PDF DOWNLOAD: Yale A7S3 (MS15UX) Forklift Service Manual

Part no.: 550224203

Revision:

1 (03/2020)

Technical information for Yale service centres

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

A7S3

MS15UX

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

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

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

Product support group

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

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

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

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

2

SERVICE GENERAL SAFETY RULES PERSONAL SAFETY •

Always wear the personal protective equipment in situations requiring it.

•

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

•

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

•

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

•

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

SAFETY AT THE WORKPLACE •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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

•

Avoid twisting chains or metal ropes.

•

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

•

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

•

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

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

•

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

3

SERVICE •

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

•

Do not short-circuit the terminals.

•

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

•

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

•

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

•

Always disconnect the battery before working on the electrical system.

•

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

•

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

•

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

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE •

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

•

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

•

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

•

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

•

Always rest the load in the race of the hook.

•

Never load the tip of the hook.

•

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

•

Never do any lifting with the ropes and belts twisted.

•

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

•

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

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

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

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

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

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

• When the sling shows signs of overloading.

4

SERVICE Belt capacity table 45° Colour

Working load capacity (kg)

purple green yellow grey red brown blue

1000 2000 3000 4000 5000 6000 8000

2000 4000 6000 8000 10000 12000 16000

1400 2800 4200 5600 7000 8400 11200

800 1600 2400 3200 4000 4800 6400

orange

10000 12000

20000 24000

14000 16800

8000 9600

15000 20000 25000 30000

30000 40000 50000 60000

21000 28000 35000 42000

12000 16000 20000 24000

1

2

1.4

0.8

orange orange orange orange orange

Coefficient

Rope capacity table

Working load capacity (kg)

Colour

Width (mm)

black purple black green yellow grey red brown blue orange

35 50 50 60 75 120 150 180 240 300

500 1000 1500 2000 3000 4000 5000 6000 8000 10000

1000 2000 3000 4000 6000 8000 10000 12000 16000 20000

700 1400 2100 2800 4200 5600 7000 8400 11200 14000

400 800 1200 1600 2400 3200 4000 4800 6400 8000

1

2

1.4

0.8

Coefficient

Suspension element capacity table

Colour

Working load capacity (kg) Coefficient

purple green yellow grey red

1000 2000 3000 4000 5000

1400 2800 3800 5600 6600

2100 4200 6300 8400 9800

2100 4200 6300 8400 10500

1

1.4

2.1

2.1

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

5

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

Nominal diameter

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

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

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

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

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

TORQUE SETTING Nm Class 8

Class 10

M3

4

5.2

M4

7

9.15

M5

12.14

14.8

M6

17.2

20.9

M8

31.8

38.1

M 10

50.5

60.3

M 12

74.2

88.5

M 14

101.2

120.8

M 16

138.2

164.9

M 18

176.6

203.5

M 20

225.4

259.7

M 22

278.8

321.2

M 24

324.8

374.2

M 27

422.3

486.5

M 30

516.1

594.7

TORQUE SETTING Nm Pre-load N

Class 8.8

Class 10.9

mm

mm

mm

mm

M4

0.7

7

3

2400

1.92

1.44

3.07

2.3

4.17

3.13

M5

0.8

8

4

3880

3.88

2.91

6.2

4.65

8.43

6.33

M6

1

10

5

5490

6.58

4.94

10.5

7.9

14.3

10.8

M8

1.25

13

6

9990

16

12

25.6

19.2

34.8

26.1

M8

1

13

6

10700

17.1

12.8

27.4

20.5

37.3

27.9

M 10

1.5

16

8

15825

31.7

23.8

51

38

69

52

M 10

1.25

16

8

16700

33.4

25.1

53

40.1

73

55

M 12

1.75

18

10

23025

55

41.4

88

66

120

90

M 12

1.25

18

10

25150

60

45.3

96

72

130

98

M 14

2

21

12

31400

88

66

140

105

190

145

M 14

1.5

21

12

34125

96

72

155

115

210

155

M 16

2

24

14

42850

135

105

220

165

300

225

M 16

1.5

24

14

45600

145

110

235

175

320

240

M 20

2.5

30

17

66875

270

200

430

320

580

435

M 20

1.5

30

17

74250

295

225

475

355

650

485

= with lubricant

6

Class 5.8

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

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

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

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

TORQUE SETTINGS

UNF thread

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

UNF thread

REVOLVING FEMALE jic 37° Torque setting Nm Size

Nominal torque

min / max

M 12x1.5

6

20

15 -25

7/16-20

-4

15

9 - 21

M 14x1.5

8

38

30 - 45

1/2-20

-5

20

13 - 27

45

38 - 52

9/16-18

-6

30

18 - 42

3/4-16

-8

50

30 - 70

7/8-14

-10

69

44 - 94

1.1/16-12

-12

98

63 - 133

1.3/16-12

-14

118

73 - 163

1.5/16-12

-16

140

90 - 190

1.5/8-12

-20

210

135 - 285

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

8 10 10 12 12 14 15

51

43 - 85

58

50 - 65

74

60 - 88

M 24x1.5

16

74

60 - 88

1.7/8-12

-24

290

200 - 380

M 26x1.5

18

105

85 - 125

2.1/2-12

-32

450

300 - 600

135

115 - 155

166

140 - 192

30

240

210 - 270

35

290

255 - 325

330

280 - 380

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

UNF thread G1/4

20 22 25 28

38 42

BSP REVOLVING FEMALE Torque setting Nm

UNF thread

ORFS REVOLVING FEMALE Torque setting Nm Size

Nominal torque

max.

Nominal torque

max

20

15 - 25

9/16-18

-4

14

16

-6

24

27 47

G3/8

34

27 - 41

11/16-16

G1/2

60

42 - 76

13/16-16

-8

43

G5/8

69

44 - 94

1-14

-10

60

68

G3/4

115

95 - 135

1.3/16-12

-12

90

95

G1

140

115 - 165

1.3/16-12

-14

90

95

G1.1/4

210

140 - 280

1.7/16-12

-16

125

135

G1.1/2

290

215 - 365

1.11/16-12

-20

170

190

G2

400

300 - 500

2-12

-24

200

225

2-1/2-20

-32

460

490

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

7

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

• • • • • • •

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

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

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

8

SERVICE CONTENTS Presentation.........................................................................................10 Installation............................................................................................14 Diagnostics and measurement..........................................................19 Electrical system.................................................................................24 Hydraulic system.................................................................................38 Mechanics of the base truck..............................................................52 Mast......................................................................................................62 Braking system....................................................................................68 Maintenance.........................................................................................70

9

PRESENTATION

SERVICE

TRUCK PRESENTATION The stacker with driving on ground model MS15UX 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 MS15UX

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)

697

1.9

Wheelbase

y (mm)

1383

2.1

Service weight (with battery)

kg

1170/1195/1210/1220

2.2

Axle loading with load (front/rear)

kg

1440 / 1280

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)

520

3.7

Rear track width

b 11 (mm)

405 / 530

4.2

Height, mast closed

h 1 (mm)

2050/2210/2410

4.3

Free lift (optional)

h 2 (mm)

1570/1740/1940

4.4

Lift height

h 3 (mm)

4500/5000/5600

4.5

Height, mast extended

h 4 (mm)

5030/5510/6110

4.9

Extended height in driving position, min/max

h 14 (mm)

670 / 1300

4.15

Height with forks lowered

h 13 (mm)

90 1950

870 / 350 Polyurethane 250 x 70

1x + 1 / 4

4.19

Total length

l 1 (mm)

4.20

Length to face of forks

l 2 (mm)

878

4.21

Overall width

b 1 (mm)

820

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)

2450

4.34

Aisle width with pallet 800mm x 1200mm crossways

A st (mm)

2420

4.35

Turning radius

W a (mm)

1575

5.1

Travel speed with/without load

km/h

5.8 / 6

5.2

Lifting speed laden/unladen

m/s

0.11 / 0.15

5.3

Lowering speed laden/unladen

m/s

0.12 / 0.12

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 (300)

6.5

Battery weight

kg

220 (260)

Battery size (L x w x h) Additional data

Yale MS15UX

8.4

Sound pressure level at operator position DIN 12503

Electro magnetic

mm

dB (A)

1.2 (AC)

625x254x500

65

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 - 3 stage FFL

MS15UX

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

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.

15

SERVICE

INSTALLATION

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

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

Item

Controller

Check points Tiller

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

Brake clearance

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

Tiller

Check the tightening level and rotation flexibility.

Oil pipe

Check for leak.

Hydraulic oil

Check that the quantity of oil is adequate.

6

Lifting oil cylinder

Check for leak.

7

Pins, screws and all fastening devices

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

8

State of wear

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

9

Upload

Check the battery charge level on the display.

Electrolyte

Check the electrolyte level and density.

Connection line

Check the connections

Horn

Press the horn to check its operation

Operation

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

Truck frame

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

Operation

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

Check that there are no anomalous noises.

1 Braking system 2 3

Steering

4 5

Hydraulic system

Wheels

10

Battery

11 12

Horn

13

Instrumentation

15 Other 16

16

Description

(e.g.

SERVICE

INSTALLATION

17

DIAGNOSTICS AND MEASUREMENTS

CONTROLLER DESCRIPTION TRACTION CONTROL DEVICE 1230

(C)

18

(B)

(A)

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

KC-1 Key switch input KC-2 Interlock KC-3 Slow travel request KC-4 Not used KC-5 Not used KC-A6 Throttle potentiometer output KC-A7 Not used KC-A8 Not used KC-A9 Negative reference KC-A10 Not used KC-A11 Lifting request KC-A12 Descent request KC-A13 Forward travel request KC-A14 Reverse travel request KC-A15 Emergency reverse request (Belly) KC-A16 Emergency reverse control KC-A17 Not used KC-A18 Not used KC-A19 Not used KC-A20 Not used KC-A21 Not used KC-A22 General contactor coil driver KC-A23 Pump contactor coil driver KC-A24 Descent solenoid valve driver KC-B1 12V traction motor encoder output KC-B2 Phase A encoder input KC-B3 Brake return KC-B4 Encoder phase B input KC-B5 Encoder power supply negative reference KC-B6 Electromagnetic brake driver KC-C1 Serial line reception KC-C2 Negative power supply MDI reference KC-C3 Serial line transmission KC-C4 12V MDI power supply

19

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 MAIN MENU MONITOR  Inputs PARAMETER THROTTLE INPUT Angular displacement of the traction control butterfly INTERLOCK SWITCH Interlock button enable/disable FORWARD SWITCH Forward travel button enable/disable REVERSE SWITCH Reverse travel button enable/disable MODE SWITCH Mode selector (Mode 1 or Mode 2).

EMERGENCY REVERSE SWITCH Emergency travel reverse button enable/disable

MAIN MENU MONITOR  Motor + Battery PARAMETER BATTERY VOLTAGE Voltage in Volts at the key input BSOC Battery charge level MOTOR SPEED Motor speed in rpm MOTOR VOLTAGE Motor voltage in Volts MOTOR FREQUENCY Motor frequency in Hertz SLIP Motor sliding frequency in Hertz 20

SERVICE

DIAGNOSTICS AND MEASUREMENTS

MAIN MENU MONITOR  Controller PARAMETER TEMPERATURE Controller internal temperature MAIN CONTACTOR Main contactor opening/closing TOTAL HOURMETER HOURS Total service hour meter TOTAL HOURMETER HOURS Traction Hour Meter

21

DIAGNOSTICS AND MEASUREMENTS

SERVICE

TROUBLESHOOTING

The control device is equipped with a status LED which provides information relating to both the fault code and the fault categories. The integrated status LED positioned on the upper part of the control device shows the fault code when it occurs. During normal operation, in the absence of faults, the status LED turns on with steady light; if a fault is detected, a flashing two-digit code appears, which remains until the fault is resolved.

For example the code 3.2 (main contactor fault), appears as 3 consecutive flashes, a short pause and two consecutive flashes; after a longer pause the cycle is repeated (see figure below).

Please note that only one alarm at a time is displayed on the LED; even if more than one alarm is present at the same time, these are not displayed in sequence.

FAULTS LIST Led Code

Display message Motor speed encoder

1.2

Description The motor encoder pulses are not correct

• Incorrect encoder wiring.

• Control device fault.

The motor is stalled or turns faster than desired.

• Incorrect encoder wiring.

• Motor blocked.

• Insufficient braking torque.

• The P Gain settings at I gain of the motor control are too low.

• Failsafe delay time too short.

Motor phase overcurrent

• Wrong motor wiring.

• Control device fault.

Anomalous control device output

• Wrong motor wiring.

• Control device fault.

Error in the static return to OFF (SRO) sequence

• Wrong start, interlock and direction sequence.

• Wrong type of SRO selected.

• Open direction switch malfunction.

• Sequence delay time too low.

The throttle voltage is too high

• The throttle is damaged • Wrong type of throttle selected.

Motor failsafe

Motor overcurrent 1.3

1.4

Static return to off

2.1

Throttle wiper high

2.2

Emergency Reverse wiring open

2.3

22

MOTOR CHARACTERIZATION FAULT

High pedal disable

Possible cause

Fault in emergency travel reverse wiring.

• Wire and control wire for emergency travel reverse damaged.

Tiller disable sequence error (HPD)

• Wrong start, interlock and direction sequence.

• Wrong type of HDP selected.

• Throttle malfunction.

• Ignition and interlock switch disabled.

• Sequence delay time too low.

• Wrong type of throttle selected.

SERVICE Led Code

DIAGNOSTICS AND MEASUREMENTS

Display message

Description

2.4

Throttle wiper low

Throttle voltage too low

3.1

Multiplexer fault

Multiplexer malfunction

Possible cause • The throttle is damaged.

• Wrong type of throttle selected.

• Multiplexer not correctly wired • Badly inserted or defective multiplexer card.

General contactor soldered or missing.

• Main contactor coil open.

• Main contactor missing or soldered.

• Shorted main contactor driver.

Pre-charge fault

• Control device fault • Low battery voltage.

Wiring or electromagnetic brake driver fault

• Brake coil shorted or open circuit.

• Brake driver fault.

The number of hours set with the Total Disable Hours parameter has been reached

• It is necessary to perform maintenance and set the SERVICE TOTAL EXPIRED parameter to off

The number of hours set with the Drive Disable Hours parameter has been reached

• It is necessary to perform maintenance and set the SERVICE DRIVER EXPIRED parameter to off

The number of hours set with the Total Service Hours parameter has been reached

• It is necessary to perform maintenance and set the SERVICE TOTAL EXPIRED parameter to off

The number of hours set with the Drive Service Hours parameter has been reached

• It is necessary to perform maintenance and set the SERVICE DRIVE EXPIRED parameter to off

The battery voltage is too high

• Battery voltage in overvoltage condition.

• Operation with charger connected.

The battery voltage is too low Battery under voltage

• Battery voltage in the undervoltage condition.

• Battery terminal damaged.

• Damaged battery.

4.3

Temperature cutback

The radiator of the control device is too hot or too cold.

• The temperature of the control device is> 85°C or <-25°C. • Truck overloaded.

• Control device incorrect assembly.

• Operation in extreme environment.

4.4

Anti Tiedown

The mode button is activated at startup.

• The mode button is short-circuited.

• The mode button is in position M2.

5.1

Hardware failure

The hardware is in error

• Control device fault

5.2

Software failure

The software is in error

• Control device fault

5.3

Parameters corrupt

The parameters are corrupt

• Control device fault

Main contactor 3.2 Precharge 3.3

Brake fault

Service total disabled

Service drive disabled 4.1 Service total expired

Service drive expired

Battery overvoltage 4.2

23

ELECTRICAL SYSTEM

WIRING DIAGRAMS Ref

24

Description

KC

Traction control

WK

Tiller board

M1

Traction motor 1.2 kW

M2

Pump motor 3 kW

KM1

Main contactor

KM2

Pump contactor

K1

Emergency switch

K2

Key switch

K3

Interlock sensor

K4

Lift height limit switch

L

Electromagnetic brake

L1

Lowering solenoid valve

SERVICE

ELECTRICAL SYSTEM

3

SERVICE

25

SERVICE

ELECTRICAL SYSTEM

TRUCK COMPONENTS

1 6 2 7 3

8

4

9

5

10

Ref.

26

Description

1

Tiller

2

Traction control

3

Electromagnetic brake

4

Traction motor

5

Lowering solenoid valve

6

Pump control device

7

Pump motor

8

On-board charger

9

Pump unit

10

Castor wheel

SERVICE

ELECTRICAL SYSTEM

ELECTRICAL PANEL COMPONENTS

5

1 2

3

4

6

7

Ref.

Description

1

Traction control device

2

Battery charge level indicator

3

Wrench

4

Fuse

5

Emergency button

6

Contactor

7

Horn button

27

SERVICE

ELECTRICAL SYSTEM

CONTROLS KEY TO TILLER CONTROLS AND MAIN PANEL

5 6

4 1

3

2

8

7

9

10

Ref.

28

Description

1

Tiller control sensor

2

On-Off push button for fork lifting and lowering

3

On-Off push button for fork lifting and lowering

4

Creep Speed Button

5

Emergency reversal button

6

Throttle button

7

Battery charge level indicator

8

Electric lock

9

Power On

10

Power Off

SERVICE

ELECTRICAL SYSTEM

TRUCK FUNCTIONS FORWARD/REVERSE TRACTION ACTUATION CONTROLS

Forward travel (operator side)

Actuators involved

Reverse travel (fork side)

Status

Key switch

ON

Emergency switch

ON

Tiller tilt sensor

ON*

Forward/reverse traction control throttle

forward/reverse rotation

* OFF when the "snail" button is pressed

29

ELECTRICAL SYSTEM

SERVICE

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

Release braking.

Braking on direction reversal.

Emergency braking.

Parking brake.

BRAKING SYSTEM

WHEN DOES IT COME INTO OPERATION?

Release braking

Release of the butterfly drive control

Braking on direction reversal

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

Emergency braking

Parking brake

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

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

SNAIL FUNCTION The "snail" function is used to slow down the truck.

With active acceleration throttle, by pressing the "snail" button (ref.B fig.1) the truck travels at reduced speed. This function is used during a curve to move between the shelves during the goods pick-up phase.

To return to normal operating speed, release the "snail" button while keeping the acceleration throttle activated.

30

B

A

SERVICE

ELECTRICAL SYSTEM

STEERING WHEEL ACTUATION CONTROLS

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

Actuators involved

status

Key switch

ON

Emergency switch

ON

Tiller sensor

ON

Tiller rotation

right/left rotation

31

SERVICE

ELECTRICAL SYSTEM FORK LIFTING/LOWERING ACTUATION CONTROLS

B

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

Actuators involved Key switch

ON

Emergency switch

ON

Fork lifting/lowering

ON-OFF button lifting/ lowering active

Tiller sensor *Only in the case of fork lowering

32

status

ON*

SERVICE

ELECTRICAL SYSTEM

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

control of the 1.2 KW AC motor control for the 3 KW hydraulic pump alarms performances

Technical specifications: Inverter for asynchronous three phase AC motors and chopper for DC pump motors Digital control via microcontroller Nominal voltage:............................................................................24V PWM operating frequency.............................................................16 kHz Maximum control output frequency...............................................>200 Hz Operating temperature in operating environment..........................-40°C ÷ 50°C Operating temperature in storage environment.......-40°C ÷ 85°C

33

ELECTRICAL SYSTEM

SERVICE

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.

1230 CONTROL DEVICE 1230 / program menu / vehicle / rates

1230 / program menu / vehicle / multimode

PARAMETER

Default

PARAMETER

Default

M1 ACCEL RATE

4 sec.

COAST DECEL RATE

2 sec.

M 2 ACCEL RATE

4 sec.

M1 DECEL RATE

1 sec.

M2 DECEL RATE

1.8 sec.

M1 BRAKE RATE

0.1 sec.

M2 BRAKE RATE

0.1 sec.

1230 / program menu / vehicle / speeds

34

1230 / program menu / vehicle / throttle PARAMETER

Default

THROTTLE MAX

80%

THROTTLE MAP

20%

1230 / system / hourmeter

PARAMETER

Default

PARAMETER

Default

M1 MIN SPEED

0%

SERVICE TOTAL EXPIRED

OFF

M2 MIN SPEED

0%

SERVICE DRIVE EXPIRED

OFF

M1 MAX SPEED

100%

M2 MAX SPEED

17%

SERVICE

ELECTRICAL SYSTEM

1230 / program menu / vehicle / rates PARAMETER M1 ACCEL RATE

min.

max.

0.1 sec.

5 sec.

Defines the time taken by the control in mode 1 to accelerate from 0% to 100% with full acceleration request.

M2 ACCEL RATE

0.1 sec.

5 sec.

Defines the time taken by the control in mode 2 to accelerate from 0% to 100% with full acceleration request.

M1 DECEL RATE

0.1 sec.

10 sec.

Defines the time taken by the control in mode 1 to decelerate from 100% to 0% with complete acceleration request.

M2 DECEL RATE

0.1 sec.

10 sec.

Defines the time taken by the control in mode 2 to decelerate from 100% to 0% with complete acceleration request M1 BRAKE RATE

0.1 sec.

5 sec.

Defines the time taken by the control in mode 1 to brake from 100% to 0% when a new direction is selected.

M2 BRAKE RATE

0.1 sec.

5 sec.

Defines the time taken by the control in mode 2 to brake from 100% to 0% when a new direction is selected.

1230 / program menu / vehicle / speeds PARAMETER M1 MIN SPEED

min.

max.

0%

50%

It defines the control output in mode 1 with full acceleration when the speed limitation potentiometer is in the lower position or the speed limitation button requires the minimum speed.

M2 MIN SPEED

0%

50%

It defines the control output in mode 2 with full acceleration when the speed limitation potentiometer is in the lower position or the speed limitation button requires the minimum speed.

M1 MAX SPEED

5%

100%

It defines the control output in mode 1 with full acceleration when the speed limitation potentiometer is in the upper position or the speed limitation button requires the maximum speed.

M2 MAX SPEED

5%

100%

It defines the control output in mode 2 with full acceleration when the speed limitation potentiometer is in the upper position or the speed limitation button requires the maximum speed.

35

SERVICE

ELECTRICAL SYSTEM 1230 / program menu / vehicle / multimode PARAMETER COAST DECEL RATE

min.

max.

0.1 sec.

20 sec.

Defines how quickly the control device reduces the signal to zero when the throttle is released.

1230 / program menu / vehicle / throttle PARAMETER THROTTLE MAX

min.

max.

40%

100%

5%

90%

min.

max.

off

on

Defines the throttle voltage or resistance required to reach 100%. controller output THROTTLE MAP Changes the truck response based on the acceleration input

1230 / system / hourmeter PARAMETER SERVICE TOTAL EXPIRED

Parameter set automatically to on, when the total estimated maintenance time has passed.

SERVICE DRIVE EXPIRED

off

Parameter set automatically to on, when the total estimated maintenance time has passed.

36

on

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 37

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.

38

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.

The "restraining" valves, as opposed to the latter ones are equipped with an opposing spring mechanism. In the direction of free flow, the oil pressure must exceed the force exerted by the spring.

39

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM SYMBOLS

TWO POSITION SOLENOID VALVE

PRESSURE RELIEF VALVE

FILTER

ONE-WAY VALVE

CYLINDER WITH ROD

PUMP

SINGLE ACTING CYLINDER

40

M

ELECTRIC MOTOR

PISTON CYLINDER

BALANCER

LINE CONNECTION

RESERVOIR

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM

41

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

42

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR FORK LIFTING

43

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR FORK LOWERING

44

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

45

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.

46

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.

KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS

A B Ref.

Description

A

Solenoid valve body

B

Coil

47

HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS 3 STAGE FULL FREE LIFT

48

SERVICE

SERVICE

Pos. 1 2

3

4

5

HYDRAULIC SYSTEM

Description

Pos.

Hydraulic Reservoir

7

Washer 16.5

Screw M5X12 (cold room

8

Coupling

Screw M6X12 (normal) Locking washer M5 (cold room)

9

Locking washer M6 (normal) Washer 5 (cold room)

Hydraulic pump 3kW/2.5CC (normal) Hydraulic pump 3kW/3.5CC (cold room) Pipe - lifting height 4.5 m

10

Pipe - lifting height 5.0 m

Washer 6 (normal)

Pipe - lifting height 5.6 m

Flexible hose - lifting height 4.5 m

Cylinder - lifting height 4.5 m /fixed forks

Flexible hose - lifting height 5.0 m

11

Flexible hose - standard configuration

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

Flexible hose - lifting height 5.6 m 6

Description

12

Solid pipe

13

Coupling

14

Solid pipe

15

Solid pipe

16

Coupling

17

Washer

18

Junction block - coupling seat

19

Coupling

20

Exhaust Valve

21

Junction block - coupling seat Cylinder - lifting height 4.5 m Epas

22

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

23

Belt 12X400

24

Hose

49

HYDRAULIC SYSTEM OIL CYLINDER ASSEMBLY THREE STAGE MAST

50

SERVICE

SERVICE

Pos.

HYDRAULIC SYSTEM

Description

Pos.

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

Cylinder - lifting height 4.5 m 10

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

Connecting rod - lifting height 4.5 m 9

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

51

TRUCK BASE MECHANICS

REDUCTION UNIT - DRIVE WHEEL KEY TO TRACTION WHEEL COMPONENTS AND REDUCTION UNIT

52

SERVICE

SERVICE

Ref.

TRUCK BASE MECHANICS

Description

Ref.

Description

1

Bracket

23

Oil drain plug

2

Washer C8

24

Steel magnetic key

3

Washer 8

25

Oil gaskets

4

Screw M8x80

26

5

Revolving unit bearing

27

6

O-Ring 150x2.65

28

Lock nut

7

Gasket cover

29

Lateral cover

8

Screw M6x16

30

Key 14x9x22

9

Reduction unit body

31

O ring 150x3.55

10

Gear 1.25M23

32

Bearing

11

Key

33

Key 6x6x14

12

M14x1.5 Nut

34

Gear 1.25M89

13

2.5x25 Nut

35

M16x1.5 Nut

14

Nut

36

Knob

15

Screw M6x20

37

Ball

16

Screw M24

38

Spring

17

Shaft assembly

39

Cap

18

Seal ring 55x72x8

40

O Ring 75x2.65

19

Bearing

41

Key 5x5x18

20

Seal ring 72

42

Clip 15

Rubber tyres 250x70

43

Cap

21 22

Gear assembly

Polyurethane tyres 250x70 Screw M4x12

53

TRUCK BASE MECHANICS

CASTOR WHEEL ASSEMBLY KEY TO CASTOR WHEEL ASSEMBLY COMPONENTS

54

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

55

SERVICE

TRUCK BASE MECHANICS

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

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

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

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

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

Proceed with the replacement.

A

A

A

Fig. 1

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

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

Proceed with the replacement.

Fig. 2

E C

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

Proceed with the replacement.

56

D

E

D B

SERVICE

TRUCK BASE MECHANICS

LOAD WHEELS KEY TO COMPONENTS OF THE LOAD WHEELS

Pos.

Description

1

Bearing

2

Wheel

3

Circlip

4

Pin

5

Rocker arm

57

SERVICE

TRUCK BASE MECHANICS LOAD WHEEL REMOVAL AND DISASSEMBLY

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

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

Turn the keyswitch to OFF and disconnect the battery.

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

A

Fig. 1

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

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

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

Proceed with the replacement.

E C E

58

D

B Fig. 2

SERVICE

TRUCK BASE MECHANICS

AC MOTOR 1.2KW KEY TO AC 1.2KW MOTOR COMPONENTS

Pos.

Description

1

AC Motor

2

Encoder-I

59

TRUCK BASE MECHANICS TILLER ASSEMBLY KEY TO TILLER ASSEMBLY COMPONENTS

60

SERVICE

SERVICE

TRUCK BASE MECHANICS

Pos.

Description

1

Tiller

2

Screw

3

Final plug

4

Gas spring

5

Screw

6

Ring clip 10

7

Bracket

8

Fixed plate

9

Screw

10

Lock washer

11

Screw M16x1.5

12

Bearing

13

Rubber catch

61

MAST

3 STAGE FULL FREE LIFT MAST KEY TO COMPONENTS

62

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 5.6 m

35

Bearing

4

Screw M6X40

36

Ring 62

5

Locking washer M6

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 clamp

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 M8x20

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

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SERVICE

MAST

CHECKS TO BE CARRIED OUT ON THE MASTS •

Check the masts channels and the rollers (fig. 1).

Fig. 1

•

Check the tube assembly and pulley rotation and clearance (fig. 2).

Fig. 2

•

Check the upper cylinder condition (fig. 3).

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Fig. 3

SERVICE

MAST

•

Check the upper cylinder condition (fig. 4).

•

Check that the tension of the mast chains is well proportioned (fig. 5).

•

Make sure that the forks are level (fig. 6).

Fig. 4

Fig. 5

Fig. 6

•

Make sure that the space between the channels is uniform and that the channels of the internal and intermediate mast are not interlocked with each other (fig. 7).

Fig. 7

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SERVICE

MAST

•

Use the adjustment screw to set the longitudinal distance (ref.

A fig. 8). Check the sliding bearing (ref. B fig. 8) and lock it with a locking nut

Fig. 8

A

66

B

SERVICE

MAST

67

BRAKING SYSTEM

ELECTROMAGNETIC BRAKE KEY TO COMPONENTS

68

SERVICE

SERVICE

BRAKING SYSTEM

HOW TO ADJUST THE BRAKE CLEARANCE After using the truck for a certain period, 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. As shown in the figure, in braking status use a thickness gauge to check the distance between the pad and the magnetic steel and 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 24V DC power supply; the brake start sound can be heard clearly.

69

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.

70

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.

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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.

72

SERVICE

MAINTENANCE

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

CHASSIS

BRAKING SYSTEM

Operation description

Maintenance intervals every 50 hrs 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 hrs 1 month

every 600 hrs 3 months

every 1200 hrs 6 months







Check the general conditions and the presence of anomalies



Check the correct operation of the horn



Frame, operation, cracks, lubrication status, loose fasteners



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



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



Tiller seal and flexibility



Oil leaks in the pipes



Correct dosing of hydraulic oil



Oil leaks in the lifting cylinder



Filter cleaning



ELECTRICAL SYSTEM

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

HYDRAULIC SYSTEM

x



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

x

Plug operation and faults



Key switch operation



Contactor performance and operation



Microswitch operation



Control operation



Traction motor wear



Lifting motor, carbon brush and commutator wear



Steering motor, carbon brush and switch wear



Fuse, complete or not complete



Wiring and terminals, loose or faulty



Polish the irregular contacts with abrasive paper





Replace in case of malfunctions

x

x

Carbon brush and commutator wear



Electrolyte capacity, liquid level check, distilled water





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





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SERVICE

MAINTENANCE

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

REDUCTION UNIT

ELECTRICAL SYSTEM

Operation description

Maintenance intervals every 8 hrs 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 1000 hrs 1 year

every 2000 hrs 24 months

every 3000 hrs 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.

74

SERVICE

MAINTENANCE

75

Part no.: 550224203

Revision: 0 (08/2019)