Yale E842 MP 18-22 L Service Manual - PDF DOWNLOAD

Part No.: 524301820

Revision:

0 (04/2009)

Technical information for Yale customer care centres

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

E842.....

MP18 - MP20 MP20L - MP22

PREFACE

SERVICE

IMPORTANT This manual contains detailed information about the routine and preventive maintenance, troubleshooting, disassembly/assembly of components, adjustment procedures for the following Hyster models: MP18 - MP20 - MP20L - MP22.

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.

2

Product support group

SERVICE

PREFACE

HOW TO USE THE MANUAL SECTIONS This manual is divided in the following sections: Section1: Section 2: Section 3: Section 4: Secttion 5: Sezione 6: Sezione 7: Sezione 8: Sezione 9:

Presentation Installation and settings Diagnostics and measurements Electrical system Hydraulic system Mechanics Reduction unit Braking system Ordinary maintenance

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

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

It indicates a danger due to high temperatures.

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.

ASSEMBLY PROCEDURE For the assembly carry out the disassembly procedure in the reverse order complying with the information and the notes concerning the correct operation of the truck.

3

PREFACE

SERVICE

GENERAL SAFETY STANDARDS PERSONAL SAFETY •

Always use the personal protective equipment when it is required.

•

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.

•

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.

•

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

•

IIf you use compressed air to clean the parts, wear glasses with lateral guards. The air pressure must not be higher than 1 bar.

SAFETY IN THE WORKPLACE •

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.

•

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

•

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

•

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

•

ver use petrol, gas oil or other flammable liquids as detergents: use commercial non-toxic and nonflammable solvents.

•

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.

•

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.

•

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.

•

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.

•

Do not twist chains or metal ropes.

•

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.

•

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

•

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.

•

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.

4

SERVICE

PREFACE

•

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 chek the pressure of the plant use the proper devices.

•

BANDS, ROPES AND HANGING ROPES: SUGGESTIONS FOR THE USE

•

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: • Slings with 2 arms, consider them as the slings with 1 arm.

• 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: • When the components are deformed, cut or when there are cracks, hollows, notches or abrasions on them.

• When the wear of the components is higher than 10% of the initial dimensions.

• When the sling is overloaded.

5

SERVICE

PREFACE Band capacity table

Colour

Working capacity (kg)

violet green yellow grey red brown blue

1000 2000 3000 4000 5000 6000 8000

2000 4000 6000 8000 10000 12000 16000

1400 2800 4200 5600 7000 8400 11200

800 1600 2400 3200 4000 4800 6400

orange

10000 12000

20000 24000

14000 16800

8000 9600

15000 20000 25000 30000

30000 40000 50000 60000

21000 28000 35000 42000

12000 16000 20000 24000

1

2

1,4

0,8

orange orange orange orange orange

Coefficient

Rope capacity table

Working capacity (kg)

Coefficient

6

Colour

Width (mm)

black violet black green yellow grey red browm blue orange

35 50 50 60 75 120 150 180 240 300

500 1000 1500 2000 3000 4000 5000 6000 8000 10000

1000 2000 3000 4000 6000 8000 10000 12000 16000 20000

700 1400 2100 2800 4200 5600 7000 8400 11200 14000

400 800 1200 1600 2400 3200 4000 4800 6400 8000

1

2

1,4

0,8

SERVICE

PREFACE

Hanging rope capacity table

Colour

Working capacity (kg) Coefficiente

violet green yellow grey red

1000 2000 3000 4000 5000

1400 2800 3800 5600 6600

2100 4200 6300 8400 9800

2100 4200 6300 8400 10500

1

1,4

2,1

2,1

Working capacity: the working capacity is calculated with an angle in the centre of 90°.

7

SERVICE

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.

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°C) in oder to eliminate the effect of LOCTITE 270.

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

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

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

Preloading N

Class 8

Class 10

M3

4

5,2

M4

7

9,15

M5

12,14

14,8

M6

17,2

20,9

M8

31,8

38,1

M 10

50,5

60,3

M 12

74,2

88,5

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

DRIVING TORQUE Nm Class 5.8

Class 8.8

Class 10.9

M4

0,7

7

3

2400

1,92

1,44

3,07

2,3

4,17

3,13

M5

0,8

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

1,5

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

1,75

18

10

23025

55

41,4

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

1,5

21

12

34125

96

72

155

115

210

155

M 16

2

24

14

42850

135

105

220

165

300

225

M 16

1,5

24

14

45600

145

110

235

175

320

240

M 20

2,5

30

17

66875

270

200

430

320

580

435

M 20

1,5

30

17

74250

295

225

475

355

650

485

= with lubricant

8

DRIVING TORQUE Nm

Nominal diameter

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 TORQUE

Thread UNF

ROTARY METRIC FEMALE CONNECTOR Driving torque Nm External diameter Nominal torque min / max of the pipe

M 12x1,5

6

20

15 -25

M 14x1,5

8

38

30 - 45

M 16x1,5 M 18x1,5 M 20x1,5 M 22x1,5

8

45

10 10 12 12 14 15

38 - 52

51

43 - 85

58

50 - 65

74

60 - 88

Thread UNF

ROTARY METRIC FEMALE CONNECTOR jic 37° Driving torque Nm Dimension

Nominal torque

min / max

7/16-20

-4

15

9 - 21

1/2-20

-5

20

13 - 27

9/16-18

-6

30

18 - 42

3/4-16

-8

50

30 - 70

7/8-14

-10

69

44 - 94

1.1/16-12

-12

98

63 - 133 73 - 163

1.3/16-12

-14

118

1.5/16-12

-16

140

90 - 190

-20

210

135 - 285

M 24x1,5

16

74

60 - 88

1.5/8-12

M 26x1,5

18

105

85 - 125

1.7/8-12

-24

290

200 - 380

2.1/2-12

-32

450

300 - 600

M 30x2 M 36x2 M 42x2 M 45x2 M 52x2

20

135

115 - 155

166

140 - 192

30

240

210 - 270

35

290

255 - 325

330

280 - 380

22 25 28

38 42

ROTARY FEMALE CONNECTOR BSP Driving torque Nm

Thread UNF

ROTARY FEMALE CONNECTOR ORFS Driving torque Nm Dimension

Thread UNF

Nominal torque

max

9/16-18

-4

14

16

G1/4

20

15 - 25

11/16-16

-6

24

27

G3/8

34

27 - 41

13/16-16

-8

43

47

G1/2

60

42 - 76

1-14

-10

60

68

G5/8

69

44 - 94

1.3/16-12

-12

90

95

Nominal torque

max.

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 to galvanized steel connectors. Different values correspond to connectors of different materials.

9

PREFACE

SERVICE

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.

10

SERVICE

PREFACE

SECTION INDEX

Presentation

1

Installation and settings

2

Diagnostics and measurements

3

Electrical system

4

Hydraulic system

5

Mechanics

6

Reduction unit

7

Braking system

8

Ordinary maintenance

9

11

PREFACE

12

SERVICE

SERVICE

PRESENTATION

presentation TRUCK PRESENTATION ������������������������������������������������������������������������������������������������������������������������������������������� 2 VIEWS OF THE TRUCK ��������������������������������������������������������������������������������������������������������������������������������������������� 3 TRUCK AND LOAD IDENTIFICATION DATA ������������������������������������������������������������������������������������������������������������ 4 TRUCK IDENTIFICATION DATA PLATE ��������������������������������������������������������������������������������������������������������������������� 4 TRUCK SERIAL NUMBER ������������������������������������������������������������������������������������������������������������������������������������������ 4 LOCATION OF DOCUMENTATION ���������������������������������������������������������������������������������������������������������������������������� 5 GENERAL SPECIFICATIONS ������������������������������������������������������������������������������������������������������������������������������������ 6

1

PRESENTATION

SERVICE

TRUCK PRESENTATION The new range of tiller operated pallet trucks is comprised of four models, with nominal load capacities of 1800 kg - 2000 kg - 2200 kg: • • • •

MP18 MP20 MP20L MP22

Electrical system AC technology improves truck performance; the traction motor benefits from 3-phase alternating current technology, making for a longer service life and reduced maintenance costs.

Regenerative braking ensures superior battery efficiency.

The Curtis electronic controller communicates via the CAN-Bus system (Controller Area Network Bus).

Hydraulic system The 1 kW and 1.4 kW pump motors guarantee excellent performance with solenoid valve controlled fork lifting/lowering.

Guidance system These are pedestrian pallet trucks. The tiller is mounted on the traction assembly. The low anchor point of the tiller affords minimal steering effort. Thanks to the SNAIL function the pallet truck can also operate in narrow spaces.

2

SERVICE

PRESENTATION

VIEWS OF THE TRUCK

3

PRESENTATION

SERVICE

TRUCK AND LOAD IDENTIFICATION DATA TRUCK IDENTIFICATION DATA PLATE

The truck identification data plate is located on the motor compartment cover

• • • • •

Manufacturer's name.

Model Serial number Weight without battery Year of manufacture

• • • • •

Max. weight battery Min weight battery Battery voltage Nominal Load capacity Persons on board

TRUCK SERIAL NUMBER

The truck serial number is located on top of the frame under the battery compartment cover.

4

SERVICE

PRESENTATION

LOCATION OF DOCUMENTATION

The truck documentation is located in the battery compartment.

5

PRESENTATION

GENERAL SPECIFICATIONS MP18 - MP20

6

SERVICE

SERVICE

PRESENTATION

WHEELS AND CHASSIS

WEIGHTS

CHARACTERISTICS

GENERAL SPECIFICATIONS 1.2

model

MP18

MP20

1.3

power: battery, diesel, LPG, petrol, electric

Battery

Battery

1.4

steering: tiller, pedestrian, standing, sitting

tiller

tiller

1.5

load capacity, load

Q (t)

1.8

2.0

1.6

centre of gravity

c (mm)

600

600

1.8

load distance from load wheel axle

x (mm)

1001

1001

1.9

wheelbase (WB)

y (mm)

1331

1331

2.1

unladen weight

kg

503

503

2.2

load per axle when loaded (front/rear)

kg

806 / 1497

876 / 1627

2.3

load per axle when unladen (front/rear)

kg

399 / 104

399 / 104

3.1

tyres: full rubber, polyurethane, vulkollan (front/rear)

polyur. / vulk.

polyur. / vulk.

3.2

front wheel size

ø 230 x 75

ø 230 x 75

3.3

rear wheel size

ø 85 x 90

ø 85 x 90

3.4

additional wheels (size)

ø 100 x 40

ø 100 x 40

3.5

wheels: quantity, (x= traction) (front/rear)

1x+2 / 2

1x+2 / 2

3.6

front track width

b 10 (mm)

470

470

3.7

rear track width

b 11 (mm)

395

395

4.4

lifting

h3 (mm)

130

130

4.9

height of tiller in operating position (min/max)

h14 (mm)

735 / 1200

735 / 1200

h13 (mm)

88

88

4.19 total length

l1 (mm)

1683

1683

4.20 length to fork heel

l2 (mm)

500

500 (1)

ELECTRICAL MOTORS

PERFORMANCE

DIMENSIONS

4.15 fully lowered forks height

(1)

4.21 total length

(1)

b1/b2 (mm)

700

700

s/e/l (mm)

55 / 170 / 1180

55 / 170 / 1180

4.25 width over forks

b5 (mm)

560

560

4.32 ground clearance at wheelbase centre

m2 (mm)

20

20

4.33 working aisle width with 1000 x 1200 pallet

4.22 fork size

Ast (mm)

1711

(1)

1711 (1)

4.34 working aisle width with 800 x 1200 pallet

Ast (mm)

1911 (1)

1911 (1)

4.35 turning radius

Wa (mm)

1512 (1)

1512 (1)

5.1

travel speed with/without load

km/h

6/6

6/6

5.2

fork lifting speed with/without load

m/s

0.032 / 0.046

0.034 / 0.046

5.3

fork lowering speed with/without load

m/s

0.08 / 0.08

0.08 / 0.08

5.8

maximum gradeability with/without load

%

10 / 20

10 / 20

electromagnetic

electromagnetic

5.10 service brakes 6.1

traction motor, S2 60 minutes

kW

1.2

1.2

6.2

lifting motor

kW

1

1

no

no

V/Ah

24 / 150 (200)

24 / 150 (200)

kg

150 (225)

150 (225)

AC ~ Mosfet

AC ~ Mosfet

6.3

battery BS, DIN 43531/35/36 A,B,C, no

6.4

battery voltage/nominal capacity

6.5

battery weight (+/- 5%)

8.1

type of control

Tiller in vertical position

7

PRESENTATION

MP20L - MP22

8

SERVICE

SERVICE

PRESENTATION

WHEELS AND CHASSIS

WEIGHTS

CHARACTERISTICS

GENERAL SPECIFICATIONS 1.2

model

MP20L

MP22

1.3

power: battery, diesel, LPG, petrol, electric

Battery

Battery

1.4

steering: tiller, pedestrian, standing, sitting

tiller

tiller

1.5

load capacity, load

Q (t)

2.0

2.2

1.6

centre of gravity

c (mm)

600

600

1.8

load distance from load wheel axle

x (mm)

1001

1001

1.9

wheelbase (WB)

y (mm)

1403

1403

2.1

unladen weight

kg

523

530

2.2

load per axle when loaded (front/rear)

kg

883 / 1640

955 / 1775

2.3

load per axle when unladen (front/rear)

kg

415 / 108

422/ 108

3.1

tyres: full rubber, polyurethane, vulkollan (front/rear)

polyur. / vulk.

polyur. / vulk.

3.2

front wheel size

ø 230 x 75

ø 230 x 75

3.3

rear wheel size

ø 85 x 90

ø 85 x 90

3.4

additional wheels (size)

ø 100 x 40

ø 100 x 40

3.5

wheels: quantity, (x= traction) (front/rear)

1x+2 / 2

1x+2 / 2

3.6

front track width

b 10 (mm)

470

470

3.7

rear track width

b 11 (mm)

395

395

4.4

lifting

h3 (mm)

130

130

4.9

height of tiller in operating position (min/max)

h14 (mm)

735 / 1200

735 / 1200

h13 (mm)

88

88

4.19 total length

l1 (mm)

1755

1755

4.20 length to fork heel

l2 (mm)

572

572 (1)

ELECTRIC MOTORS

PERFORMANCE

DIMENSIONS

4.15 fully lowered forks height

4.21 total length

(1)

b1/b2 (mm)

700

700

s/e/l (mm)

55 / 170 / 1180

55 / 170 / 1180

4.25 width over forks

b5 (mm)

560

560

4.32 ground clearance at wheelbase centre

m2 (mm)

20

4.33 working aisle width with 1000 x 1200 pallet

4.22 fork size

20

Ast (mm)

1783

(1)

1783 (1)

4.34 working aisle width with 800 x 1200 pallet

Ast (mm)

1983 (1)

1983 (1)

4.35 turning radius

Wa (mm)

1512 (1)

1512 (1)

5.1

travel speed with/without load

km/h

6/6

6/6

5.2

fork lifting speed with/without load

m/s

0.034 / 0.046

0.032 / 0.046

5.3

fork lowering speed with/without load

m/s

0.08 / 0.08

0.08 / 0.08

5.8

maximum gradeability with/without load

%

10 / 20

10 / 20

electromagnetic

electromagnetic

1.2

1.2

5.10 service brakes 6.1

traction motor, S2 60 minutes

kW

6.2

lifting motor

kW

6.3

battery BS, DIN 43531/35/36 A,B,C, no

6.4

battery voltage/nominal capacity

6.5

battery weight (+/- 5%)

8.1

type of control

1.4

(2)

1.4 (2)

DIN 43535 B

DIN 43535 B

V/Ah

24 / 220 (250) (3)

24 / 220 (250) (3)

kg

222 (240)

222 (240)

AC ~ Mosfet

AC ~ Mosfet

(1)

Tiller in vertical position

(2)

S3 6%

(3)

Maximum battery capacity = 24/300 V/Ah with “non Din” battery (lateral removal option not available)

9

PRESENTATION

10

SERVICE

SERVICE

INSTALLATION AND SETTINGS

installation and settings BEFORE INSTALLATION ������������������������������������������������������������������������������������������������������������������������������������������� 2 WEIGHT TABLE ���������������������������������������������������������������������������������������������������������������������������������������������������������� 2 TRUCK ASSEMBLY ��������������������������������������������������������������������������������������������������������������������������������������������������� 3 LIST OF MATERIALS RECEIVED FROM THE DEALER ������������������������������������������������������������������������������������������� 3 UNLOADING THE TRUCK ������������������������������������������������������������������������������������������������������������������������������������������ 4 TOPPING UP THE OIL RESERVOIR ������������������������������������������������������������������������������������������������������������������������� 5 INSTALLATION OF THE BATTERY ���������������������������������������������������������������������������������������������������������������������������� 6 List of the SETTINGS AND ADJUSTMENTS to be carried out ����������������������������������������������������������������� 9 SETTING THE BATTERY VOLTAGE �������������������������������������������������������������������������������������������������������������������������� 9 CHECK THE CONDITIONS OF USE OF THE TRUCK �������������������������������������������������������������������������������������������� 10

1

SERVICE

INSTALLATION AND SETTINGS

BEFORE INSTALLATION Make sure in advance that all the tools required to unload the truck are available (bridge crane, lift truck, lifting slings, etc. ). Before handover of the truck to the customer it is very important to check the suitability of the place where the truck is to be used.

WEIGHT TABLE

Model

Fork dimensions

Weight (excluding battery)

Battery voltage/ capacity

mm

kg

V/Ah

kg

kg

283

24/150 (24/200)

150 (225)

433 (508)

295

24/150 (24/200)

150 (225)

445 (520)

309

24/150 (24/200)

150 (225)

459 (534)

319

24/210 (24/250) (24/300*)

223 (240) (260)

542 (559) (579)

333

24/210 (24/250) (24/300*)

223 (240) (260)

556 (573) (593)

803 x 520 803 x 560 973 x 520 MP18 MP20

973 x 560 973 x 650 1183 x 520 1183 x 560 1183 x 650 980 x 520 980 x 560

MP20L MP22

980 x 650 1163 x 520 1163 x 560 1163 x 650

Battery weight Overall weight

* Battery does not conform to DIN standards (lateral removal option not available with batteries of this size)

2

SERVICE

INSTALLATION AND SETTINGS

TRUCK ASSEMBLY LIST OF MATERIALS RECEIVED FROM THE DEALER

2

1

3

4

5 6

The materials received from the dealer may vary according to whether or not optional accessories are included.

Ref.

Description

1

Truck

2

Battery connection plug extension lead (with lateral removal)

3

External battery charger

4

Battery

5

Top up bottle for battery electrolyte

6

Rollerway for lateral battery removal

3

SERVICE

INSTALLATION AND SETTINGS UNLOADING THE TRUCK Equipment and tools

fork lift truck load capacity 1000 kg

bridge crane load capacity 1000 kg

2 lifting slings load capacity 1000 kg

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Phase 1 FORKLIFT TRUCK Pick up the pallet using the lift truck, raise it and carry it to a safe place, away from the transit areas of other vehicles and pedestrians.

Phase 2 BRIDGE CRANE - 2 LIFTING SLINGS Remove the packaging.

Attach the two lifting slings to the lifting attachments on the truck base (fig.1).

Fig. 1 Ensure that the bridge crane is positioned vertically above the truck to be lifted.

Attach the lifting slings to the bridge crane, lift the truck off the pallet and slowly lower it to the ground.

4

SERVICE

INSTALLATION AND SETTINGS

TOPPING UP THE OIL RESERVOIR Before topping up the oil in the hydraulic oil reservoir make sure that the forks are fully lowered.

Equipment and tools

funnel

oil resistant gloves

T handle hex key 5 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from the transit areas of other vehicles and pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

A

A

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Phase 2 OIL RESISTANT GLOVES - FUNNEL Unscrew the oil reservoir cap (ref.B fig.2), place the funnel in the filler hole and top up the oil level.

Do not overfill the reservoir.

After topping up the oil level, replace the screw on filler cap.

B

Fig. 2

5

INSTALLATION AND SETTINGS

SERVICE

INSTALLATION OF THE BATTERY Equipment and tools

bridge crane load capacity 1000 kg

spreader bar

open ended spanner 12 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

A Fig. 1 Phase 1 12 mm open ended spanner Raise the cover of the battery compartment Using the open ended spanner, loosen the bolts securing the battery restraints (ref.A fig.1) and remove the battery restraints.

Phase 2 BRIDGE CRANE - SPREADER BAR Attach the spreader bar to the bridge crane.

Attach the spreader bar to the battery, lift the battery using the bridge crane and position it over the battery compartment.

Lower the battery very carefully into the battery compartment (fig.2).

Unhook the spreader bar from the battery.

Phase 3 12 mm open ended spanner Reposition the battery restraints. Using the open ended spanner, tighten the battery retaining bolts.

6

Fig. 2

SERVICE

INSTALLATION AND SETTINGS

WITH LATERAL REMOVAL Equipment and tools Fig. 1

bridge crane load capacity 1000 kg

spreader bar

rollerway

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from the transit areas of other vehicles and pedestrians.

Fig. 2

Phase 1 ROLLERWAY Position the rollerway alongside the battery compartment and adjust the height so that the top of rollerway is aligned with the bottom of the battery compartment.

Phase 2 BRIDGE CRANE - SPREADER BAR Lower the battery retaining clip (fig.1) Hook the spreader bar to the bridge crane.

Attach the spreader bar to the battery; lift the battery using the bridge crane and place it on the rollerway (fig.2).

Detach the spreader bar and carefully slide the battery into the battery compartment of the truck (fig.3).

Fig. 3

Phase 3 Reposition the battery retaining clip.

Connect the battery leads to the plug.

7

INSTALLATION AND SETTINGS

SERVICE

CONNECTION OF CABLES TO BATTERY The positive battery terminal is identified with the red marking or the symbol + , while the negative pole is identified with blue marking or the symbol .

The battery connector cables are in turn marked with a red tag for the connection to the positive pole and a blue tag for the connection to the negative pole.

After connecting the cables to the battery terminals, apply Vaseline to protect against corrosion.

_ +

BLUE tag Connection of the cable to the negative terminal RED tag Connect lead to positive terminal

BLUE negative terminal RED positive terminal

+

8

_

SERVICE

INSTALLATION AND SETTINGS

List of the SETTINGS AND ADJUSTMENTS to be carried out After assembling all the machine's components as described in the previous pages, the following operations must be carried out in the sequence given:

• Set the battery voltage • Check the conditions of use of the truck SETTING THE BATTERY VOLTAGE BATTERY CHARGE INDICATOR The battery charge indicator does not require any adjustments.

However, the preset value can be modified if necessary, i.e. if the fully charged or discharged indication on the battery display does not correspond to the actual status of the battery.

Fig. 1 Equipment and tools

A

A

precision flat T handle hex key blade screwdriver 5 mm

Procedure Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Open the cover.

With the truck switched off, use the flat blade screwdriver to adjust the setting screw placed on the rear of the display (ref.B fig.3), increasing or diminishing the voltage value per cell (the voltage value beneath which the battery discharged indicator will be activated) in accordance with the following table: Setting

Volts/Battery cell discharged

K

1.57

L

1.63

M

1.68

N

1.73 (factory setting)

O

1.78

P

1.82

Q

1.84

R

1.86

S

1.89

T

1.91

U

1.93

Fig. 2

B

Fig. 3 9

INSTALLATION AND SETTINGS

SERVICE

CHECK THE CONDITIONS OF USE OF THE TRUCK In order to ensure the safety personnel and materials, before proceeding with the operations described below, it is important to assess the following:

• the type of load to be moved • The general conditions of the warehouse, the aisles and the flooring Having carried out these assessments, check whether the conditions encountered are compatible with the truck performance levels set:

• • • • •

maximum traction speed traction acceleration reduction of traction speed maximum fork lifting/lowering speed braking

If necessary, reduce truck performance by using the programmer to customise the truck configuration parameter (see "TRUCK FUNCTIONS" section "ELECTRICAL SYSTEM").

In order not to jeopardize the safety of the truck, the only way in which the truck configuration parameters may be modified is by reducing the factory-set values.

Parameter values that exceed the factory-set values are not permitted.

10

SERVICE

DIAGNOSTICS AND MEASUREMENTS

diagnostics and measurements DESCRIPTION OF MODULE CONNECTORS ����������������������������������������������������������������������������������������������������������� 2 COMBI MODULE �������������������������������������������������������������������������������������������������������������������������������������������������������� 2 MENU �������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 4 MONITOR menu �������������������������������������������������������������������������������������������������������������������������������������������������������� 4 faults menu ���������������������������������������������������������������������������������������������������������������������������������������������������������� 10 CONTROLLER INFORMATION MENU �������������������������������������������������������������������������������������������������������������������� 11 TROUBLESHOOTING: MODULE DIAGNOSIS SYSTEM ��������������������������������������������������������������������������������������� 12 ALARMS �������������������������������������������������������������������������������������������������������������������������������������������������������������������� 12 ELECTRICAL COMPONENT MEASUREMENTS ���������������������������������������������������������������������������������������������������� 23 SOLENOID VALVE COILS ���������������������������������������������������������������������������������������������������������������������������������������� 23 ELECTROMAGNETIC BRAKE COILS ��������������������������������������������������������������������������������������������������������������������� 23 MOTORS ������������������������������������������������������������������������������������������������������������������������������������������������������������������� 24

1

DIAGNOSTICS AND MEASUREMENTS

DESCRIPTION OF MODULE CONNECTORS COMBI MODULE

35 23 12

A

24 13

A1 Key switch digital input (+24V) A2 Auxiliary functions digital output (+24V) A3 Lowering solenoid valve digital output (+24V) A4 Hydraulic pump contactor coil digital output (+24V) A5 Electromagnetic brake coil digital output (+24V) A6 Main contactor coil digital output (+24V) A7 Encoder negative (GND) A8 Traction motor temperature sensor analog input A9 Tiller digital input (+24V) A10 Not used A11 Not used

2

1

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

A12 Battery discharged signal digital input (+24V) A13 Coils positive (+24V) A14 Not used A15 Not used A16 Not used A17 Not used A18 Not used A19 Auxiliary functions digital output (+24V) A20 Horn relay digital output (+24V) A21 Not used A22 Belly switch digital input (+24V) A23 Can High A24 Not used A25 Output (+12V) A26 Output (+5V) A27 Not used A28 Serial line transmission A29 Serial line reception A30 Not used A31 Encoder phase A A32 Encoder phase B A33 Not used A34 Not used A35 Can Low

3

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MENU The main input and output signals can be measured in real time using the MONITOR function of the programmer. The programmer acts as a multimeter capable of reading voltage, current and temperature.

Certain of these menu parameters refer to functions whose status is received via Can bus, others refer to functions directly connected to the analog/digital inputs of the module. The following list shows the relative measurements.

MONITOR menu MAIN MENU MONITOR  Throttle Inputs PARAMETER RAW CAN THROTTLE

measurement unit Number

Numeric status level of traction control butterfly rotation MAPPED CAN THROTTLE

%

Percentage status level of traction control butterfly rotation RAW REDUNDANT THROTTLE Not used MAPPED REDUNDANT THROTTLE Not used

MAIN MENU MONITOR  Tiller Switch Inputs PARAMETER NEUTRAL SWITCH

measurement unit ON/OFF

Traction control butterfly level: ON if in rest position EMER REV SWITCH

ON/OFF

Emergency reverse button selection SNAIL SWITCH

ON/OFF

"Snail" mode button selection HORN SWITCH

ON/OFF

Horn button selection FORK LIFT SWITCH

ON/OFF

Slow fork lifting button selection FORK LOWER SWITCH

ON/OFF

Slow fork lowering button selection MAST LIFT SWITCH Slow fork lifting button selection

4

ON/OFF

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER MAST LOWER SWITCH

measurement unit ON/OFF

Forks lowering button selection

MAIN MENU MONITOR  Maintenance Timers PARAMETER TOTAL HOURS LEFT

measurement unit h

Number of key-on operating hours remaining before servicing TRACTION HOURS LEFT

h

Number of traction hours remaining before servicing PUMP HOURS LEFT

h

Number of hydraulic pump operating hours remaining before servicing

MAIN MENU MONITOR  Inputs PARAMETER THROTTLE COMMAND

measurement unit %

Angular displacement of the traction control butterfly MAPPED THROTTLE

%

Angular displacement of the traction control butterfly evaluated after mapping THROTTLE POT Not used BRAKE COMMAND Not used MAPPED BRAKE Not used POT2 RAW Not used PD THROTTLE Not used INTERLOCK

ON/OFF

Tiller status level: ON during activation EMER REV

ON/OFF

Emergency direction reversal level: ON during direction reversal

5

DIAGNOSTICS AND MEASUREMENTS

PARAMETER

SERVICE measurement unit

ANALOG 1 Not used ANALOG 2

Volts

Thermal sensor voltage sensor measured on input A8 SWITCH 1 Not used SWITCH 2

ON/OFF

Not used SWITCH 3

ON/OFF

Status level of the tiller measured on input A9 SWITCH 4 Not used SWITCH 5 Not used SWITCH 6

ON/OFF

Battery discharge status level measured on input A12 SWITCH 7

ON/OFF

Belly switch status level measured on input A22 SWITCH 8 Not used DRIVER 1 INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver 1 PWM DRIVER 2 INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver 2 PWM DRIVER 3 INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver 3 PWM DRIVER 4 INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver 4 PWM PD INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver PWM DIGOUT6 INPUT See the parameter main menu monitor / Outputs / Digital Out 6

6

ON/OFF

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER DIGOUT7 INPUT

measurement unit ON/OFF

See parameter main menu monitor / Outputs / Digital Out 7 SWITCH 16 Not used

MAIN MENU MONITOR  Outputs PARAMETER

measurement unit

ANALOG OUT Not used DIGITAL OUT 6

ON/OFF

Status level of the auxiliary functions on output A19 DIGITAL OUT 7

ON/OFF

Status level of the horn control signal on output A20 DRIVER 1 PWM

%

Percentage level of main contactor coil control on output A6 DRIVER 2 PWM

%

Percentage level of electromagnetic brake control on output A5 DRIVER 3 PWM

%

Percentage level of hydraulic pump contactor coil control on output A4 DRIVER 4 PWM

%

Percentage level of solenoid valve control on output A3 PD PWM

%

Percentage level of auxiliary functions on output A2 PD CURRENT

Amps

Current measured on output A2 5 VOLTS

Volts

Voltage measured on output A26 EXTERNAL SUPPLY CURRENT

mA

Current measured on outputs A25 - A26 POT LOW Not used BDI

%

Battery charge percentage level

7

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MAIN MENU MONITOR  Battery PARAMETER CAPACITOR VOLTAGE

measurement unit Volts

Voltage at internal capacitor bank, measured at terminal B+ of the controller KEYSWITCH VOLTAGE

Volts

Key switch voltage measured at input A1

MAIN MENU MONITOR  Motor PARAMETER MOTOR RPM

measurement unit RPM

Motor speed TEMPERATURE

°C

Motor temperature read by thermal sensor MOTOR SPEED A

RPM

Rpm of phase A of the motor encoder MOTOR SPEED B

RPM

Rpm of phase B of the motor encoder

MAIN MENU MONITOR  Controller PARAMETER CURRENT (RMS)

measurement unit Amps

Controller current draw MODULATION DEPTH

%

Voltage percentage applied to the motor FREQUENCY

Hz

Rotation frequency applied to the motor TEMPERATURE

°C

Controller internal temperature MAIN STATE

Number

Status of the main contactor 0 = open

1 = precharge

2 = welding check

3 = closure delay

4 = missing check

5 = closed (with parameter Main Enable  ON)

6 = delay

7 = arc check

8 = opening delay

9 = error

10 = closed (with parameter Main Enable  OFF) 8

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER

measurement unit

REGEN

ON/OFF

ON during all phases of current regeneration VCL ERROR MODULE

Number

Software runtime error (code 68); information on the cause/s of the error are saved in the parameters VCL Error Module and VCL Error.

VCL ERROR

Number

Software runtime error (code 68); information on the cause/s of the error are saved in the parameters VCL Error Module and VCL Error.

MOTOR CHARACTERIZATION ERROR

Number

An error in the motor (code 87) will save information in the variable of this parameter: 0 = no error 1 = encoder detected but impossible to determine the encoder step size 2 = temperature sensor error 3 = high motor temperature cutback error 4 = controller over-temperature cutback error 5 = controller under-temperature cutback error 6 = undervoltage cutback error 7 = severe over-voltage error 8 = encoder signal not detected; one or both channels not found 9 = motor parameters out of range

MAIN MENU MONITOR  Controller  Cutbacks PARAMETER MOTOR TEMP CUTBACK

measurement unit %

Percentage of cutback during motor temperature reduction stage CONTROLLER TEMP CUTBACK

%

Percentage of cutback during controller temperature reduction stage UNDERVOLTAGE CUTBACK

%

Percentage of cutback during under-voltage reduction stage OVERVOLTAGE CUTBACK

%

Percentage of cutback during over-voltage reduction stage

MAIN MENU MONITOR  Controller  Motor Tuning PARAMETER BASE SPEED CAPTURED

measurement unit RPM

Highest speed reached by the motor during last stage of acceleration

9

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MAIN MENU MONITOR  Vehicle PARAMETER

measurement unit

VEHICLE SPEED

km/h

Speed of the truck VEHICLE ODOMETER

m

Distance travelled in forward drive VEHICLE ACCELERATION

g

Acceleration of the truck TIME TO SPEED 1

sec

Time required to reach 0 km/h from a speed value pre-defined in the software BRAKING DISTANCE CAPTURED

m

Distance travelled during all phases of the braking action DISTANCE SINCE STOP

m

Total distance travelled by the truck, calculated as the sum of distances travelled in both directions. This value is reset to zero each time the truck is stopped.

DISTANCE FINE

m

Net distance travelled by the truck calculated as the sum of the distances travelled in the direction the operator is facing (positive value) and in the opposite direction (negative value).

faults menu FAULTS MAIN MENU PARAMETER SYSTEM FAULTS List of current alarms on the truck FAULT HISTORY Log of all alarms previously detected on the truck CLEAR FAULT HISTORY Reset the alarms log.

10

SERVICE

DIAGNOSTICS AND MEASUREMENTS

CONTROLLER INFORMATION MENU CONTROLLER INFORMATION MAIN MENU PARAMETER MODEL NUMBER Controller model number PROTOCOL VERSION Protocol version SERIAL NUMBER Controller serial number MFG DATA CODE Date of manufacture of the controller The first two digits indicate the year, the last three digits indicate the day.

HARDWARE VERSION Hardware version OS VERSION Latest version of the operating system installed BUILD NUMBER First version of the operating system installed SM VERSION Version of the Start Manager installed on the controller PARAM BLK VERSION Version of the Parameter Block installed on the controller VCL APP VERSION Version of the programming language software installed

11

DIAGNOSTICS AND MEASUREMENTS

SERVICE

TROUBLESHOOTING: MODULE DIAGNOSIS SYSTEM The module is equipped with two LEDs (one red, one yellow) which, in the event of a fault, will flash the corresponding error code. The red LED flashes once to indicate that the system is about to signal first digit of the error code, then the yellow LED will emit the number of flashes corresponding to this first digit. The red LED now flashes twice to indicate that the system is about to signal second digit of the error code, then the yellow LED will emit the number of flashes corresponding to this second digit.

The two LEDs have four operating modes which are used to signal different type of information.

RED LED

YELLOW LED

Off

Off

Off

Flashing

On

On

The controller is in Flash Program mode.

On

Off

Watchdog error or software not installed.

Turn off and restart the truck or install the software.

Flashing

Flashing

The controller has detected an error. The two digit code is signalled by the flashing of the two LEDs in a cyclical sequence.

STATUS

The controller is switched off or damaged.

The controller is in operation.

ALARMS ALARM

troubleshooting

12 - “Controller Overcurrent” Possible causes: - External shortcircuit on connections of phases U, V or • • W to the motor - Motor parameters incorrect • - Controller fault • Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

Turn off and restart the truck.

Check the wiring and for a short-circuit or low impedance on the phases U, V and W. Check the motor parameters are correct.

If no fault is found in the wiring or the parameters but the alarm persists, then the problem lies in the module.

13 - “Current Sensor Fault” Possible causes: - Dispersion of current from phases U, V or W to the truck • chassis (short circuit of motor stator) • - Controller fault • Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

12

Turn off and restart the truck.

Check motor insulation If no fault is found and the alarm persists, then the problem lies in the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

14 - “Precharge failed” Possible causes: • - External load on capacitor bank (connected to B+) pre• venting capacitors from charging Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

•

Release all the tiller controls.

Check the value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage If no fault is found and the alarm persists, then the problem lies in the module.

15 - “Controller Severe Undertemp” • Possible causes: - The controller is operating in too low temperature condi• tions (below -40°C) Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

•

Check the value of the parameter MAIN MENU MONITOR / Controller / Temperature Bring the temperature to above the lower limit of -40°C, release all tiller controls, turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

16 - “Controller Severe Overtemp” Possible causes: • - The controller is operating in too high temperature conditions (above 95°C) • - Truck overloaded - Controller incorrectly installed • Effects: • - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

17 - “Severe Undervoltage”

• Possible causes: - Incorrect battery parameters • - Battery resistance too high - Battery disconnected during truck operation • - Loss of capacitor charge to below critical limit • - Fuse on positive feed to key switch disconnected or • blown • - The main contactor did not close • Effects: - Drive reduced

Check the value of the parameter MAIN MENU MONITOR / Controller / Temperature Return the temperature to below the maximum limit of 95°C, release all the tiller controls, remove all loads from the truck, turn off and restart the truck.

Check that the module is installed correctly.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage Return the capacitor voltage to above the minimum critical value.

Check the battery parameters.

Check the battery wiring.

Check the fuses Check the status of the main contactor.

If no fault is found and the alarm persists, then the problem lies in the module.

13

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

18 - “Severe Overvoltage” Possible causes: • - Incorrect battery parameters - Battery resistance too high to supply regenerative cur• rent - Battery disconnected during regenerative braking • - Voltage at capacitors above critical limit • Effects: • - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

21 - “Controller Undertemp Cutback”

•

Possible causes: • - The controller is operating in low temperature conditions (below -30°C) Effects: - Reduced performance

•

22 - “Controller Overtemp Cutback”

• Possible causes: - The controller is operating in high temperature conditions • (above 85°C) - Truck overloaded - Controller incorrectly installed • Effects: • - Drive reduced - Braking effect reduced

Check the value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage Return the capacitor voltage to below the maximum permitted value. Turn off and restart the truck.

Check the battery parameters.

Check the battery wiring.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Controller / Temperature Bring the temperature to above the lower limit of value -30°C, release all tiller controls, turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Controller / Temperature Return the temperature to below the maximum limit of 85°C, release all the tiller controls, remove all loads from the truck, switch off the truck, wait a few minutes, then switch it on again.

Check that the module is installed correctly.

If no fault is found and the alarm persists, then the problem lies in the module.

23 - “Undervoltage Cutback” Possible causes: - The battery is discharged and the controller has reduced truck performance.

- Incorrect battery parameters - Battery resistance too high - Battery disconnected during truck operation - Fuse on positive feed to key switch disconnected or blown - The main contactor did not close - Excessive loss of capacitor charge Effects: - Drive reduced

14

• • • • • • •

Check the value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage Return the capacitor voltage to above the minimum permitted value.

Check the battery parameters.

Check the battery wiring.

Check the fuses Check the status of the main contactor.

If no fault is found and the alarm persists, then the problem lies in the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

24 - “Overvoltage Cutback” Possible causes: - Voltage at battery too high during regenerative braking - Incorrect battery parameters - Battery resistance too high to supply regenerative current - Battery disconnected during regenerative braking - Voltage at capacitors above maximum limit

• • • • •

Effects: - Braking action reduced

Check the value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage Return the capacitor voltage to below the maximum permitted limit. Turn off and restart the truck.

Check the battery parameters.

Check the battery wiring.

If no fault is found and the alarm persists, then the problem lies in the module.

25 - “+5V Supply Failure” Possible causes: • - The external charge impedance on the +5V output (pin 26) is too low (outside range ±10%) • Effects: - None

Return the voltage on pin 26 to within the permitted range. Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

26 - “Digital Out 6 Overcurrent” Possible causes: • - The external charge impedance on Digital Output 6 (pin • 19) is too low (the current exceeds 15 mA) Effects: - The Digital Out 6 driver is not activated

Identify the cause of the overcurrent.

If no fault is found and the alarm persists, then the problem lies in the module.

27 - “Digital Out 7 Overcurrent” Possible causes: • -The external charge impedance on Digital Output 7 (pin 20) is too low (the current exceeds the limit by 15 mA) • Effects: - The Digital Out 7 driver is not activated

Identify the cause of the overcurrent.

If no fault is found and the alarm persists, then the problem lies in the module.

28 - “Motor Temp Hot Cutback” Possible causes: - The temperature of the motor has reached or exceeded the limit value set in the parameter MAIN MENU PROGRAM / Motor / Temperature Control / Temperature Hot - Motor temperature parameters incorrect Effects: - Reduced drive

• • • •

Check values of the parameters MAIN MENU MONITOR / Motor / Temperature and Inputs / Analog2 Check the motor parameters.

Return the motor temperature to within the permitted limits.

If no fault is found and the alarm persists, then the problem lies in the module.

15

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

29 - “Motor Temp Sensor Fault”

• Possible causes: - The motor thermistor is not connected correctly or is • faulty.

- The analog input of the temperature sensor (pin 8) is • 0V or 10V Effects: - Reduced maximum speed - Motor temperature cutback disabled

SERVICE

•

Check values of the parameters MAIN MENU MONITOR / Motor / Temperature e Inputs / Analog2 Check the status of the temperature sensor thermistor.

Bring the thermistor voltage back to within the limits.

If no fault is found and the alarm persists, then the problem lies in the module.

31 - “Coil 1 Driver Open/Short” Possible causes: • - Driver of the main contactor coil open or short circuit (pin 6) • - Connector dirty • - Wiring damaged Effects: - Main contactor driver stopped

Check wiring of the main contactor, clean the connectors and check that the fastons are firmly connected.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

32 - “EM Brake Driver Open/Short” Possible causes: - Driver of the electromagnetic brake coil open or short • circuit (pin 5) • - Connector dirty • - Wiring damaged Effects: - Truck stops - Electromagnetic brake activated

Check the brake wiring, clean the contacts.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

33 - “Coil 3 Driver Open/Short” Possible causes: • - Driver of the hydraulic pump coil open or short circuit (pin 4) • - Connector dirty • - Wiring damaged Effects: - Hydraulic pump contactor driver stopped

Check the wiring of the hydraulic pump contactor; clean the contacts.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

34 - “Coil 4 Driver Open/Short” Possible causes: - Driver of solenoid valve Q1 open or short circuit (pin 3) - Connector dirty - Wiring damaged Effects: - Solenoid valve driver stopped

16

• • •

Check the solenoid valve wiring, clean the connectors Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

35 - “PD Open/Short” Possible causes: - Auxiliary function driver open or short circuit (pin 2) - Connector dirty - Wiring damaged

• • •

Check the wiring, clean the connectors Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

•

Check the value of the parameter MAIN MENU MONITOR / Motor / Motor RPM Check the motor wiring, clean the connectors.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

Effects: - Auxiliary function driver stopped

36 - “Encoder Fault” Possible causes: - Motor encoder phase error - Wiring damaged Effects: - Electromagnetic brake activated

• • •

37 - “Motor Open” Possible causes: - One the motor phases is open - Wiring damaged Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

• • • •

Check the wiring on phases U, V and W. Check continuity of the motor phases.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

38 - “Main Contactor Welded” Possible causes: - Main contactor contacts soldered • - Phase U or V disconnected or open • - Just before closing the main contactor, the capacitor bank (connected to B+) is charged for a brief period but is not discharged • • Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

Check the wiring on phases U and V. Check the power wiring of the main contactor, clean the connectors and check that the fastons are firmly connected.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

17

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

39 - “Main Contactor Did Not Close” Possible causes: - The main contactor did not close - The contacts of the main contactor are oxidised or burned or disconnected - External load on the capacitor bank (connected to B+) preventing capacitors from charging - Fuse on positive feed to keyswitch disconnected or blown Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

•

• • • •

Check the power wiring of the main contactor, clean the connectors and check that the fastons are firmly connected.

Check value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage Check the fuses Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

41 - “Throttle Wiper High” Possible causes: - Voltage on pin 16 (not used) too high

•

This kind of failure is not connected to external components. When it appears persistently the module must be replaced.

•

This kind of failure is not connected to external components. When it appears persistently the module must be replaced.

•

This kind of failure is not connected to external components. When it appears persistently the module must be replaced.

•

This kind of failure is not connected to external components. When it appears persistently the module must be replaced.

•

This kind of failure is not connected to external components. When it appears persistently the module must be replaced.

Effects: - Butterfly drive control deactivated

42 - “Throttle Wiper Low” Possible causes: - Voltage on pin 16 (not used) too low Effects: - Butterfly drive control deactivated

43 - “Brake Wiper High” Possible causes: - Voltage on pin 17 (not used) too high Effects: - Electromagnetic brake activated

44 - “Brake Wiper Low” Possible causes: - Voltage on pin 17 (not used) too low Effects: - Electromagnetic brake activated

45 - “Pot Low Overcurrent” Possible causes: - Voltage on pin 18 (not used) too high Effects: - Butterfly drive control deactivated - Electromagnetic brake activated

18

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

46 - “EEPROM Failure”

• Possible causes: - Error writing to the Eeprom caused by programming language or the Can Bus or by incorrect parameter editing • with the console or installation of new software.

Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

• •

47 - “HPD/Sequencing Fault”

• •

Possible causes: Incorrect start up sequence - Wiring or connectors or pushbuttons damaged Effects: - Butterfly drive control deactivated

• •

If this error occurs after editing parameters or installing new software, restore conditions existing prior to the error.

Download and install the correct software; use the standard parameter configuration.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

Follow the correct start up sequence Check the tiller wiring and the electrical panel wiring Check condition of pushbutton connectors, clean if necessary.

If no fault is found and the alarm persists, then the problem lies in the module.

47 - “Emer Rev HPD” • Possible causes: - After an emergency reversing manoeuvre, some of the • inputs may not have returned to neutral position.

• • Effects: - Butterfly drive control deactivated - Electromagnetic brake activated

Release all tiller controls.

Check that the belly button is released.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

49 - “Parameter Change Fault” Possible causes: - The truck was not turned off and restarted after editing • one or more parameters • Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

51 - “CAN Startup Failure” Possible causes: - Communication with tiller failed - Short or open circuit on pins 35-23 Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

• • •

Check that there no faults on the line.

Check the wiring.

Check that the connectors are clean.

19

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

52 - “CAN PDO Timeout” Possible causes: - Failure to receive message via CAN within 50 ms - Short or open circuit on pins 35-23 Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

• • •

Check that there no faults on the line.

Check the wiring.

Check that the connectors are clean.

• • • •

Release all the tiller controls.

Check that the belly button is released.

Switch the truck off and then back on.

If no fault is found and the alarm persists, then the problem lies in the module.

• •

Release all the tiller controls.

Follow the correct startup sequence.

•

Check values of the parameters MAIN MENU MONITOR / Controller / VCL Error Module e VCL Error.

This error can be compared with “VCL module ID” and the definition of the error code that can be found in the “information file” of the operating system.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

61 - “BB Sequence Fault” Possible causes: - Belly button activation request with tiller at rest - Short or open circuit on pin 22 Effects: - All truck functions disabled - Electromagnetic brake activated

62 - “Interlock SRO” Possible causes: - Startup with tiller in operating position - Short to power on pin 9 Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

68 - “VCL Runtime Error” Possible causes: - Error in the programming language code Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

69 - “External Supply Out Of Range”

• •

• Possible causes: - External supply current on 5V (pin 26) and 12V (pin 25) • outputs too high or too low • Effects: - None

20

Check value of the parameter MAIN MENU MONITOR / Outputs / External Supply Current Bring the external supply current to within the limits.

If no fault is found and the alarm persists, then the problem lies in the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

71 - “OS General” Possible causes: - Controller internal fault Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

• •

Turn off and restart the truck.

If the alarm persists, replace the module.

• •

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

•

Identify valid signals at the encoder and check that the parameters MAIN MENU MONITOR / Motor / Motor RPM and Inputs / Throttle Command return to 0.

Check the general mechanical condition.

Check that the electromagnetic brake is released when energised.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

72 - “PDO Timeout” Possible causes: - Delay in reception of CAN PDO message Effects: - Tiller deactivated

73 - “Stall Detected” Possible causes: - Motor stalled - Motor encoder fault - Wiring damaged - Problems with the power supply to the motor encoder Effects: - Electromagnetic brake activated

87 - “Motor Characterization Fault” Possible causes: - Motor characterization process failed Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

• • • •

• • • • •

Identify fault from the parameter MAIN MENU MONITOR / Controller / Motor Characterization Error Turn off and restart the truck.

Check the condition of the motor.

Check that the motor is in good condition.

If no fault is found and the alarm persists, then the problem lies in the module.

89 - “Motor Type Fault” Possible causes: - The Motor_type parameter is out of range Effects: - Main contactor K2 open - All truck functions disabled - Electromagnetic brake activated

• •

Turn off and restart the truck.

If no fault is found and the alarm persists, the problem lies in the motor.

21

DIAGNOSTICS AND MEASUREMENTS

ALARM 92 - “EM Brake Failed To Set”

• Possible causes: - The electromagnetic brake is unable to block rotation of the motor so the truck continues to move • Effects: - Butterfly drive deactivated

SERVICE

troubleshooting This alarm is displayed for few seconds then disappears. If it is present in the Fault History, check the efficiency of the brake.

Turn the butterfly drive control a few times to restore brake operation.

93 - “Encoder LOS (Limited Operating Strategy) Possible causes: - The LOS has been activated due to an error (code 36 or 73) • - Vehicle stalled • - Motor encoder fault - Wiring damaged

Turn off and restart the truck.

Follow the troubleshooting guide for the faults Stall Detected or Encoder Fault

Effects: - LOS mode activated

94 - “Emer Rev Timeout” Possible causes: - Emergency reverse time has elapsed and the emergency • reverse input remains ser to ON Effects: - Butterfly drive deactivated - Electromagnetic brake activated

22

Check the condition of the belly button and the internal microswitch.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ELECTRICAL COMPONENT MEASUREMENTS SOLENOID VALVE COILS

1

Ref.

solenoid valve

Value measured (Ohm)

1

Q1

27

ELECTROMAGNETIC BRAKE COILS

Drive wheel electromagnetic brake

Coil

Value measured (Ohm)

Electromagnetic brake

17.9

23

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MOTORS To measure the motor insulation resistance, disconnect the phase wires (U, V, W). Connect one of the tester probes to the U phase and the other probe to the bodywork. The resistance reading ( ) on the tester should be infinity ( ). If not. the motor is not insulated and the module connected to the motor in question will diagnose the alarm "capacitor charge".

Repeat the operation with the other two phases (V, W).

24

SERVICE

ELECTRICAL SYSTEM

electrical system ELECTRICAL WIRING DIAGRAMS �������������������������������������������������������������������������������������������������������������������������� 2 ELECTRICAL COMPONENTS ����������������������������������������������������������������������������������������������������������������������������������� 4 KEY TO ELECTRICAL COMPONENTS ���������������������������������������������������������������������������������������������������������������������� 4 TILLER BOARD ���������������������������������������������������������������������������������������������������������������������������������������������������������� 6 CONTROLS �������������������������������������������������������������������������������������������������������������������������������������������������������������� 8 KEY TO TILLER CONTROLS AND MAIN PANEL ������������������������������������������������������������������������������������������������������� 8 DISPLAY (battery charge level indicator) ���������������������������������������������������������������������������������������������� 10 BATTERY CHARGE LEVEL INDICATOR ����������������������������������������������������������������������������������������������������������������� 11 HOUR METER ���������������������������������������������������������������������������������������������������������������������������������������������������������� 11 MDI (OPTIONAL) ������������������������������������������������������������������������������������������������������������������������������������������������������ 12 BATTERY CHARGE LEVEL INDICATOR ����������������������������������������������������������������������������������������������������������������� 13 ALARM AND MAINTENANCE WARNING INDICATOR �������������������������������������������������������������������������������������������� 13 TRUCK FUNCTIONS ������������������������������������������������������������������������������������������������������������������������������������������������ 14 FORWARD/REVERSE TRACTION ��������������������������������������������������������������������������������������������������������������������������� 14 STEERING ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 18 FORK LIFTING/LOWERING ������������������������������������������������������������������������������������������������������������������������������������� 19 STANDARD CONFIGURATION OF MODULE PARAMETERS ������������������������������������������������������������������������������� 21 MAIN MENU PROGRAM ������������������������������������������������������������������������������������������������������������������������������������������ 21 MODULE PARAMETER DESCRIPTION ������������������������������������������������������������������������������������������������������������������ 23 MODULE: INTRODUCTION ������������������������������������������������������������������������������������������������������������������������������������� 28 POSITIONING OF THE "PC TOOL" CONNECTOR ������������������������������������������������������������������������������������������������� 29 MODULE REPLACEMENT: INSTRUCTIONS ����������������������������������������������������������������������������������������������������������� 30 REMOVAL OF ELECTRICAL COMPONENTS �������������������������������������������������������������������������������������������������������� 32 REPLACEMENT OF THE GENERAL EMERGENCY SWITCH �������������������������������������������������������������������������������� 32 REPLACEMENT OF THE DISPLAY �������������������������������������������������������������������������������������������������������������������������� 34 REPLACEMENT OF THE KEY SWITCH ������������������������������������������������������������������������������������������������������������������ 35 REPLACEMENT OF THE HORN ������������������������������������������������������������������������������������������������������������������������������ 36 FUSE REPLACEMENT ��������������������������������������������������������������������������������������������������������������������������������������������� 37 tiller board: configuration and calibration ������������������������������������������������������������������������������������� 38 TILLER BOARD REPLACEMENT ����������������������������������������������������������������������������������������������������������������������������� 41 REPLACEMENT OF TILLER BUTTONS ������������������������������������������������������������������������������������������������������������������ 42 REPLACEMENT OF THE TILLER CONTROL SPRINGS ����������������������������������������������������������������������������������������� 43 REPLACEMENT OF THE TILLER ENABLES SENSOR ������������������������������������������������������������������������������������������ 45

1

SERVICE

ELECTRICAL SYSTEM

ELECTRICAL WIRING DIAGRAMS COMPONENTS Ref.

2

CONNECTORS Description

Ref.

Description

A1

Combi controller

XA1

35 pin male connector

A2

Tiller controller

X28

XCJ2

A3

Battery charge level indicator

X3

XAJ2

B1

Encoder

B2

Heat sensor

XJP2

XJP10

C1

Battery

XJP12

X4

F1

Power fuse - 175 A

X31

X15

F2

10 A fuse for 24V power supply to keyswitch

F3

10 A fuse for 24V power supply to horn relay

K1

Horn relay

XJP13

XJP14

K2

Main contactor coil

XJP15

XJP16 2 pin male connectors

K3

Pump coil

XJP17

X6

K4

Reversing warning buzzer

X7

X14

XJP1

X30

8 pin male connectors 6 pin male connectors 4 pin male connectors 3 pin male connector

XJP11

M

Complete traction motor

XFF2

XFF3

M1

Traction motor

XFF4

XFF5

M2

Pump motor

XFF9

XFF10

P

Button not used

XFF11

XFF12

P1

Horn

XFF14

XFF15

P2

Reversing warning buzzer

XFF16

XFF17

P3

On-off lifting button

XFF21

XFF22

P4

On-off lowering button

XFF23

XTF25

P5

On-off lifting button

XTF26

XTF27

P6

On-off lowering button

XTF28

P7

Horn button

XTR1

P8

Bellyswitch

XTR24

P9

Snail button

Q1

Solenoid valve 1

R1

Varistor

R2

Electromagnetic brake

S1

Emergency button

S2

Battery charger socket-plug microswitch

S3

Keyswitch

S4

Tiller sensor

T1

Battery charger

XTR13

female terminals

ring terminals

SERVICE

ELECTRICAL SYSTEM

* * When T1 and S2 are not present (no load on board)connect XFF21 to terminal 15-54 of S3.

**

** As reference us the colour X of the individual wire (or the number printed on it, if the wire is black)

2a

SERVICE

ELECTRICAL SYSTEM

*

* As reference us the colour X of the individual wire (or the number printed on it, if the wire is black)

2b

SERVICE

ELECTRICAL SYSTEM

2c

SERVICE

ELECTRICAL SYSTEM

3

SERVICE

ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS KEY TO ELECTRICAL COMPONENTS

Ref.

4

Description

Ref. wiring diagram

1

Traction motor

M1

2

Pump motor

M2

3

Electromagnetic brake

R2

4

Tiller control sensor

S4

5

Battery

C1

6

Battery charge level indicator

A3

7

Horn relay

K1

8

Controller

A1

9

Power fuse - 175 A

F1

10

Main contactor - emergency button

S1

11

Horn relay fuse - 10 A

F3

12

Keyswitch fuse - 10A

F2

13

Horn

P1

14

Main contactor coil contacts

K2

15

Main contactor auxiliary connector contacts

16

Pump contactor

K3

17

3 way connector for PC connection

X30

18

Tiller board

A2

19

Battery charger

T1

SERVICE

ELECTRICAL SYSTEM

13

12

18 15 14

11

16

10

9 17 2

3

8

7

19

1 5

4

6

4a

SERVICE

ELECTRICAL SYSTEM

5

ELECTRICAL SYSTEM

SERVICE

TILLER BOARD

Ref.

6

Description

1

LED display for butterfly traction control calibration

2

Rapid reverse microswitch

Ref. wiring diagram P8

3

Horn enabling microswitch

4

Tiller control cable connector

XJP1

P7

5

Tiller enabling sensor connector

XJP2

6

Connector not used

XAJ2

7

Configuration jumper

8

Fork lifting ON/OFF button connector

XJP10

9

Can Bus connector

XCJ2

10

Fork lowering ON/OFF button connector

XJP12

11

Fork lifting ON/OFF button connector

XJP14

12

Fork lowering ON/OFF button connector

XJP15

13

Connector not used

XJP16

14

Connector not used

XJP17

15

Connector not used

XJP11

16

Connector not used

XJP13

17

Enabling microswitch for slow travel with tiller vertical

P9

SERVICE

ELECTRICAL SYSTEM

2

1

17 3 16 15 14 13 12 11 10 9 8 7

6

5

4

7

SERVICE

ELECTRICAL SYSTEM

CONTROLS KEY TO TILLER CONTROLS AND MAIN PANEL

4

5

5

2 3 1

6

8

4

SERVICE

ELECTRICAL SYSTEM

7

8

Ref.

Description

Ref. wiring diagram

1

Rapid reverse button

P8

2

Horn button

P7

3

Forward/reverse traction control butterfly

4

Fork lowering button

P4 - P6

5

Fork lifting button

P3 - P5

6

Slow travel enabling button with tiller in rest position

P9

7

Emergency button

S1

8

Keyswitch

S3

9

ELECTRICAL SYSTEM

DISPLAY (battery charge level indicator)

1

2

Ref.

10

Description

1

Battery charge level indicator

2

Total operating hours indicator

SERVICE

SERVICE

ELECTRICAL SYSTEM

BATTERY CHARGE LEVEL INDICATOR The battery charge level is indicated on display with 10 bars, each of which corresponds to 10%.

When the charge level falls 30% the third bar starts to flash.

When the charge level falls to 20%, the first two bars start to flash and lifting of the forks is inhibited.

To reset the battery discharge indicator, recharge the battery. When the charge level reaches 75%, the battery discharge indicator is reset and fork lifting is enabled.

If a battery is installed in the truck that is not supplied by the truck manufacturer, in order for the battery charge indicator to work correctly the "BATTERY VOLTAGE SETTING" procedure must be performed on installation of the new battery (see “INSTALLATION AND SETTINGS” section).

HOUR METER When any truck function is active (tiller lowered, traction, lift/lowering) the hourglass symbol flashes, indicating that the battery level indicator is recording the operating hours.

If the battery charge level indicator is replaced the truck operating hours will be lost.

11

ELECTRICAL SYSTEM

SERVICE

MDI (OPTIONAL)

1

2

Ref.

3

4

Description

1

Total operating hours and alarms indicator

2

Green LED - hour meter ON

3

Yellow LED - battery low

4

Red LED - alarm and maintenance warning

On starting the truck (key-on) the MDI performs a number of tests, and each element will illuminate for one second. On completion of the tests, the display will show the total truck operating hours for a few seconds, followed by the battery charge status. The green operating LED will illuminate.

12

SERVICE

ELECTRICAL SYSTEM

When the tiller is lowered or a traction command is given, the total number of traction hours are displayed for a few seconds.

When a lifting or lowering command is given, the total operating hours of the truck pump appear on the display for a few seconds.

BATTERY CHARGE LEVEL INDICATOR The battery charge status is indicated on the display.

When the battery charge state reaches 20%, fork lifting is inhibited.

The "battery low" indicator LED illuminates.

To reset the "battery low" indicator recharge the battery. When the charge level reaches 75%% the "battery low" indicator is reset and fork lifting is enabled.

ALARM AND MAINTENANCE WARNING INDICATOR The MDI provides an indication of the truck's alarm status. When an alarm signal is generated, the red LED will start flashing.

The code number of the fault which caused the alarm condition will appear on the display (see the section" DIAGNOSTICS”).

When the number of truck operating hours reaches the value at which maintenance is required, the red LED will illuminate. After carrying out the necessary maintenance, reset the parameters MAIN MENU PROGRAM / display functions / maintenance timers / reset total maintenance - reset traction maintenance - reset pump maintenance (see “DESCRIPTION OF MODULE PARAMETERS”).

13

ELECTRICAL SYSTEM

SERVICE

TRUCK FUNCTIONS FORWARD/REVERSE TRACTION CONTROLS

To command forward traction, rotate the butterfly control backwards, to command reverse traction, rotate the butterfly control forwards.

The direction of travel is indicated by the two hall effect sensors, one for forward travel and the other for reverse travel.

Devices involved

Status

Symbol on diagram

Keyswitch

ON

S3

Emergency switch

ON

S1

Tiller tilt sensor

ON*

S4

Forward/reverse traction control butterfly * OFF when the button (P9) "snail" is pressed

14

forward/reverse rotation

SERVICE

ELECTRICAL SYSTEM

CONFIGURATION PARAMETERS

MODULE

main menu program forward max forward map forward dead band reverse dead band reverse map reverse max snail speed

max speed max accel max decel neutral braking max braking temperature hot temperature max

For the standard values of each individual parameter, see the paragraph "STANDARD CONFIGURATION OF MODULE PARAMETERS".

For a description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".

SPEED AND ACCELERATION The maximum traction speed and acceleration can be set via the programmer.

Setting the maximum forward/backward traction speed main menu program / traction / normal mode / max speed Setting the acceleration main menu program / traction / normal mode / max accel The minimum rotation of the butterfly control required to enable forward/reverse travel can be set via the programmer.

Setting the minimum butterfly rotation for forward travel main menu program / throttle setup / CAN throttle / forward dead band Setting the minimum butterfly rotation for reverse travel main menu program / throttle setup / CAN throttle / reverse dead band

SPEED REDUCTION AND TRACTION LOCKOUT If the traction motor temperature reaches 115°C the current supplied to the motor is limited, leading to a reduction in the truck speed. If the motor temperature reaches 140°C, the motor lockout is tripped. The temperature threshold values can be set via the programmer.

Setting the temperature threshold for motor speed reduction main menu program / motor / temperature control / temperature hot Setting the temperature threshold for motor lockout main menu program / motor / temperature control / temperature max

15

ELECTRICAL SYSTEM

SERVICE

BRAKING The truck is equipped with four braking systems:

• • • •

Release braking.

Braking on direction reversal.

Emergency braking.

Parking brake

Truck braking will be performed in different ways according to which of the above systems is implemented. For further information on the braking systems see "BRAKING SYSTEMS" “BRAKING SYSTEM” section.

BRAKING SYSTEMS

WHEN APPLIED

Release braking

Release of the butterfly traction control

Braking on direction reversal

Inversion of the direction of travel using the butterfly control Through operation of the emergency braking button

Emergency braking

Parking brake

An alarm has been generated that requires traction to be halted immediately.

The machine is stationary and no traction control is activated

With the programmer it is possible to set the deceleration ramps for release braking, emergency braking and direction reversal braking.

Setting the deceleration ramp for release braking main menu program / traction / normal mode / neutral braking Setting the deceleration ramp for emergency braking main menu program / traction / normal mode / max braking Settingthe deceleration ramp for direction reversal braking main menu program / traction / normal mode / max decel

EMERGENCY REVERSE MANOEUVRE The emergency reverse manoeuvre is a safety function that is applied in the event that the operator, when driving forwards (direction of the traction wheel), hits an object.

In this event, pressing the button P8 causes the truck to immediately reverse, thereby preventing the operator from being crushed.

The emergency reverse procedure is activated with the truck in forward drive, will the tiller in driving position (tiller sensor S4 active) and the "BELLY SWITCH" button pressed.

16

emergency reverse function activation button

SERVICE

ELECTRICAL SYSTEM

SNAIL FUNCTION The "snail" function enables traction even when the tiller is in the rest position (tiller sensor S4 not active).

This allows to operator to drive the truck even when there is not enough room to lower the tiller. The "snail" function is activated by pressing the button on the tiller head (P9). Once the "snail" button is pressed, traction control is assigned to the butterfly control.

It is possible to set the traction speed in "snail" mode using the programmer.

Setting the traction speed in "snail" mode. main menu program / traction / snail speed

tiller sensor

butterfly control potentiometer (accelerator)

snail function activation button

17

ELECTRICAL SYSTEM

SERVICE

STEERING CONTROLS

To steer to the right or to the left rotate the steering tiller in the corresponding direction.

Devices involved

status

Symbol on diagram

Keyswitch

ON

S3

Emergency switch

ON

S1

Tiller tilt sensor

ON

S4

Tiller rotation

18

rotation right/left

SERVICE

ELECTRICAL SYSTEM

FORK LIFTING/LOWERING CONTROLS

D c

A B

To lift the forks, press the on/off button “A” or “C”.

To lower the forks, press the on/off button "B" or “D”.

Devices involved

status

Symbol on diagram

Keyswitch

ON

S3

Emergency switch

ON

S1

Fork lifting/lowering

ON/OFF button for lifting/ lowering activated

P3 - P4 - P5 - P6

ON*

S9

Tiller tilt sensor

* Only where the forks are being lowered (OFF if the (P10) "snail" button is pressed)

CONFIGURATION PARAMETERS

MODULE

main menu program 803 lockout enable lift run time BDI warning enable lift delay time valve 1-2 lowering delay time valve 1-2

For the standard values of each individual parameter, see the paragraph "STANDARD CONFIGURATION OF MODULE PARAMETERS".

For the description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".

19

ELECTRICAL SYSTEM

SERVICE

LIFTING LOCKOUT WITH LOW BATTERY When the level of the battery charge drops below 20% fork lifting is inhibited. To restore initial operating conditions the battery must be recharged.

When the battery charge reaches 75% the "battery low" indicator is reset and normal fork operation is restored.

Lifting lockout due to low battery may be disabled via the programmer.

Enabling/disabling lifting lockout with battery low main menu program / hydraulic functions / 803 lockout enable off: disabled

on: enabled With the optional 840 display this parameter must be set to OFF, otherwise, depending on the battery charge level, only lowering of the forks will be permitted.

Enabling/disabling lifting lockout with battery low (with optional MDI) main menu program / display functions / bdi warning enable off: disabled

on: enabled With the optional 840 display, the level of battery charge at which the "battery low" condition is activated can be modified using the programmer.

Battery low level (with optional MDI) main menu program / display functions / warning bdi

TIMED LIFTING LOCKOUT On pressing the "lift" button (P3/P5) the forks start to rise and continue to rise for the maximum time that can be set using the programmer.

Setting the maximum fork lift run time. main menu program / hydraulic functions / lift run time Once this time period has elapsed, to continue lifting, you must first press the "lower" button and then press the "lift" button again.

END POINT SLOWDOWN lifting/LOWERING FORKS When lifting, the forks rise to their maximum height without slowing down, the motion stopping when the cylinder reaches its mechanical end-of-stroke position.

During lowering, the forks reach their lowest position without slowing down, the motion stopping at the mechanical travel limit.

20

SERVICE

ELECTRICAL SYSTEM

STANDARD CONFIGURATION OF MODULE PARAMETERS It is advisable to retain the factory settings seeing as they have been designed to achieve the best compromise between performance and part wear and tear. It is however possible to customise the performance to suit the customer's requirements, the characteristics of the warehouse and the materials to be moved, but no parameters must be changed if this jeopardises the safety of the truck.

MAIN MENU PROGRAM MAIN MENU PROGRAM  MAIN MENU PROGRAM  Throttle Setup  CAN Throttle MAIN MENU PROGRAM  Hydraulic Functions MAIN MENU PROGRAM  Traction MAIN MENU PROGRAM  Traction  Normal Mode MAIN MENU PROGRAM  Display Functions MAIN MENU PROGRAM  Display Functions  Maintenance Timers MAIN MENU PROGRAM  Display Functions  Hour Meter Preset MAIN MENU PROGRAM  Motor  Temperature Control MAIN MENU PROGRAM LEVEL 2 PARAMETER OR MENU

LEVEL 3 PARAMETER OR MENU

LEVEL 4 PARAMETER

value

INTERLOCK TIMEOUT

120 sec

BUZZER OPTION

0

BUZZER DEAD BAND

70 rpm

THROTTLE SETUP

HYDRAULIC FUNCTIONS

TRACTION

CAN THROTTLE

FORWARD MAX

4095

FORWARD MAP

30%

FORWARD DEAD BAND

190

REVERSE DEAD BAND

-190

REVERSE MAP

30%

REVERSE MAX

-4095

803 LOCKOUT ENABLE

On

LIFT RUN TIME

4.3 sec

LIFT DELAY TIME VALVE 1-2

0.3 sec

LOWERING DELAY TIME VALVE 1-2

0.3 sec

SNAIL SPEED

1000 rpm

NORMAL MODE

MAX SPEED

4430 rpm

MAX ACCEL

1.5 sec

MAX DECEL

0.5 sec

NEUTRAL BRAKING

1 sec

MAX BRAKING

0.4 sec

21

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PROGRAM LEVEL 2 PARAMETER OR MENU

LEVEL 3 PARAMETER OR MENU

DISPLAY FUNCTIONS

BDI WARNING ENABLE

On

BDI WARNING

20%

MAINTENANCE TIMERS

HOUR METER PRESET

MOTOR

22

TEMPERATURE CONTROL

LEVEL 4 PARAMETER

value

TOTAL MAINTENANCE ENABLE

On

TRACTION MAINTENANCE ENABLE

On

PUMP MAINTENANCE ENABLE

On

MAINTENANCE INTERVAL

1000 h

RESET TOTAL MAINTENANCE

Off

RESET TRACTION MAINTENANCE

Off

RESET PUMP MAINTENANCE

Off

10S OF HOURS

0

REMAINING HRS IN MINS

0

PRESET TOTAL HOURMETERS

Off

PRESET TRACTION HOURMETERS

Off

PRESET PUMP HOURMETERS

Off

TEMPERATURE HOT

115°C

TEMPERATURE MAX

140°C

SERVICE

ELECTRICAL SYSTEM

MODULE PARAMETER DESCRIPTION MAIN MENU PROGRAM PARAMETER INTERLOCK TIMEOUT

min

max

0 sec

120 sec

Maximum time period the truck may remain with the tiller in the operating position without any command being given.

BUZZER OPTION

0

2

0 rpm

1000 rpm

0: reversing warning buzzer not present 1: reversing warning buzzer active only when reversing 2: reversing warning buzzer active in both directions of travel BUZZER DEAD BAND

Minimum motor rpm at which the buzzer can be activated (the buzzer only sounds when the motor is running at speeds equal to or greater than this rpm).

MAIN MENU PROGRAM  Throttle Setup  CAN Throttle PARAMETER FORWARD MAX

min

max

3500

6000

Rotation of the butterfly control in direction of forward travel corresponding to the maximum speed of the truck.

FORWARD MAP

0%

100%

This parameter enables the user to adjust the correspondence between the rotation of the butterfly control and the speed of the truck (during forward travel) in accordance with a specific map (fig.1).

PERCENTAGE OF MAX. TRUCK SPEED (OUT)

Fig. 1 Increase in Forward Max

Increase in Forward Map Increase in Forward Dead Band

FORWARD DEAD BAND

FORWARD MAP FORWARD MAX

BUTTERFLY ROTATION (IN) FORWARD TRAVEL (positive values)

23

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PROGRAM  Throttle Setup  CAN Throttle PARAMETER FORWARD DEAD BAND

min

max

0

500

-500

0

0%

100%

Minimum rotation of butterfly control required to enable forward travel (dead band).

REVERSE DEAD BAND Minimum rotation of butterfly control required to enable reverse travel (dead band).

REVERSE MAP

This parameter enables the user to adjust the correspondence between the rotation of the butterfly control and the speed of the truck (during reverse travel) in accordance with a specific map (fig.2).

REVERSE MAX

-6000

-3500

Rotation of the butterfly control in direction of forward travel corresponding to the maximum speed of the truck.

Increase in Reverse Max

Increase in Reverse Map Increase in Reverse Dead Band

REVERSE MAP REVERSE MAX

REVERSE DEAD BAND

PERCENTAGE OF MAX. TRUCK SPEED (OUT)

Fig. 2

BUTTERFLY ROTATION (IN) REVERSE TRAVEL (negative values)

MAIN MENU PROGRAM  Hydraulic Functions PARAMETER 803 LOCKOUT ENABLE

min

max

ON: lockout enabled OFF: lockout disabled

Enables/disables lifting lockout when battery low (with the optional display this parameter must be set to OFF).

LIFT RUN TIME Maximum time for which continuous fork lifting is enabled.

24

0 sec

10 sec

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PROGRAM  Hydraulic Functions PARAMETER LIFT DELAY TIME VALVE 1-2

min

max

0 sec

5 sec

When lifting the forks, the maximum time for which the optional auxiliary valves remain open after the hydraulic pump is stopped.

LOWERING DELAY TIME VALVE 1-2

0 sec

5 sec

When lowering the forks, the maximum time for which the optional auxiliary valves remain open after the lowering valve is deactivated.

MAIN MENU PROGRAM  Traction PARAMETER SNAIL SPEED

min

max

0 rpm

1000 rpm

min

max

0 rpm

4430 rpm

0.1 sec

5 sec

Maximum rpm permitted in SNAIL mode.

MAIN MENU PROGRAM  Traction  Normal Mode PARAMETER MAX SPEED Maximum rpm permitted by the truck.

MAX ACCEL

Time required to accelerate from 0% to 100% of the maximum truck speed with the butterfly control fully rotated.

MAX DECEL

0.1 sec

5 sec

Braking time required when the traction direction is inverted using the butterfly control.

NEUTRAL BRAKING

0.1 sec

5 sec

0.1 sec

5 sec

min

max

Braking time required on releasing the butterfly control.

MAX BRAKING Braking time required on releasing the tiller.

MAIN MENU PROGRAM  Display Functions PARAMETER BDI WARNING ENABLE

ON: lockout enabled OFF: lockout disabled

If the optional BDI is present, enables/disables lifting lockout and illumination of "battery low" LED when battery discharged.

BDI WARNING

0%

100%

If the optional BDI is present, battery charge level percentage at which the "battery low" condition is activated.

25

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PROGRAM  Display Functions  Maintenance Timers PARAMETER TOTAL MAINTENANCE ENABLE

min

max

ON: signalling enabled OFF: signalling disabled

If the optional BDI is present, enables/disables maintenance signalling when the truck's number of key-on operating hours reaches the preset value (parameter MAIN MENU PROGRAM / Monitor / Maintenance Timers / Total Hours Left = 0).

TRACTION MAINTENANCE ENABLE

ON: signalling enabled OFF: signalling disabled

If the optional BDI is present, enables/disables maintenance signalling when the truck's number of traction operating hours reaches the preset value (parameter MAIN MENU PROGRAM / Monitor / Maintenance Timers / Traction Hours Left = 0).

PUMP MAINTENANCE ENABLE

ON: signalling enabled OFF: signalling disabled

If the optional BDI is present, enables/disables maintenance signalling when the truck's number of pump operating hours reaches the preset value (parameter MAIN MENU PROGRAM / Monitor / Maintenance Timers / Pump Hours Left = 0).

MAINTENANCE INTERVAL

10 h

20000 h

Number of truck operating hours after which maintenance is required.

RESET TOTAL MAINTENANCE

ON: maintenance carried out OFF: maintenance not carried out

When set to ON, the remaining key-on operating hours before the next maintenance interval expires are reset to the value indicated by the parameter MAIN MENU PROGRAM / Display Functions / Maintenance Timers / Maintenance Interval. After setting to ON following maintenance, switch the truck off and then on again.

RESET TRACTION MAINTENANCE

ON: maintenance carried out OFF: maintenance not carried out

When set to ON, the remaining traction operating hours before the next maintenance interval expires are reset to the value indicated by the parameter MAIN MENU PROGRAM / Display Functions / Maintenance Timers / Maintenance Interval. After setting to ON following maintenance, switch the truck off and then on again.

RESET PUMP MAINTENANCE

ON: maintenance carried out OFF: maintenance not carried out

When set to ON, the remaining pump operating hours before the next maintenance interval expires are reset to the value indicated by the parameter MAIN MENU PROGRAM / Display Functions / Maintenance Timers / Maintenance Interval. After setting to ON following maintenance, switch the truck off and then on again.

MAIN MENU PROGRAM  Display Functions  Hour Meter Preset PARAMETER 10S OF HOURS

min

max

0

20000

Value used to preset the operating hours count. Each unit corresponds to 10 hours (e.g. the value 23 corresponds to 230 hours).

26

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PROGRAM  Display Functions  Hour Meter Preset PARAMETER

min

max

0

600

REMAINING HRS IN MINS

Value used to preset the operating hour meter, expressed in minutes (the value 360 corresponds to 6 hours).

PRESET TOTAL HOURMETERS

ON: presetting performed OFF: presetting not performed

When set to ON, the number of truck operating hours (key-on) is preset to the value defined in the parameters MAIN MENU PROGRAM / Display Functions / Hour Meter Preset / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10) + (“Remaining HRs in Mins” / 60) The value of the parameter MAIN MENU MONITOR / Maintenance Timers / Total Hours Left is updated.

PRESET TRACTION HOURMETERS

ON: presetting performed OFF: presetting not performed

When set to ON, the number of truck traction hours is preset to the value defined in the parameters MAIN MENU PROGRAM / Display Functions / Hour Meter Preset / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10) + (“Remaining HRs in Mins” / 60) The value of the parameter MAIN MENU MONITOR / Maintenance Timers / Traction Hours Left is updated.

PRESET PUMP HOURMETERS

ON: presetting performed OFF: presetting not performed

When set to ON, the number of truck pump operating hours is preset to the value defined in the parameters MAIN MENU PROGRAM / Display Functions / Hour Meter Preset / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10) + (“Remaining HRs in Mins” / 60) The value of the parameter MAIN MENU MONITOR / Maintenance Timers / Pump Hours Left is updated.

MAIN MENU PROGRAM  Motor  Temperature Control PARAMETER TEMPERATURE HOT

min

max

0°C

150°C

Temperature limit above which the current supplied to the motor starts to be reduced.

TEMPERATURE MAX

0°C

150°C

Maximum temperature limit above which the amount of current supplied to the motor is cut to zero.

27

ELECTRICAL SYSTEM

SERVICE

MODULE: INTRODUCTION The module has been designed to perform all the electrical functions normally present on the truck: • control of the 1.2 kW AC motor • control of the 1 kW - 1.4 kW hydraulic pump • driver for the porportional solenoid valve • CanBus interface • Interface with the tiller Can Bus • alarms • performance Technical specifications: Inverter for asynchronous three phase AC motors and chopper for DC pump motors Regenerative braking functions Digital control via microcontroller Voltage: ........................................................................................24V Maximum inverter current (24V):...................................................200A (RMS) for 2’ PWM operating frequency.............................................................10 kHz Maximum encoder frequency........................................................15 kHz Maximum control output frequency...............................................300 kHz External temperature limits............................................................-40°C to 50°C

A

28

SERVICE

ELECTRICAL SYSTEM

The module is connected and communicates through the CANBUS network, which allows access to truck diagnostics or programming via PC or laptop.

The connector for the cable kit interface connection ("PC TOOL") is connected to the module and can be accessed from the battery compartment.

The module is equipped with flash memory, which enables the software to be updated by connecting a PC to the CANBUS network (Can flash).

POSITIONING OF THE "PC TOOL" CONNECTOR

PC connector

PC interface cable kit cod.580039670

29

SERVICE

ELECTRICAL SYSTEM MODULE REPLACEMENT: INSTRUCTIONS Equipment and tools

Fig. 1

socket wrench 10 mm

resistor 100 Ohm 25w isolated

T handle hex key 5 mm

A

A

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Use the T handle hex key to remove the reduction unit cover screws (ref.B fig.2).

Phase 2 100 Ohm 25 W RESISTOR Connect the resistor between the positive (B+) and negative (B-) of the module (fig.3).

Wait approximately 10 seconds for the internal capacitors to discharge and then disconnect the resistor.

To avoid short circuits, it is important that the resistor is isolated.

If it is not possible to use an external resistor to run down the capacitors, it will be necessary to wait at least 90 seconds before disconnecting the power cables.

30

B

B

Fig. 2 Fig. 3

SERVICE

ELECTRICAL SYSTEM

Phase 3 10 mm SOCKET WRENCH Using the socket wrench loosen and remove the power cable retaining screws.

Disconnect the module wiring connector.

Label the power cables before disconnecting them.

C

Phase 4 10 mm SOCKET WRENCH Using the socket wrench remove the screws securing the module to the truck chassis (ref.C fig.4) and recover the washers.

Remove the module including the heat sink and proceed with replacement.

C

Fig. 4

CONFIGURATION ADAPTER - PROGRAMMER Connect the adapter to the “PC CONSOLE" connector.

Connect the USB connector of the interface cable to the USB port on the PC. Connect the battery and switch on the truck (starter key to ON). Start the PC Console program.

Create a new configuration and copy the factory configuration or a customised configuration.

ACQUISITION OF OPERATING HOURS The truck operating hours are saved in the display memory.

After replacing the controller, on switching on the truck make a note of the operating hours shown on the display (value H: e.g. 138.9). Divide the value H by 10. The result will be in the format XX.YY (e.g. 13.89).

Procedure With the truck switched off (keyswitch OFF), connect the programmer.

Switch on the truck (keyswitch ON) and select the parameter main menu program / display functions / hour meter preset / 10s of hours.

Set the parameter to the value XX (e.g.13).

Select the parameter main menu program / display functions / hour meter preset / remaining hrs in mins.

Set the parameter to the value YY·6 (e.g. 89·6=534).

Select the parameter main menu program / display functions / hour meter preset / preset total hourmeters.

Set the parameter to “ON”.

Switch off the truck (Keyswitch OFF) and switch it back on again ( Keyswitch ON).

At this point the module will make the necessary modifications to the monitor menu parameters regarding maintenance hours and will reset the parameter preset total hourmeters to “OFF“.

31

SERVICE

ELECTRICAL SYSTEM

REMOVAL OF ELECTRICAL COMPONENTS REPLACEMENT OF THE GENERAL EMERGENCY SWITCH Equipment and tools Fig. 1

T handle hex key 5 mm

pin punch Ø 3 mm

open ended spanner 13 mm

A

A

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 2

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Phase 2 PIN PUNCH Insert the end of the pin punch in the hole under the red general emergency switch (ref.B fig.2).

Rotate the knob until the pin punch enters the hole in the shaft inside the knob.

Unscrew and remove the knob.

Phase 3 13 mm OPEN ENDED SPANNER Using the open ended spanner, loosen the nuts securing the contactor power cables (ref.C fig.3).

32

B

C

C

Fig. 3

SERVICE

ELECTRICAL SYSTEM

Phase 4 MEDIUM PHILIPS SCREWDRIVER Unscrew the screws securing the general emergency switch (ref.D fig.4), recover the washers (ref.E fig.4).

Withdraw the contactor in a downward direction (fig.4).

Fig. 4

D

E

Phase 5 Disconnect the wiring connectors and proceed with replacement.

INSTALLATION Before reconnecting the Faston connectors, check that they are firmly attached. If not, tighten the connectors with Faston pliers.

33

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE DISPLAY

Fig. 1

Equipment and tools

A

A

T handle hex key 5 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 2

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Fig. 3

Phase 2 Disconnect the wiring connector (ref.B fig.3).

Loosen the nuts securing the retaining bracket (ref.C fig.3). Remove the bracket (ref.D fig.3).

Remove the display (fig.4) and proceed with replacement.

B D C

Fig. 4

34

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE KEY SWITCH

Fig. 1

Equipment and tools

A

A

T handle hex key 5 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Fig. 2

B

Fig. 3

Phase 2 Remove the starter key(fig.2).

Unscrew the nut (ref. B fig.2), remove the switch block from the console (fig.3).

Disconnect the wiring connectors and proceed with the replacement.

INSTALLATION Before reconnecting the Faston connectors, check that they are firmly attached. If not, tighten the connectors with Faston pliers.

35

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE HORN Equipment and tools

Fig. 1

T handle hex key 5 mm

open ended spanner 10 mm

A

A

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 2

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

B

C Phase 2 5 MM T HANDLE HEX KEY - 10 mm OPEN ENDED SPANNER Using the open ended spanner, counterhold the nut (ref.B fig.2), and with the T handle hex key loosen and remove the screw securing the horn (ref.A fig.3). Recover the washers.

Disconnect the wiring connectors, remove the horn and proceed with the replacement.

INSTALLATION Before reconnecting the Faston connectors, check that they are firmly attached to the wires. If not, tighten the connectors with Faston pliers.

36

Fig. 3

SERVICE

ELECTRICAL SYSTEM

FUSE REPLACEMENT • •

24V horn relay power fuse (F3) Keyswitch fuse (F2)

Equipment and tools Fig. 1

small flat blade screwdriver

T handle hex key 5 mm

A

A

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the carriage to a safe place, away from areas of transit of other vehicles and pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 2

F2 Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

B

F3

Phase 2 SMALL FLAT BLADE SCREWDRIVER Using the small flat blade screwdriver, push in the retaining tabs (ref.B Fig.2) and withdraw the fuse holder.

Remove the old fuse and fit a new one.

Fig. 3

37

SERVICE

ELECTRICAL SYSTEM

tiller board: configuration and calibration configuration When should this procedure be carried out?

- When the tiller board is replaced.

In order to avoid accidentally operating the horn microswitch during the configuration operation, it is advisable to carry out the procedure before inserting the card in the tiller casing.

B

C A Fig. 1 Procedure Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Move the jumper on the tiller board from position P (Parking) to position C (Configuration) (fig.1).

Fig. 2

Connect the battery and turn the starter key to ON. Phase 2 Fig. 3 The LED display shows 0 (no configuration) or a number identifying the type of configuration saved on the board (fig.2).

Press the Snail microswitch (ref.B fig.1) to increase the value until the configuration number 3 (trucks with on-off type lifting and lowering buttons) appears on the LED display.

To decrease the value, press the horn microswitch (ref.A fig.1).

Phase 3 Confirm the configuration by pressing the Bellyswitch microswitch (ref.C fig.3). On the LED display a decimal point appears after the configuration number (fig.3).

38

SERVICE

ELECTRICAL SYSTEM

Phase 4 Switch off the truck.

Move the jumper on the tiller circuit board from position C (Configuration) to position P (Parking) (fig.1).

Phase 5 Insert the board in its slot in the tiller casing.

Calibration

Fig. 4

D

Fig. 5

When should this procedure be carried out?

- When the tiller board is replaced.

- When at top speed the truck does not travel at a steady speed.

- If traction stops when the butterfly control is in the fully rotated position.

- When there is a considerable difference in speed between forward and reverse travel.

Procedure Before starting work check that all the lifting and lowering buttons are connected to the tiller board and that the board is firmly inserted in its slot.

Turn the keyswitch to OFF. Phase 1 Move the jumper on the tiller board from position P (Parking) to position T (Teaching) (fig.1).

Turn the keyswitch to ON. Fig. 6 Phase 2 The LED display shows zero (fig.2).

Press and release the lift button located on the left-hand side of the tiller casing (JP14, ref.D fig.5) to save the neutral position of the butterfly control.

E

Fig. 7

If the LED display shows the value 8, indicating that at the moment the position was saved, the butterfly control was not in neutral position (at exactly 90° relative to the axis of rotation).

Phase 3 The LED display will show a dash (fig.4).

Rotate the butterfly control fully to the right and hold it in this position (fig.5). Press and release the lift button located on the left-hand side of the tiller casing (ref. D fig.5).

The LED display will show another dash, indicating that the butterfly position has been successfully saved (fig.6).

39

SERVICE

ELECTRICAL SYSTEM Phase 4 Release the butterfly control.

Rotate the butterfly control fully to the left and hold it in this position (fig.7).

Press and release the lowering button located on the left-hand side of the tiller casing (ref.E fig.7).

The LED display will show another dash, indicating that the butterfly position has been successfully saved (fig.8).

Fig. 8

Phase 5 Release the butterfly control.

Move the jumper on the tiller circuit board from position T (Teaching) to position P (Parking) (fig.1).

A decimal point will appear on the LED display (fig.9).

Fig. 9

Turn the keyswitch to OFF. If the truck is switched off before the jumper is moved to position P (parking), the calibration values will be lost and the procedure will have to be repeated.

40

SERVICE

ELECTRICAL SYSTEM

TILLER BOARD REPLACEMENT Equipment and tools

T handle hex key 2.5 - 4 mm

small flat blade screwdriver

A Fig. 1

B

C

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

D Fig. 2

Phase 1 4mm T HANDLE HEX KEY Unscrew the bolts securing the upper casing ref.A,B,C fig.1).

EF G

H

Phase 2 Lift the upper casing and detach it from the lower casing (fig.2). Disconnect the serial cable connector (ref.D fig.2) and place the cover on a clean work bench.

Fig. 3

Phase 3 2.5mm T HANDLE HEX KEY Loosen the screw securing one of the two butterfly controls (ref.E fig.3) and recover the washer (ref.F fig.3). Slide the butterfly off the pin (ref.G fig.3). Remove the other butterfly control complete with the guide pin (ref.H fig.3).

Phase 4 SMALL FLAT BLADE SCREWDRIVER Unscrew the screw securing the tiller board retaining clip (ref.I fig.4).

Remove the retaining clip (ref.J fig.4) and the board from its slot (ref.K fig.4), disconnect the connectors of the various microswitches.

Proceed with replacement.

After installing the new board, carry out the configuration and calibration procedure (see "TILLER BOARD: CONFIGURATION AND CALIBRATION").

K

J Fig. 4

I

41

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF TILLER BUTTONS Equipment and tools

A T handle hex key 4 mm

small flat blade screwdriver

Fig. 1

B

C

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

D Fig. 2

Fig. 3

Phase 1 4mm T HANDLE HEX KEY Unscrew the bolts securing the upper casing (ref.A,B,C fig.1).

Phase 2 Lift the upper casing and detach it from the lower casing (fig.2). Disconnect the serial cable connector (ref.D fig.2) and place the cover on a clean work bench.

Phase 3 SMALL FLAT BLADE SCREWDRIVER Using the screwdriver, prise open the clips (fig.4) and push the button its seat (fig.4,5).

Proceed with replacement.

Fig. 4

Fig. 5 42

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE TILLER CONTROL SPRINGS Equipment and tools

T handle hex key 2.5 - 4 mm

small flat blade screwdriver

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

A Fig. 1

B

C

Phase 1 4 mm T HANDLE HEX KEY Unscrew the bolts securing the upper casing (ref.A,B,C fig.1).

D Phase 2 Lift the upper casing and detach it from the lower casing (fig.2). Disconnect the serial cable connector (ref.D fig.2) and place the cover on a clean work bench.

Fig. 2

EF G

Fig. 3

H

Phase 3 2.5 mm T HANDLE HEX KEY Loosen the screw securing one of the two butterflies (ref.E fig.3) and recover the washer (ref.F fig.3). Slide the butterfly off the pin (ref.G fig.3). Remove the other butterfly control complete with the guide pin (ref.H fig.3).

43

SERVICE

ELECTRICAL SYSTEM BUTTERFLY CONTROL SPRING

Fig. 4

Phase 4 SMALL FLAT BLADE SCREWDRIVER With the screwdriver, prise out the butterfly control guide bush (ref.I fig.4).

In the same way, prise out the butterfly control spring (ref.J fig.4).

Proceed with the replacement.

J

I BELLY AND HORN BUTTON SPRINGS Fig. 5

Phase 4 SMALL FLAT BLADE SCREWDRIVER With the screwdriver, apply leverage under the belly button in correspondence with the locking pin (fig.5). Remove the button (ref.K fig.6)and recover the spring(ref.L fig.6).

In the same way, apply leverage under the horn button in correspondence with the locking pin (fig.5). Remove the button (ref.M fig.6)and recover the spring(ref.N fig.6).

Proceed with the replacement.

Fig. 6

K L

N

M

44

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE TILLER ENABLES SENSOR Equipment and tools Fig. 1

T handle hex key small cross-head 4-5 mm screwdriver

A

A

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Use the T handle hex key to remove the reduction unit cover screws (ref.B fig.2).

Phase 2 4 mm T HANDLE HEX KEY Unscrew the bolts securing the upper tiller casing (ref.C fig.3).

B

B

Fig. 2

C Fig. 3

C

C

Phase 3 Lift the upper casing and detach it from the lower casing (fig.4). Disconnect the wiring connector of the tiller sensor cable (ref.D fig.4).

D Fig. 4

45

SERVICE

ELECTRICAL SYSTEM Phase 4 SMALL CROSS-HEAD SCREWDRIVER While keeping the tiller lowered, use the small cross-head screwdriver to unscrew the set screw securing the sensor (ref.E fig.6).

Remove the sensor from its housing (fig.6), recover the wire and proceed with the replacement.

The optimal distance between the sensor and the cam is 4 mm.

Fig. 5 Fig. 6

46

E

SERVICE

HYDRAULIC SYSTEM

hydraulic system HYDRAULIC FUNCTIONS ����������������������������������������������������������������������������������������������������������������������������������������� 2 OIL SUPPLY TO THE HYDRAULIC CIRCUIT ������������������������������������������������������������������������������������������������������������� 3 PRESSURE CONTROL VALVES �������������������������������������������������������������������������������������������������������������������������������� 3 DIRECTIONAL VALVES ���������������������������������������������������������������������������������������������������������������������������������������������� 3 HYDRAULIC DIAGRAMS ������������������������������������������������������������������������������������������������������������������������������������������� 4 symbols ������������������������������������������������������������������������������������������������������������������������������������������������������������������� 4 MAIN HYDRAULIC DIAGRAM ������������������������������������������������������������������������������������������������������������������������������������ 5 HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS ������������������������������������������������������������������������������������������� 6 SOLENOID VALVE OPERATION TABLE �������������������������������������������������������������������������������������������������������������������� 6 HYDRAULIC DIAGRAM FOR FORK LIFTING ����������������������������������������������������������������������������������������������������������� 7 HYDRAULIC DIAGRAM FOR FORK LOWERING ������������������������������������������������������������������������������������������������������ 8 HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE ����������������������������� 9 HYDRAULIC COMPONENTS ���������������������������������������������������������������������������������������������������������������������������������� 10 REMOVAL OF THE PRESSURE RELIEF VALVE ����������������������������������������������������������������������������������������������������� 10 CALIBRATION OF THE PRESSURE RELIEF VALVE ���������������������������������������������������������������������������������������������� 11 CARTRIDGE SOLENOID VALVES �������������������������������������������������������������������������������������������������������������������������� 12 KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS ������������������������������������������������������������������������������������� 12 REMOVAL OF THE SOLENOID VALVE ������������������������������������������������������������������������������������������������������������������� 13 CYLINDERS �������������������������������������������������������������������������������������������������������������������������������������������������������������� 15 SINGLE ACTING CYLINDER ������������������������������������������������������������������������������������������������������������������������������������ 15 LIFTING CYLINDER �������������������������������������������������������������������������������������������������������������������������������������������������� 15 KEY TO LIFTING CYLINDER COMPONENTS ��������������������������������������������������������������������������������������������������������� 16 REMOVAL OF THE LIFTING CYLINDER ����������������������������������������������������������������������������������������������������������������� 17 BLEEDING AIR FROM THE LIFTING CYLINDER ���������������������������������������������������������������������������������������������������� 19 REPLACEMENT OF THE LIFTING CYLINDER SEALS ������������������������������������������������������������������������������������������� 20 lift pump ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 22 KEY TO LIFT PUMP COMPONENTS ����������������������������������������������������������������������������������������������������������������������� 22 REMOVAL OF THE LIFT PUMP ������������������������������������������������������������������������������������������������������������������������������� 24 REPLACEMENT OF THE PUMP ������������������������������������������������������������������������������������������������������������������������������ 26 REPLACEMENT OF THE CYLINDER SUPPLY PIPE ���������������������������������������������������������������������������������������������� 27

1

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC FUNCTIONS • •

Fork Lifting Fork Lowering

FORK LIFTING/LOWERING The fork lifting speed is determined by the rpm at which the pump motor transmits drive to the pump drive shaft.

In the lowering stage the check valve prevents the flow of oil through the pump and the oil returns to the reservoir through the flow control valve.

2

SERVICE

HYDRAULIC SYSTEM

OIL SUPPLY TO THE HYDRAULIC CIRCUIT Fixed displacement pumps With fixed displacement pumps, the oil flow is constant, providing the rotation speed of the motor shaft remains unchanged.

A reduction in the shaft rpm will reduce the pump capacity: if the rpm are reduced so is the flow rate and vice versa; the pressure, providing the load is unchanged, remains constant.

PRESSURE CONTROL VALVES Pressure limiting valves The "pressure limiting" or "pressure relief" valves are mainly used to guarantee the maximum pressure permitted in the system and to protect the pump from damaging pressure levels that exceed its own structural characteristics.

Pump The use of pressure limiting devices is not restricted functions described above, but they are commonly used in many devices where it is crucial to prevent pressure build ups. An example is anti-shock valves.

As long as the circuit is not subjected to excess pressure conditions, the pressure limiting device remains in the closed position: the force exerted by the pressurised oil is lower than that exerted by the opposing spring. With the piston at its end-of-stroke or if an anomalous situation arises which generates forces in excess of the set level (for example with a load in excess of the load capacity), the over-pressured oil overcomes the force of the spring and flows towards the oil outlet.

DIRECTIONAL VALVES One-way and check valves.

The function of "one-way" or "non-return" valves is to allow the oil to flow in one direction only, while preventing the flow in the opposite direction.

They are essentially comprised of a fixed part connected to the end of the pipe; the internal seat contains the moving element, which might be a ball or a conical plug.

Check valves instead have an opposing spring. In the direction of free flow, the oil pressure must overcome the force exerted by the spring.

3

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS symbols

3-POSITION SOLENOID VALVE

2-POSITION SOLENOID VALVE

ONE-WAY VALVE

FILTER

DOUBLE ACTING CYLINDER

PROPORTIONAL VALVE

SINGLE ACTING CYLINDER

PUMP

RESERVOIR

HYDRAULIC MOTOR

LINE CONNECTION

4

M

ELECTRIC MOTOR

PRESSURE RELIEF VALVE

FLOW VALVE

MANUAL COCK

BY-PASS VALVE

SERVICE

HYDRAULIC SYSTEM

MAIN HYDRAULIC DIAGRAM

M

5

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS •

Fork Lifting

•

Fork Lowering

•

Oil drain through pressure relief valve

SOLENOID VALVE OPERATION TABLE

Function Slow fork lifting

Pump

Q1

P

+

Slow fork lowering Oil drain through pressure relief valve

= pump in operation P + = solenoid valve coil energised

6

Q1

P

pressure relief valve

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR FORK LIFTING

M

7

HYDRAULIC SYSTEM HYDRAULIC DIAGRAM FOR FORK LOWERING

M

8

SERVICE

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE Pressure relief or pressure limiting valves are used in hydraulic systems to maintain the pressures permitted by the system and to protect and safeguard the system against sudden pressure surges that could seriously damage the components.

The pressure relief valve may intervene in the following cases: • • •

Pressure control not suitable for the truck load capacity.

Attempt to lift a load in excess of the truck's load capacity Faulty or stuck valve

M

9

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC COMPONENTS REMOVAL OF THE PRESSURE RELIEF VALVE Malfunction of the pressure relief valve can be caused by the presence of dirt or weakening of the internal spring.

In the first case thorough cleaning is required, in the second case the valve needs to be replaced.

Equipment and tools Fig. 1

medium flat blade T handle hex key oil resistant gloves screwdriver 5 mm

open ended spanner 22 mm

A

A

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 2

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Open the cover.

Phase 2 22 mm OPEN ENDED SPANNER - OIL RESISTANT GLOVES - MEDIUM FLAT BLADE SCREWDRIVER Wear the oil resistant gloves.

Using the open ended spanner, unscrew and remove the valve cap (ref.B fig.3).

Using the socket wrench, unscrew and remove the complete valve (ref.C fig.3), recover the spring (ref.D fig.3) and proceed with the replacement.

INSTALLATION On installation, tighten the valve with a torque wrench to 13 Nm. 10

Fig. 3

D B C

SERVICE

HYDRAULIC SYSTEM

CALIBRATION OF THE PRESSURE RELIEF VALVE The pressure relief valve must be calibrated following replacement.

Equipment and tools

medium flat blade screwdriver

open ended spanner 22 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Fig. 1 Fig. 2

Phase 1 Connect the battery and switch on the truck (starter key to ON).

Place on the forks a load equivalent to the truck's load capacity, as indicated on the truck's dataplate.

Phase 2 22 mm OPEN ENDED SPANNER - MEDIUM FLAT BLADE SCREWDRIVER Using the open ended spanner, unscrew and remove the valve cap (ref.A fig.2).

With the screwdriver turn the adjuster screw (ref.B fig.3) counter-clockwise until, while holding pressed press one of the fork lifting buttons on the tiller (fig.4), the pressure is reduced and the oil drains into the reservoir (lifting stops). At this point, turn the adjuster screw in the opposite direction (clockwise) until the point where the forks start to lift again.

Release the fork lift button and screw in the adjuster screw by a further ¼turn.

Carry out a few trial lifts and lowering manoeuvres with the load on the forks, checking that the pressure setting is sufficient to cope with the pressure surge during the initial lifting stage.

If not, tighten the screw by a further ¼ turn.

A Fig. 3

B

Fig. 4

INSTALLATION On installation, tighten the valve cap to a torque of 12 Nm.

11

SERVICE

HYDRAULIC SYSTEM

CARTRIDGE SOLENOID VALVES The solenoid valves of the directional control valve are of the screw-in cartridge type.

This type of valve is comprised of a body with a fixed hex nut, a threaded part, a set of static seals; inside a moving element allows communication between the various chambers.

KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS

1

3

2

Ref.

12

Description

1

Coil

2

Valve body

3

Coil retaining plug

SERVICE

HYDRAULIC SYSTEM

REMOVAL OF THE SOLENOID VALVE Equipment and tools

oil resistant gloves

small cross-head T handle hex key screwdriver 5 mm

open ended spanner 24 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Open the cover.

Fig. 1

A

A

Phase 2 SMALL PHILIPS SCREWDRIVER Unscrew the retaining screws and disconnect the connector of the power supply to the solenoid valve coil (fig.2).

Phase 3 OIL RESISTANT GLOVES - 24mm OPEN ENDED SPANNER Unscrew and remove the coil retaining plug (ref.B fig.3) and recover the seal (ref.C fig.3).

Withdraw the coil (ref.D fig.3) and recover the seals.

Fig. 2 13

HYDRAULIC SYSTEM Use the open ended spanner to unscrew the valve body from the hydraulic block and proceed with replacement.

SERVICE B

INSTALLATION On installation, tighten the valve retaining screws to a torque of 39 to 51 Nm.

C

D

Fig. 3

14

SERVICE

HYDRAULIC SYSTEM

CYLINDERS SINGLE ACTING CYLINDER Single acting cylinders receive and discharge the oil through a single pipe and the pressurised oil acts on just one side of the piston (single acting pushing cylinders) or on the flat face of the rod in the case of plunger type cylinders.

Single-acting plunger type cylinders In this type of cylinder the piston is replaced by the flat end face of the piston rod or plunger; these cylinders are usually mounted vertically or in other positions in which the force of gravity returns the plunger to the rest position. Usually the diameter of the lower end of the rod is increased by a few millimetres in order to avoid it slipping out at the end of it's upstroke; this gives rise to a hydraulic damping effect during the last stages of the stroke which helps the slowing of the rod and avoids recoil on the upper end cap. Static seals located in the end cap prevent oil leaking outside the cylinder.

To replace these seals it is necessary to unscrew the seal carrier bush.

Single acting cylinder with hollow rods differ in that before the lifting stroke begins the rod is also filled with oil. This solution is used on particularly tall truck masts to increase the resistance of the cylinders at the maximum height and make it possible to use smaller cylinder barrels and rods.

Static seals and dynamic seals Dynamic seals, installed on the piston, prevent oil from leaking between the chambers of the cylinder barrel, while the static seals, located at the joint between two parts (seal carrier bush - barrel) or between the sliding parts (rod barrel), prevent oil leaking from the inside to the outside of the cylinder.

LIFTING CYLINDER

Type of cylinder Type “A” single-acting plunger cylinder with solid rod

Rod diameter mm

Height H3 mm

50

130

H3

15

SERVICE

HYDRAULIC SYSTEM KEY TO LIFTING CYLINDER COMPONENTS The cylinder is of the single-acting plunger type.

After cylinder replacement, the air must be led through the bleed valve.

The static seals can be replaced with the cylinder installed in the truck.

7

5

3

4

1

2

Ref.

16

6

Description

1

Barrel and end cap

2

Piston rod

3

Rod end cap

4

Piston

5

Seal

6

Seal kit

7

Air bleed screw

SERVICE

HYDRAULIC SYSTEM

REMOVAL OF THE LIFTING CYLINDER Equipment and tools

hoist load capacity 2000 kg

2 lifting slings load capacity 2000 kg

T handle hex key 5 mm

oil resistant gloves

"Parker" service plug

combination spanner 16 mm

open ended spanner 16-19 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Use the T handle hex key to remove the reduction unit cover screws (ref.B fig.2).

Phase 2 HOIST - 2 LIFTING SLINGS Attach the two lifting slings to the attachment points on the truck base.

Attach the lifting slings to the hoist and take up the slack.

Fig. 1

A

B

A

B

Fig. 2

17

SERVICE

HYDRAULIC SYSTEM Phase 3 OIL RESISTANT GLOVES - 19 mm OPEN ENDED SPANNER - "PARKER" PLUG Wear the oil resistant gloves.

Using the spanner, unscrew the hydraulic hose union (ref.F fig.4).

Fit the service plug to the hydraulic hose.

Fig. 3

D

C

Phase 4 16 mm OPEN ENDED SPANNER - 16 mm COMBINATION SPANNER Using the open ended spanner, restrain the nut of the upper cylinder mounting (ref.C fig.3) while unscrewing the cylinder mounting bolt using the combination spanner (ref.D fig.3) Using the hoist, lift the truck 100 mm from the ground and remove cylinder cap from its housing.

Phase 5 16 mm OPEN ENDED SPANNER - 16 mm COMBINATION SPANNER Using the open ended spanner, restrain the nut of the lower cylinder mounting while unscrewing the lower cylinder mounting bolt using the combination spanner (ref.E fig.3) Withdraw the cylinder from the lower housing, place it on a clean workbench with vice and proceed with disassembly or replacement.

E

INSTALLATION Before tightening the hydraulic fittings, consult the reference table, (see "CORRECT METHOD FOR APPLYING FEMALE FITTINGS" "PREFACE" section).

After installation, bleed the air from the cylinder (see “BLEEDING AIR FROM THE LIFTING CYLINDER”).

F

Fig. 4

18

SERVICE

HYDRAULIC SYSTEM

BLEEDING AIR FROM THE LIFTING CYLINDER Equipment and tools

oil resistant gloves

socket wrench with flexible handle 10 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1 OIL RESISTANT GLOVES - 10 mm SOCKET WRENCH WITH FLEXIBLE HANDLE Wear the oil resistant gloves.

Using the socket wrench, loosen the air bleed screw (ref.B fig.1).

Connect the battery and turn the starter key to ON. Phase 2 10 mm SOCKET WITH FLEXIBLE HANDLE Lift the forks using the button located on the tiller; continue lifting until oil flows out of the air bleed valve (ref.A fig.1).

Stop lifting and tighten the bleed screw (ref.B fig.1).

Wipe the cylinder with a clean cloth.

Fig. 1

A B

19

SERVICE

HYDRAULIC SYSTEM REPLACEMENT OF THE LIFTING CYLINDER SEALS Equipment and tools

small flat blade screwdriver

oil resistant gloves

C spanner

work bench

vice

brush

chain wrench

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground.

Fig. 1

A

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

B Phase 1 Carry out the lifting cylinder removal procedure (see “REMOVAL OF THE LIFTING CYLINDER”).

Phase 2 WORK BENCH - VICE - OIL RESISTANT GLOVES - C SPANNER CHAIN WRENCH Wear the oil resistant gloves.

Secure the cylinder in the vice, interposing a rubber protection between the vice jaws and the cylinder barrel.

Apply the C spanner to one of the notches on the seal carrier bush (ref.A fig.1) and apply the pipe wrench to the cylinder barrel (ref.B fig.1). Unscrew the bush from the cylinder and slide it off the rod (fig.1).

20

C

D Fig. 2

SERVICE

HYDRAULIC SYSTEM

REPLACEMENT OF THE STATIC SEALS

Fig. 3

Phase 3 SMALL FLAT BLADE SCREWDRIVER Using the screwdriver, remove the internal seals (ref.C fig.2) and the seals external to the bush (ref.D fig.2) and proceed with replacement.

REPLACEMENT OF THE DYNAMIC SEAL Phase 4 SMALL FLAT BLADE SCREWDRIVER Remove the rod from the cylinder (fig.3).

Using the flat blade screwdrivers, remove the dynamic seal from the piston (ref.E fig.4).

INSTALLATION

Fig. 4

E

Fitting the seals is a delicate stage in the lifting cylinder assembly procedure. Most cylinder maintenance operations can be attributed to defective seals.

Clean the seal carrier bush and lubricate the seal contact faces in the bush and the seals themselves with clean hydraulic oil before installation.

The seal carrier bush should be tightened to a torque of 340 Nm.

21

HYDRAULIC SYSTEM

lift pump KEY TO LIFT PUMP COMPONENTS

Ref.

22

Description

1

Pump motor

2

Directional control valve

3

Pump body

4

Reservoir

5

Proportional solenoid valve EV1

6

Drive coupling

7

Pressure relief valve

8

Oil intake pipe

9

Oil outlet pipe

10

Oil flow control valve

11

Filter

SERVICE

SERVICE

HYDRAULIC SYSTEM

1

1

5

6

10

2

7 3

9 8 4

11

23

SERVICE

HYDRAULIC SYSTEM REMOVAL OF THE LIFT PUMP

The same hydraulic system is used on all the different lift truck series. The only difference lies in the pump motor which on MP18 - MP20 trucks has a power rating of 1000W and on MP20L - MP22 trucks has a power rating of 1400W. All the other components are the same and are removed in the same way.

Equipment and tools Fig. 1

bridge crane load capacity 1000 kg

spreader bar

T handle hex key 5-6 mm

open ended spanner 11-12-19 mm

small cross-head oil resistant gloves screwdriver

A

A

Fig. 2 Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

C

B

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Open the cover.

24

D

Fig. 3

SERVICE

HYDRAULIC SYSTEM

Phase 2 11 mm open ended spanner Remove the terminal protection caps, then use the open ended spanner to unscrew the nuts securing the pump motor power cables (ref.B fig.2).

Make a note of the cable positions. Remove the cables and disconnect the connectors.

E Fig. 4

Phase 3 SMALL CROSS-HEAD SCREWDRIVER Unscrew the retaining screws and disconnect the power supply connector of the solenoid valve coil (ref.C fig.3).

Fig. 5

Phase 4 OIL RESISTANT GLOVES -19mm OPEN ENDED SPANNER Using the open ended spanner, unscrew the union of the hydraulic pipe (ref.D fig.3).

Phase 5 12 mm open ended spanner Using the open ended spanner, loosen the bolts securing the battery restraints (ref.E fig.4) and remove the battery restraints.

Phase 6 BRIDGE CRANE - SPREADER BAR Hook the spreader bar to the bridge crane. Position the bridge crane above the battery compartment.

Attach the spreader bar to the battery; carefully lift the battery clear of the battery compartment with the bridge crane (fig.5).

Gently lower the battery to the ground and detach the spreader bar.

F Fig. 6

Phase 7 6 mm T HANDLE HEX KEY Support the pump assembly with one hand and unscrew the screws securing it to the truck frame using the T handle hex key (ref.F fig.6).

Recover the pump and proceed with replacement or disassembly.

25

HYDRAULIC SYSTEM

SERVICE

REPLACEMENT OF THE PUMP Equipment and tools

T handle hex key 4 mm

small flat blade screwdriver

oil resistant gloves

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the procedure to remove the lift pump (see "REMOVAL OF THE LIFT PUMP").

Fig. 1

A Fig. 2

Phase 2 SMALL FLAT BLADE SCREWDRIVER Loosen the screw of the steel clip securing the reservoir to the flange (ref.A fig.2). Withdraw the pump complete with flange from the reservoir.

Phase 3 4 mm T HANDLE HEX KEY Unscrew and remove the nuts securing the pump body to the flange (ref.B fig.3), remove the pump and proceed with replacement.

B

INSTALLATION On installation tighten the nuts securing the pump to the flange with a torque wrench to 5 Nm. Use medium Loctite.

26

Fig. 3

SERVICE

HYDRAULIC SYSTEM

REPLACEMENT OF THE CYLINDER SUPPLY PIPE Equipment and tools Fig. 1

T handle hex key 5-6 mm

open ended spanner 19 mm

"Parker" service oil resistant gloves plugs

A

A

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

B

B

Fig. 2 Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Open the cover.

Use the T handle hex key to remove the reduction unit cover screws (ref.B fig.2).

Phase 2 OIL RESISTANT GLOVES - 19 mm OPEN ENDED SPANNER - "PARKER" PLUGS Wear the oil resistant gloves.

Using the open ended spanner, unscrew the unions of the hydraulic pipe (ref.C-D fig.3).

Fit the service plugs to the unions. Recover the hydraulic pipe and proceed with replacement.

C

D

27

HYDRAULIC SYSTEM

28

SERVICE

SERVICE

MECHANICS

mechanics DRIVE WHEEL ������������������������������������������������������������������������������������������������������������������������������������������������������������ 2 KEY TO DRIVE WHEEL COMPONENTS ������������������������������������������������������������������������������������������������������������������� 2 REMOVAL OF THE DRIVE WHEEL ���������������������������������������������������������������������������������������������������������������������������� 3 PIVOTING WHEEL ASSEMBLY ��������������������������������������������������������������������������������������������������������������������������������� 4 KEY TO PIVOTING WHEEL ASSEMBLY COMPONENTS ���������������������������������������������������������������������������������������� 4 REMOVAL OF THE PIVOT WHEEL ASSEMBLY �������������������������������������������������������������������������������������������������������� 5 LOAD WHEELS ���������������������������������������������������������������������������������������������������������������������������������������������������������� 7 KEY TO LOAD WHEEL COMPONENTS �������������������������������������������������������������������������������������������������������������������� 7 REPLACEMENT OF THE LOAD WHEELS ���������������������������������������������������������������������������������������������������������������� 8 LOAD WHEEL ASSEMBLY REPLACEMENT ������������������������������������������������������������������������������������������������������������� 9 LINKAGE ������������������������������������������������������������������������������������������������������������������������������������������������������������������ 10 KEY TO LINKAGE ASSEMBLY COMPONENTS ������������������������������������������������������������������������������������������������������ 10 REMOVAL OF THE LINKAGE ASSEMBLY ��������������������������������������������������������������������������������������������������������������� 11 LINKAGE ASSEMBLY GREASING POINTS ������������������������������������������������������������������������������������������������������������� 15 TILLER ���������������������������������������������������������������������������������������������������������������������������������������������������������������������� 16 KEY TO TILLER COMPONENTS ������������������������������������������������������������������������������������������������������������������������������ 16 REMOVAL OF THE TILLER �������������������������������������������������������������������������������������������������������������������������������������� 17 TILLER SPRING REPLACEMENT ���������������������������������������������������������������������������������������������������������������������������� 19 traction motor �������������������������������������������������������������������������������������������������������������������������������������������������� 21 KEY TO TRACTION MOTOR COMPONENTS ��������������������������������������������������������������������������������������������������������� 21 REMOVAL OF THE TRACTION MOTOR ������������������������������������������������������������������������������������������������������������������ 22 OIL SEAL REPLACEMENT ��������������������������������������������������������������������������������������������������������������������������������������� 24 BEARING REPLACEMENT �������������������������������������������������������������������������������������������������������������������������������������� 26

1

MECHANICS

DRIVE WHEEL KEY TO DRIVE WHEEL COMPONENTS

2

1

Ref.

2

Description

1

Vulkollan ring complete with hub

2

Drive wheel retaining nut

SERVICE

SERVICE

MECHANICS

REMOVAL OF THE DRIVE WHEEL Equipment and tools

hydraulic jack

2 wooden blocks

T handle hex key 6 mm

socket 19 mm

ratchet with extension bar

extension bar

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Raise the forks to the maximum height, turn the keyswitch to OFF and disconnect the battery.

A A

A

Phase 1 6 mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Fig. 1 Fig. 2

Phase 2 HYDRAULIC JACK - N. 2 WOODEN STOCKS Position the hydraulic jack on the right-hand side of the truck body and raise the truck sufficiently to insert the wooden block underneath. Lower the jack so that the truck rests on the wooden block. Repeat the operation on the left-hand side of the truck body (fig.2) Phase 3 19 mm socket - ratchet - extension bar - TORQUE WRENCH Unscrew and remove the nuts securing the drive whell to the reduction unit (ref.B. fig.3), recover the washers and remove the wheel.

INSTALLATION The traction wheel retaining nuts must be tightened using a torque wrench to a torque of 85 Nm.

B Fig. 3 3

SERVICE

MECHANICS

PIVOTING WHEEL ASSEMBLY KEY TO PIVOTING WHEEL ASSEMBLY COMPONENTS

3

3

1 4 12

2

11

3 2 3 5 6

9

7

Ref.

4

8

10

Description

8

7

Ref.

Description

1

Pivot pin

7

Dust cap

2

Damper

8

Bearing

3

Circlip

9

Polyurethane wheel

4

Screw

10

Spacer

5

Wheel retaining screw

11

Washer

6

Screw

12

Rubber bush

SERVICE

MECHANICS

REMOVAL OF THE PIVOT WHEEL ASSEMBLY Equipment and tools

hydraulic jack

2 wooden blocks

T handle hex key 8 mm

open ended spanner 19 mm

A A

A socket 19 mm

ratchet

small flat blade screwdriver

small external circlip pliers

Fig. 1 Fig. 2

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Raise the forks to the maximum height, turn the keyswitch to OFF and disconnect the battery.

Phase 1 6 mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Fig. 3

B

Phase 2 HYDRAULIC JACK - 2 WOODEN BLOCKS Position the hydraulic jack on the right-hand side of the truck body and raise the truck sufficiently to insert the wooden block underneath. Lower the jack so that the truck rests on the wooden block. Repeat the operation on the left-hand side of the truck body (fig.2)

5

SERVICE

MECHANICS Phase 3 8 MM FLEXIBLE T HANDLE HEX KEY Using the T handle hex key, unscrew the four screws securing the pivoting wheel assembly to the truck body (ref.B fig.3).

Remove the wheel assembly and proceed with its replacement or disassembly.

REMOVAL OF THE PIVOTING WHEEL

C D

Phase 4 19 mm socket - ratchet - 19 mm open ended spanner Counterhold the self-locking nut (ref.E fig.4) with the open ended spanner while unscrewing and removing the screw securing the pivoting wheel (ref.D fig.4) using the socket and ratchet. Recover the screw and the self-locking nut and remove the wheel from its support.

Proceed with replacement.

DISASSEMBLY OF THE PIVOTING WHEEL

Fig. 4 Fig. 5

E

F

Phase 5 SMALL FLAT BLADE SCREWDRIVER Using the small sized flat blade screwdriver, prise off the dust cap (ref.E fig.5) and recover the bearings (ref.F fig.5) and the spacer (ref.G fig.5).

Proceed with replacement

E

G F

Fig. 6

H

REMOVAL OF THE DAMPERS Phase 6 small external circlip pliers Using the external circlip pliers, remove the circlips (ref.H fig.6) and remove the damper.

Proceed with replacement

H J

REMOVAL OF THE BUFFER Phase 7 19 mm socket - ratchet - 19 mm open ended spanner Counterhold the self-locking nut (ref.I fig.7) with the open ended spanner, while unscrewing and removing the screws of the fork (ref.J. fig.7) using the socket and the wrench. Remove the buffer (ref.K fig.8).

Proceed with replacement INSTALLATION The nut securing the pivoting wheel must be tightened using a torque to a torque of 85 Nm.

6

I

Fig. 7

Fig. 8

K

SERVICE

MECHANICS

LOAD WHEELS KEY TO LOAD WHEEL COMPONENTS

1 3

1

4

2 2

4

4

8 6

7

5

9 7

Ref.

6

Description

1

Spring pin

2

Tie-rod pivot pin

3

Roller

4

Bush

5

Load wheel screw

6

Dust cover

7

Bearing

8

Load wheel

9

Spacer 7

SERVICE

MECHANICS REPLACEMENT OF THE LOAD WHEELS Equipment and tools

Fig. 1

T handle hex key 8 mm

small flat blade screwdriver

2 wooden blocks 150x150x500 mm

grease gun

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Raise the forks to the maximum height, turn the keyswitch to OFF and disconnect the battery.

Fig. 2

B

A

Phase 1 2 WOODEN BLOCKS Position the wooden blocks under the forks (fig.1). Lower the forks so that they rest on the wooden blocks and continue lowering until the load wheels are raised off the ground by about 2 cm.

Turn the keyswitch to OFF and disconnect the battery.

C

D E

Phase 2 Fig. 5 8 mm T HANDLE HEX KEY Using the T handle hex key, unscrew and remove the load wheel retaining screw (ref.A fig.2). Withdraw the load wheel from its support (ref.B fig.2) and proceed with its disassembly or repalcement.

Phase 3 SMALL FLAT BLADE SCREWDRIVER Using the small flat blade screwdriver, prise off the dust cap (ref.C fig.3) and recover the bearings (ref.D fig.4) and the spacer (ref.E fig.4).

Proceed with the replacement INSTALLATION Following installation of new load wheels, grease the bearings using a grease gun.

8

SERVICE

MECHANICS

LOAD WHEEL ASSEMBLY REPLACEMENT Equipment and tools Fig. 1

hammer

driving tool Ø 15 mm

2 wooden blocks 150x150x500 mm

pin punch Ø 4 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Raise the forks to the maximum height.

Phase 1 2 WOODEN BLOCKS Position the wooden blocks under the forks (fig.1). Lower the forks so that they rest on the wooden blocks and continue lowering until the load wheels are raised off the ground by about 2 cm.

B A Fig. 2

C

Fig. 3

Turn the keyswitch to OFF and disconnect the battery.

Phase 2 HAMMER - PIN PUNCH - DRIVING TOOL Using the hammer and the pin punch, drive out the spring pin securing the pivot pin (ref.A fig.2). Drive out the pivot pin (ref.B fig.2) using the driving tool and the hammer.

D

Phase 3 HAMMER - PIN PUNCH - DRIVING TOOL Using the hammer and the pin punch, drive out the spring pin securing the pivot pin (ref.C fig.3). Drive out the pivot pin (ref.D fig.3) using the driving tool and the hammer. Withdraw the load wheel assembly from its housing.

Proceed with replacement.

9

SERVICE

MECHANICS

LINKAGE KEY TO LINKAGE ASSEMBLY COMPONENTS

1 2 3 3

2 6

5 4

7

7

10

2 2

2 12

11

4 9

2 10

7

2

8 4

Ref.

10

Description

1

Load wheels assembly

2

Bush

3

Pivot pin

4

Spring pin

5

Roller

6

Tie rod

7

Grease nipple

8

Linkage assembly pivot shaft

9

Truck base pivot pin

10

Retaining plate

11

Drive unit pivot pin

12

Cotter pin

7

4

SERVICE

MECHANICS

REMOVAL OF THE LINKAGE ASSEMBLY Equipment and tools Fig. 1

hoist load capacity 2000 kg

2 lifting slings load capacity 1500 kg

truck stand

T handle hex key 5-6 mm

lifting rope load capacity 1500 kg

open ended spanner 2x10 mm 12-16-19 mm

spreader bar

A

A

combination spanner 16 mm

B

B oil resistant gloves

hammer

"Parker" plug

driving tool Ø 15 mm

socket 9 mm

ratchet

long nose pliers

pin punch Ø 4 mm

Fig. 2

Procedure

C C

C Fig. 3

Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

D Fig. 4 11

SERVICE

MECHANICS Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Use the T handle hex key to remove the reduction unit cover screws (ref.B fig.2).

Fig. 5

Phase 2 6mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.C fig.3).

Remove the cover.

Fig. 6

Phase 3 12 mm open ended spanner Using the open ended spanner. loosen the bolts securing the battery restraints (ref.D fig.4) and remove the battery restraints.

Phase 4 BRIDGE CRANE - SPREADER BAR Hook the spreader bar to the bridge crane. Position the bridge crane above the battery compartment.

Attach the spreader bar to the battery; carefully lift the battery clear of the battery compartment with the bridge crane (fig.5).

Gently lower the battery to the ground and detach the spreader bar.

Phase 5 HOIST - 2 LIFTING SLINGS - TRUCK STAND Attach the two lifting slings to the lifting attachments on the truck base.

Attach the slings to the hoist, lift the truck and place it on the stand. Tighten the crossbar of the stand and detach the lifting slings.

12

E

F

Fig. 7

SERVICE

MECHANICS

Phase 6 OIL RESISTANT GLOVES - 19mm OPEN ENDED SPANNER - "PARKER" PLUG Wear the oil resistant gloves.

Using the spanner, unscrew the hydraulic hose union (ref.E fig.6).

Fit the plug to the hydraulic hose.

H

G

Phase 7 2 x 10 mm OPEN ENDED SPANNERS Using the two spanners, unscrew the nuts securing the traction motor power supply cables (ref.F fig.6). Note the position of the cables prior to removing them. Disconnect all the wiring connectors.

Phase 8 HOIST - LIFTING ROPE Attach the lifting rope to the reduction unit support, passing the rope behind the drive wheel (fig.7). Attach the two ends of the lifting rope to the overhead crane and take up the slack in the rope.

Phase 9 16 mm OPEN ENDED SPANNER - 16 mm COMBINATION SPANNER Using the open ended spanner, restrain the nut of the upper cylinder mounting (ref.G fig.8) while unscrewing the cylindermounting bolt using the combination spanner (ref.H fig.8).

Fig. 8

I

J

Fig. 9

Phase 10 9 mm SOCKET - RATCHET Using the socket wrench, unscrew and remove the grease nipples of the pivot pins of the reduction unit support (ref.I fig.9) Recover the retaining plates (ref.J fig.9).

Fig. 10

K L

Phase 11 LONG NOSE PLIERS - HAMMER - DRIVING TOOL Using the long nose pliers, remove the cotter pins securing the pivot pins of the reduction unit support (ref.K fig.10) Drive out the pivot pins using the hammer and the driving tool (ref.L fig.10).

13

SERVICE

MECHANICS Phase 12 Using the hoist, remove the drive unit from the chassis (fig.11) Rest the drive unit on the ground, keeping it vertical to prevent oil leaking out.

Detach the lifting rope.

Fig. 11

Phase 13 HOIST - 2 LIFTING SLINGS Attach the two lifting slings to the attachment points on the truck base.

Attach the lifting slings to the hoist and take up the slack.

Phase 14 HAMMER - PIN PUNCH - DRIVING TOOL Using the pin punch and hammer, drive out the spring pins securing the pivot pins to the forks (ref.M fig.12) Drive out the pivot pin (ref.N fig.12) using the driving tool and the hammer.

Phase 15 HAMMER - PIN PUNCH - DRIVING TOOL Using the pin punch and hammer, drive out the spring pin securing the pivot pins to the truck base (ref.O fig.13) Drive out the pivot pin (ref.P fig.13) using the driving tool and the hammer.

Phase 16 Using the hoist, lift and remove the truck base. Rest the chassis on the ground.

Proceed with the disassembly or replacement of the linkage assembly.

N M Fig. 12

O P Fig. 13

14

SERVICE

MECHANICS

LINKAGE ASSEMBLY GREASING POINTS

Access to the two grease nipples on the linkage pivot pins is through the battery compartment.

Remove the battery before proceeding.

Grease gun

Remove the wheel cover.

15

SERVICE

MECHANICS

TILLER KEY TO TILLER COMPONENTS

1

3

4

13 2 9 8

12

5 11

10

6 7

Ref.

16

Description

1

Tiller casing

2

Spring

3

Upper tiller spring nut

4

Upper tiller spring retaining screw

5

Lower tiller spring retaining screw

6

Locknut

7

Bush

8

Buffer retaining screw

9

Buffer bracket

10

Buffer

11

Drive unit pivot pin

12

Spring pin

13

Plug

SERVICE

MECHANICS

REMOVAL OF THE TILLER Equipment and tools

2 open ended spanners 13 mm

T handle hex key 4-5-6 mm

hammer

driving tool Ø 15 mm

pin punch Ø 4 mm

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

A

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Use the T handle hex key to remove the reduction unit cover screws (ref.B fig.2).

A

B

B

Phase 2 6mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.C fig.3).

Remove the cover.

Fig. 2

C

C

C

Fig. 3 17

SERVICE

MECHANICS Phase 3 4 mm T HANDLE HEX KEY Using the T handle hex key, unscrew and remove the screws securing the tiller buffer (ref.D fig.5). Recover the buffer (ref.E fig.5).

Fig. 4

Removing the buffer relieves the force of the tiller spring, thereby making it easier to remove and install the tiller.

Phase 4 2 x 13 mm OPEN ENDED SPANNERS Disconnect the tiller wiring connector.

Using one of the spaners, restrain the self-locking nut securing the tiller spring (ref.F fig.6) and unscrew and remove the spring retaining bolt with the other spanner (ref.G fig.6). Recover the self-locking nut.

Phase 5 HAMMER - PIN PUNCH - DRIVING TOOL Lower the tiller.

Using the pin punch and hammer, drive out the spring pin securing the drive unit pivot pin (ref.H fig.7) Drive out the pivot pin (ref.I fig.7) using the driving tool and the hammer.

Remove the tiller assembly and proceed with its disassembly or replacement.

Fig. 5

E

D Fig. 6

G

F

Fig. 7

I H

18

SERVICE

MECHANICS

TILLER SPRING REPLACEMENT Equipment and tools

2 open ended spanners 13 mm

T handle hex key 4-5-6 mm

Procedure

Fig. 1

Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the key switch to OFF and disconnect the battery.

A

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Use the T handle hex key to remove the reduction unit cover screws (ref.B fig.2).

A

B

B

Phase 2 6 mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.C fig.3).

Remove the cover.

Fig. 2

C

C

C

Fig. 3 19

SERVICE

MECHANICS Phase 3 4 mm T HANDLE HEX KEY Using the T handle hex key, unscrew and remove the screws securing the motor cover (ref.B fig.5). Recover the buffer.5

Fig. 4

Removing the buffer relieves the force of the tiller spring, thereby making it easier to remove and install the tiller.

Phase 4 2 x 13 mm OPEN ENDED SPANNERS Disconnect the tiller wiring connector.

Using one of the spaners, restrain the self-locking nut securing the tiller spring (ref.F fig.6) and unscrew and remove the spring retaining bolt with the other spanner (ref.G fig.6). Recover the self-locking nut.

Phase 5 6 mm T HANDLE HEX KEY With the T handle hex key, remove the screw securing the upper part of the spring (ref.H fig.7).

Withdraw the spring from the tiller (fig.7) and proceed with replacement.

Fig. 5

E

D Fig. 6

G

F

Fig. 7

HS

20

SERVICE

MECHANICS

traction motor KEY TO TRACTION MOTOR COMPONENTS

1

2

3

4 5

10 11

14

6 9

7 8

13

12

16 17 18 15 19

Ref.

Description

Ref.

Description

1

Speed sensor

11

Brake guide retaining key

2

Circlip

12

Stator

3

Upper flange retaining screws

13

Rotor

4

Upper flange

14

Reduction unit pinion retaining key

5

Rubber cable guide

15

Lower bearing

6

Circlip

16

Thrust washer

7

Upper bearing

17

Circlip

8

Circlip

18

Oil seal

9

Gear wheel

19

Lower flange

10

Circlip 21

SERVICE

MECHANICS REMOVAL OF THE TRACTION MOTOR Equipment and tools

2 open ended spanners 10 mm

T handle hex key 10 mm

brush

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

A

Phase 1 Carry out the electromagnetic brake removal procedure (see "REMOVAL OF THE ELECTROMAGNETIC BRAKE" in the "BRAKING SYSTEM" section).

Phase 2 2 x 10 mm OPEN ENDED SPANNERS Using the two spanners, unscrew the nuts securing the traction motor power supply cables (ref.F fig.1) Note the position of the cables prior to removing them. Disconnect all the wiring connectors.

Phase 3 10 mm FLEXIBLE T HANDLE HEX KEY Unscrew and remove the screws securing the traction motor to the reduction unit (ref.A fig.2).

B

Fig. 2

22

SERVICE

MECHANICS

Phase 4 Lift the motor until the shaft is completely clear of the reduction unit.

Remove it from the truck body and proceed with replacement or disassembly.

INSTALLATION Before installing the motor on the reduction unit, lubricate the drive shaft with a thin, even layer of special grease: "SHELL STAMINA GREASE RL 2" or "ALBIDA GREASE EP2".

During the coupling stage, carefully rotate the wheel shaft to help the motor shaft engage with the pinion (fig.3).

The screws securing the reduction unit to the chassis must be tightened using a torque wrench to a torque of 24 Nm.

Fig. 3

23

SERVICE

MECHANICS OIL SEAL REPLACEMENT Equipment and tools

open ended spanmedium ner adjustable pliers 13 mm

plastic hammer

bush

puller

medium flat blade screwdriver

torque wrench

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Phase 1 Carry out the traction motor removal procedure (see “REMOVAL OF THE TRACTION MOTOR”).

B A

Fig. 1

Phase 2 13 mm OPEN ENDED SPANNER - MEDIUM ADJUSTABLE PLIERS CLOTH Wrap the cloth around upper part of the rotor and and hold it still using the adjustable pliers. Using the open ended spanner remove the nut (ref.A fig.1) securing the reduction unit drive pinion. Recover the washer.

C Fig. 2 24

SERVICE

MECHANICS

Phase 3 PULLER - MEDIUM ADJUSTABLE PLIERS Using the puller, remove the reduction unit drive pinion (ref.B fig.1).

Using the adjustable pliers, extract the pinion retaining key (ref.C fig.2).

Phase 4 MEDIUM FLAT BLADE SCREWDRIVER Using the flat blade screwdriver, prise the oil seal from its housing (ref.D fig.3).

Proceed with the replacement

D

Fig. 3

INSTALLATION Install the new oil seal using the plastic hammer and the bush.

The nut securing the reduction unit drive pinion must be tightened using a torque wrench to a torque of 35 Nm.

25

SERVICE

MECHANICS BEARING REPLACEMENT Equipment and tools

Fig. 1

A T handle hex key 6 mm

medium adjustable pliers

puller

medium extermal circlip pliers

Fig. 2

B medium internal circlip pliers

plastic hammer

bush

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

C Phase 1 Carry out the oil seal replacement procedure (see "OIL SEAL REPLACEMENT").

Phase 2 MEDIUM ADJUSTABLE PLIERS Using the adjustable pliers, extract the key securing the brake guide (ref.A fig.1).

Phase 3 MEDIUM EXTERNAL CIRCLIP PLIERS Using the circlip pliers, remove the circlip securing the upper flange (ref.B fig.2)

26

Fig. 3

SERVICE

MECHANICS

Phase 4 HEXAGONAL 6 mm "T" SECTION SPANNER Using the T handle hex key, unscrew and remove the screws joining the upper flange to the lower flange (ref.C fig.3). Recover both flanges.

Fig. 4

D E

Phase 5 MEDIUM INTERNAL CIRCLIP PLIERS Use the circlip pliers to remove the circlip securing the upper bearing (ref.D fig.4).

Recover the bearing (ref.E fig.4) and proceed with the replacement.

Phase 6 BEARING PULLER Using the bearing puller, remove the lower bearing from its housing (ref.F fig.5) Proceed with the replacement

Fig. 5

F

INSTALLATION Assemble the new bearings using the plastic hammer and the bush.

27

MECHANICS

28

SERVICE

SERVICE

REDUCTION UNIT

reduction unit KEY TO REDUCTION UNIT COMPONENTS ������������������������������������������������������������������������������������������������������������� 2 REMOVAL OF THE REDUCTION UNIT ��������������������������������������������������������������������������������������������������������������������� 4 DISASSEMBLY OF THE REDUCTION UNIT �������������������������������������������������������������������������������������������������������������� 6 CHANGING THE REDCUTION UNIT OIL ���������������������������������������������������������������������������������������������������������������� 10

1

SERVICE

REDUCTION UNIT

KEY TO REDUCTION UNIT COMPONENTS 1

2

3

31 30

4

29

5

28

6

27 7

26 25

8

24 9

15

14

23

10 11 13

12

22 21

16

20 14

15

17

18

32

19

gearbox type

supplier code TYP.

part number

32

CODE C.P.N.

production date

2

DATE

NR

serial number

SERVICE

Ref.

REDUCTION UNIT

Description

Ref.

Description

1

Traction motor

17

Circlip

2

Reduction unit drive pinion

18

Circlip

3

Motor flange O-ring

19

Oil seal

4

Retaining ring

20

Drive wheel

5

Stud bolt and self-locking nut

21

Hex head screw

6

Breather plug

22

Washer

7

Flanged pivot bearing

23

Bevel gear pair

8

Tiller support retaining screw

24

Bevel pinion

9

Tiller support

25

Pinion retaining key

10

Oil filler plug

26

Lower taper roller bearing

11

Reduction unit housing

27

Shims

12

Oil drain plug

28

Spacer

13

Crown wheel

29

Upper taper roller bearing

14

O-ring

30

Helical gear

15

Spacer

31

Hex nut

16

Ball bearings

32

data plate

3

SERVICE

REDUCTION UNIT

REMOVAL OF THE REDUCTION UNIT Equipment and tools Fig. 1

T handle hex key 8 mm

hydraulic jack

2 wooden blocks

extension bar

ratchet

oil pan

socket 13 mm

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

A

Fig. 2

Phase 1 Carry out the drive wheel removal procedure (see “REMOVAL OF THE DRIVE WHEEL” in the “MECHANICS” section).

Phase 2 Carry out the tiller removal procedure (see “REMOVAL OF THE TILLER” in the “MECHANICS” section).

B

Phase 3 Carry out the traction motor removal procedure (see “REMOVAL OF THE TRACTION MOTOR” in the “MECHANICS” section).

Fig. 3 4

SERVICE

REDUCTION UNIT

Phase 4 OIL PAN - 8 mm FLEXIBLE T HANDLE HEX KEY Position the oil pan under the reduction unit.

Using the flexible T handle hex key, loosen and remove the oil filler plug (ref.A fig.2).

Using the same key, loosen and remove the oil drain plug (ref.B fig.3).

Drain all the oil into the pan.

Clean the drain plug thoroughly to remove any impurities that may have accumulated during operation of the reduction unit and screw it back in place.

C

Fig. 4 Phase 5 HYDRAULIC JACK - 13 mm SOCKET - EXTENSION BAR - RATCHET Position the hydraulic jack beneath the reduction unit and lift until the jack is supporting the reduction unit.

Using the socket, the extension bar and the ratchet, unscrew the screws securing the reduction unit to the chassis (ref.C fig.4).

Lower the jack completely, being careful to support the reduction unit.

Recover the reduction unit, place it on the clean workbench and proceed with replacement or disassembly.

INSTALLATION The screws securing the reduction to the chassis must be tightened using a torque wrench to a torque of 25 Nm.

5

SERVICE

REDUCTION UNIT DISASSEMBLY OF THE REDUCTION UNIT Equipment and tools

vice

medium/large bearing puller

hex bit socket 8 mm

ratchet

A

driving tool

hammer

slide hammer puller

open ended spanner 30 mm

B

Fig. 1

C

Fig. 2 oil resistant gloves

medium extrnal circlip pliers

large internal circlip pliers

medium flat blade screwdrivers

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Phase 1 OIL RESISTANT GLOVES Wear the oil resistant gloves.

Carry out the reduction unit removal procedure (see “REMOVAL OF THE REDUCTION UNIT”).

D

Fig. 3

E

F

Fig. 4 6

SERVICE

REDUCTION UNIT

Phase 2 VICE - MEDIUM FLAT BLADE SCREWDRIVER Hold the reduction unit firmly in the vice.

Using the flat blade screwdriver, prise out the oil seal (ref.A fig.1).

G

Phase 3 LARGE INTERNAL CIRCLIP PLIERS Use the circlip pliers to remove the circlip securing the crown wheel of the bevel gear pair (ref.B fig.2). Recover the spacers (ref.C fig.2).

Fig. 5

H Phase 4 SLIDE HAMMER PULLER Screw the threaded part of the puller shaft into the hole in the hub (ref.D fig.3). Extract the complete crown wheel (fig.3).

I

Phase 5 MEDIUM EXTERNAL CIRCLIP PLIERS Use the circlip pliers to remove the circlip securing the bearings (ref.E fig.4). Recover the spacers (ref.F fig.4).

Phase 6 LARGE BEARING PULLER Use the bearing puller to remove the two hub bearings (ref.G fig.5).

Fig. 6 Phase 7 LARGE INTERNAL CIRCLIP PLIERS Use the circlip pliers to remove the circlip securing the flanged pivot bearing (ref.H fig.6). Remove the pivot bearing (ref.I fig.6).

J

Phase 8 6 mm HEX BIT SOCKET - RATCHET Using the hex bit socket and the ratchet, unscrew and remove the screws securing the steering pivot bearing (ref.J fig.7). Recover the complete pivot bearing assembly.

Fig. 7 7

SERVICE

REDUCTION UNIT Phase 9 30 mm OPEN ENDED SPANNER - HAMMER - DRVING TOOL Using the open ended spanner, loosen and remove the nuts securing the bevel pinion to the helical gear (ref.K fig.8). Using the hammer and the driving tool, drive out the the bevel pinion and withdraw it through the inside of the reduction unit (fig.8). Withdraw the helical gear (ref.L fig.9) and recover the pinion shaft retaining keys (ref.M fig.9).

K

Phase 10 MEDIUM BEARING PULLER Recover the upper bearing (ref.N fig.10) and the spacers (ref.O,P fig.10).

Using the bearing puller remove the bearing from the pinion (ref.Q fig.10) and recover the spacers (ref.R,S,T, fig.10).

Fig. 8

M

L

INSTALLATION To facilitate bearing installation, during removal make a note of the positioning of the spacers.

Use Loctite 243 when assembling the parts and tighten the bolts following the indications given in fig.11.

Fig. 9

R O N S Q

P

T

Fig. 10

8

SERVICE

REDUCTION UNIT

25 - 35 Nm 60 - 70 Nm

25 - 27 Nm

45 - 50 Nm

20 - 25 Nm

20 - 25 Nm 83 - 109 Nm

Fig. 11

9

SERVICE

REDUCTION UNIT

CHANGING THE REDCUTION UNIT OIL Equipment and tools

oil resistant gloves

oil pan

hydraulic jack

2 wooden blocks

A A

A T handle hex key 6-8 mm

oil syringe

torque wrench

Fig. 1 Fig. 2

Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the key switch to OFF and disconnect the battery.

Use caution as the oil in the reduction unit will be hot after use of the truck. Wear oil resistant gloves capable of withstanding high temperatures.

Do not dispose of used oil in the ground or by pouring it down the drain. Contact a waste disposal company specialised in the disposal and recycling of industrial oils.

B Phase 1 6 mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

10

Fig. 3

SERVICE

REDUCTION UNIT

Phase 2 HYDRAULIC JACK - 2 WOODEN BLOCKS Position the hydraulic jack on the right-hand side of the truck body and raise the truck sufficiently to insert the wooden block underneath. Lower the jack so that the truck rests on the wooden block. Repeat the operation on the left-hand side of the truck body (fig.2)

Phase 3 OIL RESISTANT GLOVES - OIL PAN Clean the area around the oil filler and drain plugs thoroughly. Place a suitably sized oil pan beneath the drain plug.

Phase 4 OIL RESISTANT GLOVES - OIL PAN - 8 mm FLEXIBLE T HANDLE HEX KEY - TORQUE WRENCH - OIL SYRINGE Using the flexible T handle hex key, loosen and remove the oil filler plug (ref.B fig.3).

Using the same key, loosen and remove the oil drain plug (ref.C fig.4).

Drain all the oil into the pan.

Clean the drain plug thoroughly to remove any impurities that may have accumulated during operation of the reduction unit and screw it back in place.

C

Fig. 4 Fig. 5

The oil drain plug must be tightened using a torque wrench to a torque of 22 Nm.

Use Standard Cold store

Oil type

Quantity

ESSO UNIFARM 15W - 40

1.4 litres

SHELL TRANSAXLE 75 W 90

1.4 litres

Using an oil syringe to fill the reduction unit (fig.6) makes for quick and easy oil changes.

The correct quantity of oil is achieved when the oil reaches the lower edge of the oil filler hole or, at most, overflows out of the filler hole.

Fig. 6

L

OI

The oil filler plug must be tightened using a torque wrench to a torque of 22 Nm.

11

REDUCTION UNIT

12

SERVICE

SERVICE

BRAKING SYSTEM

braking system KEY TO THE ELECTROMAGNETIC BRAKE COMPONENTS ��������������������������������������������������������������������������������� 2 OPERATION ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 3 BRAKING systems �������������������������������������������������������������������������������������������������������������������������������������������������� 3 REMOVAL OF THE ELECTROMAGNETIC BRAKE ������������������������������������������������������������������������������������������������� 4 ELECTROMAGNETIC BRAKE ADJUSTMENT ���������������������������������������������������������������������������������������������������������� 6

1

SERVICE

BRAKING SYSTEM

KEY TO THE ELECTROMAGNETIC BRAKE COMPONENTS

1

2 3 5

4 6

8

7

9

10

Ref.

2

Description

1

Retaining screw

2

Electromagnet

3

Brake plate

4

Circlip

5

Adjusting screw

6

Pinion

7

Rotor

8

Friction disc

9

Dust cover

10

Disc

SERVICE

BRAKING SYSTEM

OPERATION The electromagnetic brake mounted on the traction motor is a spring-operated brake.

When the electromagnet is powered, it attracts the brake plate and releases the friction disc, allowing the latter to rotate freely.

When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction disc, thus applying the brake.

BRAKING systems There are 4 braking systems used:

• • • •

drive control release

Release braking Braking on direction reversal Emergency braking Parking brake

A) Release braking Controls the deceleration ramp when the drive control is released.

B) Braking on direction reversal Controls the deceleration ramp when the travel direction is inverted.

“Braking on direction reversal", also know as counter current braking, consists of reversing the current supplied to the motor, thus changing the direction of travel when the truck is in motion.

The braking current must be adjusted so that the truck stops in a distance that is at least not less than the length of the truck itself.

direction reversal

C) Emergency braking Emergency braking occurs when an alarm is triggered that requires an immediate arrest of truck traction or when the tiller sensor is deactivated (tiller in rest position or fully lowered).

The braking action is performed by the electromagnetic brake mounted on the traction motor.

D) Parking brake The "parking brake" action is performed by the electromagnetic brake and is applied when the truck is stationary and the tiller is in the rest position.

3

SERVICE

BRAKING SYSTEM

REMOVAL OF THE ELECTROMAGNETIC BRAKE Equipment and tools Fig. 1

T handle hex key 5 mm

open ended spanner 15 mm

large cross-head screwdriver

puller

scissors

external circlip pliers

A

A

B

B Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the key switch to OFF and disconnect the battery.

Fig. 2

Fig. 3

C When replacing the rotor, the pinion must also be replaced.

Phase 1 5mm T HANDLE HEX KEY Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

Use the T handle hex key to remove the reduction unit cover screws (ref.B fig.2).

4

D

SERVICE

BRAKING SYSTEM

Phase 2 open ended spanner - 5 mm T handle hex key - scissors Remove the dust cover (ref.C fig.3).

Using the open ended spanner, loosen the three adjustment nuts (ref.D fig.3).

Using the T handle hex key, unscrew the three screws securing the electromagnetic brake to the traction motor (ref.E fig.4).

Use the scissors to cut the cable ties to release the electromagnetic brake power cable. Disconnect the wiring connector and withdraw it from the tab.

Remove the electromagnetic brake from the motor (fig.4).

Phase 3 EXTERNAL CIRCLIP PLIERS - PULLER Withdraw the rotor (ref.F fig.5) from the pinion.

Using the circlip pliers, remove the circlip from the drive shaft (ref.H fig.6).

Using the puller, remove the pinion (ref.G fig.6).

E

Fig. 4

Fig. 5

F

INSTALLATION After installation, proceed with the adjustment of the electromagnetic brake.

Fig. 6

G H

5

BRAKING SYSTEM

SERVICE

ELECTROMAGNETIC BRAKE ADJUSTMENT

C

A B

Fig. 1

After re-installing the electromagnetic brake assembly, before using the truck, the friction disc must be adjusted.

To obtain a good braking action, the distance between the friction disc and the brake plate (ref.A fig.1) must not be greater than 0.35 mm. A feeler gauge of this size is therefore required.

With the three nuts loose (ref.B fig.1), insert the feeler gauge near one of the bolts, tighten the retaining screw (ref.C fig.1) with the hex key and position the plate so the feeler gauge can be withdrawn with a little friction. Repeat the operation with all three bolts.

Tighten the nuts using the open ended spanner (ref.B fig.1).

6

SERVICE

ORDINARY MAINTENANCE

ordinary maintenance OILS AND LUBRICANTS ������������������������������������������������������������������������������������������������������������������������������������������� 4 PRODUCTS FOR THE CLEANING ���������������������������������������������������������������������������������������������������������������������������� 4 PLANNED MAINTENANCE ���������������������������������������������������������������������������������������������������������������������������������������� 5

1

ORDINARY MAINTENANCE

SERVICE

WARNINGS •

If maintenance operations are carried out immediately after the truck stop, some parts of the motor or of the hydraulic system may be hot. Always wear the individual protection devices, if it is required.

•

Do not wear rings, watches, jewells, untied clothes such as scarfs, undone shoes, unbuttoned coats or blouse with the opened zip that may get stuck in the moving parts.

•

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

•

Do not carry out any operation on the truck if there are operators working with it, unless they are authorized and are assisting the operation to be carried out.

•

To clean the components use compressed air and during this operation wear proper goggles with lateral protections. The maximum air pressure must not exceed 1 bar.

•

Never use petrol, oil or other inflammable liquids as detergents: we recommend using not inflammable and not toxic solvents.

•

Do not accumulate rags soaked in grease or oil: they may cause fire risk. Always put them in a closed metallic container.

•

The capacitors located in the transitor gearcase may keep an electric charge also after the battery has been disconnected. To avoid electrical shock and personal injuries, discharge the capacitors before checking or repairing any component of the electric compartment. Wear goggles. Make sure that the battery has been disconnected.

•

Do not file or lubricate the remote control switch contacts. This may cause the union of the contacts and therefore the loss of control, damage to things or personal injuries.

•

Drain oil must be gathered. Avoid letting it off in the common discharge ducts. Qualified companies must dispose of or recycle the industrial oils, according to the laws in force in each Country.

•

An apparently invisible fluid might come out of a small hole and have enough force to pass through the skin In such cases we recommend checking the penetration force by means of a piece of card or a piece of wood.

•

During the fluid check or the filter replacement prevent dirt from contaminating the hydraulic system.

•

Never enable the pump if the fluid in the hydraulic system is not enough. If the hydraulic fluid levels are low, the hydraulic pump will be damaged.

•

Do not put tools on the battery. Metall objects on the battery may cause short circuits and possible damages or injuries.

•

The batteries produce explosive gases. Keep the air outlets always clean. Keep sparks and flames away from the battery compartment. Do not produce sparks when disconnecting the battery cables.

Disconnect the battery during the maintenance operations.

•

Always use a space bar and slings to lift the battery vertically by means of the proper eyelets. Do not use chains or slings without using the space bar, because this might damage the battery case. Check that the battery compartment is clean and dry. When the battery is in operation, the aeration plugs must be installed. If the plugs are not installed, the electrolyte, might come out and corrode the battery case and compartment.

2

SERVICE

ORDINARY MAINTENANCE

•

The acid contained in the electrolyte may cause damage. If the electrolyte is accidentally released, clean carefully with water. Neutralize the acid with a sodium bicarbonate solution (baking soda). In case of contact with the skin, immediately flush the skin with water. In case of contact with the eyes, wash the eyes thoroughly with water for at least 10 minutes, then seek medical advice.

•

The batteries are a part of the truck counterweight system. By installing a too small battery, the truck might not weigh enough to reach the rated capacity. When replacing the battery, check that the rated capacity and dimensions of the battery comply with the data indicated on the plate. Refer to the “ TRUCK AND LOAD IDENTIFICATION DATA” of the section “PRESENTATION”, in order to know the correct battery specifications for the truck in object.

•

Do not work under the lifted roller plate. Lower the roller plate or use a safety chain in order to avoid that the roller plate lowers during the maintenance operations on the mast and on the lifting chains.

•

Never repair damaged forks by heating or welding them. The forks are made up of tempered steel..

Replace the damaged forks.

•

Before proceeding with the maintenance of the hydraulic system, it is necessary to remove any possible residual pressures inside it.

At the end of the maintenance operations, close the valves.

3

SERVICE

ORDINARY MAINTENANCE

OILS AND LUBRICANTS Application

Std

OIL for the lubrication of the HYDRAULIC CIRCUIT



OIL for the lubrication of the GEARBOX



GREASE for lubrication LINKAGE PIVOT PINS

Cold store







Trademark

Type

Specifications

Shell

TELLUS T32

DIN 51524

Shell

AEROSHELL FLUID 41

MIL-H-5606G

Shell

SPIRAX A 80W-90

API GL-5 MIL-L-2105D

Shell

TRANSAXLE OIL 75W-90

API GL-4 API GL-5

Shell

ALVANIA EP0

PRODUCTS FOR THE CLEANING GUARD AND PLASTIC COVER CLEANING - TRUCK PAINTED PART CLEANING For the truck general cleaning use only dry water, wet rags or degreasing solvents.

Do not use water jets, vapours, solvents or inflammable products that may damage the truck or that can be dangerous for the operator. motor and electronic system cleaning For the general cleaning use only dry water at low pressure and a clean dry brush.

Do not use wet rags, water jets, vapour, solvents or products that may damage the truck or that may be dangerous for the operator.

MAST PROFILE AND MAST CLEANING Use degreasing solvents.

Do not use water jets, vapour, solvents or inflammable products that may damage the mast or that may be dangerous for the operator.

4

SERVICE

ORDINARY MAINTENANCE

PLANNED MAINTENANCE  = check and maintenance  = operator check x = replacement

TRUCK BASE

Operation description

Maintenance intervals every 8 hours 1 day

every every every every 500 h 1000 h 2000 h 3000 h 6 months 12 months 24 months 36 months

Check welded joints



Lubrification of tiller gudgeon



Greasing the linkage pivot pins



Lubrication of linkage pivot pins-forks-carriage (3)



Check efficiency of tiller gas spring



Check tiller control housing



Check steering thrust block bearing





Lubrification of steering thrust block



PLANT ELECTRICAL

REDUCER

HYDRAULIC SYSTEM

MOTORS

BRAKING SYSTEM

General cleaning



Check the efficiency of the electromagnetic brake coil





Check release braking





Check reverse braking





Check emergency braking





Check parking mode braking





Check brake lining wear (1)

General cleaning



Check motor insulation



Check cable connections



Check fastening bolts



General cleaning with compressed air



Check for oil leaks at pump connections





Check for oil leaks at cylinder head connections





Check for oil leaks at motor housing distributor connections





Check flexible pipes

(2)



Replace oil in hydraulic tank

x

Oil filter cleaning



Check valve operation



Reducer oil replacement Visual oil leak check

x 



Check general condition of reducer



Check steering crown gear and steering pinion wear



General cleaning



Check all electrical connections



Check the condition of electric cables



Sensor check



General cleaning of electrical panel, remote-control switches and contacts using dry air at low pressure



Check traction wheel wear (1) WHEELS





Check the tightening of traction wheel fastening nuts



Check tightening of pivoting wheel fastening nuts Check load bearing wheel wear (1) Check load bearing wheel bearings (1)

 



 

5

SERVICE

ORDINARY MAINTENANCE

 = check and maintenance  = check by operator x = replacement

BATTERY

Operation description

every 8 hours 1 day

Check cable connections



Check for liquid leakage



every every every every 500 h 1000 h 2000 h 3000 h 6 months 12 months 24 months 36 months

Check battery insulation



Check electrolyte density



Check electrolyte level (4)



General cleaning

(5)

Check all machine functions using activation controls (1)

Maintenance intervals

 

replace if it is necessary

replace in the following situations: • movement of the pipe fittings; • damage, cuts, or abrasions on the surface layer; • hardening or stiffness of the pipe, presence of burnings or cracks due to heat; • cracks, damage or corrosion on the pipe fitting; • leaks on the pipe or on the pipe fitting; • permanent folds, squashings, flattenings or twists on the pipe; • blisters, softening or wear of the external layer.

(2)

(3)

lubricate with spray can.

(4)

top up whenever the electrolyte level decreases to 5-10 mm with respect to the plate unit

(5)

keep the battery clean and dry by using, if possible, antistatic clothes

6

.

SERVICE

ORDINARY MAINTENANCE

7

Code: 524301820

Revision: 0 (04/2009)