Download PDF: Service Manual for Yale A473 (MP20DL) Forklift

Part no.: 550005245

Overhaul:

0 (09/2009)

Technical information for Yale service centres

This manual is intended solely for the specialized technicians of the Yale service network.

A473.....

MP20DL

SERVICE

INTRODUCTION

IMPORTANT This manual gives detailed information on the routine and special maintenance procedures, troubleshooting, disassembly/assembly of components and settings related to the following models: MP20DL. These procedures require specific technical knowledge and must be performed by qualified and trained personnel. We recommend you read this manual carefully in order to avoid accidents with personnel or damage and keep it in a good condition so it is always decipherable and complete.

This manual does not replace the use and maintenance manual, it is a supplement to it.

Product support group

2

SERVICE

INTRODUCTION

GUIDE TO USING THE MANUAL SECTIONS This handbook is composed of the following sections: Presentation Installation and settings Diagnostics and measurements Electrical system Hydraulic system Mechanics Reduction gear Braking system Standard maintenance

Section 1: Section 2: Section 3: Section 4: Section 5: Section 6: Section 7: Section 8: Section 9:

Use the sections index with the numbered black bands to go quickly to the desired section.

SYMBOLS Signals a danger that can cause accidents to people or damage to the machine.

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

Signals disposal/recycling of harmful substances under the protection of current legislation.

INSTALLATION PROCEDURES For the installation procedures, carry out the reverse procedure to disassembly, observing any notes and information given for the truck to function properly.

3

INTRODUCTION

SERVICE

GENERAL SAFETY RULES PERSONAL SAFETY •

Always wear the personal protective equipment in situations requiring it.

•

Pay particular attention to the risk of getting crushed due to moving parts, oscillations, material not properly secured when performing lifting operations or moving loads.

•

Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbuttoned jackets or tops with open zippers that can get caught up in moving parts.

•

Never do any cleaning, lubrication or maintenance work with the battery connected.

•

Using compressed air to clean the parts, protect yourself with goggles that have side protection. The maximum air pressure must not exceed 1 bar.

SAFETY AT THE WORKPLACE •

Make sure that all the work tools are perfectly efficient and ready for use. Keep the work surfaces clean and clear of debris that can come into contact with parts of the machine and cause damage.

•

Make sure you keep sparks, naked lights and cigarettes away from fuels or flammable materials such as the gas of the batteries and fuels.

•

Make sure that the work area is ventilated, will illuminated, dry and clean. Remove any puddles of water or oil stains.

•

Make sure that the equipment, devices or lifting machinery used is able to sustain the load in a stable manner.

•

Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable and non-toxic trade solvents.

•

When working outside the garage, move the machine preferably onto the level and block it. If working on a slope is inevitable, block the machine beforehand and move it onto a level area as soon as possible with a certain margin of safety.

•

Disconnect the batteries and label all the controls to signal that work is in progress. Block the machine and every attachment that has to be raised.

•

Never perform any servicing on the machine with persons at the controls, unless they are accredited operators and help with the operation to be performed.

•

When towing use solely the prescribed coupling points and check that the pins and/or bolts are firmly secured before pulling. Lift and handle all the heavy parts with lifting equipment of adequate capacity.

Use the lifting eyebolts intended for this purpose. Make sure no one is near the load to be lifted.

•

Avoid twisting chains or metal ropes.

•

Do not trust bent or damaged chains or ropes: do not use them for lifting or pulling. Always wear the safety gloves to handle them.

•

Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away into a closed metal container.

•

Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.

Special companies can be employed to dispose of or recycle industrial oils according to the laws in force in individual countries.

•

When welding is necessary, you must use appropriate safety protection: dark goggles, hard hat, overalls, gloves, safety footwear. Dark goggles must be worn also by those who are not doing the work if they remain nearby during the welding.

4

SERVICE

INTRODUCTION

•

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

•

Do not short-circuit the terminals.

•

The gas released when charging is highly flammable. When charging, leave the battery compartment uncovered for more effective ventilation and take off the plugs.

•

Never check the battery charge with "jumpers" obtained by putting metal items on the terminals.

•

Before taking any action, check that no elements are shorted.

•

Always disconnect the battery before working on the electrical system.

•

For battery chargers and similar equipment, use solely auxiliary power sources with an effective ground connection to avoid any electric shocks.

•

Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate under the skin; in such cases, having to make a check, use a card or a piece of wood.

•

Having to check the system pressure, use the specific instruments.

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE •

Keep a record of all the suspension elements used, stating the characteristics of the suspension elements and the data given on the identification plate .

•

Never leave belts, cords or suspension elements in use whose identification plate has been lost.

•

Always use belts, ropes or suspension elements of suitable dimensions. Concerning the suspension elements, take into consideration the lifting angle and any unbalancing of the load.

•

The bells on the suspension elements must be sized in proportion to the hook of the overhead travelling crane and anyhow must be free to move easily.

•

Always rest the load in the race of the hook.

•

Never load the tip of the hook.

•

When lifting, avoid sudden operations that can jerk on the ropes and belts.

•

Never do any lifting with the ropes and belts twisted.

•

Knots are not permissible. Always protect the ropes and belts when they come into contact with sharp edges.

•

When moving with no load, to prevent impact and accidental hooking, hang the hooks in the bells and close the safety ones.

Using suspension elements under conditions of unbalanced load If lifting unbalanced loads it is advised as a precaution to downrate the load capacities of the lifting elements: • Slings with 2 booms, consider them as corresponding to 1 boom.

• Slings with 3 and 4 booms, consider them as corresponding to 2 booms.

Tips for maintenance Periodically examine the belts, ropes and suspension elements according to current legislation to define their state of service.

Change them in the following cases: • When the components show: deformation, cracks, hollows, cuts or abrasions.

• When the wear of the components exceeds 10% of the original dimensions.

• When the sling shows signs of overloading.

5

SERVICE

INTRODUCTION Belt capacity table

Colour

Working load capacity (kg)

purple 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 load capacity (kg)

Coefficient

6

Colour

Track (mm)

black purple black green yellow grey red brown 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

INTRODUCTION

Suspension element capacity table

Colour

Working load capacity (kg) Coefficient

purple 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 load capacity: the working load capacity is calculated with an angle at the centre of 90°

7

SERVICE

INTRODUCTION

TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS Before disassembling the various parts and nuts and bolts, read the following carefully.

To make the threaded matings secure, LOCTITE 270 is used for tightening the screws.

If it is not possible to unscrew the bolts because this product has been used, avoid applying extensions to the tools, instead slightly heat the area (at most 50°C) so as to eliminate the LOCTITE 270 effect.

In the cases described, reapply LOCTITE 270 during installation in a moderate quantity (30% of the mating surface).

The torque setting used for tightening the threaded couplings is extremely important to make the coupling secure and the machine safe.

The tables on this page give the classes of bolts normally used with the relevant torque settings.

TORQUE SETTING Nm

Nominal diameter

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

M10

50.5

60.3

M12

74.2

88.5

M14

101.2

120.8

M16

138.2

164.9

M18

176.6

203.5

M20

225.4

259.7

M22

278.8

321.2

M24

324.8

374.2

M27

422.3

486.5

M30

516.1

594.7

TORQUE SETTING Nm Pre-load N

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

M10

1.5

16

8

15825

31.7

23.8

51

38

69

52

M10

1.25

16

8

16700

33.4

25.1

53

40.1

73

55

M12

1.75

18

10

23025

55

41.4

88

66

120

90

M12

1.25

18

10

25150

60

45.3

96

72

130

98

M14

2

21

12

31400

88

66

140

105

190

145

M14

1.5

21

12

34125

96

72

155

115

210

155

M16

2

24

14

42850

135

105

220

165

300

225

M16

1.5

24

14

45600

145

110

235

175

320

240

M20

2.5

30

17

66875

270

200

430

320

580

435

M20

1.5

30

17

74250

295

225

475

355

650

485

= with lubricant

8

Class 5.8

SERVICE

INTRODUCTION

CORRECT METHOD FOR APPLYING FEMALE FITTINGS To assure a reliable seal between female fittings and the adapters in this manual, it is necessary to observe the following procedure, which differs from the one for assembling rigid pipes.

Female fittings without a gasket (metal/metal joint) Screw on the nut by hand and then, with the aid of a wrench, tighten by another quarter turn.

Female fittings with O-ring Screw on the nut by hand and then, with the aid of a wrench, tighten by another half turn.

In every case make sure that the pipe is properly aligned before tightening the nut on the adapter.

TORQUE SETTINGS

UNF thread

METRIC REVOLVING FEMALE Torque setting Nm Outside diameter Nominal torque min / max of the pipe

REVOLVING FEMALE jic 37° Torque setting Nm

UNF thread

Size

Nominal torque

min / max

M 12x1.5

6

20

15 -25

7/16-20

-4

15

9 - 21

M 14x1.5

8

38

30 - 45

1/2-20

-5

20

13 - 27

45

38 - 52

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

1.3/16-12

-14

118

73 - 163

1.5/16-12

-16

140

90 - 190

1.5/8-12

-20

210

135 - 285

M 16x1.5 M 18x1.5 M 20x1.5 M 22x1.5

8 10 10 12 12 14 15

51

43 - 85

58

50 - 65

74

60 - 88

M 24x1.5

16

74

60 - 88

1.7/8-12

-24

290

200 - 380

M 26x1.5

18

105

85 - 125

2.1/2-12

-32

450

300 - 600

135

115 - 155

166

140 - 192

30

240

210 - 270

35

290

255 - 325

330

280 - 380

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

20 22 25 28

38 42

REMOVING FEMALE BSP Torque setting Nm

UNF thread

REVOLVING FEMALE ORFS Torque setting Nm

UNF thread

Nominal torque

max

G1/4

20

15 - 25

9/16-18

-4

14

16

-6

24

27 47

Size

Nominal torque

max.

G3/8

34

27 - 41

11/16-16

G1/2

60

42 - 76

13/16-16

-8

43

G5/8

69

44 - 94

1-14

-10

60

68

G3/4

115

95 - 135

1.3/16-12

-12

90

95

G1

140

115 - 165

1.3/16-12

-14

90

95

G1.1/4

210

140 - 280

1.7/16-12

-16

125

135

G1.1/2

290

215 - 365

1.11/16-12

-20

170

190

G2

400

300 - 500

2-12

-24

200

225

2-1/2-20

-32

460

490

The values given in the tables refer to galvanized steel fittings. Fittings of other materials have other values.

9

INTRODUCTION

SERVICE

INSTRUCTIONS FOR INSTALLING FLEXIBLE HOSES AND FITTINGS Inspection of pipes and fittings When even just one of the following conditions arises the pipe must immediately be disconnected and replaced:

• • • • • • •

a shift of the connection on the pipe; the presence of damage, cuts or abrasions on the superficial layer; hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure; the presence of cracks, damages or strong corrosion on the connection; the presence of leaks along the pipe or at the coupling joint; the presence of permanent creases, compression, flattening or twists in the pipe; the presence of blisters, softening, wear of the external coat.

Pre-installation inspection Before installing a flexible hose it is necessary to inspect the pipes carefully. First check that the type, size, reference code and length are correct, then check there is no debris, blockages, bubbles, peeling of the outer layer or any other visible defects.

Installation Avoid twisting the pipe, which could cause it to burst under pressure.

There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assembled pipe decreases considerably when below the minimum radius of curvature.

The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly greater length than the requirement in order to compensate for these changes.

10

SERVICE

INTRODUCTION

SECTION CONTENTS

Presentation

1

Installation and settings

2

Diagnostics and measurements

3

Electrical system

4

Hydraulic system

5

Mechanics

6

Reduction gear

7

Braking system

8

Standard maintenance

9

11

INTRODUCTION

12

SERVICE

SERVICE

PRESENTATION

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

1

PRESENTATION

SERVICE

TRUCK PRESENTATION The new range of electric pallet trucks with the operator on the ground and double lifting is composed of a model with a nominal load capacity of 2000 kg with initial lifting and 700 kg with supplementary lifting: •

MP20DL

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

Hydraulic system The 1.4 kW pump motor ensures excellent performance thanks to the technology with an ON/OFF solenoid valve block that splits the hydraulic flow between the main lift and the supplementary one. A pressure switch ensures a maximum load capacity of 700 kg for supplementary lifting.

The lifting cylinders are single-acting plungers with a solid stem.

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

TRUCK VIEWS

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

RESIDUAL LOAD PLATE

The load capacity data plate is on the battery compartment casing The load plate bears the following data:

• Model • Liftable load values up to varying heights up to the maximum load with different distances from the load centre of gravity of the forks.

4

SERVICE

PRESENTATION

Always refer to the load plate to be sure to lift an admissible load to an appropriate height.

TRUCK SERIAL NUMBER

The truck Serial number is located in side the engine compartment.

LOCATION OF DOCUMENTATION

The truck documentation is located in the battery compartment.

5

PRESENTATION

GENERAL SPECIFICATIONS

6

SERVICE

SERVICE

PRESENTATION

ELECTRIC MOTORS

PERFORMANCE

DIMENSIONS

WHEELS AND CHASSIS WEIGHTS

CHARACTERISTICS

GENERAL SPECIFICATIONS 1.2

model

MP20DL

1.3

power: battery, diesel, LPG, petrol, electric

battery

1.4

steering: tiller, pedestrian, standing, sitting

1.5

load capacity, load

Q (t)

2.0

load capacity, load with fork lifting

Q (t)

0.7

tiller

load capacity, load with clamp lifting

Q (t)

2.0

1.6

centre of gravity

c (mm)

600

1.8

load distance from load wheel axle

x (mm)

906 (1)

1.9

wheelbase (WB)

y (mm)

1380 (1)

2.1

unladen weight

kg

615

2.2

load per axle when loaded (front/rear)

kg

780 / 1835 (2)

2.3

load per axle when unladen (front/rear)

kg

3.1

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

3.2

front wheel size

440 / 175 polyurethane / vulkollan ø 230 x 75

3.3

rear wheel size

ø 85 x 74

3.4

additional wheels (size)

ø 100 x 40

3.5

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

1x+4 / 2

3.6

front track width

b 10 (mm)

470

3.7

rear track width

b 11 (mm)

375

4.4

lifting

h3 (mm)

560

4.6

initial lifting

h5 (mm)

130

4.9

height of tiller in operating position (min/max)

h14 (mm)

735 / 1200 (2)

4.15 fully lowered forks height

h13 (mm)

92

4.19 total length

l1 (mm)

1843

l2 (mm)

650

4.21 total length

4.20 length to fork heel

b1/b2 (mm)

700

4.22 fork size

s/e/l (mm)

70 / 190 / 1190

4.25 width over forks

b5 (mm)

570

4.32 ground clearance at wheelbase centre

m2 (mm)

20

4.33 working aisle for pallet length 800 x 1200

Ast (mm)

2054

4.34 working aisle for pallet width 800 x 1200

Ast (mm)

2044

4.35 turning radius

Wa (mm)

1560 (1)

5.1

travel speed with/without load

km/h

6/6

5.2

lifting speed with/without load

m/s

0.043 / 0.043 (3)

5.3

lowering speed with/without load

m/s

0.072 / 0.072 (3)

5.8

maximum gradeability with/without load

%

8 / 20

5.10 service brakes

electromagnetic

6.1

traction motor, S2 60 minutes

kW

1.2

6.2

lift motor, S3 6%

kW

1.4

6.3

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

no

6.4

battery voltage/nominal capacity

V/Ah

24/200

6.5

battery weight (+/- 5%)

kg

185

6.6

consumption second VDI cycle

kWh/h

0.44

8.1

type of control

(1)

With a load section at 100mm of lift: -31mm

(2)

Tiller in vertical work position (first gear)

(3)

Initial lifting

AC ~ Mosfet

7

PRESENTATION

8

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 ����������������������������������������������������������������� 8 SETTING THE BATTERY VOLTAGE �������������������������������������������������������������������������������������������������������������������������� 8 CHECK THE CONDITIONS OF USE OF THE TRUCK ���������������������������������������������������������������������������������������������� 9 NORMAL OPERATING CONDITIONS ��������������������������������������������������������������������������������������������������������������������� 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

MP20DL

2

Fork dimensions

Weight (excluding battery)

Battery voltage/ capacity

mm

kg

V/Ah

kg

kg

1190 x 570

430

24/200

185

615

Battery weight Overall weight

SERVICE

INSTALLATION AND SETTINGS

TRUCK ASSEMBLY LIST OF MATERIALS RECEIVED FROM THE DEALER

1

2

3

4

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

Ref.

Description

1

Truck

2

External battery charger

3

Battery

4

Top up bottle for battery electrolyte

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 areas of transit of other vehicles and pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

A

A

Phase 1 5 MM HEXAGONAL "T" SECTION SPANNER 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

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.1

Phase 1 Raise the battery compartment cover to engage the latch (ref.A Fig.1).

Raise the battery compartment cover solely by using the specific handle.

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.

6

A

Fig. 2

SERVICE

INSTALLATION AND SETTINGS

CONNECTION OF CABLES TO BATTERY The positive battery terminal is identified with the redmarking 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 negative terminal

_

+

To close the battery compartment cover, pull the spring pin (Fig.3).

Fig.3

7

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.

Equipment and tools Fig. 1

A

precision flat T handle hex key blade screwdriver 5 mm

A

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

Remove 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:

8

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

SERVICE

INSTALLATION AND SETTINGS

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 clamp 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.

9

SERVICE

INSTALLATION AND SETTINGS

NORMAL OPERATING CONDITIONS START UP Release all the controls and make sure that the emergency button (H) is raised in position 1. Turn the ignition key (I) from position 0 (off) to position 1 (on).

FORWARD/REVERSE TRACTION For forward/reverse traction, lower the tiller (A) into the working position and turn the traction throttle (B).

With the tiller in the rest position, for traction you need to keep the first gear push button (C) pressed besides turning the throttle (B).

FORK LIFTING/LOWERING For fork lifting/lowering, lower the tiller (A) into the working position and press the lifting (D) or lowering (E) push button on the right-hand side of the tiller. With the tiller in the rest position, for fork lifting/lowering you need to keep the first gear push button (C) pressed besides pressing buttons (D,E).

CLAMP LIFTING/LOWERING For clamp lifting/lowering, lower the tiller (A) into the working position and press the lifting (F) or lowering (G) push button on the left-hand side of the tiller. With the tiller in the rest position, for clamp lifting/lowering you need to keep the first gear push button (C) pressed besides pressing buttons (F,G).

COMMON ALARMS If the correct firing sequence is not observed, the truck will shut down as a safety measure. Switch off the truck and perform the correct sequence.

If the tiller is lowered into the working position and stays there for 120 seconds without performing any operations, the truck will shut down as a safety measure. Switch off the truck and perform the firing sequence again.

A

G

F B

B

H

I

10

E

D

C

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

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11

2

A

24 13

Key switch digital input (+24V) Q2 fork solenoid valve digital output (+24V) Q1 lowering solenoid valve digital output (+24V) Hydraulic pump contactor coil digital output (+24V) Electromagnetic brake coil digital output (+24V) Main contactor coil digital output (+24V) Encoder negative (GND) Traction motor temperature sensor analog input Tiller digital input (+24V) Not used Not used

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 Q3 clamp solenoid valve digital output (+24V) A20 Horn relay digital output (+24V) A21 Not used (bridge with pin 34) 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 (bridge with pin 21) 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 solenoid valve control Q3 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 Q1 on output A3 PD PWM

%

Percentage level of solenoid valve control Q2 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

measurement unit

CAPACITOR VOLTAGE

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 Status of the main contactor

8

Number

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)

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

STATUS

Off

Off

The controller is switched off or damaged.

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.

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

2

3

1

Ref.

solenoid valve

Value measured (Ohm)

1

Q1

28

2

Q2

28,2

3

Q3

28,2

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 ������������������������������������������������������������������������������� 22 MAIN MENU PROGRAM ������������������������������������������������������������������������������������������������������������������������������������������ 22 MODULE PARAMETER DESCRIPTION ������������������������������������������������������������������������������������������������������������������ 24 MODULE: INTRODUCTION ������������������������������������������������������������������������������������������������������������������������������������� 29 POSITIONING OF THE "PC TOOL" CONNECTOR ������������������������������������������������������������������������������������������������� 30 MODULE REPLACEMENT: INSTRUCTIONS ����������������������������������������������������������������������������������������������������������� 31 REMOVAL OF ELECTRICAL COMPONENTS �������������������������������������������������������������������������������������������������������� 33 REPLACEMENT OF THE GENERAL EMERGENCY SWITCH �������������������������������������������������������������������������������� 33 REPLACEMENT OF THE DISPLAY �������������������������������������������������������������������������������������������������������������������������� 35 REPLACEMENT OF THE KEY SWITCH ������������������������������������������������������������������������������������������������������������������ 36 REPLACEMENT OF THE HORN ������������������������������������������������������������������������������������������������������������������������������ 37 FUSE REPLACEMENT ��������������������������������������������������������������������������������������������������������������������������������������������� 38 tiller board: configuration and calibration ������������������������������������������������������������������������������������� 39 TILLER BOARD REPLACEMENT ����������������������������������������������������������������������������������������������������������������������������� 42 REPLACEMENT OF TILLER BUTTONS ������������������������������������������������������������������������������������������������������������������ 43 REPLACEMENT OF THE TILLER CONTROL SPRINGS ����������������������������������������������������������������������������������������� 44 REPLACEMENT OF THE TILLER ENABLES SENSOR ������������������������������������������������������������������������������������������ 46

1

SERVICE

ELECTRICAL SYSTEM

ELECTRICAL WIRING DIAGRAMS CONNECTORS

COMPONENTS Ref.

2

Ref.

Description

XA1

35 pin male connector

Description

A1

Combi controller

A2

Tiller controller

X28

XCJ2

A3

Battery charge level indicator

X3

XAJ2

B1

Encoder

B2

Heat sensor

XJP2

XJP10

B3

Pressure switch

XJP12

X4

C1

Battery

X31

X15

F1

Power fuse - 175 A

X16

4-way female connector

F2

10 A fuse for 24V power supply to keyswitch

X30

3 pin male connector

F3

10 A fuse for 24 V horn relay power supply

XJP11

XJP13

K1

Horn relay

XJP14

XJP15

K2

Main contactor coil

XJP16

XJP17

K3

Pump coil

X6

X7

K4

Recycling diode

X14

X17

M

Complete traction motor

X18

X19

M1

Traction motor

XFF2

XFF3

M2

Pump motor

XFF4

XFF5

P1

Horn

XFF9

XFF10

Q1

Solenoid valve 1

XFF11

XFF12

Q2

Solenoid valve 2

XFF14

XFF15

Q3

Solenoid valve 3

XFF16

XFF17

R1

Varistor

XFF21

XFF22

R2

Electromagnetic brake

XFF23

XTF25

S

Button not used

XTF26

XTF27

S1

Emergency button

XTF28

XFF31

S2

Battery charger socket-plug microswitch

XFM30

male terminal

S3

Keyswitch

XFFM32

female-male terminal

S4

Tiller sensor

S5

Fork lifting on/off push button

S6

Fork lowering on/off push button

S7

Clamp lifting on/off push button

S8

Clamp lowering on/off push button

S9

Horn button

S10

Belly button

S11

Snail button

T1

Battery charger

XJP1

XTR1

XTR13

XTR24

8 pin male connectors 6 pin male connectors 4 pin male connectors

2-way male connectors

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

2.12

2.12 0V -Batt.

0V -Batt.

17 18

Brake Pot Wiper Pot Low

/.3

13-B

29 25

Serial TX Serial RX +12V Out

21 34 27 30 33 24

CAN Term H CAN Therm L Brake Pot High Analog Output Switch 8 Switch 1

/.7

-X31

101-D

TO CONSOLE/ TO OPTIONAL MDI Can High 901-B

Can Low 900-B

+ -X30

Data out Clock in Belly out NC +24 in

4 5 6

GND

-XJP11

2

1

/.5 /.7 /.11

D

2

-XJP13

1

-S

GND

UNUSED

3

GND

D

C

-XAJ2

2

-S

B

UNUSED

-XJP17

2

UNUSED

1

GND

1

GND

+5V

2

Sel 1

Sel 2

1

+5V D

8

2

-S

7

1

+5V

-XJP16

6

2

1

D

GND

Sel 0

CAN-H

+5V

-S8

5

4

3

2

CAN-L

UNUSED

GND

2

4

3

-XJP15

A

-X3

1

1

-XCJ2

901-C

Fe

D

901-A

2

-X3

4

2

Tiller in

+5V A

23

-S4 900-C

-XJP2

3

+24V

-S10

+24V (out)

D

-XJP14

CANH

2 101-E

1

GND Belly out NO

Data out

1

2

Snail + tiller

-XJP12

900-A

4

723

6

4

3

-S7

35

1

725

3

4

+5V

Belly out NC

-S6

CANL

3

540-A

5

3

A

-S11

724

540-B

540-C

Interlock + snail switching

4

+5V

-S5

28

9

/.5

541

-S9

Switch 3 Interlock in

Belly switching

-XJP1

D

22

-A2 GND

1

-XJP10

2

GND

10-A

+24V

- Hours meter

1

24V +Key

5

1

+ Key switch

2

10-B

Switch 7 Belly in

101-B

6

+ Relay

3

24V +Key

101-D

16

Throttle Pot Wiper

- Relay (out)

10-D

101-E

15

Throttle Pot High

-B 4

24V +Key

101-B

14

Switch 16

-A1 10

-XA1

Switch 4

/.3

519

-X28

12

-A3 - Hours meter

2.12

5

2.12

Switch 6

13-B

2.12

24V +Aux.

6

2.12

7

8

SERVICE ELECTRICAL SYSTEM

35-B

UNUSED UNUSED

-S

D

TO PC TOOLS

/.11

101-A

2c

o

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 charger

T1

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

Battery charge level indicator

A3

15

Main contactor coil contacts

16

Pump contactor

K3

17

3-way connector for PC connection

X30

18

Tiller board

A2

SERVICE

ELECTRICAL SYSTEM

12

13 11 18

14

15

16 17 10

9 2

3 8

5

1

6

7

4

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 S10

3

Horn enabling microswitch

S9

4

Tiller control cable connector

XJP1

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

Clamp lifting ON/OFF button connector

XJP14

12

Clamp 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

S11

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

6

2 3 1

8

8

7

SERVICE

ELECTRICAL SYSTEM

9

10

Ref.

Description

Ref. wiring diagram

1

Rapid reverse button

S10

2

Horn button

S9

3

Forward/reverse traction control butterfly

4

Clamp lowering button

S8

5

Clamp lifting button

S7

6

Fork lifting button

S5

7

Fork lowering button

S6

8

Slow progress enabling button with tiller in rest position

S11

9

Emergency button

S1

10

Key switch

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

3

4

Ref.

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 warning status. When a warning is generated, the red LED starts blinking.

The display shows the error code that generated the warning identified by a number (see “DIAGNOSTICS” section).

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 (S11) "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 S10 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 and fork and clamp lifting/lowering 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 (S11). 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

18

status

Symbol on diagram

Keyswitch

ON

S3

Emergency switch

ON

S1

Tiller tilt sensor

ON

S4

Tiller rotation

rotation right/left

SERVICE

ELECTRICAL SYSTEM

FORK LIFTING/LOWERING CONTROLS

D c

A B

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

To lower the forks, press the on/off button "B".

To lift the clamps press the on/off button “C”.

To lower the clamps press the on/off button “D”.

Devices involved

status

Symbol on diagram

Keyswitch

ON

S3

Emergency switch

ON

S1

ON/OFF button for lifting/ lowering activated

S5-S6-S7-S8

ON*

S4

Fork/clamp lifting/lowering Tiller tilt sensor * OFF when the button (S11) "snail" 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

SERVICE

ELECTRICAL SYSTEM

When the tiller is in the rest position, to be able to perform lifting, press the first gear pushbutton simultaneously with the normal lifting buttons.

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

FORK/CLAMP LIFTING BLOCK DUE TO EXCEEDING LOAD CAPACITIES OR LIMIT STOP When operating the fork lifting button (S5), if the maximum set load capacity limit is exceeded (or the limit stop is reached), fork and clamp lifting is blocked. To restore clamp lifting, you need to press first the fork lowering button (S6) and then the clamp lifting button (S7).

When lifting or lowering the forks, it is not possible to lift or lower the clamps at the same time and vice versa.

20

SERVICE

ELECTRICAL SYSTEM

TIMED LIFTING LOCKOUT On pressing a lift button (S5 or S7) the forks (or clamps) start to rise and continue to rise for the maximum time that can be set using the programmer.

Setting the maximum fork/clamp 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.

21

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

120 sec

BUZZER OPTION

0

BUZZER DEAD BAND

70 rpm

HYDRAULIC FUNCTIONS

TRACTION

CAN THROTTLE

“Off” with optional MDI

FORWARD MAX

4095

FORWARD MAP

30%

FORWARD DEAD BAND

190

REVERSE DEAD BAND

-190

REVERSE MAP

30%

REVERSE MAX

-4095

803 LOCKOUT ENABLE

On (1)

LIFT RUN TIME

8 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

22

value

INTERLOCK TIMEOUT

THROTTLE SETUP

(1)

LEVEL 4 PARAMETER

MAX SPEED

4430 rpm

MAX ACCEL

1.5 sec

MAX DECEL

0.5 sec

NEUTRAL BRAKING

1 sec

MAX BRAKING

0.4 sec

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

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

23

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)

24

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PROGRAM  Throttle Setup  CAN Throttle PARAMETER

min

max

0

500

-500

0

0%

100%

FORWARD DEAD BAND 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.

PERCENTAGE OF MAX. TRUCK SPEED (OUT)

Fig. 2 Increase in Reverse Max

Increase in Reverse Map Increase in Reverse Dead Band

REVERSE MAP REVERSE MAX

REVERSE DEAD BAND

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

0 sec

10 sec

Maximum time for which continuous fork (or clamp) lifting or lowering is enabled.

25

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 (or clamps), the maximum time for which the optional auxiliary valves (Q2 - Q3) remain open after the pump has stopped.

LOWERING DELAY TIME VALVE 1-2

0 sec

5 sec

When lowering the forks (or clamps), the maximum time for which the optional auxiliary valves (Q2 - Q3) 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 MDI is present, it enables/disables lifting lockout and illumination of "battery low" LED when battery discharged.

BDI WARNING

0%

100%

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

26

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 MDI is present, it 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 MDI is present, it 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 MDI is present, it 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).

27

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

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

28

150°C

SERVICE

ELECTRICAL SYSTEM

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 • controlling the 1.4 kW hydraulic pump • 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

29

ELECTRICAL SYSTEM

SERVICE

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

30

SERVICE

ELECTRICAL SYSTEM

MODULE REPLACEMENT: INSTRUCTIONS Equipment and tools

socket wrench 10 mm

resistor 100 Ohm 25w isolated

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.

Phase 1 Remove the motor compartment cover, the wheel cover and the motor cover (see "REMOVAL OF THE COVERS” in the "MECHANICS" section).

Phase 2 100 Ohm 25 W RESISTOR Connect the resistor between the positive (B+) and negative (B-) of the module (fig.1).

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

Fig. 1

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.

31

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.

A

Phase 4 10 mm SOCKET WRENCH Using the socket wrench remove the screws securing the module to the truck chassis (ref.A fig.2) and recover the washers.

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

A

Fig. 2

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“.

32

SERVICE

ELECTRICAL SYSTEM

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

pin punch Ø 3 mm

open ended spanner 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.

Fig. 1

A

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

Phase 2 PIN PUNCH Insert the end of the pin punch in the hole under the red general emergency switch (ref.A fig.1).

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.B fig.2).

B

B

Fig. 2

33

SERVICE

ELECTRICAL SYSTEM Phase 4 MEDIUM PHILIPS SCREWDRIVER Unscrew the screws securing the general emergency switch (ref.C fig.3), recover the washers (ref.D fig.3).

Withdraw the contactor in a downward direction (fig.3).

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.

34

Fig. 3

C

D

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE DISPLAY Equipment and tools Fig. 1

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 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

A Phase 2 Disconnect the wiring connector (ref.A fig.2).

Loosen the nuts securing the retaining bracket (ref.B fig.2). Remove the bracket (ref.C fig.2).

Remove the display (fig.3) and proceed with replacement.

C B

Fig. 3

35

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE KEY SWITCH Equipment and tools Fig. 1

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

A Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

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

Unscrew the nut (ref.A 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.

36

Fig. 3

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE HORN Equipment and tools

T handle hex key 5 mm

open ended spanner 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.

Fig. 1

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

Phase 2 5 MM T HANDLE HEX KEY - 10 mm OPEN ENDED SPANNER Using the hexagonal “T” section spanner, keep the screw fixing the horn locked (ref.A fig.2), while using the open ended spanner to unscrew and remove the nut (ref.B fig.2). Recover the washers.

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

INSTALLATION

Fig. 2

B A

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

37

SERVICE

ELECTRICAL SYSTEM FUSE REPLACEMENT • •

key switch (F2) fuse 24V horn relay power fuse (F3)

Equipment and tools

small flat blade screwdriver

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. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

F2 A

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

Phase 2 SMALL FLAT BLADE SCREWDRIVER Using the small flat blade screwdriver, push in the retaining tabs (ref.A Fig.1) and withdraw the fuse holder.

Remove the old fuse and fit a new one.

Fig. 2

38

F3

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 proportional 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).

39

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.

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 (JP14, ref.D fig.5).

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

40

E

Fig. 7

SERVICE

ELECTRICAL SYSTEM

Phase 4 Release the butterfly control.

Rotate the butterfly control fully to the right and hold it in this position (fig.7). Press and release the lowering button located on the left-hand side of the tiller casing (JP15, 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.

41

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 4 mm 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 2.5 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).

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").

42

K

J Fig. 4

I

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 4 mm 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 43

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.

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).

44

Fig. 2

EF G

Fig. 3

H

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

45

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE TILLER ENABLES SENSOR Equipment and tools

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

A Fig. 1

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.

B Fig. 2

Phase 1 Remove the motor compartment cover, the wheel cover and the motor cover (see "REMOVAL OF THE COVERS” in the "MECHANICS" section).

Phase 2 4 mm T HANDLE HEX KEY Unscrew the bolts securing the upper casing (ref.A fig.1).

Fig. 3 Fig. 4

Phase 3 Lift the upper casing and detach it from the lower casing (fig.2). Disconnect the wiring connector of the tiller sensor cable (ref.B fig.2).

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.C fig.4).

Remove the sensor from its housing (fig.4), recover the wire and proceed with the replacement.

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

46

C

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM HYDRAULIC FUNCTIONS ����������������������������������������������������������������������������������������������������������������������������������������� 3 OIL SUPPLY TO THE HYDRAULIC CIRCUIT ������������������������������������������������������������������������������������������������������������� 4 PRESSURE CONTROL VALVES �������������������������������������������������������������������������������������������������������������������������������� 4 DIRECTIONAL VALVES ���������������������������������������������������������������������������������������������������������������������������������������������� 4 pressure switches ��������������������������������������������������������������������������������������������������������������������������������������������� 5 HYDRAULIC DIAGRAMS ������������������������������������������������������������������������������������������������������������������������������������������� 6 symbols ������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6 MAIN HYDRAULIC DIAGRAM ������������������������������������������������������������������������������������������������������������������������������������ 7 HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS ������������������������������������������������������������������������������������������� 8 SOLENOID VALVE OPERATION CHART ������������������������������������������������������������������������������������������������������������������� 8 HYDRAULIC DIAGRAM FOR FORK LIFTING ����������������������������������������������������������������������������������������������������������� 9 HYDRAULIC DIAGRAM FOR FORK LOWERING ���������������������������������������������������������������������������������������������������� 10 HYDRAULIC DIAGRAM FOR CLAMP LIFTING ������������������������������������������������������������������������������������������������������ 11 HYDRAULIC DIAGRAM FOR CLAMP LOWERING ������������������������������������������������������������������������������������������������� 12 HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE ��������������������������� 13 hydraulic components ���������������������������������������������������������������������������������������������������������������������������������� 14 hydraulic component identification �������������������������������������������������������������������������������������������������������� 14 DISASSEMBLY of the Manifold ������������������������������������������������������������������������������������������������������������������������ 15 DISASSEMBLY OF THE PRESSURE SWITCH ������������������������������������������������������������������������������������������������������� 17 REMOVAL OF THE PRESSURE RELIEF VALVE ����������������������������������������������������������������������������������������������������� 18 CALIBRATION OF THE PRESSURE RELIEF VALVE ���������������������������������������������������������������������������������������������� 19 CARTRIDGE SOLENOID VALVES �������������������������������������������������������������������������������������������������������������������������� 20 KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS ������������������������������������������������������������������������������������� 20 SOLENOID VALVE DISMANTLING �������������������������������������������������������������������������������������������������������������������������� 21 CYLINDERS �������������������������������������������������������������������������������������������������������������������������������������������������������������� 22 SINGLE ACTING CYLINDER ������������������������������������������������������������������������������������������������������������������������������������ 22 LIFTING CYLINDERS ���������������������������������������������������������������������������������������������������������������������������������������������� 22 IDENTIFICATION OF “A" TYPE CLAMP LIFTING CYLINDER COMPONENTS ����������������������������������������������������� 23 IDENTIFICATION OF “B" TYPE FORK LIFTING CYLINDER COMPONENTS ������������������������������������������������������� 24 REMOVAL OF THE CLAMP LIFTING CYLINDER ���������������������������������������������������������������������������������������������������� 25 REMOVAL OF THE FORK LIFTING CYLINDER ������������������������������������������������������������������������������������������������������ 27 BLEEDING AIR FROM THE LIFTING CYLINDERS ������������������������������������������������������������������������������������������������� 29 REPLACEMENT OF THE CLAMP LIFTING CYLINDER SEALS ����������������������������������������������������������������������������� 30 REPLACEMENT OF THE FORK LIFTING CYLINDER SEALS �������������������������������������������������������������������������������� 32 lift pump ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 34 KEY TO LIFT PUMP COMPONENTS ����������������������������������������������������������������������������������������������������������������������� 34 REMOVAL OF THE LIFT PUMP ������������������������������������������������������������������������������������������������������������������������������� 36

1

HYDRAULIC SYSTEM

SERVICE

REPLACEMENT OF THE PUMP ������������������������������������������������������������������������������������������������������������������������������ 38 REPLACEMENT OF THE CYLINDER SUPPLY PIPE ���������������������������������������������������������������������������������������������� 39 REPLACEMENT OF THE FORK CYLINDER SUPPLY PIPE ����������������������������������������������������������������������������������� 40

2

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC FUNCTIONS • • • •

Fork Lifting Fork Lowering Clamp lifting Clamp lowering

FORK AND CLAMP 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.

A pressure switch ensures that the maximum load capacity on the forks cannot be exceeded, preventing them from lifting.

3

HYDRAULIC SYSTEM

SERVICE

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.

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 maximum extension or if an abnormal situation may arise which requires an effort 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.

Parachute valves (LB) These are blocking valves fixed directly onto the lift cylinders and are designed to stop an uncontrolled lowering of the load in the event of a pipe subject to high pressure should break.

If the pressure exceeds the set value (80 litres/min) a plate, which is lifted through elastic reaction from the seat of the valve, is pressed by the electrodynamic forces involved, against the valve chassis, leading to the closure of the valve itself. They are equipped with a draining hole.

DIRECTIONAL VALVES

Parachute valve

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.

4

SERVICE

HYDRAULIC SYSTEM

pressure switches Pressure switches with one threshold The function of the pressure switches with one threshold is to convert a certain hydraulic pressure signal into an electrical one, keeping the oil flow pressure under control.

They are basically composed of a piston with a counter spring connected to movable electric contacts.

When the oil pressure reaches the highest setting, the movable contacts close the electric circuit; if the pressure decreases or is cancelled the electric circuit opens, signalling an error.

5

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS symbols

6

RESERVOIR

FILTER

PUMP

PRESSURE RELIEF VALVE

ONE-WAY VALVE

SOLENOID VALVE ON/OFF

SOLENOID VALVE ON/OFF WITH CHECK

PARACHUTE VALVE

CYLINDER

LINE CONNECTION

SERVICE

HYDRAULIC SYSTEM

MAIN HYDRAULIC DIAGRAM

CLAMP CYLINDER

FORK CYLINDER

LB C1

Q3

C2

Q2

P

A

CH

Q1

P F

7

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS •

Fork Lifting

•

Fork Lowering

•

Clamp lifting

•

Clamp lowering

•

Oil outlet through the pressure relief valve

SOLENOID VALVE OPERATION CHART Function

Pump

Fork Lifting

P

P = pump in operation + = solenoid valve coil energised

8

Q3

Q2

+

P P

Q3

Q1

+ +

Clamp lowering Oil drain through pressure relief valve

Q2

+ +

Fork Lowering Clamp lifting

Q1

-

+ -

-

pressure switch

pressure relief valve

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR FORK LIFTING

CLAMP CYLINDER

FORK CYLINDER

LB C1

Q3

C2

Q2

P

A

CH

Q1

P F

9

SERVICE

HYDRAULIC SYSTEM HYDRAULIC DIAGRAM FOR FORK LOWERING

CLAMP CYLINDER

FORK CYLINDER

LB C1

C2

Q2

Q3

P

A

CH

P F

10

Q1

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR CLAMP LIFTING

CLAMP CYLINDER

FORK CYLINDER

LB C1

C2

Q2

Q3

P

A

CH

Q1

P F

11

SERVICE

HYDRAULIC SYSTEM HYDRAULIC DIAGRAM FOR CLAMP LOWERING

CLAMP CYLINDER

FORK CYLINDER

LB C1

Q3

C2

Q2

P

A

CH

P F

12

Q1

C1

SERVICE

C2

HYDRAULIC SYSTEM

Q2

Q3

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 P Faulty or stuck valve

A

CH

Q1

P F

13

SERVICE

HYDRAULIC SYSTEM

hydraulic components hydraulic component identification

5

6 7

1 4

8

2 9 3

10

Ref.

14

Description

Ref.

Description

1

On/off solenoid valve Q1

6

On/off solenoid valve with check Q3

2

Pump

7

Manifold

3

Filter

8

Pressure switch

4

Pressure relief valve

9

Clamp lifting cylinder

5

On/off solenoid valve with check Q2

10

Fork lift cylinder

SERVICE

HYDRAULIC SYSTEM

DISASSEMBLY of the Manifold Equipment and tools Fig. 1

T handle hex key small cross-head oil resistant gloves 5 mm screwdriver

open ended spanner 18-19 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 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

Fig. 2

B C

A

Phase 2 18 - 19 mm OPEN ENDED SPANNER - OIL PROTECTING GLOVES PARKER PLUGS Wear the oil resistant gloves.

Using the open ended spanners, unscrew and remove the connectors of the hydraulic hoses of the pump (ref.A fig.2), clamp lifting cylinder (ref.B fig.2) and fork lifting cylinder (ref.C fig.2) and apply the caps.

Phase 3 SMALL PHILIPS SCREWDRIVER Unscrew the fastening screws and disconnect the energy supply connectors of the solenoid valve coils with check Q2 and Q3 (fig.3).

Fig. 3

15

SERVICE

HYDRAULIC SYSTEM Phase 4 5mm T HANDLE HEX KEY Use the T handle hex key to unscrew and remove the manifold fixing screws (ref.D fig.4) and remove the washers.

Remove the manifold with the solenoid valves and proceed with disassembly or replacement.

D

ASSEMBLY Before tightening the hydraulic connections, consult the table of reference (see "CORRECT METHOD OF APPLYING FEMALE CONNECTIONS” "INTRODUCTION" section).

16

Fig. 4

SERVICE

HYDRAULIC SYSTEM

DISASSEMBLY OF THE PRESSURE SWITCH Equipment and tools

open ended spanner 23 mm

oil protecting gloves

"Parker" service plug

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. 1

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 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

Phase 2 23 mm OPEN ENDED SPANNER - OIL PROTECTING GLOVES - PARKER PLUG Disconnect the connector (X19) of the pressure switch (fig.1).

Wear the oil resistant gloves.

Using the open ended spanner, unscrew and remove the pressure switch from the connector (ref. A Fig.2) and fit the cap on the connector.

Proceed with replacement

X19

Fig. 2

A

17

SERVICE

HYDRAULIC SYSTEM 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

oil resistant gloves

medium flat blade screwdriver

open ended spanner 22 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. 1

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 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

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.A fig.2).

Using the socket wrench, unscrew and remove the complete valve (ref.B fig.2), recover the spring (ref.C fig.2) and proceed with the replacement.

INSTALLATION On installation, tighten the valve with a torque wrench to 13 Nm. 18

Fig. 2

C A B

SERVICE

HYDRAULIC SYSTEM

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

Equipment and tools Fig. 1

medium flat blade screwdriver

open ended spanner 22 mm

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

Fig. 2 Phase 1 Connect the battery and switch on the truck (starter key to ON).

Place on the clamps 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 the clamp lifting button 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 clamps start to lift again.

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

Carry out a few trial lifts and lowering manoeuvres with the load, 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.

19

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.

20

Description

1

Coil

2

Valve body

3

Coil retaining plug

SERVICE

HYDRAULIC SYSTEM

SOLENOID VALVE DISMANTLING Equipment and tools Fig. 1

oil resistant gloves

small cross-head screwdriver

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.

Fig. 2

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

B 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.

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

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

C

D

Fig. 3

21

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 CYLINDERS Type of cylinder

Rod diameter mm

Height mm

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

50

h5 130

Type “B” with simple plunging effect and solid shaft

45

h3 560

h3 h5

22

SERVICE

HYDRAULIC SYSTEM

IDENTIFICATION OF “A" TYPE CLAMP LIFTING CYLINDER COMPONENTS The cylinder is of the single-acting plunger type.

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

Replacement of the static gaskets and the dynamic gasket on the piston requires removing and disassembling the cylinder.

7

5

3

4

1

2

Ref.

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

23

SERVICE

HYDRAULIC SYSTEM IDENTIFICATION OF “B" TYPE FORK 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.

3

5

4

1

2

Ref.

24

7

Description

1

Barrel and end cap

2

Piston rod

3

Rod end cap

4

Guide bushing

5

Parachute valve

6

Seal kit

7

Air bleed screw

6

SERVICE

HYDRAULIC SYSTEM

REMOVAL OF THE CLAMP LIFTING CYLINDER Equipment and tools

hoist load capacity 2000 kg

2 lifting slings load capacity 2000 kg

oil resistant gloves

"Parker" service plug

combination spanner 16 mm

open ended spanner 16-18 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 Remove the motor compartment cover, the wheel cover and the motor cover (see "REMOVAL OF THE COVERS” in the "MECHANICS" section).

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.

A Fig. 1 25

SERVICE

HYDRAULIC SYSTEM Phase 3 OIL RESISTANT GLOVES - 18 mm OPEN ENDED SPANNER - "PARKER" SERVICE PLUG Wear the oil resistant gloves.

Using the spanner, unscrew the hydraulic hose union (ref.A fig.1).

Fit the service plug to the hydraulic hose.

Fig. 2

C

B

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.B fig.2) while unscrewing the upper cylinder mounting bolt using the spanner (ref.C fig.2) 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 spanner (ref.D fig.2) Withdraw the cylinder from the lower housing, place it on a clean workbench with vice and proceed with disassembly or replacement.

INSTALLATION Before tightening the hydraulic connections, consult the table of reference (see "CORRECT METHOD OF APPLYING FEMALE CONNECTIONS” "INTRODUCTION" section).

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

26

D

SERVICE

HYDRAULIC SYSTEM

REMOVAL OF THE FORK LIFTING CYLINDER Equipment and tools

tackle load capacity 1000 kg

oil resistant gloves

lifting rope load capacity 1000 kg

wooden beam 100x100x500 mm

"Parker" service round-nose pliers plugs

open ended spanner 19 mm

hex bit socket 17-19 mm

ratchet

strips

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. Raise the clamps to the maximum height. 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 HOIST - LIFTING ROPE Secure the fork base plate with the lift belt.

Hook the belt onto the tackle and make taut to slacken the chain (fig.1).

A

Fig. 1

Phase 2 ROUND-NOSE PLIERS - STRIPS Using the pliers, remove the split pins on the journal of the chain fixing plug located on the side of the cylinder. Remove the pivot (ref.A fig.1).

Extract the chain from the hose sheave and secure it with a clamp to the forks.

27

SERVICE

HYDRAULIC SYSTEM Phase 3 TACKLE - LIFT ROPE - WOODEN BEAM Using the tackle, raise the forks 550 mm off the ground.

Position the wooden beam beneath the forks (ref.B fig.2).

Lower the forks and rest them on the beam, keeping the lift rope under tension (fig.2).

Phase 4 OIL RESISTANT GLOVES - 19 mm OPEN ENDED SPANNER - "PARKER" SERVICE PLUGS Wear the oil resistant gloves.

Using the open ended spanner, unscrew the union of the hydraulic pipe at the fork cylinder (ref.C fig.3).

Fit the service plugs to the unions.

B

Fig. 2

Fig. 2 Phase 5 HEXAGONAL 17 mm SOCKET WRENCH - RATCHET Using the hex socket wrench and the ratchet, unscrew and remove the lower bolt of the cylinder (ref.D fig.3) and retrieve the washer.

E

Phase 6 19 mm HEX BIT SOCKET - RATCHET Using the hex socket wrench and the ratchet, unscrew and remove the side bolt of the cylinder (ref.E fig.3) and retrieve the washer.

Withdraw the cylinder from the housing, place it on a clean workbench with vice and proceed with disassembly or replacement.

ASSEMBLY Before tightening the hydraulic connections, consult the table of reference (see "CORRECT METHOD OF APPLYING FEMALE CONNECTIONS” "INTRODUCTION" section).

C

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

D

28

SERVICE

HYDRAULIC SYSTEM

BLEEDING AIR FROM THE LIFTING CYLINDERS Equipment and tools

oil resistant gloves

socket wrench with flexible handle 8-10 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.

Fig. 1

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.

A B

Carry out the procedure according to the cylinder from which air needs to be bled.

Phase 1 OIL RESISTANT GLOVES - 8-10 mm SOCKET WRENCH WITH FLEXIBLE HANDLE Wear the oil resistant gloves.

Using the socket wrench, loosen the air bleed screw (ref.B fig.1,2) of the cylinder.

Connect the battery and turn the starter key to ON.

Fig. 2

A B

Phase 2 8-10 mm SOCKET WRENCH WITH FLEXIBLE HANDLE Raise the forks (resp. the clamps) using the button located on the tiller; continue lifting until oil flows out of the air bleed valve (ref.A fig.1,2).

Stop lifting and tighten the bleed screw (ref.B fig.1,2).

Wipe the cylinder with a clean cloth.

29

SERVICE

HYDRAULIC SYSTEM REPLACEMENT OF THE CLAMP 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 CLAMP 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).

30

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.

31

SERVICE

HYDRAULIC SYSTEM REPLACEMENT OF THE FORK 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 FORK 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).

32

C

D Fig. 2

SERVICE

HYDRAULIC SYSTEM

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.

INSTALLATION 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.

33

HYDRAULIC SYSTEM

lift pump KEY TO LIFT PUMP COMPONENTS

Ref.

34

Description

1

Pump motor

2

Directional control valve

3

Pump body

4

Reservoir

5

On/off solenoid valve Q1

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

5

6

10 2

7 3

4 9

8

11

35

SERVICE

HYDRAULIC SYSTEM REMOVAL OF THE LIFT PUMP Equipment and tools Fig. 1

B bridge crane load capacity 1000 kg

spreader bar

T handle hex key 6 mm

open ended spanner 19 mm

small cross-head oil resistant gloves screwdriver

hex socket wrench 11 mm

ratchet

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 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

Phase 2 11 mm SOCKET WRENCH - RATCHET Remove the terminal protection caps, then use the open ended spanner to unscrew the nuts securing the pump motor power cables (ref.A fig.1).

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

36

A

C

Fig. 2 Fig. 3

SERVICE

HYDRAULIC SYSTEM

Phase 3 SMALL CROSS-HEAD SCREWDRIVER Unscrew the retaining screws and disconnect the power supply connector of the solenoid valve coil (ref.D fig.1).

Fig. 4

Phase 4 OIL RESISTANT GLOVES - 19 mm open ended spanner - "PARKER" PLUG Wear the oil resistant gloves.

Using the open ended spanner, unscrew the union of the hydraulic pipe (ref.C fig.2).

Apply the cap.

D Phase 5 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.3).

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

Phase 6 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.D fig.4).

Recover the pump and proceed with replacement or disassembly.

37

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.

38

Fig. 3

SERVICE

HYDRAULIC SYSTEM

REPLACEMENT OF THE CYLINDER SUPPLY PIPE Equipment and tools

open ended spanner 19 mm

"Parker" service oil resistant gloves plugs

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. 1

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 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

A

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

Using the fixed spanner unscrew the coupling of the hydraulic pipe (ref.A-B fig.1).

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

39

SERVICE

HYDRAULIC SYSTEM REPLACEMENT OF THE FORK CYLINDER SUPPLY PIPE Equipment and tools

wooden beam 500x100x100 mm

open ended spanner 19 mm

"Parker" service oil resistant gloves plugs

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.

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.

A

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS" in the "MECHANICS" section).

Fig. 1

Phase 2 WOODEN BEAM Using the controls on the tiller lift the forks 550 mm off the ground.

Position the wooden beam beneath the forks (ref.A fig.1).

Lower the forks and rest them on the beam (fig.1).

Position the key switch to OFF and disconnect the battery.

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

Using the open ended spanner unscrew the connector of the hydraulic pipe at the manifold (ref.B fig.2).

Apply the connector cap.

B Fig. 2

40

SERVICE

HYDRAULIC SYSTEM

Phase 4 19 mm OPEN ENDED SPANNER - "PARKER" SERVICE PLUG Using the open ended spanner, unscrew the union of the hydraulic pipe at the fork cylinder (ref.C fig.3).

Apply the connector cap. Remove the hydraulic hose extracting it from the truck base and replace it.

INSTALLATION When installing, pass the hose through the hole in the truck base behind the left pivot wheel (fig.4).

C Fig. 3

Fig. 4

41

HYDRAULIC SYSTEM

42

SERVICE

SERVICE

MECHANICS

MECHANICS COVERS ��������������������������������������������������������������������������������������������������������������������������������������������������������������������� 2 REMOVAL OF THE COVERS ������������������������������������������������������������������������������������������������������������������������������������� 2 DRIVE WHEEL ������������������������������������������������������������������������������������������������������������������������������������������������������������ 3 KEY TO DRIVE WHEEL COMPONENTS ������������������������������������������������������������������������������������������������������������������� 3 REMOVAL OF THE DRIVE WHEEL ���������������������������������������������������������������������������������������������������������������������������� 4 PIVOTING WHEEL ASSEMBLY ��������������������������������������������������������������������������������������������������������������������������������� 6 KEY TO PIVOTING WHEEL ASSEMBLY COMPONENTS ���������������������������������������������������������������������������������������� 6 REMOVAL OF THE PIVOT WHEEL ASSEMBLY �������������������������������������������������������������������������������������������������������� 8 ADJUSTMENT OF THE WHEEL HEIGHT ���������������������������������������������������������������������������������������������������������������� 10 LOAD WHEELS �������������������������������������������������������������������������������������������������������������������������������������������������������� 12 KEY TO LOAD WHEEL COMPONENTS ������������������������������������������������������������������������������������������������������������������ 12 REPLACEMENT OF THE LOAD WHEELS �������������������������������������������������������������������������������������������������������������� 13 LOAD WHEEL ASSEMBLY REPLACEMENT ����������������������������������������������������������������������������������������������������������� 15 LINKAGE ������������������������������������������������������������������������������������������������������������������������������������������������������������������ 16 KEY TO LINKAGE ASSEMBLY COMPONENTS ������������������������������������������������������������������������������������������������������ 16 REMOVAL OF THE LINKAGE ASSEMBLY ��������������������������������������������������������������������������������������������������������������� 17 ADJUSTMENT OF THE LINKAGE ASSEMBLY �������������������������������������������������������������������������������������������������������� 21 LINKAGE ASSEMBLY GREASING POINTS ������������������������������������������������������������������������������������������������������������� 22 TILLER ���������������������������������������������������������������������������������������������������������������������������������������������������������������������� 23 KEY TO TILLER COMPONENTS ������������������������������������������������������������������������������������������������������������������������������ 23 REMOVAL OF THE TILLER �������������������������������������������������������������������������������������������������������������������������������������� 24 TILLER SPRING REPLACEMENT ���������������������������������������������������������������������������������������������������������������������������� 26 FORK SMALL MAST ���������������������������������������������������������������������������������������������������������������������������������������������� 28 IDENTIFICATION SMALL MAST COMPONENTS ���������������������������������������������������������������������������������������������������� 28 REMOVAL OF THE FORK LIFT CHAIN ������������������������������������������������������������������������������������������������������������������� 29 REMOVAL OF THE FORK SMALL MAST

������������������������������������������������������������������������������������������������������������� 31

BEARING AND SLIDING SKID REPLACEMENT ���������������������������������������������������������������������������������������������������� 33 CHAIN GUIDEWAY PULLEY ������������������������������������������������������������������������������������������������������������������������������������ 34 IDENTIFICATION OF HOSE SHEAVE COMPONENTS ����������������������������������������������������������������������������������������� 34 REPLACEMENT OF THE CHAIN GUIDEWAY PULLEY ������������������������������������������������������������������������������������������ 35 traction motor �������������������������������������������������������������������������������������������������������������������������������������������������� 37 KEY TO TRACTION MOTOR COMPONENTS ��������������������������������������������������������������������������������������������������������� 37 REMOVAL OF THE TRACTION MOTOR ������������������������������������������������������������������������������������������������������������������ 38 OIL SEAL REPLACEMENT ��������������������������������������������������������������������������������������������������������������������������������������� 40 BEARING REPLACEMENT �������������������������������������������������������������������������������������������������������������������������������������� 42

1

SERVICE

MECHANICS

COVERS REMOVAL OF THE COVERS Equipment and tools

T handle hex key 5-6 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.

Fig. 1

A

A

MOTOR COMPARTMENT COVER Phase 1 5 MM HEXAGONAL "T" SECTION SPANNER Use the T handle hex key to remove the motor cover screws (ref.A fig.1).

Remove the cover.

WHEEL COVER

B

Phase 2 HEXAGONAL 6 mm "T" SECTION SPANNER Use the T handle hex key to remove the wheel cover screws (ref.B fig.2).

Remove the cover.

B

B

Fig. 2

MOTOR COVER Phase 3 5 MM HEXAGONAL "T" SECTION SPANNER Use the T handle hex key to remove the motor cover screws (ref.C fig.3).

Remove the cover.

C

Fig. 3

2

C

SERVICE

MECHANICS

DRIVE WHEEL KEY TO DRIVE WHEEL COMPONENTS

2

1

Ref.

Description

1

Vulkollan ring complete with hub

2

Drive wheel retaining nut

3

SERVICE

MECHANICS REMOVAL OF THE DRIVE WHEEL Equipment and tools

hydraulic jack

2 wooden blocks

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 clamps to the maximum height, turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Phase 1 Remove the wheel cover (see "REMOVAL OF THE COVERS").

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 other side of the truck body (fig.1).

Phase 3 19 mm socket - ratchet - extension bar - TORQUE WRENCH Unscrew and remove the nuts securing the drive wheel to the reduction unit (ref.A. fig.2), recover the washers and remove the wheel.

A Fig. 2

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

4

SERVICE

MECHANICS

5

SERVICE

MECHANICS

PIVOTING WHEEL ASSEMBLY KEY TO PIVOTING WHEEL ASSEMBLY COMPONENTS

1

15

2

16 17

3

19

16

13

17

14 4

11

15

18 5 10 12 9

6

11

13 14

6

8

7

SERVICE

MECHANICS

Ref.

Description

1

Cap

2

Circlip

3

Upper plate

4

Pivot assembly rotation bearing

5

Elastic ring

6

Yoke

7

Nut

8

Screw

9

Rubber bush

10

Wheel lower yoke

11

Split pin

12

Wheel pin

13

Adjustable segment

14

Flanged screw

15

Dust cover

16

Spacer

17

Wheel bearing

18

Wheel

19

Bush

7

MECHANICS

SERVICE

REMOVAL OF THE PIVOT WHEEL ASSEMBLY Equipment and tools

hydraulic jack

2 wooden blocks

T handle hex key 8 mm

open ended spanner 13 -19 mm

socket 13 -19 mm

ratchet

small flat blade screwdriver

small external circlip pliers

Fig. 1

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 clamps to the maximum height, turn the keyswitch to OFF and disconnect the battery.

Phase 1 Remove the wheel cover (see "REMOVAL OF THE COVERS").

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 other side of the truck body (fig.1).

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.A fig.2).

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

8

Fig. 2

A

SERVICE

MECHANICS

REMOVAL OF THE PIVOTING WHEEL Phase 4 13 mm socket wrench - ratchet - 13 mm OPEN ENDED SPANNER - DRIVING TOOL - HAMMER Using the open ended spanner, lock one of the two screws fastening the pivot wheel pin, while with the socket wrench and ratchet unscrew and remove the other screw (ref.B fig.3). Using the hammer and driving tool, extract the wheel pin (ref.D fig.3), remove the adjuster segment (ref.C fig.3) and extract the wheel from its seat.

Proceed with replacement.

D C B Fig. 3

DISASSEMBLY OF THE PIVOTING WHEEL Phase 5 SMALL FLAT BLADE SCREWDRIVER Using the small flat blade screwdriver, extract the dust cap (ref.E fig.4), remove the spacers (ref.F fig.4), bearings (ref.G fig.4) and bush (ref.H fig.4).

Proceed with replacement

Fig. 4

E F G

H

G

REMOVAL OF THE BUFFERS Phase 6 19 mm socket wrench - ratchet - 19 mm open ended spanner Counterhold the self-locking nut (ref.I fig.5) with the open ended spanner, while unscrewing and removing the screws of the yoke (ref.J. fig.5) using the socket wrench and the ratchet. Remove the buffers (ref.K fig.5).

Proceed with replacement

F E J K

REMOVAL OF THE UNIT ROTATION BEARING Phase 7 MEDIUM pliers for opening circlips - LARGE pliers for closing circlips - SMALL FLAT BLADE SCREWDRIVER Using the screwdriver, remove the plug (ref.L fig.6). Using the medium external circlip pliers, remove the ring fastening the upper plate to the yoke (ref.M Fig.6), extract the plate together with the bearing. Using the large pliers for closing circlips, remove the locking ring (ref.O fig.6) and remove the bearing (ref.N fig.6).

Proceed with replacement INSTALLATION

Fig. 5

l

I Fig. 6

m

n o

The screw securing the pivoting wheel must be tightened using a torque wrench to a torque of 85 Nm.

9

SERVICE

MECHANICS ADJUSTMENT OF THE WHEEL HEIGHT

The pivot wheel assembly is equipped with a system for adjusting the height of the wheels, to be done when: • the drive wheel is worn out and slips when driving • one of the two pivot wheels is much more worn than the other one • both pivot wheels are worn out and the weight of the truck rests solely on the drive wheel Wear on the wheels must be checked on a perfectly flat floor.

Equipment and tools

hydraulic jack

2 wooden blocks

open ended spanner 13 mm

socket 13 mm

ratchet

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. Raise the clamps to the maximum height, turn the keyswitch to OFF and disconnect the battery.

Phase 1 Remove the wheel cover (see "REMOVAL OF THE COVERS").

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 other side of the truck body (fig.1).

Fig. 2

A

10

A

SERVICE

MECHANICS

Phase 3 13 mm socket wrench - ratchet - 13 mm OPEN ENDED SPANNER Using the open ended spanner, lock one of the two screws fastening the pivot wheel pin, while with the socket wrench and ratchet loosen the other screw (ref.A fig.2). Loosen the two screws until the adjuster ring nuts (ref.B fig.3) can be sufficiently extracted so as to be able to adjust the desired height using the reference split pins (ref.C fig.3).

Screw the fixing screws back on and carry out the same operation on the other wheel.

B C Fig. 3

11

SERVICE

MECHANICS

LOAD WHEELS KEY TO LOAD WHEEL COMPONENTS

1 3 5

1

4

2 4

3

3

8

10

9 11

7

8 9

12

4

Ref.

12

6

Description

1

Spring pin

2

Clamp pivot pin

3

Bush

4

Grease nipple

5

Tie-rod pivot pin

6

Load wheel screw

7

Dust cover

8

Spacer

9

bearing

10

Load wheel

11

Load wheel bush

12

Load wheel pin

7

SERVICE

MECHANICS

REPLACEMENT OF THE LOAD WHEELS Equipment and tools

T handle hex key 8 mm

driving tool Ø 12 mm

small flat blade wooden stock screwdriver 150x150x1000 mm

hammer

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 clamps to the maximum height, turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Phase 1 WOODEN STOCK Place the wooden stock under the clamps (fig.1). Lower the clamps so that they rest on the wooden stock and continue lowering until the load wheels are raised off the ground by about 2 cm.

Fig. 2

Turn the keyswitch to OFF and disconnect the battery.

Phase 2 8 mm "T" HANDLE HEX KEY - HAMMER - DRIVING TOOL Using the T handle hex key, unscrew and remove the wheel pin retaining screw (ref.A fig.2). Using the hammer and the driving tool, drive out the pin of the load wheel (ref.B Fig.2). Withdraw the load wheel from its support (ref.C fig.2) and proceed with its disassembly or replacement.

A

C

B

13

SERVICE

MECHANICS Phase 3 SMALL FLAT BLADE SCREWDRIVER Using the small flat blade screwdriver, extract the dust cap (ref.D fig.3), remove the bearings (ref.E fig.3), spacers (ref.F fig.3) and bush (ref.G fig.3).

Proceed with replacement

D F E

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

G E

F D

14

Fig. 5

SERVICE

MECHANICS

LOAD WHEEL ASSEMBLY REPLACEMENT Equipment and tools Fig. 1

hammer

driving tool Ø 15 mm

wooden stock 150x150x1000 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 clamps to the maximum height.

Phase 1 WOODEN STOCK Place the wooden stock under the clamps (fig.1). Lower the clamps so that they rest on the wooden stock and continue lowering until the load wheels are raised off the ground by about 2 cm.

Raise the forks by 500 mm.

B

A

Fig. 2

Fig. 3

C

Turn the keyswitch to OFF and disconnect the battery.

D 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.

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.

15

SERVICE

MECHANICS

LINKAGE KEY TO LINKAGE ASSEMBLY COMPONENTS

1

3

6

2

5

4

7

8

5 9

10 2

5

7

2

7

7

14 7

13

2

7

5 11

2

Ref.

16

5 12

Description

1

Load wheels assembly

2

Grease nipple

3

Tie rod pivot pin - load wheels

4

Pivot pin for load wheels - clamp

5

Spring pin

6

Adjustable tie rod end

7

Bush

8

Tie rod adjuster pin

9

Tie rod adjuster locknut

10

Tie rod

11

Linkage assembly pin

12

Truck base pivot pin

13

Retaining plate

14

Drive unit pivot pin

2

SERVICE

MECHANICS

REMOVAL OF THE LINKAGE ASSEMBLY Equipment and tools

hoist load capacity 2000 kg

2 lifting slings load capacity 1500 kg

oil resistant gloves

"Parker" plug

hammer

driving tool Ø 15 mm

lifting rope load capacity 1500 kg

open ended spanner 2 x 10 mm 16-18 mm

spreader bar

truck stand

pin punch Ø 4 mm

combination spanner 16 mm

socket 9 mm

ratchet

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. 1

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS").

Remove the wheel cover (see "REMOVAL OF THE COVERS").

Remove the motor cover (see "REMOVAL OF THE COVERS").

Remove the forks (see “REMOVAL OF THE FORK SMALL MAST”).

17

SERVICE

MECHANICS Phase 2 HOIST - 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.1).

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

Fig. 2

A

Phase 3 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.

B Phase 4 OIL PROTECTING GLOVES - 18 mm OPEN ENDED SPANNER - "PARKER" CAP Wear the oil resistant gloves.

Using the spanner, unscrew the hydraulic hose union (ref.A fig.2).

Fit the service plug to the hydraulic hose.

Fig. 3

Phase 5 2 x 10 mm OPEN ENDED SPANNERS Using the two spanners, unscrew the nuts securing the traction motor power supply cables (ref.B fig.2) Note the position of the cables prior to removing them. Disconnect all the wiring connectors.

Phase 6 HOIST - LIFTING ROPE Attach the lifting rope to the reduction unit support, passing the rope behind the drive wheel (fig.3). Attach the two ends of the lifting rope to the overhead crane and take up the slack in the rope.

Phase 7 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.4) while unscrewing the cylinder mounting bolt using the combination spanner (ref.D fig.4).

18

SERVICE

MECHANICS

Phase 8 9 mm SOCKET WRENCH - RATCHET Using the socket wrench, unscrew and remove the grease nipples of the pivot pins of the reduction unit support (ref.E fig.5) Recover the retaining plates (ref.F fig.5)

D

C

Phase 9 PIN PUNCH - HAMMER - DRIVING TOOL Using the hammer and pin punch, remove the circlips of the pivot pins at the reduction unit assembly support (ref.H fig.6).

Drive out the pivot pins using the hammer and the driving tool (ref.G fig.6)

Phase 10 Using the hoist, remove the drive unit from the chassis (fig.7). Rest the drive unit on the ground, keeping it vertical to prevent oil leaking out.

Detach the lifting rope.

Phase 11 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 12 HAMMER - PIN PUNCH - DRIVING TOOL Using the pin punch and hammer, drive out the split pins securing the pivot pins to the clamps (ref.I fig.8) Drive out the pivot pin (ref.J fig.8) using the driving tool and the hammer.

Fig. 4 Fig. 5

E F

Fig. 6

H G

Phase 13 HAMMER - PIN PUNCH - DRIVING TOOL Using the pin punch and hammer, drive out the split pin securing the pivot pins to the truck base (ref.K fig.9) Drive out the pivot pin (ref.L fig.9) using the driving tool and the hammer.

19

SERVICE

MECHANICS Phase 14 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.

Fig. 7

j

i

Fig. 8

L

K

20

Fig. 9

SERVICE

MECHANICS

ADJUSTMENT OF THE LINKAGE ASSEMBLY In order to adjust the linkage well, the truck must be equipped with a full set of new, drive, pivot and load wheels. It must be set on a perfectly level surface raised off the floor to permit screwing in and unscrewing the adjusters.

The tie rods must be adjusted when, with forks and clamps completely lowered, the height of the forks off the ground measured with a metre rule is greater or less than the optimal height (88 mm - fig.1). In addition, the adjustment must also be made when a pair of load wheels does not touch the ground (fig.2). This means that a tie rod has been incorrectly adjusted.

Equipment and tools Fig. 1 88 mm

metre

open ended spanner 36-41 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.

Fig. 2 36 - 41 mm OPEN END SPANNER Set the truck on a perfectly flat base plate so that, after adjustment, all the support points (wheels) adhere completely to the floor.

Raise the forks by 500 mm.

Raise the clamps to the cylinder limit stop.

Using the 41 mm open ended spanner, loosen the lock nuts of the adjusters (ref.A fig.3).

Using the 36 mm open ended spanner, lengthen or shorten the adjusters of the tie rods (ref.B fig.3) to reach the desired distance.

After adjusting the tie rods, use the 41 mm open ended spanner to tighten the lock nuts.

A

B

Fig. 3

21

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.

22

SERVICE

SERVICE

MECHANICS

TILLER KEY TO TILLER COMPONENTS

1

3

13

4

2 12 8

11

10

5

9

Ref.

7

6 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 23

SERVICE

MECHANICS REMOVAL OF THE TILLER Equipment and tools

2 open ended spanners 13 mm

T handle hex key 4 mm

hammer

driving tool Ø 15 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 key switch to OFF and disconnect the battery.

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS").

Remove the wheel cover (see "REMOVAL OF THE COVERS").

Remove the motor cover (see "REMOVAL OF THE COVERS").

pin punch Ø 4 mm

Fig. 1

Fig. 2

Phase 2 HEXAGONAL 4 mm "T" SECTION SPANNER Using the T handle hex key, unscrew and remove the screws securing the tiller buffer (ref.A fig.2). Recover the buffer (ref.B fig.2).

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

Phase 3 2 x 13 mm OPEN ENDED SPANNERS Disconnect the tiller wiring connector.

Using one of the spanners, restrain the self-locking nut securing the tiller spring (ref.C fig.3) and unscrew and remove the spring retaining bolt with the other spanner (ref.D fig.3). Recover the self-locking nut.

24

B

A Fig. 3

D

C

SERVICE

MECHANICS

Phase 4 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.E fig.4) Extract the pivot (ref.F fig.4) using the driving tool and the hammer.

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

Fig. 4

F E

25

SERVICE

MECHANICS TILLER SPRING REPLACEMENT Equipment and tools

2 open ended spanners 13 mm

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

Fig. 1

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVERS").

Remove the wheel cover (see "REMOVAL OF THE COVERS").

Remove the motor cover (see "REMOVAL OF THE COVERS").

Fig. 2

B

Phase 2 HEXAGONAL 4 mm "T" SECTION SPANNER Using the T handle hex key, unscrew and remove the screws securing the tiller buffer (ref.A fig.2). Recover the buffer (ref.B fig.2).

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

Phase 3 2 x 13 mm OPEN ENDED SPANNERS Disconnect the tiller wiring connector.

Using one of the spanners, restrain the self-locking nut securing the tiller spring (ref.C fig.3) and unscrew and remove the spring retaining bolt with the other spanner (ref.D fig.3). Recover the self-locking nut.

26

Fig. 3

D

C

SERVICE

MECHANICS

Phase 4 HEXAGONAL 6 mm "T" SECTION SPANNER With the hexagonal "T" section spanner unscrew the fastening screw holding the upper part of the spring (ref.E fig.4).

Extract the spring from the tiller (fig.4) and proceed with the replacement.

Fig.4

E

27

SERVICE

MECHANICS

FORK SMALL MAST IDENTIFICATION SMALL MAST COMPONENTS

2

2 1

4

3 12

5

11

6 7

8

Ref.

28

10

9

Description

1

Load support plate

2

Fixed fork

3

Chain tensioner

4

Pin

5

Cotter pin

6

Nut

7

Bearing

8

Washer

9

Elastic ring

10

Sliding skid fastening screw

11

Washer

12

Sliding skid

SERVICE

MECHANICS

REMOVAL OF THE FORK LIFT CHAIN When replacing the chain it is recommended to change the chain tensioner too.

Equipment and tools

wooden beam round-nose pliers 100x100x1000 mm

ratchet

hexagonal socket wrench 24 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.

Fig.1

Phase 1 WOODEN BEAM Using the controls on the tiller lift the forks 200 mm off the ground.

Position the wooden beam beneath the forks (ref.A fig.1).

Lower the forks until they rest on the beam (fig.1), continue the descent until the chain is loose.

A

Turn the keyswitch to OFF and disconnect the battery.

Fig.2 Phase 2 TAPER END PLIERS - 24 mm SOCKET WRENCH - RATCHET Using the pliers, remove the cotter pin on the chain tensioner pin located on the load-bearing plate(ref.B Fig.2).

Using the socket wrench and ratchet, unscrew and remove the nut locking the chain tensioner (ref.C Fig.2).

B C

29

MECHANICS

SERVICE

Phase 4 ROUND-NOSE PLIERS Using the pliers, remove the split pins on the journal of the chain fixing plug located on the side of the cylinder. Remove the pin (ref.D fig.4).

Slip off the chain including the chain tensioners and proceed with the replacement.

Fig.3

INSTALLATION Do not reuse the chain anchoring safety pins, use new cotter pins, ensuring they are the correct size.

After assembly adjust the chain tensioners so that, in the completely lowered position, the chain remains taught.

D

Fig.4

30

SERVICE

MECHANICS

REMOVAL OF THE FORK SMALL MAST Equipment and tools Fig.1

workbench

tackle load capacity 1000 kg

lifting rope

bent hexagonal wrench 10 mm

A taper end pliers

Procedure

B

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

Turn the keyswitch to OFF and disconnect the battery.

C B

Phase 1 HEXAGONAL 4 mm "T" SECTION SPANNER Raise the battery compartment cover to engage the latch (ref.A Fig.1).

Using the T handle hex key, unscrew and remove the screws (ref.B Fig.2) fastening the two fork locking plates (ref.C Fig.2).

C

Fig.2

Fig.3

Phase 2 HOIST - LIFTING ROPE Secure the fork base plate with the lift belt.

Hook the belt onto the tackle and make taut to slacken the chain (fig.3).

31

SERVICE

MECHANICS Phase 2 TAPER END PLIERS - 24 mm SOCKET WRENCH - RATCHET Using the pliers, remove the cotter pin on the chain tensioner pin located on the load-bearing plate (ref.D Fig.4.

Using the socket wrench and ratchet, unscrew and remove the nut locking the chain tensioner (ref.E Fig.4).

Extract the chain tensioner from its seat.

Fig.4

D E

Phase 3 Using the tackle, raise the forks to extract them completely from the guide (Fig.5), move the small mast away from the truck and put it on a workbench.

Fig.5

INSTALLATION To close the battery compartment cover, pull the spring pin (Fig.6).

Fig.6

32

SERVICE

MECHANICS

BEARING AND SLIDING SKID REPLACEMENT Equipment and tools

medium elastic T handle hex key ring opening pliers 8 mm

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

BEARING REPLACEMENT Phase 1 WORKBENCH - MEDIUM SIZE PLIERS TO OPEN ELASTIC RINGS Using the circlip opening pliers remove the circlip (ref.A fig.1), remove the spacer (ref.B fig.1) and extract the bearing (ref.C fig.1).

Repeat the operation for the other bearings and proceed with the replacement.

C Fig.1

REPLACEMENT OF SLIDING SKIDS Phase 2 WORK BENCH - HEXAGONAL 8 mm "T" SECTION SPANNER Using the T handle hex key, unscrew and remove the fixing screws (ref.D fig.2). Remove the spacers (ref.E fig.2) and the sliding block (ref.F fig.2).

Repeat the operation for the other skid and proceed with the replacement.

B

A

F

E

D

Fig.2

33

SERVICE

MECHANICS

CHAIN GUIDEWAY PULLEY IDENTIFICATION OF HOSE SHEAVE COMPONENTS

2

3

1

1

4

5

Ref.

34

Description

1

Hose sheave bearing

2

Bush

3

Chain guideway pulley

4

Pin locking screw

5

Hose sheave pin

SERVICE

MECHANICS

REPLACEMENT OF THE CHAIN GUIDEWAY PULLEY Equipment and tools Fig.1

tackle load capacity 1000 kg

spreader bar

wooden beam 100x100x1000 mm

taper end pliers

hammer

driving tool Ø 15 mm

open ended spanner 10 mm

A

Procedure

Fig.2

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.

Phase 1 WOODEN BEAM Using the controls on the tiller lift the forks 200 mm off the ground.

Position the wooden beam beneath the forks (ref.A fig.1).

Lower the forks until they rest on the beam (fig.1), continue the descent until the chain is loose.

Turn the keyswitch to OFF and disconnect the battery.

Phase 2 TAPER END PLIERS Using the pliers, remove the split pins on the journal of the chain fixing plug located on the side of the cylinder. Remove the pin (ref.B fig.3).

Extract the chain from the hose sheave and rest it on the forks.

B

Fig.3 35

MECHANICS

SERVICE

Phase 3 HOIST - SPREADER BAR Raise the battery compartment cover to engage the latch (ref.C Fig.4).

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.

Fig.4

Phase 4 10 mm OPEN ENDED SPANNER - HAMMER - DRIVING TOOL Unscrew and remove the screw fastening the hose sheave pin (ref.D Fig.6). Using the hammer and driving tool expel the hose sheave pin (ref.E Fig.6).

Remove the hose sheave and proceed with the replacement.

C

Fig. 5 INSTALLATION To close the battery compartment cover, pull the spring pin.

Fig. 6

E

D

36

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 37

MECHANICS

SERVICE

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

38

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

39

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 40

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 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.

41

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)

42

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 replacement

Fig. 5

F

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

43

MECHANICS

44

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

CODE

production date

DATE

32

C.P.N.

2

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

A oil resistant gloves

oil pan

hydraulic jack

2 wooden blocks

A

A Fig. 1 Fig. 2

T handle hex key 6-8 mm

oil syringe

torque 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, 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

Oil type

Quantity

Standard

ESSO UNIFARM 15W - 40

1.4 litres

Cold store

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

A scissors

external circlip pliers

B

large cross-head screwdriver

puller

C

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.

Fig. 3 When replacing the rotor, the pinion must also be replaced.

Phase 1 Remove the motor compartment cover, the wheel cover and the motor cover (see “REMOVAL OF THE COVERS” in the “MECHANICS” section).

D

Fig. 4

E F

4

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).

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

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

STANDARD MAINTENANCE

standard maintenance OILS AND LUBRICANTS ������������������������������������������������������������������������������������������������������������������������������������������� 4 CLEANING PRODUCTS ��������������������������������������������������������������������������������������������������������������������������������������������� 4 SCHEDULED MAINTENANCE ����������������������������������������������������������������������������������������������������������������������������������� 5

1

STANDARD MAINTENANCE

SERVICE

WARNINGS •

If maintenance operations are carried out immediately after the truck is stopped, some components of the motor and of the hydraulic system could be hot. Always wear the personal protective equipment in situations requiring it.

•

Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbuttoned jackets or tops with open zippers that can get caught up in moving parts.

•

Never do any cleaning, lubrication or maintenance work with the battery connected.

•

Never perform any servicing on the machine with persons at the controls, unless they are accredited operators and help with the operation to be performed.

•

Using compressed air to clean the parts, protect yourself with goggles that have side protection. The maximum air pressure must not exceed 1 bar.

•

Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable and non-toxic trade solvents.

•

Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away into a closed metal container.

•

The capacitors in the transistor control unit can keep an electric charge even after disconnecting the battery. To avoid electric shocks and personal injury, discharge the capacitors before inspecting or repairing any component in the electric compartment. Wear safety glasses. Make sure the battery has been disconnected.

•

Do not file or lubricate the contacts of the contactors. This could cause the contacts to stick and, as a result, loss of control and damage to property or injury to people.

•

Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.

Special companies can be employed to dispose of or recycle industrial oils according to the laws in force in individual countries.

•

Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate under the skin; in such cases, having to make a check, use a card or a piece of wood.

•

Protect the hydraulic system from dirt or contaminants getting inside when checking the fluid level of changing the filter.

•

Never operate the pump without an adequate quantity of fluid in the hydraulic system. Operation with low levels of hydraulic fluid will damage the hydraulic pump.

•

Do not place any tools on the battery. Metal items on the battery can generate accidental short-circuiting and possibly damage or injury.

•

The batteries generate explosive gases. Keep the vents clean. Keep sparks and flames well away from the battery compartment. Pay attention not to create any sparks when disconnecting the battery cables. Disconnect the battery during maintenance work.

•

Always use a spreader bar and slings to raise the battery vertically with the specific eyelets. Do not use chains or slings without a spreader bar, you would risk damaging the battery casing. Check that the battery compartment is clean and dry. When the battery is in service, the aeration plugs must all be installed. If the aeration plugs are not installed, electrolyte can come out, corroding the battery casing and compartment.

2

SERVICE

STANDARD MAINTENANCE

•

The acid in the electrolyte can cause injury. If the electrolyte gets spilled it should be cleaned up with water. Neutralize the acid with a solution of sodium bicarbonate (soda). Areas of the skin that come into contact with the acid must be rinsed with water immediately. Acid splashed into the eyes must be washed away with water constantly for at least 10 minutes, then call a doctor.

•

The batteries belong to the counterweight system of the lift truck. When installing a battery that is too small, the lift truck might not have enough weight for the nominal load. When replacing a battery, see the truck identification data plate to check that the battery has the rated capacity and correct dimensions. See “TRUCK AND LOAD CAPACITY IDENTIFICATION DATA” in the “PRESENTATION” section for the exact battery specifications for the lift truck at issue.

•

Do not work under a raised carriage. Lower the carriage or use a safety chain to prevent the carriage from lowering during maintenance work on the mast and on the lifting chains.

•

Never repair damaged forks using heat or welding. The forks are made of steel that is hardened with special procedures. Replace damaged forks.

•

Before servicing the hydraulic system you must eliminate any residual pressure inside it.

Close the valves at the end of the maintenance work.

3

SERVICE

STANDARD MAINTENANCE

OILS AND LUBRICANTS Application

Std

OIL for lubrication HYDRAULIC CIRCUIT



OIL for lubrication GEARBOX







GREASE for lubrication TIE ROD PINS, MAST PROFILES AND BEARING PINS GREASE for lubrication MAST BEARINGS (1) SPRAY for lubrication CHAINS (2) (1) (2)

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

Shell

ALBIDA GREASE EP2

Shell

AEROSHELL GREASE 6

Shell

ADVANCE TEFLON CHAIN

MIL-G-24139A

Lubrication is not necessary; bearings are already screened and greased for life New chains are supplied ready-lubricated.

CLEANING PRODUCTS Casing and plastic cover cleaning - Cleaning of painted truck parts For general cleaning of the truck, use only dry air, damp rags or degreasing detergents.

Do not use water jets, vapours, solvents or flammable products that may damage the truck or that can be dangerous for the operator.

Motor and electronic system cleaning For general cleaning purposes use dry air at low pressure and a clean dry brush.

Do not use wet rags, water jets, vapour, solvents or flammable products that may damage the truck or that may be dangerous for the operator.

Mast profile and SMALL MAST cleaning Use degreasing solvents.

Do not use water jets, vapour, solvents or flammable products that may damage the small mast or be harmful to the operator.

4

SERVICE

STANDARD MAINTENANCE

SCHEDULED MAINTENANCE  = check and maintenance  = operator check x = replacement

Maintenance intervals

TRUCK BASE

Operation description

every 8 hours 1 day

every 500 hours 6 months

every 1000 hours 12 months

every every 2000 3000 hours hours 24 months 36 months

Check welded joints



Lubrication of tiller pin



Grease tie rod pins



Lubrication of linkage pivot pins-forks-carriage (3)



Check efficiency of tiller gas spring



Check tiller control housing



Check steering thrust bearing





Lubrication of steering thrust bearing



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 cylinder end cap connections Check for oil leaks at motor housing control valve connections Check hydraulic pipes









REDUCER PLANT ELECTRICAL



Check flexible hoses (2)



Change the oil in the hydraulic tank

x

Oil filter cleaning



Check valve operation

WHEELS



Check for oil leaks at pump connections



Reducer oil change

x

Visual oil leak check





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 (9)







Check wear of pivot wheels (9)







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

STANDARD MAINTENANCE

 = check and maintenance  = operator check x = replacement

SMALL MAST AND FORK BASE PLATE

Operation description

Maintenance intervals every 8 hours 1 day

every 500 hours 6 months

every 1000 hours 12 months

Check link and pin wear on lift chains (4)



Check chain elongation (4)



Check chain tensioner

(4)





Clean chains (3) Chain lubrication

every every 2000 3000 hours hours 24 months 36 months

 (3)



Bearing check Check state of forks

 (7)





Check that forks are parallel





Check opening angle



(8)



BATTERY

General cleaning



Check cable connections



Check for liquid leakage



Check battery insulation



Check electrolyte specific gravity



Check electrolyte level (5)



General cleaning (6) Check all machine functions using activation controls (1)

 

replace if necessary

replace in the following situations: • a shift of the connection on the pipe; • the presence of damage, cuts or abrasions on the superficial layer; • hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure; • the presence of cracks, damages or strong corrosion on the connection; • the presence of leaks along the pipe or at the coupling joint; • the presence of permanent creases, compression, flattening or twists in the pipe; • the presence of blisters, softening, wear of the external coat.

(2)

the chains must be cleaned with paraffin, gasoline, diesel fuel or turpentine.

Lubricate with aerosol spray (see oils and lubricants table).

Normally a layer of universal grease is applied to chains operating in refrigerated cells or damp environments.

(3)

replace chains if they have stretched beyond 3% of their length or if the links, the hinge pins or the chain tensioner are worn to such an extent that their replacement is called for Measure the extension with a callipers (fig.1) on many sections 10 steps apart taken in the more stressed sections.

(4)

A) Pin wear B) Pin damage C) Link damage D) Link edge wear E) Wear and ovalization of the links F) Too much play between the links G) Oxidization check H) Wear and ovalization of the chain tensioner I) Wear of the chain hinge gudgeon

6

SERVICE

STANDARD MAINTENANCE

c

A

h

b

i

f

G

e

Fig. 1

d

Fig. 3

Fig. 2

If chains are not excessively worn and stretched, replace them every 3 years (3000 hours) under normal working conditions. Replace them every 2 years (2000 hours) when the truck is used in cold rooms or in corrosive environments.

(5)

fill up the electrolyte levels whenever they fall to 5 - 10 mm from the plate units.

(6)

keep the battery clean and dry, using anti-static cloths if possible.

in the presence of cracks in the structure of the forks and particularly at welded joins (ref.A fig.4). If any cracks are visible then replace the fork. Do not attempt any repairs by welding;

(7)

in cases where there is a permanent deflection between the vertical bracket (ref.E fig.4) and the blade (ref.F fig.4), the maximum acceptable angle is 93 degrees. If the angle (ref.G fig.4) exceeds 93°, the fork must be replaced.

(8)

when necessary, replace or adjust the height of the pivoting wheels if possible

A

E

A

G F

(9)

Fig. 4

7

Code: 550005245

Overhaul: 0 (09/2009)

Part no.: 550072197

Revision:

0 (12/2012)

KEYPAD

This manual is intended solely for the specialized technicians of the Yale service network

MULTIFUNCTION KEYPAD

KEYPAD

SERVICE

IMPORTANT We recommend you read this manual carefully in order to avoid accidents with personnel or damage and keep it in a good condition so it is always decipherable and complete.

This manual does not replace the use and maintenance manual, it is a supplement to it.

2

Product support group

SERVICE

KEYPAD

Contents INTRODUCTION.......................................................................................................................................................... 4 CONNECTIONS........................................................................................................................................................... 4 KEYPAD....................................................................................................................................................................... 5 SWITCHING ON AND ENABLING THE TRUCK FOR USE....................................................................................... 5 Entering the password..................................................................................................................................... 6 user changeover................................................................................................................................................. 7 supervisor menu.................................................................................................................................................. 8 create a new user................................................................................................................................................ 9

3

KEYPAD

SERVICE

INTRODUCTION The Keypad is a multifunction instrument comprised of a keypad, display and internal memory.

This device allows truck operation to be enabled on entry of an identification code.

SPECIFICATIONS •

Required length of the identification code: 5 characters

•

Maximum number of permitted users: 256 (plus an administrator user)

CONNECTIONS

4-pin connector: 1) +VBatt 24 Vdc (max 30 Vdc) 2) GND 3) No Relay 4) No Relay

4

SERVICE

KEYPAD

KEYPAD The keypad is composed of 10 numeric keys (from 0 to 9) and two alphanumeric keys “*“ and “#”.

Keys "2" and "0" have a double function as they allow the administrator user to move within the supervisor menu.

The "#" key is used to confirm an operation.

The “*“ key is used to delete a value entered or to go back to the previous menu.

SWITCHING ON AND ENABLING THE TRUCK FOR USE Turn the key switch to ON (1).

The display will light up and show the version of the firmware.

After approximately 2 seconds the welcome message will appear.

It is now possible to enter the identification code (PIN).

There are two levels of identification: •

User -The PINs of the various users are created by the administrator (Master) or by the specialist technician (Service). Enter the five-digit user code with the numeric keypad and confirm with “#” to enable use of the truck by the user.

•

Administrator - Enter the administrator code 56789 (default value) with the numeric keypad and confirm with “#” to access the supervisor menu where you can: - Create a new user - Block or unblock a user - Read and change the password of a user - Read and change the administrator's password

5

KEYPAD

SERVICE

Entering the password On pressing a numerical key the display shows the screen for entering the password,

where the "+" symbol indicates the digits already entered and "-" those still to be entered.

Any digit entered after the maximum number allowed (five) is not considered by the system.

To delete an incorrect digit, press To confirm the password entered press

. .

If the password entered is correct, the display will show the enabled user's number (for example user 3):

All the truck's functions are now enabled.

On the contrary, if the password entered is not correct (or the user has been blocked by the administrator), the display will show this message:

If instead confirmation is given with "#" before entering all the digits forming the password,

the display will show this message:

6

SERVICE

KEYPAD

user changeover The device can be controlled by one user at a time. In the case of access by an enabled user, if another one tries to obtain access by entering his own password, no operations are carried out.

User 3 switches on the truck and enters the password.

The password is correct and user 3 can begin using the truck.

User 1 enters his own password.

Use of the truck remains enabled for user 3.

To allow another user to be able to access and use the truck, the user that has it in use must first disconnect by entering the password.

User 3 switches on the truck and enters the password.

The password is correct and user 3 can begin using the truck.

User 3 enters the password again to be disconnected.

The password is correct and the device is ready to accept a new user.

If the key switch is turned OFF (0), the device automatically disconnects the user.

7

SERVICE

KEYPAD

supervisor menu To access this menu it is necessary to enter the Master password (56789 by default).

On entering the Master password, at any time, all active functions are switched off to permit access to the supervisor menu.

The display shows a guide to the enabled keys,

which have the following functions: • "0": scrolls through the list of registered users in ascending order, passing from the first item of "New User" to the last one of "Master".

• "2": scrolls through the list of registered users in descending order, passing from the last item of "Master" to the first one of "New User".

• “#”: select.

• “*”: exit.

... ...

8

SERVICE

KEYPAD

create a new user To create a new user, go onto "New User" using keys "0" and "2" and confirm your choice with the "#" key.

The display will request the password for the new user:

It is now possible to enter the password and confirm with the "#" key or go back to the previous menu without creating a user by pressing the "*" key.

If an existing password is entered, the user is still created but he will not be able to access the truck functions since, for the same password, the first user in the list takes priority over the others.

If the same password is wrongly entered by the administrator user (Master), the user is in any case created but the password remains associated with the administrator.

If you try to create a user when the maximum limit on the number of users that can be registered (256) has already been reached, the following message will appear on the display:

9

Code: 550072197

Revision: 0 (12/2012)