PDF DOWNLOAD: Yale A7R0 (MP20KUX) Forklift Service Manual

Revision: 0 (08/2019)

Part no.: 550224095

Technical information for Yale service centres

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

A7R0

MP20KUX

SERVICE IMPORTANT The Service Manuals are updated regularly, but may not contain the most recent product design modifications. The updated technical information is in any case available from your nearest authorised Yale® dealer. The Service Manuals provide the guidelines for correct maintenance and are designed for use by appropriately trained technicians. Incorrect maintenance or non-compliance with the instructions contained in this manual could cause damage to property or injury and even death to people.

We therefore recommend that you read this manual carefully 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

SYMBOLS Signals a danger that can cause injury 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 for disassembly, observing any notes and information provided for correct truck operation.

2

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, well 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.

3

SERVICE •

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 across 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.

4

SERVICE Belt capacity table 45° 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)

Colour

Width (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

Coefficient

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°

5

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

Nominal diameter

To make the threaded matings secure, a threadlocking glue 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 thread-locking glue effect.

In the cases described, reapply the thread-locking glue 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 Class 8

Class 10

M3

4

5.2

M4

7

9.15

M5

12.14

14.8

M6

17.2

20.9

M8

31.8

38.1

M 10

50.5

60.3

M 12

74.2

88.5

M 14

101.2

120.8

M 16

138.2

164.9

M 18

176.6

203.5

M 20

225.4

259.7

M 22

278.8

321.2

M 24

324.8

374.2

M 27

422.3

486.5

M 30

516.1

594.7

TORQUE SETTING Nm Pre-load N

Class 8.8

Class 10.9

mm

mm

mm

mm

M4

0.7

7

3

2400

1.92

1.44

3.07

2.3

4.17

3.13

M5

0.8

8

4

3880

3.88

2.91

6.2

4.65

8.43

6.33

M6

1

10

5

5490

6.58

4.94

10.5

7.9

14.3

10.8

M8

1.25

13

6

9990

16

12

25.6

19.2

34.8

26.1

M8

1

13

6

10700

17.1

12.8

27.4

20.5

37.3

27.9

M 10

1.5

16

8

15825

31.7

23.8

51

38

69

52

M 10

1.25

16

8

16700

33.4

25.1

53

40.1

73

55

M 12

1.75

18

10

23025

55

41.4

88

66

120

90

M 12

1.25

18

10

25150

60

45.3

96

72

130

98

M 14

2

21

12

31400

88

66

140

105

190

145

M 14

1.5

21

12

34125

96

72

155

115

210

155

M 16

2

24

14

42850

135

105

220

165

300

225

M 16

1.5

24

14

45600

145

110

235

175

320

240

M 20

2.5

30

17

66875

270

200

430

320

580

435

M 20

1.5

30

17

74250

295

225

475

355

650

485

= with lubricant

6

Class 5.8

SERVICE 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

UNF thread

REVOLVING FEMALE jic 37° Torque setting Nm 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

UNF thread G1/4

20 22 25 28

38 42

BSP REVOLVING FEMALE Torque setting Nm

UNF thread

ORFS REVOLVING FEMALE Torque setting Nm Size

Nominal torque

max.

Nominal torque

max

20

15 - 25

9/16-18

-4

14

16

-6

24

27 47

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.

7

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.

8

SERVICE CONTENTS Presentation.........................................................................................10 Installation............................................................................................14 Diagnostics e measurements.............................................................16 Electrical system.................................................................................26 Hydraulic system.................................................................................44 Truck base mechanics........................................................................52 Reduction gear....................................................................................72 Braking system....................................................................................74 Maintenance.........................................................................................76

9

PRESENTATION

SERVICE

TRUCK PRESENTATION The transpallet pedestrian model MP20KUX is equipped with storage batteries and AC motor which provide the dynamic source and the tractive force respectively.

The forks are lifted by a DC motor and a hydraulic transmission system.

Peculiar characteristics of this truck are its high efficiency, energy saving, simple and stable operation, safety and reliability, reduced noise.

10

SERVICE

PRESENTATION

TRUCK IDENTIFICATION DATA PLATES

The truck identification data plate is located on the truck base

• • • • • • • • • •

Manufacturer's name Serial number Model Year of manufacture Nominal load capacity Weight without battery Min./max. battery weight Persons on board Rated power Battery voltage

11

PRESENTATION

GENERAL SPECIFICATIONS MP20KUX

12

SERVICE

SERVICE

PRESENTATION

Motor units

Performance

Dimensions

Wheels, frame

Weight

Characteristics

GENERAL SPECIFICATIONS 1.1

Manufacturer (initials)

1.2

Model designation

1.3

Power assembly: battery, diesel, LPG, petrol, electrical

1.4

Operation: manual, pedestrian, standing, seated, order pickers

1.5

Rated capacity/rated load

Q (kg)

2000 600

Battery Pedestrian

1.6

Load centre of gravity

c (mm)

1.8

Load distance from wheel axle to fork shoulder (1)

x (mm)

885

1.9

Wheelbase

y (mm)

1280

2.1

Service weight (with battery)

kg

620

2.2

Axle loading with load (front/rear)

kg

1170 /1450

2.3

Axle loading without load (front/rear)

kg

3.1

Cover: solid tyre, polyurethane, vulkollan (front/rear)

3.2

Tyre size, front

ø (mm x mm)

250 x 70

3.3

Tyre size, rear

ø (mm x mm)

82 x 126

3.4

Additional wheels (dimensions)

ø (mm x mm)

3.5

Wheel quantity (x= traction) (front/rear)

470 / 150 Polyurethane

127 x 57 1x + 2 / 2 (4)

3.6

Front track width

b 10 (mm)

510

3.7

Rear track width

b 11 (mm)

370 / 5055

4.4

Lifting height

h 3 (mm)

120 550 / 1230

4.9

Extended height in driving position, min/max

h 14 (mm)

4.15

Height with forks lowered

h 13 (mm)

82

4.19

Total length

l 1 (mm)

1705

4.20

Length to face of forks

l 2 (mm)

555

4.21

Overall width

b 1 (mm)

775

4.22

Fork size(14)

s/e/l (mm)

54 / 180 / 1150

4.25

Fork outer gauge (10)

b 5 (mm)

550 / 685

4.32

Ground clearance at wheelbase centre

m 2 (mm)

28

4.33

Aisle width with pallet 1000mm x 1200mm crossways

A st (mm)

2296

4.34

Aisle width with pallet 800mm x 1200mm crossways

A st (mm)

2150

4.35

Turning radius

W a (mm)

1491

5.1

Travel speed with/without load

km/h

5.5 / 5.6

5.2

Lifting speed laden/unladen

m/s

0.039 / 0.056

5.3

Lowering speed laden/unladen

m/s

0.044 / 0.035

5.7

Gradient, with/without load

%

6 / 12

5.8

Maximum gradeability with/without load

%

5.10

Service brake

8 / 20 Electromagnetic

6.1

Traction motor power

kW

6.2

Lifting motor power

kW

0.8

6.4

Battery voltage/capacity

(V)/(Ah)

24 / 210

6.5

Battery weight

kg

180

Battery size (L x w x h) Additional data

Yale MS20KUX

8.4

Sound pressure level at operator position DIN 12503

mm

dB (A)

1.2 (AC)

750x170x534

70

13

SERVICE

INSTALLATION

INSTALLING THE BATTERY 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 all pedestrians.

Phase 1 Remove the lateral door of the battery compartment (fig. 1).

Phase 2 Place the battery on a roller trolley, bring it close to the battery compartment and push the battery inside it (fig. 2).

Phase 3 Connect the battery to the battery connector, then replace the side door of the battery compartment (fig.3).

Fig. 2

Fig. 1

Fig. 3

It is recommended to handle the battery with care during lifting and transport; otherwise the battery could be damaged or there could be danger to the operator.

After installing the battery and assembling any other components, it is mandatory to completely check the truck before starting it up.

In order to safeguard the safety of people and materials, before proceeding with the following operations, it is recommended to check: the type of load to be handled and the general conditions of the warehouse, the aisles and the flooring

14

SERVICE

INSTALLATION

15

DIAGNOSTICS AND MEASUREMENTS

CONTROLLER DESCRIPTION TRACTION CONTROL DEVICE AC0

16

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

KC-A1 Main remote control switch coil negative KC-A2 Output + 24V contactor coil and electromagnetic brake power supply KC-A3 Electromagnetic brake coil negative KC-A4 Pump contactor coil negative KC-A5 Output + 24V lifting contactor coil and lowering solenoid valve power supply KC-A6 Lowering solenoid valve coil negative KC-A7 Can Low KC-A8 Not used KC-A9 Motor encoder positive KC-A10 Motor encoder negative KC-A11 Not used KC-A12 Motor power supply negative reference KC-A13 Motor temperature sensor input KC-A14 Safety Steer - Not used KC-A15 Speed reduction KC-A16 Not used KC-A17 Can High KC-A18 Not used KC-A19 Input A encoder KC-A20 Input B encoder KC-B1 Key switch power supply KC-B2 Not used KC-B3 Tiller sensor input KC-B4 Slow travel request KC-B5 Reverse travel request KC-B6 Forward travel request KC-B7 Emergency reverse request (Belly) KC-B8 Forks lowering request KC-B9 Forks lifting request KC-B10 Output 0 - 5V throttle potentiometer KC-C1 Positive serial line reception KC-C2 Negative serial line reception KC-C3 Positive serial line transmission KC-C4 Negative serial line transmission KC-C5 Negative console power supply KC-C6 Positive console power supply

17

SERVICE

DIAGNOSTICS AND MEASUREMENTS

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

Some 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.

COMBI AC0 TRACTION CONTROL TESTER MENU PARAMETER KEY VOLTAGE

measurement unit Volts

Level of battery voltage measured at the KC-B1 input MOTOR VOLTAGE

%

The voltage supplied to the motor by the it is expressed as a percentage of the maximum voltage (which depends on the battery voltage) FREQUENCY

Hz

Estimated frequency applied to the motor control and to the AC traction motor ENCODER

Hz

Real speed detected by the AC traction motor encoder SLIP VALUE

Hz

Speed difference between the rotation field and the motor rotor, expressed in the same unit as the frequency CURRENT RMS

Arms

RMS current applied to the AC traction motor BATTERY CURRENT

A

Battery current BATTERY CHARGE

%

Battery charge level percentage TEMPERATURE

°C

Temperature of the inverter measured on the heat sink MOTOR TEMPERATURE

°C

Traction motor temperature ACCELERATOR

V

Throttle potentiometer voltage BRAKE PEDAL POT Brake potentiometer voltage percentage value

18

%

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER

measurement unit

LIFTING SWITCH “Lifting button” digital input enable/disable DESCENT SWITCH “Lowering button” digital input enable/disable FORWARD SWITCH “Forward travel button” digital input enalbe/disable BACKWARD SWITCH “Reverse travel button” digital input enalbe/disable QUICK INVERSION “Belly button” digital input enable/disable CUTBACK SWITCH 1 Speed reduction 1 microswitch enable/disable CUTBACK SWITCH 2 Speed reduction 2 microswitch enable/disable CUTBACK SWITCH 3 Speed reduction 3 microswitch enable/disable

19

DIAGNOSTICS AND MEASUREMENTS

SERVICE

TROUBLESHOOTING

The alarms are signalled by a diagnostic LED that blinks intermittently to indicate the various alarms as described in the following table: 1 blink

Faults in the logical device

2 blinks

Traction request at start-up and traction request errors Anomalies related to capacitor charge or phase voltage

3 blinks 4 blinks

Errors related to the throttle

5 blinks

Errors related to the current sensor

6 blinks

Errors related to the contactor driver

7 blinks

Excessive temperature

8 blinks

Incorrect detection from the Can Bus

prolonged blinking

20

Battery low

SERVICE

DIAGNOSTICS AND MEASUREMENTS

FAULTS LIST By connecting the diagnostic tool it is possible to display the alarms present Alarm

Troubleshooting

WATCHDOG

It is a self-diagnostic test inside the control and is • If the alarm occurs, replace the control. carried out during operation and in stand-by mode.

EEPROM KO

This alarm is due to a fault in the memory where the adjustment parameters are stored. This alarm blocks the machine operations, but the truck operates with default values.

• Switch the truck off and then back on. If the alarm persists replace the control. If the problem has been solved, keep in mind that the values set have been replaced by default values.

• It is likely that a overvoltage or undervoltage condition has occurred This alarm appears when the module detects • Or, it is likely that a fault has occurred in the overvoltage or undervoltage conditions. logic board that manages the protections against overvoltage. Replace the control.

LOGIC FAILURE #1

LOGIC FAILURE #2

A fault in the hardware section of the logic board • Replace the control. that controls the retroaction of the phase voltage.

LOGIC FAILURE #3

Hardware problem in the circuit of the logic board • Replace the control. for protection against hardware current.

CHECK UP NEEDED

This message is only a warning that it is time to • Perform scheduled maintenance. carry out the scheduled maintenance.

INCORRECT START

It is an incorrect start sequence alarm.

• Possible causes: error in the microswitch; error in the start sequence by the operator; wiring or connections problem.

• If the alarm persists, replace the control.

FORW + BACK

• Possible causes: error in the microswitch; error in the start sequence by the operator; wiring or This message only appears when both the (forward connections problem. and backward) motion requests are activated at • If the alarm persists, replace the control. the same time.

HANDBRAKE

• Possible causes: error in the microswitch; error in the start sequence by the operator; wiring or The cart does not start because the handbrake connections problem. switch is open.

• If the alarm persists, replace the control.

21

DIAGNOSTICS AND MEASUREMENTS

SERVICE

CAPACITOR CHARGE

To better understand the meaning of this alarm, refer to the following diagram:

When the key is turned to ON, the inverter tries to charge the capacitor through the power resistance and check if the capacitor is charged within a certain time frame. If this doesn't happen, the alarm appears; the main remote-control switch is not closed.

• There is an external load parallel to the capacitors, which lowers the module pre charge circuit current, preventing its charging. Check if a lamp or a dc/dc converter or an auxiliary load is connected.

• The charge resistor is open; add a power resistor on the contactor terminals; if the alarm disappears it means that the charge resistor inside the control is damaged. Replace the control.

• The charging circuit is faulty inside the control.

Replace the control.

• There is a problem in the control power section.

Replace the control.

VMN LOW, VMN HIGH

Possible causes: The test is performed in diagnosis and in stand-by. • Problems in the motor connections or in the motor power circuit..

• Check that the three phases are connected.

• Check for motor dispersions to the frame.

• Fault in the inverter, replace it.

VACC NOT OK

Possible causes: • The potentiometer is not calibrated correctly The test is performed in stand-by.

This alarm occurs if the accelerator value is greater • The potentiometer is defective. than 1.0 V compared to the minimum value set by • Restart the system and make a new traction request. the PROGRAM VACC function.

PEDAL WIRE KO

The alarm appears if a fault is detected in the • Check the voltage on NPOT and the connections of the potentiometer. accelerator wiring (the NPOT or PPOT cable is disconnected).

STBY I HIGH

• Fault in the current sensor.

The test is performed in stand-by. Check that the • Logic failure: replace the control. If the alarm current is at 0. If this does not occur, this alarm persists replace the control. appears which stops the machine operations.

22

SERVICE

DIAGNOSTICS AND MEASUREMENTS

COIL SHORTED

This alarm appears when there is an overload of the main contactor driver or of the electromagnetic brake driver. As soon as the overload condition is removed, the alarm disappears automatically when making a new traction request.

DRIVER SHORTED

• Check that there are no external short circuits and that the ohmic value of the coils of the main contactor and of the electromagnetic brake are correct. If not, replace the control.

•

When switched on by key, the microprocessor checks that the contactor coil is not short-circuited. • If it is, this alarm is activated.

Check the coil(s) connections check that it is not short-circuited.

Replace the control.

CONTACTOR DRIVER

The contactor coil driver is not capable of piloting • the load.

Replace the control.

CONTACTOR OPEN

The main contactor coil is activated by the module, but the contactor does not close. Two possible • causes: a) the battery cables are not connected correctly. • b) contactor contact does not work correctly.

Check the coil wiring.

Try replacing the remote-control switch.

AUX OUTPUT KO

Possible causes: The microprocessor that governs the • The output transistor is damaged. electromagnetic brake driver. If the state of the • Defect in logic. driver output does not correspond to the signal • Check the electromagnetic brake coil wiring. from the microprocessor, the alarm is triggered.

23

DIAGNOSTICS AND MEASUREMENTS

SERVICE

HIGH TEMPERATURE

Temperature of the control higher than 78°. The If the alarm is generated when its temperature is not maximum current is reduced proportionally as really above 78°, replace the control the temperature increases. The control stops at a temperature of 100°.

THERMIC SENSOR KO

The inverter temperature sensor range is always • Check the sensors connection. under control. The alarm is generated when the temperature is outside the range.

CAN BUS KO

The CanBus line diagnosis is present only if the • Firstly check the wiring. inverter uses this connection (this depends on the • If the problem is not in the wiring then it is in the software version). The alarm is generated if the control, which needs to be replaced. inverter does not receive any message from the CanBus line.

BATTERY LOW

If the “Battery Check” option is active, an algorithm is run on the battery discharge. When the battery charge level is at 10%, this alarm is activated and the current is reduced to a value equal to half the set level.

MOTOR TEMPERATURE

The motor temperature is above the expected • This is just a warning: no checks will be performed. value.

24

SERVICE

DIAGNOSTICS AND MEASUREMENTS

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 in an unpainted zone. The resistance reading ( W) on the tester should be infinity (~). Otherwise, the motor is not insulated and must be replaced immediately.

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

25

ELECTRICAL SYSTEM

WIRING DIAGRAMS Ref

26

Description

KC

Traction controller

WK

Tiller board

M1

Traction motor 1.2 Kw

M2

Pump motor 0.8 Kw

K1

Emergency Switch

K2

Key Switch

K4

Speed limitation sensor

K5

Tiller sensor

K6

Lift Switch

L

Electromagnetic brake

L1

Lowering solenoid valve

MC

Main contactor

PC

Pump contactor

SERVICE

SERVICE

ELECTRICAL SYSTEM

27

ELECTRICAL SYSTEM

SERVICE

TRUCK COMPONENTS

4 1 5 6 2

7

3

8

Ref.

28

Description

1

Control device

2

Lift cylinders

3

Battery charger

4

Pump motor assembly

5

Valve block

6

Oil tank cap

7

Oil level check

8

Oil drain

SERVICE

ELECTRICAL SYSTEM

CONTROLS KEY TO TILLER CONTROLS AND MAIN PANEL

2

1

3

5 4

8

6

7

Ref.

Description

1

Snail button

2

Horn

3

Emergency reversing button (belly)

4

Forward/reverse traction control throttle

5

Fork lifting/lowering button

6

BDI

7

Emergency button

8

Wrench

29

SERVICE

ELECTRICAL SYSTEM

TRUCK FUNCTIONS FORWARD/REVERSE TRACTION ACTUATION CONTROLS

Forward travel (operator side)

Reverse travel (fork side)

Actuators involved

Status

Key switch

ON

Emergency switch

ON

Tiller tilt sensor

ON*

Forward/reverse traction control throttle

forward/reverse rotation

* OFF when the "snail" button is pressed

CONFIGURATION PARAMETERS parameter change menu Acceler delay Release braking Inverse braking Pedal. braking Speed limit brk Brake cutback Q.I. accel delay Q.I. inv braking Max speed forw Max speed back Cutback speed Ctb. spd diag.

30

Frequency creep Acc. smooth Stop smooth Brk smooth Stop brk smooth Auxiliary time Emb ins delay

adjustment menu Adjust key volt Adjust battery Throttle X0 zone Throttle X1 map Throttle Y1 map Throttle X2 map Throttle Y2 point Throttle X3 point Throttle Y3 point Check up time Check up done Check up hours

SERVICE

ELECTRICAL SYSTEM

BRAKING The truck is equipped with four braking systems: • • • •

Release braking.

Braking on direction reversal.

Emergency braking.

Parking brake.

BRAKING SYSTEM

WHEN DOES IT COME INTO OPERATION?

Release braking

Release of the butterfly drive control

Braking on direction reversal

Inversion of the direction of travel using the drive control Emergency brake button operation.

Emergency braking

Parking brake

AN alarm has been generated that requires traction to be halted immediately The tiller is released in the rest position. Drive motor electrical braking with subsequent engagement of the electromagnetic brake

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 “EMERGENCY REVERSE” button (ref.A fig.1) causes the truck to immediately reverse, thereby preventing the operator from being crushed.

SNAIL FUNCTION The "snail" function enables traction even when the tiller is in the rest position (tiller sensor not active). This allows the 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 (ref. B fig.1). Once the "snail" button is pressed, the traction request is performed by the potentiometric throttle

B

A

Fig. 1

31

SERVICE

ELECTRICAL SYSTEM STEERING WHEEL ACTUATION CONTROLS

To steer to the right or to the left rotate the tiller to the right or left.

Actuators involved

32

status

Key switch

ON

Emergency switch

ON

Tiller sensor

ON

Tiller rotation

right/left rotation

SERVICE

ELECTRICAL SYSTEM

FORK LIFTING/LOWERING ACTUATION CONTROLS

A To lift / lower the forks press the button“A”.

Actuators involved

status

Key switch

ON

Emergency switch

ON

Slow fork lifting/lowering Tiller sensor

ON-OFF button lifting/ lowering active ON*

*Only in the case of fork lowering

33

ELECTRICAL SYSTEM

SERVICE

STANDARD CONFIGURATION OF MODULE PARAMETERS It is always advisable to keep the factory settings as designed in order to have the best compromise between performance and component wear. It is however possible to customise the performance based on the client's request, the characteristics of the warehouse and the materials to be moved, but no parameter must be changed if this jeopardises the safety of the truck.

34

SERVICE

ELECTRICAL SYSTEM

“COMBI” MODULE COMBI / menu parameter change / COMBI / menu set options / COMBI / menu adjustment /

PARAMETER CHANGE MENU

MENU SET OPTIONS

PARAMETER

Default

PARAMETER

Default

ACCELER DELAY

2

TILLER SWITCH

0=HANDLE

RELEASE BRAKING

9

A13 TEMP SENSOR

1=PRESENT

INVERSE BRAKING

8

SET INPUT #2

0=PRESENT

PEDAL BRAKING

9

CUTBACK 2 N.C.

0=OFF

SPEED LIMIT BRK

2

HS CUTBACK NC

0=OFF

BRAKE CUTBACK

5

SET INPUT#4

0=BELLY

TILLER BRAKING

7=6

HOUR COUNTER

1=KEY ON

Q.I. ACCEL DELAY

0

BATTERY CHECK

1=LEVEL

Q.I. INV BRAKING

9=3

MAX SPEED FORW

100 Hz

MAX SPEED BACK

100 Hz

CUTBACK SPEED

5=60%

A15 CUTBACK

50%

CUTBACK SPEED 3

8=90%

BDI LOW SPEED

4=50%

CURVE CUTBACK

2=40%

H & S CUTBACK

3=26%

FREQUENCY CREEP

3=1.20 Hz

MAXIMUM CURRENT

9

INCHING SPEED

0 Hz

INCHING TIME

0 sec.

AUXILIARY TIME

4 sec.

Q.I.TIME

2

TILLER DELAY

0

STEER ANGLE MIN

15

STEER ANGLE MAX

75

B.M.S.

1=ON

HYDRO KEY ON

0=OFF

STOP ON RAMP

1=ON

AUX OUTPUT #1

2=BRAKE

PEDAL BRAKING

0=NONE

QUICK INVERSION

2=TIMED

AUX VOLTAGE #1

6=69%

DISPLAY TYPE

5=LEVEL

EPS

1=PRESENT

QUICK INV. LOGIC

0=OPTION#1

OPTION 09

1=OPTION#2

CONTACTOR CLOSED

0=OFF

CAN TILLER

0=ABSENT

A14 FUNCTION

3=OPTION#3

BELLY ALARM

1=ON

MDI SPEED

0=OFF

PUMP WITHOUT TIL

1=ON

TILLER OPEN

0=OFF

TILLER OPEN ALAR

0=OFF

35

ELECTRICAL SYSTEM

MENU ADJUSTMENT

36

PARAMETER

Default

SET POT BRK MIN

0.0 V

SET POT BRK MAX

108=2,1 V

MOTOR OVERTEMP

5=120°C

SET MOT TEMP.

101=21°C

SET BATTERY TYPE

0=24V

ADJUST BATTERY

131=25,1V

THROTTLE 0 ZONE

5=9%

THROTTLE X POINT

4=54%

THROTTLE Y POINT

2=25%

ADJUSTMENT #01

2

ADJUSTMENT #02

6

LOAD HM FROM MDI

0=OFF

CHECK UP DONE

0=OFF

CHECK UP TYPE

0=NONE

CUTBACK SENS CNT

20

SPEED FACTOR

139

BDI LOW BATTERY

15%

SERVICE

SERVICE

ELECTRICAL SYSTEM

DESCRIPTION OF MODULES PARAMETERS “COMBI” MODULE COMBI / main menu parameter change / COMBI / menu set options / COMBI / menu adjustment / PARAMETER CHANGE MENU PARAMETER ACCELER. DELAY Traction acceleration ramp RELEASE BRAKING Throttle release braking deceleration ramp.

INVERS. BRAKING Direction reversal braking deceleration ramp PEDAL BRAKING Deceleration slope with throttle released but not completely at 0 SPEED LIMIT BRK. Deceleration ramp when a speed limit is active.

MAX SPEED FORW Maximum forward traction speed MAX SPEED BACK Maximum backward traction speed.

CUTBACK SPEED Speed reduction CUTBACK SPEED 3 Speed reduction BDI LOW SPEED Speed reduction with low battery FREQUENCY CREEP It determines the frequency applied to the motor when the traction control is in the minimum position.

37

ELECTRICAL SYSTEM

SERVICE

SET OPTIONS MENU PARAMETER HOUR COUNTER Selects the hourmeter mode: KEY ON= hourmeter active at start up; RUNNING = during a request for traction, pump activation or valves activation.

38

SERVICE

ELECTRICAL SYSTEM

CONTROL DEVICES TRACTION - PUMP The module has been designed to perform all the electrical functions normally present on the truck: • • • •

Inverter for three-phase asynchronous AC motors Regenerative braking functions CanBus interface Digital control via two redundant microcontrollers.

Technical specifications: Voltage:............................................................................................................................................... 24V Inverter maximum current (24V):................................................................................... 150A (RMS) for 2’ Operating frequency......................................................................................................................... -8kHz External temperature............................................................................................................. -30°C - 40°C Inverter maximum temperature......................................................................................................... 78°C Encoder interface

39

SERVICE

ELECTRICAL SYSTEM TILLER HEAD IDENTIFICATION OF TILLER HEAD COMPONENTS

Pos.

40

Description

Pos.

Description

1

Horn

13

Right grip

2

Screw 2.9X6.5

14

Left grip

3

Microswitch clip insert

15

Throttle control - Curtis assembly

4

Spring for spring button

16

Screw M4X12

5

Microswitch

17

Washer 4 gasket

6

Upper cover group

18

Ring 1 bushing support

7

Spring gasket

19

Ring 2 bushing support

8

Emergency reverse button cover

20

Upper and lower part cover

9

Right button

21

Screw M5X35

10

Left button

22

Bolt M5X50

11

Screw M3X12

23

Reduced speed button

12

Locking washer 3

24

Wire harness

SERVICE

ELECTRICAL SYSTEM

BUTTONS KEY TO RIGHT BUTTON ASSEMBLY COMPONENTS

Pos.

Description

1

Right Cover

2

Pin

3

Spring

4

Right button

5

Microswitch

6

Screw 2.2X12

41

ELECTRICAL SYSTEM BUTTONS KEY TO LEFT BUTTON ASSEMBLY COMPONENTS

Pos.

42

Description

1

Left Cover

2

Pin

3

Microswitch

4

Screw 2.2X12

5

Microswitch

6

Spring

SERVICE

SERVICE

ELECTRICAL SYSTEM

43

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC FUNCTIONS • •

Forks lifting Forks lowering

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

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

The proportionality of the lowering phase is handled by the proportional solenoid valve.

44

SERVICE

HYDRAULIC SYSTEM

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

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

PRESSURE CONTROL VALVES Pressure limiting valves The "pressure limiting" or "pressure relief" valves are mainly used to guarantee that the maximum permissible system pressure is not exceed in the system and to protect the pump from damaging pressure levels that exceed its structural characteristics.

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

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

DIRECTIONAL CONTROL VALVES One-way valves 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; in the appropriate inner housing runs the moving element which might be a bearing or a conical plug.

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

45

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM SYMBOLS TWO POSITION SOLENOID VALVE

FILTER

46

THREE POSITION SOLENOID VALVE

ONE-WAY VALVE

DOUBLE ACTING CYLINDER

PROPORTIONAL VALVE

SINGLE ACTING CYLINDER

PUMP

TANK

HYDRAULIC MOTOR

LINE CONNECTION

ELECTRIC MOTOR

PRESSURE RELIEF VALVE

FLOW VALVE

MANUAL COCK

BY-PASS VALVE

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC FORK LIFTING DIAGRAM

47

ELECTRICAL SYSTEM

HYDRAULIC FORK LOWERING DIAGRAM

48

SERVICE

SERVICE

ELECTRICAL SYSTEM

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

Pressure control setting not suitable for the truck load capacity Attempt to lift a load in excess of the truck's load capacity Faulty or stuck valve

49

HYDRAULIC SYSTEM

SERVICE

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

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

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

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

A B

Phase 2 Unscrew the high pressure oil pipe and install a pressure gauge with 20Mpa capacity on the high pressure oil outlet. Press the lift button to measure the system pressure. For trucks with a capacity of 1500 Kg, the nominal pressure must be equal to 16Mpa. If the oil pressure does not correspond with the specified value, loosen the nut of the pressure relief valve (ref.A fig.1). Turn the screw (ref. B fig.1) to the right or left until the specified value is reached; turning the screw clockwise increases the pressure, while turning the screw counterclockwise decreases the pressure.

Once the adjustment has been made, tighten the nut again.

50

Fig. 1

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.

Pos.

Description

Pos.

Description

1

Rod

7

Cylinder

2

Gasket housing bushing

8

Piston

3

O-Ring 35.5X2.65

9

Back-up ring

4

O-Ring 40X3.1

10

Thrust washer

5

Seal ring

11

Bearing

6

Rod ends

12

Ring 20 51

TRUCK BASE MECHANICS

DRIVE WHEEL KEY TO COMPONENTS OF THE DRIVE WHEEL

5

3

4

2 1

Ref.

52

Description

1

Screws M24

2

Screws M6

3

Nut

4

Drive wheel

5

Shaft

SERVICE

SERVICE

TRUCK BASE MECHANICS

CASTOR WHEEL ASSEMBLY KEY TO CASTOR WHEEL ASSEMBLY COMPONENTS

53

TRUCK BASE MECHANICS

Pos.

54

Description

1

Screw M12x100

2

M12 nut

3

Dust cover

4

Locking ring

5

M24 nut

6

Washer

7

O Ring

8

Roller bearing

9

Bearing housing

10

Bearing

11

O-ring

12

Rotating plate assembly

13

Tire Assy

14

Bearing

15

Screw M16

16

Bushing

17

Bearing

18

Wheel

19

Nut

20

Shaft

21

Screw M12

22

Lock nut M6

23

Adjustable shaft

24

Screw M6

SERVICE

SERVICE

TRUCK BASE MECHANICS

REMOVAL AND DISASSEMBLY OF THE CASTOR WHEEL ASSEMBLY 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 all pedestrians.

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

DISASSEMBLY OF THE CASTOR WHEEL Phase 1 Position the hydraulic jack on the centre of the truck body and raise the truck sufficiently to insert the wooden blocks underneath.

Position the wooden blocks at the truck sides, lower the jack and place the truck so that it rests on the blocks.

Phase 2 Unscrew the screws securing the pivoting wheel assembly to the truck body (ref.A fig.1). Retrieve the wheel assembly and proceed with the replacement.

Proceed with the replacement.

A

A

Fig. 1

A

55

SERVICE

TRUCK BASE MECHANICS

DISMANTLING OF THE CASTOR WHEEL Phase 3 Lock the self-locking nut of the castor wheel (ref.B fig.2), while with the socket wrench and the ratchet unscrew and remove the fastening screws of the castor wheel (ref.C fig.2).

Recover the screw and the self-locking nut and remove the wheel from its support.

Proceed with the replacement.

Phase 4 Put the wheel in a vice. Extract the bushes (ref.D fig.2) and recover the bearings (ref. E fig.2).

Proceed with the replacement.

Fig. 2

E

C D

56

E

D

B

SERVICE

TRUCK BASE MECHANICS

LOAD WHEELS KEY TO COMPONENTS OF THE LOAD WHEELS

Pos.

Description

1

Bearing

2

Wheel

3

Circlip

4

Pin

5

Rocker arm

57

SERVICE

TRUCK BASE MECHANICS LOAD WHEEL REMOVAL AND DISASSEMBLY

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 all pedestrians.

Phase 1 Raise the forks by 1500 mm using the lifting button. Sling the fork small mast with the lifting belt Hook the belt to the hoist and tension it.

Turn the keyswitch to OFF and disconnect the battery.

Phase 2 Position the hydraulic jack beside the load wheel and lift until the wooden stock can pass beneath. Position the wooden block beneath the clamp and rest the truck on the block.

A

Fig. 1

Phase 3 Remove the pin (ref.A fig.1) and remove the load wheel assembly from its seat.

DISASSEMBLY OF THE LOAD WHEEL Phase 4 Remove the circlip of the pin (ref.B fig.2). Drive out the pivot (ref.C fig.2) using a driving tool and the hammer. Extract the load wheel from its lodging.

Then remove the circlip (ref.D fig.2) and recover the bearings (ref.E fig.2).

Proceed with replacement.

E C E

58

D

B Fig. 2

SERVICE

TRUCK BASE MECHANICS

TILLER ASSEMBLY IDENTIFICATION OF TILLER ASSEMBLY COMPONENTS

Pos.

Description

1

Tiller

2

Screw M8X16

3

Washer 8

4

Screw M5X8

5

Gas spring

6

Slide-locking

7

Safety ring D5

8

Pin with groove

9

Wheel

10

Safety ring 30

11

Plate U

59

TRUCK BASE MECHANICS

Pos.

60

Description

12

Washer 10

13

Pin

14

M8 nut

15

Screw M8X25

16

Bearing

17

Safety ring 62

18

Insulation damping ring

19

Steering support gear housing

20

Washer 10

21

Screw M10X25

22

Screw M4X8

23

Bearing - air spring

24

Gas spring 228X70X430-450N

25

Bearing

26

Pin

27

Washer

28

Locking washer M6 bearings

29

Screw M6X12

30

Tiller assembly - seat

31

Screw M8X20

32

Seal

SERVICE

SERVICE

TRUCK BASE MECHANICS

AC MOTOR 1.5KW KEY TO AC 15KW MOTOR COMPONENTS

Pos.

Description

1

AC Motor

2

Encoder-II

61

TRUCK BASE MECHANICS DC STEERING MOTOR KEY TO DC STEERING MOTOR COMPONENTS

Pos.

62

Description

1

DC Steering motor

2

Terminal TY10

3

Encoder

SERVICE

SERVICE

TRUCK BASE MECHANICS

SINGLE LOAD WHEEL TIE ROD

Pos. 1

Description

Pos.

Description

Rocker arm

6

Bearing

Connector rod - 1100

7

Pin

Connector rod - 1150

8

Pin 6X40

Connector rod - 1220

9

M24X2 nut

3

Load wheel support

10

Junction hook

4

Pin

11

Pin

2

5

Wheel - Ø82 Wheel - Ø78

63

TRUCK BASE MECHANICS

SERVICE

TANDEM LOAD WHEELS TIE ROD

Pos. 1

2

3 4 5

64

Description

Pos.

Description

Rocker arm

6

Bearing

Connector rod

7

Pin

Connector rod

8

Pin 6X40

Connector rod

9

M24X2 nut

Load wheel support

10

Junction hook

Wheel - Ø82

11

Pin

Wheel - Ø78 Bearing

SERVICE

TRUCK BASE MECHANICS

ROCKER ARM

Pos.

Description

1

Wheel

2

Rocker arm

3

Bearing

4

Bearing

5

Pin

6

Pin 6X40

65

TRUCK BASE MECHANICS JUNCTION HOOK

Pos.

66

Description

1

Hook

2

Ring

3

Pin

4

Bearing

5

Spacer wheel

6

Bearing

SERVICE

SERVICE

TRUCK BASE MECHANICS

LOAD WHEEL

Pos.

Description

1

Wheel

2

Bearing

3

Bushing

4

Dust cover seal

67

TRUCK BASE MECHANICS TANDEM LOAD WHEEL Ø82

Pos.

68

Description

1

Support plate

2

Wheel

3

Bearing

4

Bushing

5

Dust cover seal

6

Pin

7

Pin 5X32

8

Greasing point - lubricator 6

SERVICE

SERVICE

TRUCK BASE MECHANICS

TANDEM LOAD WHEEL Ø78

Pos.

Description

1

Support plate

2

Wheel

3

Bearing

4

Bushing

5

Dust cover seal

6

Pin

7

Pin 5X32

8

Greasing point - lubricator 6

69

TRUCK BASE MECHANICS LOAD WHEEL DISASSEMBLY

Pos.

70

Description

1

Fastening nut M10

2

Sleeve

3

Wheel

4

Bearing

5

Screw M10X70

SERVICE

SERVICE

TRUCK BASE MECHANICS

71

REDUCTION UNIT

REDUCTION UNIT

72

SERVICE

SERVICE Pos.

REDUCTION UNIT

Description

Pos.

Description

1

O-Ring 75X2.65

29

2

Ring 62

30

3

Bearing

31

4

Bolt M8X20

32

Oil seal washer 10

5

Washer 8

33

Spacer sleeve

6

Seal ring 145X175X14

34

Bearing

7

Mounting plate

35

Flange adjustment coil

8

Steering gear ring

36

Nut

9

Screw M10X50

37

O-Ring 80X2.65

10

Drive wheel gearbox

38

Backshell

11

Bearing housing

39

O-Ring 145X2.65

12

Bearing

40

Bearing

13

Flange adjustment coil 1

41

Flat key 8X7X20

14

Pin for gear and pinion

42

Nut

15

Bearing

43

Gear 2M58Z

16

Screw M8X30

44

Washer

17

Screw M24

45

Gear

18

Wheel bolt

46

Spring

19

Wheel nut

47

Breather plug

Wheel 250X80 PU

48

oil breather

Wheel 250X80 rubber

49

Oil ball bearing 3

21

Seal for rotary axis

50

Oil Cap

22

Flange adjustment coil 2

51

O-Ring 10X2.65

23

Screw M6X20

52

Inductive mounting ring

24

O-Ring 103X2.65

53

Screw M6X16

25

Bearing

54

Screw M6X10

26

Flat key 16X10X50

55

Screw M8X25

20

27 28

Cap

Gear

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BRAKING SYSTEM

ELECTROMAGNETIC BRAKE KEY TO COMPONENTS

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SERVICE

BRAKING SYSTEM

HOW TO ADJUST THE BRAKE CLEARANCE After using the truck, if the brake performance is reduced or the pads are blocked and are not released in case of braking due to their wear, it is necessary to adjust the brake clearance. Referring to the figure, use a thickness gauge to check the distance between the pad and the magnetic steel if the value exceeds 0.5 mm, the clearance must be adjusted; before this operation remove dirt and dust from the clutch plate.

During the adjustment loosen the coupling screw, adjust the length of the hollow screw and then tighten the screw again; then make sure that the distance between the pad and the magnetic steel component remains between 0.2 and 0.3 mm. To keep this distance, adjust the three screws evenly. After adjustment, operate the brake with a 24V DC power supply several times and check its correct operation.

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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.

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•

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 fork 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 circuit pressure.

Close the valves at the end of the maintenance work.

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MAINTENANCE

OILS AND LUBRICANTS Application

OIL for lubrication HYDRAULIC CIRCUIT

Standard storage

Storage in cold room

Type Shell Tellus S3 V 46

• •

Shell Tellus S3 V 32

OIL for lubrication of the REDUCTION UNIT

•

•

Double curve gear oil 85W-90(GL-5)

OIL for lubrication of the GEARS

•

•

Shell Advance Teflon Chain

GREASE for lubrication of the PINS

•

Shell Albida Grease EP2

•

Aeroshell Grease 6

CLEANING PRODUCTS CLEANING OF CASINGS, PLASTIC COVERS, PLATES, DECALS AND PAINTED PARTS Use only dry air, cloths moistened with water, or cleaning products.

Do not use jets of water or steam, solvent or explosive, oxidizing, flammable, toxic, corrosive and harmful/irritant products which can damage the truck, plates, decals or that can be dangerous for the operator.

CLEANING OF ENGINES, BRAKING SYSTEM AND ELECTRIC SYSTEM Use only dry air at low pressure and a dry clean 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.

CLEANING OF HYDRAULIC SYSTEM, REDUCTION GEAR AND BEARING SLIDING GUIDES Use degreasing products.

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

To clean the battery, follow the directions in the battery manual.

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

FRAME

BRAKING SYSTEM

Operation description

Maintenance intervals every 50 hours 1 week

Pull the tiller to make it pass between zones A and B; the brake makes noise



Remove dirt residues and oil from the steering wheel



Keep the brake clearance between 0.2 and 0.8 mm



every 200 hours 1 month



Check the general conditions and the presence of anomalies



Check the correct operation of the horn



Frame, operation, cracks, lubrication status, loose fasteners



Connecting rod and transport wheel, operation, cracks, bends, deformations, lubrication status



every every 600 hrs 1200 hours 3 months 6 months



Replace the load wheels and bearings depending on their wear STEERING WHEEL



Tiller seal and flexibility



HYDRAULIC SYSTEM

x

Pull the rudder to make it pass between zones A and B; the brake makes an absorption sound

Oil leaks in the pipes



Correct dosing of hydraulic oil



Oil leaks in the lifting cylinder



Filter cleaning



ELECTRICAL SYSTEM





Replace hydraulic oil, check for leaks in the lifting cylinder and replace gaskets if necessary

x

Plug operation and faults



Key switch operation



Contactor performance and operation



Microswitch operation



Control operation



Traction motor wear



Lifting motor, carbon brush and commutator wear



Steering motor, carbon brush and switch wear



Fuse, complete or not complete



Wiring and terminals, loose or faulty



Polish the irregular contacts with abrasive paper





Replace in case of malfunctions

x

x

Carbon brush and commutator wear



Electrolyte capacity, liquid level check, distilled water





Electrolyte density, after recharging the test should give a value of 1.28 g/ml





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

REDUCTION UNIT

ELECTRICAL SYSTEM

Operation description

Maintenance intervals every 8 hours 1 day

Clean the battery, secure the cap, rinse with tap water



Check the contactor, polish the rough side of the contacts with abrasive paper



Replace the oil

every every every 1000 hours 2000 hours 3000 hours 1 year 24 months 36 months

x

Trucks working in cold stores must be lubricated every 500 hours, or even more frequently in the case of particularly intensive use.

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Part no.: 550224095

Revision: 0 (08/2019)