Download PDF: Service Manual for Yale A989 (MT70-MT80) Forklift

Part no.: 550181164

Revision:

0 (02/2018)

Technical information for Yale service centres

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

A989

MT70 MT80

INTRODUCTION

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

2

SERVICE

INTRODUCTION

SECTIONS This handbook is composed of the following sections: Presentation Installation and setting Diagnostics and measurement Electrical system Basic truck mechanics Routine maintenance

Section 1: Section 2: Section 3: Section 4: Section 5: Section 6:

Use the sections index with the numbered black bands to go quickly to the desired section.

SYMBOLS Signals a danger that can cause accidents 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 to disassembly, observing any notes and information given for the truck to function properly.

3

INTRODUCTION

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.

4

SERVICE

INTRODUCTION

•

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

•

Do not short-circuit the terminals.

•

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

•

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

•

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

•

Always disconnect the battery before working on the electrical system.

•

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

•

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.

5

SERVICE

INTRODUCTION 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)

Coefficient

6

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

SERVICE

INTRODUCTION

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°

7

SERVICE

INTRODUCTION

TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS carefully.

Before disassembling the various parts and nuts and bolts, read the following

Nominal diameter

To make the threaded matings secure, LOCTITE 270 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 LOCTITE 270 effect.

In the cases described, reapply LOCTITE 270 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

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 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

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

8

Class 5.8

SERVICE

INTRODUCTION

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.

9

INTRODUCTION

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.

10

SERVICE

INTRODUCTION

SECTION CONTENTS

Presentation

1

Installation and settings

2

Diagnostics and measurement

3

Electrical system

4

Truck base mechanics

5

Routine maintenance

6

11

INTRODUCTION

12

SERVICE

SERVICE

PRESENTATION

PRESENTATION TRACTOR PRESENTATION................................................................................................................2 V I E W S O F T H E T R A C T O R .................................................................................................3 TRACTOR IDENTIFICATION DATA.....................................................................................................................7 TRACTOR IDENTIFICATION DATA PLATE.................................................................................................7 TRACTOR PUNCHING........................................................................................................................7 LOCATION OF DOCUMENTATION................................................................................................................................8 G E N E R A L S P E C I F I C AT I O N S...................................................................................................9

1

PRESENTATION

SERVICE

TRACTOR PRESENTATION The range of Yale towing tractors consists of two models (T70 and T80) with 3 and 4 wheels with nominal towing capacity of 7000 Kg and 8000 Kg respectively.

Both models can be supplied with or without cab.

The standard equipment includes a 48 Volt AC control device, four different braking systems, a single central headlight, side lights and rear braking lights, a horn, a reverse buzzer and a flashing light that is activated turning the key switch.

The tractor is equipped with a deadman sensor, located under the seat, which prevents the tractor from running when the driver is not seated.

The 4 wheel version is also equipped with electric steering.

The tractors, in standard version, are supplied without battery, which can be requested as an option, as well as the single or double trolley for its extraction.

2

SERVICE

PRESENTATION

VIEWS OF THE TRACTOR MT70

3

PRESENTATION VIEWS OF THE TRACTOR MT80

4

SERVICE

SERVICE

PRESENTATION

VIEWS OF THE TRACTOR MT70 WITH CAB

5

PRESENTATION VIEWS OF THE TRACTOR MT80 WITH CAB

6

SERVICE

SERVICE

PRESENTATION

TRACTOR AND LOAD IDENTIFICATION DATA TRACTOR IDENTIFICATION DATA PLATE

The tractor identification data plate is located on the battery compartment

• • • • •

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

TRACTOR SERIAL NUMBER PUNCHING

The serial number of the tractor is punched on the frame under the main controller in the rear section of the tractor

7

PRESENTATION

SERVICE

DOCUMENTATION POSITION

The truck documentation is located in the dedicated storage compartment in the front of the truck

8

SERVICE

PRESENTATION

GENERAL SPECIFICATIONS MT70

9

PRESENTATION

MT70 WITH OPTIONAL CAB

10

SERVICE

SERVICE

PRESENTATION

(1) (2)

(3)

1.1

Manufacturer (initials)

Yale

1.2

Model designation

MT70

1.3

Power: electrical (battery or mains), diesel, LPG, petrol

1.4

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

1.5

Rated capacity/rated load

Q (t)

7.0

1.7

Traction force

F (N)

1400 (6)

1.9

Wheelbase

y (mm)

1080

2.1

Weight in service (1) (2) (3)

kg

1243

Electric: Battery Seated

2.2

Axle loading, with front/rear load (1) (2) (4)

kg

559 / 884

2.3

Axle loading, without front/rear load (1) (2)

kg

559 / 684

3.1

Wheels: L=pneumatic, V= cushion, SE= superelastic

SE

SE

3.2

Tyre size, front

ø (mm x mm)

376 x 114

3.3

Tyre size, rear

ø (mm x mm)

376 x 114

3.5

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

3.6

Front track width

b 10 (mm)

1/2 (x) -

3.7

Rear track width

b 11 (mm)

882

4.7

Upper guard height (cab)

h 6 (mm)

2055

4.8

Seat height in reference to the SIP (seat index point) specification / platform height

h 7 (mm)

1067

4.12

Tow hitch height

h 10 (mm)

345

4.13

Loading, unloading height

h 11 (mm)

670

4.16

Loading surface length

l 3 (mm)

400

4.17

Protrusion

l 5 (mm)

472

4.17.1

Protrusion, cab

l 5.1 (mm)

0

4.18

Loading surface width

b 9 (mm)

765

4.19

Total length

l 1 (mm)

1950

4.21

Overall width

b 1 / b 2 (mm)

1000

4.32

Ford height, wheelbase centre

m 2 (mm)

120

4.35

Turning radius

W a F (mm)

1726

4.35

Turning radius

W a R (mm)

1089

4.36

Internal turning radius

b 13 (mm)

550

5.1

Travel speed, with load / without load

km/h

11 / 14

5.1.1

Traverse speed, with load/without load, in reverse

km/h

5

5.5

Traction speed, with load / without load

N

10045

5.6

Maximum traction speed, with load / without load

N

10045

5.7

Gradeability with/without load

%

6 / 25

5.8

Maximum gradeability with / without load

%

5.10

Operating brake

6.1

Drive motor, power S2 60 minutes

6 / 25

6.3

Battery according to DIN 43531/35/36 A,B,C, no

6.4

Battery voltage/capacity K5 at 5 hours

6.5

Battery weight (5)

6.6

Consumption per VDI cycle (2012)

Traction

Hydraulic

8.1

Traction control

Additional data

Motor units

Performance

Dimensions

Wheels, frame

Weight

Characteristics

GENERAL SPECIFICATIONS

10.7

Noise level at operator position

kW

4

(V)/(Ah)

48 / 315 (7)

43531 / A

kg

548

kWh/h

3.93 AC-Controller

dB (A)

50.5

Values referred to the version without cab Version without cab: 2.1

Weight in service (3)

kg

1414

2.2

Axle loading, with front/rear load

(4)

kg

663 / 951

2.3

Axle loading, without front/rear load

kg

663 / 751

With useful load: MT70 1489 kg (without cab) MT70 1619 kg (with cab)

(4) 200 kg useful load on the rear axle (5) These values ​​can vary by +/- 5%.

(6) On a flat and dry surface with rolling resistance of 200N / t.

(7) See “Batteries” table “Installation and Settings” section.

11

PRESENTATION

GENERAL SPECIFICATIONS MT80

12

SERVICE

SERVICE

PRESENTATION

GENERAL SPECIFICATIONS MT80 WITH OPTIONAL CAB

13

SERVICE

PRESENTATION

(1) (2)

(3)

Manufacturer (initials)

Yale

1.2

Model designation

MT80

1.3

Power: electrical (battery or mains), diesel, LPG, petrol

1.4

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

1.5

Rated capacity/rated load

Q (t)

8.0

1.7

Traction force

F (N)

1600 (6)

1.9

Wheelbase

y (mm)

1095

2.1

Weight in service (1) (2) (3)

kg

1215

2.2

Axle loading, with front/rear load (1) (2) (4)

kg

547 / 868

2.3

Axle loading, without front/rear load

kg

547 / 668

3.1

Wheels: L=pneumatic, V= cushion, SE= superelastic

3.2

Electric: Battery Seated

(1) (2)

SE

SE

Tyre size, front

ø (mm x mm)

376 x 114

3.3

Tyre size, rear

ø (mm x mm)

376x 114

3.5

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

2/2 (x)

3.6

Front track width

b 10 (mm)

858

3.7

Rear track width

b 11 (mm)

882

4.7

Upper guard height (cab)

h 6 (mm)

2055

4.8

Seat height in reference to the SIP (seat index point) specification / platform height

h 7 (mm)

1067

4.12

Tow hitch height

h 10 (mm)

345

4.13

Loading, unloading height

h 11 (mm)

670

4.16

Loading surface length

l 3 (mm)

400 472

4.17

Protrusion

l 5 (mm)

4.17.1

Protrusion, cab

l 5.1 (mm)

0

4.18

Loading surface width

b 9 (mm)

765

4.19

Total length

l 1 (mm)

1950

4.21

Overall width

b 1 / b 2 (mm)

1000

4.32

Ford height, wheelbase centre

m 2 (mm)

120

4.35

Turning radius

W a F (mm)

2048

4.35

Turning radius

W a R (mm)

1576

4.36

Internal turning radius

b 13 (mm)

1050

5.1

Travel speed, with load / without load

km/h

11 / 14

5.1.1

Traverse speed, with load/without load, in reverse

km/h

5

5.5

Traction speed, with load / without load

N

10045

5.6

Maximum traction speed, with load / without load

N

10045

5.7

Gradeability with/without load

%

5 / 25

5.8

Maximum gradeability with / without load

%

5.10

Operating brake

6.1

Drive motor, power S2 60 minutes

6.3

Battery according to DIN 43531/35/36 A,B,C, no

6.4

Battery voltage/capacity K5 at 5 hours

6.5

Battery weight (5)

6.6

Consumption per VDI cycle (2012)

Traction

8.1

Traction control

10.7

Noise level at operator position

kW

14

4 43531 / A

(V)/(Ah)

48 / 315 (7)

kg

548

kWh/h

4.58 AC-Controller

dB (A)

Values referred to the version without cab Version without cab: 2.1

Weight in service (3)

kg

1414

2.2

Axle loading, with front/rear load (4)

kg

663 / 951

2.3

Axle loading, without front/rear load

kg

663 / 751

With useful load: MT80 1489 kg (without cab) MT80 1619 kg (with cab)

5 / 25 Hydraulic

Additional data

Motor units

Performance

Wheels, frame

Weight

Characteristics

GENERAL SPECIFICATIONS 1.1

(4) 200 kg useful load on the rear axle (5) These values ​​can vary by +/- 5%.

(6) On a flat and dry surface with rolling resistance of 200N / t.

(7) See “Batteries” table “Installation and Settings” section.

59.3

SERVICE

INSTALLATION AND SETTINGS

INSTALLATION AND SETTINGS B E F O R E T H E I N S TA L L AT I O N ........................................................................................2 B AT T E R Y A N D W E I G H T TA B L E ......................................................................................2 MACHINE

A S S E M B L Y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

L I S T O F M AT E R I A L S R E C E I V E D F R O M T H E D E A L E R ....................................................4 UNLOADING THE TRUCK MODEL MT70...............................................................5 UNLOADING

THE

TRUCK

MODEL

MT80.............................................6

PA R K I N G B R A K E R E L E A S E P R O C E D U R E I N C A S E O F FA I L U R E ...................................8 B AT T E R Y I N S TA L L AT I O N - R E P L A C E M E N T.....................................................................9 W I T H V E RT I C A L E X T R A C T I O N............................................................................................9 WITH LATERAL EXTRACTION..................................................................................................................................10 B AT T E R Y C A B L E C O N N E C T I O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 LIST AND DESCRIPTION OF ADJUSTMENTS AND SETTINGS TO BE CARRIED OUT................................13 CHECK THE CONDITIONS OF USE OF THE TRACTOR.....................................................................................13 SETTING THE BATTERY VOLTAGE.......................................................................................................................14

1

SERVICE

INSTALLATION AND SETTINGS

BEFORE INSTALLATION Make sure in advance that all the tools required to unload the tractor 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 tractor is to be installed.

BATTERY AND WEIGHT TABLE

2

Yale

1.1

Manufacturer

1.2

Model designation

2.1

Weight in service (1)

Kg

1140

1243

1240

1280

2.2

Axle loading, with front / rear load (2)

Kg

513/827

559/884

558/882

576/904

2.3

Axle loading, without front / rear load

Kg

513/627

559/684

558/682

576/704

6.3

Battery in compliance with DIN 43531/35/36 A, B, C, no

43531/A

43531/A

43531/A

43531/A

6.4

Battery voltage / capacity K5

(V)/(Ah)

48/240

48/315

48/345

48/375

6.5

Weight in service (3)

Kg

445

548

545

585

1.1

Manufacturer

1.2

Model designation

2.1

Weight in service (1)

Kg

1112

1215

1212

1252

2.2

Axle loading, with front / rear load (2)

Kg

500/812

547/868

545/867

563/889

2.3

Axle loading, without front / rear load

Kg

500/612

547/668

545/667

563/689

6.3

Battery in compliance with DIN 43531/35/36 A, B, C, no

43531/A

43531/A

43531/A

43531/A

6.4

Battery voltage / capacity K5

(V)/(Ah)

48/240

48/315

48/345

48/375

6.5

Weight in service (3)

Kg

445

548

545

585

1.1

Manufacturer

1.2

Model designation

2.1

Weight in service (1)

Kg

1262

1365

1362

1402

2.2

Axle loading, with front / rear load (2)

Kg

593/869

642/923

640/922

659/943

2.3

Axle loading, without front / rear load

Kg

593/669

642/923

640/722

5659/743

6.3

Battery in compliance with DIN 43531/35/36 A, B, C, no

43531/A

43531/A

43531/A

43531/A

6.4

Battery voltage / capacity K5

(V)/(Ah)

48/240

48/315

48/345

48/375

6.5

Weight in service (3)

Kg

445

548

545

585

MT70 WITHOUT CAB

Yale MT80 WITHOUT CAB

Yale MT70 WITH CAB

SERVICE

INSTALLATION AND SETTINGS

Yale

1.1

Manufacturer

1.2

Model designation

2.1

Weight in service (1)

Kg

1297

1400

1397

1437

2.2

Axle loading, with front / rear load (2)

Kg

610/887

658/942

640/922

659/943

2.3

Axle loading, without front / rear load

Kg

610/687

658/742

657/740

675/762

6.3

Battery in compliance with DIN 43531/35/36 A, B, C, no

43531/A

43531/A

43531/A

43531/A

6.4

Battery voltage / capacity K5

(V)/(Ah)

48/240

48/315

48/345

48/375

6.5

Weight in service (3)

Kg

445

548

545

585

MT80 WITH CAB

(1)

With useful load: MT70 1443 kg, T8.0HS4 1415 kg. (without cab) MT70 1565 kg, T8.0HS4 1600 kg. (with cab) (2) 200 kg useful load on the rear axle (3) These values ​​can vary by +/- 5%.

All values in ​​ the tables are nominal and subject to tolerances. For more information, please contact the manufacturer.

Yale products can be changed without notice.

The trucks illustrated may be equipped with optional equipment. The values may ​​ vary depending on the different configurations.

3

SERVICE

INSTALLATION AND SETTINGS

MACHINE ASSEMBLY LIST OF MATERIALS RECEIVED FROM THE DEALER

2

3

1 4

5

6

The materials received from the dealer may vary according to whether or not optional accessories are included.

Ref.

4

Description

1

Tractor

2

Battery plug extension

3

Battery charge plug (optional)

4

External battery charger (optional)

5

Battery (optional)

6

Top up bottle for battery electrolyte (optional)

(optional)

SERVICE

INSTALLATION AND SETTINGS

UNLOADING THE TRUCK MODEL MT70 Equipment and tools

forklift truck load capacity 1500 kg

bridge crane load capacity 2000 kg

spacer bar

no. 4 lift belt load capacity 2000 kg

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

Phase 1 FORKLIFT TRUCK Pick up the pallet using the lift truck, raise and carry the tractor to a safe place, away from the transit areas of other vehicles and pedestrian traffic.

Remove the packaging.

Phase 2 BRIDGE CRANE - SPACER BAR - LIFT BELT Sling the truck with the lifting slings through the holes at the base of the bodywork (ref.A fig.1) and attach them to the spacer bar.

Ensure that the bridge crane is positioned vertically above the tractor to be lifted.

Attach the slings to the pendant and attach it to the bridge crane, lift the tractor and position it on the ground slowly.

5

INSTALLATION AND SETTINGS

SERVICE

UNLOADING THE TRUCK MODEL MT80 Equipment and tools

forklift truck load capacity 1500 kg

bridge crane load capacity 2000 kg

spacer bar

no. 4 lift belt load capacity 2000 kg

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

Phase 1 FORKLIFT TRUCK Pick up the pallet using the lift truck, raise and carry the tractor to a safe place, away from the transit areas of other vehicles and pedestrian traffic.

Remove the packaging.

Phase 2 BRIDGE CRANE - 4 LIFTING SLINGS Sling the truck with the lifting slings through the holes at the base of the bodywork (ref.A fig.1).

Ensure that the bridge crane is positioned vertically above the tractor to be lifted.

Attach the slings to the pendant and attach it to the bridge crane, lift the tractor and position it on the ground slowly.

6

SERVICE

INSTALLATION AND SETTINGS

If it is not possible to unload the tractor from the truck using a forklift and/or overhead crane, it is advisable to connect an auxiliary battery to the tractor so that the tractor can be moved normally.

If an auxiliary battery is not available, it is advisable to lift the tractor with a forklift of adequate capacity.

7

SERVICE

INSTALLATION AND SETTINGS PARKING BRAKE RELEASE PROCEDURE IN CASE OF FAILURE Equipment and tools

In the event that the tractor can not be moved due to a fault, it is necessary to release the parking brake in order to move it.

Fig. 1

A flat head screwdriver

Procedure Before starting work, ensure that you are wearing suitable protective clothing. Remove the load and disconnect the battery.

B C

Phase 1 Make sure that the gear selector lever (ref.A fig.1) of the tractor is in the neutral position.

Fig. 2

C

Phase 2 FLAT HEAD SCREWDRIVER Use a flat head screwdriver to loosen the 6 screws (ref.B fig.2) that secure the load plate (ref.C fig.2) to the bodywork and remove it.

1 2 Fig. 3

Phase 3 Turn off the electromagnetic parking brake, disconnecting the connector (1) (ref.C fig.3) and connecting it to the connector (2) (ref.D fig.4).

D

At this point the tractor can be moved.

1

Fig. 4 8

2

SERVICE

INSTALLATION AND SETTINGS

INSTALLATION - BATTERY REPLACEMENT VERTICAL EXTRACTION Equipment and tools

bridge crane load capacity 2000 kg

lift belt load capacity 2000 kg

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

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

Phase 1 Open the battery compartment cover (Fig. 1) Phase 2 BRIDGE CRANE - LIFT BELTS Hook the battery using the dedicated holes (fig. 2 pos. A).

Make sure you have disconnected and removed the battery cables Ensure that the bridge crane (fig. 2 pos. B), is positioned at right-angles to the battery Lift the battery and position it at right-angles to the battery compartment.

Carefully lower the battery, making sure it is placed on a level surface, then release it.

Fig. 1

B

A

CAUTION! Pay attention to the hands when placing the battery in its compartment in order to avoid injury.

During this step, be careful not to pinch the battery cable between the battery and the tractor chassis.

Phase 3 Connect the battery to the electric system of the tractor and close the battery compartment cover

Fig. 2

9

SERVICE

INSTALLATION AND SETTINGS WITH LATERAL REMOVAL

Equipment and tools

bridge crane load capacity 1600 kg

spacer bar

rollerway

Fig. 1

A C

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

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

Phase 1 Switch off the tractor. Open the lateral door of the battery compartment and disconnect the battery from the electrical system using the appropriate handle (fig. 1 pos.A) Open the right door of the tractor, if present, (fig. 2 pos.B), release the safety hook (fig. 2 pos.C) of the door so that it can be fully opened.

Phase 2 Open the left door, if present (fig. 3).

Then open the upper cover of the battery compartment (fig. 3 pos. E) and release the battery lock.

10

Fig. 2

D

It the tractor is provided with PVC doors they must be rolled up.

The battery socket and tractor plug must only be separated when the tractor is switched off.

B

E

SERVICE

INSTALLATION AND SETTINGS

Phase 3 Hook the battery using the dedicated holes (fig.4 pos F).

With a forklift truck of suitable capacity, equipped with a special accessory, lift the battery slightly and at the same time remove it carefully from inside the battery compartment. Lower the battery very carefully and place it in a safe place.

To insert the battery, hook it using the dedicated holes (fig. 4 pos. F).

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

Pay attention to the hands when placing the battery in its compartment in order to avoid injury.

During this step, be careful not to pinch the battery cable between the battery and the tractor chassis.

F

Fig. 4

Make sure the battery is properly inserted, checking that it does not protrude beyond the tractor outline.

D

G

E

Phase 4 Turn the battery block, if present (fig. 5 pos. G) downward until it locks.

Connect the battery socket with the tractor plug.

The battery socket and tractor plug must only be connected when the tractor is switched off.

Fig. 5

Phase 5 Close the battery compartment lateral door (pos. A fig.5).

Close the upper cover of the battery compartment.

Close the left door.

Re-insert and hook the safety hook on the right door (fig. 2 pos. C) and close it.

11

INSTALLATION AND SETTINGS

SERVICE

CONNECTION OF CABLES TO BATTERY The battery poles are marked with the colour red or the + symbol to identify the positive pole, and with the colour blue or the symbol to identify the negative pole.

The battery connector cables are in turn marked with a stripe in red for the connection to the positive pole and a stripe in blue for the connection to the negative pole.

After connecting the cables to the battery terminals, apply Vaseline to protect against corrosion.

_ +

BLUE clamp. Cable connection to negative pole

RED clamp. Cable connection to positive pole

Positive pole - colour RED

+

12

Negative pole colour BLUE

_

SERVICE

INSTALLATION AND SETTINGS

LIST AND DESCRIPTION OF THE SETTINGS AND ADJUSTMENTS TO BE CARRIED OUT After assembling all the machine's components as described in the previous pages, the following operations must be carried out in the sequence given:

• Check the conditions of use of the tractor • Battery voltage setting CHECK THE CONDITIONS OF USE OF THE TRACTOR In order to ensure the safety personnel and materials, before proceeding with the operations described below, it is important to assess the following:

• the type of load to be moved • The general conditions of the warehouse, the aisles and the flooring Having carried out these assessments, check whether the conditions encountered are compatible with the tractor performance levels set:

• • • •

maximum traction speed traction acceleration reduction of traction speed braking

13

INSTALLATION AND SETTINGS

SERVICE

BATTERY VOLTAGE SETTING If a battery that is not provided by the factory is installed on the truck, the battery voltage on the COMBI AC module must be set.

To carry out this regulation, it is good practice to proceed with an additional charging period for the battery used on the carriage in order that it may provide the maximum voltage.

Equipment and tools

Programmer

Tester

Procedure With the engine turned off connect the programmer Turn the machine on(ON switch) and select the following parameter: COMBI / config menu adjustment / adjust key volt. (fig.3) COMBI / config menu adjustment / adjust battery (fig.4) With the tester measure the exact voltage of the battery on the traction controller between the negative pole (-Batt) and the positive pole measured on "pin 10" of the connector A (fig. 3). The parameter "adjust key volt." must be set with the value of this voltage.

With the tester measure the exact voltage of the battery on the traction controller between the negative pole (-Batt) and the positive power connection (+Batt) (fig.4). The parameter "adjust battery" must be set with the value of this tension.

Save the parameters.

Turn the machine off (switch key OFF) and disconnect the programmer.

Turn the machine back on (ON switch).

It may occur that using the truck and discharging the battery, after the first full charge the battery charge indicator signals a value less than 100%.

If this happens, with the machine off connect the programmer. Switch on the machine (key ON) and select the following parameter: COMBI / config menu adjustment / bat. max adj.

Increase the regulating level to adapt the charge algorithm to the kind of battery.

14

SERVICE

INSTALLATION AND SETTINGS

-BATT

+

24

35

13

23

1

12

Fig. 3

-BATT

+BATT

+

24

35

13

23

1

12

Fig. 4

15

SERVICE

DIAGNOSTICS AND MEASUREMENTS

DIAGNOSTICS AND MEASUREMENTS DESCRIPTION OF MODULE CONNECTORS...........................................................................................2 COMBI ACE2 MODULE..........................................................................................2 MENU .........................................................................................................................................4 T E S T E R M A I N M E N U ...............................................................................................................4 TROUBLESHOOTING ACE2 MODULE DIAGNOSIS SYSTEM............................................................................. 6 ELECTRICAL COMPONENT MEASUREMENTS............................................................................................13 ELECTROMAGNETIC BRAKE COILS......................................................................................................13 MOTORS.................................................................................................................................................................14

1

DIAGNOSTICS AND MEASUREMENTS

DESCRIPTION OF MODULE CONNECTORS COMBI ACE2 MODULE

Ref. A

Ref. B

2

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

WIRING DIAGRAM PIN REFERENCE A: A1: A2: A3: A4: A5: A6: A7: A8: A9: A11: A12: A13: A14: A15: A16: A17: A18: A22: A23: B: B5: B6:

Upper connector Power supply connection through 10 Amp fuse Accelerator power positive Accelerator power signal Forward gear input Reverse gear input Seat input. Active when connected to - BATT. Motor incremental encoder phase A input Motor incremental encoder positive power supply accelerator power negative and seat switch If not connected to -BATT, the main contactor, the EMP coils and the coil supply output are deactivated. In the combi configuration it is connected to the Safety Out (CAN#19) of the pump control device When connected to A21 (CAN H), it introduces a thermal resistance of 120 Ω between CAN H and CAN L Speed reduction input (manual brake). Active with open switch. Not active with switch closed on -BATT Motor incremental encoder phase B input Motor encoder negative power supply Line contactor coil output. The coil is negatively driven.

EMG positive and line contactor coil positive Electromagnetic brake negative. It controls the electromagnetic brake Positive input for motor temperature sensor (analog or digital) Negative input for motor temperature sensor (analog or digital) Lower connector MDI display power supply (negative) MDI display power supply (positive)

3

SERVICE

DIAGNOSTICS AND MEASUREMENTS

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

Certain of these menu parameters refer to functions whose status is received via Can bus, others refer to functions directly connected to the analog/digital inputs of the module. The following list shows the relative measurements.

TESTER MAIN MENU PARAMETER BATTERY VOLTAGE

measurement unit Volt/100

Battery voltage measured between B+ and B- on the control MOTOR VOLTAGE

%

Voltage supplied to the motor by the inverter; it is expressed as a percentage of the maximum voltage (which depends on the battery voltage) VOLTAGE BOOSTER

%

This is the voltage booster supplied to the motor in the load condition and is expressed as a percentage of the total voltage.

FREQUENCY

Hz/100

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

Hz/100

Real speed detected by the AC traction motor encoder SLIP VALUE

Hz/100

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

Amps

RMS current applied to the AC traction motor MOTOR POWER It is the power supplied to the motor.

BATTERY CHARGE

%

Battery charge percentage level.

TEMPERATURE

°

Temperature of the inverter measured on the heat sink MOTOR TEMPERATURE Traction motor temperature.

4

°

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER

measurement unit

ACCELERATOR

Arms

Accelerator potentiometer voltage (CPOT). The voltage level is shown on the left side of the console display and the percentage value is shown on the right.

HANDLE/SEAT SW Level of the handle/seat digital input. ON active input, OFF input not active FORWARD SWITCH Forward gear digital input level. ON active input, OFF input not active BACKWARD SWITCH Reverse gear digital input level. ON active input, OFF input not active BACKING ENABLE If ON: the inching function is available. A19 input enable, A4 input forward gear request and A5 reverse gear request CUTBACK SWITCH Speed​reduction microswitch level. ON active input of the speed reduction microswitch. OFF non-active input of the speed reduction microswitch HANDBRAKE Brake pedal microswitch level. ON active input of the brake pedal. OFF non-active input of the microswitch.

BRAKE / Q.I. POW. Brake pedal pressure percentage. (100% pedal totally pressed, 0% pedal released) 2ND HOURMETERS It displays the working hours of the traction control device

5

DIAGNOSTICS AND MEASUREMENTS

SERVICE

TROUBLESHOOTING: ACE2 MODULE DIAGNOSIS SYSTEM The diagnosis system is divided into two main groups: ALARMS When an alarm is detected, the current to the motors of the modules involved is cut off. The remote-control switch opens and the electromagnetic brake is activated.

These alarms are connected to: • breakdowns in the motors/modules, the power system is no longer able to supply current to the motors.

• breakdowns connected with safety.

WARNINGS When a warning occurs, the module is operating properly but it is found conditions to reduce performance, or to stop the truck, without affecting the power devices.

These warnings are connected to: • incorrect starting sequences by the operator.

• conditions that require a reduction of performance (as for example high temperatures, ...)

The alarms are shown on the display with the following format xxAyyy, where xx is the node and yyy is the MDI code.

ACE2 - ALARMS MODULE Alarm

Code MDI

WATCHDOG#1

8

Cause: At the start-up the watchdog signal is active even before the software has generated it.

In stand-by or operating conditions, the watchdog signal is not active.

WATCHDOG#2

The watchdog hardware circuit or module are damaged. Replace the module.

8

Cause: At the start-up the watchdog signal is active even before the software has generated it.

In stand-by or operating conditions, the watchdog signal is not active.

LOGIC FAILURE #3

The watchdog hardware circuit or module are damaged. Replace the module.

17

Cause: A hardware problem pertaining to the logic card as a protection against high current values (overload).

STBY I HIGH Cause: In standby condition, the sensor detects a current value different from zero

6

Troubleshooting

This type of failure is not connected to external components, so when it manifests itself the module needs replacing.

53 The current sensor or the current feedback circuit is damaged. Replace the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

Alarm

Code MDI

Troubleshooting

LOGIC FAILURE #1

54

• The alarm can be caused by a key input signal characterized by a voltage below the threshold that could be due to external loads such as DC/AC converters start, relays or contactors switching on, activation or disabling of the solenoid valves. Remove these loads.

• If no voltage is detected on the power supply line and the alarm is present each time the key is turned, the fault is probably in the hardware part of the module. Replace the module.

• If the fault is displayed after the motor is started or after an acceleration or following a hydraulic request, check the batteries charge status and the electrical connections.

Cause: This alarm appears when the module detects an under voltage condition. The limit for the under voltage is 11 V for the 36/48V and 30 V modules for the 80V modules.

LOGIC FAILURE #2

55

Cause: A fault in the hardware section of the logic card that oversees the retroaction of the phase voltage.

CAPACITOR CHARGE

This type of failure is not connected to external components, so when it manifests itself the module needs replacing.

60

Cause: To get a better understanding of the significance of this alarm, take a look at the following diagram: • Check that there is an external load in parallel with the capacitors, that lowers the module pre-charge circuit current, preventing its charging.

Check if a lamp or a dc/dc converter or an auxiliary load is connected.

• The charge resistance is open; add a power resistance over the remotecontrol switch terminals; if the alarm goes off it means that the module's internal charge resistance is damaged. Replace the module.

• The charging circuit is faulty inside the module. Replace the module.

• There's a problem in the module's power section. Replace the module.

When the key is turned on at ON, the inverter tries to load the condenser through the power resistance and check if the condenser has charged within a certain time frame. If the capacitor voltage is less than 20% of the nominal voltage of the battery, an alarm is generate and the general remote control switch is not closed.

THERMIC SENS. NOT OK

61 This alarm is not connected to external components, it is necessary to replace the module.

Cause: The output value of the module heat sensor is out of the interval.

TH.PROTECTION

62

Cause: This alarm appears if the temperature measured on the control heat sink is above 85°C. When this temperature is reached, the current is reduced proportionally to the increase in temperature up to the value of 0 Ampere corresponding to 105°C.

MOTOR TEMP

• Check the temperature of the control.

• If the alarm appears when the module is cold,there could be a fault in the thermal sensor and a fault in the logic card. In this case the control needs to be replaced.

65

Cause: This warning appears when the temperature sensor is open or if the MAX MOTOR TEMP threshold has been exceeded.

AUX COIL SHORT Cause: The electromechanical brake or auxiliary solenoid coil driver is short-circuited

68

Check the heat sensor inside the motor; check the ohms value of the sensor and the wiring. If the sensor is OK, improve the motor ventilation. If the alarm is present when the motor is cold, the problem is located inside the module, which must be replaced.

• Check if a short-circuit or low-impedance occurred between NEB/NAUX (CNA#18) and -BATT • The circuit of the driver of the logic board is damaged. Replace the module.

7

DIAGNOSTICS AND MEASUREMENTS

Alarm

Code MDI

FLASH CHECKSUM

71

Cause: After switching the key to on, the software checks the integrity of the program saved in the flash memory. If the check has a negative result, this alarm is generated.

WRONG RAM MEMORY

71

• Try to carry out a reset of the EEPROM (clear eeprom) using the programming console.

• Turn off the key "key-OFF" and then restart "key-ON" and check the result.

• If the alarm persists, replace the module.

• If the alarm goes off, the parameters previously memorized will be replaced by default parameters.

72

• •

Cause: Before switching on the remote control switch, the software checks the voltage on the jumper without operating it.

DRIVER SHORTED

• •

74

Cause: The driver of the main remote-control switch coil has shorted out.

CONTACTOR DRIVER

75 Check the remote-control switch power contacts; replace the remotecontrol switch if necessary.

76

Cause: Problems on the hardware circuits which manage the guard against the main remote control switch and electromagnetic brake short circuit

MC COIL SHORT Cause: This alarm is generated when there is a short circuit of the M coils connected to the CNA#16 output. After eliminating the causes of the overload, the alarm disappears automatically and when a traction request is activated.

8

• Check if there is a short circuit or a low pull-down impedance between the A16 and -BATT. • The driver circuit inside the module is damaged and the module must be replaced.

This kind of failure is not connected to external components; replace the module.

Cause: Before activating the remote-control switch coil, the module verifies if the remote-control switch is blocked. The module activates the power section for a few milliseconds trying to discharge the remote-control switch capacitors. If this doesn't happen an error status is recorded.

COIL SHORT HW NOT OK

Check the motor power cables Check the impedance between the U, V, and W and -Batt terminals of the module.

Check the motor loss to the truck motor If the motor connections are OK and there is no low external impedance, the problem is within the module that had to be replaced.

75

Cause: The remote-control switch coil driver is not capable of piloting the load. This same device or the piloting circuit are damaged.

CONTACTOR CLOSED

The problem could be in the flash memory of the microprocessor that could be damaged or in the program saved in it that could be corrupted.

Reprogram the logic again.

If the alarm persists, the problem is in the microcontroller and the ACE logic board must be replaced

Switch the tractor off and then back on.

If the alarm persists, replace the module.

Cause: This alarm is due to a defect in the hardware or in the non volatile memory software that supports the module parameters.

This alarm does not block machine operation, but the tractor operates under default values.

VNM LOW

Troubleshooting

71

Cause: The algorithm implemented to check the main RAM registers detects incorrect content: the register is “dirty”. This alarm inhibits the operation of the machine.

EEPROM NOT OK

SERVICE

• If the alarm appears, then the problem is inside the module.

• Replace the module.

76 The most frequent causes for this type of error are to be found in the wiring or charging coil. Therefore, check the connections between the outputs of the control device and the loads.

If no anomalies or faults are found, the problem is in the control device which must be replaced.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

Alarm

Code MDI

KEY OFF SHORT

76 • Check that the battery has the same nominal voltage as the inverter.

• Check the battery voltage, if it is out of range, replace the battery.

• If the problem persists, replace the logic board.

Cause: The logic board measures a voltage on the key that is constantly out of range below the minimum allowed value.

CONTACTOR OPEN

77

Cause: The main remote-control switch coil is activated by the module, but the remote-control switch doesn't close.

VACC NOT OK

• Check the wiring • Check the mechanical calibration and the operation of the accelerator potentiometer.

• Acquire the maximum and minimum value of the potentiometer through the PROGRAM VACC function.

• If the problem persists, replace the logic board.

78

Cause: The accelerator pedal is not set correctly.

FORW + BACK

• Reprogram the VACC settings.

80

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

VACC OUT RANGE

• Acquire the minimum and maximum value of the potentiometer via the PROGRAM VACC function. If the alarm persists, check the mechanical calibration and the operation of the potentiometer. If the alarm persists, the fault is inside the module that must be replaced.

86

Cause: The safety input is open and as a result the main remote control switch is open and the coil of the electromagnetic brake or auxiliary devices is operated.

POWER MOS. SHORTED Cause: The DC-link voltage drops to zero when a MOSFET is activated.

When this warning message appears, the traction is stopped.

• Check that the forward and reverse gear requests are not active at the same time.

• Check the status of the FW and BW inputs using the TESTER function.

• Check the wiring of the FW and BW inputs • Check for any faults with the microswitches.

If the problem persists, replace the module.

85

Cause: The value on the CPOT input read from the module is not included in the Vacc_min_max interval, programmed using the "PROGRAM VACC" function

SAFETY INPUT

• The cables of the remote-control switch coil are interrupted or not connected, check the coil cabling.

• The problem could also be connected to a remote-control switch contact that doesn't work. Try replacing the remote-control switch

78

Cause: The test is carried out with the tractor on, immediately after the traction requests have been disabled. This alarm occurs if the ACCELERATOR parameter reading in the tester menu is 1.0 V greater than the minimum value acquired during the PROGRAM VACC procedure.

PROG VACC NOT OK

Troubleshooting

• Check the CAN#11 input, if it is connected to -Batt and the alarm is generated, the fault is in the SAFETY IN hardware circuit. Replace the module.

89

• Check that the motor phases are connected correctly.

• Check that there is no ground dispersion for each phase of the motor.

• If the problem persists, replace the module.

9

DIAGNOSTICS AND MEASUREMENTS

Alarm

Code MDI

Troubleshooting

CURRENT GAIN

92

Check the internal motor connections (ohm continuity) Check the motor power cable connections.

Check the leak to the tractor frame If the motor connections are OK, the problem is within the module, which must be replaced.

Cause: At start-up, the VMN feedback is not included in a range of allowed values ​​around 2.5V

WRONG 0 VOLTAGE

92

Cause: The gain parameters of maximum current have default values, therefore the adjustment procedure of the maximum current has not yet been performed.

ANALOG INPUT

• Contact the technical support

96

Cause: The analog/digital conversion has returned a negative value on all the signals converted for more than 400 msec. The aim of this diagnosis is to find a fault in the A//D converter or a problem in the code that omits the updating of the conversion of the analog signal.

SLIP PROFILE Cause: The deviation parameters of the hardware setting menu are not correct.

10

SERVICE

If the problem appears regularly, the module needs replacing.

99 If this error occurs, the control needs to be replaced.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ACE MODULE - WARNINGS REF. is the number with which the error is saved in the visible alarm list using PC Tools Warning

REF

VMN HIGH

31

Cause: Before switching on the remote control switch, the software checks the voltage of the jumper without activating it.

The software should detect a voltage level equal to a constant value.

The alarm occurs when the value is too high.

AUX DRIVER SHORT.

254

Cause: The driver of the coil of the electromechanical brake / auxiliary solenoid valve has shorted.

BATTERY LOW

66

Cause: Battery voltage is low.

WRONG SET BATT 05

251

Cause: When starting up, the module checks that the battery voltage (measured at the key input) is within the range of ± 20% with respect to the nominal value.

CHECK UP NEEDED

Cause: The safety output driver is shorted.

Check if there is a short circuit or a low pull-down impedance between NEB/NAUX (CNA#18) and –BATT. The circuit driver is damaged inside the module, which must be replaced.

• Recharge the battery.

• Check that the battery voltage is set correctly in the module.

• Check that the SET BATTERY parameter among the ADJUSTMENT parameters matches the battery nominal voltage.

• Using the TESTER function, check that the voltage reading on the key indicates the same value as the voltage on the key measured with a voltmeter on pin A1. If the values do not match, change the ADJUST BATTERY parameter according to the value read by the voltmeter.

• Replace the battery

After having carried out the maintenance, set the COMBI / main adjustment menu / check up done parameter to ON.

246

Cause: The driver of the electromagnetic brake/auxiliary devices coil is not capable of supplying power the load.

The device or the traction circuit are damaged.

SAFETY OUTPUT

If the problem appears on start up (the remote-control switch doesn't close at all), check: • Check the motor voltage cables • Check the impedance value between the U, V and W and -Batt terminals • Check the leak from the motor to the tractor frame • If the motor connections are OK and there are no low impedance values, the problem is in the control and must be replaced

249

Cause: This message indicates that the time has come to carry out the maintenance program.

AUX DRIVER OPEN

Troubleshooting

This kind of failure is not connected to external components. Replace the module.

239

• Check if a short circuit or a low impedance occurred between SAFETY OUT (CAN#19) and -BATT. • The circuit of the driver of the logic board is damaged. Replace the module.

11

DIAGNOSTICS AND MEASUREMENTS

Warning

REF

HARDWARE FAULT

240

Hardware Fault 20 cause: Before activating the remote control coil, the module checks that the Mosfet drivers have been deactivated due to the Watchdog signal inactivity. If the signals have not been deactivated, this alarm is generated.

Hardware Fault 21 cause Before activating the remote control switch coil, the module checks that the electromagnetic brake/auxiliary devices driver has been deactivated due to the Watchdog signal inactivity. If the signal has not been deactivated, this alarm is generated.

Hardware Fault 21 cause Before activating the remote control switch coil, the module checks that the remote control switch/auxiliary devices driver has been deactivated due to the Watchdog signal inactivity. If the signal has not been deactivated, this alarm is generated

BRAKE RUN OUT

234 • Check the mechanical calibration and the operation of the brake potentiometer. If the alarm persists, replace the module.

235

Cause: A traction request is sent when the manual brake input is active.

TILLER OPEN Cause: The seat input is inactive for more than 30 seconds.

12

Troubleshooting

• If the alarm appears, then the problem is inside the module. Replace the module.

Cause The CPOTBRAKE input read by the microprocessor is at maximum value without a manual brake request.

HANDBRAKE

SERVICE

228

• Check that the manual brake is not active by mistake.

• Check the status of the SR/HB inputs using the TESTER function.

• Check the wiring.

• Check for any faults with the microswitches.

• If the problem persists, the logic board needs replacing.

• Activate the seat input • Check the status of the seat input using the TESTER function.

• Check the wiring • Check for any faults with the microswitches.

If the problem persists, replace the logic board.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ELECTRICAL COMPONENT MEASUREMENTS ELECTROMAGNETIC BRAKE COILS

Electromagnetic brake

Coil

Value measured (Ohm)

Electromagnetic brake

15

13

DIAGNOSTICS AND MEASUREMENTS

SERVICE

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 axle in an unpainted zone. The resistance reading ( W) on the tester should be infinity (~). If not, the motor is not insulated and the module related to the motor in question will diagnose the "capacitor charge” alarm.

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

14

SERVICE

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM WIRING

DIAGRAM....................................................................................3

MODEL MT70 ................................................................................................................................3 MODEL MT80 ������������������������������������������������������������������������������������������������������������������������������������������������������������� 4 E L E C T R I C A L C O M P O N E N T S...................................................................................................5 I D E N T I F I C AT I O N O F E L E C T R I C A L C O M P O N E N T S..............................................................5 CONTROLS.....................................................................................................9 I D E N T I F I C AT I O N O F S T E E R I N G W H E E L A N D M A I N PA N E L

C O N T R O L S...........................9

M D I D I S P L AY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 B AT T E R Y C H A R G E S TAT U S I N D I C AT O R .........................................................................12 SPEED REDUCTION INDICATOR.......................................................................................................12 H O U R-M E T E R.........................................................................................................................12 ALARMS AND MAINTENANCE INDICATOR ...........................................................................................................13 T R A C TO R F U N C T I O N S......................................................................................................14 F O RWA R D / B A C K WA R D T R A C T I O N ....................................................................................14 A C T U AT I O N C O N T R O L S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 C O N F I G U R AT I O N PA R A M E T E R S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 B R A K I N G............................................................................................................................16 S T E E R I N G W H E E L..................................................................................................17 ACTUATION CONTROLS............................................................................................................................................17 PROCEDURE FOR ACCESS TO CONFIGURATION PARAMETERS.......................................................................18 STANDARD CONFIGURATION OF MODULE PARAMETERS........................................................18 PARAMETERS THAT CAN BE DISPLAYED AND CHANGED BY THE DEALER.................................................................18 PARAMETERS THAT CAN BE DISPLAYED BY THE DEALER.............................................19 D E S C R I P T I O N O F M O D U L E S PA R A M E T E R S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 INTRODUCTION MODULES.....................................................................................................................25 “PC TOOL” CONNECTORS POSITIONING........................................................................................................25 ACE2 MODULE.................................................................................................................................................................26 REPLACEMENT OF THE ACE2 MODULE .....................................................................................................27 ELECTRICAL COMPONENTS DISMANTLING..............................................................................................................29 REPLACEMENT OF THE GENERAL EMERGENCY SWITCH...........................................................................29 REPLACEMENT OF THE DISPLAY......................................................................................................................30 REPLACEMENT OF THE KEY SWITCH..................................................................................................................31 REPLACEMENT OF THE HORN.............................................................................................................................32 REPLACEMENT OF THE 10A FUSES.....................................................................................................................33 REPLACEMENT OF THE 50 A - 250 A POWER FUSES ......................................................................................34 1

ELECTRICAL SYSTEM

SERVICE

REPLACEMENT OF HORN RELAY...............................................................................................................................35 REPLACEMENT OF THE 180 A - 80 A REMOTE CONTROL SWITCH ....................................................................36 REPLACEMENT OF THE LIGHTS FUSES............................... ..................................................................................37 REPLACEMENT OF THE REVERSING BUZZER .......................................................................................................38 REPLACEMENT OF THE DC/DC CONVERTER .......................................................................................................39 REPLACEMENT OF THE FRONT AND REAR LIGHTS............................................................................................40 REPLACEMENT OF THE FRONT HEADLIGHT.......................................................................................................41 REPLACEMENT OF THE FLASHING LIGHT................ .........................................................................................42

2

SERVICE

ELECTRICAL SYSTEM

WIRING DIAGRAMS MT70 MODEL

The G and J connectors could be coupled into a single connector

SERVICE

ELECTRICAL SYSTEM

MODEL MT80

The G and J connectors could be coupled into a single connector

ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS IDENTIFICATION OF ELECTRICAL COMPONENTS

Ref.

5

Description

1

Traction motor

2

Electromagnetic brake

3

Reverse buzzer

4

Horn

5

Emergency button

6

Key switch

7

MDI display

8

Windshield washer fluid button

9

Inching function activation button

10

Turn indicator light (optional)

11

Turn signal indicator light (optional)

12

Front headlight and side lights switch

13

Engaged parking brake indicator light

14

DC DC Converter

15

50A Power Fuse

16

250A Power Fuse (MT80 model only)

17

80A general remote control switch (MT80 model only)

18

80A general remote control switch

19

180A general remote control switch

20

COMBI ACE module

21

Horn relay

22

10A fuses

23

2A fuses

24

5A fuses

25

Electric controls fuse box

SERVICE

SERVICE

ELECTRICAL SYSTEM

5

7

3

8 9

6

10 11

12

15

14

1

4

13

25

16

2

17 18 20 19 5 23

21

22

24

ELECTRICAL SYSTEM

Ref.

7

Description

26

Front turn signal lights

27

Front side lights

28

Front headlight

29

Rear side lights - rear turn signals - brake lights

30

Reverse lights

31

Flashing light

32

Windshield wiper activation button (only for MT80 model with cab)

33

Cab heater assembly (only for MT80 model with cab)

34

Battery socket

35

Battery

36

Electric steering (only for MT80 model)

SERVICE

SERVICE

ELECTRICAL SYSTEM 29

31

31 29

30 32

28 29

26

33

30

27

34

36

35

SERVICE

ELECTRICAL SYSTEM

CONTROLS IDENTIFICATION OF STEERING WHEEL AND MAIN PANEL CONTROLS

1

2

3

Ref.

Description

1

Horn button

2

Forward / reverse gear lever

3

Turn signal lever (optional)

9

SERVICE

ELECTRICAL SYSTEM

2

1 4

3

5

6

9

7

8

Ref.

10

Description

1

MDI display

2

Emergency button

3

Key switch

4

Inching function switch

5

Front headlight switch, side lights and reverse lights

6

Engaged parking brake indicator light

7

4 flashing indicator lights indicator (optional)

8

Turn signal indicator light (optional)

9

Windshield washer fluid button (optional)

SERVICE

ELECTRICAL SYSTEM

MDI DISPLAY

1

88888 2

3

4

5

Ref.

Description

1

Total worked hours and alarms indicator

2

Hourglass icon indicating the active hour meter

3

Wrench icon indicating alarm and maintenance status

4

Battery icon indicating battery charge status

5

Red LED indicating the alarm status

When the tractor is turned on (key-on), the MDI performs some tests, the red LED lights up for 1 second and then all its elements are displayed for about 3 seconds. After the tests, the display shows the program version for a few seconds, then the next update, if available, then the total working hours, and finally the battery charge status. The hourglass icon flashes.

EP016

EP057

322

322

11

SERVICE

ELECTRICAL SYSTEM

When the accelerator pedal is pressed, a traction request occurs, numeric intervals are displayed on the display indicating the progressive speed.

1-2

1-6

2-2

BATTERY CHARGE STATUS INDICATOR The battery charge status is signalled on the 10-bar display, each bar corresponds to 10%. The bars then switch off one after the other, proportionally to the remaining battery power. The battery charge status is displayed continuously; it is interrupted only in the event of an alarm in progress.

322

If a battery not supplied by the factory is installed on the tractor, a "BATTERY VOLTAGE SETTING" procedure must be carried out on the installation (see the "INSTALLATION AND SETTING" section) for correct operation of the battery charge indicator.

HOUR METER The hourglass flashes indicating that the MDI is storing the hours worked by the tractor.

When the MDI display is replaced, the operating hours of the tractor will be reset (the new indicator will restart from 0 hours).

12

322

SERVICE

ELECTRICAL SYSTEM

ALARMS AND MAINTENANCE INDICATOR The MDI provides an indication of the tractor alarm status. When an alarm is generated, the LED starts flashing and the wrench symbol appears.

The display shows the error code that generated the alarm (xxxAyy), made up of a number that identifies the node (XX) and one (YY) that identifies the alarm (see "DIAGNOSTICS" section).

XXXAYY

13

SERVICE

ELECTRICAL SYSTEM

TRACTOR FUNCTIONS FORWARD/BACKWARD TRACTION ACTUATION CONTROLS

Reverse gear

Actuators involved

Status

Key switch

ON

Emergency switch

ON

Forward/reverse gear lever

14

Forward gear

movement forward/reverse

SERVICE

ELECTRICAL SYSTEM

CONFIGURATION PARAMETERS parameter change menu Acceleration 0 Inv Acceleration 0 Acceleration 1 Acceleration 2 Acceleration 3 Acc prof. Freq 1 Acc prof. Freq 2 Acc prof. Freq 3 Release Braking Invers. Braking Decel. Braking Tiller Braking Max speed forw Max speed back Frequency creep Maximum Current Brk. Smooth Stop Brk Smooth Backing Speed Backing Time Auxiliary time

adjustment menu Set battery type Adjust battery Throttle X zone Throttle X map Throttle Y map Bat. min. adj.

Bat. max. adj.

Adjustment#3 Speed factor Load HM from MDI Check up done Check up type Mc voltage Aux. voltage Mc voltage rid Aux.voltage rid.

Set options Display type Till/seat switch Hour counter Battery check Stop on ramp Aux input #1 2.5 pot Backing

For the description of each individual parameter, see the "MODULE PARAMETERS DESCRIPTION" paragraph.

15

ELECTRICAL SYSTEM

SERVICE

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

Service braking Release braking.

Braking on direction reversal.

Emergency braking.

The tractor braking takes place differently depending on which of the systems listed above is operated.

BRAKING SYSTEM

WHEN DOES IT OPERATE?

Service braking

Brake pedal pressing

Release braking

Gradual release of the acceleration pedal

Braking on direction reversal

Direction of travel reversing using the forward/reverse gear lever

Emergency braking

Emergency brake button operation.

Through the programmer it is possible to set the deceleration ramp of the release braking Release braking deceleration ramp setting ACE2 / main menu parameter change / release braking

16

SERVICE

ELECTRICAL SYSTEM

STEERING WHEEL ACTUATION CONTROLS

To turn left or right, turn the steering wheel to the right or left.

Actuators involved Key switch

status ON

Emergency switch

CLOSED/ON

Steering wheel rotation

right/left rotation

17

ELECTRICAL SYSTEM

SERVICE

PROCEDURE FOR ACCESS TO CONFIGURATION PARAMETERS All parameters on the tractor can be displayed by hand-set.

Using the appropriate hand-set, it is also possible to configure some of these parameters

STANDARD CONFIGURATION OF MODULE PARAMETERS It is always advisable to keep the factory settings as designed in order to have the best compromise between performance and components wear. It is however possible to customize some performances according to customer requests, to the characteristics of the warehouse and the materials to be handled, but no parameters must be changed if this compromises the tractor safety.

PARAMETERS THAT CAN BE DISPLAYED AND CHANGED BY THE DEALER The following parameters can be displayed or changed by the dealer: ADJUSTMENT MENU

PARAMETER CHANGE MENU

18

PARAMETER

Default

PARAMETER

Default

RELEASE BRAKING

3 sec

SET BATTERY TYPE

48V

MAX SPEED FORW

11/14 Km/h

ADJUST BATTERY

As req.

MAX SPEED BACK

5 Km/h

SERVICE

ELECTRICAL SYSTEM

PARAMETERS THAT CAN BE DISPLAYED BY THE DEALER The following parameters can be only displayed by the dealer: PARAMETER CHANGE MENU

ADJUSTMENT MENU

PARAMETER

Default

PARAMETER

Default

ACCELERATION 0

2.0

THROTTLE 0 ZONE

3%

INV ACCELERATION 0

0.5

THROTTLE X POINT

36%

ACCELERATION 1

2.0

THROTTLE Y POINT

57%

ACCELERATION 2

2.0

ACCELERATION 3

BAT. MIN ADJ.

0%

2.0

BAT. MAX ADJ.

0%

ACC PROF. FREQ 1

20 Hz

ADJUSTMENT#3

10%

ACC PROF. FREQ 2

80 Hz

SPEED FACTOR

140

ACC PROF. FREQ 3

110 Hz

LOAD HM FROM MDI

OFF

INVERS. BRAKING

3 sec.

CHECK UP DONE

OFF

DECEL. BRAKING

9 sec.

CHECK UP TYPE

Option#1

FREQUENCY CREEP

0.60 Hz

MC VOLTAGE

100%

MAX. CURRENT

100%

AUX VOLTAGE

100%

BRK SMOOTH

1.0

MC VOLTAGE RID.

80%

STOP BRK SMOOTH

10 Hz

BACKING SPEED

4%

BACKING TIME

2.0 sec

AUXILIARY TIME

0.0 sec

MENU SET OPTIONS PARAMETER

Default

DISPLAY TYPE

4

TILL/SEAT SWITCH

Seat

HOUR COUNTER

Running

BATTERY CHECK

2

STOP ON RAMP

ON

2.5 POT

OFF

BACKING

OFF

The parameters mentioned above can only be displayed and not be changed by the dealer.

19

SERVICE

ELECTRICAL SYSTEM

DESCRIPTION OF MODULES PARAMETERS ACE2 MODULE ACE2 / main menu parameter change / ACE2 / menu set options / ACE2 / menu adjustment / PARAMETER CHANGE MENU PARAMETER ACCELERATION 0

min.

max.

0.3 sec

10 sec

0.3 sec

10 sec

0.3 sec

10 sec

0.3 sec

10 sec

0.3 sec

10 sec

0 Hz

200 Hz

Acceleration ramp of the motor at 0 Hz. INV. ACCELERATION 0 Acceleration ramp of the motor at 0 Hz after a direction reversal.

ACCELERATION 1 Acceleration ramp of the motor corresponding to ACC PROF. FREQ1 [Hz].

ACCELERATION 2 Acceleration ramp of the motor corresponding to ACC PROF. FREQ2 [Hz] ACCELERATION 3 Acceleration ramp of the motor corresponding to ACC PROF. FREQ3 [Hz].

ACC PROF. FREQ 1

At this frequency in [Hz], the acceleration is defined by the ACCELERATION 1 parameter ACC PROF. FREQ 2

0 Hz

200 Hz

At this frequency in [Hz], the acceleration is defined by the ACCELERATION 2 parameter ACC PROF. FREQ 3

0 Hz

200 Hz

At this frequency in [Hz], the acceleration is defined by the ACCELERATION 3 parameter RELEASE BRAKING

0.3 sec.

10 sec.

0.1 sec.

10 sec.

0.1 sec.

10 sec.

0.1 sec

10 sec.

Deceleration ramp after the acceleration pedal is released.

This parameter can be changed by the dealer INVERS. BRAKING Deceleration ramp in case of direction reversal while driving.

DECEL. BRAKING Deceleration ramp in case of partial release of the acceleration pedal TILLER BRAKING deceleration ramp when the seat switch is released.

20

SERVICE

ELECTRICAL SYSTEM

PARAMETER MAX SPEED FORW

min.

max.

5 Hz

200Hz

Maximum forward speed in percentage with respect to the TOP MAX SPEED parameter.

This parameter can be changed by the dealer MAX SPEED BACK

5 Hz

200Hz

Maximum reverse speed in percentage with respect to the TOP MAX SPEED parameter.

This parameter can be changed by the dealer FREQUENCY CREEP

0.6 Hz

4 Hz

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

MAX. CURRENT

0%

100%

1

5

Maximum current applied to the motor BRK SMOOTH

Deceleration profile: 1 corresponds to a linear ramp; higher values ​​correspond to progressively less linear profiles STOP BRK SMOOTH

3 Hz

20 Hz

3 Hz

20 Hz

0.1 sec

10 sec

0 sec

10 sec

Frequency at which the smoothing effect ends BACKING SPEED It defines the frequency at which the traction motor moves in steps BACKING TIME It defines the time in which the traction motor moves in steps AUX TIME

It defines how long the tractor is in the STOP ON RAMP position, if this version is active

21

SERVICE

ELECTRICAL SYSTEM ADJUSTMENT MENU PARAMETER SET BATTERY

min.

max.

36 V

48 V

0%

100%

0%

100%

0%

100%

-12.8%

12.7%

-12.8%

12.7%

0

255

Nominal battery voltage. Available options: 36V - 48V. This parameter can be changed by the dealer ADJUST BATTERY Adjustment of the battery voltage measured by the module.

This parameter can be changed by the dealer THROTTLE 0 ZONE Amplitude of the dead zone in the acceleration curve THROTTLE X MAP Throttle rotation angle value corresponding to the Y traction speed THROTTLE Y MAP Throttle rotation angle value corresponding to the X traction speed BAT. MIN ADJ. It adjusts the lower value of the battery charge status table BAT. MAX ADJ. It adjusts the upper value of the battery charge status table ADJUSTMENT#3 It adjusts the battery charge update after turning on (key-on) SPEED FACTOR

It defines the coefficient used to evaluate the truck speed (in Km/h) from the motor frequency (in Hz) LOAD HM FROM MDI

ON = hour counter transfer active.

OFF = hour counter transfer inactive.

It enables or disables the hour meter transfer to the MDI unit ON = scheduled maintenance carried out.

CHECK UP DONE

OFF = scheduled maintenance not carried out.

It defines if scheduled maintenance has been carried out CHECK UP TYPE

NONE

OPTION #3

It enables/disables the scheduled maintenance start and methods: None alarm disabled; Option#1 = alarm after 300 hours; Option#2: alarm after 300 hours and speed reduction after 340 hours; Option#3 = alarm after 300 hours, speed reduction after 340 hours, tractor blocking after 380 hours

22

SERVICE

ELECTRICAL SYSTEM

PARAMETER MC VOLTAGE

min.

max.

0%

100%

It specifies the PWM cycle applied to the output of the main remote control switch during the first second after the activation signal.

AUX VOLTAGE

0%

100%

It specifies the PWM cycle applied to the output of the auxiliary remote control switch during the first second after the activation signal.

MC VOLTAGE RID.

0%

100%

It defines a percentage of the MC VOLTAGE parameter and determines the cycle applied after the first second of activation of the remote control switch.

SET OPTIONS MENU PARAMETER DISPLAY TYPE

min.

max.

0

4

It defines the type of display connected to the inverter (0 = none; 1 = MDI PRC; 2 = ECO DISPLAY; 3 = SMART DISPLAY; 4 = MDI CAN

TILL/SEAT SWITCH

HANDLE = the input is managed as a tiller input (no delay when released).

SEAT = the entrance is managed as a seat input (with a delay when released).

The input opens when the operator leaves the tractor

HOUR COUNTER

RUNNING = the hour counter only records the running time.

KEY ON = the counter records when the key switch is closed.

It records the working hours BATTERY CHECK

0

3

It specifies how a low battery charge is managed 0 = nothing happens, the battery charge level is evaluated but ignored; 1 = the BATTERY LOW alarm occurs when the battery level is evaluated to be less than or equal to 10% of the entire charge. In this case the module reduces the maximum speed to 24% of full speed and also reduces the maximum current at 50% of the total current.

2 = the BATTERY LOW alarm occurs when the battery level is evaluated to be less than or equal to 10% of the entire charge.

3 = the BATTERY LOW alarm occurs when the battery level is evaluated to be less than or equal to 10% of the entire charge. In this case the module reduces the maximum speed to 24% of full speed.

23

ELECTRICAL SYSTEM

SERVICE

PARAMETER

STOP ON RAMP

ON = The stop-on-ramp function is executed for a time defined in the "AUXILIARY TIME" parameter. after this time the behaviour of the tractor will depend on the AUX OUT FUNCTION” option OFF = The stop-on-ramp function is not carried out

It enables or disables the stop-on-ramp function (the tractor is electrically maintained in position on a slope for a defined period.

2.5 POT

ON = There are no direction switches.

Reverse travel when the potentiometer is below half the interval; forward travel when the potentiometer is above half the interval.

OFF = Normal operation of the potentiometer with turn indicator switches present

Potentiometer operation.

BACKING Inching function

24

ON = Inching function available.

OFF = Inching function not present

SERVICE

ELECTRICAL SYSTEM

MODULES: INTRODUCTION The MT70 - MT80 models can be fitted with the “COMBI ACE2” module The module is connected and communicates through the CANBUS network, which allows access to truck diagnostics or programming by using a PC (or laptop) or keyboard.

The connector for connecting the console is connected to the “ACE“ module and can be accessed from the electrical system compartment. The connector for connecting the interface cable kit (“PC CONSOLE”) is connected to the “ACE” module and can be accessed below the instrument panel.

PC interface cable kit code.580039670

ZAPI Console

25

ELECTRICAL SYSTEM

SERVICE

ACE2 MODULE It has been developed to perform all the electrical functions normally present on the tractor: • control for the 1.27 kW ACE motor • CanBus interface • performances monitoring • alarms Technical specifications: Inverter for AC three-phase asynchronous motors and regenerative braking functions. Digital control through microprocessor.

Voltage:.............................................................................................................................................48V Inverter maximum current (48V):................................................................................... 350A (RMS) for 2’ Continuous output current (48V):......................................................................................... 175A (RMS)’ Inverter operating frequency:.....................................................................................8 kHz Chopper operating frequency:...............................................................................8 kHz External temperature limits.................................................................................... -30°C ÷ 40°C Inverter maximum temperature (at maximum power):..................................................................85°C

26

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE ACE2 MODULE Equipment and tools

screwdriver flat head

100Ohm resistor 25W insulated

hex socket wrench

T-handle hex key

Procedure 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 pedestrian traffic.

Turn the keyswitch to OFF and disconnect the battery.

DISMANTLING THE REAR LOAD CARRIER PLATE Phase 1 FLAT HEAD SCREWDRIVER Using the screwdriver unscrew and remove the 6 screws (ref.A fig.1) that secure the load plate (ref.B fig.1). Then remove the plate.

Fig. 1

B A

Phase 2 T-HANDLE HEX KEY Using the T-handle key, unscrew and remove the 2 screws (ref.C fig.2) and the washers that lock the plate that protects the electrical system (ref.D fig.2), pull it towards the engine (fig.3), turn it 90° and remove it

Fig. 2

D

D

C

Fig. 3

90°

Fig. 4 27

SERVICE

ELECTRICAL SYSTEM from the engine compartment (fig.4).

DISMANTLING THE ACE2 MODULE Phase 3 RESISTANCE 100 Ohm 25 W Connect a resistance between the positive (B+) and negative (B-) of the module (fig.5). Wait approximately 10 seconds for the internal capacitors to discharge and then disconnect the resistor.

Fig. 5 To avoid short circuits, it is important that the resistance is insulated.

If it is not possible to have an external resistance to discharge the capacitors, it will be necessary to wait at least 90 seconds before disconnecting the power cables.

C

Phase 4 HEX SOCKET WRENCH Using the hex socket wrench, unscrew and remove the power cables fastening screws (ref.B fig.6).

Disconnect the connector for the module connection (ref.C fig.6).

Mark the power cables for reassembling and then disconnect them.

B

Fig. 6

Phase 5 HEX SOCKET WRENCH Using the hex socket wrench, unscrew and remove the fastening screws of the module to the truck base (fig.7), retrieve the washers.

Remove the module and proceed with the replacement.

28

Fig.7

SERVICE

ELECTRICAL SYSTEM

DISMANTLING THE ELECTRICAL COMPONENTS REPLACEMENT OF THE GENERAL EMERGENCY SWITCH Equipment and tools

T-handle hex key

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

A

Fig. 1 Phase 1 T-HANDLE HEX KEY Using the T-handle key unscrew the three screws that secure the protective plate of the MDI panel (ref.A fig.1). Then remove it.

Phase 2 Disconnect the connectors.

Remove the block on the back of the panel that secures the main switch (ref.B fig.2).

Fig. 2

C Phase 3 Pull out the switch from the top and proceed with the replacement (ref.C fig.2).

B

29

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE DISPLAY Equipment and tools

T-handle hex key

open ended spanner

A

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

Fig. 1 Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 T-HANDLE HEX KEY Using the flat head screwdriver unscrew the three screws that secure the protective plate of the MDI panel (ref.A fig.1). Then remove it.

Fig. 2

C Phase 2 OPEN ENDED SPANNER Disconnect the electrical connection connector.

B

Unscrew the lock nuts of the locking bracket (ref.B fig.2). Remove the bracket (ref.C fig.2).

Remove the display (fig.3) and proceed with its replacement.

Fig. 3 30

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE KEY SWITCH Equipment and tools

T-handle hex key

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

A Phase 1 T-HANDLE HEX KEY Using the flat head screwdriver unscrew the three screws that secure the protective plate of the MDI panel (ref.A fig.1). Then remove it.

Fig. 1

Phase 2 Disconnect the connectors.

Pull of the ignition key (ref.B fig.2).

Remove the switch block from the back of the panel (ref.C fig.2).

Proceed with replacement.

B

INSTALLATION Before reconnecting them, check that the faston clamps are properly secure. If not, tighten the connectors with pliers for faston clamp.

C

Fig. 2 31

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE HORN Equipment and tools

open ended spanner

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the “DISMANTLING THE REAR LOAD CARRIER PLATE” procedure described in this section.

Phase 2 OPEN ENDED SPANNER Using the open ended spanner unscrew the nut that secures the horn to the bracket (ref.A fig.2).

Disconnect the connectors, remove the horn and proceed with the replacement.

Fig. 1

INSTALLATION Before reconnecting them, check that the faston clamps are properly secure. If not, tighten the connectors with pliers for faston clamp.

Fig. 2

A

32

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE 10 AMP FUSES Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the “DISMANTLING THE REAR LOAD CARRIER PLATE” procedure described in this section.

Phase 2 Remove the fuses to be replaced (fig.1-2) and proceed with its replacement.

Fig. 1

Fig. 2

Refer to the wiring diagram to replace the fuses correctly.

33

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE 50 A - 250 A POWER FUSES Equipment and tools

open ended spanner

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

250 AMP

50 AMP

Phase 1 Carry out the “DISMANTLING THE REAR LOAD CARRIER PLATE” procedure described in this section.

Fig. 1 Fig. 2

Phase 2 OPEN ENDED SPANNER Remove the plastic caps that cover the screws, then use the open ended spanner to unscrew and remove the screws fastening the power cables (ref.A fig.2-3).

Mark the power cables for reassembling and then disconnect them.

A

Proceed with replacing the power fuses (ref.B fig.3).

After reassembly, make sure the reposition the plastic caps that were previously removed.

Fig. 3

A

B For the MT80 model, a 50 AMP power fuse is also included; for replacement, follow the same instructions in this paragraph.

34

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE HORN RELAY Equipment and tools

Phillips screwdriver

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the “DISMANTLING THE REAR LOAD CARRIER PLATE” procedure described in this section.

Fig. 1

A

Phase 2 PHILLIPS SCREWDRIVER Disconnect the connector from the horn relay.

Using the screwdriver, unscrew and remove the fastening screws of the relay (ref.A fig.2).

Proceed with replacement.

Fig. 2

35

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE 180 A - 80 A REMOTE CONTROL SWITCH

open ended spanner

Phillips screwdriver

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

80 A

Phase 1 Carry out the “DISMANTLING THE REAR LOAD CARRIER PLATE” procedure described in this section.

Phase 2 OPEN ENDED SPANNER Remove the plastic caps that cover the screws, then use the open ended spanner to unscrew and remove the screws fastening the power cables (ref.A fig.2).

Mark the power cables for reassembling and then disconnect them.

80 A

180 A

Fig. 1 Fig. 2

A Phase 3 PHILLIPS SCREWDRIVER Using the screwdriver, unscrew and remove the screws fastening the remote control switch to the support plate (ref.B fig.3) Remove the remote switch and proceed with the replacement.

Proceed in the same way to replace the 80 A remote control switch After reassembly, make sure the reposition the plastic caps that were previously removed.

For the MT80 model, a 80 A remote control switch is also included, for its replacement follow the same instructions in this paragraph.

36

D

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE LIGHTS FUSES Equipment and tools

flat head screwdriver small

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Phase 1 SMALL FLAT HEAD SCREWDRIVER Using the small flat head screwdriver press the tabs (ref.A fig.2) and pull off the fuse holder cover.

Remove the fuse to be replaced and proceed with its replacement.

1: brake light fuse 2: lights fuse 3: turn indicators fuse

A

Fig. 2

4: horn fuse 5: windshield wipers fuse 6: flashing light fuse

1

8

6

3 4

7: reverse lights fuse 8: gear selector fuse 2

5

7

37

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE REVERSE BUZZER Equipment and tools

open ended spanner

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the “DISMANTLING THE REAR LOAD CARRIER PLATE” procedure described in this section.

Phase 2 Remove the electrical connections for the reversing buzzer

Fig. 1

B Phase 3 OPEN ENDED SPANNER Using the open ended spanner unscrew and remove the bolt (ref.A fig.2) that secure the buzzer to the electrical system compartment. Pull out the buzzer (ref.B fig.2) from the opposite side and proceed with the replacement.

38

A Fig. 2

SERVICE

ELECTRICAL SYSTEM

DC DC CONVERTER REPLACEMENT Equipment and tools

hex socket wrench

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1 Phase 1 Carry out the “DISMANTLING THE REAR LOAD CARRIER PLATE” procedure described in this section.

Phase 2 Remove the electrical connector and replace it in the new unit.

Phase 3 HEX SOCKET WRENCH Disconnect all the electrical wires.

Using the socket wrench unscrew and remove the 4 screws that secure the DC DC converter to the bodywork, retrieve the washers (ref.A fig.2).

Then proceed with replacement.

Then reconnect the electrical wires.

Fig. 2

A

39

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF FRONT AND REAR LIGHTS Equipment and tools

Fig. 1

small Phillips screwdriver

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 2

Phase 1 SMALL PHILLIPS SCREWDRIVER Use the screwdriver to unscrew and remove the 2 screws (ref.A fig.2) that fasten the reflector (ref.B fig.2) to the bodywork.

A

B

B A Fig. 3

Phase 2 Remove the reflector and proceed with the lamp replacement.

Proceed for the rear lights as for the front lights (fig.4) Fig. 4

B A 40

B A

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE FRONT HEADLIGHT Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Phase 1 Push the front headlight inwards with your hands until it comes out of its seat (fig.2).

Afterwards remove the rubber gasket from the front (fig.3).

Then replace the headlight.

Fig. 2

INSTALLATION To refit the headlight, first insert the rubber gasket on the front and then insert the headlight from the inside.

Fig.3

41

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE FLASHING LIGHT Equipment and tools

Fig. 1 open ended spanner

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 2

Phase 1 OPEN ENDED SPANNER Using the open ended spanner unscrew and remove the 3 screws (ref.A fig.2) that secure the flashing light protection grille.

A

Phase 2 Remove the reflector and proceed with the lamp replacement.

Carry out the same procedure for the flashing light of the version with cab (fig.4) Fig. 3 Fig. 4

42

A

SERVICE

MECHANICS

BASIC TRUCK MECHANICS CAB (OPTIONAL)...........................................................................................................................3 IDENTIFICATION OF CAB COMPONENTS......................................................................................................4 DISMANTLING THE CAB............................................................................................................5 REPLACEMENT OF PVC ROLL-UP ONLY FOR MODEL MT70................................................................................6 S E AT A S S E M B LY..............................................................................................................7 I D E N T I F I C AT I O N O F S E AT C O M P O N E N T S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 D I S M A N T L I N G T H E S E AT A S S E M B LY..................................................................................9 TOW HOOK...................................................................................................................................10 IDENTIFICATION OF TOW HOOK COMPONENTS................................................................................11 D I S M A N T L I N G T H E TO W H O O K..................................................................................12 R E A R A X L E ......................................................................................................................13 I D E N T I F I C AT I O N O F R E A R A X L E C O M P O N E N T S................................................................13 D I S M A N T L I N G T H E R E A R A X L E...............................................................................14 REPLACEMENT OF REAR SUSPENSIONS.................................................................................................15 R E P L A C E M E N T O F W H E E L....................................................................................................16 BRAKES.........................................................................................................................................17 R E A R B R A K E C O M P O N E N T S I D E N T I F I C AT I O N....................................................................17 IDENTIFICATION OF FRONT BRAKE COMPONENTS MODEL MT70..............................................18 IDENTIFICATION OF FRONT BRAKE COMPONENTS MODEL MT80..............................................19 D I S M A N T L I N G T H E B R A K E S .........................................................................................20 FRONT AXLE...................................................................................................................................22 I D E N T I F I C AT I O N O F F R O N T A X L E C O M P O N E N T S M O D E L M T70.........................................22 IDENTIFICATION OF FRONT AXLE MODEL COMPONENTS MT80.....................................................24 DISMANTLING THE FRONT AXLE MODEL MT70................................................................................26 REPLACEMENT OF THE SHOCK ABSORBER MODEL MT70.......................................................................27 REPLACEMENT OF THE FRONT AXLE CHAIN MODEL MT70................................................................................28 DISMANTLING THE FRONT AXLE MODEL MT80................................................................................29 REPLACEMENT OF THE FRONT AXLE SUSPENSIONS MODEL MT80........................................................30 REPLACEMENT OF THE FRONT AXLE CYLINDER TOW MODEL MT80...........................................................31 BRAKING AND ACCELERATOR ASSEMBLY......................................................................................32 IDENTIFICATION OF BRAKING AND ACCELERATOR ASSEMBLY COMPONENTS.................................32 DISMANTLING THE ACCELERATOR PEDAL.............................................................................................................34 DISMANTLING THE BRAKE PEDAL.............................................................................................................35 REPLACEMENT OF THE BRAKE CYLINDER.............................................................................................................37 S T E E R I N G A S S E M B LY M O D E L M T 70...........................................................................39 IDENTIFICATION OF STEERING ASSEMBLY AND CONTROL LEVERS COMPONENTS...............................39 1

MECHANICS

SERVICE

STEERING ASSEMBLY MODEL MT80...........................................................................................40 IDENTIFICATION OF STEERING ASSEMBLY AND CONTROL LEVERS......................................................40 DISMANTLING THE FRONT/REVERSE GEAR LEVER AND THE TURN SIGNAL LEVER (OPTIONAL)......41 DISMANTLING THE STEERING COLUMN MODEL MT70........................................................................................42 DISMANTLING THE STEERING COLUMN AND VALVE MODEL MT80................................................................44 TRACTION MOTOR - ELECTROMAGNETIC BRAKE...................................................................................46 IDENTIFICATION OF TRACTION MOTOR AND ELECTROMAGNETIC BRAKE COMPONENTS .......................46 REPLACEMENT OF TRACTION MOTOR AND ELECTROMAGNETIC BRAKE...........................................47 DISMANTLING THE TRACTION MOTOR..................................................................................49 REPLACEMENT OF THE ELECTRIC STEERING WHEEL ONLY MODEL MT80..........................................51

2

SERVICE

MECHANICS

CAB (OPTIONAL) IDENTIFICATION OF CAB COMPONENTS

3

2

5 1 2

6

6

4

6 4 7

Ref.

Description

1

Cab structure

2

Door

3

Pvc roll-up

4

Fastening screws to the tractor bodywork

5

Flashing light

6

Rearview mirror

7

Windscreen wiper

3

SERVICE

MECHANICS DISMANTLING THE CAB Equipment and tools

socket wrench

lifting belt capacity 1000 kg

bridge crane load capacity 2000 kg

Allen key

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fase1 BRIDGE CRANE - NO. 1 LIFTING SLING After opening both doors, align the cab with the lifting belt and hook it to the bridge crane, tension it (fig.1).

Fig. 1

A Phase 2 SOCKET WRENCH After removing the guards, unscrew the 4 screws (2 on each side) that secure the cab to the front cover of the tractor (ref.A fig.2).

Phase 3 ALLEN KEY Using the Allen key unscrew and remove the 2 screws (ref.B fig.3) that fasten the plate (ref.C fig.3) supporting the steering column so you can separate the plate from the tractor dashboard and pull out the entire cab.

Fig. 2

C B

4

Fig. 3

SERVICE

MECHANICS

Phase 4 SOCKET WRENCH Using the socket wrench unscrew the 4 screws (2 on each side) that secure the cab to the tractor platform (ref.D fig.4).

Phase 5 SOCKET WRENCH Move the seat forward to release access to the 5 screws that secure the rear of the cab to the tractor frame (ref.E fig.5).

D

Fig. 4

Phase 6 BRIDGE CRANE At this point, operate the bridge crane and lift the cab, then proceed with the replacement.

E Fig. 5

5

SERVICE

MECHANICS REPLACEMENT OF PVC ROLL-UP ONLY FOR MT70 MODEL Equipment and tools

Phillips screwdriver

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 PHILLIPS SCREWDRIVER Using the Phillips screwdriver, unscrew the 8 screws that secure the pvc roll-up to the cab (ref.A fig.1).

A

Fig. 1

Proceed with the replacement.

A A A

6

SERVICE

MECHANICS

SEAT ASSEMBLY IDENTIFICATION OF SEAT ASSEMBLY COMPONENTS

2

3 1

4

Ref.

4

Description

1

Seat body

2

Seat belt

3

Seat belt buckle

4

Seat sliding rails

7

MECHANICS

SERVICE

DISMANTLING THE SEAT ASSEMBLY Equipment and tools

open ended spanner

Procedure Fig. 1

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 pedestrian traffic. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Disconnect the deadman sensor, inserted into the seat.

Fig. 2

Phase 2 Open at 90° the door of the battery compartment onto which the seat is fastened (fig.1).

Then slide the seat forward until the nylon spacers and the fastening bolts are accessible (fig.2).

Fig. 3

Phase 3 Unscrew the 4 screws on the opposite side of the door (ref.A fig.3), then proceed with the replacement of the seat

8

A

SERVICE

MECHANICS

SEAT BELT Phase 4 OPEN ENDED SPANNER Using the open ended spanner unscrew the screw securing the seat belt (ref.B fig.4) or the seat belt buckle and proceed with the replacement.

B Fig. 4

9

SERVICE

MECHANICS TOW HOOK IDENTIFICATION OF TOW HOOK COMPONENTS

1

2

3

Ref.

10

Description

1

Tow hook pin

2

Tow hook

3

Washer

4

Fastening screw

4

SERVICE

MECHANICS

TOW HOOK HEIGHT Equipment and tools

socket wrench

Procedure 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 pedestrian traffic.

Turn the keyswitch to OFF and disconnect the battery.

Phase 1 SOCKET WRENCH Using the socket wrench unscrew and remove the 4 screws that secure the tow hook to the bodywork (ref.A fig.1), retrieve the washers (ref.B fig.1) and the complete hook, then proceed with the replacement.

Fig. 1

B

A

Please note the tow hook weight

11

SERVICE

MECHANICS

REAR AXLE IDENTIFICATION OF REAR AXLE COMPONENTS

9

10

8

11

12

7

6

14 13

3 2

5 4

Ref.

12

1

Description

1

Axle shaft

2

Traction motor

3

Electromagnetic brake

4

Ref.

Description

9

Washer

10

Bolt fastening the suspension to the bodywork

Wheel

11

Grease nipple

5

Wheel nut

12

6

Lock nut

Bolt for fastening the suspension to the axle

7

Suspension body

13

Connection plate

8

Nut

14

Bush

SERVICE

MECHANICS

DISMANTLING THE REAR AXLE Equipment and tools

tackle load capacity 1000 kg

lifting belt capacity 1000 kg

wooden blocks

cartridge grease gun

open ended spanner

large flat head screwdriver

hydraulic jack

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 LARGE FLAT HEAD SCREWDRIVER Using the screwdriver unscrew and remove the 6 screws (ref.A fig.1) that secure the load plate (ref.B fig.1). Then remove the plate.

Fig. 1

B A

Phase 2 TACKLE - LIFT BELT Disconnect the engine power and parking brake cables. Secure the rear axle by wrapping a lifting belt around the shaft (fig.2). Attach the belts to the tackle and raise until taught.

Phase 3 HYDRAULIC JACK - WOODEN BLOCKS Place the wooden blocks under the tractor chassis. To place the blocks, lift up the tractor with a hydraulic jack until the wooden block fits beneath, then lower the jack. Repeat the operation until all the blocks have been placed: the tractor must be in a high position so as to allow the technician to access from below.

When the operation is finished, make sure the tractor sits well on the blocks.

Make sure the rear axle is well secured to the hoist with a lifting belt,

Fig. 2 13

SERVICE

MECHANICS because it could loosen when the bolts are removed.

C

D

Fig. 3

Phase 4 2 OPEN ENDED SPANNERS Use one open ended spanner to lock the fastening bolt (ref.C fig.3), and use the other to unscrew the nut on the opposite side (ref.D fig.3).

Repeat the operation for all 6 screws securing the rear axle to the frame. (ref.1-2-3-4-5-6 fig.4).

Phase 5 TACKLE - LIFT BELT Slowly place the axle on the ground, using the lifting belt and the hoist. Make sure that, due to the weight of the motor, the axle does not rotate on itself, extract it from under the tractor and proceed with the dismantling (fig.5).

1

4

2

5

3

6

Fig. 4 Fig. 5

INSTALLATION Before reassembling the rear axle, check the axle oil level, top up if necessary using "SEA85W/140" oil Before tightening the fastening screws, apply grease to all the greasing points.

14

SERVICE

MECHANICS

REPLACEMENT OF REAR SUSPENSIONS Equipment and tools

open ended spanner

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the “DISMANTLING THE REAR AXLE“ procedure described in this section.

Fig. 1

A

A Phase 2 Make sure that the rear axle is positioned so that the suspension attachment plate (ref.A fig.1), is parallel to the ground.

B

Phase 3 2 OPEN ENDED SPANNERS Use one open ended spanner to lock the fastening bolt (ref.C fig.2), and use the other to unscrew the nut on the opposite side (ref.D fig.2).

Repeat the operation for all 4 bolts that fasten the plate.

Retrieve the suspension and proceed with the replacement.

Perform the same procedure for the other suspension.

Fig. 2

C

15

SERVICE

MECHANICS WHEEL REPLACEMENT Equipment and tools

hydraulic jack

socket wrench

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1 Phase 1 HYDRAULIC JACK Position the hydraulic jack on the wheel side and lift the tractor up to detach the wheel from the ground (fig.1).

Phase 2 SOCKET WRENCH Unscrew the 5 nuts (ref.A fig.2) that secure the wheel to the drum (ref.B fig.2), then pull off the wheel and replace it.

Repeat the same procedure for the other wheels.

Fig. 2

A

Make sure all the surfaces are clean before replacing the wheel.

B 16

SERVICE

MECHANICS

BRAKES IDENTIFICATION OF REAR BRAKE COMPONENTS

1

3

4

2 5

6

7

8

12

9

10

11

13

Ref.

Description

Ref.

Description

1

Screw

8

Pin

2

Washer

9

Cover

3

Rear plate

10

Spring

4

Brake cylinder

11

Spring

5

Spring

12

Spacer

6

Spring

13

Jaw with regulator

7

Jaw

17

SERVICE

MECHANICS IDENTIFICATION OF FRONT BRAKE COMPONENTS MODEL MT70

1

2

3

4

5

6

7

8

10

Ref.

18

Description

1

Screw

2

Washer

3

Rear plate

4

Elastic washer

5

Screw

6

Cylinder

7

Jaw

8

Spring

9

Spring

10

Spring

9

SERVICE

MECHANICS

IDENTIFICATION OF FRONT BRAKE COMPONENTS MODEL MT80

4

1

2

5

6

3

8 7

9 10

11

12

Ref.

Description

1

Plate

2

Spring

3

Hook

4

Brake cylinder

5

Rear plate

6

Screw

7

Dust cap

8

Screw

9

Spring

10

Jaw

11

Spring

12

Regulator

19

SERVICE

MECHANICS DISMANTLING THE BRAKES Equipment and tools

hydraulic jack

socket wrench size 10/13 mm

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1 Phase 1 HYDRAULIC JACK Position the hydraulic jack on the wheel side and lift the tractor up to detach the wheel from the ground (fig.1).

Phase 2 Carry out the “DISMANTLING THE WHEEL” procedure described in this section.

A B

Phase 3 SOCKET WRENCH Unscrew the four bolts that secure the brake drum (ref.A fig.2), then extract the drum (ref.B fig.2).

A

20

Fig. 2

SERVICE

MECHANICS

Phase 4 Remove the brake drum, check it the rear plate (ref.C fig.3-4-5), the jaws (ref.D fig.3-4-5) and the cylinder (ref.E fig.3-4-5).

REAR BRAKE

C

Fig. 3

E

At this point proceed with the replacement of the parts that require it.

D

D

FRONT BRAKE MODEL MT70

Fig. 4

C

E D

D

FRONT BRAKE MODEL MT80

Fig. 5

E

C

D

D

21

SERVICE

MECHANICS

FRONT AXLE IDENTIFICATION OF FRONT AXLE COMPONENTS MODEL MT70

1

2

3

15

14

13

4

12

5

10

8

6

7

22

11

9

SERVICE

MECHANICS

Ref.

Description

1

Nut

2

Mounting plate

3

Chain

4

Screws

5

Front axle assembly

6

Wheel

7

Wheel fastening nut

8

Damper

9

Nut

10

Washer

11

Screw

12

Toothed sprocket/Pinion

13

Washer

14

Lock washer

15

Screw

23

SERVICE

MECHANICS IDENTIFICATION OF FRONT AXLE COMPONENTS MODEL MT80

18

17

15

19 16

15

3 2

14

7

13 1 4

5

6

12

8 10 11

24

9

SERVICE

MECHANICS

Ref.

Description

1

Wheel locking nut

2

Wheel

3

Front axle assembly

4

Grease nipple

5

Frame fastening screws

6

Plate

7

Bush

8

Clamp plate

9

Washer

10

Lock washer

11

Screws securing the suspensions to the front axle

12

Nut

13

Washer

14

Steering cylinder

15

Axle crossbeam

16

Steering arm

17

Bearing

18

Washer

19

Steering arm pin

25

SERVICE

MECHANICS DISMANTLING THE FRONT AXLE MODEL MT70 Equipment and tools

bridge crane load capacity 2000 kg

spacer bar

no. 4 lift belt load capacity 2000 kg

2 open ended spanners

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 BRIDGE CRANE - SPACER BAR - LIFT BELT Sling the tractor as described in the "INSTALLATION AND SETTING" section.

Phase 2 2 OPEN ENDED SPANNERS Secure the tractor on the wooden blocks, at this point, inserting under the tractor, lock the screws with a key while with the other unscrew and remove the bolts that fix the front axle to the frame of the tractor (ref.1-2-3-4 fig.1).

Fig. 1

1

3

2

4

Retrieve the front axle and place it upside down (fig.2) on a work surface, then proceed with the dismantling of the parts to be replaced.

26

Fig. 2

SERVICE

MECHANICS

REPLACEMENT OF THE SHOCK ABSORBER MODEL MT70 Equipment and tools

2 open ended spanners

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the “DISMANTLING THE FRONT AXLE“ procedure described in this section.

Phase 2 2 OPEN ENDED SPANNERS Use a wrench lock the screws (ref.A fig.2) that secure the shock absorber (ref.B fig.2) to the front axle, while using the other wrench to unscrew and remove the bolts (ref.C fig.2). Retrieve the washers and proceed with the shock absorber replacement.

Fig. 1

Fig. 2

C A B

27

SERVICE

MECHANICS REPLACEMENT OF THE FRONT AXLE CHAIN MODEL MT70 Equipment and tools

2 open ended spanners

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the “DISMANTLING THE FRONT AXLE“ procedure described in this section.

Phase 2 OPEN ENDED SPANNER Using the open ended spanner unscrew the nuts (ref.A fig.2) that secure the lower part of the front axle, in order to allow free access to the chain (ref.B fig.2). Retrieve the chain and proceed with the replacement.

Fig. 1

Fig. 2

A

INSTALLATION Before reassembling the chain, fully grease with "E2" lithium grease.

28

B

SERVICE

MECHANICS

DISMANTLING THE FRONT AXLE MODEL MT80 Equipment and tools

bridge crane load capacity 2000 kg

spacer bar

no. 4 lift belt load capacity 2000 kg

wooden blocks

oil resistant gloves

cap

2 open ended spanners

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 BRIDGE CRANE - SPACER BAR - LIFT BELT Sling the tractor as described in the "INSTALLATION AND SETTING" section.

Phase 2 WOODEN BLOCKS - OIL RESISTANT GLOVES - CAP Set the tractor in safe conditions on the wooden blocks.

Wearing gloves, unscrew the hydraulic tubes and apply the caps to ensure there are no leaks. Contain and mop up any leaks.

Phase 3 2 OPEN ENDED SPANNERS Get under the tractor, lock the screws with a wrench while with the other one unscrew and remove the bolts that secure the front axle to the tractor frame (ref.1-2-3-4 fig.1).

Retrieve the screws, bolts and washers.

1 2

3 4

Fig. 1 Fig. 2

Place the front axle upside down on a work surface, then proceed with the dismantling of the parts to be replaced (fig.2).

29

SERVICE

MECHANICS REPLACEMENT OF THE FRONT AXLE SUSPENSIONS MODEL MT80 Equipment and tools

2 open ended spanners

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the “DISMANTLING THE FRONT AXLE“ procedure described in this section.

Phase 2 OPEN ENDED SPANNER Using the open ended spanner unscrew and remove the screws (ref.A fig.2) that secure the springs to the front axle, retrieve the washers (ref.B fig.2), the clamp plate (ref.C fig.2) and the suspension to be replaced (ref.D fig.2).

Fig. 1

Fig. 2

A

Proceed with the replacement.

B

C

B

D 30

SERVICE

MECHANICS

REPLACEMENT OF THE FRONT AXLE CYLINDER MODEL MT80 Equipment and tools

open ended spanner

circlip pliers

driving tool

hammer

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Fig. 2 Phase 1 Carry out the “DISMANTLING THE FRONT AXLE“ procedure described in this section.

A B C D

Phase 2 OPEN ENDED SPANNER With the circlip pliers remove the circlips (ref.A fig.2) that lock the cylinder pin. Using the hammer and the driving tool (ref.B fig.2) and retrieve the bush (ref.C fig.2).

Perform the same operation for both pins that lock the cylinder (ref.B fig.3) retrieve the cylinder (ref.D fig.2-3) and proceed with the replacement.

Please be very careful with the cylinder weights.

A

B B D

31

SERVICE

MECHANICS

BRAKING AND ACCELERATOR ASSEMBLY IDENTIFICATION OF BRAKING AND ACCELERATOR ASSEMBLY COMPONENTS

27 18

26 24

19 17

14

20 21

15

25

22

23 16

13 12 8

7

11

9

5

10 4

6

3

1

29 2

32

28

SERVICE

MECHANICS

Ref.

Description

1

Accelerator pedal protective plate

2

Protective plate fastening screw

3

Accelerator assembly

4

Accelerator assembly fastening screw

5

Washer

6

Nut

7

Brake pedal

8

Spring

9

Washer

10

Nylon bush

11

Brake pedal fastening screw

12

Self-locking nut

13

Brake cylinder

14

Push rod/piston

15

Fork pin

16

Copper washers

17

Pipe

18

Fastening screw

19

Pressure switch

20

Washer

21

Connector

22

Nut

23

Washer

24

Clip

25

Pipe

26

Brake fluid tank

27

Tank support

28

Accelerator pedal lock

29

Accelerator pedal lock screws

33

SERVICE

MECHANICS DISMANTLING THE ACCELERATOR PEDAL Equipment and tools

flat head screwdriver

Procedure

Fig. 1

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 SCREWDRIVER Using the screwdriver unscrew and remove the 2 bolts (ref.A fig.2) that secure the protective plate of the accelerator (ref.B fig.2). Then remove the plate.

B A Fig. 2

Phase 2 SCREWDRIVER Using the screwdriver unscrew and remove the two screws (ref.C fig.3) that secure the accelerator assembly (ref.D fig.3), retrieve the fastening nuts and washers.

Proceed with the replacement of the whole assembly

D C

Fig. 3 34

SERVICE

MECHANICS

DISMANTLING THE BRAKE PEDAL Equipment and tools

open ended spanner

flat head screwdriver

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

A

Phase 1 OPEN ENDED SPANNER Using the wrench, unscrew and remove the three screws that secure the front cover of the steering assembly (ref.A fig.1), retrieve the washers and bolts and remove the cover.

Phase 2 SCREWDRIVER Using a screwdriver pry off the pin of the fork (ref.B fig.3), to release the brake pedal.

Fig. 2

Fig. 3

B

35

SERVICE

MECHANICS Phase 3 2 OPEN ENDED SPANNERS Use one wrench to lock the brake fastening screw (ref.Cfig.5), and use the other to unscrew the self-locking nut (ref.Dfig.5). Retrieve the nut, washers and fastening screw.

Then, remove the brake and proceed with the replacement

Fig. 4

Fig. 5

D

36

C

SERVICE

MECHANICS

REPLACEMENT OF THE BRAKE CYLINDER Equipment and tools

open ended spanner

oil resistant gloves

cap

hex socket wrench

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

A

Phase 1 OPEN ENDED SPANNER Using the wrench, unscrew and remove the three screws that secure the front cover of the steering assembly (ref.A fig.1), retrieve the washers and bolts and remove the cover.

Fig. 2

Phase 2 OIL RESISTANT GLOVES - CAPS Disconnect the hydraulic tubes and apply the caps (ref.B-C fig.3).

Fig. 3

C

B

37

SERVICE

MECHANICS Phase 3 HEX SOCKET WRENCH With the socket wrench, unscrew the two screws that fasten the brake cylinder to the support plate (ref.D fig.4).

Extract the cylinder from its seat and dismantle or replace.

Fig. 4

D

D

38

SERVICE

MECHANICS

STEERING ASSEMBLY MODEL MT70 IDENTIFICATION OF STEERING ASSEMBLY AND CONTROL LEVER COMPONENTS

6

2

1

3 4

14 15

5

13

12

7 8 Ref.

Description

1

Steering wheel cap

2

Steering wheel

3

Nut

4

Washer

5

Forward / reverse gear lever

6

Turn signal lever (optional)

7

Steering wheel clamp

8

Clamp plate

9

nut

10

Steering column

11

Universal joint

12

Screw

13

Screw

14

Washer

15

Lever support

9 10

11

39

SERVICE

MECHANICS

STEERING ASSEMBLY MODEL MT80 IDENTIFICATION OF STEERING ASSEMBLY AND CONTROL LEVER COMPONENTS

2 1

3 4 13 14 6

15 16

5 7 8 9 10 11

Ref.

40

Description

12

Ref.

Description

1

Steering wheel cap

9

Screw

2

Steering wheel

10

Lock washer

3

Nut

11

Washer

4

Washer

12

Steering valve

5

Forward / reverse gear lever

13

Washer

6

Turn signal lever (optional)

14

Lock washer

7

Screw

15

Lever fastening screw

8

Washer

16

Steering column

SERVICE

MECHANICS

DISMANTLING OF THE FORWARD/BACKWARD GEAR LEVER AND TURN SIGNAL LEVER (OPTIONAL) Equipment and tools

socket wrench

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

FORWARD/REVERSE GEAR LEVER

Phase 1 HEX SOCKET WRENCH Using the socket wrench unscrew the 2 screws (ref.A fig.1) that secure the forward/reverse gear lever (ref.B fig.1) to the steering column. Recover the washers and the support, disconnect the connector and proceed with the replacement.

B

Fig.1

A

TURN SIGNAL LEVER (OPTIONAL)

Phase 2 HEX SOCKET WRENCH Using the socket wrench unscrew the 2 screws (ref.C fig.2) that secure the turn signal lever (ref.D fig.2) to the forward/ reverse gear lever (ref.B fig.2). Place the gear lever on the tractor cover.

Retrieve the washers, disconnect the turn signal lever connector and proceed with the replacement.

Fig.2

B

D

C

41

SERVICE

MECHANICS DISMANTLING THE STEERING COLUMN MODEL MT70 Equipment and tools

open ended spanner

flat head screwdriver

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 OPEN ENDED SPANNER Using the wrench, unscrew and remove the three screws that secure the front cover of the steering assembly (ref.A fig.1), retrieve the washers and bolts and remove the cover.

Fig. 1

A

Fig. 2

B

Phase 2 FLAT HEAD SCREWDRIVER - OPEN ENDED SPANNER Using the screwdriver, pry off the steering wheel cap (ref.B fig.2), then with the open ended spanner unscrew and remove the nut that locks the steering wheel (ref.C fig.3) At this point remove the steering wheel from the steering column.

Fig. 3 Phase 3 Carry out the “DISMANTLING THE FORWARD/REVERSE GEAR LEVER AND TURN SIGNAL LEVER” procedure.

42

C

SERVICE Phase 4 OPEN ENDED SPANNER Using the open ended spanner unscrew and remove the bolts (ref.D fig.4) that secure the terminal (ref.E fig.4) of the steering column. Retrieve the front plate.

MECHANICS

Fig.4

E D

E F

Fig.5

Phase 5 Pry off the protective rubber (ref.F fig.5).

Widen the clamp and remove the steering column from the universal joint (fig.6), then pull it upwards and proceed with the replacement.

Fig.6

43

SERVICE

MECHANICS DISMANTLING THE STEERING COLUMN AND VALVE MODEL MT80 Equipment and tools

flat head screwdriver

oil resistant gloves

cap

open ended spanner

Procedure 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 pedestrian traffic. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 OPEN ENDED SPANNER Using the wrench, unscrew and remove the three screws that secure the front cover of the steering assembly (ref.A fig.1), retrieve the washers and bolts and remove the cover.

Fig. 1

A

Fig. 2

B

Phase 2 FLAT HEAD SCREWDRIVER - OPEN ENDED SPANNER Using the screwdriver, pry off the steering wheel cap (ref.B fig.2), then with the open ended spanner unscrew and remove the nut that locks the steering wheel (ref.C fig.3) At this point remove the steering wheel from the steering column.

Fig. 3 Phase 3 Carry out the “DISMANTLING THE FORWARD/REVERSE GEAR LEVER AND TURN SIGNAL LEVER” procedure.

44

C

SERVICE

MECHANICS

Phase 4 OPEN ENDED SPANNER Using the open ended spanner unscrew and remove the 4 bolts (ref.D fig.4) that secure the steering column to the steering valve. Retrieve the washers.

Fig.4

D

Phase 5 CAPS - OIL RESISTANT GLOVES - OPEN ENDED SPANNER Disconnect the hydraulic tubes and apply the appropriate caps.

Using the open ended spanner unscrew and remove the 4 bolts (ref.E fig.4) that secure the steering valve to the support plate. Retrieve the washers.

Phase 6 Pull out a small section of the steering column (ref.F fig.5) upwards to remove the steering valve (ref.G fig.5).

E

F

Fig.5

G

Once the steering valve has been removed, remove the steering column from below. Then proceed to replace the piece that requires it.

45

SERVICE

MECHANICS

TRACTION MOTOR - ELECTROMAGNETIC BRAKE IDENTIFICATION OF TRACTION MOTOR AND ELECTROMAGNETIC BRAKE COMPONENTS

2 15

3 14 4 1

5

6 7

13 8

9 10

11

12 16

Ref.

46

Description

Ref.

Description

1

Motor

9

Frame

2

Frame

10

Circlip

3

Stator

11

Brake rail coupling ring

4

Rotor

12

Circlip

5

Circlip

13

Encoder sensor

6

Spacer

14

Temperature sensor

7

Bearing with sensor

15

Power cables connection plate

8

O-ring

16

Electromagnetic brake

SERVICE

MECHANICS

REPLACEMENT OF TRACTION MOTOR AND ELECTROMAGNETIC BRAKE Equipment and tools

bridge crane load capacity 2000 kg

no. 4 lift belt load capacity 2000 kg

spacer bar

T-handle hex key

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 BRIDGE CRANE - SPACER BAR - LIFT BELT Sling the tractor as described in the "INSTALLATION AND SETTINGS" section.

Fig. 1 Phase 2 Carry out the “DISMANTLING THE REAR AXLE“ procedure

TRACTION MOTOR

Phase 3 Once the rear axle is resting on a work table, unscrew the 4 screws that secure the motor to the axle using an Allen wrench (ref.A fig.2), place the motor on the work table

Fig. 2

A

47

SERVICE

MECHANICS ELECTROMAGNETIC BRAKE Phase4 T-HANDLE HEX SPANNER With the Allen wrench, unscrew and remove the 4 screws that secure the electromagnetic brake to the motor (ref.B fig.3). At this point, proceed with the dismantling or replacement of the motor.

INSTALLATION Before installing the motor, lubricate the drive shaft with a thin, even layer of special lubricating grease.

Before tightening the screws that fasten the motor to the axle, apply "Loctite 243".

48

Fig. 3

B

SERVICE

MECHANICS

DISMANTLING THE TRACTION MOTOR Equipment and tools

medium adjustable pliers

circlip pliers

3-5 mm T-handle hex spanner

flat head screwdriver

Procedure 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 pedestrian traffic. Turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Phase 1 Carry out the traction motor and the electromagnetic brake dismantling procedure (see "REPLACEMENT OF TRACTION MOTOR AND ELECTROMAGNETIC BRAKE").

Phase 2 MEDIUM ADJUSTABLE PLIERS - CIRCLIP PLIERS Using the adjustable pliers extract the brake guide coupling key (ref.A fig.1), then remove the 2 circlips using the circlip pliers (ref.B fig.1).

Phase 3 T-HANDLE HEX SPANNER Using the T-handle hex spanner unscrew and remove the 4 screws securing the motor frame (ref.C fig.1).

C

A

B 49

SERVICE

MECHANICS Phase 4 CIRCLIP PLIERS Using the circlips pliers pull off the circlips of the bearing assembly (ref.D fig.2), remove the bearing (ref.E fig.2) and the spacer (ref.F fig.2).

Then replace the bearing.

Fig. 2

F D

50

E

SERVICE

MECHANICS

REPLACEMENT OF THE ELECTRIC STEERING MOTOR, ONLY MODEL MT80 Equipment and tools

bridge crane load capacity no. 4 lift belt load capacity 2000 kg 2000 kg

spacer bar

oil resistant gloves

cap

flat head screwdriver

open ended spanner

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

Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 FLAT HEAD SCREWDRIVER Using the screwdriver unscrew and remove the 6 screws (ref.A fig.1) that secure the load plate (ref.B fig.1). Then remove the plate.

Fig. 1

B Phase 2 OIL RESISTANT GLOVES - CAPS Disconnect the hydraulic tubes and apply the caps (ref.C fig.2).

A

Fig. 2 Phase 3 BRIDGE CRANE - SPACER BAR - LIFT BELT Sling the tractor as described in the "INSTALLATION AND SETTINGS" section.

C

51

SERVICE

MECHANICS

Phase 4 OPEN ENDED SPANNER Lift the tractor up enough to get under it.

Unscrew the two screws (ref.D fig.3) that secure the steering wheel pump to the support plate

Fig. 3

D

Fig. 4 Phase 5 BRIDGE CRANE - LIFTING SLINGS Place the tractor on the ground, then sling the electric steering motor with the lifting belts, place it on a work table and proceed with the replacement (fig.4).

52

SERVICE

ROUTINE MAINTENANCE

ROUTINE MAINTENANCE WARNINGS..............................................................................................................................................................2 O I L S A N D L U B R I C A N T S..........................................................................................................4 C L E A N I N G P R O D U C T S .....................................................................................................4 S C H E D U L E D M A I N T E N A N C E ..........................................................................................5 NOTE ON TIRE SAFETY....................................................-.................................................................6

1

ROUTINE 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.

2

SERVICE

ROUTINE 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.

3

ROUTINE MAINTENANCE

SERVICE

OILS AND LUBRICANTS Lubrication point Brake cylinder tank

(1) (2)

Lubricant Universal fluid for brakes DOT 4

Front steering wheel pins(1)

Lithium grease LITHIUM EP2

Front suspension shafts (2)

Lithium grease LITHIUM EP2

Front suspension oscillating boom (2)

Lithium grease LITHIUM EP2

Front swivel support bearing (2)

Lithium grease LITHIUM EP2

Crossbow brackets

Lithium grease LITHIUM EP2

Front wheel bearings

Lithium grease LITHIUM EP2

Rear axle traction unit

Transmission oil EP Texaco Geartex EP-A-80W

Electric steering wheel pump tank (1)

Hydraulic oil ISO Grade 32

Hook hinges on seat sliding guides

Generic oil LUBE OIL

Only for model MT80 Only for model MT70

CLEANING CLEANING OF CASINGS, PLASTIC COVERS, 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 tractor, plates, decals or that can be dangerous for the operator.

CLEANING OF ENGINES, BRAKING SYSTEM AND ELECTRIC PANEL 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 tractor or that may be dangerous for the operator.

CLEANING OF ELECTRIC BRAKE PUMP, SWIVEL SUPPORT Use degreasing products.

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

To clean the battery, follow the directions on the manual of the battery.

4

SERVICE

ROUTINE MAINTENANCE

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

Maintenance intervals 1 week every 25 hours

CHASSIS

Operation description

1 month every 100 hours

Chassis and cab check

BRAKING SYSTEM WHEEL TRACTION



Braking system adjustment



Brake pipe check



Brake fluid level check



Brake cylinders, shoes and jaws check



Traction motor cables check



Motor/axle installation and tightening check



Axle pin, springs, bolts check



Check the rear axle oil level



(3)

Rear axle oil change (1)

x

Front bearings condition and wear check

(2)

Tyres condition, pressure and wear check

 (3)



GREASING POINTS

Wheels bearings condition and wear check



Moving parts lubrication with grease



Greasing points lubrication



INSTRUMENTATION CONTROLS

SEAT

STEERING WHEEL

Steering wheel joints, tubes and cylinders check

ELECTRONIC SYSTEM

18 months every 1500 hours



Braking system check (3)

BATTERY

3 months every 300 hours

Front axle swivel support check



(3) (5)



Electric steering wheel pump fluid check (4)



Electric steering wheel pump fluid condition (4)

x

Steering wheel chain wear and tensioning check (5)



Seat fastening screws check



Battery / seat cover hinges check



Seat /seat belt conditions and operation check



Horn operation check



Emergency button operation check



Flashing light operation check



Turn indicator, braking and side lights operation check



Optional equipment check



Battery plug/socket integrity check



Contactors tips check



Control device connections and wiring check



Cleaning and tightening of all connections check



Battery check and topping up (use only distilled water)

The first oil change must be carried out after the first 150 hours.

Use grease suitable for wheel bearings (3) The first check must be carried out after the first 30 hours.



(1)

(4)

(2)

(5)

Only for model MT80 Only for model MT70

5

SERVICE

ROUTINE MAINTENANCE

NOTE ON TYRE SAFETY The tyres are the only parts of a tractor that are always in contact with the ground. They provide grip for movement and friction for braking. The correct tyres in good condition are an essential aid to safe and efficient operations. The wrong tyres for the application, or tyres in poor condition or excessively worn, are a potentially dangerous and expensive hazard.

The choice of tyre will depend on the type of truck and the working environment. Tyres must only be fitted or repaired by a fully trained engineer.

Tyres can be vulnerable to damage. When the tyres are damaged, in poor condition, or when they are under or over inflated , they may adversely affect the stability of the tractor.

It is recommended to check the conditions of all the tyres daily.

The tyres must have a minimum of 1mm of tread over the center and 75% of tread around the complete circumference.

Solid rubber resilient tyres may be used until they are worn to the wear indicator, also known as the J-line Cushion, press-on band, and conical base tyres can be used until 2/3rds of the original thickness remains.

They should be changed if there is any sign of damage or deformation.

Wear is recommended up to the TWI (Tread Wear Indicator) index which is positioned on the tread. The height of the TWI was defined according to a study based on safety and economy at the user’s interest.

SOLID TYRES - THE J LINE J Line

The J line marks the top of a solid tyre sidewall and the start of the tread. The tread depth is measured from this point

6

SERVICE

ROUTINE MAINTENANCE

7

Codice: 550181164

Revision: 0 (02/2018)