PDF DOWNLOAD: Yale A7R0 (MP40KUX) Forklift Service Manual

Maintenance

SERVICE MANUAL MP40KUX (A7R0)

PART NO. 550241330

8000 YRM 2428

Table of Contents

TABLE OF CONTENTS General safety rules ............................................................................................................................................... 1 Torque settings for screws nuts and fittings ........................................................................................................... 5 Special Torque Specifications................................................................................................................................. 7 Correct method for applying female fittings ............................................................................................................8 PRESENTATION................................................................................................................................................... 11 INSTALLATION..................................................................................................................................................... 12 FRAME..................................................................................................................................................................14 How To Remove Covers.....................................................................................................................................14 Disassemble the Front and Rear Carriage Frames............................................................................................16 LIFTING MECHANISM..........................................................................................................................................17 OPERATION.......................................................................................................................................................17 LIFT CYLINDER................................................................................................................................................. 17 LOAD WHEEL.................................................................................................................................................... 19 WHEEL SPECIFICATION................................................................................................................................ 19 SINGLE LOAD WHEEL MODEL......................................................................................................................20 INSTALL...........................................................................................................................................................21 TWO LOAD WHEEL MODEL.......................................................................................................................... 21 INSTALL...........................................................................................................................................................24 CASTER............................................................................................................................................................. 24 ADJUSTMENT.................................................................................................................................................24 REPLACE........................................................................................................................................................ 26 DISASSEMBLE................................................................................................................................................27 ASSEMBLE......................................................................................................................................................27 REAR LINK AND LOAD WHEEL ASSEMBLY................................................................................................... 27 REMOVE..........................................................................................................................................................27 INSTALL...........................................................................................................................................................28 ROCKER ARM AND PULL ROD........................................................................................................................28 REMOVE..........................................................................................................................................................28 INSTALL...........................................................................................................................................................31 FORK HEIGHT ADJUSTMENT..........................................................................................................................31 MASTER DRIVE UNIT..........................................................................................................................................32 Remove Drive Wheel Assembly......................................................................................................................... 32 Steering Bearing.................................................................................................................................................35 Install.................................................................................................................................................................. 35 Remove Electric Traction Motor......................................................................................................................... 35 Drain Oil From Gearbox......................................................................................................................................37 ELECTRICAL SYSTEM........................................................................................................................................ 38 WIRING DIAGRAMS.......................................................................................................................................... 38 Electrical Schematics by Controller and Battery Type..................................................................................... 40 TRUCK FUNCTION............................................................................................................................................40 EMERGENCY REVERSE MANOEUVRE.......................................................................................................... 40 SNAIL FUNCTION..............................................................................................................................................41 STEERING WHEEL............................................................................................................................................42 FORK LIFTING/LOWERING.............................................................................................................................. 43 STANDARD CONFIGURATION OF MODULE PARAMETERS......................................................................... 44 COMBI MODULE.............................................................................................................................................44 TRACTION-PUMP........................................................................................................................................... 46 ELECTRICAL SYSTEM COMPONENTS...........................................................................................................46 CHARGER..........................................................................................................................................................47 Remove............................................................................................................................................................48 Charger Mode/Battery Type Selection............................................................................................................. 48 Troubleshooting............................................................................................................................................... 49

©2021 Yale Materials Handling Corp.

i

Table of Contents

TABLE OF CONTENTS (Continued) Error Modes..................................................................................................................................................... 50 BOLT FUSE........................................................................................................................................................ 51 Remove............................................................................................................................................................52 CONTACTS........................................................................................................................................................ 52 Remove............................................................................................................................................................53 AC CONTROLLER............................................................................................................................................. 53 Remove............................................................................................................................................................54 HORN'S WAVE FILTER......................................................................................................................................54 Remove............................................................................................................................................................55 ELECTRIC HORN.............................................................................................................................................. 56 Remove............................................................................................................................................................56 BRAKE................................................................................................................................................................56 TILLER HANDLE................................................................................................................................................56 Remove............................................................................................................................................................57 MICROSWITCH..................................................................................................................................................57 Remove............................................................................................................................................................58 LEAD-ACID BATTERY....................................................................................................................................... 58 Remove............................................................................................................................................................58 KEY SWITCH..................................................................................................................................................... 58 Remove............................................................................................................................................................58 GAUGE...............................................................................................................................................................58 Remove............................................................................................................................................................59 DC POWER SWITCH.........................................................................................................................................59 Remove............................................................................................................................................................60 HYDRAULIC SYSTEM..........................................................................................................................................61 OPERATION.......................................................................................................................................................61 Lifting A Load................................................................................................................................................... 61 HYDRAULIC SYSTEM SPECIFICATION........................................................................................................ 63 Lowering A Load.............................................................................................................................................. 63 Hydraulic Lines.................................................................................................................................................63 Hydraulic Oil.....................................................................................................................................................63 Clean................................................................................................................................................................63 Sound Level..................................................................................................................................................... 63 OIL SUPPLY TO THE HYDRAULIC CIRCUIT................................................................................................... 64 HYDRAULIC UNITS........................................................................................................................................... 64 Remove............................................................................................................................................................64 Install................................................................................................................................................................64 Hydraulic Pump.................................................................................................................................................. 65 Remove............................................................................................................................................................65 Install................................................................................................................................................................65 PRESSURE CONTROL VALVES.......................................................................................................................65 PRESSURE RELIEF VALVE ADJUSTMENT.................................................................................................. 66 DIRECTIONAL CONTROL VALVES.................................................................................................................. 67 LIFT CYLINDER................................................................................................................................................. 67 Remove............................................................................................................................................................67 PIPES................................................................................................................................................................. 68 BRAKING SYSTEM.............................................................................................................................................. 69 ELECTROMAGNETIC BRAKE...........................................................................................................................69 ADJUST BRAKE CLEARANCE..........................................................................................................................69 BRAKE CHECK..................................................................................................................................................71 REMOVE BRAKE...............................................................................................................................................72 INSTALL BRAKE................................................................................................................................................ 74

ii

Table of Contents

TABLE OF CONTENTS (Continued) DIAGNOSTICS AND MEASUREMENTS..............................................................................................................75 TESTER MENU..................................................................................................................................................76 COMBI AC0 TRACTION CONTROL............................................................................................................... 76 TROUBLESHOOTING........................................................................................................................................78 ERROR CODE OF AC-0 CONTROLLER...........................................................................................................78 Error Codes of 1230 Controller...........................................................................................................................82 MECHANICAL FAULTS......................................................................................................................................85 ZAPI AC0 CONTROL CONFIGURATION.......................................................................................................... 86 Change OPTIONS menu................................................................................................................................. 89 Change ADJUSTMENT Menu......................................................................................................................... 89 CURTIS CONFIGURATION............................................................................................................................... 90 CONNECTION.................................................................................................................................................90 Power Up ........................................................................................................................................................ 90 Display............................................................................................................................................................. 91 Access Level....................................................................................................................................................91 Key Functions.................................................................................................................................................. 92 ACCESS FAULT LOG IN CONTROLLER........................................................................................................93 MOTORS............................................................................................................................................................ 94 MAINTENANCE.................................................................................................................................................... 95 OILS AND LUBRICANTS................................................................................................................................... 95 CLEANING PRODUCTS.................................................................................................................................... 95 CLEANING OF CASINGS, PLASTIC COVERS, PLATES, DECALS AND PAINTED PARTS.........................95 CLEANING OF ENGINES, BRAKING SYSTEM AND ELECTRIC SYSTEM.................................................. 95 CLEANING OF HYDRAULIC SYSTEM, REDUCTION GEAR AND BEARING SLIDING GUIDES.................95 SCHEDULED MAINTENANCE.......................................................................................................................... 96 CONSUMABLES AND PARTS MAINTENANCE................................................................................................98 How to Move a Faulted Forklift...........................................................................................................................98 How to Raise Drive/Steer Tire............................................................................................................................ 99 Electrical Schematics by Controller and Battery Type MP20KUX (MP40KUX) [A7R0] ..................................... 102

iii

8000 YRM 2428

General safety rules

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.

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.

1

General safety rules •

•

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.

•

•

•

•

• •

•

2

8000 YRM 2428 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.

8000 YRM 2428

General safety rules

Belt capacity table

Colour

Working load capacity

purple

1000

2000

1400

800

green

2000

4000

2800

1600

yellow

3000

6000

4200

2400

grey

4000

8000

5600

3200

red

5000

10000

7000

4000

brown

6000

12000

8400

4800

blue

8000

16000

11200

6400

orange

10000

20000

14000

8000

orange

12000

24000

16800

9600

orange

15000

30000

21000

12000

orange

20000

40000

28000

16000

orange

25000

50000

35000

20000

orange

30000

60000

42000

24000

1

2

1.4

0.8

Coefficient

Rope capacity table

Working load capacity (Kg)

Coefficient

Colour

Width (mm)

black

35

500

1000

700

400

purple

50

1000

2000

1400

800

black

50

1500

3000

2100

1200

green

60

2000

4000

2800

1600

yellow

75

3000

6000

4200

2400

grey

120

4000

8000

5600

3200

red

150

5000

10000

7000

4000

brown

180

6000

12000

8400

4800

blue

240

8000

16000

11200

6400

orange

300

10000

20000

14000

8000

1

2

1.4

0.8

3

General safety rules

8000 YRM 2428

Suspension element capacity table

Colour

Working load capacity (Kg)

Coefficient

purple

1000

1400

2100

2100

green

2000

2800

4200

4200

yellow

3000

3800

6300

6300

grey

4000

5600

8400

8400

red

5000

6600

9800

10500

1

1.4

2.1

2.1

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

4

8000 YRM 2428

Torque settings for screws nuts and fittings

Torque settings for screws nuts and fittings NOTE: Before disassembling the various parts and nuts and bolts, read the following carefully.

To make the threaded matings secure, thread lock solution 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 lock solution effect. In the cases described, reapply thread lock solution 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.

NUT TORQUE SETTING Nm

Nominal diameter

Class 8

Class 10

M3

4 (2.95 lbf ft)

5.2 (3.83 lbf ft)

M4

7 (5.16 lbf ft)

9.15 (6.74 lbf ft)

M5

12.14 (8.95 lbf ft)

14.8 (10.91 lbf ft)

M6

17.2 (12.68 lbf ft)

20.9 (15.41 lbf ft)

M8

31.8 (23.45 lbf ft)

38.1 (28.10 lbf ft)

M10

50.5 (37.24 lbf ft)

60.3 (44.47 lbf ft)

M12

74.2 (54.72 lbf ft)

88.5 (65.27 lbf ft)

M14

101.2 (74.64 lbf ft)

120.8 (89.09 lbf ft)

M16

138.2 (101.93 lbf ft)

164.9 (121.62 lbf ft)

M18

176.6 (130.25 lbf ft)

203.5 (150.09 lbf ft)

M20

225.4 (166.25 lbf ft)

259.7 (191.54 lbf ft)

M22

278.8 (205.63 lbf ft)

321.2 (236.9 lbf ft)

M24

324.8 (239.56 lbf ft)

374.2 (276 lbf ft)

M27

422.3 (311.47 lbf ft)

486.5 (358.82 lbf ft)

M30

516.1 (380.66 lbf ft)

594.7 (438.63 lbf ft)

5

Torque settings for screws nuts and fittings

8000 YRM 2428

SCREW TORQUE SETTING Nm Preload N

6

Class 5.8

Class 8.8

with lubr.

Class 10.9

with lubr.

with lubr.

M4

0.7

7

3

240 0

1.92 (1.41 lbf ft)

1.44 (1.06 lbf ft)

3.07 (2.26 lbf ft)

2.3 (1.69 lbf ft)

4.17 (3.07 lbf ft)

3.13 (2.30 lbf ft)

M5

0.8

8

4

388 0

3.88 (2.86 lbf ft)

2.91 (2.14 lbf ft)

6.2 (4.57 lbf ft)

4.65 (3.42 lbf ft)

8.43 (6.21 lbf ft)

6.33 (4.66 lbf ft)

M6

1

10

5

549 0

6.58 (4.85 lbf ft)

4.94 (3.64 lbf ft)

10.5 (7.74 lbf ft)

14.3 10.8 7.9 (5.82 (10.54 lbf (7.96 lbf lbf ft) ft) ft)

M8

1.25

13

6

25.6 19.2 34.8 26.1 999 16 (11.80 12 (8.85 (18.88 lbf (14.16 lbf (25.66 lbf (19.25 lbf 0 lbf ft) lbf ft) ft) ft) ft) ft)

M8

1

13

6

17.1 12.8 27.4 20.5 37.3 27.9 107 (12.61 lbf (9.44 lbf (20.20 lbf (15.12 lbf (27.51 lbf (20.57 lbf 00 ft) ft) ft) ft) ft) ft)

M10

1.5

16

8

31.7 23.8 158 51 (37.61 38 (28.02 69 (50.89 52 (38.35 (23.38 lbf (17.55 lbf 25 lbf ft) lbf ft) lbf ft) lbf ft) ft) ft)

M10

1.25

16

8

33.4 25.1 40.1 167 53 (39.09 73 (53.84 55 (40.56 (24.63 lbf (18.51 lbf (29.57 lbf 00 lbf ft) lbf ft) lbf ft) ft) ft) ft)

M12

1.75

18

10

41.4 120 230 55 (40.56 88 (64.90 66 (48.67 90 (66.38 (30.53 lbf (88.50 lbf 25 lbf ft) lbf ft) lbf ft) lbf ft) ft) ft)

M12

1.25

18

10

45.3 130 251 60 (44.25 96 (70.80 72 (53.10 98 (72.28 (33.41 lbf (95.88 lbf 50 lbf ft) lbf ft) lbf ft) lbf ft) ft) ft)

M14

2

21

12

140 314 88 (64.90 66 (48.67 (103.26 00 lbf ft) lbf ft) lbf ft)

105 (77.44 lbf ft)

190 (140.14 lbf ft)

145 (106.95 lbf ft)

M14

1.5

21

12

341 96 (70.80 72 (53.10 25 lbf ft) lbf ft)

155 (114.32 lbf ft)

115 (84.81 lbf ft)

210 (154.89 lbf ft)

155 (114.32 lbf ft)

M16

2

24

14

135 105 428 (99.57 lbf (77.44 lbf 50 ft) ft)

220 (162.26 lbf ft)

165 (121.7 lbf ft)

300 (221.27 lbf ft)

225 (165.95 lbf ft)

M16

1.5

24

14

456 00

235 (173.33 lbf ft)

175 (129.07 lbf ft)

320 (236.02 lbf ft)

240 (177.01 lbf ft)

145 (106.95 lbf ft)

110 (81.13 lbf ft)

8000 YRM 2428

Special Torque Specifications

M20

2.5

30

17

668 75

270 (199.14 lbf ft)

200 (147.51 lbf ft)

430 (317.15 lbf ft)

320 (236.02 lbf ft)

580 (427.79 lbf ft)

435 (320.84 lbf ft)

M20

1.5

30

17

742 50

295 (217.58 lbf ft)

225 (165.95 lbf ft)

475 (350.34 lbf ft)

355 (261.83 lbf ft)

650 (479.42 lbf ft)

485 (357.72lb f ft)

Special Torque Specifications Alternator Pulley Nut 58.4 to 78.9 N•m (43.1 to 58.2 lbf ft)

Flywheel Housing Bolts 78 to 90 N•m (58 to 66 lbf ft)

Bearing Cap Set Bolt 138 to 147 N•m (102 to 108 lbf ft)

Idler Gear Mounting Screw 24 to 27 N•m (18 to 20 lbf ft)

Camshaft Position Pulsar Gear Mounting Screw 4.7 to 5.6 N•m (41.6 to 50 lbf in)

Intake Air Temperature Sensor Mounting Screw 30 to 39 N•m (22 to 28 lbf ft)

Camshaft Position Sensor Mounting Screw 4 to 5 N•m (35 to 44 lbf in)

Oil Pressure Switch Screw 15 to 19 N•m (11 to 14 lbf ft)

Connecting Rod Bolt 79 to 83 N•m (58 to 61 lbf ft)

Rocker Arm Bracket Nut 49 to 55 N•m (37 to 41 lbf ft)

Coolant Temperature Sensor 16 to 23 N•m (12 to 17 lbf ft)

Starter Solenoid Nut (B Terminal) 9.8 to 11 N•m (87 to 97 lbf in)

Crankshaft Position Sensor Mounting Screw 4 to 5 N•m (35 to 44 lbf in)

Timing Gear Case Cover Mounting Screw 24 to 27 N•m (18 to 20 lbf ft)

Crankshaft Pulley Bolt 255 to 274 N•m (188 to 202 lbf ft)

Timing Gear Case Plate Mounting Screw 24 to 27 N•m (18 to 20 lbf ft)

Cylinder Head Bolt 98.1 to 107 N•m (72.4 to 79.5 lbf ft)

Thermostat Cover Bolts 23 to 28 N•m (17 to 21 lbf ft)

Cylinder Head Cover Screw 10 to 11 N•m (61 to 99 lbf in)

Controller posts (5) 6 N•m (4.5 lbf ft)

Engine Oil Pump Cover Screw 7.9 to 9.3 N•m (70 to 82 lbf in)

Fuse posts (4) 6 N•m (4.5 lbf ft)

Engine Oil Cooler to Cylinder Block Adapter/ Mounting Bolt 40 to 44 N•m (29 to 32 lbf ft)

Lead-acid battery posts (8 for American model and 2 for European model) 8.5 N•m (6.3 lbf ft)

Flywheel Bolts 98.1 to 107 N•m (72.4 to 79.5 lbf ft)

7

Correct method for applying female fittings

8000 YRM 2428

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.

METRIC REVOLVING FEMALE UNF thread

Outside diamater of the pipe

M 12X1.5 M 14X1.5 M 16X1.5 M 18X1.5 M 20X1.5 M 22X1.5

Nominal torque

min / max

6

20 (14.75 lbf ft)

15 - 25 (11.06 - 18.43 lbf ft)

8

38 (28.02 lbf ft)

30 - 45 (22.12 - 33.19 lbf ft)

45 (33.19 lbf ft)

38 - 52 (28.02 - 38.35 lbf ft)

51 (37.61 lbf ft)

43 - 85 (31.71 - 62.69 lbf ft)

58 (42.77 lbf ft)

50 - 65 (36.87 - 47.94 lbf ft)

74 (54.57 lbf ft)

60 - 88 (44.25 - 64.90 lbf ft)

8 10 10 12 12 14 15

M 24X1.5

16

74 (54.57 lbf ft)

60 - 88 (44.25 - 64.90 lbf ft)

M 26X1.5

18

105 (77.44 lbf ft)

85 -125 (62.69 - 92.19 lbf ft)

135 (99.57 lbf ft)

115 - 155 (84.81 -114.32 lbf ft)

168 (123.91 lbf ft)

140 - 192 (103.26 - 141.61 lbf ft)

M 30X2 M 36X2

20 22 25 28

M 42X2

30

240 (177.01 lbf ft)

210 - 270 (154.89 - 199.14 lbf ft)

M 45X2

35

290 (213.89 lbf ft)

255 - 325 (188.08 - 239.71 lbf ft)

330 (243.4 lbf ft)

280 - 380 (206.52 - 280.27 lbf ft)

M 52X2

8

Torque setting Nm

38 42

8000 YRM 2428

Correct method for applying female fittings

REVOLVING FEMALE jic 37° UNF thread

Size

7/16-20

Torque setting Nm Nominal torque

min / max

-4

15 (11.06 lbf ft)

9-21 (6.63 - 15.48 lbf ft)

1/2-20

-5

20 (14.75 lbf ft)

13-27 (9.58 - 19.91 lbf ft)

9/16-18

-6

30 (22.12 lbf ft)

18-42 (13.27 - 30.97 lbf ft)

3/4-16

-8

50 (36.87 lbf ft)

30-70 (22.12 - 51.62 lbf ft)

7/8-14

-10

69 (50.89 lbf ft)

44-94 (32.45 - 69.33 lbf ft)

1.1/16-12

-12

98 (72.28 lbf ft)

63-133 (46.46 - 98.09 lbf ft)

1.3/16-12

-14

118 (87.03 lbf ft)

73-163 (53.84 - 120.22 lbf ft)

1.5/16-12

-16

140 (103.26 lbf ft)

90-190 (66.38 - 140.14 lbf ft)

1.5/8-12

-20

210 (154.89 lbf ft)

135-285 (99.57 - 210.21 lbf ft)

1.7/8-12

-24

290 (213.89 lbf ft)

200-380 (147.51 - 280.27 lbf ft)

2.1/2-12

-32

450 (331.9 lbf ft)

300-600 (221.27 - 442.54 lbf ft)

BSP REVOLVING FEMALE UNF thread

Torque setting Nm Nominal torque

max

G1/4

20 (14.75 lbf ft)

15 -25 (11.06 - 18.43 lbf ft)

G3/8

34 (25.07 lbf ft)

27 - 41 (19.91 - 30.24 lbf ft)

G1/2

60 (44.25 lbf ft)

42 - 76 (30.97 - 56.05 lbf ft)

G5/8

69 (50.89 lbf ft)

44 - 94 (32.45 - 69.33 lbf ft)

G3/4

115 (84.81 lbf ft)

95 - 135 (70.06 - 99.57 lbf ft)

G1

140 (103.26 lbf ft)

114 - 165 (84.08 - 121.7 lbf ft)

G1.1/4

210 (154.89 lbf ft)

140 - 280 (103.26 - 206.52 lbf ft)

G1.1/2

290 (213.89 lbf ft)

215 - 365 (158.58 - 269.21 lbf ft)

G2

400 (295.02 lbf ft)

300 - 500 (221.27 - 368.78 lbf ft)

9

Correct method for applying female fittings

8000 YRM 2428

ORFS REVOLVING FEMALE UNF thread

Size

9/16-18

Torque setting Nm Nominal torque

max.

-4

14 (10.32 lbf ft)

16 (11.80 lbf ft)

11/16-16

-6

24 (17.70 lbf ft)

27 (19.91 lbf ft)

g13/16-16

-8

43 (31.71 lbf ft)

47 (34.66 lbf ft)

1-14

-10

60 (44.25 lbf ft)

68 (50.15 lbf ft)

1.3/16-12

-12

90 (66.38 lbf ft)

95 (70.0 lbf ft)

1.3/16-12

-14

90 (66.38 lbf ft)

95 (70.06 lbf ft)

1.7/16-12

-16

125 (92.19 lbf ft)

135 (99.57 lbf ft)

1.11/16-12

-20

170 (125.39 lbf ft)

190 (140.14 lbf ft)

2-12

-24

200 (147.51 lbf ft)

225 (165.95 lbf ft)

2-1/2-20

-32

460 (339.28 lbf ft)

490 (361.41 lbf ft)

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

10

8000 YRM 2428

PRESENTATION

PRESENTATION PRESENTATION The transpallet pedestrian model MP40KUX is equipped with storage batteries and AC motor that provide dynamic source and tractive force respectively.

IDENTIFICATION DATA PLATE The truck identification data plate is located on the truck base.

Figure 1. Yale nameplate •

Manufacturer's name

•

Weight without battery

•

Serial number

•

Minimum/maximum battery weight

•

Model

•

Persons on board

•

Year of manufacturer

•

Rated power

•

Nominal load capacity

•

Battery voltage

11

INSTALLATION

8000 YRM 2428

INSTALLATION INSTALLING THE BATTERY

ALERT 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 pedestians.

1.

Remove the lateral door of the battery compartment.

Figure 2. Door Removal

12

8000 YRM 2428 2.

INSTALLATION

Place the battery on a roller trolley, bring it close to the battery compartment, and then push the battery

inside the battery compartment.

3.

Connect the battery to the battery connector, and then replace the side door of the battery compartment.

13

FRAME

8000 YRM 2428

FRAME HOW TO REMOVE COVERS 1.

To remove the baffle, first remove two screws (item 1) and another two screws (item 2), and then remove the baffle (item 3).

Figure 3. Remove Baffle 2.

14

To remove the rear cover, first remove two screws (item 1) and another two screws (item 3), and then remove the rear cover (item 2).

8000 YRM 2428

FRAME

Figure 4. Remove Rear Cover 3.

To remove the hood cover, first remove two screws (item 1) and another two screws (item 2), and then remove the hood covers (item 3 and 4).

Figure 5. Remove Hood Cover

15

FRAME

8000 YRM 2428

DISASSEMBLE THE FRONT AND REAR CARRIAGE FRAMES 1.

2.

Remove the electrical wires before disassembling mechanical parts.

Remove screws (item 1) and spacers (item 2) of the upper pivot point of the oil cylinder, each on the left side and the right side respectively.

3.

Pull out the rollers (item A) on both sides of the front frame (item 3) from the guide rail (item B) on the rear frame (item 4).

4.

Detach the front frame (item 3) and the rear frame (item 4).

Figure 6. Disassemble Front and Rear Carriage Frames

16

8000 YRM 2428

LIFTING MECHANISM

LIFTING MECHANISM OPERATION •

Lift cylinder, 1 each

•

Rocker arm, 1 each

move the pull rods forward in the direction of the drive motor. The movement of the pull rods causes the rear links and load wheels to pivot down, lifting the rear of the fork frame. This helps lift the fork frame and keep the forks parallel with the ground.

•

Pull rods, 2 each

NOTE: The lift linkage is not adjustable.

•

Load wheel assemblies, 2 each

•

Rear links (wheel support), 2 each

The lifting mechanism consists of:

The lifting mechanism connects the main frame to the fork frame. The lift cylinder and rocker arms are parts that connect the main frame to the fork frame. The pull rods are installed between the rocker arm and the load wheel assemblies.

The lifting mechanism is operated by the lift pump and motor assembly. When the lift button on the control handle is depressed, the lift pump sends hydraulic fluid to the lift cylinder. The lift cylinder extends, lifting the fork frame. This action operates the rocker arm, which

LIFT CYLINDER REMOVE To remove lift cylinder, do the following steps.

1.

Unscrew the screw (item 1) and spacer (item 2) of the upper pivot point of the oil cylinder.

2.

Unscrew the screw (item 4) and spacer (item 3) of the lower pivot point of the oil cylinder.

3.

Raise the front frame slightly to remove the oil cylinder (item 5), each on left and right side.

17

LIFTING MECHANISM

8000 YRM 2428

Figure 7. Remove Lift Cylinder

18

8000 YRM 2428

LOAD WHEEL REMOVE CAUTION 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.

LIFTING MECHANISM

WHEEL SPECIFICATION Unit

Size

Item

Torque

Drive wheel ø 70 x 250 Hub nut Polyurethan e

160 N•m (118 lbf ft)

ø 70 x 250 Rubber

160 N•m (118 lbf ft)

Hub nut

Load wheel ø 78 x 126 Pin Polyurethan e

NA

ø 82 x 126 Pin Polyurethan e

NA

ø 78 x 78 Pin Polyurethan e

NA

ø 78 x 82 Pin Polyurethan e

NA

19

LIFTING MECHANISM

8000 YRM 2428

SINGLE LOAD WHEEL MODEL

3.

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.

4.

Press the lower button to relieve pressure from the hydraulic system.

5.

Turn the keyswitch to OFF and disconnect the battery.

To remove the load wheel, do the following steps.

1.

Move the lift truck to a safe and level area.

2.

Use the lift button to raise the forks by 1500 mm (59 inches). Sling the fork small mast with the lifting belt. Hook the belt to the hoist and tension it.

1 2

WHEEL ASSEMBLY WHEEL FRAME

3 4

BUSHING PIN ROLL

5

SPRING PIN

Figure 8. Single Load Wheel Model 6.

20

Remove the spring pin.

7.

Remove the pin roll and the wheel will fall off naturally.

8000 YRM 2428

1

DUST RING

LIFTING MECHANISM

2 3

WHEEL BEARING

4

SHAFT SLEEVE

Figure 9. Single Load Wheel Assembly 8.

9.

Remove the shaft sleeve from each end of the load wheel.

TWO LOAD WHEEL MODEL

Remove the bearings from each end of the load wheel. It may be necessary to use a brass drift punch to drive the bearings out of the load wheel.

1.

Move the lift truck to a safe and level area.

2.

Use the lift button to raise the forks by 1500 mm (59 inches). Sling the fork small mast with the lifting belt. Hook the belt to the hoist and tension it.

3.

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.

To remove the load wheels, do the following steps.

10. Remove all old lubricant from the load wheel.

Clean and inspect all parts. Replace all defective parts as necessary.

INSTALL 1.

Install one of the bearings into the load wheel and the dust ring.

2.

Install the other bearing into the load wheel.

4.

3.

Install the shaft sleeves into both ends of the load wheel.

Press the lower button to relieve pressure from the hydraulic system.

5.

Turn the keyswitch to OFF and disconnect the battery.

4.

Align the load wheel assembly with the opening in the rear link, and install the pin roll and spring pin.

21

LIFTING MECHANISM

1

TANDEM WHEEL ASSEMBLY

8000 YRM 2428

2 3

WHEEL FRAME BUSHING

Figure 10. Two Load Wheel Model

22

4

BUSHING

8000 YRM 2428

1 2 3

DUST RING WHEEL BEARING

LIFTING MECHANISM

4 5 6

SHAFT SLEEVE PIN ROLL SPRING PIN

7 8

NOZZLE SUPPORT BOARD

Figure 11. Two Wheel Assembly 6.

Remove the spring pin.

7.

Remove the pin roll and the wheels will fall off naturally.

8.

Remove the support board.

9.

Remove the shaft sleeve from each end of the load wheel.

10. Remove the bearings from each end of the load wheel. It may be necessary to use a brass drift punch to drive the bearings out of the load wheel.

11. Remove all old lubricant from the load wheel.

Clean and inspect all parts. Replace all defective parts as necessary.

23

LIFTING MECHANISM

INSTALL 1.

Install one of the bearings into the load wheel and the dust ring.

2.

Install the other bearing into the load wheel.

3.

Install the shaft sleeves into both ends of the load wheel.

4.

Install the support board.

5.

Align the load wheel assembly with the opening in the rear link, and install the pin roll and spring pin.

CASTER ADJUSTMENT ADJUSTMENT WARNING In normal operation, the casters should continuously contact the floor. As the drive tire wears, the frame will move closer to the floor and

24

8000 YRM 2428 the casters will carry more of the load. If the casters are not periodically adjusted, they will bear too much of the lift truck's weight and reduce the load on the drive tire necessary to maintain traction. This can interfere with the drive tire's ability to control the steering and stopping functions of the truck.

Periodically, the casters must be adjusted to compensate for drive tire wear/replacement. Excess rocking is often a sign of under adjusted casters. This may occur when a new drive tire is installed. Loss of traction may be caused by over adjusted casters. This may occur when the drive tire diameter has decreased because of regular wear. The casters ideally should be level with the bottom of the drive tire (just touching the floor). A gap of not more than 1.50 mm (0.06 in.) between the caster wheels and the floor is acceptable, as is the casters being compressed to the floor not more than 1.50 mm (0.06 in.). Refer to the following instructions for the proper caster checking and adjustment procedures.

NOTE: The casters include an eccentric mounting of the caster wheels to facilitate adjustment.

8000 YRM 2428

1 2

SCREW GASKET

LIFTING MECHANISM

3 4

GASKET FRAME

5 6

ADJUSTING SPACER BALANCE WHEEL

Figure 12. Adjust Caster 1.

Park the lift truck on a smooth and level surface with the control handle centered and with no load on the forks. Lower the forks completely.

2.

Turn the key switch to the OFF position and disconnect the battery (DO NOT remove the battery).

3.

Place the lift truck on blocks on both sides of the drive frame.

4.

Loosen the wheel axle screws on either side of the caster wheel until the adjusting spacer can be pulled away from the caster assembly clear of the frame.

5.

Balance the contact between the balance wheel and the ground by raising or lowering the adjusting spacer, so that the balance wheel is not suspended and can rotate normally.

6.

Push the adjusting spacer into engage the frame.

7.

Remove the left truck from the blocks and check the casters for proper contact with the floor.

8.

Connect the battery, turn the key switch to the ON position, and test for proper operation.

9.

Tighten the axle screws.

25

LIFTING MECHANISM

8000 YRM 2428

REPLACE ALERT Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

Figure 13. Remove Caster Wheel

26

8000 YRM 2428

LIFTING MECHANISM Legend for Figure 13.

1 2 3 4 5 6

DUST COVER BEARING SEAT RETAINING RING (Ø62) BEARING WASHER BEARING

7 WASHER 8 RETAINING RING (Ø62) 9 BALANCE WHEEL SEAT 10 RETAINING RING (Ø17) 11 GROOVED PIN ROLL 12 COMPRESSION SPRING

1.

To remove the caster, park the lift truck on a smooth and level surface. Turn the key switch to the OFF position and disconnect the battery.

2.

Raise the drive wheel off the floor. Block the lift truck.

3.

Remove the screws, nuts, and washers retaining the caster to the frame, and then remove the caster wheel.

NOTE: The caster does not have to be removed from the lift truck frame in order to replace the wheel or the wheel axle. Tor replace the wheel or wheel axle, follow these steps: a

b

Remove the axle screw and adjuster from one side of the caster. Drive the wheel axle/adjuster out of the caster wheel and remove the wheel from the caster frame.

Align the caster wheel between the arms of the caster frame and install the axle/adjuster into the caster frame and the caster wheel. Install the adjuster and axle screw. Tighten the screw to 35 N•m (25 lbf ft).

4.

To reinstall the caster, align the caster with the holes in the frame and install the screws. Tighten the nuts to 56 to 58 N•m (41 to 43 lbf ft).

5.

Repeat procedure to replace the second caster, if necessary.

4.

Remove the plug from the top of the caster assembly and remove the retaining ring.

5.

Separate the top bearing seat from the balance wheel frame.

6.

Remove the retaining ring from the bottom of the top bearing seat and remove the bearing.

ASSEMBLE 1.

Install the bearing in the top bearing seat and install the retaining ring.

2.

Install the top bearing seat onto the balance wheel frame. Install the retaining ring and dust plug.

3.

If removed, install the wheel frame into the balance wheel frame. Install the pivot bolt and tighten the lock nut to 85 N•m (63 lbf ft).

4.

Install the dust covers, washers, bearings, and bushing into the caster wheel.

5.

Align the caster wheel within the wheel frame and insert the axle.

6.

Install the adjusting spacer into the wheel frame and lock in place with the axle screws.

7.

Align the holes in the top bearing seat with the holes in the lift truck frame. Install the screws, washers, and nuts that are removed during disassembly.

DISASSEMBLE 1.

Remove the caster wheel from the frame. Refer to Caster Replacement in this section.

2.

Remove the axle screws and the adjusting spacers from the caster. Drive the axle from the caster wheel and remove the wheel.

3.

Remove the dust cover, washers, bearings, and bushing from the caster wheel.

NOTE: If necessary, the wheel frame can be separated from the balance wheel frame by removing the pivot bolt. This should only be required when servicing the caster springs.

13 BALANCE WHEEL FRAME 14 WHEEL 15 RETAINING RING (Ø40) 16 BEARING 17 GROOVED PIN ROLL

REAR LINK AND LOAD WHEEL ASSEMBLY REMOVE 1.

Move the lift truck to a safe and level ground.

2.

Press the Lift button to lift the fork to its maximum height.

27

LIFTING MECHANISM

8000 YRM 2428

3.

Put blocks under both forks and on both sides (front and back) of the drive wheel to prevent movement of the lift truck.

4.

Press the Lower button to relieve pressure from the hydraulic system.

5.

Turn the key switch to the OFF position and disconnect the battery.

1

SPRING PIN

2

6.

Remove the spring pin retaining the rear link pin roll to the fork frame.

7.

Remove the rear link pin roll.

8.

Remove the rear link and load wheel assembly from the lift truck.

PIN ROLL

3

FRAME

Figure 14. Remove Rear Link

INSTALL

ROCKER ARM AND PULL ROD

1.

REMOVE

Align the linkage wheel carrier with the rear link and install the pin roll. Align the spring pin hole in the pin roll with the opening in the casting. Install the spring pin into the rear link casting and through the hole in the prin roll.

2.

Align the rear link with the fork frame and install the rear link pin roll. Install the spring pin into the fork frame.

3.

Lubricate all linkage pin rolls with multipurpose grease.

28

WARNING When performing service that will require the rocker arm to be removed, the main frame and fork frame must be securely supported so that they cannot lower or tilt when the linkage is disconnected.

8000 YRM 2428

LIFTING MECHANISM the main frame, near the rocker arms. The blocks must be thick enough to just fit under the main frame. The main frame must not lower or tilt when the rocker arms or upper links are disconnected.

Put blocks under both forks and on both sides of the drive tire.

WARNING Batteries are heavy. Use care when working near or moving to avoid injury.

DO NOT put hands, arms, feet, and/or legs between the battery and a solid object. Make sure the capacity of the lifting device and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of metal or it must have insulated straps.

1.

Move the lift truck to a safe and level area.

2.

Use the Lift button to raise the forks to maximum height.

3.

When performing service that will require the rocker arms or the upper links to be removed, put a solid wood or metal block under each side of

1 2

LOAD WHEEL SPRING PIN LOAD WHEEL PIN ROLL

3 4

4.

Turn the key switch to the OFF position and disconnect the battery. Remove the battery.

5.

Separate the frame.

6.

Remove the spring pin retaining the load wheel assemblies to the fork frame. Remove the load wheel pin rolls from the fork frame.

7.

Remove the screws retaining the rocker arm pin rolls to the fork frame, and then remove the rocker arm pin rolls.

FRAME ROCKER ARM PIN ROLL

5 6

SPACER SCREW

Figure 15. Remove Pin Roll

29

LIFTING MECHANISM

8000 YRM 2428

8.

Remove the lift linkage assembly from the fork frame.

9.

Remove the load wheel spring pin retaining the load wheel pin roll to the rocker arm assembly.

1 2

ROCKER ARM SPRING PIN ROCKER ARM PIN ROLL

3 4

10. Remove the load wheel pin roll and separate the load wheel from the rocker arm assembly.

LINKAGE WHEEL LOAD WHEEL SPRING PIN

5

LOAD WHEEL PIN ROLL

Figure 16. Remove Linkage and Wheel Carrier Assembly

30

8000 YRM 2428

INSTALL 1.

2.

Insert the front of the lift linkage into the rocker arm assembly and install the rocker arm pin roll.

Install the rocker arm spring pin to retain the pin roll.

LIFTING MECHANISM 10. Remove the blocks from the lift truck and install the battery.

11. Test the operation of the lift truck before returning the truck to service.

FORK HEIGHT ADJUSTMENT CAUTION

CAUTION The rocker arm is heavy. Support the rocker arm assembly during installation.

3.

Align the rocker arm assembly with the lift linkage attached with pin roll holes in the fork frame.

4.

Install the rocker arm pin rolls into the fork frame and rocker arm assembly.

5.

Align the load wheel assembly with the lift linkage end and install the load wheel pin roll. Install the load wheel spring pins into the load wheel assembly and through the pin roll.

6.

Align the load wheel assembly and lift linkage with the load wheel pin roll hole in the fork frame.

7.

Install the load wheel pin roll and the spring pin to retain the load wheel pin roll to the fork frame.

8.

Lubricate the load wheel assemblies and all linkage pin rolls with multipurpose grease.

9.

Assemble the frame.

Improper adjustment to the linkage can cause excessive and uneven wear to the load wheels, which may result in porno pallet entry and exit.

When making any adjustments, be certain the measurements are the same on both forks. If an equal measurement cannot be obtained, the problem may be a twisted frame. A twisted frame cannot be repaired and must be replaced.

NOTE: A full size battery must be installed in the truck to obtain accurate fork height measurements.

The linkage must be adjusted to the machined surface on top of the rear link contact the stop blocks on the underside of the fork frame in the lowered position. If the rear link machined surface does not contact the stop blocks on the fork frame or if the load wheels are not carrying the load equally, an adjustment must be made. Make certain to check both forks and both load wheels.

1.

Loose the nuts (item 2 and 3), and adjust the linkage length by rotating the nut (item 1). Extend the linkage to decrease the height or shorten the linkage to increase the height.

31

MASTER DRIVE UNIT

8000 YRM 2428

MASTER DRIVE UNIT REMOVE DRIVE WHEEL ASSEMBLY The master drive unit (MDU) has five main components: the traction motor, brake, steering control handle, drive unit, and drive tire and wheel assembly.

Separate parts of the MDU can be removed without removing the complete MDU. It is not necessary to perform each step of the entire procedure to remove some parts of the MDU. The procedure has steps to remove and disassemble the complete MDU. Read the entire procedure first and perform only the steps necessary to make the required repairs.

WARNING Cleaning solvents can be flammable, toxic, and can cause skin irritation. Wear protective gear when handling solvents and always follow the recommendations of the manufacturer.

WARNING Put blocks under each side of the truck under the MDU frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

32

NOTE: Ensure the truck is blocked high enough to remove the drive unit from below the truck frame.

1.

Raise the drive tire off the floor. Block the lift truck.

WARNING Always disconnect the battery connector so that the connector is completely free before repairing the brake system. If the connector is not completely free, it can reconnect the battery. Tag the connector - DO NOT CONNECT. 2.

Turn the key switch to the OFF position and disconnect the battery connector.

3.

Remove the drive unit compartment cover to access the MDU.

4.

Discharge the capacitors.

5.

Remove the screw (item 4) with installation torque of 19.1N•m (14 lbf ft).

6.

Remove the drive wheel assembly with a lift device.

8000 YRM 2428

MASTER DRIVE UNIT

Figure 17. Disassemble Drive Wheel Assembly 7.

Remove the screws (item 1 and 2) and the nuts (item 4), and then remove the drive wheel.

33

MASTER DRIVE UNIT

8000 YRM 2428

Figure 18. Remove Drive Wheel 8.

Identify and tag all wires and cables connected to MDU for later installation.

9.

Disconnect all wires and cables connected to MDU and the harness clamps on the drive motor.

10. Tag and disconnect the wiring from the steering tiller to the lift truck.

11. Support the steering tiller and remove the four screws and washers securing the tiller to the master drive unit.

34

12. Remove the tiller from the lift truck.

13. Remove the traction motor and brake as a single assembly. See Remove Electric Traction Motor 14. Use a jack to support the drive unit. Remove the screws attaching the drive unit to the steer bearing.

15. Remove the drive unit from the truck and place on a clean work bench.

8000 YRM 2428

MASTER DRIVE UNIT

STEERING BEARING

6.

Install the traction motor.

NOTE: It is necessary to remove the master drive unit, before the steering bearing can be removed.

7.

Install and adjust the brake if removed.

8.

Mount the drive wheel on the axle shaft and install nuts. Tighten nuts to 120 N•m (88 lbf ft).

9.

Connect the motor wires and cables. Attach the harness clamps.

1.

2.

From underneath the master drive unit mounting casting, remove the screws retaining the steering bearing to the mounting casting.

Carefully use a pry bar or other device to remove the steering bearing from the casting.

INSTALL WARNING To avoid personal injury when installing the drive unit in the lift truck, keep the drive unit supported at all times.

1.

Install the steering bearing on the mounting casting.

2.

Align the mounting holes in the bearing with the holes in the casting.

3.

Install the screws to retain the bearing to the casting. Torque the mounting screws to 23 N•m (17 lbf ft).

4.

Use a jack to position the drive unit.

5.

Align the drive unit with the screw holes in the steering bearing and install the screws attaching the drive unit to the bearing. Tighten all of the screws to 23 N•m (17 lbf ft).

NOTE: The traction motor is easily installed AFTER the MDU has been mounted to the frame of the lift truck.

10. Install the steer components as removed.

11. Lower the truck to the floor.

12. Connect the battery and turn the key switch to the ON position.

13. Test the operation of the truck.

14. Install the drive unit compartment cover and return truck to service

REMOVE ELECTRIC TRACTION MOTOR 1.

Remove the screw (item 1) and spacers (item 2 and3), and then remove the motor assembly (item 4).

2.

Remove the screw (item 11), and then remove the motor base (item 10).

To remove the brake assembly at the rear end of the motor (item 9), remove the brake (item 6), the retaining ring (item 7), the flat key (item 13) and the brake shaft sleeve (item 8).

3.

To remove the motor (item 9), remove the split pin (item 14), the nut (item 15), the flat key (item 16) and the gear (item 12).

35

MASTER DRIVE UNIT

8000 YRM 2428

Figure 19. Remove Electric Traction Motor

36

8000 YRM 2428

MASTER DRIVE UNIT

DRAIN OIL FROM GEARBOX

3.

1.

Remove the gearbox plug screw (item 1) and the compound gasket (item 2).

2.

Remove the oil drain plug screw (item 3) and the compound gasket (item 4).

Drain the oil in the gearbox (dispose the waste oil according to the local law and regulation).

Figure 20. Remove Drain Plug

37

ELECTRICAL SYSTEM

8000 YRM 2428

ELECTRICAL SYSTEM WIRING DIAGRAMS

Figure 21. Wiring Diagram

38

8000 YRM 2428

Ref

ELECTRICAL SYSTEM

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

Tiler sensor

K6

Lift Switch

L

Electromagnetic brake

L1

Lowering solenoid valve

MC

Main contactor

PC

Pump contactor

39

ELECTRICAL SYSTEM

8000 YRM 2428

Electrical Schematics by Controller and Battery Type

Controller and Battery Type MP20KUX (MP40KUX) [A7R0] .

For details about electrical schematics by controller and battery type, see Electrical Schematics by

TRUCK FUNCTION FORWARD/REVERSE TRACTION ACTUATION CONTROLS

DOWNWARD ARROW: FORWARD TRAVEL (OPERATOR SIDE)

UPWARD ARROW: REVERSE TRAVEL (FORK SIDE)

Figure 22. Actuation Controls Actuators involved

Status

Actuators involved

Status Forward/reverse rotation

Key switch

ON

Emergency switch

ON

Forward/reverse traction control throttle

Tiller tilt sensor

ON*

NOTE: * OFF when the Snail button is pressed.

40

8000 YRM 2428

ELECTRICAL SYSTEM

EMERGENCY REVERSE MANOEUVRE

Figure 23. 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 (item A) causes the truck to immediately reverse, thereby preventing the operator from being crushed.

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 (item B). Once the snail button is pressed, the traction request is performed by the potentiometric throttle.

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

41

ELECTRICAL SYSTEM

8000 YRM 2428

STEERING WHEEL ACTUATION CONTROLS

Figure 24. Steer Wheel To steer to the right or left, rotate the tiller to right or left direction.

Actuators involved

Status

Key switch

ON

Emergency switch

ON

42

Actuators involved

Status

Tiller sensor

ON

Tiller rotation

Right/left rotation

8000 YRM 2428

ELECTRICAL SYSTEM

FORK LIFTING/LOWERING ACTUATION CONTROL

Figure 25. Fork Lifting/Lowering To lift/lower forks, press Button A. Actuators involved Actuators involved

Status

Key switch

ON

Emergency switch

ON

Slow fork lifting/lowering

ON-OFF button for lifting/ lowering activity

Tiller sensor

Status *

ON

NOTE: *Only in the case of fork lowering

43

ELECTRICAL SYSTEM

8000 YRM 2428

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.

COMBI MODULE COMBI/menu parameter change/ COMBI/menu set options

COMBI/menu adjustment

Table 1. Parameter Change Menu Parameter

Default Value

Description

Acceler delay

2

Traction acceleration ramp

Release braking

9

Throttle release braking deceleration ramp

Inverse braking

8

Direction reversal braking deceleration ramp

Pedal braking

9

Deceleration slope with throttle released but not completely at 0

Speed limit brake

2

Deceleration ramp when a speed limit is active

Brake cutback

5

Tiller braking

7=6

Q.I. acceler delay

0

Q.I. inverse barking

9=3

Max speed forward

100 Hz

Maximum forward traction speed

Max speed back

100 Hz

Maximum backward traction speed

Cutback speed

5=60%

Speed reduction

A15 cutback

50%

Cutback speed 3

8=90%

Speed reduction

BDI low speed

4=50%

Speed reduction with low battery

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

44

It determines the frequency applied to the motor when the traction control is in the minimum position.

8000 YRM 2428

ELECTRICAL SYSTEM

Table 1. Parameter Change Menu (Continued) Parameter

Default Value

Tiller delay

0

Steer angle min

15

Steer angle max

75

Description

Table 2. Menu Set Options Parameter

Default value

Tiller switch

0=HANDLE

A13 temp sensor

1=PRESENT

Set input *2

0=PRESENT

Cutback 2 N.C.

0=OFF

HS cutback NC

0=OFF

Set input #4

0=BELLY

Hour counter

1=KEY ON

Battery check

1=LEVEL

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

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

45

ELECTRICAL SYSTEM

8000 YRM 2428

Table 2. Menu Set Options (Continued) Parameter

Default value

Tiller open alarm

0=OFF

Table 3. Menu Adjustment Parameter

Default Value

Set pot brk min

0.0 V

Set pot brk max

108=2, 1 V

Motor overtemp

5=120°C

Set motor temp

101=21°C

Set battery type

0=24 V

Adjust battery

131=25, 1 V

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%

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

Table 4. Technical Specifications Voltage

24V

Inverter maximum current(24V)

150A (RMS) for 2’

•

Inverter for three-phase asynchronous AC motors Regenerative braking functions

Operating frequency

-8kHz

•

CAN Bus interface

External temperature

-30°C - 40°C

•

Digital control microcontrollers

Inverter maximum temperature

78°C

•

46

via

two

redundant

8000 YRM 2428

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM COMPONENTS

1 2 3 4 5

CHARGER BOLT FUSE CONTACTS AC CONTROLLER HORN'S WAVE FILTER

6 TILLER HANDLE 7 ELECTRIC HORN 8 ELECTROMAGNETIC BRAKE 9 AC MOTOR 10 MICROSWITCH

11 LEAD-ACID BATTERY 12 KEY SWITCH 13 GAUGE 14 DC POWER SWITCH

Figure 26. Electrical System Components

47

ELECTRICAL SYSTEM

8000 YRM 2428

CHARGER

1

SCREW Figure 27. Charger

The optional built-in charger has a switch function during charging. When the forklift is in charging, turning on the key switch will not power the forklift.

For the optional external charger, it is necessary to pull out the battery connector and connect it to the charger’s connector when charging. At this time, the vehicle is not connected with the battery.

Remove NOTE: External charger can be replaced directly.

1.

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

2.

Remove drive unit compartment cover.

3.

Remove the connecting wire of the built-in charger, and then remove screws to remove the charger.

48

Charger Mode/Battery Type Selection WARNING DO NOT use battery types that are not approved for the charger or improper mode settings.

Damage to the batteries or charger may occur if the mode setting is not correct for the type of batteries being used. If the battery manufacture of the battery you are using is not listed, contact Service Engineering through the Contact Management System.

NOTE: If the manufacturer of the battery you are using is not listed, contact Service Engineering through the Contact Management System.

Mode settings can be checked by connecting the battery charger to a 120V AC power source and watching the LED display. The LED display on the charger will flash to indicate the selected battery mode.

8000 YRM 2428

ELECTRICAL SYSTEM c.

Table 5. Battery Mode Mode

LED Status

Waiting mode

ON (Green)

Charging mode

FLASH (Yellow)

Full charged mode

ON (green)

Charge error mode

FLASH (Red)

Troubleshooting NOTE: The charger runs a pre-qualifying test (yellow charging light flashing) at the beginning of the charge cycle to determine the condition of the battery. This test may last from 45 minutes to five hours. After the test is complete, the charger should begin charging (yellow charging light continuous) or may display an Error Mode by flashing one or more of the red LEDs. If an Error Mode is displayed, stop the general troubleshooting and follow the chart and procedures in Error Modes in this section.

1.

(2) NO: Check AC power supply to charger.

Inspect all cabling for proper connections (check for loose or corroded connectors) or broken wires. Repair as necessary and repeat Step 1. If LEDs still do not flash at least once upon connecting power, replace the charger.

2.

(2) NO: Change the charger mode to the proper setting for the battery type being used. See or Changing Mode Setting .

After changing the mode setting repeat Step b to verify the proper mode has been selected.

NOTE: The charger runs a pre-qualifying test (yellow charging light flashing) at the beginning of the charge cycle to determine the condition of the battery. This test may last from 45 minutes to five hours. After the test is complete, the charger should begin charging (yellow charging light continuous) or may display an Error Mode by flashing one or more of the red LEDs. If an Error Mode is displayed, stop the general troubleshooting and follow the chart and procedures in Error Modes in this section.

3.

Check AC power supply to charger: a. Connect the charger plug to a 120 volt AC power source using a 20 amp rated extension cord. b. Do all 5 LEDs simultaneously flash at least once upon connection? (LEDs should flash between one to four times depending on battery type/ mode configuration.)

(1) YES: Proceed to Step 2.

(1) Connect the charger plug to a 120 volt AC power source using a 20 amp rated extension cord.

(2) How many times do all 5 LEDs flash upon connection?

Is the Power On LED illuminated continuously when the charger is connected to a 120 volt AC power source? a. YES: Proceed to Step 4. b. NO: Replace the charger.

4.

Is the Detection LED illuminated continuously when the charger is connected to a 120 volt AC power source? a. YES: Battery is not connected to charger or battery voltage is less than 2V. Check connections. If connections are clean and tight, troubleshoot the battery pack. b. NO: Proceed to Step 5.

5.

Is the Charging LED either flashing or illuminated continuously when the charger is connected to a 120 volt AC power source? a. YES: Proceed to Step 6.

Check that the charger is configured for the proper battery mode/type: a. What is the proper charger mode for the type batteries being used?

Refer to Charger Mode/Battery Type Selection. b. What mode is the charger currently set on?

Is the charger currently set to the proper mode for the battery type being used?

(1) YES: Proceed to Step 3.

b. NO: If no other LEDs are flashing, replace charger.

6.

Check the output of the charger using a digital voltmeter: Connect the voltmeter to the charger's positive (Red) and negative (Black) connections at the battery terminals. Record the voltage and then monitor it for approximately 3 minutes. Did the voltage INCREASE while monitoring?

(1) YES: The charger is functioning correctly.

Proceed to Step 7.

49

ELECTRICAL SYSTEM

8000 YRM 2428

(2) NO: Replace the charger.

7.

b. Check if LED flashes? If not, there is something wrong with the Li-ion battery packs. c. Check if battery is out of use? If yes, replace it.

Was the voltage reading in Step 6 higher than 16VDC? a. YES: Proceed to Battery Pack Troubleshooting.

9.

a. Confirm the AC plug is well connected.

b. NO: It is recommended that all batteries in the battery pack be replaced.

8.

The power LED is OFF. b. Turn on the power switch before charging. c.

If charger does not work when LED is on (green)?

Check if the charger is broken? If yes, repair it.

a. Confirm the connection of output plug.

Error Modes The three red LEDs are used to troubleshoot the charger. Observe the operation of the Power On,

Abnormal Shutdown, and the Detection Error LEDs to determine the cause for the error notification.

Table 6. LED Error Codes Conditions

LED 1

LED 2

LED 3

LED 14

LED 5

Battery Voltage High

Off

Off

Off

Off

Flash

Battery Pack Unbalanced

Off

Off

Flash

Off

Off

Excessive Charging Time

Off

Off

Flash

Flash

Flash

Battery Testing 1

Off

Flash

Off

Off

Flash

Battery Testing 2

Off

Flash

Off

Flash

Off

Inhibit Control Defective

Off

Flash

Off

Flash

Flash

Internal Over Temperature

Off

Flash

Flash

Off

Flash

Mode Selected Not Valid

Flash

Off

Off

Flash

Off

Database Save Error

Flash

Off

Off

Flash

Flash

Discharge Error

Flash

Flash

Off

Off

Off

Severe Discharge Error

Flash

Flash

Flash

Off

Off

Battery Storage Error

Flash

Off

Flash

Off

Flash

Critical Battery Error

On

On

Off

Off

Off

LEDs Frozen (no activity) or Charger seems inoperable: Battery may have been subjected to an Over-Discharge condition. Using a voltmeter check if

50

battery voltage is well under its 100% depth of discharge level defined as 1.75V per cell for lead acid batteries. For example, if a 24V lead acid battery

8000 YRM 2428 measures well under 21V, then this condition may have occurred as a result of batteries left in lengthy storage without a trickle charge applied to it. Try removing the output leads from the battery pack (while A.C. Power is disconnected from the charger) and reconnecting the output leads.

Battery Voltage High: Charger’s DC cord set possibly connected to a battery pack with voltage higher than the output rating of the charger.

Battery Pack Unbalanced: Caused by unbalanced battery condition and or excessive battery plate sulphation. Example: some batteries are at a much higher state of charge than others. This may require replacement of the batteries. Refer to the Equipment’s Operators manual for instructions on servicing the battery pack.

Excessive Charging Time: Occurs when charging took too long. Possible causes include: use of a battery load that is draining energy from the battery while the charger is trying to charge that same battery, aged or unbalanced battery cell conditions, etc.

Battery Testing: This error is only generated by one of two conditions found during the Pre- Qualification Test Stage. Condition 1: A severely discharged battery pack did not charge up to 1.75Vdc per cell ( 21Vdc for 24V-battery ), within 4 hrs. Condition 2: A heavy load applied prevents charger from charging battery pack above 1.75Vdc per cell.

Inhibit Lockout Control Defective: If an Equipment Lockout Cable (Inhibit) is installed and supposed to be active, but it is not. Check Inhibit vehicle wiring. If correct, internal inhibit switch may have been overload. Contact factory.

ELECTRICAL SYSTEM Mode Selected Empty: The selected Charge Algorithm, set via the dip switches, is empty and not a valid setting for charging batteries. Reset the mode select switches to a valid value.

Database Write Error: While disconnecting the charger output leads from a battery pack, if the charger was in the process of saving information back into memory, this error may be produced. Contact the factory to have a reset programming cable sent to you to field reset the charger.

Discharge Error: Based on 1.75V/cell, this error is produced when cell voltage falls below this value (example: 21Vdc for 24V Battery Pack). A.C. Power should be connected to charger and charging initiated immediately.

Severe Discharge Error: Based on 1.417V/cell, this error is produced when cell voltage falls below this value (example: 17Vdc for 24V Battery Pack). A.C. Power should be connected to charger and charging initiated immediately. Damage to battery pack, resulting in reduced capacity, may have occurred and may be permanent. Check battery with Load Tester after re-charge complete.

Battery Storage Error: Battery has sat in storage for greater than 30 days and requires charging. Connect A.C. Power and Charge Battery.

Critical Battery Error: Battery has drained to a critically low level possibly resulting from many months of storage, parasitic drains including equipment key left in ‘ON’ position. Disconnect the charger’s positive battery lead, wait a few seconds and then reconnect the lead.

Internal Over Temperature: Charger shut down due to an internal over temperature condition. Check fan operation and remove blockages, if any.

51

ELECTRICAL SYSTEM

8000 YRM 2428

BOLT FUSE

1

NUT

2

BOLT TYPE FUSE Figure 28. Bolt Fuse

Remove

2.

Remove drive unit compartment cover.

1.

3.

Loosen two nuts and then remove the bolt type fuse for replacement.

52

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

8000 YRM 2428

ELECTRICAL SYSTEM

CONTACTS

1

NUT

2

SCREW Figure 29. Contact

Remove 1.

2.

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

3.

Loosen two nuts and remove the connected power cord.

4.

Remove two screws, and then remove the contacts.

Remove drive unit compartment cover.

53

ELECTRICAL SYSTEM

8000 YRM 2428

AC CONTROLLER

1

TERMINAL SCREW

2

SETSCREW Figure 30. AC Controller

Remove 1.

2.

54

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

Remove drive unit compartment cover.

3.

Remove five terminal screws and pull out the wire harness connector.

4.

Remove four setscrews and remove the controller.

8000 YRM 2428

ELECTRICAL SYSTEM

HORN'S WAVE FILTER

1

SETSCREW Figure 31. Horn Wave Filter

Remove

2.

Remove drive unit compartment cover.

1.

3.

Pull out the wire harness connector, remove the setscrew and then remove the wave filter.

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

55

ELECTRICAL SYSTEM

ELECTRIC HORN Remove 1.

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

2.

Remove drive unit compartment cover.

3.

Tag and remove the wires attached to the horn.

4.

Remove the setscrew, pull out the spring and replace the horn.

BRAKE The truck is equipped with four braking systems: •

Release braking

•

Braking on direction reversal

•

Emergency braking

56

8000 YRM 2428 •

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 braking

Emergency brake button operation An alarm has been generated that requires traction to be halted immediately.

Parking brake The tiller is released in the rest position. Drive motor electrical braking with subsequent engagement of the electromagnetic brake.

8000 YRM 2428

ELECTRICAL SYSTEM

TILLER HANDLE

1

SCREW

2

SCREW

3

UPPER COVER

Figure 32. Tiller Handle

Remove

3.

Remove four screws with an Allen key.

1.

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

4.

Remove the upper cover and pull out the connecting wire.

2.

Remove drive unit compartment cover.

5.

Remove three screws to replace the tiller handle.

57

ELECTRICAL SYSTEM

8000 YRM 2428

MICROSWITCH

1

SCREW

2

SCREW Figure 33. Microswitch

Remove

LEAD-ACID BATTERY

1.

Remove

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

1.

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

2.

Remove drive unit compartment cover.

3.

Remove the screw fixing the microswitch.

2.

Remove drive unit compartment cover.

4.

Remove two screws fixing the connecting wire, and then remove the connecting wire and replace the microswitch.

3.

Pull out the connector and replace the Lead-Acid battery assembly.

KEY SWITCH Remove 1.

58

Remove the set screw, unplug the connector, and then replace the key switch,

8000 YRM 2428

ELECTRICAL SYSTEM

GAUGE

1

NUT

2

BENT PLATE Figure 34. Gauge

Remove

2.

Remove drive unit compartment cover.

1.

3.

Loosen two nuts, remove the bent plate, and then remove the gauge from the top of the replacement.

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

59

ELECTRICAL SYSTEM

8000 YRM 2428

DC POWER SWITCH

1

MUSHROOM

2 3

HOLE SCREW

4

BOLT

Figure 35. DC Power Switch

Remove 1.

Position lift truck on level surface. Turn the key switch to the OFF position and disconnect the battery.

2.

Remove drive unit compartment cover.

3.

Put the screwdriver into the hole, rotate the mushroom counterclockwise, and remove the mushroom.

60

4.

Remove two screws and remove the DC power switch.

5.

Remove the bolt, and then remove the connecting power line to replace the DC power switch.

8000 YRM 2428

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM OPERATION

Figure 36. Forks Lifting/Lowering •

Forks lifting

•

Forks lowering

Lifting A Load To raise a load, the lift button must be depressed.

Depressing this switch will activate the pump motor.

This torque is transferred to the pump from the motor through the motor shaft and shaft coupling.

Hydraulic oil is pumped through the system as the pump begins to operate. A vacuum created inside of the pump draws oil out of the reservoir through the suction line. Air which is drawn into the reservoir through the breather displaces the pumped oil, allowing it to be sent through the system. If the breather is clogged or blocked the ability of the system to lift a load will be greatly reduced.

As oil is pushed out of the pump, it passes through a one-way check valve to the lift cylinder. The check

valve prevents oil from flowing back to the pump when lifting ceases, holding the lift cylinder in the raised position until lowered.

The piston will begin to lift the load when fluid pressure acting against it is high enough to overcome the weight of the load at rest on the forks/ platform.

When the piston is fully extended to the end of its stroke or if the load is too heavy, pressure will continue to build until the rated pressure needed to operate the relief valve is reached. When this occurs, the relief valve, which is normally closed, is forced back against its spring, creating a path for the fluid to flow back to the reservoir.

Once relief valve pressure is reached, hydraulic oil will continue to be diverted from the lift cylinder to the reservoir until the lift button is released or electrical power is interrupted.

61

HYDRAULIC SYSTEM

1 2 3

LIFTING CYLINDER RELIEF VALVE OIL PUMP (1.0CC/R)

8000 YRM 2428

4 5 6

OIL TANK (1.6L) OIL FILTER SPEED LIMIT VALVE

7 8 9

MOTOR (0.8KW) ONE-WAY VALVE SOLENOID VALVE

Figure 37. Hydraulic Schematic Diagram

1 2 3 4 5

CONNECTOR COMPOUND GASKET HIGH PRESSURE HOSE CONNECTOR CONNECTOR SEAT

6 SCREW 7 WASHER 8 WASHER 9 HIGH PRESSURE HOSE 10 COMPOUND WASHER 11 CONNECTOR Figure 38. Hydraulic System

62

12 CONNECTOR 13 COMPOUND WASHER 14 CYLINDER ASSEMBLY 15 SCREW 16 HYDRAULIC STATION ASSEMBLY

8000 YRM 2428

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM SPECIFICATION Voltag e

System Pressure No Load

24V

Heavy Load

Current No Load

2.5Mp 13.5Mpa 28A a

Lift Pressure and Current

Lift Time

Lower Time

Heavy Load

Maximum pressure

Curren No t Load

Full Load

No Load

Full Load

74A

17Mpa

90A

4.8s

4s

3.5s

Lowering A Load A load is lowered by depressing the lower button.

When the lower button is depressed, electric current is sent to the normally closed solenoid lowering valve, which causes it to change position and open a path for the trapped hydraulic oil to flow from the cylinder back to the reservoir.

4s

Clean Adhere to the following precautionary steps to ensure that the hydraulic system remains clean.

1.

Flush the entire system when a failure is encountered to make sure all paint, metal chips, welding shot, and debris are removed.

2.

Filter each change of oil to prevent the introduction of contaminants into the system.

When making repairs, use the least number of fittings and connections to minimize flow resistance and the possibility of leakage.

3.

Provide continuous protection from airborne contamination by keeping the breather clean and serviceable.

Hydraulic Oil

Sound Level

The hydraulic oil in the system performs the dual function of the power transmission and lubrication.

Using the correct fluid is essential to proper system operation.

Hydraulic system noise is caused by both improperly selected oil and loose or damaged system components.

Hydraulic Lines All hydraulic lines must be thoroughly cleaned before installation.

•

Check the reservoir level when troubleshooting lifting problems. Low oil levels will make it appear that a problem exists with the battery or hydraulic system.

Recommended specifications: • • •

Hydraulic oil: L-HV 32 type conforming GB/ T11118.1, DIN 51524 (II) standards Gear oil: Hypoid gear oil 85 W / 90 (GL-5) (about 1.7 L) Grease: No. 3 lithium grease

•

Hydraulic oil with high or moderately high viscosities - At startup, temperatures can cause pump noises due to cavitation and also impedes the release of trapped air. Air does not have sufficient time to purge itself from the fluid while in the reservoir before recycling through the system.

Aerated Hydraulic Oil - Results in system noise that is similar to cavitation. Aerated oil is caused by the ingestion of air through the pipe joints of the inlet lines and high velocity discharge lines, as well as cylinder rod packing. Aeration can also be caused by oil discharging above the fluid level.

CAUTION All waste liquids, such as hydraulic oil, gear oil and grease, will pollute the environment. Please recycle replaced working media or dispose them according to local regulations.

63

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 is reduced so is the flow rate and vice versa. The pressure remains constant, providing the load is unchanged.

HYDRAULIC UNITS Remove WARNING Batteries are heavy and can cause personal injury.

Use care to avoid injury. DO NOT put hands, arms, feet, and/or legs between the battery and a solid object. Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of metal or it must have insulated straps.

WARNING Put blocks under each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

8000 YRM 2428 1.

Remove the drive unit compartment cover.

2.

Disconnect the battery. Use a spreader bar and lifting device to remove the battery. DO NOT allow the battery move from side to side. Make sure the battery cables have clearance.

3.

Raise the drive wheel off the floor and put blocks under both sides of the drive unit frame.

4.

Discharge the capacitor.

5.

Drain the hydraulic oil from the hydraulic unit into an appropriate container.

6.

Tag and disconnect all of the electrical wires from the hydraulic unit.

7.

Remove the hydraulic line from the hydraulic unit.

8.

Loosen and remove the two capscrews attaching the hydraulic unit to the frame. Remove the hydraulic unit and place in a clean work area.

Install 1.

Align the hydraulic unit with the mounting holes in the frame and install the two capscrews. Tighten the hydraulic unit mounting capscrews to 35 N•m (26 lbf ft).

2.

Install the hydraulic line to the hydraulic unit.

3.

Connect all the electrical wires to the hydraulic unit.

4.

Remove the blocks and lower the lift truck to the floor.

5.

Remove the breather and add the recommended hydraulic oil until the oil level reaches the full level mark. Replace the breather. If too much hydraulic oil is added, the oil will leak from the breather during operation.

6.

Install and connect the battery. Operate the lift truck until the hydraulic oil reaches operating temperature. Add additional oil if necessary.

Check for hydraulic oil leaks.

7.

Install the drive unit compartment cover. Test the operation of the lift truck prior to returning the truck to service.

WARNING The capacitor in the controller can hold an electrical charge after the battery is disconnected.

To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected. Refer to Special Precautions in this manual.

CAUTION Make certain the hydraulic cylinder is fully collapsed.

64

8000 YRM 2428

HYDRAULIC SYSTEM

HYDRAULIC PUMP

8.

Install the hydraulic unit.

Remove

9.

Remove the breather and fill the reservoir with the recommended oil. Add oil until the oil is up to the full mark. If too much oil is added, the oil will leak from the breather during operation. If too much oil has been added, drain the excess or use a suction device to remove some of the oil.

1.

Remove the hydraulic unit from the lift truck.

2.

Clean the reservoir and pump area to prevent contaminants from entering the hydraulic system.

3.

Remove the capscrews retaining the reservoir to the hydraulic unit. Tap around the perimeter to break the seal and separate the reservoir from the motor assembly.

4.

Remove the spring retaining screw from the suction tube.

5.

Remove the suction tube and strainer by pulling down and out.

6.

Remove the four capscrews retaining the pump to the drive motor.

7.

Disassemble the pump assembly and coupling from the adapter.

Install

10. Run the pump for 5 seconds and energize the lowering valve at the same time so that oil gets through the pump body and valve at 0.0 psi.

Operate the forks up and down three or four times to remove air from the system. Operate the lift truck until the hydraulic oil reaches operating temperature. Remove the breather and check the hydraulic oil level. Add additional oil if necessary.

Check for hydraulic oil leaks.

11. Install the drive unit compartment cover. Test the operation of the motorized hand truck before returning the truck to service.

PRESSURE CONTROL 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.

1.

Clean and lubricate all components using clean hydraulic oil.

2.

Replace all O-rings and seals within the unit.

3.

Grease the coupler and coupler cavity with the motor resting with the adapter plate up. Align the pump mounting holes with the holes in the motor.

Ensure that the tank is seated into the motor.

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 the pressure build ups. An example is anti-shock and antiknock valves.

4.

Install the four capscrews and tighten to 13.6 to 16.3 N•m (10 to 12 lbf ft).

5.

Install the O-rings into the pump cavities. Apply grease to the return tubes. Insert tubes into pump cavities and O-rings. Grease the suction tube and insert into locking device with hole. Install and tighten the spring retaining screw to secure the suction tube.

6.

Remove the retainer and replace the O-ring.

Lightly grease the O-ring before installation.

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 overpressured oil overcomes the force of the spring and flows towards the oil outlet.

7.

Align the reservoir so the hose connections will be in the same position as they were prior to removal. Install the four capscrews to retain the reservoir.

65

HYDRAULIC SYSTEM

8000 YRM 2428

PRESSURE RELIEF VALVE ADJUSTMENT WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repair. Report the problem to your supervisor immediately. If repairs are necessary, turn the key switch to the OFF position, attach a DO NOT OPERATE tag to the control handle, and disconnect the battery.

Always wear the proper protective equipment including eye protection and petroleum resistant gloves when servicing hydraulic components.

Thoroughly wash oil from exposed areas of skin as soon as possible.

Completely lower all lift components and relieve pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

NOTE: Check the hydraulic oil level in the reservoir when oil is at room temperature. Remove breather cap and add recommended hydraulic oil to proper level, as required.

1.

Verify the key switch is in the OFF position and the battery is disconnected.

2.

Remove the hydraulic reservoir.

3.

Loosen the locking nut on the relief valve.

4.

Adjust the relief valve screw in small increments.

Turn the adjustment screw clockwise to increase pressure. Turn the adjustment screw counterclockwise to decrease pressure.

5.

Tighten the lock nut and torque to 15 N•m (11 lbf ft).

6.

Install the hydraulic reservoir as removed.

7.

Connect the battery and turn key to the ON position.

8.

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

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Never put your hands on pressurized hydraulic components. Pressurized hydraulic oil escaping through pin-hole leaks can be injected into the skin.

CAUTION DO NOT OVERFILL. Oil will leak from the breather/ filler cap if too full.

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

For trucks with a capacity of 1500 Kg, the nominal pressure must be equal to 16 Mpa.

66

8000 YRM 2428

A

LOCK NUT

HYDRAULIC SYSTEM

B

ADJUSTMENT SCREW Figure 39. Pressure Relief Valve

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

LIFT CYLINDER

DIRECTIONAL CONTROL VALVES ONE-WAY VALVES AND CHECK VALVES

WARNING

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 that 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.

Put blocks under each fork. Position blocks on both sides of the drive wheel. The blocks must prevent the lift truck from falling and causing personal injury or damage.

Remove To remove lift cylinder, do the following steps.

1.

Raise the forks of the lift truck to maximum height.

2.

Place blocks under the forks and block the drive tire.

67

HYDRAULIC SYSTEM

8000 YRM 2428

3.

Lower the forks onto the blocks.

6.

4.

Remove the drive unit compartment cover from the lift truck.

Unscrew the screw (item 1) and spacer (item 2) of the upper pivot point of the oil cylinder.

7.

Remove the top center and main center covers covering the hydraulic cylinder.

Unscrew the screw (item 4) and spacer (item 3) of the lower pivot point of the oil cylinder.

8.

Raise the front frame slightly to remove the oil cylinder (item 5), each on left and right side.

5.

Figure 40. Remove Lift Cylinder

PIPES

Pre-installation inspection

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.

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.

• • • • •

68

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.

8000 YRM 2428

BRAKING SYSTEM

BRAKING SYSTEM ELECTROMAGNETIC BRAKE

1 2 3

HOLLOW SCREW COUPLING SCREW SPRING

4 5 6 7

ARMATURE MOTOR SHAFT SPLINE HOUSING FRICTION DISK

8 STATOR 9 COVER 10 MOUNTING SCREW

Figure 41. Electromagnetic Brake Components

ADJUST 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 ELECTROMAGNETIC BRAKE, use a thickness gauge to check the distance between the pad and the magnetic steel.

4.

Adjust the three screws evenly to keep this clearance.

5.

Finally, operate the brake with a 24V DC power supply several times and check its correct operation.

If the value exceeds 0.5 mm, the clearance must be adjusted. To adjust clearance, do the following steps.

1.

Remove dirt and dust from the clutch plate.

2.

Loosen the coupling screw, adjust the length of the hollow screw and then tighten the screw again.

3.

Make sure that the distance between the pad and the magnetic steel component remains between 0.2 mm and 0.6 mm (0.0078 inch - 0.0236 inch).

69

BRAKING SYSTEM

8000 YRM 2428 •

WARNING •

•

•

•

•

•

•

•

•

•

•

70

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.

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.

8000 YRM 2428 •

•

BRAKING SYSTEM

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.

BRAKE CHECK HOLD ON GRADE TEST WARNING DO NOT stand below or ride on the lift truck when performing the hold on grade test.

1.

The brake should be checked for hold capacity every 2000 hours or yearly or any time substandard brake performance is suspected.

1

CAPACITY LOAD

2

2.

Load a stable, full-capacity load on the forks and position the lift truck at the base of a 10-percent grade (1.0m rise in 10.0m(3 ft rise in 30 ft)) grade with the forks facing uphill.

3.

Standing to the side of the lift truck, slowly drive the lift truck up the grade and bring the lift truck to a stop using the directional controls (plugging).

4.

Move the control hands on the BRAKE ON position to apply the parking brake. See Figure 42. If the brake fails to hold the lift truck on the grade, the brake assembly must be repaired or replaced. For instructions on repairing or replacing the brake, refer to REMOVE BRAKE in this section.

10% GRADE

3

FORKS UPHILL

Figure 42. Hold On Grade Test

71

BRAKING SYSTEM

REMOVE BRAKE

8000 YRM 2428 2.

Remove the drive unit compartment cover.

3.

Disconnect the brake wiring connector from the main wiring harness connector.

4.

Remove the capscrews that hold the brake assembly to the traction motor and remove the brake assembly. See Figure 43.

5.

Remove the screws holding the adapter to the magnet body and remove the adapter and the friction disk.

CAUTION The brake is not adjustable. Be careful not to alter the position standoff bolts during repairs.

Some parts of the steering control handle must be disconnected to disassemble the brakes.

1.

72

Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery. Block the wheels to prevent unexpected movement.

8000 YRM 2428

1 2

BRAKE ASSEMBLY SNAP RING

BRAKING SYSTEM

3 4

SHAFT SLEEVE WOODRUFF KEY

5 6

SNAP RING TRACTION MOTOR

Figure 43. Remove Brake

73

BRAKING SYSTEM

8000 YRM 2428 4.

Install the upper snap ring on the end of the motor shaft.

Use caution when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause personal injury. Always use the correct snap ring pilfers and wear eye and face protection during removal and installation.

5.

Replace the adapter and friction disk and tighten the screws that hold the adapter to the brake.

Torque to 11 N•m (8 lbf ft).

6.

Replace the brake and install the lockwashers and capscrews that hold the brake to the motor.

6.

Remove the snap ring from the top of the traction motor shaft securing the shaft sleeve in place.

7.

Tighten the capscrews. Torque to 12 to 14 N•m (8.8 to 10.3 lbf ft).

7.

Slide the shaft sleeve up off the traction motor shaft. Recover the Woodruff key. Remove the lower snap ring if necessary.

8.

Connect the brake wiring connector to the main wiring harness.

9.

Check the brake switch at the control handle base for operation and to ensure that the wires are connected and that there is no obstruction of movement.

WARNING

INSTALL BRAKE WARNING Use caution when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause personal injury. Always use the correct snap ring pilfers and wear eye and face protection during removal and installation.

1.

Install lower snap ring if removed.

2.

Position the woodruff key into the groove on the traction motor shaft as removed.

3.

Align the woodruff key with the groove inside the shaft sleeve. Slide the shaft sleeve down onto the traction motor shaft and woodruff key.

74

10. Install the drive unit compartment cover.

11. Remove the blocks. Connect the battery and test the operation of the lift truck prior to returning the lift truck to service.

NOTE: The brake must hold the lift truck with a maximum rated load on a 10 percent grade [0.305 m (1 ft) rise in 3.05 m (10 ft)]. The truck should operate without any drag when the handle is in the operating position.

8000 YRM 2428

DIAGNOSTICS AND MEASUREMENTS

DIAGNOSTICS AND MEASUREMENTS CONTROLLER DESCRIPTION TRACTION CONTROL DEVICE AC0

Figure 44. Control device AC0 Code

Remarks

KC-A1

Main remote control switch coil negative

KC-A2

Output +24V contractor coil and electromagnetic brake power supply

KC-A3

Electromagnetic brake coil negative

KC-A4

Pump contractor coil negative

KC-A5

Output +24V lifting contractor 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

75

DIAGNOSTICS AND MEASUREMENTS

8000 YRM 2428

Code

Remarks

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

TESTER MENU

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.

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.

COMBI AC0 TRACTION CONTROL Tester Menu Parameter Key voltage Volts Level of battery voltage measured at the KC-B1 input Motor voltage % The voltage supplied to the motor which is expressed as a percentage of the maximum voltage (depending on 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

76

Measurement Unit

8000 YRM 2428

DIAGNOSTICS AND MEASUREMENTS

Parameter

Measurement Unit

Slip value Hz Speed difference between the rotation field and the motor rotor, which is expressed in the same unit as frequency Current RMS Arms RMS current applied to the AC traction motor Battery current A Battery current Battery Charge Battery charge level percentage

%

Temperature Temperature of the inverter measured on the heat sink

°C

Motor temperature Traction motor temperature

°C

Accelerator Throttle potentiometer voltage

V

Brake pedal pot Brake potentiometer voltage percentage value

%

Lifting switch Lifting button digital input enabled/disabled Descent switch Lowering button digital input enabled/disabled Forward switch Forward travel button digital input enabled/disabled Backward switch Reverse travel button digital input enabled/disabled Quick inversion Belly button digital input enabled/disabled Cutback switch 1 Speed reduction 1 microswitch enabled/disabled Cutback switch 2 Speed reduction 2 microswitch enabled/disabled Cutback switch 3 Speed reduction 3 microswitch enabled/disabled

77

DIAGNOSTICS AND MEASUREMENTS

8000 YRM 2428

TROUBLESHOOTING The alarms are signalled by a diagnostic LED that blinks intermittently to indicate 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

3 blinks

Anomalies related to capacitor charge or phase voltage

4 blinks

Errors related to throttle

5 blinks

Errors related to current sensor

6 blinks

Errors related to contractor driver

7 blinks

Excessive temperature

8 blinks

Incorrect detection from Can Bus

Prolonged blinking

Battery low

ERROR CODE OF AC-0 CONTROLLER Error Code

Fault Description

Fault Name

Troubleshooting •

Clear EEPROM.

It is a self-diagnostic test inside the control Watchdog and is carried out during operation and in stand-by mode.

•

Check whether the controller connector is connected properly. if so, replace the controller to see if the error is eliminated.

76

This alarm appears when there is an Coil shorted overload of the main contractor 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.

•

Check that there are no external short circuits and that the ohmic value of the coils of the main contractor and of the electromagnetic brake are correct.

If not, replace the control.

17

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

•

The coil output circuit is suddenly open during operation.

240

Wrong configuration

8

78

Configuration error

Logic failure #3

8000 YRM 2428

Error Code 60

DIAGNOSTICS AND MEASUREMENTS

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

Fault Name Capacitor charge

Troubleshooting •

•

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, and the main remote-control switch is not closed.

30/31

The test is performed in diagnosis and in stand-by.

• •

VMN LOW, VMN HIGH

Possible causes:

•

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.

•

Check the encoder of the motor.

• • •

253

Encoder error

75

The contractor coil driver is not capable of Contractor piloting the load. driver

•

Check whether there is a short circuit between the controllers A1 and A2. If not, replace the controllers.

49

Drive current cannot be stopped

•

If there is no problem with the three-phase connection of the motor, replace the controller.

53

The test is performed in stand-by. Check STBY I high that the current is at 0. If this does not occur, this alarm appears which stops the machine operations.

•

Fault in the current sensor.

•

Logic failure: replace the control. If the alarm persists replace the control.

Contractor open

•

The coil circuit of main contacts is open.

Main contacts damaged.

38

Encoder fault

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 contractor 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.

I=0 ever

Main contacts open

• 74

When switched on by key, the Driver shorted microprocessor checks that the contractor 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 controller.

79

DIAGNOSTICS AND MEASUREMENTS

Error Code 254

19

Fault Description

8000 YRM 2428

Fault Name

The microprocessor that governs the Aux output KO electromagnetic brake driver. If the state of the driver output does not correspond to the signal from the microprocessor, the alarm is triggered.

This alarm appears when the module detects overvoltage or undervoltage conditions.

Logic failure #1

Troubleshooting Possible causes: •

The output transistor is damaged.

•

Defect in logic.

•

Check the electromagnetic brake coil wiring.

•

Check the battery voltage. It is likely that a overvoltage or undervoltage condition has occurred.

Check whether the ADJUST BATTERY in the controller is consistent with the actual battery voltage.

•

18

A fault in the hardware section of the logic Logic failure #2 board that controls the retraction of the phase voltage.

•

•

248

80

•

If there are no problems found for the above two items, replace the controller.

The Can Bus line diagnosis is present CAN bus KO only if the inverter uses this connection (this depends on the software version).

The alarm is generated if the inverter does not receive any message from the Can Bus line.

•

Firstly check the wiring.

•

If the problem is not in the wiring then it is in the control, which needs to be replaced.

This message only appears when both the FORW+BACK (forward and backward) motion requests are activated at the same time.

•

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

If the alarm persists, replace the controller.

• 79

It is an incorrect start sequence alarm.

Incorrect start

•

• 78

86

80

Check whether there are problems in the power circuit of the motor, including the fuse of the controller .

Check the parameter table.

Accelerator is not OK

Accelerator malfunction

The alarm appears if a fault is detected in Pedal wire KO the accelerator wiring (the NPOT or PPOT cable is disconnected).

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

If the alarm persists, replace the controller.

•

Reset the accelerator.

•

The accelerator Replace it.

•

Check the voltage on NPOT and the connections of the potentiometer.

is

damaged.

8000 YRM 2428

Error Code

DIAGNOSTICS AND MEASUREMENTS

Fault Description

Fault Name

Troubleshooting

61

Temperature of the control is higher than 78°C. The maximum current is reduced proportionally as the temperature increases. The control stops at a temperature of 100°C.

High temperature

•

If the alarm is generated when its temperature is not really above 78°, replace the control.

13

This alarm is due to a fault in the memory EEPROM KO 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 controller. If the problem has been solved, reset it parameter and keep in mind that the values set have been replaced by default values.

65

The motor temperature is above the expected value.

Motor temperature

•

This is just a warning: no checks will be performed.

251

The cart does not start because the handbrake switch is open.

Handbrake

•

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

If the alarm persists, replace the controller.

• Thermic sensor KO

•

Check the sensors connection.

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

Check up needed

•

Perform scheduled maintenance.

69

Data acquisition

Data updating error

•

Settings of controller parameters cannot be changed while the controller is in use.

247

PEV not ok

99

Input error #1

Input error 1

•

Check whether the A13 input is normal.

37

Main contacts stuck together

Contractor closed

•

Check whether the main contacts are stuck together.

236

Wrong battery

Voltage level setting error

•

Check whether the battery voltage is normal.

235

CAN Bus KO EPS

234

EPS rele open

237

Slip profile

238

Lower switch is triggered

Lift low active

•

Lower switch is triggered when the controller is started. Check the Lower switch.

250

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

0

Reload HM from MDI

249

81

DIAGNOSTICS AND MEASUREMENTS

Error Code

8000 YRM 2428

Fault Description

Fault Name

Troubleshooting

lift+lower

•

Check whether the signals of the handle’s switches are normal.

CAN Bus KO tiler

Handle communication error

•

Check CAN bus.

98

Input error #2

Input error 2

•

Check whether the A14 input is normal.

230

Reset cutback 1

233

CAN Bus KO BMS

Power manager communication error

•

Check CAN bus.

239

Lift and Lower switches are triggered simultaneously

232

End teach KO

228

Card tiler

227

ERROR CODES OF 1230 CONTROLLER LED Codes

1311 Display

1 and 2 Encoder of the motor speed Motor failsafe

Description

Possible Reasons

No speed sensor signal

Angle sensor invalid or correct

Motor speed is out of normal range

Speed sensor fault

Controller error Electromagnetic brake of the motor is not released completely Insufficient braking torque Motor control P gain and I gain settings to low Failsafe delay too short

1 and 3 Motor over-current

Motor over-current

Incorrect motor wiring Controller error

Motor output fault 1 and 4 Static return to off

Controller output abnormal

Incorrect motor wiring

SR0 sequencing error

Improper sequence of KSI, interlock and direction inputs

Controller error Wrong SR0 type selected Direction switch malfunction Sequencing delay too short

2 and 1 Throttle wiper high

Accelerator voltage too Throttle damaged high Wrong accelerator type selected

2 and 2 EMR

EMR

82

Emergency reverse wire or check wire broken

8000 YRM 2428

LED Codes

DIAGNOSTICS AND MEASUREMENTS

1311 Display

2 and 3 High pedal disable

Description

Possible Reasons

HPD sequencing error KSI HPD Accelerator malfunction Key switch and linkage power off Sequencing delay too short Wrong accelerator type selected

2 and 4 Throttle wiper low

Accelerator voltage too Throttle damaged low Wrong accelerator type selected

3 and 1 Multiplexer malfunction

Multiplexer malfunction Multiplexer malfunction

3 and 2 Main contactor

Main contacts misalign Main contacts coil short circuit or welded Main contacts jammed in the closed position Welded main contacts Main contacts coil drive short circuit

Precharge

Precharge fault

Controller error Low battery voltage

3 and 3 Brake failure

Electromagnetic brake Brake coil shorted or open failure Brake drive failure

4 and 1 Service total disabled

Total KSI timer expired KSI timer expired

Service driver disabled

Total driving timer expired

Total driving timer expired

Service total expired KSI

KSI

Service driver expired

Setting (driver) of service timer expired

Setting (driver) of service timer expired

4 and 2 Battery over-voltage Battery voltage too high Battery undervoltage

Battery voltage too high

Battery voltage too low Low battery voltage Corroded battery terminal Battery damaged

4 and 3 Temperature decreasing

Controller heat sink is too hot or too cold

Low power from controller Vehicle overload for a long time Poor heat absorption

4 and 4 Counter tie down

Mode switch is closed at start-up

Sticked mode switch

5 and 1 Hardware fault

Hardware fault

Controller error

5 and 2 Software fault

Software fault

Controller error

Switch is in M2 position

83

DIAGNOSTICS AND MEASUREMENTS

LED Codes

1311 Display

5 and 3 Parameters corrupt

8000 YRM 2428

Description Parameters corrupt

For instance, LED code 2 and 4 means that LED flashes 2 times continuously and then 4 times after a few seconds.

To check 1230 controller with motor encoder, perform system measurement and troubleshooting with the connecting line and voltage of the motor encoder.

Normally, the voltage between the positive and negative poles is 12 V.

Possible Reasons Controller error The voltage between A (J2-2) and the negative (J2-5) should be 0 V or 10 V. The voltage between B (J2-4) and the negative (J2-5) should be 0 V or 10 V. Alternate adding 0 V or 10 V voltage to negative (J2-5), encoder output should be 5 V and unchanged on high speed application.

BMS ERROR DESCRIPTION BMS Alarm Code

Remarks

B11

Single level 1 error low charging temperature

B12

Single level 2 error low charging temperature

B13

Single level 3 error low charging temperature

B14

Single level 1 error high feeding temperature

B15

Single level 2 error high charging temperature

B16

Single level 3 error high charging temperature

B17

Single level 1 error low discharging temperature

B18

Single level 2 error low discharging temperature

B19

Single level 3 error low output temperature

B20

Single level 1 error high discharging temperature

B21

Single level 2 error high discharging temperature

B22

Single level 3 error high discharging temperature

B23

Unit voltage too low, Level 1 error

B24

Unit voltage too low, Level 2 error

B25

Unit voltage too low, Level 3 error

B26

Unit voltage too high, Level 1 error

B27

Unit voltage too high, Level 2 error

B28

Unit voltage too high, Level 3 error

B29

Unit pressure difference error, Level 1 error

B30

Unit pressure difference error, Level 2 error

B31

Unit pressure difference error, Level 3 error

B32

Unit temperature difference error, Level 1 error

B33

Unit temperature difference error, Level 2 error

B34

Unit temperature difference error, Level 3 error

B35

SOC too low, Level 1 error

84

8000 YRM 2428

DIAGNOSTICS AND MEASUREMENTS

BMS Alarm Code

Remarks

B36

SOC too low, Level 2 error

B37

SOC too low, Level 3 error

B38

Fast charging current too high, Level 1 error

B39

Fast charging current too high, Level 2 error

B40

Fast charging current too high, Level 3 error

B41

Feedback current too high, Level 1 error

B42

Feedback current too high, Level 2 error

B43

Feedback current too high, Level 3 error

B44

Discharging current too high, Level 1 error

B45

Discharging current too high, Level 2 error

B46

Discharging current too high, Level 3 error

B47

Module connection lost, Level 1 error

B48

Module connection lost, Level 2 error

B49

Module connection lost, Level 3 error

B50

Single temperature sensor fault, Level 1 error

B51

Single temperature sensor fault, Level 2 error

B52

Single temperature sensor fault, Level 3 error

B53

Total pressure too low, Level 1 error

B54

Total pressure too low, Level 2 error

B55

Total pressure too low

B56

Total pressure too high, Level 1 error

B57

Total pressure too high, Level 2 error

B58

Total pressure too high, Level 3 error

B59

Discharge relay fault, Level 1 error

B60

Discharge relay fault, Level 2 error

B61

Discharge relay fault, Level 3 error

B62

Charging seat temperature too high, Level 1 error

B63

Charging seat temperature too high, Level 2 error

B64

Charging seat temperature too high, Level 3 error

B65

Charging seat temperature sensor fault, Level 1 error

B66

Charging seat temperature sensor fault, Level 2 error

B67

Charging seat temperature sensor fault, Level 3 error

B68

Park

B69

Discharge current limited

B70

Speed limiter

B71

Warning

85

DIAGNOSTICS AND MEASUREMENTS

8000 YRM 2428

MECHANICAL FAULTS Fault Abnormal noise during lift operation

Possible Cause

Procedure/Action

Suction filter clogged

Clean or replace suction filter.

Oil and foam leaking from suction hose

Tighten the connector, and check oil level or add oil.

Hydraulic pump or motor damaged

Contact our company's maintenance staff.

Seal failed with air entering oil pump Contact our company's maintenance staff.

Incorrect oil viscosity and low oil level

Change or add oil.

Hydraulic system is incapable or the Pump is noisy and unable to suck oil Change or add oil. pressure is too low Oil pump damaged Contact our company's maintenance staff.

Unstable oil pressure

Forklift cannot start

Poor/heavy steering

No brake

Brake is not released

86

Valve block is faulty

Contact our company's maintenance staff.

Tube raptured or leaked.

Replace the oil tube or tighten the connector.

Oil viscosity is too low to cause leakage.

Replace Oil.

Same as that of abnormal noise

See troubleshooting of abnormal noise.

Lift cylinder or sealing ring is worn

Replace the liner or sealing ring.

Oil is not enough

Add oil.

Battery depleted

Check, charge or replace the battery.

Wire connector loosen

Tighten the connector screws.

Fuse burned

Replace fuse.

Accelerator malfunction

Replace accelerator.

Foreign object stuck in the steering gear

Clean up the foreign matter.

Worn steering bearing

Replace bearings.

Electromagnetic brake shoe damaged

Replace the electromagnetic brake.

No power supply to the electromagnetic

Check Circuit.

The clearance of the electromagnetic brake is too large

Change the electromagnetic brake.

8000 YRM 2428

DIAGNOSTICS AND MEASUREMENTS

ZAPI AC0 CONTROL CONFIGURATION

1 2 3 4

INVERTER "C" CONNECTOR CONSOLE CONNECTOR DISPLAY BUTTONS Figure 45. Zapi AC0 Controller

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DIAGNOSTICS AND MEASUREMENTS

8000 YRM 2428

Figure 46. Zapi AC0 Menu

88

8000 YRM 2428

Change OPTIONS menu To change OPTIONS menu, do the following steps (See ZAPI AC0 CONTROL CONFIGURATION): 1.

Open Zapi Menu.

2.

Press top Left & Right buttons to enter Config menu.

The display will show SET MODEL.

3.

9.

To change ADJUSTMENT menu, do the following steps (See ZAPI AC0 CONTROL CONFIGURATION): 1.

Open Zapi Menu.

2.

Press top Left & Right buttons to enter Config menu.

The display will show SET MODEL.

3.

Press ENTER to go into the SET MODEL menu.

Press ROLL UP or ROLL DOWN button until desired option appears.

6.

Press SET UP or SET DOWN button to modify changes.

4.

Press OUT to exit the menu.

5.

Press ROLL UP or ROLL DOWN button until desired parameter is reached.

6.

Press SET UP or SET DOWN button to modify adjustment.

7.

Press OUT to exit the menu.

Confirmation message appears.

8.

Press ENTER to accept the changes, or press OUT if you do not accept changes.

SET OPTIONS menu appears.

Press ENTER to go into the ADJUSTMENT menu.

The display will show BATTERY TYPE.

New option appears.

7.

Press ROLL UP or ROLL DOWN button until ADJUSTMENT menu appears.

ADJUSTMENT appears on the display.

The display will show the first option.

5.

Press OUT again. The display now shows the opening Zapi menu.

Change ADJUSTMENT Menu

Press ROLL UP or ROLL DOWN button until SET MODEL menu appears.

SET OPTIONS appears on the display.

4.

DIAGNOSTICS AND MEASUREMENTS

Confirmation message appears.

Press ENTER to confirm adjustment.

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DIAGNOSTICS AND MEASUREMENTS

8000 YRM 2428

CURTIS CONFIGURATION

the other for interfacing with a PC. It also has a battery compartment and a memory card slot.

CONNECTION The handheld programmer Curtis has two connectors, one for communicating with the motor controller and

1 2

CONNECTORS USB CONNECTOR

3 4

SYSTEM CONNECTOR SD MEMORY CARD SLOT

5

BATTERY COMPARTMENT (LOCATED ON UNDERSIDE)

Figure 47. Curtis •

• •

•

90

System connector: Use this connector with the supplied cable to connect the programmer to the motor controller.

USB connector: Use this connector with a USB cable to connect the programmer to a PC. Batteries: A compartment on the underside of the unit holds two AA batteries. Power is supplied to the programmer by the controller.

The batteries in the programmer keep its real time clock running.

SD card: SD card provides additional memory.

It is a convenient interface between a PC and the programmer. Note that SD card must be inserted into the programmer with face down.

Power Up Connect the handheld programmer into the control system by plugging it into the controller's charger or programmer port. The programmer automatically powers up and displays the loading screen.

Once the programmer has uploaded the information from the controller, it displays the Main Menu See Display.

If the controller is not run on when the programmer is connected, you can power up the programmer by pressing the Power key. A message will be displayed "No system detected".

8000 YRM 2428

DIAGNOSTICS AND MEASUREMENTS

Display The high-resolution clarity of the LCD screen allows a wealth of information to be displayed.

1 2

TIME AND DATA CONNECTION TO SYSTEM

3 4

ACCESS LEVEL 1313 BATTERY STATE-OFCHARGE

5 6

SOFTKEY TEXT ADDITION TEXT

Figure 48. Main Menu In Main Menu, highlight the System Info icon and press Select to display system information.

programmer can access data at its own level and the levels below it.

Pressing Go Offline allows you to use the programmer when it is not connected to a controller.

Access Level The handheld programmer provides four access levels: OEM, Dealer, Service, and User. A

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DIAGNOSTICS AND MEASUREMENTS

8000 YRM 2428

Key Functions The pushbutton keys on the programmer's keypad allow you to navigate easily through menus.

Figure 49. Keys •

•

92

Softkeys: These three softkeys are blank because their function is context-specific. At any given time, their function is shown directly above them on the LCD screen.

The symbol "»" indicates more options.

Pressing the softkey under the "»" will scroll to another set of options.

Arrow keys: With these four keys you can scroll up and down, and right and left, within the display. In the Main Menu, you can use the arrow keys to highlight one item, and then open the highlighted item using the Select softkey.

Within menus (other than the Main Menu), the left-arrow key is used to navigate backward, and the right-arrow key is used to navigate forwards, for example, to open highlighted submenus or items.

•

•

+/- keys: These two keys allow you to increase or decrease the value of parameter settings.

They also are used as "+ = Yes" and "- = No" buttons. In some cases, they are used to scroll through several options, for instance, when you select an access level or a language).

Power key: It is not necessary to use the Power key to turn on the programmer when you plug it into an active control system. The programmer will turn on automatically. To turn off the programmer, press and hold the Power key for a few seconds. You will then be asked whether you want to power off the programmer, and the softkey text will offer you the choices "Yes" and "No." If you have turned off the programmer, or if it has timed out and shut itself off, pressing the Power key will turn it on again.

8000 YRM 2428 •

•

DIAGNOSTICS AND MEASUREMENTS

Favourites: This key is an alternate way to bring up the Favourites menu. You can access the Favourites menu by highlighting its icon in the Main Menu, or by using the Favourites key.

See the Favourites menu section for more information.

Main Menu keyThis key will return you directly to the Main Menu, from wherever you are.

When the Main Menu is displayed, you can also

•

use this key to cycle through the individual menus. You can use either this key or the arrow keys to navigate within the Main Menu, whichever you prefer.

Help: This key is used to display contextspecific Help texts. It is a toggle key. You can press it again to close the Help text window. You can also close Help text windows with the "Exit" softkey or by pressing the left-arrow key.

ACCESS FAULT LOG IN CONTROLLER 1.

In Main Menu, highlight the Diagnostics icon and press Select to open the Diagnostics menu.

Figure 50. Main Menu In the Diagnostics menu, there are two folders: Present Errors and Fault History.

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DIAGNOSTICS AND MEASUREMENTS

8000 YRM 2428 Fault History folder This folder lists all the faults encountered since the Fault History was cleared. You can clear the entire contents of this folder to start a brand-new Fault History.

Figure 51. Diagnostic Menu NOTE: Sometimes the fault circuits catch a temporary event that is not a true fault in the system. It is always a good idea to turn off the control system and back on again to see whether the fault clears.

All existing faults are listed here in chronological order.

You can only remedy an fault to remove it from the folder. The 1/3 in the upper right corner of the screen means that Missing Contractor is the first of three present faults.

Figure 53. Fault History folder

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).

Figure 52. Present Errors folder

94

8000 YRM 2428

MAINTENANCE

MAINTENANCE OILS AND LUBRICANTS Application Oil for lubrication

Standard storage

Storage in cold room

•

Type Shell Tellus

Hydraulic circuit

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

•

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

Shell Albida Grease EP2 •

Aeroshell Grease 6 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.

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

Use only dry air at low pressure and a dry clean brush.

95

MAINTENANCE

8000 YRM 2428

SCHEDULED MAINTENANCE ●= check and maintenance

Maintenance

■= operator check x = replacement

Braking System

Frame

Operation description

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 mm and 0.8 mm.

■

every 200 hours 1 month

every 600 hrs 3 months

every 1200 hours 6 months

●

●

●

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

■

Replace the load wheels and bearings depending on their wear.

x

Steering Pull the rudder to make it pass Wheel between zones A and B. The brake makes an absorption sound.

■

Tiller seat and flexibility

■

Hydraulic Oil leaks in the pipes System Correct dosing of hydraulic oil

■

Oil leaks in the lifting cylinder

■

Filter cleaning

■

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

96

■ ● x

8000 YRM 2428

MAINTENANCE

●= check and maintenance

Maintenance

■= operator check x = replacement Operation description

every 50 hours 1 week

every 600 hrs 3 months

every 1200 hours 6 months

Polish the irregular contacts with abrasive paper

●

●

Replace in case of malfunctions

x

x

Carbon brush and commutator wear

●

Electrical Plug operation and faults System Key switch operation

every 200 hours 1 month ■ ■

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

●

Electrolyte capacity, liquid level check, distilled water

■

■

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

■

■

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

●

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

●

Reductio Replace the oil n Unit

x

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

97

MAINTENANCE

8000 YRM 2428

CONSUMABLES AND PARTS MAINTENANCE Items

Operation

Maintenance cycle

Wheel's bearings

Replace

1200 hours

Forklift's wheels

Replace

1200 hours

Seals

Replace

1200 hours

Gearbox

Replace grease

1000 hours

Hydraulic oil

Replace

1000 hours

High-pressure oil tube

Replace

2000 hours

Hydraulic tank's strainer mesh

Clean

1000 hours

Driving motor

Check carbon brush and bearings

1000 hours

Electric motor of oil pump

Check carbon brush and bearings

1000 hours

98

Remarks

Replace if damaged

Replace if damaged

8000 YRM 2428

MAINTENANCE

HOW TO MOVE A FAULTED FORKLIFT

Figure 54. Remove Brake 1.

With the hood cover removed, remove the screw (item 1) and the brake (item 2). At this time, drag the forklift to the maintenance or charging area by hands.

2.

Or use other means of transport (for instance, forklift and crane) to transport the forklift to the maintenance or charging area.

99

MAINTENANCE

8000 YRM 2428

HOW TO RAISE DRIVE/STEER TIRE

Figure 55. Putting Lift Tuck on Blocks-1

Figure 56. Putting Lift Tuck on Blocks-2

100

8000 YRM 2428

MAINTENANCE

Figure 57. Raise Lift Truck 1.

Put blocks on each side (front and back) of the loadwheels to prevent movement of the lift truck.

2.

Use a special low clearance hydraulic jack, crane, or another lift truck to raise the drive tire. Make sure that the jack, crane, or other lift truck has the correct capacity rating. The capacity must equal to 2/3 the weight of the lift truck, including the battery. See the capacity plate.

3.

Raise the lift truck only enough to suspend the drive tire. Install additional blocks under the frame near the drive tire.

101

Electrical Schematics by Controller and Battery Type MP20KUX (MP40KUX) [A7R0]

8000 YRM 2428

Electrical Schematics by Controller and Battery Type MP20KUX (MP40KUX) [A7R0]

102

8000 YRM 2428

Figure 58. Electrical Schematic - 1230 Controller with Lead-Acid Battery

103/(104 blank)

8000 YRM 2428

Figure 59. Electrical Schematic - 1232E Controller with Lithium-Ion Battery

105/(106 blank)

8000 YRM 2428

Figure 60. Electrical Schematic - AC0 Controller with Lead-Acid Battery

107/(108 blank)

8000 YRM 2428

Figure 61. Electrical Schematic - 1232E Controller with Lead-Acid Battery

109/(110 blank)

8000 YRM 2428

Figure 62. Electrical Schematic - AC0 Controller with Lithium-Ion Battery

111/(112 blank)

8000 YRM 2428

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