in the reverse order After the assembly carry out the procedure for the steering acquisition (see “ACQUISITION OF THE ST EERING POTENTIOMETER SENSOR” on page 64 in the“ELECTRIC SYSTEM” section.

Fig. 3

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SERVICE 4.00

FRAME MECHANICS

COMPONENTS OF THE DRIVE WHEEL MOD. ALL MODELS

11

9

8

3

10

1

7 4 5

6

2

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

UPDATE

0 1

Description of the component 4.5Kw AC complete drive motor External stator Internal rotor Upper flange Lower flange Encoder bearing Screw for the assembly of the upper and lower flange with the stator Terminal block Grommets Motor shaft snap ring Lining pinion snap ring

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SERVICE

FRAME MECHANICS 4.01

REMOVAL OF THE DRIVE WHEEL MOD. ALL MODELS

Necessary tools

large slotted screwdriver

13 - 17 mm open ended spanner

10 - 13 mm socket wrench

ratchet with extension

5 - 6 mm Allen wrench

scissors

Fig. 1

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen and remove the fastening screws of the motor bonnet. Remove the bonnet to reach the motor compartment (fig. 1).

Fig. 2 Step 2 Remove the steering motor (see “REMOVAL OF THE STEERING MOTOR” on page 10 of this section) (fig. 2).

Step 3 Remove the electromagnetic brake (see “REPLACEMENT OF THE ELCTROMAGNETIC BRAKE LINING” on page 4, steps 1-2 section “BRAKING SYSTEM) (fig. 3).

Fig. 3

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SERVICE

FRAME MECHANICS

Step 4 13 mm OPEN ENDED SPANNER Remove the protection cover from the motor terminals, loosen and remove the nuts fastening the drive motor supply cables by means of the spanner (ref.A fig.3). Mark the cable position for the reassembly.

A

During the reassembly check that the nuts behind the cable terminals are not loosened.

Remove the supply cables and disconnect the connectors of the encoder cables and of the temperature sensor.

Step 5 6 mm ARTICULATED ALLEN WRENCH Loosen and remove the fastening screws securing the drive motor to the supporting plate (ref. B fig. 4).

Lift the motor up to the removal of the keyed pin from the reduction gear (fig.5).

Remove it from the chassis and position it on a workbench. Replace or disassemble it to replace the various components.

B

Fig. 4

Reassemble the new motor by carrying out the procedure in the reverse order.

Fig. 5

4.02

MOTOR ASSEMBLY

Before assembling the motor on the reduction gear, lubricate the keyed shaft (ref.C fig.6) with special grease (“SHELL STAMINA GREASE RL 2” o “ALBIDA GREASE EP2”).

While assembling rotate carefully the crown wheel shaft or the electric motor transmission shaft (according to the kind of assembly), till the control shaft is inserted in the pin splined hub connetion.

Possible damages may cause louder noises during the operation and a early failure of the toothed shaft.

C

Fig. 6

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SERVICE

FRAME MECHANICS 4.03

REPLACEMENT OF THE ENCODER BEARING MODEL ALL MODELS

Necessary tools

large external circlip pliers

rubber hammer

13mm open ended spanner

small slotted screwdriver

6mm Allen wrench

The motor encoder bearing is and intergral part of the motor upper flange. In case of encoder failure, it is necessary to replace the complete flange.

Procedure

A B

Before starting to work wear suitable safety clothes.

Fig. 1 Step 1 Remove the drive motor (see “REMOVAL OF THE DRIVE MOTOR” on page 13) and position it on a clean workbench in horizontal position.

C

Step 2 CIRCLIP PLIERS Remove the keeper (ref. A fig. 1). By using the pliers remove the two snap rings of the motor shaft (ref. B fig. 1) and extract the distance washer.

Step 3 RUBBER HAMMER Hit by means of a hammer the upper part of the motor shaft (ref.C fig.2) to remove the stator (fig.3) gently.

Step 4 17 mm OPEN ENDED SPANNER - SCREWDRIVER By using the open ended spanner loosen and remove the nuts from the stator pins (ref. D fig. 3). By means of the screwdriver loosen and remove the two fastening screws of the terminal block (ref.E fig. 3) and remove it from the stator case by means of a screwdriveri (fig.5).

Fig. 2

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D

Fig. 3

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SERVICE

FRAME MECHANICS

Step 5 6 mm ALLEN WRENCH - RUBBER HAMMER By using the wrench loosen and remove the four screws connecting the flanges to the stator (ref. F fig. 4). By using the rubber hammer, remove the lower flange (ref. G fig. 4) and the upper flange (ref. H fig. 4). Replace the upper flange complete with encoder bearing (fig. 5).

H

Reassemble the new flange complete with bearing by carrying out the procedure in the reverse order.

The upper and the lower flange are provided with a restrained joint for a correct connection with the stator (ref.M fig.6).

F

G

Fig. 4

M

After the assembly no adjustment is required.

Fig. 5

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SERVICE

FRAME MECHANICS 5.00

REMOVAL OF THE HYDRAULIC POWER UNIT MOD. MO20 - MO20LF - MO20F

Necessary tools

large slotted screwdriver

small cross-head screwdriver

13-17-19mm open ended spanner

oil proof gloves

8mm Allen wrench

9/16” male plug

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen and remove the fastening screws of the motor bonnet. Remove the bonnet.

Step 2 19 mm OPEN ENDED SPANNER - MALE PLUG By using the open ended spanner, loosen the fitting of the hose delivering oil to the cylinder (ref. A fig. 2). By means of the same key, put the male plug to the hose.

Fig. 1

A

Step 3 13 mm OPEN ENDED SPANNER, 8mm OPEN ENDED SPANNER Remove the plug from the motor terminals. By using the 13mm spanner loosen and remove the nuts fastening the pump motor supply cables (ref. B fig. 2). Remove the supply cables. By means of 8mm spanner loosen and remove the screw of the earthing cable (yellow-green cable).

B Fig. 2

When reassembling check that the nuts behind the cable terminals are not loosened.

C Step 4 SMALL CROSS-HEAD SCREWDRIVER Loosen the screw fastening the connector to the solenoid valve coils (ref.

C fig. 3). Remove the connectors.

Fig. 3

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SERVICE

FRAME MECHANICS

Step 5 17 mm OPEN ENDED SPANNER By using the spanner loosen and remove the fastening screws securing the power unit to the frame (ref. D fig. 4-5), remove the power unit and the distance washers (ref. E fig. 5), which must be used again to replace the new power unit. Replace the power unit or disassemble it to replace its components.

D

Reassemble the new power unit by carrying out the procedure in the reverse order.

After the assembly no adjustment is required.

Fig. 4

E

D Fig. 5

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SERVICE

FRAME MECHANICS 5.01

PUMP REPLACEMENT MOD. MO20 - MO20LF - MO20F

After removing the hydraulic unit, place it on a clean workbench.

Necessary tools

medium slotted screwdriver

5mm Allen wrench

oil proof gloves

Procedure

A

Before starting to work wear suitable safety clothes.

Fig. 1

Step 1 MEDIUM SLOTTED SCREWDRIVER By using the screwdriver loosen the fastening screw of the cable clamp securing the oil tank to the power unit (ref. A fig. 1) and extract the tank, by paying attention not to pour the oil.

Before reassembling the tank, replace the exhausted oil with the new one.

Step 2 5 mm ALLEN WRENCH Remove the filter and the suction pipe (ref. B fig. 2). By using the wrench loosen and remove the two bolts fastening the pump body to the power unit (ref. C fig. 2), remove the pump body and replace it.

Reassemble the new pump body by carrying out the procedure in the reverse order.

After the assembly no adjustment is required.

C B Fig. 2

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SERVICE 5.02

FRAME MECHANICS

REMOVAL AND REPLACEMENT OF THE PUMP MOTOR MOD. MO20 - MO20LF - MO20F Necessary special tools

Necessary tools

large slotted screwdriver

internal bearing puller

11-13mm open ended spanner

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Fig. 1

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Step 2 Remove the hydraulic power unit and place it on a clean workbench (see “REMOVAL OF THE HYDRAULIC POWER UNIT” on page 16).

Step 3 11mm OPEN ENDED SPANNER - PULLER Loosen and remove the two bolts fastening the motor to the flange (ref.B fig.3), remove the motor cover. Extract the external stator and then the internal rotor.

Remove the joint connecting the motor to the pump (ref.C fig. 3).

Remove the puller from the flange (ref.D fig.3). Replace the pump motor complete with bearings.

Fig. 2

B The joint connecting the motor and the pump must be used again and positioned correctly.

C

Install the new motor by carrying out the procedure in the reverse order.

D

After the assembly no adjustment is required.

Fig. 3

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SERVICE

FRAME MECHANICS 5.03

REPLACEMENT OF THE PUMP MOTOR BRUSHES MOD. ALL MODELS

Necessary tools

large slotted screwdriver

11mm open ended spanner

medium cross-head screwdriver

spring tightener

B

A

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Fig. 1

Step 2 11mm OPEN ENDED SPANNER Loosen and remove the two bolts fastening the motor to the flange (ref.A fig.1), lift the cover (ref.B fig.1) by holding the motor on the flange and making the brush holder see (fig.2).

Step 3 CROSS HEAD SCREWDRIVER - TIGHTENER FOR SPRING By using the screwdriver loosen and remove the screws fastening the brushes to the brush holder (ref.C fig.3) and using the spring tightener lift the spring pressing the brush on the rotor (ref.D fig.3), extract the brushes and replace them.

Fig. 2

D C

Install the new brushes by carrying out the procedure in the reverse order.

Fig. 3 After the assembly no adjustment is required.

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SERVICE 5.04

FRAME MECHANICS

DRIVING TORQUE OF THE HYDRAULIC POWER UNIT NUTS AND BOLTS MODELS ALL MODELS

After assembling the motor, respect the driving torque of the bolts and the nuts as shown in the figure below.

2

2 1

1 8

7

9

10 6

6

5 3

5 11

4 4

Ref. 1 2 3 4 5 6 7 8 9 10 11

UPDATE

Description of the component No. 2 M8 check nuts of the supply cables No. 3 M8 bolts fastening the motor to the power unit No. 4 M6 bolts fastening the tank to the power unit No. 2 M6 bolts fastening the pump body to the power unit RV1 relief valve body EV1 proportional solenoid valve body EV2 solenoid valve body for the fork lowering EV3 solenoid valve body for the outrigger lifting/lowering EV4 solenoid valve body for the fork lifting RV2 relief valve body No. 4 M3 bolts fastening the valve unit

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Driving torque 12 Nm 5 Nm 4 Nm 22 Nm 10 Nm 30 Nm 30 Nm 30 Nm 30 Nm 12 Nm 31 Nm

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SERVICE

FRAME MECHANICS 6.00

REMOVAL OF THE HYDRAULIC POWER UNIT MODELS MO20S - MO20SLF

Necessary tools

large slotted screwdriver

small cross-head screwdriver

13-19mm open ended spanner

8mm Allen wrench

Fig. 1

oil proof gloves

No.2 9/16” male plugs

A

Procedure

Fig. 2

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

B

Step 1 LARGE SLOTTED SCREW DRIVER Loosen and remove the fastening screws of the motor bonnet. Remove the bonnet.

Fig. 3

Step 2 19 mm OPEN ENDED SPANNER - MALE PLUGS By using the spanner loosen the fitting of the hoses delivering the oil (ref.

A fig. 2). By means of the same spanner put the plugs to the hoses to avid oil leakages.

C

Step 3 Fig. 4 SMALL CROSS-HEAD SCREWDRIVER Loosen the screws fastening the connectors to the solenoid valve coils (ref.B fig.3). Remove the connectors.

Step 4 13 mm OPEN ENDED SPANNER - 8mm OPEN ENDED SPANNER Remove the plugs from the motor terminals. By using the 13mm open ended spanner loosen and remove the screws fastening the pump motor supply cables (ref.C fig.4). Remove the supply cables.

By using the 8mm open ended spanner, loosen and remove the fastening screw of the earthing cable (yellow-green cable) During the reassembly check that the nuts located behind the cable terminals are not loosened.

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Step 5 17 mm OPEN ENDED SPANNER By using the spanner, loosen and remove the fastening screws securing the power unit to the frame (ref. D fig. 4-5), remove the power unit and the distance washers (ref. E fig. 5), which must be reused when assembling the new power unit. Replace the power unit or disassemble it to replace its components.

Reassemble the new power unit by carrying out the procedure in the reverse order.

D

Fig. 5

After the assembly, no maintenance is required.

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SERVICE

FRAME MECHANICS 6.01

PUMP REPLACEMENT MODELS MO20S - MO20SLF

After removing the hydraulic unit, position it on a clean workbench.

Necessary standard tools

medium cross slotted screwdriver

10 mm open ended spanner

5 mm Allen wrench

oil proof gloves

medium slotted screwdriver

Procedure Before starting to work wear suitable safety clothes.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the fastening screws of the motor bonnet. Remove the bonnet.

Step 2 Remove the hydraulic power unit and position it on a clean workbench (see “REMOVE THE HYDRAULIC POWER UNIT” on page 20).

Step 3 10mm OPEN ENDED SPANNER - SMALL-SLOTTED SCREWDRIVER By using the screwdriver loosen the screw of the clamp securing the tank to the flange (ref. A fig. 2). By means of the same spanner loosen and remove the four screws securing the tank to the flange (ref. B fig. 2), extract the electric pump complete with flange from the tank (fig. 3).

Step 4 5mm ALLEN WRENCH Lower the keeper of the hose complete with filter (ref. C fig. 3) and extract the hose from the pump body. By using the key loosen and remove the two bolts fastening the pump body to the flange (ref. D fig. 3), remove the pump and replace it.

Fig. 1

B

A

Fig. 2

Install the pump carrying out the procedure in the reverse order.

D

Tighten the nuts fastening the pump to the flange with 22Nm driving torque. Use Loctite of average texture.

After the assembly no adjustment is required.

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Fig. 3

SERVICE 6.02

FRAME MECHANICS

REMOVAL OF THE PUMP MOTOR MODELS MO20S - MO20SLF

Necessary tools

large slotted screwdriver

Special tools

13 mm open ended spanner

6 mm Allen wrench

internal bearing puller

Procedure Before starting to work wear suitable safety clothes.

Fig. 1

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

D F

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Step 2 Remove the hydraulic power unit and position it on a clean workbench (see “REMOVAL OF THE HYDRAULIC POWER UNIT” on page 20)

E

B

C

Step 3 6 mm ALLEN WRENCH - 10 mm OPEN ENDED SPANNER - PULLER By using the Allen wrench, loosen and remove the bolts fastening the Fig. 3 valve unit to the power unit (ref. B fig. 3), (pay attention to the spacer with spring located on the throttle valve (ref. C fig. 3). By using the 10mm open ended spanner loosen and remove the bolts fastening the motor to the flange (ref. D fig. 3), remove the complete motor by lifting it. Remove the joint connecting the motor and the pump (ref. E fig. 3). By means the puller extract the bearing from the flange (ref. F fig. 3). Replace the complete motor or disassemble it to replace its components.

The joint connecting the motor and the pump must be used again and position correctly.

Reassemble the new motor by carrying out the procedure in the reverse order.

After the assembly no adjustment is required.

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SERVICE

FRAME MECHANICS 7.00

COMPONENTS OF THE STEERING CARDANIC JOINT MODELS ALL MODELS 13 5 6 14 7

25

4

1

15

8 11

10

12

3

23

22 21

20

9

2

17

16

19

24 18

7.01

REFERENCE TABLE FOR THE COMPONENTS OF THE STEERING Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Description of the component Complete cardanic joint shaft Complete cardanic joint shaft Upper pinion control shaft Upper support Upper pinion Spacer Upper bearing of the upper support Lower bearing of the upper support Lower snap ring of the upper pinion shaft Upper snap ring of the upper pinion shaft Snap ring locking the lower bearing of the upper support Lockpin anchoring the upper pinion to the shaft Keeper securing the pinion to the upper shaft Snap ring locking the upper bearing of the upper support Lower pinion control shaft Lower support Lower pinion Snap ring locking the lower bearing of the lower support Keeper securing the pinion to the lower shaft Upper bearing of the lower support Snap ring locking the upper bearing of the lower support Lower snap ring of the lower pinion shaft Slockpin anchoring the lower pinion to the shaft Lower bearing of the lower support Upper snap ring of the lower pinion shaft

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SERVICE 7.02

FRAME MECHANICS

REMOVAL OF THE STEERING CARDANIC JOINT MODEL ALL MODELS

Necessary tools

large slotted screwdriver

15mm socket wrench

ratchet

A Fig. 1

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Step 2 SOCKET WRENCH - RATCHET Loosen and remove the screws fastening the upper support of the cardanic joint (ref.A fig.1). Loosen and remove the screws fastening the lower support of the cardanic joint (ref.B fig.3).

Step 3 Extract the steering cardanic joint unit from the motor compartment (fig.4) and replace it or disassemble it to replace possible damaged parts.

Fig. 2

Reassemble the new cardanic joint by carrying out the procedure in the reverse order.

B

Before tightening the screws fastening the cardanic joint carry out the adjustment process on page 26.

Fig. 3

Fig. 4

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SERVICE

FRAME MECHANICS 7.03

CENTERING OF THE WHEEL WITH THE STEERING TILLER ALL MODELS

Necessary tools

large slotted screwdriver

15mm socket wrench

50Nm torque wrench

Procedure Before starting to work wear suitable safety clothes.

Fig. 1

A

Step 1 Center the drive wheel according to the direction of travel (ref. A fig. 1-3).

C

Step 2 Rotate the tiller, until the V-shaped notch (ref. B fig. 1-3) coorsponds to the central mark of the adhesive located at the tiller base (ref. C fig. 2).

Step 3 SOCKET WRENCH - TORQUE WRENCH Assemble the cardan shaft by keeping the pinion teeth well fixed in their crowns and fix the supports by tightening the screws with a driving torque of di 48Nm.

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SERVICE

FRAME MECHANICS

NOTES:

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SERVICE

FRAME MECHANICS 8.00

COMPONENTS OF THE STEERING TILLER MOD. ALL MODELS

10

3

8

9

11

2

12

6

4

5

20

7

18

19

13

16

17

14

21

22 24

23 25

23

15 30

26

27

1

28 29

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SERVICE 8.01

FRAME MECHANICS

REFERENCE TABLE FOR THE COMPONENTS OF THE STEERING TILLER MOD. ALL MODELS Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

UPDATE

Description of the component Complete electric steering tiller Tiller Tiller support Tiller return gas spring Tiller hinge pin screw Drive bushing Tiller stop vibration-damping Cam reading the sensor enabling the tiller Screws fastening the sensor reading cam Tiller enabling sensor guard Screws fastening the sensor guards Tiller enabling sensor Shims between the upper and lower sensor Screws fastening the lower support to the upper support Screws fastening the steering flange Screw fastening the tiller unit to the chassis Snap ring Tiller lower rubber pad Steering flange Upper bearing Bushing for torsion bar Torsion bar Hinge pin of torsion bar - ring gear Lower bearing Hinge pin of torsion bar - bushing tiller support Steering potentiometer Ring gear for connection with the cardanic joint shaft Lower bearing Snap ring locking the bearing Upper support Lower support

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SERVICE

FRAME MECHANICS 8.02

REPLACEMENT OF THE TILLER GAS SPRING MOD. ALL MODELS

Necessary tools

4mm Allen wrench

medium cross-head screwdriver

external circlip pliers

A

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Fig. 1

Step 1 4mm ALLEN WRENCH Loosen the 3 bolts fastening the upper control case body (ref.A fig.1).

Lift the upper case body disconnect the connectors and remove it from the lower control case body.

Step 2 MEDIUM CROSS-HEAD SCREWDRIVER Loosen the screws fastening the vibration-damping rubber pad (ref.B fig.3), remove the rubber pad (ref.C fig.3).

Step 3 CIRCLIP PLIERS Remove the snap rings locking the gas spring located in the lower part (ref.D fig.4) and in the upper part (ref.E fig.6).

Extract the spring from the bottom and replace it.

Fig. 2

B

B

Reassemble the spring by carrying out the procedure in the reverse order

C

After the assembly no adjustment is required

Fig. 3 Fig. 5

E

D Fig. 4

Fig. 6

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SERVICE 8.03

FRAME MECHANICS

REPLACEMENT OF THE TILLER MOD. ALL MODELS

Necessary tools

A

Fig. 1 4mm Allen wrench

13 - 24 open ended spanner

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 Remove the return gas spring of the tiller (see REPLACEMENT OF THE TILLER GAS SPRING on page 30).

Fig. 2

Step 2 13mm OPEN ENDED SPANNER Loosen and remove the two screws fastening the lower control case to the tiller (ref.B fig.3). Remove the lower control case. This must be assembled on the new tiller.

B

B

Step 3 24mm OPEN ENDED SPANNER Loosen and remove the two hinge pins securing the tiller to the tiller support (ref.C fig.4). Remove the tiller and replace it.

Fig. 3

Reassemble the new tiller by carrying out the procedure in the reverse order.

After the assembly no adjustment is required.

C C Fig. 4

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SERVICE

FRAME MECHANICS 8.04

REPLACEMENT OF THE STEERING TILLER TORSION BAR MOD. ALL MODELS

Necessary tools

15 mm socket wrench

ratchet

hammer

pin extractor with 5 mm diameter

A Fig. 1

external circlip pliers

bearing puller

large slotted screwdriver

6mm Allen wrench

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the screws fastening the motor bonnet and the upper bonnet. (fig.1).

A

Fig. 2

Fig. 2

B

Step 2 15 mm SOCKET WRENCH - RATCHET Loosen and remove the screws fastening the upper cardan joint unit of the steering (rif.A fig.2), remove the cardan shaft to release the tiller unit (fig.3).

Fig. 3

D

B

Step 3 15 mm SOCKET WRENCH - RATCHET - 17mm OPEN ENDED SPANNER By using the open ended spanner lock the nut (ref. B fig. 4). By using the socket wrench complete with ratchet loosen and remove the screws (ref.

C fig. 4) fastening the upper support of the motor compartment bonnet (ref. D fig. 4). Remove the support.

C

Fig. 4

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FRAME MECHANICS

Step 4 15 mm SOCKET WRENCH - RATCHET Disconnect the two connectors of the electric cables, Loosen and remove the screws fastening the tiller unit to the chassis (ref.E fig.5), remove the unit (fig.6) and position it on a work bench.

E

Fase 5 15 mm SOCKET WRENCH - RATCHET Loosen and remove the screws fastening the lower support (ref.F fig.7) and remove the lower support (ref.H fig.7).

Fig. 5

If there are some shims (ref.G fig.7) they must be reassembled.

Step 6 EXTERNAL CIRCLIP PLIERS - PULLER By using the pliers remove the snap ring locking the bearing (ref.I fig.8) and extract the bearing from the shaft by means of the puller (ref.L fig.8) Step 7 Before removing the steering crown gear, rotate the steering until the potentiometer centring holes are aligned, insert the centring spring (ref.

M fig, 8)

Step 8 HAMMER - PIN EXTRACTOR By means of the hammer and the pin extractor remove the hinge pin securing the flange to the torsion bar (ref. N fig. 10). Extract the flange from the bottom (ref. O fig. 11) and remove the potentiometer sensor (ref. P fig. 11).

Fig. 6

G

G

F Fig. 7

F

H

The hinge pin must not be used again.

During the assembly, use a new pin.

L Fig. 8

I M

P O

N

Fig. 11

UPDATE

Fig. 10

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Fig. 9

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SERVICE

FRAME MECHANICS Step 9 6mm ALLEN WRENCH Loosen and remove the screws fastening the lower support for the mechanical steering block (ref. Q fig. 12), extract the support toward the bottom (fig. 13).

Step 10 EXTERNAL CIRCLIP PLIERS By using the pliers remove the snap ring of the tiller unit (ref. R fig. 13) Remove the tiller base from the support (fig. 14).

Q Fig. 12

Step 11 HAMMER - PIN EXTRACTOR By using the hammer and the pin extractor remove the hinge pin of the torsion bar kit (ref. S fig. 14-15), extract the torsion bar (ref. T fig. 16), remove the bushing (ref. U fig. 16) and replace it.

R The hinge pin must not be used again.

During the assembly use a new pin.

Fig. 13

Reassemble the torsion bar and the tiller kit by carrying out the the procedure in the reverse order.

After assembling the tiller on the truck carry out the procedure for the steering acquisition (see “paragraph 7.06 “ST EERING POTENTIOMETER SENSOR ACQUISITION” on page 64 electric section)

S

Fig. 14

S

U T

Fig. 15

Fig. 16

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SERVICE 8.05

FRAME MECHANICS

REPLACEMENT OF THE TILLER BASE BEARINGS MOD. ALL MODELS

B

Standard tools

hammer

drift

Procedure Before starting to work wear suitable safety clothes.

Fig. 1

A

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 Carry out the disassembly as described on pages 34, 35, 36 paragraph xxx “REPLACEMENT OF THE STEERING TILLER TORSION BAR” from step 1 to step 11.

Step 2 HAMMER, DRIFT By using the tools remove the lower and upper bearing (ref. A-B fig. 1) and replace them.

Reassemble the bearing and the tiller kit by carrying out the procedure in the reverse order.

After the assembly of the tiller on the truck, carry out the procedure in the reverse order (see “paragraph 7.06 “STEERING POTENTIOMETER SENSOR ACQUISITION” on page 64 electric section).

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SERVICE

FRAME MECHANICS 9.00

REPLACEMENT OF THE PLATFORM BEARINGS MOD. ALL MODELS

Standard tools

500g vulkollan hammer

Ø 20mm drift

8mm Allen wrench

external circlip pliers

Fig. 1

Special tools

bridge crane

1m hanging rope with two hooks

Fig. 2 Procedure

B

Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 8mm ALLEN WRENCH Remove the platform back (it is stuck, no tools are required) (ref. A fig.

1). Use the Allen wrench, loosen and remove the fastening screw securing the cylinder rod to the platform (ref. B fig. 3).

By using the same tool loosem amd remove the setscrew of the lifting platform (ref. C fig. 3).

C

Fig. 3

Step 2 BRIDGE CRANE - HANGING ROPE WITH TWO ARMS Hook the hanging rope hooks to the platform back and the hanging rope connecting ring to the bridge crane hook (fig. 4). Enable the bridge crane and lift the platform about 500mm. Disconnect the connector of the board sensor supply cable. Keep on lifting, remove the platform from the mast (fig. 5) and position it to the ground (fig. 6).

Fig. 4

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Step 3 CIRCLIP PLIERS - HAMMER - DRIFT By using the pliers, remove the snap ring securing the bearing to the pin (ref. D fig. 8), extract the distance washer (rif. E fig. 8). By means of the hammer and the drift extract the bearing from the pin (ref. F fig. 8) and replace it. Repeat the same operation to remove the other bearings.

Before assembling the new bearing place the distance washer in their position.

Reassemble the new bearings by carrying out the procedure in the reverse order.

After the assembly no adjustment is required.

Fig. 5

Fig. 6

F

D

Fig. 8

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E

Fig. 7

G

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SERVICE

FRAME MECHANICS 10.00

CHAIN GREASING MODELS: MO20LF - MO20SLF

The element that gives a long life to the chains is their lubrication.

Therefore a periodical lubrication with a proper oil must be performed by means of a brush or by means of aerosol cans. The frequency with which this operation must be repeated depends much on the type of work and the environmental conditions, but usually every 500 working hours.

10.01 CHAIN ELONGATION With the use, the chains tend to stretch. Such elongation can be reduced by acting on the chain tightener.

The maximum reduction of the chain elongation is equal to 2%. When this value is exceeded, the chain must be replaced.

10.02

CHAIN MEASURE

Measure the elongation on more sections of 10 pitches, measured on the most stressed sections. This control must be performed about every 1500/2000 working hours. The measure of the 10 pitches is represented in the table below with also an indication of the corresponding chain. If, before the control, the chains have undergone negligible elongations, lower than 2%, this does not mean the chain has remained intact and without any defect. On the contrary, you can have deformations caused by the stress; therefore it is better to carefully check the whole chain in order to control the wear state of the links, the hinge pins, the chain tightener and the chain tightener pin.

CHECK OF THE LIFTING CHAIN ELONGATION

Sample length 10 "P"

1"P" Type of chain LL 1244

Mast Simplex

Pitch length "P"

Sample length 10"P"

mm

mm

Maximum elongation allowed: 2% referred to the sample length mm

19.05

190.50

194.31

C 10.03 CHECK OF LINKS, PINS AND CHAIN TIGHTENERS Before checking, clean the chain enough by using paraffin or a paraffin derivative.

It is possible to check the chain when it is positioned.

Check the chain and its associated components (fig. beside): A) B) C) D) E) F) G) H) I)

Worn pin Damaged pin Crack of the links Wear of the link borders Wear and ovalization of the link hole Excessive play between the links Oxidation check Wear and ovalization of the chain tightener hole Worn chain hinge pin

A

G

D

B

F H

E I

If the chains show one or more of the above-mentioned wear problems, they must be replaced.

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SERVICE 11.00

FRAME MECHANICS

REMOVAL AND REPLACEMENT OF THE LIFTING CHAINS MODELS: MO20LF - MO20SLF

Special tools

Necessary tools

nosed pliers

100x100x500mm wooden beam

Procedure Before starting to work wear suitable safety clothes.

Fig. 1

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Step 1 100x100x500 mm WOODEN BEAM Activate the emergency push button and turn the key switch to “ON”.

Enable the pump and lift the forks, until the beam can pass under them (ref. A fig. 3).

Position the beam under the forks (fig. A) and enable the loweringto lower the forks until they lean against the beam. Keep on lowering to loosen the lifting chains.

B

C

Fig. 2

Turn the key switch OFF and disconnect the battery.

Step 2 PLIERS By using the pliers extract the split pins of the hinge pins securing the chains to the chain tighteners on the forks(ref. B fig. 2). By using the same pliers remove the chain hinge pins (ref. C fig. 2). Extract the chains from the chain tightener.

By using the same tool remove the split pins of the hinge pins securing the chains to the chaintighteners under the pulleys (ref. D fig. 4). By means of the same tool remove the chain hinge pins. Remove the chains and replace them.

F Fig. 3

A D

Reassemble the new chains by carrying out the procedure in the reverse order.

After the assembly carry out the adjustment of the lifting chains (see “ADJUSTMENT OF THE LIFTING CHAINS” on page 40).

Fig. 4

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FRAME MECHANICS 11.01

ADJUSTMENT OF THE LIFTING CHAINS

The fork surface must not be higher than 90 mm from the ground and the forks do not come in contact with the outrigger base (fig.3).

B

A

Necessary tools

24 mm open ended spanner

Fig. 1

Procedure Before starting to work wear suitable safety clothes.

Step 1 OPEN ENDED SPANNER By using the open ended spanner, screw or loosen the chain tightener nuts (ref. A,B fig. 1), until a height of 90mm from the ground is reached (fig. 3).

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Fig. 2

90 mm

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground, turn the key OFF and disconnect the battery.

Fig. 3

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FRAME MECHANICS

REMOVAL AND REPLACEMENT OF THE CHAIN PULLEYS

Special tools

100x100x200mm wooden beam

Necessary tools

nosed pliers

vice

17 mm open ended spanner

medium external circlip pliers

puller

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

A

Step 1 WOODEN BEAM Enable the pump and lift the forks, until the beam can pass under them (ref. A fig. 1).

Position the beam under the forks and enable the lowering, until the forks lean against the beam. Keep on lowering, until the lifting chains are loosened.

F Fig. 1

C

Turn the key switch to OFF, disconnect the battery.

Step 2 NOSED PLIERS By using the pliers remove the split pins (ref. B fig. 2) of the hinge pins securing the chains to the chain tightener. By using the same tool, extract the pins (ref. C fig. 2) and remove the chains from the chain tightener.

Extract the chains from the pulleys.

Step 3 17 mm OPEN ENDED SPANNER - EXTERNAL CIRCLIP PLIERS By using the open ended spanner loosen the screws fastening the bracket preventing the chains from fleeting (ref. D fig. 3), remove the bracket (ref. E fig. 3). By means of the circlip pliers remove the snap ring of the pulley support (ref. F fig. 3). Extract the support complete with pulleys from the cylinder rod and position it on a clean workbench.

Step 4 VICE - PULLER Place the pulley support in the vice.

By means of the puller remove the pulleys from their support (fig. 4) and replace them.

Reassemble the support complete with pulleys by carrying out the procedure in the reverse order.

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B

B Fig. 2

F E

D Fig. 3

Fig. 4

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FRAME MECHANICS 11.03

FORK REMOVAL FOR BEARING REPLACEMENT MOD. MO20LF - MO20SLF

DISASSEMBLY OF THE ROLLERS AND OF THE SLIDING BLOCKS Special tools

hoist

No. 3 lifting bands of 100x100x200mm suitable length wooden beam

Necessary tools

17 mm open ended spanner

medium external circlip pliers

nosed pliers

6 mm Allen wrench

puller for bearings

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Step 1 WOODEN BEAM Enable the pump and lift the forks, until the beam can pass under them (ref. A fig. 1).

Position the beam under the forks and enable the lowering, until the forks lean against the beam. Keep on lowering, until the lifting chains are loosened.

Turn the key switch OFF and disconnect the battery.

Step 2 Remove the lifting chains (see “REMOVAL OF THE LIFTING CHAINS” on page 39 of this section).

Step 3 Remove the pulley of the lifting chains (see “REMOVAL AND REPLACEMENT OF THE PULLEYS” on page 43 of this section).

F Fig. 1

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Step 4 8 mm ALLEN WRENCH By means of the Allen wrench loosen and remove the fastening screw of the mechanical stop on the mast (ref. B fig. 2).

Step 5 HOIST - LIFTING BANDS Place the hoist in the centre of the mast near the forks.

Hook the two bands to the forks and one band to the backrest, hook the other end to the hoist hook (fig. 3).

Lift the host and extract the carriage upward (fig. 4). Position the carriage on the ground or on two stands (fig. 5) and replace the rollers and/or the sliding blocks.

B

Fig. 2

ROLLER REPLACEMENT Step 6 CIRCLIP PLIERS - PULLER By using the pliers remove the roller snap ring (ref. C fig. 6-7), remove the distance washer. By means of a puller remove the roller from the pin (ref. D fig. 6-7) and replace it.

Fig. 3

Reassemble the roller by carrying out the procedure in the reverse order.

Reassemble the forks on the truck by carrying out the procedure in the reverse order.

Fig. 4

C

C

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FRAME MECHANICS

NOTES:

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FORK MAST MECHANICS

FORK MAST MECHANICS 1.00 COMPONENTS OF THE ROD UNIT MOD. MO20 - MO20S...............................................................................2 1.01 REFERENCE TABLE FOR THE COMPONENTS OF THE ROD UNIT MOD. MO20 - MO20S................................3 1.02 COMPONENTS OF THE ROD UNIT MOD. MO20F.................................................................................4 1.03 REFERENCE TABLE FOR THE COMPONENTS OF THE ROD UNIT MOD. MO20F..............................................5 2.00 REMOVAL OF THE FORK MAST, REPLACEMENT OF THE BEARINGS MOD. MO20 - MO20S............................6 2.01 REPLACEMENT OF THE LOAD ROLLERS MOD. MO20F - MO20 - MO20S.......................................................8 2.02 2.03 2.04 3.00

REPLACEMENT OF THE LOAD ROLLER HOLDER CLEVIS MOD.MO20F - MO20 - MO20S................................9 REMOVAL AND REPLACEMENT OF THE ROD UNIT MOD. MO20 - MO20S....................................................10 HEIGHT ADJUSTMENT OF THE ROD UNIT MOD. MO20 - MO20S.............................................................12 LINKAGE GREASING POINTS MOD. MO20 - MO20S....................................................................................14

3.01 REMOVAL OF THE ROD UNIT MOD. MO20F.........................................................................15 3.02 ROD GREASING POINTS MOD. MO20F......................................................................................................18

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1.00

COMPONENTS OF THE ROD UNIT MODELS MO20 - MO20S

6 5 9

11

7

10

8 3 12

14

13 2

19 21 18 20

1 23

17

16 22 15 4

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FORK MAST MECHANICS

REFERENCE TABLE FOR THE COMPONENTS OF THE ROD UNIT MODELS MO20 - MO20S

Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

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Description of the component Complete rod unit kit (forks) Outrigger lifting tie rods Roller holder clevis Roller holder front lever for the tie rod adjustment Rockers for couple of rollers Couple of rollers Hinge pins securing the rollers to the rockers Hinge pins securing the rear lever to the fork Hinge pins securing the tie rods to the lever Rear lever bushings for rockers Lockpin for long pins Rear lever bushings Rear side tie rod bushings Rollers for positioning the forks under the pallet Front roller for the tie rod adjustment Roller hinge pin Hinge pin securing the front lever to the fork Hinge pin securing the tie rod to the front lever Front side tie rod bushings Kit for the hinge pin lock Pin lubricators Bushings for rollers Front lever bushings

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1.02

COMPONENTS OF THE ROD UNIT MODEL MO20F

10

10

11 12

11 9

3 19

7 8 20

13

2

21

6

15 16

4

18 17

16 15 5

1 14

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FORK MAST MECHANICS

REFERENCE TABLE FOR THE COMPONENTS OF THE ROD UNIT MODEL MO20F

“MO20F”

Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

UPDATE

Description of the component Front lever connecting the mobile chassis to the frame Outrigger lifting tie rods Roller holder clevis Hinge pin securing the front lever to the mobile chassis Hinge pins securing the front lever to the frame Hinge pins securing the tie rods to the front lever Hinge pins securing the tie rods to the rear levers Hinge pins securing the rear levers to the outriggers Load bearing rollers Rockers for rollers Hinge pins securing the rollers to the rockers Rear lever self-lubricating bushings for rockers Rear lever self-lubricating bushings for tie rod hinge pin Front lever self-lubricating bushings for long pin Clips locking the hinge pins securing the tie rods and the frame Lubricators for pins. They lock the clips Lubricator for the long pin Lockpin for long pin Lockpins for rear lever hinge pins Rollers for positioning the forks under the pallet Complete mobile chassis

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FORK MAST MECHANICS 2.00 REMOVAL OF THE FORK MAST, REPLACEMENT OF THE BEARINGS MODELS MO20 - MO20S

To remove the outrigger lifting cylinder it is necessary to remove the outriggers complete with linkage.

Special tools

bridge crane

suitable hanging rope suitable hanging rope No.2 with two hooks with four hooks 100x100x800mm wooden blocks

Neccessary tools

Fig. 1

A

15mm socket wrench

ratchet with extension

19mm open ended spanner

normal pliers

Gloves

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground.

Fig. 2

Step 1 15mm SOCKET WRENCH - RATCHET WITH EXTENSION By using the tools loosen and remove the upper fastening screws securing the cylinder to the chassis (ref. A fig 2).

Step 2 WOODEN BLOCKS Enable the push button for the outrigger lifting and lift until the blocks can can pass under the outriggers. Position the wooden blocks (ref. B fig.

3), press the lowering push button, lower the outriggers and lay them on the blocks (fig. 3). Turn the key switch OFF and disconnect the battery.

Fig. 3

B C

Step 3 HANGING ROPES - BRIDGE CRANE Hook the two long hanging ropes to the front chassis in the proper holes and the ring to the bridge crane hook. Hook the two short hanging ropes on the mast to the proper hooks and the ring to the bridge crane hook (fig. 3). Enable the bridge crane and tension the hanging ropes.

D

Fig. 4

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Step 4 15mm SOCKET WRENCH - RATCHET WITH EXENSION 19mm OPEN ENDED SPANNER By using the open ended spanner loosen and remove the cylinder feeding pipe fitting (ref. C fig. 4). Remove the pipe and extract it toward the board.

By means of the socket wrench complete with ratchet and extension, loosen and remove the lower fastening screw securing the cylinder support to the chassis (ref. D fig. 4).

Step 5 Enable the bridge crane, lift the truck frame and extract the fork from the mast (fig. 5). Position the frame out of the fork working area.

Fig. 5

Step 6 PLIERS FOR SNAP RINGS - PLASTIC HAMMER By using the pliers remove the snap ring securing the bearing to the pin (ref. E fig. 6). By means of the hammer extract the bearing from the pin and replace it. Carry out the same procedure to remove the other bearings.

Reassemble the new bearings by carrying out the procedure in the reverse order.

Fig. 6

After the assembly no adjustment is required.

E

F Fig. 7

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2.01 REPLACEMENT OF THE LOAD ROLLERS MODELS MO20F - MO20 - MO20S

The truck components are interchangeable. The load rollers can be removed in the same way.

Necessary special tools

100x100x800mm wooden beam

Utensili necessari

8mm Allen wrench

MO20F

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

Fig. 1 MO20 MO20S

Step 1 WOODEN BEAM Press the fork lifting push button and lift them at the maximum height.

Place the beam under the forks (ref A fig.1-2). Press the fork lowering push button and lower until the forks come in contact with the beam. Keep on the lowering till the rollers are 20mm from the ground. Turn the key OFF and disconnect the battery.

Step 2 8mm ALLEN WRENCH. By using the wrench loosen and remove the two roller hinge pins (ref. A fig. 2-3). Remove the rollers and replace them.

A

Fig. 2

Fig. 3

B

B Reassemble the rollers by carrying out the procedure in the reverse order.

After the assembly no adjustment is required.

C

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SERVICE

FORK MAST MECHANICS

2.02 REPLACEMENT OF THE LOAD ROLLER HOLDER CLEVIS MODELS MO20F - MO20 - MO20S The truck components are interchangeable. The load rollers can be removed in the same way.

Necessary special tools

Necessary tools

100x100x800mm wooden beam

500g steel hammer

pin extractor with 5mm diam.

drift with 18mm diam.

8mm Allen wrench

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians.

MO20F

Step 1 Extract the load rollers (see paragraph 2.00 on page 6) and remove the rockers from the clevis (ref. A fig.2).

Step 2 STEEL HAMMER, PIN EXTRACTOR Remove the lockpin securing the lever hinge pin to the forks by means of the tools (ref.B fig.1-2).

Fig. 1 MO20 MO20S

Step 3 HAMMER, DRIFT. By using the tools extract the hinge pin securing the lever to the forks (ref. C fig.2-3).

Fig. 2

Step 4 HAMMER, PIN EXTRACTOR. Remove the lockpin securing the lever hinge pin to the tie rod by means of the tools (ref.E fig.2-3).

Step 5 HAMMER, DRIFT By using the tools remove the hinge pin securing the lever to the tie rod (ref.D fig.2-3) remove the lever (ref.F fig. 4) and replace it .

B C

E Fig. 3

A

D

Reassemble the levers by carrying out the procedure in the reverse order.

E

D

After the assembly no adjustment is required.

Carry out the same procedure to remove and replace the roller for the positioning of the forks under the pallet (ref. G fig. 4).

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G F

Fig. 4

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2.03

REMOVAL AND REPLACEMENT OF THE TIE ROD UNIT MODELS MO20 - MO20S

Necessary tools

500g steel hammer

Special tools

drift with 18mm diameter

pin extractor with 5mm diameter

5mm Allen wrench

10mm open ended spanner

stand

Procedure Fig. 1 Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians. Turn the key switch OFF and disconnect the battery.

Step 1 Remove the fork unit (see “REMOVAL OF THE FORK MAST” on page 6 of the same section).

Step 2 HAMMER - PIN EXTRACTOR By using the hammer and the pin extractor remove the pin securing the hinge pins of the lever unit to the forks (ref. A fig. 2).

Step 3 STAND Turn the fork mast upside down, so that the linkage are turned upward.

Position the stand under the fork ends (fig. 3) and make sure it is locked in order to carry out the disassemble safely.

A Fig. 2

Step 4 HAMMER - DRIFT By using the hammer and the drift remove the hinge pins securing the levers to the forks (ref. B fig. 4).

Fig. 3

Fig. 4

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Step 5 10mm OPEN ENDED SPANNER By using the spanner loosen and remove the lubricators from the hinge pins securing the levers to the forks (ref. C fig. 5).

Fig. 5

Step 6 5mm ALLEN WRENCH By using the wrench loosen and remove the screws and the plates of the hinge pins securing the levers to the forks (ref. D-E fig. 6)

C E

Step 7 HAMMER - DRIFT By using the hammer and the drift remove the hinge pins securing the levers to the forks (ref. F fig. 7). Remove the tie rods complete with levers and position them on a workbench (fig. 8).

D

Fig. 6

Step 8 HAMMER - DRIFT - PIN EXTRACTOR By using the hammer and the pin extractor extract the pin locking the hinge pins securing the roller holder levers to the tie rod (ref. G fig. 9).

By using the hammer and the drift extract the hinge pins securing the levers to the tie rods (ref. H fig. 9). Remove the levers complete with rollers (fig. 11).

Step 9 5mm ALLEN WRENCH - HAMMER - DRIFT By using the wrench loosen and remove the screws and the plates of locking the hinge pins securing the front levers to the tie rods (ref. I-L fig. 10). By using the hammer and the drift extract the hinge pins securing the levers to the tie rods (ref. M fig. 10). Remove the complete levers (fig. 11) and replace the tie rods.

Fig. 7

F

Fig. 8

Reassemble the new tie rods by carrying out the procedure in the reverse order.

H

After the assembly adjust the tie rods by carriyng out the procedure descibed on page 10 of this section.

G

Fig. 9 Fig. 10

L

Fig. 11

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2.04 ADJUSTMENT OF THE TIE ROD HEIGHT MODELS MO20 - MO20S To reach the adjusting devices of model MO20S, lift the platform at the maximum height (fig. 11) To reach the adjusting pins of model MO20, carry out the procedure described below.

Necessary tools Fig. 1

5mm Allen wrench

No.2 13mm open ended spanner

2x12mm slotted screwdriver

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians. Turn the key switch OFF and disconnect the battery.

Step 1 No.2 13mm OPEN ENDED SPANNERS By using the spanners loosen and remove the fastening screw of the film roll support (ref. A fig2), remove the support (fig. 3).

A

Fig. 2

C

Fig. 3

B

Step 2 SLOTTED SCREWDRIVER Remove the back cushion, which is generally stuck (ref. B fig. 4). By using the screwdriver loosen and remove the screws fastening the back seat panel (ref. C fig. 4). Disconnect the connectors of the push buttons and of the emergency push buttons and remove the panel (ref. D fig. 5)

D Fig. 4

Step 3 5mm ALLEN WRENCH By using the wrench loosen and remove the fastening screws of the roller holder rod support (ref. E fig. 5). Remove the support and the cover (ref. F fig. 6). By means of the same screw loosen and remove the fastening screws of the cover allowing reaching the adjusting pin (ref. G fig. 5), remove the cover (ref. H fig. 6).

E

F

H

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Fig. 6

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3

F

G

Fig. 5

4

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Step 4 No. 2 13mm OPEN ENDED SPANNERS By using the spanners loosen and remove the setscrew of the adjusting pin (ref. I fig 7).

I

Fig. 7

ADJUSTING

L

Step 5 SLOTTED SCREWDRIVER For a good adjustment position the truck on a perfectly levelled surface.

Lower the forks to the ground completely.

Screw or loosen the supports (ref. L fig. 8) until the two support plates (ref. M fig. 9) lean against the rollers (ref, N pag. 9). The height of the forks from the ground (85mm) must be equal to the back upper edge (fig. 10-11).

Fig. 8

After the adjustment, position the screw retaining the adjusting device to prevent the support from loosening and the tie rod from disadjusting.

M

Fig. 2

Fig. 11

N

Fig. 9

MO20S Fig. 10

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85mm

85mm

85mm

85mm

MO20

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FORK MAST MECHANICS

3.00 LINKAGE GREASING POINTS MODELS MO20 - MO20S For a good maintenance of the truck we recommend greasing the points shown in the figures every 500 working hours.

a)

b)

FRONT LEVER PIN LUBRICATORS

b)

FRONT LEVER PIN LUBRICATORS

LUBRICATORD FOR PLATFORM BEARINGS

Air pump to be used for a good greasing of the pins

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4.00 REMOVAL OF THE TIE ROD UNIT MODEL MO20F By constant use of the truck the self-lubricating bushings wear. This may cause clearances that make the truck less stable. Replace the bushings to eliminate the clearances. To replace the bushings the rod unit must be removed.

Necessary special tools

No.2 100x100x800mm wooden blocks

hanging rope with two arms

hoist

normal pliers

drift with 18mm diameter

Necessary tools

500g steel hammer

9mm open ended

pin extractor with 5mm diameter

large slotted screwdriver

Fig. 1 Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area,away from the transit of other motor vehicles and from the passage of pedestrians. Turn the key switch OFF and disconnect the battery.

Step 1 LARGE SLOTTED SCREWDRIVER Loosen the screws fastening the motor compartment screws. Remove the bonnet (fig. 1).

Step 2 Remove the operator board (fig. 1).

Step 3 NORMAL PLIERS Remove the clips securing the cylinder to the mobile chassis support (ref. A fig. 2)

A

Fig. 2

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Step 4 HANGING ROPE WITH TWO HOOKS, BRIDGE CRANE, No.2 WOODEN BEAMS Hook the hanging rope hooks to the proper mobile chassis slots and the hanging rope connecting ring to the bridge crane hook (fig. 3). Enable the bridge crane, lift completely the chassis and place the beams under the forks (ref. B fig. 3). Lower the bridge crane and lay the forks on the beams. Release the lifting device from the mobile chassis.

Step 5 HANGING ROPE WITH TWO HOOKS, BRIDGE CRANE Hook the hanging hooks to the proper frame slots and the hanging rope connecting ring to the bridge crane hook (fig. 3). Enable the bridge crane and tension the hanging rope so that the wheels do not lift from the ground (fig. 4).

B

Fig. 3

Step 6 9mm OPEN ENDED SPANNER, HAMMER, DRIFT In order to remove the frame hinge pins, you must reach the motor compartment. By using the open ended spanner loosen and remove the lubricators from the pins (ref. C fig. 6). Remove the pin locking plate (ref. D fig. 6). By using the hammer and the drift remove the pins from their seats (ref. E fig. 6) and separate the mobile chassis from the frame (fig. 7).

Fig. 4

WARNING: Pay attention to your hands! When you are extracting the pins, the mobile chassis and the frame may move thus injuring you.

Enable the bridge crane and move the chassis out of the work area.

Fig. 5 Fig. 7

C E

D

Fig. 6

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Step 7 HANGING ROPE WITH TWO HOOKS, BRIDGE CRANE Turn the mobile chassis upside down to disassemble the tie rods (fig. 9).

Step 8 HAMMER, PIN EXTRACTOR, DRIFT By using the hammer and the pin extractor remove the lockpins (ref. E-G fig. 8-10). Remove the hinge pins securing the tie rod kit to the chassis by means of the hammer and the drift (ref. F-G fig. 810). Lift and remove the tie rod kit from the chassis (fig. 11) and position it on a workbench (fig. 12).

F

E Fig. 8

F

Step 9 HAMMER, PIN EXTRACTOR, DRIFT Remove the lockpins by means of the hammer and the pin extractor (ref.

I fig. 13). By using the hammer and the drift remove the hinge pins securing the roller holder lever to the tie rods (ref. L fig. 12). Remove the levers.

Step 10 HAMMER, DRIFT, 9mm OPEN ENDED SPANNER Loosen and remove the pin lubricators by means of the open ended spanner (ref. M fig. 13). Extract the pin locking plate (ref. N fig. 12). By using the hammer and the drift remove the hinge pins securing the tie rods to the lever (ref. O fig. 13). After the disassembly replace the damaged parts.

Fig. 9 Fig. 10

H G

Reassemble the rods by carrying out the procedure in the reverse order.

After the assembly no adjustment is required since the tie rods are fixed.

O

I M

L

N Fig. 13

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5.00 LINKAGE GREASING POINTS MODELS MO20F For a good maintenance of the truck we recommend greasing the points shown in the figures every 500 working hours. To reach the lubricators easily lift the outriggers at the maximum height and remove the battery.

1

2

3

Reference

Air pump to be used for a good greasing of the pins

1 2 3

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Description Lubricators of the hinge pins securing the tie rods to lever 2 which can be reached from the battery compartment Lubricator of the hinge pin securing the lever to forks 1 which can be reached from outside Lubricator of the hinge pins securing the lever to the frame 2 which can be reached from the motor compartment chassis

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REDUCTION GEAR

REDUCTION GEAR 1.00 IDENTIFICATION OF THE REDUCTION GEAR COMPONENTS.......................................................2 1.01 MDU 115 MODEL COMPONENT TABLE..............................................................................................3 2.00 REMOVAL OF THE REDUCTION GEAR ...................................................................................................4 3.00 REMOVAL OF THE WHEEL SHAFT OIL SEAL MOD. MDU 115.................................................................7 4.00 REPLACEMENT OF THE DRIVE MOTOR SHAFT OIL SEAL MOD. MDU 115....................................9 5.00 OIL DRAIN FROM THE REDUCTION GEAR ................................................................................................. 1 0 6.00 OIL FILLING IN THE REDUCTION GEAR mod. ALL MODELS ........................................................................ 1 0 6.01 MEASUREMENT OF THE OIL LEVEL IN THE REDUCTION GEARS MOD. MDU 115 .................................... 1 1 7.00 TROUBLESHOOTING MOD. ALL MODELS ................................................................................................... 1 1 8.00 DRIVING TORQUES OF THE STEERING UNIT MOD. MDU 115 ..................................................................... 1 2

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REDUCTION GEAR

1.00 IDENTIFICATION OF THE REDUCTION GEAR COMPONENTS MODEL MDU 115

29 35

13 18 36

1

40

4

20 33

12

9

10 41

30

8

17

31

37 15 22

21

19

34

7

16

5

32

23

39

42

25

14 27 24 6

26

3

2

28

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REDUCTION GEAR

1.01 MDU 115 MODEL COMPONENT TABLE

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Component description Complete reduction gear Lower box of the reduction gear Upper half box of the reduction gear Upper support Lower box cover Drive wheel shaft Coupling steering ring gear with motor pinion Steering motor shaft pinion Upper transmission ring gear Drive motor shaft pinion Bevel gear pair Upper taper roller bearing of the cover Lower taper roller bearing of the half box Big taper roller bearing of the drive wheel shaft Small taper roller bearing of the wheel shaft Lower taper roller bearing of the bevel gear pair shaft Upper taper roller bearing of the bevel gear pair shaft Upper bearing of the drive motor shaft pinion Ring nut of the wheel shaft set and of the bearings with the reduction gear box Ring nut of the bevel gear pair shaft with the upper gear Bevel gear pair shaft spacer Bevel gear pair shim Bevel gear pair shim Wheel shaft spacer Drive wheel shaft shim Drive wheel shaft shim Drive wheel shaft oil seal protection Wheel shaft oil seal Drive motor shaft oil seal Gasket between the upper cover and the half bearing Lower bearing of the drive motor shaft pinion Oil drain plug and gasket of the reduction gear Centering bush Oil filling plug and gasket of the reduction gear Reduction gear support centering bush Fixing plate Fastening screws of the bevel gear pair cover Lower fastening screws of the upper half box with the lower box Lower fastening screws of the upper half box with the lower box Plate fastening screws Fastening screws of the steering ring gear with the half box Upper fastening screws of the upper half box with the lower box M DU 115 115

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REDUCTION GEAR 2.00 REMOVAL OF THE REDUCTION GEAR MOD. ALL MODELS

The reduction gear, which is used on the trucks, is of the type “MDU 115” and the procedure for its removal is the same one for all the models.

MO20

MO20S Fig. 1

Necessary standard tools

large screwdriver

22 mm socket wrench

ratchet

Necessary special tools

No. 2 wooden blocks with proper dimensions

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bridge crane

hanging rope with 2 arms

No. 2 male eyebolt M8

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Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SCREWDRIVER Loosen the screw fastening the motor bonnet. Remove the bonnet. (fig.2).

Step 2 Remove the steering motor (see “REMOVAL OF THE STEERING MOTOR” on page 8 section “FRAME MECHANICS” - fig.2).

Fig. 1

Step 3 Remove the electromagnetic brake (see “REMOVAL OF THE ELECTROMAGNETIC BRAKE: REPLACEMENT OF THE COMPLETE BRAKE, REPLACEMENT OF THE LINING” page 4 section “BRAKING SYSTEM” - fig.3).

Step 4 Remove the drive motor (see “REMOVAL OF THE DRIVE MOTOR” page 10 section “FRAME MECHANICS” - fig.4).

Fig. 2

Step 5 Remove the shaft of the steering cardanic joint (see “REMOVAL OF THE SHAFT OF THE STEERING CARDANIC JOINT” on page 25 section “FRAME MECHANICS” - fig.5).

Fig. 3

Fig. 5

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REDUCTION GEAR Step 6 BRIDGE CRANE - HANGING ROPE WITH TWO ARMS - WOODEN BLOCKS Hook the hanging rope arms to the holes pre-arranged for the lifting located on the chassis base (fig. 6). Hook the ends of the hanging ropes to the bridge crane (fig. 6) by means of the bridge and lift about 200mm. Remove the drive wheel (see “REPLACEMENT OF THE DRIVE WHEEL” on page 4 section “FRAME MECHANICS”).Position the wooden blocks under the chassis (fig. 7), lower the bridge crane and rest the truck on the blocks.

Step 7 Remove the oil from the reduction gear (see “DISCHARGE OF THE OIL FROM THE REDUCTION GEAR” on page 10).

Step 8 BRIDGE CRANE - EYEBOLTS - HANGING ROPES WITH TWO ARMS 22mm SOCKET WRENCH - RATCHET Screw the two eyebolts into the threaded holes of the drive motor stescrews. Hook the hanging rope hooks to the eyebolts and the hanging rope ends to the bridge crane hook. Lift the bridge crane and tension (fig.

7).

By using the socket wrench and the ratchet loosen and remove the four fastening screws securing the reduction gear to the chassis (ref. A fig.

7). Enable the bridge crane, lift the reduction gear (fig. 8) and position it on a workbench then replace or disssemble it to replace the components (fig. 9).

Fig. 6

A

Reassemble the new reduction gear by carrying out the procedure in the reverse order.

After the assembly no adjustment is required.

Fig. 7

Fig. 9

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REDUCTION GEAR

3.00 REPLACEMENT OF THE WHEEL SHAFT OIL SEAL MOD. MDU 115 The wheel shaft oil seal must be replaced when the reduction gear is placed on a clean workbench.

A

N e c e s s a r y special tools Necessary standard tools

reduction gear support

13 - 22 mm socket wrench

ratchet

medium screwdriver

Fig. 1

medium hammer small pin extractor socket wrench for Ø 40 mm selflocking ring nut

flat bar

Procedure Step 1 Remove the reduction gear (see “REMOVAL OF THE REDUCTION GEAR” page 4).

B

Fig. 2

Step 2 22 mm SOCKET WRENCH - RATCHET - REDUCTION GEAR SUPPORT Position the reduction gear on the support (fig.1) and by means of the socket wrench, the ratchet and two bolts used for fixing it to the body fix the reduction gear (ref.A fig.1) so as to disassemble it in safety conditions.

Fig. 3 Step 3 RATCHET - 13 mm SOCKET WRENCH Loosen and remove the screws (ref.B fig.2) fastening the redcution gear cover. Remove the cover to reach the gears.

C

While assembling put LOCTITE 573 on the sealing cover.

Step 4 PIN EXTRACTOR - MEDIUM HAMMER Lift the wrought lip of the washer fastening the ring nut (ref.C fig.4).

Fig. 4

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REDUCTION GEAR

Step 5 RATCHET - SOCKET WRENCH FOR RING NUT - FLAT BAR Position the flat bar between the bolts fastenings the drive wheel (ref.E fig.5), rotate the shaft so that an end of the bar contrasts the bolts of the wheel and the other end is on the bank or on the upper part of the reduction gear locking the shaft when loosing the ring nut. By means of the wrench loosen and remove the ring nut (ref.F fig.5).

When assembling use a new ring nut

Step 6 Remove the taper roller bearing (ref.G fig.6).

E

F

Fig. 5

G

Step 7 Remove the ring bevel gear (ref.H fig.7) and in the same time extract the wheel shaft (fig.8).

When the ring gear and the shaft are removed, there are some shims with different dimensions that must be kept and repositioned as before

Fig. 6

Step 8 Remove the bevel spacer (ref.I fig.9).

Step 9 SCREWDRIVERS By means of the screwdriver remove the oil seal from the seat of the reduction gear (ref.L fig.10) and replace it.

H Fig. 7

Install the new oil seal by carrying out the reverse operations.

After assembling the reduction gear on the machine fill the oil (see “OIL FILLING IN THE REDUCTION GEAR” on page 10).

Fig. 8

ROD OIL FILLING PLUG

2/3mm

OIL LEVEL

I Fig. 9

IN ORDER TO MEASURE THE OIL LEVEL, BEFORE PLUGGING, INSERT A ROD TILL IT REACHES THE GEAR, REMOVE THE ROD AND CHECK IF THE POINT IS WET WITH OIL FOR

Fig.11

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2/3 mm.

-IF THE LEVEL IS LOWER, ADD SOME OIL -IF THE LEVEL IS HIGHER, DRAIN SOME OIL

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REDUCTION GEAR

4.00 REPLACEMENT OF THE DRIVE MOTOR SHAFT OIL SEAL MOD. MDU 115 The wheel shaft oil seal must be replaced with the reduction gear installed on the truck.

Necessary standard tools

large screwdriver

medium screwdriver

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 LARGE SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Step 2 Remove the steering motor (see “REMOVAL OF THE STEERING MOTOR” page 8 section “FRAME MECHANICS”).

Fig. 1 Step 3 Remove the electromagnetic brake (see “REMOVAL OF THE ELECTROMAGNETIC BRAKE: REPLACEMENT OF THE COMPLETE BRAKE, REPLACEMENT OF THE LINING” page 4 section “BRAKING SYSTEM”).

Step 4 Remove the drive motor (see “REMOVAL OF THE DRIVE MOTOR” page 10 section “FRAME MECHANICS”).

Step 5 MEDIUM SCREWDRIVER By means of the screwdriver extract the oil seal from the seat of the reduction gear flange (ref.A fig.2) and replace it.

A Fig. 2

Install the new oil seal by carrying out the reverse operations.

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REDUCTION GEAR 5.00 OIL DRAIN FROM THE REDUCTION GEAR MOD. ALL MODELS Necessary special tools

Necessary standard tools

A

oil proof gloves

tray to collect oil

10 mm Allen wrench

Procedure After using the reduction gear, pay attention to the high temperature of the oil. Heat resistant gloves are recommended.

Clean carefully the area near the filling and drain plugs. Position a tray for the oil with proper dimensions under the drain plug.

By means of the Allen wrench loosen the oil filling plug (ref.A fig.1), remove the filling plug and the oil seal.

By means of the same Allen wrench loosen the oil drain plug (ref.B fig.1), remove the plug and the oil seal.

Drain completely the oil in the tray.

Clean carefully the drain plug from the dirty accumulated by the reduction gear during its working.

B

Fig. 1 Screw the drain plug with a new oil seal. 60 Nm driving torque.

6.00 OIL FILLING IN THE REDUCTION GEAR MOD. ALL MODELS Necessary special tools

oil proof gloves

oil syringe

Necessary standard tools

10 mm Allen wrench

Procedure For what concerns the viscosity classes refer to the table on page 2 in this section.

Loosen and remove the upper plug with its oil seal. Use a suction syringe to fill with oil easily and quickly. As to the right level and quantity of oil refer to the table on page 3. For the level check see the following page Screw the oil filling plug with a new oil seal. 45 Nm driving torque.

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REDUCTION GEAR

6.01 MEASUREMENT OF THE OIL LEVEL IN THE REDUCTION GEARS MOD. MDU 115

ROD OIL FILLING PLUG

2/3mm

OIL LEVEL

IN ORDER TO MEASURE THE OIL LEVEL, BEFORE PLUGGING, INSERT A ROD TILL IT REACHES THE GEAR, REMOVE THE ROD AND CHECK IF THE

2/3mm.

-IF THE LEVEL IS LOWER, ADD SOME OIL -IF THE LEVEL IS HIGHER, DRAIN SOME OIL POINT IS WET WITH OIL FOR

Fig. 1

7.00 TROUBLESHOOTING MOD. ALL MODELS In this table there is a description and an explanation of the problems and the failures that may occur. It is also suggested how to solve them correctly.

Problem

Cause a) Wrong assembling of the seal or damaged seal b) Damaged surface of the wheel shaft

Oil leakage in the wheel shaft

Solution a) Replace the oil seal and reassemble in the right way b) Replace the wheel shaft

a) Seal the cover of the box with the specific sealing product Oil leakage from the box cover b) Seal the bolts with the specific b) Not sealed or not tightened bolts to sealing product and tighten to the the right torque right torque a) Dirty between the oil seal and the a) Remove the dirty box Oil leakage from the filling or drain b) Use of a worn oil seal b) Use a new oil seal plug c) Not tightened plug to the right c)Tighten the plug to the right torque torque a) Seal the surface with the right a) Not sealed surfaces Oil leakage between the box and the sealing product support unit b) Not tightened bolts to the right b) Tighten the bolts to the right torque torque a) Too much oil in the transmission a) Reset the oil level Oil leakage from the motor b) Defective seal of the motor shaft compartment b) Replace the seal of the motor shaft a) Not sealed box cover

a) Damaged toothing of the pinion Too much noise of the reduction unit and of the ring gear or of the gear wheel Tinkling a) Too little oil in the reduction gear a) Not correct preloading or clearance Vibrations of the bearings

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a) Inspect the tooths and replace the damaged gears a) Reset the oil level a) Check and adjust in the right way

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REDUCTION GEAR

8.00 DRIVING TORQUES OF THE STEERING UNIT MOD. MDU 115

BOLTS TIGHTENING THE COVER FLANGE

32Nm 542 ON THE

TIGHTEN TO PUT LOCTITE

THREAD

OIL FILLING PLUG TIGHTEN TO

45Nm

PUT LOCTITE

573 NUT TIGHTENING THE PIN OF THE BEVEL GEAR PAIR TIGHTEN TO 180 Nm PUT LOCTITE 542 ON THE THREAD

BOLTS TIGHTENING THE BOLTS TIGHTENING

UPPER COVER TIGHTEN TO

65 Nm

THE BOX COVER TIGHTEN TO

NUT FASTENING THE WHEEL SHAFT TIGHTEN TO 300 Nm PUT LOCTITE 273

NUT FASTENING THE DRIVE WHEEL TIGHTEN TO

23 Nm

200 Nm OIL DRAIN PLUG TIGHTEN TO

60Nm

PUT LOCTITE

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573

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BRAKING SYSTEM

BRAKING SY STEM SYSTEM 1.00 ELECTROMAGNETIC BRAKE COMPONENTS OF THE DRIVE MOTOR.........................................2 2.00 BRAKING SYSTEMS...........................................................................................................................3 3.00 REMOVAL OF THE ELECTROMAGNETIC BRAKE.............................................................................4 3.01 REMPLACEMENT OF THE ELECTROMAGNETIC BRAKE................................................................5

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BRAKING SYSTEM

1.00

ELECTROMAGNETIC BRAKE COMPONENTS OF THE DRIVE MOTOR MODEL: ALL MODELS 2

3 4 5

6 7 1 8 9

10

Re f.

1

De scription

2

Complete electromagnetic brake Unit fastening bolts

3

Electromagnet

4

Braking plate

5

Lining adjusting nuts Snap ring

6 7 8 9 10

Lining pinion Lining Band Disk

OPERATION The electromagnetic brake, which is fixed on the drive motor, is only a parking brake with STOP or EMERGENCY function and it is a spring-loaded brake.

When the electromagnet is supplied, it attracts the braking plate (ref.4) and releases the brake lining making it rotate freely.

When the electromagnet is no more supplied, the springs push the plate downward on the brake lining enabling the braking.

This type of brake is installed on each model.

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SERVICE 2.00

BRAKING SYSTEM

BRAKING SYSTEMS MODEL: ALL MODELS

There are 5 braking systems:

• • • • •

Release braking (regenerative braking) Partial release braking (regenerative braking) Inversion braking (regenerative braking) Emergency braking Parking braking

A) RELEASE BRAKING It controls the deceleration ramp when the drive control is released - parameter “neutral braking”.

A) PARTIAL RELEASE BRAKING It controls the deceleration ramp when the drive is lower than the current speed but it is not zero - parameter “dec”.

C) INVERSION BRAKING It controls the deceleration ramp when the drive control is inverted.

During the reversal, the truck starts slowing down with a strength proportional to the current value set by means of the programming kit parameter - “regenerative braking”.

The braking current must be adjusted so that the truck stops within a space no lower than the length of the truck itself.

D) EMERGENCY BRAKING The drive emergency braking is enabled when the tiller sensor is disabled (tiller at rest or tiller completely lowered) or when an alarm requiring the immediate stop of the drive is enabled.

The braking is carried out by the electromagnetic brake fixed on the drive motor.

E) PARKING BRAKING The “parking braking” is enabled by the electromagnetic brake fixed on the drive motor.

The braking occurs when the truck is stopped and the tiller is released. In this way the electric brake coil supply is disconneted and the braking is enabled.

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SERVICE

BRAKING SYSTEM

3.00

REMOVAL OF THE ELECTROMAGNETIC BRAKE: REPLACEMENT OF THE COMPLETE BRAKE, REPLACEMENT OF THE BRAKE LINING MODEL:ALL MODELS

Necessary tools

large screwdriver

5 mm Allen wrench

13 mm open ended spanner

scissors

Fig. 1 external circlip pliers with 90° nose

A

feeler gauge

B

Procedure Before starting to work wear suitable safety clothes.

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground, turn the key OFF and disconnect the battery.

Fig. 2

C

If the drive wheel brake lining is replaced, the guide pinion must be replaced too.

Step 1 LARGE SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet.

Step 2 OPEN ENDED SPANNER - ALLEN WRENCH - SCISSORS Remove the rubber protection band (ref.A fig.1) Loosen the three stop nuts by means of the open ended spanner (ref.B fig.1).

Loosen the three screws fastening the electromagnetic brake to the drive motor (ref.C fig.2) by means of the Allen wrench .

By using the scissors cut the clamps of the electric cables to release the electromagnetic brake supply cable. Disconnect the connector and remove it from the tank.

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Step 3 EXTERNAL CIRCLIP PLIERS Extract the brake lining (ref.D fig.4) from the guide pinion.

Remove the snap ring from the motor shaft (ref.E fig.5) by means of the circlip pliers and extract the guide pinion (ref.F fig.5).

D

Replace the brake lining and the guide pinion.

Install by following the reverse procedure.

Fig. 4

After the assembly adjust it.

Fig. 5

E

3.01

F

ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE

G

D

F E Fig. 5 After assembling the electromagnetic brake unit, it is necessary to adjust the brake lining before using the truck.

The distance between the brake lining and the electromagnetic plate (ref.D fig.5) must not be higher than 0.35 mm, in order to have a good braking. Therefore it is necessary a feeler gauge of this measure.

Let the three nuts loosened (ref.E fig.5), insert the feeler gauge near a bolt (ref.F fig.5), tighten the fastening screw (ref.G fig.5) by means of the Allen wrench and bring the plate nearer at a distance that allows extracting the feeler gauge with a little friction. Repeat the operation on all three bolts.

Tighten the nuts by means of the open ended spanner (ref.E fig.5).

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