PDF DOWNLOAD: Yale A7R1 (MP20XUX) Forklift Service Manual

Part No.: 550224122

Revision: 1 (07/2020)

Technical information for Yale service centres

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

A7R1

MP20XUX

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

We therefore recommend that you read this manual carefully and keep it in a good condition so it is always decipherable and complete.

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

Product support group

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

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

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

INSTALLATION PROCEDURES For the installation procedures, carry out the reverse procedure for disassembly, observing any notes and information provided for correct truck operation.

2

SERVICE GENERAL SAFETY RULES PERSONAL SAFETY •

Always wear the personal protective equipment in situations requiring it.

•

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

•

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

•

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

•

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

SAFETY AT THE WORKPLACE •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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

•

Avoid twisting chains or metal ropes.

•

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

•

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

•

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

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

•

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

3

SERVICE •

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

•

Do not short-circuit the terminals.

•

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

•

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

•

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

•

Always disconnect the battery before working on the electrical system.

•

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

•

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

•

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

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE •

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

•

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

•

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

•

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

•

Always rest the load in the race of the hook.

•

Never load the tip of the hook.

•

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

•

Never do any lifting with the ropes and belts twisted.

•

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

•

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

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

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

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

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

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

• When the sling shows signs of overloading.

4

SERVICE Belt capacity table 45° Colour

Working load capacity (kg)

purple green yellow grey red brown blue

1000 2000 3000 4000 5000 6000 8000

2000 4000 6000 8000 10000 12000 16000

1400 2800 4200 5600 7000 8400 11200

800 1600 2400 3200 4000 4800 6400

orange

10000 12000

20000 24000

14000 16800

8000 9600

15000 20000 25000 30000

30000 40000 50000 60000

21000 28000 35000 42000

12000 16000 20000 24000

1

2

1.4

0.8

orange orange orange orange orange

Coefficient

Rope capacity table

Working load capacity (kg)

Colour

Width (mm)

black purple black green yellow grey red brown blue orange

35 50 50 60 75 120 150 180 240 300

500 1000 1500 2000 3000 4000 5000 6000 8000 10000

1000 2000 3000 4000 6000 8000 10000 12000 16000 20000

700 1400 2100 2800 4200 5600 7000 8400 11200 14000

400 800 1200 1600 2400 3200 4000 4800 6400 8000

1

2

1.4

0.8

Coefficient

Suspension element capacity table

Colour

Working load capacity (kg) Coefficient

purple green yellow grey red

1000 2000 3000 4000 5000

1400 2800 3800 5600 6600

2100 4200 6300 8400 9800

2100 4200 6300 8400 10500

1

1.4

2.1

2.1

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

5

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

Nominal diameter

To make the threaded matings secure, a threadlocking glue is used for tightening the screws.

If it is not possible to unscrew the bolts because this product has been used, avoid applying extensions to the tools, instead slightly heat the area (max. 50°C) so as to eliminate the thread-locking glue effect.

In the cases described, reapply the thread-locking glue during installation in a moderate quantity (30% of the mating surface).

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

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

TORQUE SETTING Nm Class 8

Class 10

M3

4

5.2

M4

7

9.15

M5

12.14

14.8

M6

17.2

20.9

M8

31.8

38.1

M 10

50.5

60.3

M 12

74.2

88.5

M 14

101.2

120.8

M 16

138.2

164.9

M 18

176.6

203.5

M 20

225.4

259.7

M 22

278.8

321.2

M 24

324.8

374.2

M 27

422.3

486.5

M 30

516.1

594.7

TORQUE SETTING Nm Pre-load N

Class 8.8

Class 10.9

mm

mm

mm

mm

M4

0.7

7

3

2400

1.92

1.44

3.07

2.3

4.17

3.13

M5

0.8

8

4

3880

3.88

2.91

6.2

4.65

8.43

6.33

M6

1

10

5

5490

6.58

4.94

10.5

7.9

14.3

10.8

M8

1.25

13

6

9990

16

12

25.6

19.2

34.8

26.1

M8

1

13

6

10700

17.1

12.8

27.4

20.5

37.3

27.9

M 10

1.5

16

8

15825

31.7

23.8

51

38

69

52

M 10

1.25

16

8

16700

33.4

25.1

53

40.1

73

55

M 12

1.75

18

10

23025

55

41.4

88

66

120

90

M 12

1.25

18

10

25150

60

45.3

96

72

130

98

M 14

2

21

12

31400

88

66

140

105

190

145

M 14

1.5

21

12

34125

96

72

155

115

210

155

M 16

2

24

14

42850

135

105

220

165

300

225

M 16

1.5

24

14

45600

145

110

235

175

320

240

M 20

2.5

30

17

66875

270

200

430

320

580

435

M 20

1.5

30

17

74250

295

225

475

355

650

485

= with lubricant

6

Class 5.8

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

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

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

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

TORQUE SETTINGS

UNF thread

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

UNF thread

FEMALE SWIVEL FITTING jic 37° Torque setting Nm Size

Nominal torque

min / max

M 12x1.5

6

20

15 -25

7/16-20

-4

15

9 - 21

M 14x1.5

8

38

30 - 45

1/2-20

-5

20

13 - 27

45

38 - 52

9/16-18

-6

30

18 - 42

3/4-16

-8

50

30 - 70

7/8-14

-10

69

44 - 94

1.1/16-12

-12

98

63 - 133

1.3/16-12

-14

118

73 - 163

1.5/16-12

-16

140

90 - 190

1.5/8-12

-20

210

135 - 285

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

8 10 10 12 12 14 15

51

43 - 85

58

50 - 65

74

60 - 88

M 24x1.5

16

74

60 - 88

1.7/8-12

-24

290

200 - 380

M 26x1.5

18

105

85 - 125

2.1/2-12

-32

450

300 - 600

135

115 - 155

166

140 - 192

30

240

210 - 270

35

290

255 - 325

330

280 - 380

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

UNF thread G1/4

20 22 25 28

38 42

BSP REVOLVING FEMALE Torque setting Nm

UNF thread

FEMALE ORFS SWIVEL FITTING Torque setting Nm Size

Nominal torque

max.

Nominal torque

max

20

15 - 25

9/16-18

-4

14

16

-6

24

27 47

G3/8

34

27 - 41

11/16-16

G1/2

60

42 - 76

13/16-16

-8

43

G5/8

69

44 - 94

1-14

-10

60

68

G3/4

115

95 - 135

1.3/16-12

-12

90

95

G1

140

115 - 165

1.3/16-12

-14

90

95

G1.1/4

210

140 - 280

1.7/16-12

-16

125

135

G1.1/2

290

215 - 365

1.11/16-12

-20

170

190

G2

400

300 - 500

2-12

-24

200

225

2-1/2-20

-32

460

490

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

7

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

• • • • • • •

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

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

Installation Avoid twisting the pipe, which could cause it to burst under pressure. There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assembled pipe decreases considerably when below the minimum radius of curvature. The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly greater length than the requirement in order to compensate for these changes.

8

SERVICE CONTENTS Introduction..........................................................................................10 Installation............................................................................................14 Diagnostics and measurements........................................................20 Electrical system.................................................................................46 Hydraulic system.................................................................................64 Truck base mechanics........................................................................72 Braking system....................................................................................88 Maintenance.........................................................................................90

9

INTRODUCTION

SERVICE

TRUCK PRESENTATION The MP20XUX platform pallet truck is battery powered with an electric drive motor. The forks are lifted by a DC motor and a hydraulic transmission system. The cylinders up and down movement allows the forks and the load to be lifted. Available in both mechanical steering and electric steering versions.

10

SERVICE

INTRODUCTION

TRUCK IDENTIFICATION DATA PLATES

The truck identification data plate is located on the side of the truck

• • • • • • • • • •

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

11

INTRODUCTION

SERVICE

GENERAL SPECIFICATIONS

MP20XUX

12

SERVICE

INTRODUCTION

Motor units

Performance

Wheels, frame

Weight

Characteristics

GENERAL SPECIFICATIONS 1.1

Manufacturer (initials)

1.2

Model designation

1.3

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

Battery

1.4

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

Standing

1.5

Rated capacity/rated load

Q (Kg)

2000 600

1.6

Load centre of gravity

c (mm)

1.8

Load distance from wheel axle to fork shoulder (1)

x (mm)

865

1.9

Wheelbase

y (mm)

1261

2.1

Service weight (with battery)

kg

710

2.2

Axle loading with load (front/rear)

kg

1300/1410

2.3

Axle loading without load (front/rear)

kg

3.1

Tyres: solid rubber, polyurethane, Vulkollan (front/rear)

3.2

Tyre size, front

ø (mm x mm)

250x70

3.3

Tyre size, rear

ø (mm x mm)

82x126

3.4

Additional wheels (dimensions)

ø (mm x mm)

127x57

3.5

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

3.6

Front track width

b 10 (mm)

490

3.7

Rear track width

b 11 (mm)

370/505

4.4

Lift height

h 3 (mm)

120 1070/1450

600/110 Polyamine

1x+2/2

4.9

Extended height in driving position, min/max

h 14 (mm)

4.15

Height with forks lowered

h 13 (mm)

82

4.19

Total length

l 1 (mm)

1760

4.20

Length to face of forks

l 2 (mm)

610

4.21

Overall width

b 1 (mm)

775

4.22

Fork size(14)

s/e/l (mm)

54x180x1150

4.25

Fork outer gauge (10)

b 5 (mm)

550/685

4.32

Ground clearance at wheelbase centre

m 2 (mm)

28

4.33

Aisle width with pallet 1000mm x 1200mm crossways

A st (mm)

1960

4.34

Aisle width with pallet 800mm x 1200mm crossways

A st (mm)

2010

4.35

Turning radius

W a (mm)

1600

5.1

Travel speed with/without load

km/h

6.7/7.1

5.2

Lifting speed laden/unladen

m/s

0,039/0,056

5.3

Lowering speed laden/unladen

m/s

0,064/0,050

5.7

Gradeability with/without load

%

6/12

5.8

Maximum gradeability with/without load

%

5.10

Service brake

8/20 Electromagnetic brake

6.1

Drive motor power

kW

1.2 (1.5)

6.2

Lifting motor power

kW

0.8 (1.2)

6.4

Battery voltage/capacity

(V)/(Ah)

24/210

6.5

Battery weight

kg

170

Battery size (L x w x h) Additional data

Yale MP20XUX

8.4

Sound pressure level at operator position DIN 12503

mm

dB (A)

750/170/534

70

13

INSTALLATION

SERVICE

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

INSTALLATION SHIPMENT PROCEDURE THE trucks must be suitably packaged to protect its parts, fixed on pallets in the vicinity of the forks and then loaded onto trucks for transport (fig.1). Once loaded on the truck, they are secured with a belt.

Fig. 1

14

SERVICE

INSTALLATION

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

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

Phase 2 Remove the packaging.

Attach the truck using the two lifting slings to the lifting attachments on the mast (fig.2) Ensure that the bridge crane is positioned vertically above the truck to be lifted.

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

15

INSTALLATION

SERVICE

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

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

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

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

Fig. 1

Fig. 2 16

SERVICE

INSTALLATION

Phase 3 When the battery is correctly positioned, lower the lever (fig.3).

Phase 4 Connect the battery to the battery connector, then replace the side door of the battery compartment (fig.4).

Fig. 3

Fig. 4

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

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

In order to safeguard the safety of people and materials, before proceeding with the following operations, it is recommended to check: the type of load to be handled and the general conditions of the warehouse, the aisles and the flooring 17

SERVICE

INSTALLATION

CHECKS TO BE CARRIED OUT BEFORE EVERY TIME THE TRUCK IS PUT INTO OPERATION After installing the battery and assembling any other components, it is mandatory to completely check the truck before starting it up.

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

Item

Controller

Check points Tiller

Check to see if a brake noise is heard when the tiller is rotated and changes from position A to position B.

Brake clearance

Check that the brake clearance is maintained between 0.2 and 0.8 mm.

Tiller

Check the tightening level and rotation flexibility.

Oil pipe

Check for leak.

Hydraulic oil

Check that the quantity of oil is adequate.

6

Lifting oil cylinder

Check for leak.

7

Pins, screws and all fastening devices

Check that all the wheel tightening devices screws and pins) are not loose.

8

State of wear

Check for wear and replace the wheel when its diameter is reduced by 5%.

9

Upload

Check the battery charge level on the display.

Electrolyte

Check the electrolyte level and density.

Connection line

Check the connections.

Horn

Press the horn to check its operation.

Operation

Turn on the truck and check if the instrumentation works normally and correctly.

Truck frame

Check that the truck has no breaks or is damaged in any way.

Operation

Check whether the lifting, lowering, forward, reverse and emergency reverse movements work properly.

Check that there are no anomalous noises.

1 Braking system 2 3

Steering

4 5

Hydraulic system

Wheels

10

Battery

11 12

Horn

13

Instrumentation

15 Other 16

18

Description

(e.g.

SERVICE

INSTALLATION

19

DIAGNOSTICS AND MEASUREMENTS

CONTROLLER DESCRIPTION DRIVE CONTROLLER 1232E - Mechanical steering / Electrical steering

35 23 12

20

24 13 1

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

KC1-1 Keyswitch power supply KC1-2 Not used KC1-3 Lowering solenoid valve coil negative KC1-4 Pump contactor coil negative KC1-5 Electromagnetic brake coil negative KC1-6 Main contactor coil negative KC1-7 Power supply negative reference - GND I/O KC1-8 Engine temperature sensor input KC1-9 Interlock KC1-10 Slow travel request KC1-11 Lifting request KC1-12 Descent request KC1-13 +24V coil power supply output KC1-14 Speed signal input 1 KC1-15 Not used KC1-16 Throttle potentiometer 0-5V power supply KC1-17 Not used KC1-18 Not used KC1-19 High speed limit KC1-20 Speed signal input 2 KC1-21 Can H termination KC1-22 Forward travel request KC1-23 Can High KC1-24 Emergency reverse request KC1-25 12V MDI power supply KC1-26 5V drive motor encoder output KC1-27 Not used KC1-28 Serial line transmission KC1-29 Serial line reception KC1-31 CH A encoder input KC1-32 CH B encoder input KC1-33 Reverse travel request KC1-34 Can L termination KC1-35 Can Low

21

DIAGNOSTICS AND MEASUREMENTS

EPS 1220 CONTROL DEVICE

J1(A)

J2(B) J3(C)

ELECTRIC STEERING ONLY

22

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

KC2-A1 Status Led KC2-A2 Phase A encoder KC2-A3 Not used KC2-A4 Not used KC2-A5 Safety steer KC2-A6 Steering potentiometer analog output KC2-A7 steering potentiometer and encoder 5V power supply KC2-A8 Can H KC2-A9 Phase B encoder KC2-A10 Encoder power supply negative reference - GND I/O KC2-A11 Not used KC2-A12 Can L KC2-A13 Not used KC2-A14 Steering potentiometer power supply negative reference - GND I/O KC2-B1 Serial line reception KC2-B2 I/O power supply negative reference KC2-B3 Serial line transmission KC2-B4 12V MDI power supply KC2-C1 Fault output KC2-C2 Home switch

23

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MENU Through the MONITOR MENU it is possible to access the truck operation data in real time. This information is useful during the diagnostic and troubleshooting phases and also during the parameters adjustment.

MONITOR MENU TRACTION CONTROLLER MAIN MENU MONITOR  Inputs PARAMETER THROTTLE COMMAND Angular displacement of the drive control butterfly THROTTLE MULTIPLIER Not used on this model MAPPED THROTTLE Angular displacement of the drive control butterfly evaluated after mapping THROTTLE POT Not used on this model BRAKE COMMAND Not used on this model MAPPED BRAKE Not used on this model POT2 RAW Not used on this model PD THROTTLE Not used on this model STEER POT Not used on this model STEER ANGLE (DEG) Not used on this model INTERLOCK Tiller status level: ON during activation EMER REV Emergency direction reversal level: ON during direction reversal ANALOG 1 Not used on this model

24

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ANALOG 2 Thermal sensor voltage sensor measured on input A8 SWITCH 1 Not used on this model SWITCH 2 Not used on this model SWITCH 3 Status level of the tiller measured on input 9 SWITCH 4 Not used on this model SWITCH 5 Optional steering sensor status level SWITCH 6 Not used on this model SWITCH 7 Belly switch status level measured on input 22 SWITCH 8 Not used on this model DRIVER 1 INPUT See the parameter main menu monitor / Outputs / Driver 1 PWM DRIVER 2 INPUT See the parameter main menu monitor / Outputs / Driver 2 PWM DRIVER 3 INPUT See the parameter main menu monitor / Outputs / Driver 3 PWM DRIVER 4 INPUT See the parameter main menu monitor / Outputs / Driver 4 PWM PD INPUT See the parameter main menu monitor / Outputs / PD PWM DIGOUT6 INPUT See the parameter main menu monitor / Outputs / Digital Out 6 DIGOUT7 INPUT See the parameter main menu monitor / Outputs / Digital Out 7 SWITCH 16 Status level of the optional lifting block sensor on input 14 25

DIAGNOSTICS AND MEASUREMENTS

MAIN MENU MONITOR  Outputs PARAMETER ANALOG OUT Not used on this model DIGITAL OUT 6 Not used on this model DIGITAL OUT 7 Not used on this model DRIVER 1 PWM Not used on this model DRIVER 2 PWM Not used on this model DRIVER 3 PWM Not used on this model DRIVER 4 PWM Not used on this model PD PWM Not used on this model PD CURRENT Measured current value 5 VOLTS Voltage measured on output 26 12 VOLTS Voltage measured on output 25 EXT SUPPLY CURRENT Current measured on outputs 25 - 26 POT LOW Not used on this model

26

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

MAIN MENU MONITOR  Battery PARAMETER BDI Battery charge level percentage CAPACITOR VOLTAGE Voltage at internal capacitor bank, measured at terminal B+ of the controller KEY SWITCH VOLTAGE Key switch voltage measured at input 1

MAIN MENU MONITOR  Motor PARAMETER MOTOR RPM Motor speed TEMPERATURE Motor temperature read by thermal sensor MOTORSPEED A Rpm of phase A of the motor encoder MOTORSPEED B Rpm of phase B of the motor encoder SIN INPUT A Not used on this model COS INPUT B Not used on this model ROTOR POSITION Position of the rotor

27

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MAIN MENU MONITOR  Controller PARAMETER CURRENT (RMS) Controller current draw MODULATION DEPTH Voltage percentage applied to the motor FREQUENCY Rotation frequency applied to the motor TEMPERATURE Controller internal temperature MAIN STATE General contactor status level: 0 = open 1 = pre-charge 2 = welds check 3 = closing delay 4 = missing check 5 = closed (with Main Enable parameter > ON) 6 = delay 7 = arch check 8 = opening delay 9 = error 10 = closed (with Main Enable > OFF parameter) REGEN ON during all phases of current regeneration MASTER TIMER Not used on this model VCL ERROR MODULE Software runtime error (code 68); information on the cause/s of the error are saved in the parameters VCL Error Module and VCL Error.

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

SPM AUTOCHAR STATUS Not used on this model MOTOR CHARACTERIZATION ERROR Motor characterization error.

PARAMETER MISMATCH ERROR Parameter mismatch error

28

SERVICE

DIAGNOSTICS AND MEASUREMENTS

SUPERVISION ERROR Not used on this model

MAIN MENU MONITOR  Cutbacks PARAMETER MOTOR TEMP CUTBACK Percentage of cutback during motor temperature reduction stage CONTROLLER TEMP CUTBACK Percentage of cutback during controller temperature reduction stage UNDERVOLTAGE CUTBACK Percentage of cutback during under-voltage reduction stage OVERVOLTAGE CUTBACK Percentage of cutback during over-voltage reduction stage

MAIN MENU MONITOR  Vehicle PARAMETER VEHICLE SPEED Speed of the truck VEHICLE ODOMETER Distance travelled in forward drive VEHICLE ACCELERATION Acceleration of the truck TIME TO SPEED 1 Time required to reach 0 km/h from a speed value pre-defined in the software TIME TO SPEED 2 Time required to reach 0 km/h from a speed value pre-defined in the software TIME BETWEEN SPEEDS Time taken to get from Speed ​1 to Speed ​​2 TIME TO DIST 1 Time taken to cover a pre-defined distance in the software TIME TO DIST 2 Time taken to cover a pre-defined distance in the software TIME TO DIST 3 Time taken to cover a pre-defined distance in the software 29

DIAGNOSTICS AND MEASUREMENTS

SERVICE

BRAKING DISTANCE CAPTURE Distance travelled during all phases of the braking action DISTANCE SINCE STOP Total distance travelled by the truck, calculated as the sum of distances travelled in both directions. This value is reset to zero each time the truck is stopped DISTANCE FINE Net distance travelled by the truck calculated as the sum of the distances travelled in the direction the operator is facing (positive value) and in the opposite direction (negative value).

MAIN MENU MONITOR  CAN Status PARAMETER CAN NODE ID Displays the Can node of the controller CAN NMT STATE Displays the of Can NMT status PDO1 MOSI BYTE MAP Not used on this model PDO1 MISO BYTE MAP Not used on this model PDO2 MOSI BYTE MAP Not used on this model PDO2 MISO BYTE MAP Not used on this model

30

SERVICE

DIAGNOSTICS AND MEASUREMENTS

MONITOR MENU STEERING CONTROLLER MONITOR MAIN MENU  Controller Input PARAMETER STEER COMMAND Operator steer command expressed as a percentage TARGET POSITION (DEG) Wheel position in degrees SPEED REQUEST Speed command calculated as a percentage COMMAND ANALOG 1 INPUT Analog 1 command input voltage

MAIN MENU MONITOR  Position feedback PARAMETER WHEEL POSITION (DEG) Wheel position in degrees STOP POSITION REACHED Indicates that the steering stop position has been reached ENCODER COUNTS FROM HOME Encoder count from centre position POSITION ANALOG 1 INPUT Analog 1 position feedback input voltage

MAIN MENU MONITOR  Voltage PARAMETER BATTERY VOLTAGE The battery voltage KEYSWITCH VOLTAGE Keyswitch voltage 5V OUT Voltage measured on 5V output 31

DIAGNOSTICS AND MEASUREMENTS

MAIN MENU MONITOR  Inputs and outputs PARAMETER MAIN DRIVER Status of the main relay driver FAULT OUTPUT Status of the fault output INTERLOCK SWITCH Status of the interlock switch HOME SWITCH Wheel centre position microswitch

MAIN MENU MONITOR  Controller PARAMETER TEMPERATURE Controller internal temperature MOTOR RPM Steering motor speed in rpm MOTOR CURRENT Steering motor current MOTOR TEMP CUTBACK Current reduction, as a percentage of maximum current, in case of motor overheating HOUR METER Hour meter

MAIN MENU MONITOR  Controller 

Status PARAMETER

INTERLOCK Interlock status TRACTION CONTROLLER CONNECTED Status of communication between steering controller and traction controller

32

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

MAIN MENU MONITOR 

Can Status PARAMETER

CAN NMT STATE Status of NMT controller 0 = initialisation 4 = stopped 5 = in operation 127 = pre-operation

MAIN MENU MONITOR 

From Traction Controller PARAMETER

TRACTION MOTOR RPM Indicates drive motor speed in rpm TRACTION IS READY Indicates that the traction controller is ready CAN INTERLOCK Indicates the interlock is activated

MAIN MENU MONITOR 

To Traction Controller PARAMETER

ENABLE TRACTION Indicates that steering controller enables the traction controller TRACTION CUTBACK Indicates that the steering controller enables a reduction in traction controller speed TRACTION FAULT ACTION Indicates that the steering controller triggers a fault in the traction controller 0 = no error 1 = drive stopped 2 = drive speed reduced 3 = no action

33

SERVICE

DIAGNOSTICS AND MEASUREMENTS TROUBLESHOOTING TRACTION CONTROLLER 1232E

The controller is equipped with two status LEDs: one red and one yellow. In the event of an emergency the LEDs flash cyclically in different ways to identify the different types of errors.

Refer to table below.

Message on the display

Meaning

The two LEDs are off

The controller is not powered. There is no electricity because of a battery or line fault

The yellow LED flashes

The control device is in operation

Both LEDs are on

The control software is updating

Both LEDs are flashing

The control device is faulty

DIAGNOSTICS The two LEDs installed on the control device (one red and one yellow) emit light codes that repeat all the errors set. Each code consists of two digits. The red LED flashes once to indicate that the first digit of the code will flash next; the yellow LED flashes an appropriate number of times to indicate the first digit. At this point the red LED flashes twice to indicate that the second digit will follow shortly; then the yellow LED flashes a number of times corresponding to the second digit.

Example: Battery Undervoltage (code 23) In the diagnostic tools Error Menu the words Undervoltage Cutback are displayed; the battery real-time voltage is displayed on the Monitor Menu ("Keyswitch Voltage").

The two LEDs of the control device repeat the following scheme: The numerical codes used by the yellow LED are listed in the Faults List table, which also lists possible causes of error and describes the conditions for which the alarm appears with a first troubleshooting.

RED

(First digit)

34

YELLOW

(2)

RED

YELLOW

(Second digit)

(3)

SERVICE

DIAGNOSTICS AND MEASUREMENTS

FAULTS LIST DRIVE CONTROL DEVICE 1232EE

Led Code

Console display message Fault effect

Possible Causes

Condition / solution

1.2

CONTROLLER OVERCURRENT • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

• Short circuit of the U, V, or W phases for motor connection.

• Motor parameter setting error • Control device fault.

The phase current has exceeded the current measurement limit.

Turn the key.

1.3

CURRENT SENSOR FAULT • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

• Leaks towards the trolley frame from the U, V, or W phase (short circuit in the stator) • Control device fault

The current sensors of the control device detect an invalid offset reading.

Turn the key.

PRECHARGED FAILED • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

• Refer to Monitor menu--> battery --> Capacitor Voltage • External load on the capacitor bank that prevents the capacitor bank from charging.

The pre-charge failed to recharge the capacitor bank.

Activate the interlock input or use VCL.

1.5

CONTROLLER SEVERE UNDERTEMP • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

• Refer to Monitor menu-> Controller --> Temperature • The control device is operating in an extreme environment.

Radiator temperature below -40°C. Return the radiator temperature above -40°C and activate the interlock or the key

1.6

CONTROLLER SEVERE OVERTEMP • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

1.4

• Refer to Monitor menu--> Controller --> Temperature • The control device is operating in an extreme environment.

• Truck overloaded.

Radiator temperature above + 95°C. Return the radiator temperature below +95°C and activate the interlock or the key

35

DIAGNOSTICS AND MEASUREMENTS

Led Code

Console display message

Possible Causes

Condition / solution

SEVERE UNDERVOLTAGE • Low operating torque

• The parameters in the Battery menu are not set correctly.

• The battery resistance is too high.

• The battery disconnected during operation.

• The fuse B1 has blown or the main contactor does not close.

• Refer to: Monitor menu -->Battery->Capacitor Voltage.

The capacitor bank voltage has dropped below the critical undervoltage limit with FET bridge enabled.

Return the capacitor voltage above the critical undervoltage limit.

SEVERE OVERVOLTAGE • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

• The parameters in the Battery menu are not set correctly.

• The battery resistance too high for the regenerative current supplied.

• The battery disconnected during regenerative braking.

• Refer to: Monitor menu --> Battery-->Capacitor Voltage.

The capacitor bank voltage has risen over the critical overvoltage limit with FET bridge enabled.

Return the capacitor voltage below the critical overvoltage limit.

CONTROLLER UNDERTEMP CUTBACK • Operating and braking torque reduction • VCL language in error in case the control device fails to start.

• Refer to Monitor menu --> Controller--> Temperature • The control device is operating in very limited conditions.

Radiator temperature below -30°C. Increase the temperature.

CONTROLLER OVERTEMP CUTBACK • Operating and braking torque reduction

• Refer to Monitor menu--> Controller --> Temperature • The control device is operating in an extreme environment • Excessive load on the truck • Control device incorrect assembly

Radiator temperature above + +85°C. Return the radiator temperature below +85°C.

UNDERVOLTAGE CUTBACK • Operating torque reduction

• The battery is flat • The battery parameters are not set correctly • The battery resistance is too high • The battery disconnected during operation • The fuse has blown or the main contactor does not close.

• Refer to Monitor menu -->Battery-->Capacitor Voltage.

The voltage of the capacitor bank has fallen below the undervoltage threshold. Return the voltage to above the undervoltage limit.

Fault effect

1.7

1.8

2.1

2.2

2.3

36

SERVICE

SERVICE LED Code

DIAGNOSTICS AND MEASUREMENTS

Console display message

Possible Causes

Condition / solution

OVERVOLTAGE LEADING TO PERFORMANCE CUTBACK • Reduced regenerative braking torque

• The regenerative braking current increases the battery voltage • The battery parameters are not set correctly.

• The internal resistance of the battery is too high.

• The battery disconnected during the regenerative braking.

• Refer to Monitor menu -->Battery-->Capacitor Voltage.

The capacitor bank voltage has risen over the overvoltage limit.

Return the capacitor bank voltage below the overvoltage limit.

+5 V SUPPLY FAILURE

• The external impedance value on the +5V power supply is too low.

• Refer to: Monitor Menu --> Outputs--> 5Volts and Ext Supply Current

The +5V power supply (PIN 26) is outside the +5V ± 10% range.

Keep the voltage within range.

2.6

DIGITAL OUT 6 OVERCURRENT • The digital output driver 6 is not active.

• The external impedance value on the driver of digital output 6 is too low.

The current on digital output 6 (PIN 19) is greater than 15 mA. Resolve the cause of the overcurrent and use the VCL function to enable the driver again.

2.7

DIGITAL OUT 7 OVERCURRENT • The digital output driver 7 is not active.

• The external impedance value on the driver of digital output 7 is too low.

The current on digital output 7 (PIN 20) is greater than 15 mA. Resolve the cause of the overcurrent and use the VCL function to enable the driver again.

MOTOR TEMP HOT CUTBACK • Operating torque reduction

• The motor temperature is equal to or higher than the programmed "Temperature Hot" setting and the current is decreased.

• The "Motor Temperature Control Menu" parameters are not set correctly.

• Refer to: Monitor menu --> Motor --> Temperature and --> Inputs.

Analog 2.

• If the application does not use a motor thermistor, temperature compensation and Temp Cutback should be set to off.

The voltage of the motor is 0 or above 10V. Keep the engine temperature within the range.

Fault effect

2.4

2.5

2.8

37

DIAGNOSTICS AND MEASUREMENTS

LED Code

Console display message

SERVICE

Possible Causes

Condition / solution

MOTOR TEMP SENSOR FAULT • Reduced MaxSpeed

• The motor thermistor is not connected correctly.

• If there is no "Motor Temp Sensor" thermistor it should be set to OFF.

The motor thermistor input has a voltage value at the outer limits of the permissible range (0V or 10V).

Return the motor thermistor input voltage within the permitted range.

COIL 1 DRIVER OPEN/SHORT • Driver 1 disable

• Driver load open or short-circuited.

• Connector pins are dirty.

• Wiring problems.

Driver 1 (PIN 6) could be open or short-circuited; solve the problem and reactivate the driver.

MAIN OPEN/SHORT • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped

• Driver load open or short-circuited.

• Connector pins are dirty.

• Wiring problems.

The main contactor driver (PIN 6) could be open or short-circuited; solve the problem and reactivate the driver.

COIL2 DRIVER OPEN/SHORT • Driver 2 disable

• Driver load open or short-circuited.

• Connector pins are dirty.

• Wiring problems.

Driver 2 (PIN 5) could be open or short-circuited; solve the problem and reactivate the driver.

ELECTROMAGNETIC BRAKE COIL OPEN/SHORT CIRCUIT • Electromagnetic brake operation stopped • Acceleration stopped

• Driver load open or short-circuited.

• Connector pins are dirty.

• Wiring problems.

The electromagnetic brake driver (PIN 5) could be open or shortcircuited; solve the problem and reactivate the driver.

COIL3 DRIVER OPEN/SHORT • Driver 3 disable

• Driver load open or short-circuited.

• Connector pins are dirty.

• Wiring problems.

Driver 3 (PIN 4) could be open or short-circuited; solve the problem and reactivate the driver.

COIL4 DRIVER OPEN/SHORT • Driver 4 disable

• Driver load open or short-circuited.

• Connector pins are dirty.

• Wiring problems.

Driver 4 (PIN 3) could be open or short-circuited; solve the problem and reactivate the driver.

PD OPEN/SHORT • PD stop

• Driver load open or short-circuited.

• Connector pins are dirty.

• Wiring problems.

The proportional driver (PIN 2) could be open or shortcircuited; solve the problem and reactivate the driver.

ENCODER FAULT • Electromagnetic brake stop • Acceleration stopped

• Motor encoder fault • Connector pins are dirty • Refer to Monitor Menu --> Motor RPM.

Fault detected in the motor encoder phase. Reactivate the key switch.

MOTOR OPEN • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

• The motor phase is open.

• The wires are damaged or are not connected correctly.

The motor phases U, V or W are open.

Check the phases and turn on the keyswitch again.

Fault effect

2.9

3.1

3.1

3.2

3.2

3.3

3.4

3.5

3.6

3.7

38

SERVICE LED Code

3.8

3.9

DIAGNOSTICS AND MEASUREMENTS

Console display message

Possible Causes

Condition / solution

MAIN CONTACTOR WELDED • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

• The contactor contacts are stuck.

• Incorrect connection of the U or V phase of the motor power supply or open circuit.

• Circuit connected to B+ terminal for the capacitors

Just before the main contactor closing, the capacitor bank voltage was charged for a short time and the voltage was not discharged.

Reactivate the key switch.

MAIN CONTACTOR DID NOT CLOSE • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped

• The general remote-control switch doesn't close • The contactor contacts are oxidized, burned or do not make contact.

• Presence of an external load on the capacitor bank which prevents it from charging • B+ fuse blown

With the main contactor closed, the capacitor bank voltage did not load B+.

Reactivate the key switch.

THROTTLE WIPER HIGH • Acceleration stopped

• Refer to: Monitor menu --> inputs --> Throttle Pot. • Throttle potentiometer cable voltage too high.

The voltage of the throttle potentiometer cable (PIN 16) is greater than the limit threshold. Return the throttle potentiometer cable voltage below the limit threshold.

THROTTLE WIPER LOW • Acceleration stopped

• Refer to: Monitor menu --> inputs --> Throttle Pot. • Throttle potentiometer cable voltage too low.

The voltage of the throttle potentiometer cable (PIN 16) is lower than the limit threshold. Return the throttle potentiometer cable voltage above the limit threshold.

BRAKE WIPER HIGH • Full braking force

• Refer to: Monitor menu --> inputs --> Brake Pot • Brake potentiometer cable voltage too high.

The voltage of the brake potentiometer cable (PIN 17) is greater than the limit threshold.

Return the brake potentiometer cable voltage below the limit threshold.

BRAKE WIPER LOW • Full braking force

• Refer to: Monitor menu --> inputs --> Brake Pot • Brake potentiometer cable voltage too low.

The voltage of the brake potentiometer cable (PIN 17) is lower than the limit threshold. Return the brake potentiometer cable voltage above the limit threshold.

POT LOW OVERCURRENT • Acceleration stopped • Full braking force

• Refer to: Monitor menu --> outputs --> Pot Low • The combined resistance of the potentiometer connected with the pot low is too low.

The Pot Low current (PIN 18) exceeds 10mA. Resolve the overcurrent condition and activate the key.

EEPROM FAILURE • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Interlock stop • Driver 1 - 2 - 3 - 4 stop • PD stop • Pump stopped • Full braking force

• Transcription error on EEPROM memory. The error could be caused by VCL, CAN bus, parameter adjustment by programmer or by loading a new software on the control device.

The control device cannot write to the EEPROM memory. Download the correct software and connect the default parameter settings in the control device then activate the key.

Fault effect

4.1

4.2

4.3

4.4

4.5

4.6

39

DIAGNOSTICS AND MEASUREMENTS

LED Code

4.9

6.8

Console display message Fault effect

7.2

7.3

40

Condition / solution

PARAMETER CHANGE FAULT • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped • Brake

• To safeguard the truck, any Request to restart the truck. modifications to certain parameters Restart the truck. will only take effect after the truck has been restarted

VCL RUNTIME ERROR • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Interlock stop • Driver 1 - 2 - 3 - 4 stop • PD stop • Pump stopped • Brakes

• VCL code runtime error.

• Refer to: Monitor menu --> controller --> VCL error module and VCL error.

Change the error condition of the VCL code to resolve the error condition, launch the new software and connect the default parameter values.

Reactivate the key switch.

EXTERNAL SUPPLY OUT OF RANGE

• The external load on the 5V and 12V power supplies receives too much or too little current.

• The Ext Supply Max and Ext supply Min parameters are not set correctly • Refer to: Monitor menu --> Outputs --> Ext Supply Current

The external power supply current (combined current used by 5V power supply [PIN 26] and 12V power supply [PIN 25]) is greater than the upper and the lower current threshold limit compare to the lower current threshold. The thresholds are defined through the External Supply Max and External Supply Min. parameters Return the external power supply current within the limits.

OS GENERAL • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Interlock stop • Driver 1 - 2 - 3 - 4 stop • PD stop • Pump stopped • Brakes

• Internal fault in the control device.

Detection of a fault inside the control device.

Reactivate the key switch.

PDO TIMEOUT • Interlock stop • CAN NMT is set to “preoperational”

• The time between received CAN PDO messages exceeds the PDO Timeout interval.

The time between received CAN PDO messages exceeds the PDO Timeout interval.

Reactivate the key switch and receive the CAN NMT message.

STALL DETECTED • Electromagnetic brake stop • Control mode converted to LOS (limited operation strategy)

• Motor Stalled • Motor encoder fault • Faulty wiring • Problems with the power supply for the motor encoder • Refer to: Monitor menu --> Motor -->Motor RPM

No motor encoder movement detected.

Reactivate the key or detect valid motor encoder signals during the operation in LOS mode and set Throttle Command = 0 and Motor RPM = 0.

6.9

7.1

Possible Causes

SERVICE

SERVICE LED Code

DIAGNOSTICS AND MEASUREMENTS

Console display message

Possible Causes

Condition / solution

MOTOR CHARACTERIZATION FAULT • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped • Brakes

• The motor characterization failed during the characterization process. Refer to: Monitor menu --> Controller -->Motor Characterization Error to determine the cause: 0 = none 1 = encoder signal detected, but step size not determined: set the Encoder Step Size manually 2 = motor temperature sensor fault 3 = cutback fault for high motor temperature 4 = cutback fault for control device overtemperature 5 = Cutback fault for control device undertemperature 6 = Cutback fault undervoltage 7 = Critical overvoltage fault 8 = encoder signal not detected; one or both channels missing 9 = The motor parameters are out of the characterization range.

The motor characterization failed during the characterization process.

Solve the problem.

Reactivate the key switch.

• The Encoder Steps parameter does not correspond to the present motor encoder.

8.8

ENCODER CHARACTERIZATION FAULT • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped • Brakes

The encoder characteristics are incorrect.

The frequency of the pulses of the motor encoder is a non-standard value (32, 48, 64, 80 ppr)

• The Motor_Type parameter value is out of range.

8.9

MOTOR TYPE FAULT • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped • Brakes

The Motor_Type parameter is set to an invalid value.

Set the Motor_Type value correctly and reactivate the key.

• The VCL programme of the controller and the OS programme do not match

Update the VCL and OS programmes

9.1

VCL/OS MISMATCH • Motor operation stopped • Contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Interlock stop • Driver 1 - 2 - 3 - 4 stop • PD stop • Pump stopped • Brakes

Fault effect

8.7

41

DIAGNOSTICS AND MEASUREMENTS

LED Code

9.2

Console display message

Possible Causes

Condition / solution

EM BRAKE FAILED TO SET • Electromagnetic brake operation stopped • Acceleration stopped

• A movement of the truck is perceived after enabling the electromagnetic brake.

• The electromagnetic brake is not able to stop the motor rotation.

After enabling the electromagnetic brake and after a sufficient time has passed to allow complete activation of the brake, a movement of the truck is still perceived.

Activate the throttle.

ENCODER LOS (Limited Operating Strategy) • Enter the LOS control mode

• The LOS control mode has been activated, as a result of both an Encoder Fault and a Stall Detect Fault • Motor encoder fault • Wiring problems • The truck is stalled

Encoder Fault or Stall Detect Fault has been activated and the brake or the interlock has been enabled to activate the LOS control mode, which allows to limit the motor control.

Reactivate the key switch.

EMER REV TIMEOUT • Electromagnetic brake operation stopped • Acceleration stopped

•

The emergency reverse has been activated and has ended because the EMR timeout has passed The emergency reverse input is blocked

The emergency reverse was activated and operated until the EMR Timeout passed.

Disable the emergency reverse input.

ILLEGAL MODEL NUMBER • Motor operation stopped • Main contactor operation stopped • Electromagnetic brake operation stopped • Acceleration stopped • Pump stopped • Brakes

•

The controller model cannot be identified.

The versions of the software and hardware do not match.

The controller is damaged.

Select the correct controller and download the right version of the software.

Fault effect

9.3

9.4

9.8

42

SERVICE

•

• •

SERVICE

DIAGNOSTICS AND MEASUREMENTS

FAULTS LIST EPS 1220 CONTROLLER Code

Console display message

14

15

16

• Short circuit of steering motor connections • Control device fault

Restart the truck.

CURRENT SENSOR FAULT

• Control device fault

Restart the truck.

PRECHARGE FAULT

• Control device fault

Restart the truck.

CONTROLLER SEVERE UNDERTEMP

• The controller is operating in a temperature below the recommended lower limit • Temperature sensor damaged

Restore an operating temperature above -35°C.

CONTROLLER SEVERE OVERTEMP

• Truck overload • The controller is operating in overtemperature condition • Incorrect fixing of controller

Switch off the truck, wait until the temperature of the controller falls and then restart the truck.

SEVERE UNDERVOL

• Fault in the battery or battery connections.

• Another load is connected to the battery.

• Battery flat or incorrect battery model.

Restart the truck.

SEVERE OVERVOL

• The battery resistance is too high during regenerative braking.

• The battery cable was disconnected during regenerative braking.

Restart the truck.

MOTOR OVERTEMP CUTBACK

• Truck overloaded • The controller is operating at extremely high temperatures

Reduce the motor temperature to within the normal range.

CONTROLLER OVERTEMPERATURE

• Truck overload • The controller is operating in overtemperature condition • Incorrect fixing of controller

Reduce the temperature of the controller to 85°C.

MOTOR POLARITY FAULT

• Incorrect motor polarity • Incorrect polarity of position feedback device

Restart the truck.

MAIN CONTACTOR FAULT

• Internal coil of relay damaged • Internal coil of relay open/short circuit

Check the main contactor

RELAY WELDED

• Internal relay stuck • Controller fault

Switch the truck off and then on again; if the problem persists, replace the controller.

RELAY NOT CLOSE

• The relay receives the command but does not close.

• The sheaths of the internal relay are oxidised.

Switch the truck off and then on again; if the problem persists, replace the controller.

HARDWARE FAULT

• Fault detected in the hardware • Motor voltage outside normal range • IIC communication failure • Short circuit of power supply wiring

Check the wiring and the connections

17

18

21

22

23

31

32

33

34

Solution

CONTROLLER OVERCURRENT 12

13

Possible Causes

43

DIAGNOSTICS AND MEASUREMENTS

Code

Console display message

Possible Causes

SERVICE Solution

FAULT OUTPUT FAILURE

• Connection of output cable • Control device fault

Check the wiring and the connections; if no problems are found and the fault persists, replace the controller

MOTOR LOCKED ROTOR

• Rotor of the motor stuck • Steering motor encoder fault • Steering motor cable disconnected • Mismatch between the parameter and the motor

Check the motor rotor. Check the steering motor encoder. Check the motor cable. Check match between the parameter and the motor.

MOTOR OPEN CIRCUIT

• Steering motor cable • Steering motor connection cable fault • Controller fault

Check the steering motor cable.

Check the motor connection cable.

Check the controller.

MOTOR SHORT

• Steering motor cable short circuit

Check the steering motor cable.

ANALOGUE COMMAND OUT OF RANGE

• Input J1-6 outside range • Input J1-14 outside range

Check the steering potentiometer and its connection.

PARAMETER CHANGE FAULT

• Parameter modified; restart • Parameter restored to default setting

Switch the truck off and then on again; if the problem persists, replace the controller.

STORAGE FAULT

• Memory parameters incorrect count • Controller fault

Switch the truck off and then on again; if the problem persists, replace the controller.

ENCODER FAULT

• Steering motor encoder fault

Check the supply voltage and connections of the steering motor encoder.

HOME NOT LOCATED

• Home switch fault • Incorrect installation or wiring of cable

Check the home switch. Check that the cable is installed and wired correctly.

COMMUNICATION MISSING

• RX J1-8 connection cable fault • A manual programmer is connected to the traction controller

Check the connection on pin J1-8.

Disconnect the programmer from the traction controller

SOFTWARE FAULT

• Software fault • Controller fault

Switch the truck off and then on again; if the problem persists, replace the controller.

FOLLOWING FAULT

• Incorrect parameter setting • Feedback device fault • Steering motor fault

Check that the parameter settings are correct. Check the feedback device and the steering motor.

PARAMETER CONFLICT

• Conflict between settings of two or more parameters

If some parameter settings have been changed, restore previous values. If no parameters have been changed, switch the truck off and on again; if problem persists

35

36

37

38

41-4243

45

46

47

53

62

71

73

75

44

SERVICE

DIAGNOSTICS AND MEASUREMENTS

MOTORS To measure the motor insulation resistance, disconnect the phase wires (U, V, W). Connect one of the tester probes to the U phase and the other probe to the bodywork in an unpainted zone. The resistance reading (W) on the tester should be infinity (~). Otherwise, the motor is not insulated and must be replaced immediately.

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

45

ELECTRICAL SYSTEM

WIRING DIAGRAMS electric steering Ref.

46

Description

KC1

Traction controller

KC2

Steering controller

WK

Tiller board

M1

Drive motor 1.5 kW

M2

Pump motor 1.2 kW

M3

Steering motor 0.4 kW

K1

Emergency switch

K2

Keyswitch

K3

Interlock

K4

Wheel switch

KM1

Main contactor

KM2

Pump contactor

L

Electromagnetic brake

L1

Lowering solenoid valve

SERVICE

SERVICE

ELECTRICAL SYSTEM

47

ELECTRICAL SYSTEM

WIRING DIAGRAMS mechanical steering Ref.

48

Description

KC

Traction controller

WK

Tiller board

M1

Drive motor 1.5 kW

M2

Pump motor 1.2 kW

K1

Emergency switch

K2

Keyswitch

K3

Interlock

KM1

Main contactor

KM2

Pump contactor

L

Electromagnetic brake

L1

Lowering solenoid valve

SERVICE

SERVICE

ELECTRICAL SYSTEM

49

ELECTRICAL SYSTEM

TRUCK COMPONENTS

SERVICE 12

Electric steering 1

11

10

2 3

9

4 5 8

6

7

Ref.

50

Description

1

Drive / pump controller

2

Electromagnetic brake

3

Steering controller

4

Horn

5

Drive motor encoder

6

Drive motor

7

Steering reduction unit gear

8

Steering Gear

9

Hydraulic Pump

10

Steering motor

11

Steering motor encoder

12

Lifiing travel limit microswitch

SERVICE

ELECTRICAL SYSTEM

TRUCK COMPONENTS Mechanical steering

6

4

1

2 5 3

Ref.

Description

1

Drive / pump controller

2

On board charger

3

Drive motor

4

Pump motor

5

Suspension

6

Electromagnetic brake

51

SERVICE

ELECTRICAL SYSTEM

CONTROLS KEY TO TILLER CONTROLS AND MAIN PANEL

5

3

6

4

1

2 8

7

Ref.

52

Description

1

Horn button

2

Forks raise/lower ON/OFF push button

3

Forks raise/lower ON/OFF push button

4

Creep Speed enable button

5

Emergency reversal button

6

Forward/reverse drive control throttle

7

Battery charge level indicator

8

Side guards electric lock

SERVICE

ELECTRICAL SYSTEM

TRUCK FUNCTIONS FORWARD/REVERSE DRIVE ACTUATION CONTROLS

Forward travel (operator side)

Actuators involved

Reverse travel (fork side)

Status

Key switch

ON

Emergency switch

ON

Tiller tilt sensor

ON*

Forward/reverse drive control throttle

forward/reverse rotation

* OFF when the "snail" button is pressed

53

ELECTRICAL SYSTEM

SERVICE

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

Release braking.

Braking on direction reversal.

Emergency braking.

Parking brake.

BRAKING SYSTEM

WHEN DOES IT COME INTO OPERATION?

Release braking

Release of the butterfly drive control

Braking on direction reversal

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

Emergency braking

Parking brake

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

EMERGENCY REVERSE MANOEUVRE The emergency reverse manoeuvre is a safety function that is applied in the event that the operator, when driving forwards (direction of the drive wheel), hits an object. In this event, pressing the “EMERGENCY REVERSE” button (ref.A fig.1) causes the truck to immediately reverse, thereby preventing the operator from being crushed.

SNAIL FUNCTION The "snail" function enables drive even when the tiller is in the rest position (tiller sensor not active). This allows the operator to drive the truck even when there is not enough room to lower the tiller. The "snail" function is activated by pressing the button on the tiller head (ref. B fig.1). Once the "snail" button is pressed, the drive request is performed by the potentiometric throttle

54

B

Fig. 1

A

SERVICE

ELECTRICAL SYSTEM

STEERING ACTUATION CONTROLS

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

Actuators involved

status

Key switch

ON

Emergency switch

ON

Tiller sensor

ON

Tiller rotation

right/left rotation

55

SERVICE

ELECTRICAL SYSTEM FORKS RAISE/LOWER ACTUATION CONTROLS

A

B

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

Actuators involved Key switch

ON

Emergency switch

ON

Fork lifting/lowering

ON-OFF button lifting/ lowering active

Tiller sensor *Only in the case of fork lowering

56

status

ON*

SERVICE

ELECTRICAL SYSTEM

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

control of the 1.5 KW AC motor control for the 3 KW hydraulic pump CanBus interface alarms performance

Technical specifications: Inverter for asynchronous three phase AC motors and chopper for DC pump motors Digital control via microcontroller Voltage:.........................................................................................24V Inverter maximum current (24V):...................................................250A (RMS) for 2’ Outside temperature limits............................................................-40°C to 50°C

57

ELECTRICAL SYSTEM

SERVICE

STEERING The module has been designed to perform all the electrical functions normally present on the truck: • • •

control for the 0.4 KW steering motor alarms performance

Technical specifications: Digital control via microcontroller Voltage:.........................................................................................24V Inverter maximum current (24V):...................................................40A (RMS) for 2’ Outside temperature limits............................................................-40°C to 50°C

58

SERVICE

ELECTRICAL SYSTEM

CONTROL DEVICE PARAMETERS STANDARD CONFIGURATION 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 to suit the customer's requirements, the characteristics of the warehouse and the materials to be moved, but no parameters must be changed if this jeopardises the safety of the truck.

CONTROLLER 1232E Mechanical steering / Electric steering 1232E / program menu / battery MENU BATTERY PARAMETER

Default

RESET VOLTS PER CELL

2.11 V

FULL VOLTS PER CELL

2.03 V

EMPTY VOLTS PER CELL

1.72 V

DISCHARGE TIME

60 min.

BDI RESET PERCENT

75%

PARAMETER RESET VOLTS PER CELL

min.

max.

0.9 sec

3 sec

0.9 sec

3 sec

0.9 sec

3 sec

0 sec

600 sec

0 sec

100 sec

Defines the voltage value per cell necessary to reset the BDI FULL VOLTS PER CELL Defines the voltage value per cell corresponding to 100% BDI EMPTY VOLTS PER CELL Defines the voltage value per cell corresponding to 0% BDI DISCHARGE TIME Defines the minimum time for BDI counting from 100% to 0% BDI RESET PERCENT Defines the minimum value that the BDI must have reached to be reset

59

SERVICE

ELECTRICAL SYSTEM TILLER HEAD KEY TO TILLER HEAD COMPONENTS

Pos.

60

Description

Pos.

Description

1

Horn

13

Right grip

2

Screw 2.9X6.5

14

Left grip

3

Microswitch clip insert

15

Throttle control - Curtis assembly

4

Spring for spring button

16

Screw M4X12

5

Microswitch

17

Washer 4 gasket

6

Upper cover group

18

Ring 1 bushing support

7

Spring gasket

19

Ring 2 bushing support

8

Emergency reverse button cover

20

Upper and lower part cover

9

Right button

21

Screw M5X35

10

Left button

22

Bolt M5X50

11

Screw M3X12

23

Reduced speed button

12

Locking washer 3

24

Wire harness

SERVICE

ELECTRICAL SYSTEM

BUTTONS KEY TO BUTTONS ASSEMBLY COMPONENTS

Pos. 1

Description Left Cover Right Cover

2

Pin

3

Spring button

4

Left button Right button

5

Microswitch

6

Screw 2.2X12

61

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC FUNCTIONS • •

Forks lifting Forks lowering

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

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

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

62

SERVICE

HYDRAULIC SYSTEM

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

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

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

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

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

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

They are essentially comprised of a fixed part connected to the end of the pipe; in the appropriate inner housing runs the moving element which might be a bearing or a conical plug.

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

63

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM SYMBOLS TWO POSITION SOLENOID VALVE

FILTER

64

THREE POSITION SOLENOID VALVE

ONE-WAY VALVE

DOUBLE ACTING CYLINDER

PROPORTIONAL VALVE

SINGLE ACTING CYLINDER

PUMP

TANK

HYDRAULIC MOTOR

LINE CONNECTION

ELECTRIC MOTOR

PRESSURE RELIEF VALVE

FLOW VALVE

MANUAL COCK

BY-PASS VALVE

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM

65

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS BY FUNCTION •

Forks lifting

•

Forks lowering

•

Oil release through the pressure relief valve

lowering solenoid valve proportional

SOLENOID VALVE OPERATION CHART Function

Pump

B203

Forks lifting

P

-

Slow fork lowering

-

+

Oil release through the pressure relief valve

P

-

pressure relief valve

P = pump in operation + = solenoid valve coil energised Pressure calibration screw

66

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR FORK LIFTING

67

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR FORK LOWERING

68

SERVICE

SERVICE

HYDRAULIC SYSTEM

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

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

69

HYDRAULIC SYSTEM

SERVICE

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

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

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

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

A B

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

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

70

Fig. 1

SERVICE

HYDRAULIC SYSTEM

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

Pos.

Description

Pos.

Description

1

Rod

7

Cylinder

2

Gasket housing bushing

8

Piston

3

O-Ring 35.5X2.65

9

Back-up ring

4

O-Ring 40X3.1

10

Thrust washer

5

Seal ring

11

Bearing

6

Rod ends

12

Ring 20 71

TRUCK BASE MECHANICS

DRIVE WHEEL AND REDUCTION GEAR KEY TO COMPONENTS OF THE DRIVE WHEEL

5 6

3 2

4 1

72

SERVICE

SERVICE

TRUCK BASE MECHANICS

Ref.

Description

1

Screws M24

2

Screws M6X20

3

Nut

4

Drive wheel

5

Shaft

6

Reduction unit

73

TRUCK BASE MECHANICS

CASTOR WHEEL ASSEMBLY KEY TO CASTOR WHEEL ASSEMBLY COMPONENTS

74

SERVICE

SERVICE

TRUCK BASE MECHANICS

Pos.

Description

1

Screw M12x100

2

M12 nut

3

Dust cover

4

Locking ring

5

M24 nut

6

Washer

7

O Ring

8

Roller bearing

9

Bearing housing

10

Bearing

11

O-ring

12

Rotating plate assembly

13

Tire Assy

14

Bearing

15

Screw M16

16

Bushing

17

Bearing

18

Wheel

19

Nut

20

Shaft

21

Screw M12

22

Lock nut M6

23

Adjustable shaft

24

Screw M6

75

SERVICE

TRUCK BASE MECHANICS

REMOVAL AND DISASSEMBLY OF THE CASTOR WHEEL ASSEMBLY Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians.

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

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

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

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

Proceed with replacement.

A

A

Fig. 1

76

A

SERVICE

TRUCK BASE MECHANICS

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

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

Proceed with replacement.

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

Proceed with replacement.

Fig. 2

E

C D

E

D

B

77

TRUCK BASE MECHANICS LOAD WHEELS KEY TO COMPONENTS OF THE LOAD WHEELS

Pos.

78

Description

1

Bearing

2

Wheel

3

Circlip

4

Pin

5

Rocker arm

SERVICE

SERVICE

TRUCK BASE MECHANICS

LOAD WHEEL REMOVAL AND DISASSEMBLY Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians.

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

Turn the keyswitch to OFF and disconnect the battery.

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

A

Fig. 1

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

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

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

Proceed with replacement.

E C E

D

B Fig. 2

79

SERVICE

TRUCK BASE MECHANICS FOOTBOARD KEY TO FOOTBOARD COMPONENTS

Pos.

80

Description

Pos.

Description

1

Bracket

11

Locking screw

2

Rubber floor mat

12

Pin

3

Footboard

13

Flat washer

4

Pin

14

Pin

5

Gas spring

15

Circlip

6

Platform support bracket

16

Bush

7

Shaft

17

Retaining button

8

Washer

18

Screw

9

Spring pin

19

Magnetic Ring

10

Spacer

SERVICE

TRUCK BASE MECHANICS

SIDE PANELS KEY TO SIDE PANEL COMPONENTS

Pos.

Description

Pos.

Description

1

Side panel assembly support

8

Left arm / side panel assembly

2

Right arm / side panel assembly

9

Pin 15X50

3

Gas spring

10

Pin 8X50

4

Bolt M10X20

11

Circlip 50

5

Washer 10

12

Screw M8X25

6

Washer 10

13

Spindle bracket assembly

7

Bearing

81

TRUCK BASE MECHANICS TILLER ASSEMBLY KEY TO TILLER ASSEMBLY COMPONENTS MECHANICAL STEERING

Pos.

82

Description

1

Tiller

2

Wrench 10X8X25

3

Circlip 95

4

Bearing

5

Flanged bearing seat

6

Spindle bracket

7

Spacer

SERVICE

SERVICE Pos.

TRUCK BASE MECHANICS

Description

Pos.

Description

8

Circlip 16

38

M30 nut

9

M52X1.5 round nut

39

Screw M30X80

10

Clamp

40

Screw

11

Screw M8X60

41

M12 nut

12

M8 nut

42

Spacer

13

Screw M6X20

43

Washer 10

14

Locking washer M6

44

Washer

15

Bracket

45

Greasing points

16

Screw M10X30

46

Screw M8X16

17

Washer 10

47

Screw M5X8

19

Screw M10X40

48

Gas spring

20

Mounting ring

49

Screw M8X16

21

Screw M20X150

50

Plate

22

M20 nut

51

Sliding Block

23

Adjustment screw

52

Circlip D5

24

Bracket

53

slotted pin

25

Spring

54

Wheel

26

Wheel

56

Plate

27

Drive wheel housing

57

Screw M4X8

28

Lock

58

Bearing - air spring

29

Screw M8X35

59

Gas spring

30

Washer 8

60

Bearing

31

Bearing

61

Shaft

32

Washer

62

Shaft

33

Pin

63

Hex screw M6X12

34

Screw M6X16

64

Tiller seat

35

Pin

65

Screw M8X25

36

Connecting shaft

66

Bearing

37

Spacer sleeve

83

TRUCK BASE MECHANICS TILLER ASSEMBLY KEY TO TILLER ASSEMBLY COMPONENTS ELECTRIC STEERING

84

SERVICE

SERVICE Pos.

TRUCK BASE MECHANICS

Description

Pos.

Description

1

Tiller

25

Bearing

2

Screw M8X16

26

Shaft

3

Washer 8

27

Shaft

4

Screw M5X8

28

Locking washer M6

5

Gas spring

29

Screw M6X12

6

Sliding Block

30

Tiller seat

7

Circlip D5

31

Screw M8X20

8

slotted pin

32

Bearing

9

Wheel

10

Circlip

11

Plate

12

Washer 10

13

Pin

14

M8 nut

15

Screw M8X25

16

Bearing

17

Circlip 62

18

Separator

19

Steering support gear housing

20

Washer 10

21

Screw M10X25

22

Screw M4X8

23

Bearing - air spring

24

Gas spring

85

TRUCK BASE MECHANICS 1.5 KW AC MOTOR KEY TO 1.5 KW AC MOTOR COMPONENTS

Pos.

86

Description

1

AC Motor

2

Encoder-II

SERVICE

SERVICE

TRUCK BASE MECHANICS

DC STEERING MOTOR KEY TO DC STEERING MOTOR COMPONENTS

Pos.

Description

1

DC Steering motor

2

Terminal TY10

3

Encoder

87

SERVICE

BRAKING SYSTEM

ELECTROMAGNETIC BRAKE KEY TO COMPONENTS

HOLLOW SCREW

COUPLING SCREW

SPRING ARMATURE MOTOR SHAFT

FRICTION DISC

STATOR

MOUNTING SCREW

88

SERVICE

BRAKING SYSTEM

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

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

89

MAINTENANCE

SERVICE

WARNINGS •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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

•

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

•

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

•

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

•

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

•

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

•

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

90

SERVICE

MAINTENANCE

•

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

•

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

•

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

•

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

•

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

Close the valves at the end of the maintenance work.

91

SERVICE

MAINTENANCE

OILS AND LUBRICANTS Application

OIL for lubrication HYDRAULIC CIRCUIT

Standard storage

Storage in cold room

Type Shell Tellus S3 V 46

• •

Shell Tellus S3 V 32

OIL for lubrication of the REDUCTION UNIT

•

•

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

OIL for lubrication of the GEARS

•

•

Shell Advance Teflon Chain

GREASE for lubrication of the PINS

•

Shell Albida Grease EP2

•

Aeroshell Grease 6

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

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

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

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

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

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

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

92

SERVICE

MAINTENANCE

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

FRAME

BRAKING SYSTEM

Operation description

Maintenance intervals every 50 hours 1 week

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



Remove dirt residues and oil from the steering wheel



Keep the brake clearance between 0.2 and 0.8 mm



every 200 hours 1 month



Check the general conditions and the presence of anomalies



Check the correct operation of the horn



Frame, operation, cracks, lubrication status, loose fasteners



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



every every 600 hours 1200 hours 3 months 6 months



ELECTRICAL SYSTEM

HYDRAULIC SYSTEM

STEERING

Replace the load wheels and bearings depending on their wear



x

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



Tiller seal and flexibility



Oil leaks in the pipes



Correct dosing of hydraulic oil



Oil leaks in the lift cylinder



Filter cleaning





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

x

Plug operation and faults



Key switch operation



Contactor performance and operation



Microswitch operation



Control operation



Drive motor wear



Lifting motor, carbon brush and commutator wear



Steering motor, carbon brush and switch wear



Fuse, complete or not complete



Wiring and terminals, loose or faulty



Polish the irregular contacts with abrasive paper





Replace in case of malfunctions

x

x

Carbon brush and commutator wear



Electrolyte capacity, liquid level check, distilled water





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





93

SERVICE

MAINTENANCE

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

REDUCTION UNIT

ELECTRICAL SYSTEM

Operation description

Maintenance intervals every 8 hours 1 day

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



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



Replace the oil

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

x

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

94

SERVICE

MAINTENANCE

95

Part No.:550224122

Revision: 1 (07/2020)