"PDF DOWNLOAD: Yale A7R3 (MS15XUX) Forklift Service Manual

Revision: 1 (04/2020)

Part no.: 550224149

Technical information for Yale service centres

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

A7R3

MS15XUX

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

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

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

Product support group

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

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

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

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

2

SERVICE GENERAL SAFETY RULES PERSONAL SAFETY •

Always wear the personal protective equipment in situations requiring it.

•

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

•

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

•

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

•

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

SAFETY AT THE WORKPLACE •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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

•

Avoid twisting chains or metal ropes.

•

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

•

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

•

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

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

•

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

3

SERVICE •

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

•

Do not short-circuit the terminals.

•

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

•

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

•

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

•

Always disconnect the battery before working on the electrical system.

•

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

•

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

•

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

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE •

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

•

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

•

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

•

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

•

Always rest the load in the race of the hook.

•

Never load the tip of the hook.

•

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

•

Never do any lifting with the ropes and belts twisted.

•

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

•

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

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

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

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

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

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

• When the sling shows signs of overloading.

4

SERVICE Belt capacity table 45° Colour

Working load capacity (kg)

purple green yellow grey red brown blue

1000 2000 3000 4000 5000 6000 8000

2000 4000 6000 8000 10000 12000 16000

1400 2800 4200 5600 7000 8400 11200

800 1600 2400 3200 4000 4800 6400

orange

10000 12000

20000 24000

14000 16800

8000 9600

15000 20000 25000 30000

30000 40000 50000 60000

21000 28000 35000 42000

12000 16000 20000 24000

1

2

1.4

0.8

orange orange orange orange orange

Coefficient

Rope capacity table

Working load capacity (kg)

Colour

Width (mm)

black purple black green yellow grey red brown blue orange

35 50 50 60 75 120 150 180 240 300

500 1000 1500 2000 3000 4000 5000 6000 8000 10000

1000 2000 3000 4000 6000 8000 10000 12000 16000 20000

700 1400 2100 2800 4200 5600 7000 8400 11200 14000

400 800 1200 1600 2400 3200 4000 4800 6400 8000

1

2

1.4

0.8

Coefficient

Suspension element capacity table

Colour

Working load capacity (kg) Coefficient

purple green yellow grey red

1000 2000 3000 4000 5000

1400 2800 3800 5600 6600

2100 4200 6300 8400 9800

2100 4200 6300 8400 10500

1

1.4

2.1

2.1

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

5

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

Nominal diameter

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

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

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

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

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

Pre-charge N

Class 8

Class 10

M3

4

5.2

M4

7

9.15

M5

12.14

14.8

M6

17.2

20.9

M8

31.8

38.1

M10

50.5

60.3

M12

74.2

88.5

M14

101.2

120.8

M16

138.2

164.9

M18

176.6

203.5

M20

225.4

259.7

M22

278.8

321.2

M24

324.8

374.2

M27

422.3

486.5

M30

516.1

594.7

TORQUE SETTING Nm Class 5.8

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

M10

1.5

16

8

15825

31.7

23.8

51

38

69

52

M10

1.25

16

8

16700

33.4

25.1

53

40.1

73

55

M12

1.75

18

10

23025

55

41.4

88

66

120

90

M12

1.25

18

10

25150

60

45.3

96

72

130

98

M14

2

21

12

31400

88

66

140

105

190

145

M14

1.5

21

12

34125

96

72

155

115

210

155

M16

2

24

14

42850

135

105

220

165

300

225

M16

1.5

24

14

45600

145

110

235

175

320

240

M20

2.5

30

17

66875

270

200

430

320

580

435

M20

1.5

30

17

74250

295

225

475

355

650

485

= with lubricant

6

TORQUE SETTING Nm

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

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

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

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

TORQUE SETTINGS

UNF thread

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

UNF thread

REVOLVING FEMALE jic 37° Torque setting Nm Size

Nominal torque

min / max

M 12x1.5

6

20

15 -25

7/16-20

-4

15

9 - 21

M 14x1.5

8

38

30 - 45

1/2-20

-5

20

13 - 27

45

38 - 52

9/16-18

-6

30

18 - 42

3/4-16

-8

50

30 - 70

7/8-14

-10

69

44 - 94

1.1/16-12

-12

98

63 - 133

1.3/16-12

-14

118

73 - 163

1.5/16-12

-16

140

90 - 190

1.5/8-12

-20

210

135 - 285

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

8 10 10 12 12 14 15

51

43 - 85

58

50 - 65

74

60 - 88

M 24x1.5

16

74

60 - 88

1.7/8-12

-24

290

200 - 380

M 26x1.5

18

105

85 - 125

2.1/2-12

-32

450

300 - 600

135

115 - 155

166

140 - 192

30

240

210 - 270

35

290

255 - 325

330

280 - 380

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

UNF thread G1/4

20 22 25 28

38 42

BSP REVOLVING FEMALE Torque setting Nm

UNF thread

ORFS REVOLVING FEMALE Torque setting Nm Size

Nominal torque

max.

Nominal torque

max

20

15 - 25

9/16-18

-4

14

16

-6

24

27 47

G3/8

34

27 - 41

11/16-16

G1/2

60

42 - 76

13/16-16

-8

43

G5/8

69

44 - 94

1-14

-10

60

68

G3/4

115

95 - 135

1.3/16-12

-12

90

95

G1

140

115 - 165

1.3/16-12

-14

90

95

G1.1/4

210

140 - 280

1.7/16-12

-16

125

135

G1.1/2

290

215 - 365

1.11/16-12

-20

170

190

G2

400

300 - 500

2-12

-24

200

225

2-1/2-20

-32

460

490

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

7

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

• • • • • • •

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

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

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

8

SERVICE CONTENTS Presentation.........................................................................................10 Installation............................................................................................14 Diagnostics and measurements........................................................18 Electrical system.................................................................................42 Hydraulic system.................................................................................56 Truck base mechanics........................................................................74 Mast......................................................................................................88 Reduction gear....................................................................................92 Braking system....................................................................................94 Maintenance.........................................................................................96

9

PRESENTATION

SERVICE

TRUCK PRESENTATION The stacker with platform model MS15XUX is equipped with storage batteries and AC motor which provide the dynamic source and the tractive force respectively.

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

The cylinders up and down movement allows the forks and the load to be lifted.

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

The stacker is equipped with a 24V storage battery, capable of allowing prolonged use after recharging and is used to stack and move goods on hard and flat surfaces.

10

SERVICE

PRESENTATION

TRUCK IDENTIFICATION DATA PLATES

The truck identification data plate is located on the truck base

• • • • • • • • • •

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

LOAD CAPACITY DATA PLATE

The load plate is located on the mast crossbar The load plate bears the following data: • Model • Liftable load values up to varying heights up to the maximum load with different distances from the load centre of gravity of the forks.

Always refer to the load capacity data plates to be sure to lift the load admitted at a suitable height

11

PRESENTATION

GENERAL SPECIFICATIONS MS15XUX

12

SERVICE

SERVICE

PRESENTATION

Motor units

Performance

Dimensions

Wheels, frame

Weight

Characteristics

GENERAL SPECIFICATIONS 1.1

Manufacturer (initials)

1.2

Model designation

1.3

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

Battery

1.4

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

Standing

1.5

Rated capacity/rated load

Q (kg)

1500 600

1.6

Load centre of gravity

c (mm)

1.8

Load distance from wheel axle to fork shoulder (1)

x (mm)

672

1.9

Wheelbase

y (mm)

1378

2.1

Service weight (with battery)

kg

1510

2.2

Axle loading with load (front/rear)

kg

1830 / 1140

2.3

Axle loading without load (front/rear)

kg

3.1

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

3.2

Tyre size, front

ø (mm x mm)

3.3

Tyre size, rear

ø (mm x mm)

80 x 84

3.4

Additional wheels (dimensions)

ø (mm x mm)

150 x 60

3.5

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

3.6

Front track width

b 10 (mm)

580

3.7

Rear track width

b 11 (mm)

404/530

4.2

Height, mast closed

h 1 (mm)

1735/1985/2135/2235 - 2050/2210/2410

4.3

Free lift (optional)

h 2 (mm)

1300/1550/1700/1800 - 1570/1740/1940

4.4

Lifting height

h 3 (mm)

2500/3000/3300/3500 - 4500/5000/5600

4.5

Height, mast extended

h 4 (mm)

1955/3455/3755/3955 - 5030/5510/6110

4.9

Extended height in driving position, min/max

h 14 (mm)

1150/1450

4.15

Height with forks lowered

h 13 (mm)

90 2020/2100

1040 / 470 Polyurethane 250 x 70

1x + 2 / 4

4.19

Total length

l 1 (mm)

4.20

Length to face of forks

l 2 (mm)

950

4.21

Overall width

b 1 (mm)

850

4.22

Fork size(14)

s/e/l (mm)

60 / 180 / 1070 (1150)

4.25

Fork outer gauge (10)

b 5 (mm)

570/695

4.32

Ground clearance at wheelbase centre

m 2 (mm)

31

4.33

Aisle width with pallet 1000mm x 1200mm crossways

A st (mm)

2535

4.34

Aisle width with pallet 800mm x 1200mm crossways

A st (mm)

2515

4.35

Turning radius

W a (mm)

1655

5.1

Travel speed with/without load

km/h

6.5 / 6.7

5.2

Lifting speed laden/unladen

m/s

0.11 / 0.14

5.3

Lowering speed laden/unladen

m/s

0.15 / 0.13

5.8

Maximum gradeability with/without load

%

8 / 15

5.10

Service brake

6.1

Traction motor power

kW

6.2

Lifting motor power

kW

3

6.4

Battery voltage/capacity

(V)/(Ah)

24 / 240 - 24 / 300

6.5

Battery weight

kg

220 - 260

Battery size (L x w x h) Additional data

Yale MS15XUX

8.4

Sound pressure level at operator position DIN 12503

Electro magnetic

mm

dB (A)

1.2 (AC)

625x254x500 - 675x254x540

70

1. The parameters referred to h1, I, Q must be calculated based on: h3 = 3000 mm and I = 1070 mm.

13

SERVICE

INSTALLATION

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 truck is to be installed.

Mast details - 2 stage NFL

MS15XUX

Lifting height

Free lift

Height, lowered mast

Height, extended mast

h3

h2

h1

h4

mm

mm

mm

mm

2500

0

1735

2955

3000

0

1985

3455

3300

0

2135

3755

3500

0

2235

3955

Mast details - 3 stage FFL

MS15XUX

14

Lifting height

Free lift

Height, lowered mast

Height, extended mast

h3

h2

h1

h4

mm

mm

mm

mm

4500

1570

2050

5030

5000

1740

2210

5510

5600

1940

2410

6110

SERVICE

INSTALLATION

INSTALL 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 trucks they are also blocked by a belt (fig. 2).

Fig. 2

Fig. 1

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.3) 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.

Fig. 3

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 Open the battery compartment door.

Attach slings the battery using the dedicated holes, making sure that the hoist or bridge crane is positioned vertically above the battery.

Phase 2 Lift the battery and simultaneously push it very carefully inside the compartment of the truck, just enough to make sure that lowering it, it rests on the base of the battery compartment.

Phase 3 Secure the battery using the battery catch, then close the battery compartment door.

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.

16

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

Check

Check points

Description

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 wheel

4 5

Hydraulic system

Wheels

10

Battery

11 12

Horn

13

Instrumentation

15 Other 16

(e.g.

17

DIAGNOSTICS AND MEASUREMENTS

CONTROLLER DESCRIPTION TRACTION CONTROL DEVICE 1232E

35 23 12

18

24 13 1

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

KC1-1 Key switch 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 traction 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

19

DIAGNOSTICS AND MEASUREMENTS

J1(A)

J2(B) J3(C)

EPS 1220 CONTROL DEVICE

20

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

21

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 CONTROL MAIN MENU MONITOR  Inputs PARAMETER THROTTLE COMMAND Angular displacement of the traction control butterfly THROTTLE MULTIPLIER Not used on this model MAPPED THROTTLE Angular displacement of the traction 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

22

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 23

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

24

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

25

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

26

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 27

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 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

28

SERVICE

DIAGNOSTICS AND MEASUREMENTS

29

SERVICE

DIAGNOSTICS AND MEASUREMENTS TROUBLESHOOTING

TRACTION CONTROL The control device 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.

30

RED

YELLOW

(First digit)

(2)

RED

(Second digit)

YELLOW

(3)

SERVICE

DIAGNOSTICS AND MEASUREMENTS

FAULTS LIST Led Code

Console display message Fault effect

Possible Causes

Condition / solution

1.2

CONTROLLER OVERCURRENT • Motor operation stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

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

31

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.

• 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• 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 LOW TEMPERATURE 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.

The pre-charge failed to recharge the capacitor bank.

Activate the interlock input or use VCL.

CONTROLLER OVERTEMP CUTBACK • Operating and braking torque reduction

• Refer to Monitor menu--> Controller --> Temperature • The control device operates with limited performance at this 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

• Normal operation. The anomaly indicates that the batteries must be recharged. The control device performance is limited at this voltage.

• The battery is flat • The battery parameters are not set correctly • The battery resistance is too high • The battery disconnected during operation • Refer to Monitor menu -->Battery-->Capacitor Voltage.

• The B+ fuse or main contactor does not close.

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

Return the capacitor bank voltage above the undervoltage limit.

Fault effect

1.7

1.8

2.1

2.2

2.3

32

SERVICE

SERVICE Led Code

DIAGNOSTICS AND MEASUREMENTS

Console display message

Possible Causes

Condition / solution

OVERVOLTAGE CUTBACK • Low operating torque

• Normal operation. The anomaly indicates that the regenerative braking currents have increased the battery voltage during the braking. The control device performance is limited at this voltage.

• The battery parameters are not set correctly.

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

• The battery disconnected during the regenerative braking.

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

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

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 motor temperature is equal to or higher than the Temperature Hot parameter setting.

Keep the engine temperature within the range.

Fault effect

2.4

2.5

2.8

33

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.

• The motor temperature exceeds the maximum temperature set.

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

The motor thermistor input (PIN 8) has a voltage value at the outer limits of the allowed 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• 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.

EMBRAKE OPEN/SHORT • Electromagnetic brake operation stop • Acceleration stop

• 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 stop

• 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• The motor phase is open.

• Connector pins are dirty.

The motor phases U, V or W are open.

Reactivate the key switch.

Fault effect

2.9

3.1

3.1

3.2

3.2

3.3

3.4

3.5

3.6

3.7

34

SERVICE Led Code

3.8

3.9

DIAGNOSTICS AND MEASUREMENTS

Console display message Fault effect

• The contactor contacts are soldered.

• The motor U phase is disconnected or open.

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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• 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 stop

• 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 stop

• 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 stop • 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop • Interlock stop • Driver 1 - 2 - 3 - 4 stop • PD stop

• 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.

4.2

4.4

4.5

4.6

Condition / solution

MAIN CONTACTOR WELDED • Motor operation stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

4.1

4.3

Possible Causes

35

DIAGNOSTICS AND MEASUREMENTS

Led Code

Console display message

Possible Causes

Condition / solution

HDP/SEQUENCING FAULT • Acceleration stop

• Wrong sequence of the inputs of: key switch, interlock, direction and acceleration make an incorrect sequence • Wiring problems relating to the inputs: key switch, interlock, direction, throttle.

• Refer to Monitor Menu -> Inputs

HPD (High Pedal Disable) or sequence error due to an incorrect sequence of the inputs related to: key switch, interlock, throttle direction.

Follow the correct sequence.

EMER REV HDP • Electromagnetic brake operation stop • Acceleration stop

• The emergency reverse operation is completed, but the throttle, the forward and reverse gear inputs and the interlock have not returned to the neutral position.

At the end of an emergency reverse manoeuvre, some of the inputs have not returned to neutral position.

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

• 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 Fault Checking Menu: Ext Supply Max and Ext supply Min parameters are correctly set • 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop • Interlock stop • Driver 1 - 2 - 3 - 4 stop • PD stop

• Internal fault in the control device.

Detection of a fault inside the control device.

Reactivate the key switch.

PDO TIMEOUT • Throttle stop

• 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 • Throttle 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.

Fault effect

4.7

4.7

6.8

6.9

7.1

7.2

7.3

36

SERVICE

SERVICE Led Code

DIAGNOSTICS AND MEASUREMENTS

Console display message

Possible Causes

Condition / solution

MOTOR CHARACTERIZATION FAULT • Motor operation stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

• 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 stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop • Interlock stop • Driver 1 - 2 - 3 - 4 stop • PD stop

The motor lost the IFO control and accelerated without the throttle being activated.

Make sure that the Encoder Steps parameter corresponds to the current encoder.

Reactivate the key switch.

• The Motor_Type parameter value is out of range.

8.9

MOTOR TYPE PARAMETER • Motor operation stop • Contactor operation stop • Electromagnetic brake operation stop • Acceleration stop

The Motor_Type parameter is set to an unallowed value.

Set the Motor_Type value correctly and reactivate the key.

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

• 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.

Fault effect

8.7

9.2

9.3

37

DIAGNOSTICS AND MEASUREMENTS

Led Code

9.4

38

Console display message

Possible Causes

Fault effect EMER REV TIMEOUT • Electromagnetic brake operation stop • Acceleration stop

•

•

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

SERVICE Condition / solution

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

Disable the emergency reverse input.

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

39

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

40

SERVICE

ELECTRICAL SYSTEM

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).

41

ELECTRICAL SYSTEM

WIRING DIAGRAMS Ref

42

Description

KC1

Traction controller

KC2

Steering controller

WK

Tiller board

WR

Steering potentiometer

M1

Traction motor 1.5 Kw

M2

Pump motor 3.0 Kw

M3

Steering motor 0.4 Kw

B1

Tiller sensor

B2

Electronic Module

KM1

Main contactor

KM2

Pump contactor

K1

Emergency switch

K2

Key switch

K3

Interlock sensor

K4

Wheel Sensor

K5

Speed limitation sensor

K6

Platform sensor 1

K7

Platform sensor

K8

Flip sensor

K9

Right side panel sensor

K10

Left side panel sensor

K11

Lift height limit sensor

L

Electromagnetic brake

L1

Lowering solenoid valve

SERVICE

SERVICE

ELECTRICAL SYSTEM

43

SERVICE

ELECTRICAL SYSTEM

TRUCK COMPONENTS

6

1 2

7 8

3

9 4

10

5

Ref.

44

Description

1

Tiller control sensor

2

Side guards

3

Electromagnetic brake

4

Traction motor

5

mdu

6

Emergency button

7

Gas spring

8

Steering motor

9

Pump motor

10

On-board charger

SERVICE

ELECTRICAL SYSTEM

CONTROLS TILLER CONTROLS AND MAIN PANEL

5 4

6

1

3

2

Ref.

Description

1

Horn button

2

Fork lifting lowering ON/OFF push button

3

Fork lifting lowering ON/OFF push button

4

Slow travel enabling button with tiller in rest position

5

Emergency reversal button

6

Forward/reverse traction control throttle

7

Battery charge level indicator

8

Side guards electric lock

9

Power On

10

Power Off

45

SERVICE

ELECTRICAL SYSTEM

TRUCK FUNCTIONS FORWARD/REVERSE TRACTION ACTUATION CONTROLS

Forward travel (operator side)

Actuators involved

Status

Key switch

ON

Emergency switch

ON

Tiller tilt sensor

ON*

Forward/reverse traction control throttle * OFF when the "snail" button is pressed

46

Reverse travel (fork side)

forward/reverse rotation

SERVICE

ELECTRICAL SYSTEM

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

Release braking.

Braking on direction reversal.

Emergency braking.

Parking brake.

BRAKING SYSTEM

WHEN DOES IT COME INTO OPERATION?

Release braking

Release of the butterfly drive control

Braking on direction reversal

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

Emergency braking

Parking brake

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

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

SNAIL FUNCTION

B

A

Fig. 1

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

47

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

48

status

Key switch

ON

Emergency switch

ON

Tiller sensor

ON

Tiller rotation

right/left rotation

SERVICE

ELECTRICAL SYSTEM

FORK LIFTING/LOWERING ACTUATION CONTROLS

A

B

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

Actuators involved

status

Key switch

ON

Emergency switch

ON

Fork lifting/lowering

ON-OFF button lifting/ lowering active

Tiller sensor

ON*

*Only in the case of fork lowering

49

ELECTRICAL SYSTEM

SERVICE

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

50

SERVICE

ELECTRICAL SYSTEM

STEERING WHEEL 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

51

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.

CONTROL DEVICE 1232E 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

52

SERVICE

ELECTRICAL SYSTEM

TILLER HEAD IDENTIFICATION OF TILLER HEAD COMPONENTS

Pos.

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 53

ELECTRICAL SYSTEM BUTTONS BUTTONS ASSEMBLY COMPONENTS

Pos. 1

Left Cover Right Cover

2

Pin

3

Spring button

4

54

Description

Left button Right button

5

Microswitch

6

Screw 2.2X12

SERVICE

SERVICE

ELECTRICAL SYSTEM

55

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC FUNCTIONS • •

Forks lifting Fork Lowering

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

In the lowering stage, 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.

56

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.

Parachute valves (LB) These are blocking valves fixed directly onto the lift cylinders and are designed to stop an uncontrolled descent of the load in the event of a rupture of a pressure hose.

If the flow rate exceeds the set value (80 litres/min), a sealing disk, which is normally held raised above the valve seat by spring energy, is pressed by the hydrodynamic forces against the valve seat, thus closing the valve.

They are equipped with a drain hole.

Oil flow control valves (SB) The regulator valves are used as braking valves during the lowering of the cylinders to assure constant lowering speed, almost independently of the load weight.

They are comprised of a sliding cylinder (B), complete with spool (C) and spring (D), and diaphragm bushing (A).

Pump

Parachute valve

A

B

C D Oil flow control valve

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.

57

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM SYMBOLS

TWO POSITION SOLENOID VALVE

PRESSURE RELIEF VALVE

FILTER

ONE-WAY VALVE

CYLINDER WITH ROD

PUMP

SINGLE ACTING CYLINDER

58

M

ELECTRIC MOTOR

PISTON CYLINDER

BALANCER

LINE CONNECTION

RESERVOIR

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM

59

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS BY FUNCTION •

Forks lifting

•

Fork 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

60

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR FORK LIFTING

61

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR FORK LOWERING

62

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

63

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.

64

Fig. 1

SERVICE

HYDRAULIC SYSTEM

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

This kind of valve is comprised of a chassis with a nut attached to the chassis, a threaded part, a range of static seal gaskets; inside a mobile element allows communication between the various holes.

IDENTIFICATION OF THE COMPONENTS OF CARTRIDGE SOLENOID VALVE B203

A B

Ref.

Description

A

Solenoid valve body

B

Coil

65

HYDRAULIC SYSTEM

HYDRAULIC COMPONENTS 2 STG NO FREE LIFT

66

SERVICE

SERVICE

Pos. 1 2

HYDRAULIC SYSTEM

Description Hydraulic Reservoir Screw M5X12 (cold room

Pos. 9

Description Hydraulic pump 3kW/2.5CC (normal) Hydraulic pump 3kW/3.5CC (cold room)

Screw M6X12 (normal)

10

Coupling

Locking washer M5 (cold room)

11

Pipe

Locking washer M6 (normal)

12

Coupling

Washer 5 (cold room)

13

Pipe

Washer 6 (normal)

14

Washer 16

5

Pipe

15

Coupling

6

Flexible hose standard configuration

7

Washer 16.5

8

Coupling

3

4

Cylinder - lifting height 2.5 m 16

Cylinder - lifting height 3.0 m Cylinder - lifting height 3.3 m Cylinder - lifting height 3.5 m

67

HYDRAULIC SYSTEM HYDRAULIC COMPONENTS 3 STG FULL FREE LIFT

68

SERVICE

SERVICE

Pos. 1 2

HYDRAULIC SYSTEM

Description

Pos.

Hydraulic Reservoir Screw M5X12 (cold room

Description Cylinder - lifting height 4.5 m /fixed forks

11

Screw M6X12 (normal)

Cylinder - lifting height 5.0 m /fixed forks Cylinder - lifting height 5.6 m /fixed forks

Locking washer M5 (cold room)

12

Solid pipe

Locking washer M6 (normal)

13

Coupling

Washer 5 (cold room)

14

Solid pipe

Washer 6 (normal)

15

Solid pipe

Flexible hose - lifting height 4.5 m

16

Coupling

Flexible hose - lifting height 5.0 m

17

Washer

Flexible hose - lifting height 5.6 m

18

Junction block - coupling seat

6

Flexible hose - standard configuration

19

Coupling

7

Washer 16.5

20

Exhaust Valve

8

Coupling

21

Junction block - coupling seat

3

4

5

9

Cylinder - lifting height 4.5 m Epas

Hydraulic pump 3kW/2.5CC (normal) Hydraulic pump 3kW/3.5CC (cold room)

22

Cylinder - lifting height 5.6 m Epas

Pipe - lifting height 4.5 m 10

Cylinder - lifting height 5.0 m Epas

Pipe - lifting height 5.0 m

23

Belt 12X400

Pipe - lifting height 5.6 m

24

Hose

69

HYDRAULIC SYSTEM

SERVICE

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

Single-acting pull type cylinders In this type of cylinder the piston is replaced by the flat end face of the piston rod or plunger; these cylinders are usually mounted vertically or in other positions in which the force of gravity returns the plunger to the rest position.

Usually the diameter of the bottom of the shaft is increased by a few millimetres in order to avoid it slipping out at the top of it's upstroke; this gives rise to a hydraulic damping in the final part of the stroke, supporting the slowing down of the rod and preventing backlash on the upper head. Static seals located in the end cap prevent oil leaking outside the cylinder. To replace these seals it is necessary to unscrew the seal carrier bush. Single acting cylinders with hollow rods differ in that before the lifting stroke begins the rod is also filled with oil. This solution is used on particularly tall truck masts to increase the resistance of the cylinders at the maximum height and make it possible to use smaller cylinder barrels and rods.

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

COMPONENTS OF THE WHEEL ARM LIFTING CYLINDER It is a pull type single-acting cylinder.

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

70

SERVICE

HYDRAULIC SYSTEM

OIL CYLINDER ASSEMBLY TWO STAGE MAST

Pos.

Description

Pos.

Description

1

Dust cap

2

Seal ring

3

Screw M6X8

4

Steel ball 4

5

Guide - guard

10

Bushing

6

O-ring 45X2.65

11

Piston

7

Guide belt

12

Guide belt

Connecting rod - lifting height 2.5 m

13

Thrust washer

Connecting rod - lifting height 3.0 m

14

Half-ring sealing sleeve

Connecting rod - lifting height 3.3 m

15

Ring 30

8

Cylinder - lifting height 2.5 m 9

Cylinder - lifting height 3.0 m Cylinder - lifting height 3.3 m Cylinder - lifting height 3.5 m

Connecting rod - lifting height 3.5 m

71

SERVICE

HYDRAULIC SYSTEM OIL CYLINDER ASSEMBLY THREE STAGE MAST

Pos.

Description

Description

1

Dust cap

2

Seal ring

3

Screw M6X8

4

Steel ball 4

11

Piston

5

Guide - guard

12

Half-ring thrust washer

6

O-ring 65X2.65

13

Half-ring sealing sleeve

7

Guide belt

14

Ring for pin 30

8

Ring 80

15

Guide belt

Connecting rod - lifting height 4.5 m 9

Connecting rod - lifting height 5.0 m Connecting rod - lifting height 5.6 m

72

Pos.

Cylinder - lifting height 4.5 m 10

Cylinder - lifting height 5.0 m Cylinder - lifting height 5.6 m

SERVICE

HYDRAULIC SYSTEM

73

TRUCK BASE MECHANICS

DRIVE WHEEL COMPONENTS OF THE DRIVE WHEEL

5

3

4

2 1

74

SERVICE

SERVICE

TRUCK BASE MECHANICS

Ref.

Description

1

Screws M24

2

Screws M6

3

Nut

4

Drive wheel

5

Shaft

75

TRUCK BASE MECHANICS

CASTOR WHEEL ASSEMBLY CASTOR WHEEL ASSEMBLY COMPONENTS

76

SERVICE

SERVICE

TRUCK BASE MECHANICS

Pos.

Description

1

Screw M12x100

2

M12 nut

3

Dust cap

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

77

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.

A

A

Fig. 1

78

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

79

TRUCK BASE MECHANICS LOAD WHEELS COMPONENTS OF THE LOAD WHEELS

Pos.

80

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 clamp and rest the truck on the block.

A

Fig. 1

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

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

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

Proceed with replacement.

E C E

D

B Fig. 2

81

TRUCK BASE MECHANICS

SERVICE

FOOTBOARD FOOTBOARD COMPONENTS

Pos.

82

Description

Pos.

Description

1

Bracket

11

Locking screw

2

Rubber floor mat

12

Pin

3

Footboard

13

Flat washer

4

Pin

14

Shaft

5

Gas spring

15

Gas spring

6

Platform support bracket

16

Platform support bracket

7

Shaft

17

Shaft

8

Washer

18

Washer

9

Spring pin

19

Spring pin

10

Spacer

SERVICE

TRUCK BASE MECHANICS

SIDE PANELS SIDE PANEL COMPONENTS

Pos.

Description

1

Bearing

2

Side panel assembly support

3

Circlip 50

4

Spindle bracket assembly

5

Arm - left side / side panel assembly

6

Arm - right side / side panel assembly

7

Screw M12X60

8

Screw M6X25

9

Gas spring

83

TRUCK BASE MECHANICS TILLER ASSEMBLY IDENTIFICATION OF TILLER ASSEMBLY COMPONENTS

Pos.

84

Description

1

Tiller

2

Screw M8X16

3

Washer 8

4

Screw M5X8

5

Gas spring

6

Slide-locking

7

Safety ring D5

8

Pin with groove

9

Wheel

10

Safety ring 30

11

Plate U

SERVICE

SERVICE

TRUCK BASE MECHANICS

Pos.

Description

12

Washer 10

13

Pin

14

M8 nut

15

Screw M8X25

16

Bearing

17

Safety ring 62

18

Insulation damping ring

19

Steering support gear housing

20

Washer 10

21

Screw M10X25

22

Screw M4X8

23

Bearing - air spring

24

Gas spring 228X70X430-450N

25

Bearing

26

Pin

27

Washer

28

Locking washer M6 bearings

29

Screw M6X12

30

Tiller assembly - seat

31

Screw M8X20

32

Seal

85

TRUCK BASE MECHANICS AC MOTOR 1.5KW AC 15KW MOTOR COMPONENTS

Pos.

86

Description

1

AC Motor

2

Encoder-II

SERVICE

SERVICE

TRUCK BASE MECHANICS

DC STEERING MOTOR DC STEERING MOTOR COMPONENTS

Pos.

Description

1

DC Steering motor

2

Terminal TY10

3

Encoder

87

MAST 2 STAGE NO FREE LIFT MAST COMPONENTS

88

SERVICE

SERVICE

Pos.

MAST

Description

Pos.

Description

1

Screw

17

Stop block

2

Washer

18

Baffle - chain

Protection plate 2 STG lifting height 2.5 m

19

Ring 30

Protection plate 2 STG lifting height 3.0 m

20

Ring 62

Protection plate 2 STG lifting height 3.3 m

21

Bearing

Protection plate 2 STG lifting height 3.5 m

22

Chain sheave

4

Screw M12X40

23

Screw M6X16

5

M12 nut

24

Clip

6

Bearing

7

Wheel

8

Guide adjustment bearing

9

Washer

10

Screw M8X40

26

Screw

11

Anti-vibration spacer bearing

27

Screw M16X15X50

12

Screw M10X16

28

Washer 16

Outer mast 2STG NFL 2.5 m

29

Upper block

Outer mast 2STG NFL 3.0 m

30

Screw M8X16

Outer mast 2STG NFL 3.3 m

31

Washer 12

Outer mast 2STG NFL 3.5 m

32

Washer 12

Screw M8X25

33

Screw M12X20

3

13

14

Inner mast 2STG NFL 2.5 m 25

Forks structure 570B X 1150L / 2STG NFL Forks structure 695B X 1070L / 2STG NFL Forks structure 695B X 1150L / 2STG NFL

16

Inner mast 2STG NFL 3.3 m Inner mast 2STG NFL 3.5 m

Forks structure 570B X 1070L / 2STG NFL 15

Inner mast 2STG NFL 3.0 m

Chain (121 sections) 2STG NFL 2.5 m 34

Chain (141 sections) 2STG NFL 3.0 m Chain (153 sections) 2STG NFL 3.3 m Chain (161 sections) 2STG NFL 3.5 m

Screw M8X10

89

MAST

3 STAGE FULL FREE LIFT MAST COMPONENTS

90

SERVICE

SERVICE Pos.

MAST

Description

Pos.

Description

1

Screw

31

Washer 12

2

Washer

32

Ring 47

Protection plate 3 STG lifting height 4.5 m

33

Bearing

Protection plate 3 STG lifting height 5.0 m

34

Chain sheave

Protection plate 3 STG lifting height 5.5 m

35

Bearing

4

Screw M6X40

36

Ring 62

5

Locking washer M6 - Bearing

37

Ring 30

6

Washer M6

38

Chain guide

7

Screw M8X40

39

Sleeve

8

Anti-vibration spacer bearing

9

Screw M8X25

10

Wheel

11

Screw M10X16

41

Magnetic steel bolt

12

Screw M8X30

42

Flat washer 4

13

Screw M8X10

43

Screw M4X16

14

Stop block

44

Nut

Outer mast 3STG FFL 4.5 m

45

Screw M6X25

3

15

40

Clip

Forks 570B X 1070L / 3STG FFL 46

Chain (147 sections) 17

Intermediate mast 3STG FFL 5.0 m Intermediate mast 3STG FFL 5.6 m

Outer mast 3STG FFL 5.0 m Outer mast 3STG FFL 5.6 m

16

Intermediate mast 3STG FFL 4.5 m

Forks 570B X 1150L / 3STG FFL Forks 695B X 1070L / 3STG FFL Forks 695B X 1150L / 3STG FFL

Chain (159 sections)

47

Bolt

Chain (175 sections)

48

M8 nut

18

Screw M6X16

49

Clip

19

Washer

50

Screw M10X25

20

Screw M12X12

51

Washer 10

21

M12 nut

52

Washer 10

22

Screw M12X40

23

Bearing

24

Guide adjustment bearing

25

Screw M16X15X50

54

Screw M6X10

26

Washer 16

55

Chain sheave

27

Upper block

56

Ring 80

28

Screw M8

57

Cross head chain

29

Screw M12X50

30

Washer 12

Chain (69 sections) 3STG FFL / 4.5 M 53

Chain (73 sections) 3STG FFL / 5.0 M Chain (79 sections) 3STG FFL / 5.6 M

Inner mast 3STG FFL 4.5 m 58

Inner mast 3STG FFL 5.0 m Inner mast 3STG FFL 5.6 m

91

REDUCTION UNIT

REDUCTION UNIT

92

SERVICE

SERVICE Pos.

REDUCTION UNIT

Description

Pos.

Description

1

O-Ring 75X2.65

29

2

Ring 62

30

3

Bearing

31

4

Bolt M8X20

32

Oil seal washer 10

5

Washer 8

33

Spacer sleeve

6

Seal ring 145X175X14

34

Bearing

7

Mounting plate

35

Flange adjustment coil

8

Steering gear ring

36

Nut

9

Screw M10X50

37

O-Ring 80X2.65

10

Drive wheel gearbox

38

Backshell

11

Bearing housing

39

O-Ring 145X2.65

12

Bearing

40

Bearing

13

Flange adjustment coil 1

41

Flat key 8X7X20

14

Pin for gear and pinion

42

Nut

15

Bearing

43

Gear 2M58Z

16

Screw M8X30

44

Washer

17

Screw M24

45

Gear

18

Wheel Bolt

46

Spring

19

Wheel nut

47

Breather plug

Wheel 250X80 PU

48

oil breather

Wheel 250X80 rubber

49

Oil ball bearing 3

21

Seal for rotary axis

50

Oil Cap

22

Flange adjustment coil 2

51

O-Ring 10X2.65

23

Screw M6X20

52

Inductive mounting ring

24

O-Ring 103X2.65

53

Screw M6X16

25

Bearing

54

Screw M6X10

26

Flat key 16X10X50

55

Screw M8X25

20

27 28

Cap

Gear

93

BRAKING SYSTEM

ELECTROMAGNETIC BRAKE COMPONENTS

94

SERVICE

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.

95

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.

96

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.

97

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.

98

SERVICE

MAINTENANCE

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

CHASSIS

BRAKING SYSTEM

Operation description

Maintenance intervals every 50 hours 1 week

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



Remove dirt residues and oil from the steering wheel



Keep the brake clearance between 0.2 and 0.8 mm



every 200 hours 1 month



Check the general conditions and the presence of anomalies



Check the correct operation of the horn



Frame, operation, cracks, lubrication status, loose fasteners



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



every every 600 hrs 1200 hours 3 months 6 months



ELECTRICAL SYSTEM

HYDRAULIC SYSTEM

STEERING WHEEL

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 lifting cylinder



Filter cleaning





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

x

Plug operation and faults



Key switch operation



Contactor performance and operation



Microswitch operation



Control operation



Traction motor wear



Lifting motor, carbon brush and commutator wear



Steering motor, carbon brush and switch wear



Fuse, complete or not complete



Wiring and terminals, loose or faulty



Polish the irregular contacts with abrasive paper





Replace in case of malfunctions

x

x

Carbon brush and commutator wear



Electrolyte capacity, liquid level check, distilled water





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





99

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.

100

SERVICE

MAINTENANCE

101

Part no.: 550224149

Revision: 1 (04/2020)