DOWNLOAD PDF : Yale Forklift B843 B847 A892 Service Manual

Part No: 272352200

Technical Information for YALE Servicing Centres

This manual is intended solely for the specialised technicians of the Yale servicing network

MP20X MS12X

SERVICE

Section: ELECTRICAL SYSTEM Section: CONTENTS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

GENERAL SAFETY REGULATIONS NEVER PERFORM ANY CLEANING, LUBRICATION OR MAINTENANCE WORK WITH THE BATTERY CONNECTED. DO NOT WEAR RINGS, WRIST WATCHES, JEWELLERY, LOOSE OR DANGLING ITEMS OF CLOTHING SUCH AS SCARVES, UNBUTTONED JACKETS OR OVERALLS WITH OPEN ZIP FASTENERS THAT MAY GET CAUGHT IN THE MOVING PARTS. YOU ARE RECOMMENDED TO WEAR APPROVED SAFETY CLOTHING, FOR EXAMPLE: HELMETS, NON-SLIP FOOTWEAR, GLOVES, SAFETY GOGGLES. NEVER USE PETROL, DIESEL FUEL OR OTHER INFLAMMABLE LIQUIDS AS DETERGENTS: USE INSTEAD NON-FLAMMABLE AND NON-TOXIC COMMERCIAL SOLVENTS. DO NOT SMOKE, DO NOT USE OPEN FIRE NOR CAUSE SPARKS IN THE VICINITY WHEN HANDLING EASILY FLAMMABLE MATERIALS.

In case of interventions outside the workshop, position the truck on a flat surface if possible and block it. If work on a slope is unavoidable, first block the truck and move it to a flat area as soon as possible with a certain degree of safety.

Disconnect the batteries and label all controls to signal that maintenance is being performed. Block the truck and any equipment that has to be lifted.

When towing, use only the prescribed attachment points and make sure that all pins and/or latches are fastened securely before pulling.

Lift and handle all heavy parts using lifting equipment of suitable capacity. Use the lifting eyelets prescribed for this purpose.

Watch out for people in the vicinity of the load to be lifted.

Avoid twisting chains or wire ropes.

Beware of bent or damaged chains or ropes: they must not be used for lifting or pulling. Always use protective gloves when handling them.

Handle all parts with care, do not put your hands or fingers between parts.

Wear approved safety clothing, such as goggles, gloves and safety footwear.

The zone where maintenance operations are performed must always be kept clean and dry. Always clean up immediately any pools of water or oil stains.

Do not pile greasy or oily rags on top of each other: they present a serious fire hazard. Always put back in a closed metal container.

Do not perform any service work on the truck if there are people at the controls, except if they are fully trained operators helping with the work to be performed.

If using compressed air to clean parts, always wear protective goggles with side shields.

Welding When performing welding work, use the prescribed safety equipment: dark glasses, helmets, overalls, gloves, shoes. Dark glasses must also be worn by persons not performing welding but in the area when welding is being performed. Never look at the welding arc without wearing suitable eye protection.

Batteries When using batteries, remember that the leads must be connected at both ends to the terminals as prescribed: (+) to (+) and (-) to (-).

Avoid short circuiting the terminals.

The gas released during charging is highly flammable. When charging, always leave the battery compartment open for a more effective ventilation and remove the caps.

AVOID SPARKS OR FLAMES IN THE BATTERY AREA!

Never check the state of charge of the batteries by means of “jumper connections” made by placing metal objects on the terminals.

Before any servicing check that there are no short circuits between elements.

Always disconnect the batteries before carrying out any operations on the electrical system.

For battery chargers and similar equipment, use only auxiliary power supply sources with an effective earth connection to avoid the possibility of electric shocks.

Hydraulic System A fluid leaking from a very small hole may be practically invisible yet be sufficiently strong to penetrate the skin; in such cases, if you have to perform a check, use cardboard or a piece of wood. Never use your hands.

When checking system pressures, use the appropriate instruments .

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Section: ELECTRICAL SYSTEM Section: CONTENTS

MP20X / MS12X

CONTENTS Section: ELECTRICAL SYSTEM -

ELECTRICAL FUNCTIONAL DIAGRAM MOD. MP20X ........................................................................................................... 8a

-

ELECTRICAL FUNCTIONAL DIAGRAM MOD. MP20X ........................................................................................................... 8b

-

ELECTRICAL FUNCTIONAL DIAGRAM MOD. MS12X ........................................................................................................... 8c

-

ELECTRICAL FUNCTIONAL DIAGRAM MOD. MS12X ........................................................................................................... 8d

1.1

ELECTRICAL SYSTEM COMPONENTS MOD. MP20X - MS12X ........................................................................................... 8e

1.2

TABLE OF THE ELECTRICAL SYSTEM COMPONENTS MOD. MP20X - MS12X ..................................................................... 9

1.3

TILLER CONTROL BOX MODS. MP20X - MS12X ................................................................................................................ 10

1.4

PROCEDURE FOR DISASSEMBLY, REASSEMBLY AND ADJUSTMENT OF THE POTENTIOMETER MODS. MP20X - MS12X ....................................................................................................................................................... 12

2.0

TRACTION MOTOR ELECTRONIC CONTROL ....................................................................................................................... 14

2.1

OVERVIEW ............................................................................................................................................................................ 14

2.2

DEFINITION OF THE TRUCK’S DIRECTION OF TRAVEL ........................................................................................................ 15

2.3

H1 CHOPPER GENERAL FEATURES ..................................................................................................................................... 16

2.4

CHOPPER FUNCTIONAL FEATURES ..................................................................................................................................... 18

2.5

CHOPPER MECHANICAL DRAWING ..................................................................................................................................... 19

2.6

CONNECTORS ...................................................................................................................................................................... 20

3.0

PROGRAMMING HANDSET ................................................................................................................................................... 23

3.1

OVERVIEW ........................................................................................................................................................................... 23

3.2

USING THE PROGRAMMING HANDSET ................................................................................................................................ 25

4.0

HANDSET FUNCTION MAP .................................................................................................................................................... 26

4.1

PROGRAMMING THE CHOPPER ........................................................................................................................................... 27

4.2

H1 SYSTEM CONFIGURATION TABLES MODS. MP20X AND MS12X .................................................................................. 40

4.3

TROUBLESHOOTING ........................................................................................................................................................... 42

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ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

Section: ELECTRICAL SYSTEM Section: CONTENTS

ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

CONTENTS Section: HYDRAULIC SYSTEM 1.1

LEGEND OF THE HYDRAULIC SYSTEM SYMBOLS MODS. MP20X - MS12X ....................................................................... 3

1.2

HYDRAULIC SYSTEM DRAWING MOD. MP20X ..................................................................................................................... 4

1.3

HYDRAULIC SYSTEM DRAWING MOD. MS12X (triplex and duplex) ................................................................................... 5

1.4

HYDRAULIC SYSTEM DRAWING MOD. MS12X (simplex) .................................................................................................... 6

2.0

HYDRAULIC CONTROL UNIT COMPONENTS MOD. MP20X ................................................................................................. 8

2.1

TABLE OF HYDRAULIC CONTROL UNIT COMPONENTS MOD. MP20X ................................................................................ 9

3.0

LIFTING CYLINDER COMPONENTS MOD. MP20X ............................................................................................................... 10

3.1

TABLE OF THE LIFTING CYLINDER COMPONENTS MOD. MP20X ...................................................................................... 11

3.2

CENTRAL CYLINDER COMPONENTS MOD. MS12X ............................................................................................................ 12

3.3

TABLE OF CENTRAL CYLINDER COMPONENTS MOD. MS12X .......................................................................................... 13

3.4

LATERAL CYLINDER COMPONENTS MOD. MS12X ............................................................................................................ 14

3.5

TABLE OF THE LATERAL CYLINDER COMPONENTS MOD. MS12X .................................................................................... 15

4.0

DISASSEMBLY OF THE LIFTING CYLINDERS FROM THE TRUCK MOD. MS12X ................................................................. 16

4.1

DISASSEMBLY OF THE LATERAL CYLINDERS OF THE TRIPLEX, DUPLEX, SIMPLEX MASTS MOD. MS12X ................... 18

4.2

DISASSEMBLY AND REASSEMBLY OF THE HYDRAULIC DISTRIBUTOR MOD. MS12X ..................................................... 19

4.3

ADJUSTMENT OF THE MAXIMUM PRESSURE LIFTING VALVE MOD. MS12X .................................................................... 20

5.0

DISASSEMBLY OF THE LIFTING CYLINDER MOD. MP20X .................................................................................................. 21

5.1

DISASSEMBLY OF MOTOR PUMP GROUP MOD. MP20X ................................................................................................... 24

5.2

ADJUSTMENT OF THE FORK LIFTING MAXIMUM PRESSURE VALVE MOD. MP20X ......................................................... 25

5.3

DISASSEMBLY THE SOLENOID VALVE GROUP MOD. MP20X ........................................................................................... 26

CONTENTS Section: MECHANICS - CHASSIS HOUSING 1.0

REAR CHASSIS COMPONENTS MOD. MP20X ...................................................................................................................... 2

1.1

TABLE OF REAR CHASSIS COMPONENTS MOD. MP20X ..................................................................................................... 3

1.2

REAR CHASSIS COMPONENTS MOD. MS12X ...................................................................................................................... 4

1.3

TABLE OF REAR CHASSIS COMPONENTS MOD. MS12X ..................................................................................................... 5

2.0

DISASSEMBLY OF OPERATOR PLATFORM MOD. MP20X - MS12X ..................................................................................... 6

2.1

DISASSEMBLY OF LATERAL PROTECTIONS MOD. MP20X ................................................................................................. 7

2.2

DISASSEMBLY OF LATERAL PROTECTIONS MOD. MS12X ................................................................................................. 8

3.0

DISASSEMBLY OF THE REDUCER SUPPORT GROUP SPRINGS MOD. MP20X ................................................................... 9

3.1

DISASSEMBLY OF THE REDUCER SUPPORT GROUP SPRINGS MOD. MS12X ................................................................. 11

4.0

DISASSEMBLY OF TILLER MOD. MP20X - MS12X ............................................................................................................. 14

5.0

DISASSEMBLY OF THE TRACTION MOTOR MOD. MP20X - MS12X .................................................................................. 16

6.0

DISASSEMBLY OF THE REDUCER SPRING-MOUNTED GROUP MOD. MP20X ................................................................... 18

6.1

DISASSEMBLY OF THE REDUCER SPRING-MOUNTED GROUP MOD. MS12X ................................................................... 19

7.0

DISASSEMBLY OF THE SWIVEL WHEEL GROUP MOD. MP20X ......................................................................................... 20

8.0

DISASSEMBLY OF THE SWIVEL WHEEL GROUP MOD. MS12X ......................................................................................... 22

9.0

DISASSEMBLY OF THE MOTOR PUMP MOD. MS12X ......................................................................................................... 24

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Section: ELECTRICAL SYSTEM Section: CONTENTS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

CONTENTS

1.0

MAST TYPES MOD. MS12X ................................................................................................................................................... 2

2.0

COMPOSITION OF THE SIMPLEX MAST MOD. MS12X ........................................................................................................ 2

2.1

COMPOSITION OF THE DUPLEX AND TRIPLEX MASTS MOD. MS12X ............................................................................... 4

2.2

TABLE OF COMPOSITION OF THE DUPLEX AND SIMPLEX MASTS MOD. MS12X ............................................................. 5

3.1

DISASSEMBLY OF FORK FRONT UNIT FROM TRIPLEX, DUPLEX, SINGLE MASTS MOD. MS12X ....................................... 6

3.2

DISASSEMBLY OF FORK FRONT UNIT FROM SIMPLEX MASTS MOD. MS12X .................................................................... 8

3.3

DISASSEMBLY OF INTERNAL TRIPLEX MAST MOD. MS12X ............................................................................................... 8

3.4

DISASSEMBLY OF TRIPLEX INTERMEDIATE MAST AND DUPLEX INTERNAL MAST MOD. MS12X .................................... 9

CONTENTS Section: MECHANICS - LEVER MECHANISMS 1.0

FRONT CHASSIS COMPONENTS MOD. MP20X .................................................................................................................... 2

1.1

TABLE OF FRONT CHASSIS COMPONENTS MOD. MP20X .................................................................................................. 3

2.0

DISASSEMBLY OF THE ROLLER SUPPORTING ROCKER ARMS MOD. MP20X ................................................................... 4

2.1

DISASSEMBLY OF THE COMPLETE LEVER MECHANISMS MOD. MP20X ........................................................................... 5

CONTENTS Section: REDUCER 1.0

DISASSEMBLY OF THE REDUCER FROM THE TRUCK MOD. MP20X ................................................................................... 3

2.0

DISASSEMBLY OF THE REDUCER FROM THE TRUCK MOD. MS12X ................................................................................... 6

3.0

REDUCER COMPONENTS MOD. MP20X - MS12X ................................................................................................................ 8

3.1

TABLE OF REDUCER COMPONENTS MOD. MP20X - MS12X ............................................................................................... 9

4.0

DISASSEMBLY OF REDUCER MOD. MP20X - MS12X ......................................................................................................... 10

5.0

REDUCER TIGHTENING TORQUE DIAGRAM MOD. MP20X - MS12X .................................................................................. 14

CONTENTS Section: BRAKING SYSTEM 1.0

COMPONENTS OF THE ELECTROMAGNETIC BRAKE MOD. MP20X - MS12X ..................................................................... 2

1.1

TABLE OF ELECTROMAGNETIC BRAKE COMPONENTS MOD. MP20X - MS12X ................................................................. 3

1.2

BRAKING SYSTEMS MODS. MP20X - MS12X ....................................................................................................................... 4

1.3

DISASSEMBLY AND ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE MODS. MP20X - MS12X ................................... 4

2.0

ADJUSTMENT AND PUTTING INTO OPERATION MOD. MP20X - MS12X ............................................................................. 6

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ELECTRICAL

Section: MECHANICS - MASTS

SERVICE

Section: ELECTRICAL SYSTEM Section: CONTENTS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

NOTES:

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Section: ELECTRICAL SYSTEM

MP20X / MS12X

ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

ELECTRICAL SYSTEM

UPDATE

å

COMPONENTS ................................................................................. page 2

å

MOTOR ELECTRONIC CONTROL ................................................. page 14

å

PROGRAMMING HANDSET ............................................................. page 23

å

PROGRAMMING THE CHOPPER .................................................... page 27

å

TROUBLESHOOTING ...................................................................... page 42

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

NOTES:

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Section: ELECTRICAL SYSTEM

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

Braking diode

ELECTRICAL FUNCTIONAL DIAGRAM MOD. MP20X

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X ELECTRICAL FUNCTIONAL DIAGRAM MOD. MP20X

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X ELECTRICAL FUNCTIONAL DIAGRAM MOD. MS12X

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X ELECTRICAL FUNCTIONAL DIAGRAM MOD. MS12X

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Section: ELECTRICAL SYSTEM

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X 1.1 ELECTRICAL SYSTEM COMPONENTS MOD. MP20X - MS12X

1 2 5

4

6

3

10

9

8

7

11 21 12 22

20

17

13

19

18

16 15 14

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

1.2

MP20X / MS12X

TABLE OF ELECTRICAL SYSTEM COMPONENTS ELECTRICAL

MOD. MP20X - MS12X The various electrical components shown on the opposite page are described in the table below (Tab. 01).

Key to understanding: Ref. = Reference of component on exploded view; Ref. Diagram = Reference used on the wiring diagrams, to distinguish each single component; Component Description = Function of the electric component; MP20X - MS12X = Columns indicating whether the component is present on each model.

Ref.

Diagram Ref.

Component Description

1

Control box

2

Potentiometer control throttle

3

Throttle return spring

4

P1

Fork lifting push button

5

P2

Fork lowering push button

6

P4

Horn control microswitch

7

13

Forward motion microswitch

8

12

Reverse motion microswitch

9

15

Travel inversion microswitch

10

Pot

Potentiometer

11

14

Speed slowdown microswitch, tiller rotated

12

136

Speed slowdown microswitch, lateral protections closed

13

135

Lateral protections closed microswitch

14

133

Platform closed microswitch

15

134

Microswitch operator present on open platform

16

RE

Electromagnetic brake control relay

17

DFC

Counter-current braking diode Forward – reverse contactor

18 19

T1

Pump contactor

20

F1

300A power fuse

21

F2

10A auxiliaries fuse Electronic control

22

MP20X

MS12X

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

Tab.01

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

1.3 TILLER CONTROL BOX MODS. MP20X - MS12X The control box is located on the tiller head and it contains all the controls such as push buttons, microswitches, potentiometer.

Instructions are provided below for the replacement and adjustment of the different components.

STANDARD TOOLS NEEDED

PHILIPS SCREWDRIVER MEDIUM SIZE

DISASSEMBLY OF THE SUPPORT OF THE COMPONENTS 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks (on the MS12Xwith the lever; on the MP20X with the down push button), turn the key switch to the OFF position, disconnect the battery.

3) PHILIPS SCREWDRIVER - Unscrew the 6 securing screws in the box cover at the front of the box.

4) Disconnect the sheath connector to the box controls.

5) Unscrew the locking screw of the control throttle (to the right of the driving position), and take it out.

6) Take out the left-hand throttle complete with control hinge-mounting pin by pushing on the pin from right to left with the screwdriver.

7) Remove the support complete with components from the box

REPLACEMENT OF THE FORWARD / REVERSE TRAVEL MICROSWITCHES (parts 7-8) 1) To replace the forward-reverse travel microswitches, unscrew and take out the screws that keep the two containment walls pressed together and remove the component concerned.

2) Loosen the fast-on connectors of the microswitch to be replaced, pay special attention to the connections.

3) Connect the new component correctly and insert it between the two walls and lock the screws.

4) Before locking the screws fully, ensure that the control arms of the microswitches touch the internal cams.

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

REPLACEMENT OF THE INVERSION MICROSWITCH (part 9) ELECTRICAL

1) To replace the quick inversion microswitch, unscrew its two locking screws.

2) Loosen the fast-on connectors, connect them to the new microswitch and put it in position.

3) Put the screws back in, push the microswitch in the direction of its control cam and block it.

REPLACEMENT OF THE HORN MICROSWITCH (part 6) 1) To replace the horn microswitch, unscrew its locking screws.

2) Loosen the fast-on connectors, connect them to the new part, put the screws back in and, before locking them tight, check for correspondence with the command cam.

REPLACEMENT OF THE TRACTION SPRING (part 3) 1) Replacement of the traction spring: remove the elastic ring with the pliers provided, remove the outer shell containing the spring and take it out.

2) Put in the new spring, blocking it in its inner shell and in the stop pin, pre-loading it.

3) Put the outer shell back in place and t he elastic ring and check that there is no rotary play, otherwise bend slightly the spring attachments.

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

1.4 PROCEDURE FOR DISASSEMBLY, REASSEMBLY AND ADJUSTMENT OF THE POTENTIOMETER MODS. MP20X - MS12X

DISASSEMBLY 1) Take out the large gearwheel using a screwdriver for leverage, if necessary.

2) Unscrew the stud fastening the small gearwheel to the potentiometer pin and remove the gearwheel.

3) Remove the nut holding the potentiometer to the support, take out the potentiometer.

ORANGE BLACK

GREEN

REASSEMBLY 1) Take the new potentiometer and solder the connection wires in accordance with the arrangements shown above (1-3 orange, 2 green, 4 black).

2) Put the potentiometer into its seat; position it so that the half-shells containing the spring, when they rotate, do not interfere with the connection wires.

3) Put in the washer and nut, tighten them to lock the potentiometer in place.

4) Loosen the small gearwheel locking stud and fit the small gearwheel onto the shaft of the potentiometer leaving a distance of 2÷3 mm between gearwheel and wall.

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

5) Place the untoothed part of the small gearwheel and the seat of the locking stud (G) as illustrated in the figure below.

T

G

(fig. C).

6) Insert the large gearwheel, locating the recess (T) in the right position (see figure above).

ADJUSTMENT 1) TESTER - Take an ohmmeter; connect the probes to the potentiometer at the points 2 and 4 (see figure).

1) Turn the shaft of the potentiometer until the connected tester (see figure) shows that the current zone of the potentiometer is AA1 (0 ohm).

2) Tighten the locking stud (G) of the small gearwheel on the shaft of the potentiometer

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

2.0 TRACTION MOTOR ELECTRONIC CONTROL H1B - 300A CHOPPER 2.1 OVERVIEW The H1 - 300A Chopper used by us for management and control of the traction motor relies on a microprocessor for optimization of the traction motor excitation and de-excitation curves, controlling power MOSFETs which operate at a frequency of 18 MHz. The high-frequency control of the motor permits a wide control range and more gradual acceleration and electric braking.

The H1 - 300A Chopper, supplying a filtered, 18 KHz high-frequency voltage to the traction motor, compared with low-frequency controls and at the same mean current supplied, permits levelling of the absorption, considerably reducing the peaks (as can be seen in fig. 1). This facilitates the operating conditions and increases the average lifespan of the battery and of the motor.

Non-filtered low-frequency waveform

Fig. 1

Average current 100 A Ipeak - 200 A

Non-filtered low-frequency waveform

The H1 - 300A Chopper optimizes the power output of the motor at low speeds. Power of the motor, which depends on the accelerator potentiometer, does not in fact follow a linear law, but rather a law that is a close approximation of a double ramp (see fig. 2). In this way gradual and minimal variations of the acceleration are obtained, enabling the truck to manoeuvre accurately also in the smallest of spaces.

Fig. 2

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

For compliance with the PREN 1175 directives applying to tiller trucks with a safety drive inversion push button, the microswitches for direction of travel and quick inversion must be wired in accordance with the definition of the direction of travel illustrated in the drawing below:

MP20X

ç FORWARD

REVERSE

è

REVERSE

è

MS12X

ç FORWARD

GENERAL WARNINGS AND PRECAUTIONS - DO NOT CONNECT THE CHOPPER TO OTHER ELECTRONIC CONTROLS, ESPECIALLY IF THEY OPERATE AT LOW FREQUENCY. - DO NOT CONNECT THE CHOPPER TO A BATTERY WITH A VOLTAGE RATING DIFFERENT FROM THAT SHOWN ON THE MODULE DATA PLATE. A HIGHER BATTERY VOLTAGE CAN DAMAGE THE MOS. WITH A LOWER BATTERY VOLTAGE, THE MODULE WILL NOT START. - IF YOU CHANGE THE CHOPPER, TEST THE TRACTION FUNCTIONS WITH THE TRACTION WHEEL RAISED FROM THE GROUND TO PREVENT HAZARD SITUATIONS FROM BEING CAUSED

BY CONNECTION ERRORS. - DO NOT INVERT POLARITY OF THE THE CHOPPER POWER SUPPLY

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ELECTRICAL

2.2 DEFINITION OF THE TRUCK’S DIRECTION OF TRAVEL

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

2.3 H1 CHOPPER GENERAL FEATURES The H1 Chopper is available in a single version, with a maximum operating current of 300A and supplied with a power supply voltage of 24V. Listed below are the technical data, followed by a diagram of the basic connections for a 1-field motor connected for series excitation.

Power supply voltage ...................................

Maximum permissible current ......................

Operating frequency of the Mosfet ...............

Motors (feature) ............................................

Operating environment temperature ............

Maximum attainable temperature of the Chopper body .....................................

ð ð ð ð ð

24 V 300 A 18 KHz Series excitation motors, 3 or 4 terminals in D-C. -30° ÷ +40°

ð

+85°

The Chopper can be set at any of 4 different operating configurations: 1. Traction control for 2-field motors and therefore 3 wires (H1 3 WIRES); 2. Traction control for 1-field motors without direction contactors (H1 4 WIRES S); 3. Traction control for 1-field motors with direction contactors (H1 4 WIRES T); The latter (H1 4 WIRES T) is the configuration used on the trucks dealt with in this manual.

Below is the basic diagram for the H1 4 WIRES T configuration : - Series excitation motor with 1 field and travel direction contactors.

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

The H1 chopper does not include the ”braking diodes”, which allow the braking current to be recirculated through the motor. The braking diodes are therefore fitted externally to the chopper, by connecting a module to the motor that contains 2 power diodes to be used in parallel. In some cases, when the braking currents are excessive, 2 of these modules are used so that the current may be distributed among 4 diodes. The diagram on the previous page depicts the module containing the 2 braking diodes and marked DF. The figures that follow comprise a drawing and the dimensions of a braking module, together with the wiring arrangement.

- BRAKING DIODE MODULE

- WIRING ARRANGEMENT

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ELECTRICAL

BRAKING DIODES

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

2.4 CHOPPER FUNCTIONAL FEATURES POSSIBILITY OF 3 CONFIGURATION MODES

4 WIRES T:

3 WIRES

4 WIRES S

Configuration for a 1-field motor (4 wires) with travel direction contactors (Imax permissible =300A)

Configuration for a 2-field motor (3 wires) with travel direction contactors (Imax permissible = 300A)

Configuration for a 1-field motor (4 wires) without travel contactors (Imax permissible = 150A)

ADJUSTABLE PLUGGING BRAKING EASE OF INSTALLATION AND MAINTENANCE THE CONTACTORS TURN ON AND OFF AT ZERO CURRENT START SEQUENCE SELF-DIAGNOSTICS DIAGNOSTIC LEDS FILTERED BATTERY SILENT OPERATION (INAUDIBLE FREQUENCIES) DOUBLE RAMP ACCELERATION INDEPENDENTLY ADJUSTABLE MAX. FORWARD / REVERSE SPEEDS 2 SPEED CUTBACKS AVAILABLE AUTOMATIC COUNTER-CURRENT BRAKING UPON RELEASE OF THE ACCELERATOR EMPTY/LOADED SPEED COMPENSATION MOTOR PROTECTED FROM CURRENT PEAKS CURRENT CONTROL DURING TRACTION WITH BOOSTER I MAX + 20 % FOR 3 SECONDS ANTIROLLBACK ARCING CONTACTS OF TRAVEL CONTACTORS INSIDE CHOPPER STORAGE OF THE LAST 5 ALARMS OCCURRED POSSIBILITY OF PERSONALIZING TRUCK PERFORMANCE SIMPLY AND SWIFTLY USING A PROGRAMMING HANDSET

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

.5 ∅5 M5

∅6

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r Fo

F

4 or

r Fo

5

ho

4h

ho

les

ole

s

les

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ELECTRICAL

2.5 CHOPPER MECHANICAL DRAWING

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

2.6 CONNECTORS

FUNCTION CONN. PIN

FUNCTION

A

1A 2A

-L.E.D. +L.E.D.

B

1B

PCLRXD

Serial reception positive

2B 3B 4B 5B 6B 7B 8B

NCLRXD PCLTXD NCLTXD GND +12

Serial reception negative Serial transmission positive Serial transmission negative Handset power supply negative Handset power supply positive Not used Not used

1C 2C 3C

CPOT NPOT PPOT

Potentiometer cursor input Potentiometer negative Potentiometer positive

D

1D 2D

+CH IN IR

E

1E 2E 3E 4E 5E 6E 7E 8E 9E

TILLER NT2 RV2 RV1 MI MA NT1 -

Conn.

C

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DESCRIPTION Active (Volt) Alarm LED negative pole: connect to cathode Alarm LED positive pole: connect to anode

Inactive (Volt)

NOT MEASURABLE

0 12 / /

0 12 / /

from 0 to 12 (max. speed)

0 13

0 13

Positive input from key switch - power supply Rapid inversion input

24 0/open

0 24

Traction consent microswitch input Not used Forward motion contactor control output Speed cutback 2 input Speed cutback 1 input Reverse motion microswitch input Forward motion microswitch input Reverse motion contactor control output Not used

24 0 0/open 0/open 24 24 0 -

0 24 24 24 0 0 24 -

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

Pin

Function

Description

1E - TILLER

- Traction enable signal input, normally used as the tiller microswitch input. In this case the input must be programmed through the CONFIG. I/O MENU as TILLER. If the input is programmed as SEAT, in the event of connection with a seat microswitch, the signal is stored for 2 seconds before the traction is disabled. Travel is enabled when the input is brought to +VB potential.

2E -

- NOT USED

3E - NT2

- Negative output (0V) of the forward travel contactor control. This function is active when the inputs E1 and E7 are brought to a high logic level (+VB).

4E - RV2

- Input for speed cutback 1 request. This function is active when the pin is disconnected, or connected to negative. It is de-activated when the corresponding parameter (CUTBACK 2) is set to 9 or when the input is connected to +VB. The function can also be disabled by setting the parameter relative to input to FREE in the CONFIG. I/O MENU.

5E - RV1

- Input for speed cutback 1 request. This function is active when the pin is disconnected, or connected to negative. It is de-activated when the corresponding parameter (CUTBACK 1) is set to 9 or when the input is connected to +VB. The function can also be disabled by setting the parameter relative to input to FREE in the CONFIG. I/O MENU.

E6 - MI

- Reverse travel microswitch signal input. This function is active when the input is brought to a high logic level (+VB).

E7 - MA

- Forward travel microswitch signal input. This function is active when the input is brought to a high logic level (+VB).

E8 - NT1

- Negative output (0V) of the reverse travel contactor control. This function is active when the inputs E1 and E6 are brought to a high logic level (+VB).

E9 -

1

-NOT USED

+VB is the battery voltage.

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ELECTRICAL

DESCRIPTION OF THE “E” CONNECTOR INPUTS

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

DESCRIPTION OF THE POWER CONNECTORS

(front view)

+BATT

Must be connected to the battery positive.

This is the power circuit positive, it does not therefore power the control logic.

1

Must be connected to the motor (rotor).

Supplies a direct battery positive after the current-carrying circuit.

Do not connect loads apart from the traction motor to this terminal.

-BATT

Must be connected to the battery negative, this supply is common to the control logic circuit.

2 VMNA

This is the forward travel driver ( VMNA ).

Supplies a -Batt through a Mosfet circuit when the forward travel request is active, see the diagrams for details of the wiring.

3 VMNI

This the reverse travel driver ( VMNI ).

Supplies a -Batt through a Mosfet circuit when the reverse travel request is active, see the diagrams for details of the wiring.

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

3.1 - OVERVIEW The programming handset has been designed to facilitate calibration and diagnostic of H type choppers for the user.

Featuring microprocessor technology, it has a cable to be connected to the chopper for data transmission (serial communication) and power supply.

The messages are displayed on a 2-line, 16 character LCD screen, using alphanumeric characters.

YALE COD. HAND-SET 272210700

The advantages of using the handset are: - Quick and simple calibration of the parameters, as it is no longer necessary to access inconveniently located parts of the truck to adjust the trimmers; moreover, the parameters can be modified in real time with the truck running for an immediate check.

- Quick failure diagnostic.

The user can check the pattern of the Chopper input signals in real time, (potentiometer signal, currents, voltages, etc).

In addition, in the event of a Chopper failure, the handset displays the active alarm type.

For a more complete diagnostic, the user can read the last 5 alarms that have occurred.

- Standardisation of the settings: Once they have been optimised on a particular truck, the parameters can be stored in the memory of the handset from where they can be loaded very quickly and very easily on other trucks.

- Special functions, such as learning the range of the potentiometer and the Motor Data.

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ELECTRICAL

3.0 - PROGRAMMING HANDSET

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

When switched on, the handset tries to connect to the chopper while displaying the following message:

ZAPI CONSOLE V30 Then:

WAIT CONNECT B1 H1 H2 L1 MX If the connection attempt is unsuccessful, the handset displays the following message:

CHOPPER NOT OK

At this point, check that the connections have been properly made in accordance with the enclosed diagrams.

WARNING: the problem may be that polarity of the handset connector has not been respected. In this case, the handset will mostly be damaged and must be replaced.

If communication between chopper and handset has succeeded, the display will read as follows:

ZAPI V4.0 H1 4C.T 0

The message on the display indicates the following parameters: H1 = Chopper model ZAPI = type of configuration V4.0 = version of program installed on the EPROM of the Chopper.

24V = rated power supply voltage.

300A = maximum permissible current on the installation.

00000 = hours worked by the Chopper.

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

PAY ATTENTION TO THE POLARITY OF THE HANDSET CONNECTOR WHEN IT IS INSERTED IN THE CHOPPER.

CONTROLS Description of the function of the keys: Key 3 (ENTER) Confirms the options selected.

Key 4 (OUT) Exits from the current function.

Key 5 (SET UP) Increases parameter values or selects the type of I/O connected.

Key (SET DOWN) Decreases parameter values or selects the type of I/O connected.

Key 1 (ROLL UP)

Key 2 (ROLL DOWN)

Selects the next menu option or item

Selects the previous menu option or item.

CONNECTION TO THE CHOPPER

CONSOLE CONNECTOR

THE CONNECTION TO THE CHOPPER MUST ONLY BE MADE WITH THE TRUCK TURNED OFF as the chopper and the

handset check the connection only when the truck is turned on.

- Plug the connector of the handset to connector B of the Chopper.

When connecting the connector to the chopper, pay special attention to the polarity of the connector.

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ELECTRICAL

3.2 USING THE PROGRAMMING HANDSET

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

4.0 HANDSET FUNCTION MAP

ZAPI V.4.0 H1 4C.T 0

SEL MODEL

PROGRAM

ACCELER DELAY INVERS BRAKING CUTBACK SP 1 CUTBACK SP 2 COMPENSATION I MAX BRAKING SPEED SPEED LIMIT BRK RELEASE BRAKING MAX SPEED FORW MAX SPEED BACK CREEP SPEED BACKING TIME

SELECT CONFIG

N1 - 3 WIRES N1 - 4 WIRES S N1 - 4 WIRES T 4-10 NO CONFIG

PIN E5 - RV1 - SPARE / FREE PIN E4 - RV2 - BACK / SEAT PIN D2 - INVERS - SPARE / FREE PIN E1 - HANDLE / FREE / SPARE RELEASE NORMAL / HARD / SOFT

VMN VMN DRIVER DIRECTION CUTBACK INVERSION HANDLE / SEAT CURRENT TEMPERATURE BATTERY MOTOR VOLTAGE

SAVE

RESTORE

ALARM

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

4.1.1 CONFIG. MENU To work properly, the Chopper must know the power connections chosen, auxiliaries and the power supply voltage used.

This information is passed on to the Chopper by the software, via the handset.

Configuration of the Chopper is performed by setting the data contained in the submenus listed under SELECT MENU. SEL MODEL SELECT.MENU CONFIG. I/O The methods of programming the SELECT.MENU are described below.

SELECT MENU / SEL. MODEL

Setting of this submenu enables operation of the Chopper to be set depending on the type of connection made on the electrical system.

There are 3 possible modes of operation: 4 WIRES T:

Chopper used to control a 1-field motor (4 terminals) controlled by 2 travel direction contactors. In this configuration, the chopper can deliver a max. current of 300A

3 WIRES:

Chopper used to control a 2-field motor (3 terminals) controlled by 2 travel direction contactors. In this configuration, the chopper can deliver a max. current of 300A

4 WIRES S:

Chopper used to control a 1-field motor (4 terminals) controlled directly by a MOSFET without travel contactors. In this configuration, the chopper can deliver a max. current of 150A.

The H1 Choppers installed on all YALE trucks must always be configured as 4 WIRES T.

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ELECTRICAL

4.1 PROGRAMMING THE CHOPPER

CONFIG. MENU

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

ELECTRICAL

SERVICE

Section: ELECTRICAL SYSTEM

MP20X / MS12X

Instructions for programming SET MODEL through the handset:

ZAPI V.4.0 H1 4C.T 0

SELECT MENU SEL MODEL

SELECT MODEL 1 H1 3 CAVI T

SELECT MODEL 2 H1 4 WIRES T

1)

Heading

2)

Press ROLLUP+SETUP simultaneously

3)

The SEL MODEL menu heading is displayed

4)

Press ENTER

5)

The current configuration model is displayed

6)

Press SET UP or SET DOWN to change the Chopper model

7)

The new selected model is displayed

8)

Press ENTER to confirm the change or press OUT to cancel the change

9)

The SEL MODEL menu heading is displayed

10)

Press OUT to return to the main heading, or Press ROLL UP or ROLL DOWN to scroll through the other items of the information menu

SELECT MENU SEL MODEL

ZAPI V.4.0 H1 4C.T 0

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Section: ELECTRICAL SYSTEM

MP20X / MS12X

SELECT MENU / CONFIG. I/O

4.1.2

Setting of this submenu enables operation of the Chopper to be set according to the type of connection made on the auxiliary controls connectors.

The possibilities are described below for programming of the options through the CONFIG I/O submenu, which is accessed via the handset.

PIN E5 RV1 = Presetting of the Chopper for activation of the speed cutback 1 when the +VB signal is absent on pin 5 of connector E. FREE = Parameter to be set only when speed cutback 1 is not used and pin 5 of connector E therefore remains free, not connected.

SPARE = Configuration not to be used.

PIN E4 RV2 = Presetting of the Chopper for activation of the speed cutback 2 when the +VB signal is absent on pin 4 of connector E. BACK = Associates the travel request with operator on the ground with the enabling of pin E4. By enabling pin E4, disconnecting it from +VB and simultaneously presenting a travel request, truck travel is obtained without any other traction consent activated and at a traction speed independent of the position of the accelerator. The truck travel speed will depend on the parameter programmed in BACKING SPEED. It is possible to time the motion via the BACKING TIME parameter. If this parameter is set to 9, the motion will stop only when the consent button is released.

SPARE = Configuration not to be used.

PIN D2 INVERS = Presetting of the Chopper for activation of quick inversion (for trucks with tillers) when the +VB signal is absent on pin 2 of connector D. FREE = Parameter to be set only when the system is not installed on tiller trucks and use of this function is not necessary. In this case, pin 2 of connector D is free, not connected.

SPARE = Configuration not to be used.

PIN E1 HANDLE = Enables traction consent, without disconnection delay. The microswitch activated by the direction tiller will be connected to the input of pin 1 of connector E. Travel is enabled only when a +VB signal is present on this input.

FREE = Parameter to be set only when the start sequence is not required.

SEAT = Enables traction consent with a disconnection delay of 2 seconds. To be used when the seat microswitch is present. Also in this case the start sequence must be respected: 1) seat microswitch; 2) travel microswitch.

RELEASE SOFT = Range for adjustment of plugging braking upon accelerator release, set for low currents (suitable for trucks with column).

NORMAL = Range for adjustment of plugging braking upon accelerator release, set for average currents (suitable for transporter trucks).

HARD = Range for adjustment of plugging braking upon accelerator release, set for high currents (suitable for fast transporter trucks).

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ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

ELECTRICAL

Instructions for programming SEL MODEL through the handset:

ZAPI V.4.0 H1 4C.T 0

SELECT MENU SEL MODEL

SELECT MENU 2 CONFIG I/O

SELECT CONFIG PIN E5 RV1

SELECT CONFIG PIN E4 RV2

SELECT CONFIG PIN E4 BACK

DO YOU WANT TO SAVE DATA

SELECT MENU 2 CONFIG I/O

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Part No: 272352200

1)

Heading

2)

Press ROLL UP + SET UP to access the ADJUSTMENTS SEL MENU

3)

The SEL MODEL menu heading is displayed

4)

Press ROLL UP to select the CONFIG I/O menu

5)

The CONFIG I/O menu heading is displayed

6)

Press ENTER to access the menu

7)

The first menu item is displayed

8)

Press ROLL UP or ROLL DOWN to scroll through the various items

9)

A new item is displayed

10)

Press SET UP or SET DOWN to change the configuration

11)

The new configuration is displayed

12)

Press OUT to exit from the menu

13)

A prompt to confirm the change is displayed

14)

Press ENTER to confirm the change or press OUT to cancel the changes

15)

The CONFIG I/O menu heading is displayed

16)

Press OUT to return to the heading

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Section: ELECTRICAL SYSTEM

MP20X / MS12X

SELECT MENU / PROGRAM

4.1.3

Functional characteristics of the truck such as, for example, acceleration, intensity of braking upon release of accelerator, maximum current and others, can be simply adapted to all requirements by changing the values of the parameters in the PROGRAM menu, through the handset.

For each parameter, 10 calibration intensity levels are available.

After modification of each of the parameters, it is possible to check immediately, without exiting from the programming menu, the effect of the parameter change on the truck performance.

After completing the programming, which must be performed in accordance with the instructions listed below, it is essential to disconnect power supply from the Chopper by turning the key switch to OFF, so that the new parameters are stored in the Chopper’s non-volatile memory.

DESCRIPTION OF THE PARAMETERS

ACCELER DELAY:

Acceleration time, i.e. the minimum time during which the motor voltage rises from 0V to the maximum value.

INVERS. BRAKING:

Basic braking current upon inversion of the direction of travel. A current value depending on the position of the accelerator is added to the fixed increase in current per second, depending on the value set.

CUTBACK SP.1:

1st speed cutback (RV1), linked to input E5. Maximum speed is reduced depending on the level programmed.

CUTBACK SP.2:

2nd speed cutback (RV2), linked to the input E4. Maximum speed is reduced depending on the level programmed.

If parameter PIN E4 included in the CONFIG. I/O submenu is programmed BACK, the control on E2, used in this case as a travel request without driver on board, will impose a fixed speed depending on the level programmed in BACKING SPEED.

COMPENSATION:

Depending on the programming, this enables a constant truck speed to be maintained both when empty and laden, with the accelerator in the same position.

IMAX:

Defines the maximum current admitted by the Chopper, beyond which it imposes a restriction. Can be programmed between 150A (level 0) and 300A (level 9) on the H1 300A.

BACKING SPEED:

Scale of values (in %V Battery) within which, depending on the level programmed, the Chopper will set the truck maximum travel speed with traction being controlled by push button.

Function enabled only if parameter PIN E4 in the CONFIG. I/O submenu is programmed BACK

SPEED LIMIT BRK:

Sets the speed beyond which plugging braking upon release of the accelerator (RELEASE BRAKING) is operational.

RELEASE BRAKING:

Basic braking current upon release of the accelerator. Defines the intensity of this type of braking.

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ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

Section: ELECTRICAL SYSTEM

ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

MAX SPEED FORW.:

Maximum speed in the forward direction.

MAX SPEED BACK.:

Maximum speed in the reverse direction.

CREEP SPEED:

Defines the minimum voltage value applied to the motor with the travel request on and the potentiometer still on 0.

BACKING TIME:

Time during which the travel request activation time is enabled through the button.

If programmed at level 9, there is no timing and the motion is active as long as the request is active.This function is enabled only if the PIN E4 parameter of the CONFIG. I/O submenu is programmed BACK .

Instructions for programming the PROGRAM submenu through the handset: ZAPI V.4.0 H1 4C.T 0

SELECT MENU 1 PROGRAM

ACCELER DELAY LEVEL=2

1)

Heading

2)

Press ENTER to access the main menu

3)

The heading of the first menu item is displayed, PROGRAM

4)

Press ENTER to access the function PROGRAM

5)

The first parameter of the list is displayed

6)

Use the ROLL UP and ROLL DOWN keys to scroll through the list of parameters

7)

The parameter entries are displayed

8)

Use the SET UP and SET DOWN keys to change the programming

9)

The new set value is displayed

10) 11)

Press OUT after completing programming A prompt to confirm the change is displayed

12)

Press ENTER to confirm the change, or press OUT to cancel the change

13)

The heading of the item PROGRAM is displayed

14)

Press ROLL UP or ROLL DOWN to scroll through the other items, or press OUT to go back to the starting heading.

BRAKING LEVEL 5

BRAKING LEVEL 6

DO YOU WANT TO SAVE DATA

SELECT MENU 1 PROGRAM

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Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

The TESTER function can be used to monitor in real time the operating status of the traction control and traction consent sensors, the instantaneous current and voltage of the traction motor and other important items of information, all provided in a table that may be useful for troubleshooting.

All functions displayed through this menu are shown in the table below: DISPLAY READING

DESCRIPTION

ACTIVE FUNCTION

VMN VM1>30% VM2<30%

Indicates status of the voltage on the power connector VMN. This measurement indicates whether the voltage is > higher or < less than 30% of the battery voltage. The test is active both when the truck is idle and operating

VMN VMN > 80%

This measurement indicates whether the voltage on the power connector VMN is > higher or < less than 80% of the battery voltage.

The function permits checking for presence of current leaks between the motor and the battery, stuck contactors (BYPASS or TRAVEL) or Chopper power section failures The measurement is useful for revealing if there are current leaks between the motor and the battery, stuck travel contactors or Chopper power section failures

The measurement is made on the output connectors of the contactor drivers and shows if the voltage is approx. equal to voltage (VB) or approx. zero (0V) Performs measurements on the input connectors of the speed cutback requests. The cutbacks are enabled when there is a low voltage on the connector.

Performs measurements on the rapid inversion request connector, request is activated when the signal is low (D2=0V) This measurement is made on the connector for travel enabled through the tiller or seat microswitch A reading is made of the voltage on input c of the potentiometer. Value is expressed in millivolts.

DRIVER E3=VB E3=0V

CUTBACK E5=VB E4=VB

INVERSION D2=VB VOLT HANDLE/SEAT E1=0V VOLT ACCELER M VOLT 39. 0%

An indication is given of the current read by the transducer on the Chopper, and it corresponds to the rotor current.

CURRENT AMP = 0 300 A

TEMPERATURE DEGREES=+32°C

The temperature expressed in °C, read by a transducer present on the Chopper power section.

BATTERY VOLT=25. 0. 24V

The battery voltage present on connector +CH (D1); the first figure after the text is the value read in real time, while the second figure is the battery rated voltage.

MOTOR VOLTAGE VOLT = 00.0

The voltage applied to the motor.

DIRECTION E7=0.00 E6-0

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The test is useful for detecting logic wiring defects

The test is useful for checking wiring and functions The test is useful for checking the rapid inversion wiring and microswitches Travel is enabled if the input is high (E1=VB) The test is useful for checking the signal coming from the accelerator for setting purposes The test is useful for functional tests, settings, checks of the transducer on the Chopper.

WARNING: the rotor current is not the same as the battery current, the two currents only coincide at full conduction The temperature range is between –20°C and 100°C and accuracy is ±2°C. The reading serves as a check during stress tests

This measurement is made on the travel request input connectors, the request is activated only when the input is high (=VB).

The test is useful for checking the wiring

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ELECTRICAL

MAIN MENU / TESTER

4.1.4

SERVICE

Section: ELECTRICAL SYSTEM

ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

Instructions for display of the TESTER submenu through the handset:

ZAPI V.4.0 H1 4C.T 0

SELECT MENU 1 PROGRAM

SELECT MENU 2 TESTER

VMN VM1 30% - VM2 30%

VMN VMN < 80%

SELECT MENU 2 TESTER

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Part No: 272352200

1)

Heading

2)

Press ENTER to access the main menu

3)

The first item on the list is displayed

4)

Scroll through the list using the ROLL UP or ROLL DOWN key and select TESTER

5)

The item selected is displayed (TESTER)

6)

Press ENTER to access the TESTER function

7)

The first signal tested is displayed

8)

Scroll through the signals tested using the ROLL UP or ROLL DOWN key.

9)

The next signals in the list are displayed.

10)

To go back to the heading, press OUT.

11)

The heading is displayed.

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SERVICE

Section: ELECTRICAL SYSTEM

4.1.5

MP20X / MS12X

SELECT MENU / SAVE

The SAVE function may be used to load the Chopper configuration data and the programming parameters into the handset memory. The handset has a storage capacity for up to 30 programs.

Each single program saved in the handset may be loaded again on another Chopper by means of the RESTORE function.

The SAVE function enables the following parameters to be loaded in the handset: - all the parameter values (PROGRAM); - settings of the options (CONFIG. I/O); - setting of the model (SEL MODEL).

It is recommended that each service engineer stores in his handset the programs for the truck models present in his zone. In this way, in the event of replacement of a Chopper, the newly installed one can be programmed with the same data as the previous one by means of the RESTORE function.

The Chopper purchased as a spare part contains a standard program loaded by the supplier, however, for the proper operation of each truck, the Chopper must have the corresponding program loaded on it.

Instructions for execution of the SAVE function through the handset:

ZAPI V.4.0 H1 4C.T 0

SELECT MENU 1 PROGRAM

SELECT MENU 3 SAVE

SELECT PROGRAM PROGRAM 01

1)

Heading

2)

Press ENTER to access the main menu

3)

The first item on the list is displayed

4)

Scroll through the list using the ROLL UP or ROLL DOWN key, select SAVE

5)

The item selected is displayed (SAVE)

6)

Press ENTER to access the SAVE function

7)

The function name is displayed on the top line and the memory location in which to load the program on the bottom line Use the ROLL UP and ROLL DOWN keys to select the model code

8)

SELECT PROGRAM PROGRAM 02

9)

The new code selected is displayed and the relevant conditions

10)

Press ENTER to confirm the read operation.

11)

When prompted to confirm, press ENTER again and the program will be integrated in the handset.

12)

After the operation has been completed, the mention SAVE returns on display.

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ARE YOU SURE SELECT MENU 3 SAVE

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ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

Section: ELECTRICAL SYSTEM

ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

4.1.6

MP20X / MS12X

MAIN MENU / RESTORE

The RESTORE function can be used to transfer the programs of each model stored on the handset by means of the SAVE function, so that all the data for a truck model can be loaded on the Chopper in a single operation.

The data loaded into the Chopper through the RESTORE function are: - all the parameter values (PROGRAM); - settings of the options (CONFIG. I/O); - setting of the model (SEL MODEL);

WARNING the RESTORE operation rewrites all the Chopper data; accordingly, after this operation, all the data items previously present in the Chopper memory are deleted.

Instructions for execution of the RESTORE function through the handset: ZAPI V.4.0 H1 4C.T 0

SELECT MENU 1 PROGRAM

SELECT MENU 4 RESTORE

1)

Heading.

2)

Press ENTER to access the main menu

3)

The first item on the list is displayed

4)

Scroll through the list using the ROLL UP or ROLL DOWN key, select RESTORE PARAM.

5)

The item selected is displayed (RESTORE).

6)

Press ENTER to access the RESTORE function.

7)

The code of the model selected is displayed and, on the bottom line, the type of Chopper stored in the memory (if FREE, the memory is empty).

Use the ROLL UP and ROLL DOWN keys to select the code of the model desired.

SELECT PROGRAM PROGRAM 1

8)

SELECT PROGRAM PROGRAM 2

9)

The code of the model selected is displayed and the relevant type of Chopper contained.

10)

Press ENTER to confirm the loading operation.

11)

The items that the handset is loading on the CHOPPER are listed.

12)

Press ENTER to confirm the loading operation (OUT to cancel).

13)

The list of parameter items being loaded is displayed.

14)

At the end of the operation, the name of the submenu is displayed.

PROGRAM N CONFIG

SELECT PROGRAM PROGRAM 01 SELECT MENU 4 RESTORE

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SERVICE

Section: ELECTRICAL SYSTEM

4.1.7

MP20X / MS12X

SELECT MENU / ALARM

While operating, the Chopper stores the last 5 operating failures (alarms) to occur, recording the alarm ID code, the number of times the same alarm has occurred and on which scanning line of the program it has occurred (information of use to the system vendor only).

These alarms may be displayed via the handset, by interrogating the ALARM submenu of the SELECT MENU. This function permits a more complete diagnostic to be made of the electrical system, providing information on the “past” of the Chopper.

WARNING: where no handset is available, it is possible to know which alarm has occurred by counting the number of times the LED on connector A of the Chopper blinks (see para. 4.3 on page 42 for alarm decoding).

Instructions for accessing the ALARM function through the handset:

ZAPI V.4.0 H1 4C.T 0

SELECT MENU 1 PROGRAM

SELECT MENU 5 ALARM

INCORRECT START 0H 1. 26 °C

1)

Heading

2)

Press ENTER to access the main menu

3)

The first item on the list is displayed

4)

Scroll through the list using the ROLL UP or ROLL DOWN key, select ALARM.

5)

The item selected is displayed (ALARM).

6)

Press ENTER to access the ALARM function.

7)

The code of the last alarm to occur is displayed, with the reading on the hour-counter, no. of times it occurred, program scanning line at the time of the alarm.

Use the ROLL UP key to scroll through previous alarms, ROLL DOWN to return to the recent ones.

8) ALARM NULL

SELECT MENU 5 ALARM

UPDATE

0

1

2

3

4

5

9)

Another alarm code is displayed. If no alarms have occurred, the display shows ALARM NULL.

10)

Press OUT to exit from the ALARM menu.

11)

A prompt to cancel all the stored alarms is displayed.

12)

Press ENTER to cancel. Press OUT to go back to the main menu.

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ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

Section: ELECTRICAL SYSTEM

ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

4.1.8

MP20X / MS12X

SELECT MENU / PROGRAM VACC

By means of this function, the Chopper acquires the minimum and maximum values of the accelerator signal, considering them as the two limit values for speed adjustment. This enables compensation to be made for any lack of symmetry of the mechanics commanding the potentiometer and mistakes in the fine mechanical tuning.

Instructions for execution of the PROGRAM VACC function through the handset:

ZAPI V.4.0 H1 4C.T 0

SELECT MENU 1 PROGRAM

SELECT MENU 6 PROGRAM VACC

FORW BACK 4.88 4.88

FORW BACK 0 0

1)

Heading.

2)

Press ENTER to access the main menu

3)

The first item on the list is displayed

4)

Scroll through the list using the ROLL UP or ROLL DOWN key and select PROGRAM VACC.

5)

The item selected is displayed (PROGRAM VACC.).

6)

Press ENTER to access the PROGRAM VACC. function.

7)

The values currently linked with potentiometer stroke are displayed.

8)

Press ENTER.

9)

The Chopper is now ready for recording of the new minimum and maximum values of the potentiometer signal.

10)

Press the accelerator pedal, taking care to do so slowly, all the way to the end of stroke (limit switch) with the lever.

11)

The display shows the new min. and max. values. The arrow indicates the direction selected.

12)

Press OUT.

13)

A prompt is displayed to confirm acquisition of the new values.

14)

Press ENTER to confirm or OUT to cancel.

SELECT MENU 6 PROGRAM VACC

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SERVICE

Section: ELECTRICAL SYSTEM

4.1.9

MP20X / MS12X

SELECT MENU / MOTOR DATA

This function is used to acquire the motor resistance value when the rotor is locked, for braking control. The operation is executed when the Chopper is installed on the truck.

Instructions for accessing the MOTOR DATA menu and execution of the operations: 1) Heading.

ZAPI V.4.0 H1 4C.T 0

2) Press ENTER to access the main menu 3) The first item on the list is displayed

SELECT MENU 1 PROGRAM

4) Scroll through the list using the ROLL UP or ROLL DOWN key.

SELECT MENU 7 MOTOR DATA

5) Select MOTOR DATA.

6) Press ENTER to access the MOTOR DATA function.

BLOCK MOTOR PLEASE

7) Guidance on execution of the current operation is displayed.

8) Press ENTER to arrange for the acquisition operation.

INSERT FORWARD DIRECTION (61)

9) The text of the operation to be executed is displayed.

10) Block the motor by disconnecting the electric brake and keep the truck stationary against a stop block. If programmed H0 STANDARD with the electric brake controlled by the Chopper, latter brakes automatically during the MOTOR DATA operation.

11) Bring the tiller to the travel position.

12) Select reverse travel.

13) Press the ENTER key and and wait for the message to be displayed (or press OUT to cancel the operation).

ARE YOU SURE

14) Press ENTER 15) At the end of the operation, the name of the submenu is displayed.

SELECT MENU 7 MOTOR DATA

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ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

H1 SYSTEM CONFIGURATION TABLES MODS. MP20X and MS12X

ELECTRICAL

4.2

MP20X / MS12X

MODELLI

S E L

H1 3 CAVI

M O

H1 4 CAVI S.

D E L

H1 4 CAVI T.

C O N F I G

I/O

P R O G R A

PIN E5

R V1

PIN E4

R V2

PIN D2 PIN E1 RELEASE

MP20X

MS12X

*

* SPA R E

R V1

FR EE

B A C K.

R V2

FR EE

B A C K.

IN V E R S .

FR EE

SPA R E

IN V E R S .

FR EE

SPA R E

HA N D L E

FR EE

SEA T

HA N D L E

FR EE

SEA T

N OR M A L

HA R D

SO FT

N OR M A L

HA R D

SO FT

ACCELER DELAY BRAKING CUTBACK SPEED 1 CUTBACK SPEED 2 COMPENSATION

2 5 7 5 5

D elay M ax=

9

9

9

B r ak. M ax=

9

C .s p. M ax=

9

C .s p. M ax=

9

C .s p. M ax=

9

C .s p. M ax=

9

C o mp.M ax=

9

2 5 9 7 8

D elay M ax=

B r ak. M ax=

C o mp.M ax=

9

I MAX

8

I M A X=

9

3

I M A X=

9

BACKING SPEED

FR EE

NON USATA B A C K . S P .=

SPA R E

NON USATA B A C K . S P .=

9

S P . L .B R K .M A X =9 SPEED LIMIT BRK. 2 R .B r k .M ax= 9 RELEASE BRAKING 5 S P E E D M A X= 9 MAX SPEED FORW. 9 S P E E D M A X= 9 MAX SPEED BACK. 9 C R E E P M A X= 9 CREEP SPEED 1 NON USATA T IM E M A X = 9 BACKING TIME

M

FR EE

2 5 9 9 1

9

S P . L .B R K .M A X =9 R .B r k .M ax=

9

S P E E D M A X= 9 S P E E D M A X= 9 C R E E P M A X= 9

NON USATA T IM E M A X = 9

= Parametro programmato

The following table displays, for each level of parameter programming, the values corresponding to the quantity represented by the parameter.

LIVELLO PROGRAMMATO UNITA'

0

1

2

3

4

5

6

7

8

9

ACCELERATION DELAY*

Sec.

0.38

0.66

1

1.3

1.5

1.84

2.17

2.5

2.8

3

BRAKING (CPOT = MAX)*

% IMax.

50

58

66

73

81

89

96

104

112

120

CUT BACK (1-2)*

% VBatt.

16

20

25.6

34.6

43

48.5

53.5

62.6

65

76

COMPENSATION

K (I)

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

CREEP SPEED*

% VBatt.

2.5

6.9

9.2

11.7

14

16.3

20.8

22

25

30

Amp.

75

83

92

100

108

117

125

133

142

150

Amp.

150

167

183

200

217

233

250

267

283

300

Max. SPEED (F-B)

% VBatt.

7

9.3

20

30

39.2

48.4

60

65

74

CT.

RELEASE BRAKING

% IMax.

-

18

27

36

45

54

63

72

81

90

Date: July 98

0

1

4

5

IMax. 2Q

NOT USED

IMax. 1Q

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SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

With the truck switched off, connect the programming handset, and turn ON. Normally if there are no wiring errors or defects of the component, the display will produce a heading with: manufacturer name, release of the configured model and the hour-counter reading.

If the module has already been configured, move on to step 2, otherwise proceed as indicated below.

(Follow the handset manual for details of the procedure).

1) Configure the Chopper model.

2) Select the options.

3) Check that all the wired inputs are working, including the potentiometer, through the handset tester functions.

4) Perform acquisition of the accelerator signal in the menu PROGRAM VACC. 5) Set the maximum current, programming it at the level corresponding to the desired value shown in the adjustment table.

6) Execute the MOTOR DATA function.

7) Set the acceleration by moving the truck back and forward.

8) Set the CREEP value starting from level 0; with the truck at a standstill, press the pedal gently so as to activate the travel microswitch; leaving the potentiometer at minimum, then increase the CREEP level until the truck starts to move.

9) To set the speed cutback values, activate the desired cutback request microswitch, set the compensation level value at 0, perform the speed setting (RV1 - RV2) with the truck unladen on a flat surface and accelerator pedal fully pressed down. After this, put a load on the truck or start moving uphill - under these conditions, adjust the compensation level until the desired speed is reached. Since compensation alters the unladen speed value, this operation requires various attempts to be made until the best value is achieved.

10) Inversion braking (BRAKING), to perform the setting, you will need to start the truck invert direction of travel and adjust the braking level.

11) Release braking.

12) The maximum speed (MAX SPEED FORW/BACK) is set by selecting the direction of travel in which the speed is to be restricted and then selecting the desired level. When a speed restriction is active, the compensation parameter is also involved and must be set in the same way as described at step 9.

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ELECTRICAL

CALIBRATION SEQUENCE FOR THE INITIALISATION OF A NEW CHOPPER

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

ELECTRICAL

4.3

MP20X / MS12X

TROUBLESHOOTING

DIAGNOSTIC LED ALARM CODE DECODING Description of the alarms relevant to the diagnostic LED. Indicated between brackets and in capital letters is the code of the alarm, a detailed description of which will be found in the chapter DECODING OF ALARMS DISPLAYED ON HANDSET (adjacent page).

NUMBER OF

ALARM CODE

ALARM DESCRIPTION

FLASHES 1

EEPROM DATA KO

Logic circuit failure

1

EEPROM PAR. KO

Logic circuit failure

1

EEPROM KO

Logic circuit failure

1

EEPROM CONFIG. KO

Logic circuit failure

1

EEPROM OFF-LINE

Logic circuit failure

1

CHOPPER NO CONFIG.

Logic circuit failure

1

WATCH-DOG

Logic circuit failure

2

INCORRECT START

Starting sequence incorrect

3

NO FULL COND.

Mosfet voltage error

3

VMN BACK LOW

Mosfet voltage error

3

VMN FORW LOW

Mosfet voltage error

4

VACC NON OK

Accelerator potentiometer voltage higher than 1V when idle

5

I HIGH AT STAND

High current in mosfet in idle state

5

I = 0 EVER

High current in mosfet in idle state

6

CONTACTOR DRIVER

Contactor driver circuit failure

7

TH. PROTECTION

Mosfet temperature above 75°C

8

CONTACTOR DON’T CLOSE

Contactors do not close on travel request

32

BATTERY

Battery depleted (<10% charge remaining)

FORW BACK

Both travel microswitches activated simultaneously

Lit permanently

For each alarm, a more detailed description and how to solve the problem will be found on the next page.

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Section: ELECTRICAL SYSTEM

MP20X / MS12X

DECODING OF ALARMS DISPLAYED ON HANDSET 1)

CHOPPER NO CONF. Displayed when the logic has still not been configured, so perform the model and inputs configuration procedure as described in the appropriate section of the handset manual.

This is a blocking alarm.

2)

VMN FORW LOW. The test is performed with the truck idle, if the VMN forward voltage ( terminal 2 ) is found to be less than 1/3 of the battery voltage, the alarm is given.

Possible causes: a) In the 2-quadrant configurations, check that the wiring of the stators is correct and that there are no interruptions. b) Check that there are no leaks of insulation from the motor to the chassis. c) In the 1-quadrant configurations with bypass, check that the contacts of the bypass are not stuck. d) Chopper broken, replace.

3)

VMN BACK LOW. The same remarks as for item 2 also apply.

4)

NO FULL COND. This test is performed under full conduction.

If the VMN is found to be higher than 1/3 VBatt under these conditions, this means that something is not working properly in the diagnostic circuit, with a hazard for safety, and therefore the truck is blocked.

If the defect persists, replace the logic card.

5)

CONT. DONT CLOSE Test performed with the travel request.

See if the contactor closes, by checking that the VMN rises to more than 2/3 VBatt, if this does not occur, the alarm is given.

Probable causes: a) General or travel contactor disconnected or defective, contacts isolated. b) Motor isolated or interrupted. c) Failure of the chopper power section, replace.

6)

I=Ø EVER Test performed during motion.

A check is performed if the current during motion is higher than a minimum value, if this is not the case, the alarm is raised and the truck is stopped.

Possible causes: a) Wrong motor connection, for example the rotor has been connected to chopper terminal ( +B ) instead of terminal ( 1 ). b) The current sensor is defective, replace the module.

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ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

Section: ELECTRICAL SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

I HIGH AT STAND Test performed with the truck idle, a check is performed if the current is null.

If it is not, the alarm is given - this is a blocking alarm.

Possible causes: a) A load other than the traction motor has been connected to terminal ( 1 ), for example the pump motor or auxiliary loads. b) The current sensor is broken or the logic card is defective.

First replace the logic card, if the defect remains,replace the power section.

8)

WATCH - DOG This test is performed both when idle and during motion.

It is the internal autodiagnostic of the logic card.

Replace the logic card if the alarm is given.

9)

FORW - BACK This test is always performed, it gives an alarm when two travel requests are present simultaneously.

Possible causes: a) Wiring defective. b) Travel microswitch stuck. c) Connection to NT1 interrupted. d) If the defect persists, replace the logic card.

ELECTRICAL

7)

10) INCORRECT START Wrong starting sequence.

The truck starts only if this sequence is respected: key, tiller (or seat), running Possible causes: a) Travel microswitch stuck. b) Wrong sequence followed by operator. c) Wiring wrong.

11) VACC NOT OK Test performed when idle.

The alarm means that the accelerator voltage is higher than 1Volt.

Possible causes: a) A potentiometer wire is interrupted. b) The potentiometer is not properly regulated. c) The potentiometer is defective (interrupted).

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Section: ELECTRICAL SYSTEM

MP20X / MS12X

12) CONTACTOR DRIVER This test is performed both when idle and during motion, and consists in checking that the voltage on the drivers controlling the contactors is consistent with the state of travel.

High when idle, low when the contactor is excited.

Use the handset tester function to check which of the two drivers T1 or T2 is not in the correct state ( Ø ) during travel, ( VB ) when idle.

Possible causes: a) External short circuit to -Batt of the wiring coming from NT1 or NT2. b) Drivers broken due to an overload or short-circuit to +Batt of the wiring coming from NT1 or NT2, replace the logic card after removing the cause.

13) EEPROM DATA KO Failure in the memory zone containing the hour-counter data, the motor data and the stored alarms. This is a blocking alarm.

If the defect persists after switching the key off and on again, replace the logic card.

If the alarm is cleared, remember that the clock starts again from zero, the alarms zone has been erased and the motor data will be the default data.

14) EEPROM PAR. KO Failure in the memory zone containing the data of the control parameters.

This is a blocking alarm.

If the defect persists after switching the key off and on again, replace the logic card.

If the alarm is cleared, remember that the parameters stored previously have been cleared and been replaced by the default values.

15) EEPROM CONF. KO Failure in the memory zone containing the configuration data of the chopper.

This is a blocking alarm.

Access the configuration procedure and reconfigure the chopper.

Then switch off and on again, if the defect persists, replace the logic card.

16) EEPROM KO Failure of the memory chip, replace the logic card. This is a blocking alarm.

17) TH PROTECTION This indicates that the temperature of the chopper is in excess of 75 °C. The maximum current is lowered gradually to a zero value at a temperature of 85°C. - If the alarm is given when the motor is cold: a) Check that the heat sensor is connected. b) Heat sensor defective. c) Connection to the power section is interrupted. d) Logic card failure.

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ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

Section: ELECTRICAL SYSTEM

ELECTRICAL

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

18) BATTERY The battery is exhausted.

This alarm is given simultaneously with stopping of the truck, at this point the travel request must be repeated to be able to start again.

The maximum current is reduced by 50%.

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

UPDATE

å

HYDRAULIC SYSTEM DRAWINGS .................................................. page 4

å

HYDRAULIC CONTROL UNIT ......................................................... page 8

å

HYDRAULIC CYLINDERS ................................................................ page 10

å

DISASSEMBLY OF CYLINDERS ...................................................... page 16

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HYDRAULIC

HYDRAULIC SYSTEM

Page: 1

SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

HYDRAULIC

NOTES:

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

1.1

MP20X - MS12X

LEGEND OF THE HYDRAULIC SYSTEM SYMBOLS MOD. MP20X - MS12X

The symbols used on the drawings in this section are illustrated below with their meaning.

UPDATE

0

THREE-POSITION SOLENOID VALVE

FILTER

ONE-WAY VALVE

DOUBLE-ACTING CYLINDER

PROPORTIONAL VALVE

SINGLE-ACTING CYLINDER

PUMP

TANK

HYDRAULIC MOTOR

LINE CONNECTION

ELECTRIC MOTOR

MAX. PRESSURE VAVLE

FLOW VALVE

MANUAL COCK

BY-PASS VALVE

1

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Part No: 272352200

HYDRAULIC

TWO-POSITION SOLENOID VALVE

Page: 3

SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

HYDRAULIC SYSTEM DRAWING MOD. MP20X

HYDRAULIC

1.2

MP20X - MS12X

5

6

4 1

7

8

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

HYDRAULIC SYSTEM DRAWING MOD. MS12X (triplex and duplex)

HYDRAULIC

1.3

MP20X - MS12X

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

HYDRAULIC SYSTEM DRAWING MOD. MS12X (simplex)

HYDRAULIC

1.4

MP20X - MS12X

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Part No: 272352200

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

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Part No: 272352200

HYDRAULIC

NOTES:

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

2.0

MP20X - MS12X

HYDRAULIC CONTROL UNIT COMPONENTS MOD. MP20X

HYDRAULIC

11

3

1

4 2 5

6 9 7 10

8

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Part No: 272352200

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

2.1

MP20X - MS12X

TABLE OF HYDRAULIC CONTROL UNIT COMPONENTS MOD. MP20X

The various components shown on the adjacent page are described in the table below.

Key to understanding: Reference of component on exploded view Function of component

Ref.

HYDRAULIC

Exploded view ref.

Component description

Component description

1

Pump motor

2

Hydraulic control unit body

3

Hydraulic coupling

4

Max. pressure valve kit

5

Solenoid valve kit

6

Flow control valve kit

7

Hydraulic pump kit

8

Hydraulic oil tank kit

9

Attachment plate

10

O-ring seal

11

Brushes kit

Tab. 01

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

3.0

MP20X - MS12X

LIFTING CYLINDER COMPONENTS MOD. MP20X

HYDRAULIC

1

4

5

2

3

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Part No: 272352200

Date: July 98

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

3.1

MP20X - MS12X

TABLE OF THE LIFTING CYLINDER COMPONENTS MOD. MP20X

The various components shown on the adjacent page are described in the table below.

Key to understanding: Reference of component on exploded view Function of component

Ref.

HYDRAULIC

Ref. Component description

Component description

1

Cylinder head

2

Cylinder rod

3

Cylinder cam

4

Seals kit

5

Complete cylinder

Tab. 02

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

3.2

MP20X - MS12X

CENTRAL CYLINDER COMPONENTS (plunger type) MOD. MS12X

1 5 3 HYDRAULIC

4

2

6

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Part No: 272352200

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

3.3

MP20X - MS12X

TABLE OF CENTRAL CYLINDER COMPONENTS (plunger type) MOD. MS12X

The various components shown on the adjacent page are described in the table below.

Key to understanding: Reference of component on exploded view Function of component

Ref.

HYDRAULIC

Ref. Component description

Component description

1

Cylinder rod

2

Cylinder cam

3

Seal support ring

4

Seal

5

Seal

6

Rod guide

Tab. 03

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

3.4

MP20X - MS12X

LATERAL CYLINDER COMPONENTS (single-acting type) MOD. MS12X

HYDRAULIC

1 4 3 4

2

8

5 6 7

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Part No: 272352200

Date: July 98

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

3.5

MP20X - MS12X

TABLE OF LATERAL CYLINDER COMPONENTS (single-acting type) MOD. MS12X

The various components shown on the adjacent page are described in the table below.

Key to understanding: Reference of component on exploded view Function of component

Ref.

HYDRAULIC

Ref. Component description

Component description

1

Cylinder rod

2

Cylinder cam

3

Seal support sleeve

4

Seals

5

Seals

6

Seal washer

7

Seal tightening nuts

8

Rod guide sleeve

Tab. 04

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

4.0

MP20X - MS12X

DISASSEMBLY OF THE LIFTING CYLINDERS FROM THE TRUCK MOD. MS 12X

The Triplex and Duplex masts have two types of lifting cylinders, one at the centre of the internal mast for fork lifting, which is of the plunger type, and two single-acting lateral ones for lifting of the draw-out units.

DISASSEMBLY OF THE PLUNGER TYPE CENTRAL CYLINDER SPECIAL TOOLS NEEDED

HYDRAULIC

• Wooden beam 100x100x800 STANDARD TOOLS NEEDED

SOCKET WRENCH 19-22-24 mm

BOX WRENCH WITH JACK 19-36 mm

UNIVERSAL PLIERS

SPANNER Ø 90/100 WITH PIN Ø 8

SMALL SIZE SLOT SCREWDRIVER

DISASSEMBLY PROCEDURE FOR REPLACEMENT OF SEALS (ALSO APPLIES TO SINGLE MASTS) N.B. The procedure described does not require bleeding of the air from the cylinder.

1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Pull the mast lifting lever. Lift the forks to their maximum free lifting height, check that the rod has no roughnesses or marks that could damage the seals.

3) Put the beam on the straddles of the truck (Fig. 1), pull the mast down lever, let the forks rest on the beam, let the cylinder go all the way down by slackening the lifting chains.

4) Turn the key switch to OFF, disconnect the battery.

5) BOX WRENCH 36 mm - Unscrew the locking nut of the chain sliding pulley support, take away the chain anti slip-off protection, take the chains off the pulleys, leaving them hanging from the chain-tightener.

6) SECTOR WRENCH - Unscrew the cylinder sleeve completely, take the sleeve off.

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Part No: 272352200

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

7) SLOT SCREWDRIVER - Place the sleeve on a clean bench, use the screwdriver to remove the seals from their seats, paying careful attention to their position so as not to make mistakes when reassembling.

8) Check that the sleeve is in good condition inside the seats of the seals and where the rod slides.

9) ASSEMBLING NEW SEALS - For proper seal assembly, the inside of the sleeve and the seats of the seals must be well oiled, oil the new seals as well, perform assembly, remembering to put them in the proper positions.

HYDRAULIC

Reassemble by inverting the steps of the disassembly procedure.

Fig. 1

PROCEDURE FOR DISASSEMBLY OF THE COMPLETE CYLINDER

1) See “SEAL DISASSEMBLY PROCEDURE” (steps 1-2-3-4).

2) PLIERS - Remove the cotter pins from the chain pins on the tightener behind the cylinder, take the pins out, take the chains off and place them on the forks.

3) WRENCH 22 - Unscrew the coupling of the hydraulic pipe at the by-pass block located on the internal mast.

4) BOX WRENCH 19 WITH JACK - Unscrew the bolts (4) securing the cylinder to the internal mast, lift the cylinder and remove it from above the fork front unit.

Reassemble by inverting the steps of the disassembly procedure.

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

4.1

MP20X - MS12X

DISASSEMBLY OF THE LATERAL CYLINDERS OF THE TRIPLEX, DUPLEX, SIMPLEX MASTS MOD. MS 12X

SPECIAL TOOLS NEEDED • Wooden blocks 100x100x200

HYDRAULIC

STANDARD TOOLS NEEDED

SOCKET WRENCH 13-14-22-27 mm

ALLEN WRENCH 6 mm

SPANNER Ø 50/60 WITH PIN Ø 6

PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Pull the mast lifting lever, lift until the intermediate mast for Triplex, internal mast for Duplex and Simplex, is raised about 200 - 300 mm.

3) Place the wooden block under the intermediate/internal mast.

4) WRENCH 13 - Unscrew the bolts fastening the rod (1+1) to the crosspiece of the movable mast.

5) Pull the mast down lever, let the mast rest on the wooden block, drain all oil out of the cylinders, packing the rod fully into the barrel.

6) Turn the key switch to the OFF position, disconnect the battery.

7) WRENCH 13 - Unscrew the bolts securing the cylinders located in the welded support brackets to the lateral base of the fixed mast.

8) WRENCH 22 - Unscrew the coupling of the hydraulic pipe supplying the cylinders, unscrew the valve body from the cylinder.

9) ALLEN WRENCH 6 - Unscrew the bolts securing the cylinder stop bracket, lift the cylinder up about 100 mm and take it out of the lower seat. Take away the cylinder.

REPLACEMENT OF SEALS 1) Take the cylinder to the workbench, put it in the vice taking care to protect the jaws of the vice with aluminium coverings to avoid scratching the barrel.

2) SECTOR WRENCH - Unscrew the barrel sleeve, take the rod fully out of the barrel.

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Part No: 272352200

Date: July 98

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

3) Remove the barrel from the vice, put the rod in the vice, protecting it suitably to prevent scratching.

4) WRENCH 27 - 2 REQUIRED - Unscrew nut and counter-nut from the rod, remove the seal stop washer, remove the seal.

5) Clean the seat of the seal thoroughly, grease the seat and the new seal to facilitate assembly, replace the seal.

4.2

HYDRAULIC

For reassembly of the cylinder components and the cylinders in the truck, invert the steps of the disassembly procedure.

DISASSEMBLY AND REASSEMBLY OF THE HYDRAULIC DISTRIBUTOR MOD. MS 12X

HYDRAULIC DISTRIBUTOR FEATURES • Rated capacity • Max. permissible pressure • Internal leakages at 200 bar

: 25 l/min. : 250 bar : 13 cc/min.

REMOVING THE DISTRIBUTOR FROM THE TRUCK • Lower the forks.

• Disconnect the battery.

• Remove the protective covers.

• Disconnect the hydraulic pipes from the distributor.

• Loosen the two securing screws of the distributor.

INSPECTION AND MAINTENANCE • Disassembly of the microswitch and checking that it is working properly.

• Disassembly of the shuttle group on the distributor assembly, checking the distributor body and shuttle sliding seats: no scores or scratches, good coupling.

• Thorough cleaning of the components.

• Replacement of the seals.

• Reassembly.

REASSEMBLY • To reassemble the distributor on the truck, invert the steps of the disassembly procedure.

CHECKING To check that the hydraulic distributor is functioning properly: • Lift the forks with the nominal load to about one metre off the ground.

• Measure the height with a metre and check after 10 minutes how much the forks have moved down with the load.

• The maximum descent allowed is 50 mm after 10 minutes.

WARNING:

UPDATE

0

The currently applicable regulations allow for a descent of the nominal load, with the distributor idle, of 100 mm. in a time of 10 min.

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Part No: 272352200

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

4.3

MP20X - MS12X

ADJUSTMENT OF THE MAXIMUM PRESSURE LIFTING VALVE MOD. MS 12X

The regulations require the installation of a maximum pressure valve in the hydraulic system of the truck in order to safeguard the system from sudden rises in pressure that could seriously damage the components.

The maximum pressure valve is fitted on the distributor on the left of the lever.

HYDRAULIC

STANDARD TOOLS NEEDED

SOCKET WRENCH 10 mm

ALLEN WRENCH 3 mm

ADJUSTMENT PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks to the ground and place a nominal load on the forks.

3) WRENCH 10 mm - Unscrew the counter-nut of the adjustment screw.

4) ALLEN WRENCH 3 - Place the nominal load on the forks. Unscrew the adjustment screw until the cylinders just stop lifting; at this point, invert the direction of rotation, pull the distributor lever to actuate lifting, tighten the screw until the cylinders start lifting, and bring the load to the max. height.

5) Try lifting the load several times, ensuring the adjustment made remains unaltered.

6) UNIVERSAL WRENCH 10 - Tighten the locking counter-nut.

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Date: July 98

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

5.0

MP20X - MS12X

DISASSEMBLY OF THE LIFTING CYLINDER MOD. MP20X

The lifting cylinder is mounted on the fixed chassis and hinge-mounted through the rod to the movable chassis.

It is located behind the traction motor.

SPECIAL TOOLS NEEDED

HYDRAULIC

• Wooden blocks 100x100x200 • Hoist or overhead travelling crane • M24 eyebolt / Equalizer • Hydraulic jack • 2000 kg sling STANDARD TOOLS NEEDED

ALLEN WRENCH 4-6 mm

SOCKET WRENCHES 10-19-22 mm

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks to the ground using the down push button; turn the key switch to the OFF position and disconnect the battery.

3) HYDRAULIC JACK - Lift the platform, insert the jack under the fixed chassis local to the platform, lift the truck until the wooden blocks can pass underneath. Insert the blocks on either side of the jack and lower the jack. Let the chassis rest on the blocks and take away the jack.

4) PHILIPS SCREWDRIVER - Lower the platform. Loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

5) Take out the tiller (see Section: CHASSIS HOUSING - Paragraph 4.0) B

6) ALLEN WRENCH 6 - Unscrew the bolts (2) securing the support pipe of the instrument compartment located behind the tiller.

7) ALLEN WRENCH 4 - Unscrew the bolt securing the cylinder hinge pin to the movable chassis. Remove the pin from the cylinder seat.

A

8) Insert the eyebolt or equalizer in the appropriate transport lug of the truck (see fig. item A).

9) Insert the 2000 Kg sling into the eyebolt or equalizer (see fig. item B) and hook onto the overhead crane and/or hoist.

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

10) Lift the movable chassis carefully until the two parts open into a V and lift until the cylinder is fully exposed for disassembly purposes (see figure below).

11) UNIVERSAL WRENCH 22 - Unscrew the hydraulic coupling from the cylinder and detach the pipe (ref.C).

12) WRENCH 19 - Unscrew the bolts (4) securing the cylinder to the chassis and take out the cylinder (ref. D).

HYDRAULIC

Reassemble by inverting the steps of the disassembly procedure.

Rocker arm

Wooden blocks 100x100x200 2 pieces

C

D

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Part No: 272352200

Date: July 98

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

REPLACEMENT OF SEALS

SPECIAL TOOLS NEEDED • Special wrench

HYDRAULIC

STANDARD TOOLS NEEDED

SOCKET WRENCH FOR Ø75/80 SLEEVES WITH Ø4 PIN PROCEDURE 1) Clamp the cylinder in a vice, protecting the clamped parts with rubber.

2) With the socket wrench, unscrew the cylinder sleeve. Remove the seals, paying attention to their position to facilitate reassembly.

3) Clean the seat of the seal thoroughly, grease the seat and the new seal to facilitate assembly, replace the seal.

4) Reassemble the cylinder inverting the steps of the disassembly procedure.

REASSEMBLY OF THE LIFTING CYLINDER Invert the disassembly procedure.

BLEEDING AIR FROM THE CYLINDER In order to function properly, the hydraulic circuit must be freed from the air that has accumulated in the cylinder during the seal assembly stages. It is essential that this be done as this cylinder is of the plunger type and may cause a ‘springing’ effect.

The correct bleeding operation is described below: 1) SOCKET WRENCH 10 - Slacken by one turn the nut/plug located under the cylinder sleeve.

2) Actuate the motor pump to lift the cylinder with care. Continue until no more air but only clean oil comes out from the nut, then tighten the nut; repeat the lift-descent operation 2÷3 times. With the forks raised, slacken the air bleeder nut, check that there is no more air and tighten the nut.

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Part No: 272352200

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

5.1

MP20X - MS12X

DISASSEMBLY OF MOTOR PUMP GROUP MOD. MP20X

HYDRAULIC

STANDARD TOOLS NEEDED

SOCKET WRENCH 13-17-19 mm

SMALL SLOT SCREWDRIVER

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks with the down push button and turn the key switch to OFF. Disconnect the battery.

3) PHILIPS SCREWDRIVER - Lower the platform, loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

4) WRENCH 13 - Unscrew the nuts blocking the the motor pump power supply cables (Ref. A) 5) PHILIPS SCREWDRIVER - Unscrew the solenoid valve power supply connection cap.

6) WRENCH 19 - Unscrew the hydraulic coupling of the cylinder feeder pipe from the pump.

7) WRENCH 17 - Unscrew the bolts securing the motor pump group to the chassis (Ref. B) Reassemble by inverting the steps of the disassembly procedure.

A

B

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Part No: 272352200

Date: July 98

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SERVICE

Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

5.2

MP20X - MS12X

ADJUSTMENT OF THE FORK LIFTING MAXIMUM PRESSURE VALVE MOD. MP20X

The regulations require the installation of maximum pressure valves in the hydraulic system of the truck in order to safeguard the system from sudden rises in pressure that could seriously damage the components.

The maximum pressure valve is fitted in the flange of the integral hydraulic control unit (Paragraph 2.0).

The valve adjustment procedure is described below.

BOX WRENCH 10 mm

HYDRAULIC

STANDARD TOOLS NEEDED

ALLEN WRENCH 4 mm

ADJUSTMENT PROCEDURE 1) Open the covers.

2) Lower the forks.

3) ALLEN WRENCH 10 - Unscrew the pressure adjustment screw counter-nut.

4) ALLEN WRENCH 4 - Place the nominal load on the forks, unscrew the sleeve until lifting takes place when the pump is actuated. Invert the direction of rotation (clockwise), actuate lifting by means of the push button and tighten the valve until the cylinder starts lifting.

5) Try lifting the load various times to make sure that the adjustment has not been altered.

6) ALLEN WRENCH 10 - Tighten the counter-nut.

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Section: HYDRAULIC SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

5.3

MP20X - MS12X

DISASSEMBLY OF THE SOLENOID VALVE GROUP Mod. MP20X

The hydraulic system consists of a compact group comprising the pump motor, tank and solenoid valve, thus reducing the space occupied inside the chassis.

HYDRAULIC

STANDARD TOOLS NEEDED

SOCKET WRENCH 11-20-22 mm

ALLEN WRENCH 4 mm

MEDIUM SIZE SCREWDRIVER

DISASSEMBLY PROCEDURE 1) WRENCH 11 - Unscrew the bolts located above the motor flange.

2) Lift the flange, the motor casing and the rotor.

3) WRENCH 20 - Unscrew the nut on the solenoid valve, take out the excitation coil.

4) WRENCH 22 - At the base of the aluminium body, unscrew the solenoid valve body.

5) SLOT SCREWDRIVER - Unscrew the locking screw of the steel strap fastening the tank to the body.

6) ALLEN WRENCH 4 - Unscrew the bolts securing the pump to the aluminium body.

For reassembly invert the disassembly procedure.

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Part No: 272352200

Date: July 98

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Section: MECHANICS-CHASSIS HOUSING

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

MECHANICS

UPDATE

å

CHASSIS COMPONENTS ........................................................................... page 2

å

DISASSEMBLY OF PLATFORM .................................................................... page 6

å

DISASSEMBLY OF LATERAL PROTECTIONS ............................................ page 7

å

DISASSEMBLY OF REDUCER SPRINGS .................................................. page 9

å

DISASSEMBLY OF TILLER .......................................................................... page 14

å

DISASSEMBLY OF THE TRACTION MOTOR .............................................. page 16

å

DISASSEMBLY OF THE REDUCER SPRING-MOUNTED GROUP ............ page 18

å

DISASSEMBLY OF THE SWIVEL WHEEL GROUP ..................................... page 20

å

DISASSEMBLY OF THE MOTOR PUMP ...................................................... page 24

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Part No: 272352200

CHASSIS

CHASSIS HOUSING

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Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

1.0 REAR CHASSIS COMPONENTS MOD. MP20X

PROTECTION

12

11 7

11

10 14

9 13

6 15 2 6 8

CHASSIS

15

28

29

3

30

8 27

5 15

1

4

SPRING

31 32 21

PLATFORM

MOVABLE GROUP

19 16

23

22

40 17

SWIVEL WHEEL

25

41 20

18

26

24

42

MOTOR

33

43

39

38 37

TILLER

34

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36

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Section: MECHANICS-CHASSIS HOUSING

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

1.1 TABLE OF REAR CHASSIS COMPONENTS MOD. MP20X The various components shown on the adjacent page are described in the table below.

Key to understanding: Reference of component on exploded view Function of component

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Component description Platform Platform support Platform return gas spring Platform hook-up pin Platform return gas spring hook-up pin Platform microswitch Operator LH protection Platform pin precision bush Operator protection consent microswitch Operator protection return gas spring Operator protection pin precision bush Operator protection hook-up pin Operator RH protection Protection microswitch locking plate Platform microswitch locking plate Swivel wheel group Swivel wheel hook-up pin Swivel wheel Spring-mounted group top support Reducer wheel support Top support / group support hinge pin Top support /chassis hinge pin Bracket hinge pin Reducer group support connection bracket Bushes Bushes Spring complete with damper Bush Spring hinge pin Nut Spiral spring Bush Traction motor Traction wheel Reducer group Traction slow-down microswitch support Traction slow-down microswitch Microswitch actuator cams Microswitch locking plate Bush Bush Tiller support Tiller support fastening bolt

CHASSIS

Exploded view ref.

Component description

Tab.01

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

1.2 REAR CHASSIS COMPONENTS MOD. MS12X

17

11

3

18 19

2

23

7

10

8

15

4

20

6 21

1

9

6 36

7

5

22

6 15

6

5

20

12 24 25

CHASSIS

14

31 32

26

13

28

11

27

30

29

33

34 37 14

10

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Part No: 272352200

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Section: MECHANICS-CHASSIS HOUSING

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

1.3 TABLE OF REAR CHASSIS COMPONENTS MOD. MS12X

The various components shown on the adjacent page are described in the table below.

Key to understanding: Reference of component on exploded view Function of component

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Component description Reducer group support Top support LH support RH support Reducer group support lower lever Pin precision bushes Pin precision bush Top support connecting pin Bottom spring support Spring Top spring support Traction motor Traction wheel Reducer group Top support spacer Botom lever securing washer Top and bottom support connecting pin Lateral protection pin precision bush Lateral protection connecting pin RH/LH lateral protection Lateral protection gas spring Protection foam Protection slowdown microswitch Swivel wheel support plate Swivel wheel Swivel wheel support Swivel wheel securing pin Swivel wheel bearings Load roller pin Load roller complete with bearings Roller rocker arm Roller rocker arm securing pin Tiller support Motor power supply lead gland Cable connection motor terminal block Reducer fastening bolts x 6 Tiller support fastening bolts x 4

CHASSIS

Exploded view ref.

Component description

Tab.02

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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SERVICE

MP20X / MS12X

2.0 DISASSEMBLY OF OPERATOR PLATFORM MOD. MP20X - MS12X The platform has been designed for the benefit of the operator when travelling long distances and to facilitate the loading/unloading operations.

SPECIAL TOOLS NEEDED • Extractor tool STANDARD TOOLS NEEDED

ALLEN WRENCH 6 mm

SOCKET WRENCH 10mm

MEDIUM SIZE PHILIPS SCREWDRIVER

DISASSEMBLY PROCEDURE

CHASSIS

1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks (with the distributor lever on MS12X, push button on MP20X), turn the key switch to OFF. Disconnect the battery.

3) PHILIPS SCREWDRIVER - Lower the platform, loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

4) ALLEN WRENCH 6 - Pull off the connector of the microswitch power supply cables, use the wrench to unscrew the platform support bolts, remove the platform by taking it out backwards and lifting the gas spring out of its seat in the chassis.

REPLACEMENT OF THE GAS SPRING 1) SOCKET WRENCH 10 - Unscrew the self-locking nut blocking the spring on the rod side.

2) EXTRACTOR TOOL - The gas spring is attached on the platform side by a pin dia. 8 inserted in a blind hole in the platform casting. The pin has a threaded hole dia. M5 on the outside, enabling it to be removed with the extractor tool.

3) EXTRACTION PROCEDURE (see fig. below) - take the threaded bolt (1), unscrew the nut (3) and bring it as close as possible to the bolt head (2). Slide the washer (4) towards the nut, insert the extractor tool (5) in the threaded bar (1) and screw the threaded part Ø M5 into the hole in the spring hinge-mounting pin. With the wrench 17 tighten the nut (3), applying pressure on the washer (4). Screw until the pin has been extracted completely.

Reassemble by inverting the steps of the disassembly procedure.

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SERVICE

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MP20X / MS12X

2.1 DISASSEMBLY OF LATERAL PROTECTIONS MOD. MP20X The lateral protections have been provided for greater operator safety during travel with the platform down and are attached to the top part of the fixed chassis.

STANDARD TOOLS NEEDED

SOCKET WRENCH 10 mm

BOX WRENCH 27 mm WITH JACK

MEDIUM SIZE PHILIPS SCREWDRIVER

GAS SPRING DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

3) PHILIPS SCREWDRIVER - Lower the platform, loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

4) WRENCH 17 - Loosen the bolts securing the protection support (4 bolts, see figure) so as to slacken the force of the spring.

5) WRENCH 13 - Lift the protections and secure them with a support that prevents them from dropping down. Unscrew the bolt securing the spring to the bottom part of the chassis. Unscrew the bolt securing the upper spring to the protection and take out the spring.

Securing bolts

Replace the spring.

PROCEDURE FOR COMPLETE DISASSEMBLY OF THE LATERAL PROTECTIONS GROUP 1) Proceed as indicated for the gas spring disassembly procedure (steps 1 to 5).

Spring fastening

2) Pull out the connectors ensuring connection of the microswitches of the protections.

3) WRENCH 17 - Unscrew the bolts (4 bolts, see figure) securing the protection support and remove the group.

Reassemble by inverting the steps of the disassembly procedure.

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CHASSIS

2) Lower the forks with the push button, turn the key switch to the OFF position. Disconnect the battery.

Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

2.2 DISASSEMBLY OF LATERAL PROTECTIONS MOD. MS12X The lateral protections have been provided for greater operator safety during travel with the platform down and are attached to the top part of the fixed chassis.

STANDARD TOOLS NEEDED

SOCKET WRENCH 10 mm

BOX WRENCH 27 mm WITH JACK

SMALL SIZE SLOT SCREWDRIVER

GAS SPRING DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

CHASSIS

2) Lower the forks with the push button, turn the key switch to the OFF position. Disconnect the battery.

3) PHILIPS SCREWDRIVER - Lower the platform, loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

4) WRENCH 17 - Loosen the bolts securing the protection support (4 bolts, see figure) so as to slacken the force of the spring.

5) SLOT SCREWDRIVER - Use the screwdriver for leverage under the seat of the lower pin circlip, take out the circlip, repeat the operation for the circlip of the upper pin.

6) WRENCH 17 - Loosen the bolts securing the protections assembly to facilitate extraction of the spring from the pins and take out the spring.

Reassemble by inverting the steps of the disassembly procedure.

PROCEDURE FOR DISASSEMBLY OF THE ENTIRE PROTECTIONS ASSEMBLY 1) Proceed as indicated for the gas spring disassembly procedure (steps 1 to 5).

2) Pull out the microswitch connector.

Lateral protections

3) WRENCH 17 - Unscrew the bolts (2) securing the protection support.

Reassemble by inverting the steps of the disassembly procedure.

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SERVICE

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MP20X / MS12X

3.0 DISASSEMBLY OF THE REDUCER SUPPORT GROUP SPRINGS MOD. MP20X The springs, one per side, attached to the reducer support pantograph and to the chassis, serve as shock absorbers for the reducer on rough floors, by keeping the wheel constantly on the ground.

SPECIAL TOOLS NEEDED • Wooden blocks 100x100x200 (2 pieces) • Hydraulic jack STANDARD TOOLS NEEDED

SOCKET WRENCH 19 mm (2 pieces)

BOX WRENCH 27 mm WITH JACK

ALLEN WRENCH 14 mm

MEDIUM SIZE PHILIPS SCREWDRIVER

CHASSIS

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks to the ground using the down push button. Turn the key switch to OFF, disconnect the battery.

3) HYDRAULIC JACK - Lift the platform, insert the jack under fixed chassis local to the platform. Lift the truck until the wooden blocks can fit underneath. Insert the blocks on either side of the jack and lower the jack. Let the chassis rest on the blocks and take away the jack.

4) PHILIPS SCREWDRIVER - Lower the platform: loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part beside the instrument compartment) and take off the hood.

5) WRENCH 19 - 2 REQUIRED - Slacken the counternuts (ref.A in fig.) of the pantograph limit-switch bolts. Before proceeding to move the bolts (ref.B in fig.) measure by how much the bolt is protruding (25 mm). Pack tighten the bolt.

B A

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Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

6) ALLEN WRENCH 14 - Unscrew and remove the lower spring securing bolts (ref. C, figure below).

7) ALLEN WRENCH 14 AND BOX WRENCH 27 -Unscrew and take out the bolts securing the spring top part (ref. D, figure below). Take out the spring.

Reassemble by inverting the steps of the disassembly procedure.

CHASSIS

D

C

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SERVICE

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MP20X / MS12X

3.1 DISASSEMBLY OF THE REDUCER SUPPORT GROUP SPRINGS MOD. MS12X The springs, one per side, attached to the reducer support pantograph and to the chassis, serve as shock absorbers for the reducer on rough floors, by keeping the wheel constantly on the ground.

SPECIAL TOOLS NEEDED • Threaded bar Ø14 MA • Washer • Insert for Allen wrench welded on bar (fig. 4).

STANDARD TOOLS NEEDED

ALLEN WRENCH 12 mm

JACK FOR ALLEN WRENCH CHASSIS

MEDIUM SIZE PHILIPS SCREWDRIVER

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks to the ground using the down lever. Turn the key switch to OFF, disconnect the battery.

3) HYDRAULIC JACK - Lift the platform, insert the jack under the fixed chassis local to the platform. Lift the truck until the wooden blocks can fit underneath. Insert the blocks on either side of the jack and lower the jack. Let the chassis rest on the blocks and take away the jack.

4) PHILIPS SCREWDRIVER - Lower the platform: loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

5) WRENCH 19 - 2 REQUIRED - Slacken the counternuts of the pantograph limit-switch bolts. Before proceeding to move the bolts, measure by how much the bolt is protruding (25 mm). Pack tighten the bolt.

6) THREADED BAR TOOL, JACK - ALLEN WRENCH 12 - Insert the tool in the upper support of the spring (see fig. 1), screw the threaded bar to the lower support, making the washer rest against the upper support, use the Allen wrench to lock and tighten the spring until the two supports come out of their seats (see fig. 2).

7) Remove the Allen wrench and take out the complete spring.

8) Insert the lower support of the spring in a well tightened vice (see fig. 3) 9) Before starting to slacken the tool for recovery of the spring, for faster reassembly, you are recommended to measure the total length of the compressed spring (required measure : 280 mm), proceed with recovery by unscrewing the tool with care.

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Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

CHASSIS

For fitting and reassembly of the spring, invert the steps of the disassembly procedure.

Fig. 2

Fig. 1

Fig. 4

Fig. 3

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MP20X / MS12X

CHASSIS

NOTES:

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Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

4.0 DISASSEMBLY OF TILLER MOD. MP20X / MS12X

3

1

4

CHASSIS

5

6

2

8

3

7

The various components shown on the adjacent page are described in the table below.

Key to understanding: Ref. Component description

Reference of the component in the figure Function of component

Ref.

Component description

1

Tiller column

2

Motor cable sheath support

3

Tiller fastening bolts

4

Tiller sheath connector

5

Electromagnetic brake sheath connector

6

Motor cable sheath

7

Sheath connector support

8

Electromagnetic brake

Tab.03

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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MP20X / MS12X

The tiller consists of three parts, tiller, swivel joint, steering-column. The latter is fastened by means of 4 bolts to the upper flange of the traction motor.

STANDARD TOOLS NEEDED

MEDIUM PLIERS FOR OPENING CIRCLIPS

SWIVEL-HEAD BOX WRENCH 13 mm

SOCKET WRENCH 13-24 mm

LARGE SLOT SCREWDRIVER

MEDIUM SIZE PHILIPS SCREWDRIVER

SMALL SIZE SLOT SCREWDRIVER

CHASSIS

TILLER COMPLETE DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks, turn the key switch to the OFF position, disconnect the battery.

3) PHILIPS SCREWDRIVER - Lower the platform, unscrew the bolts securing the motor hood (4 bolts).

4) Pull the connectors out of the sheaths of the tiller control box and electromagnetic brake (Pos. 4 - 5) 5) BOX WRENCH 13 WITH EXTENSION - Unscrew the bolts (4, Pos. 3) securing the tiller to the motor, pull out the motor cable sheath support, the connector support and take away the complete tiller.

SPRING DISASSEMBLY 1) PHILIPS SCREWDRIVER - Unscrew the 6 fastening screws of the tiller control box cover. Identify the gas spring support pin.

2) SMALL SIZE SLOT SCREWDRIVER - Exert leverage on the circlip of the spring stop pin in the tiller control box, remove the circlip from the spring stop pin located in the tiller swivel joint.

3) LARGE SCREWDRIVER - Exert leverage on the bottom end of the spring simultaneously with another screwdriver, remove it from the pin and take the spring out of the tiller.

4) FITTING A NEW SPRING - Fit the spring from below (swivel joint/box), insert the end of the spring into the pin in the box, put the circlip on.

5) LARGE SCREWDRIVER - Exert leverage under the spring until the hole mates with the pin. Exert pressure from the side, insert the spring and put the circlip on.

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Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

CHASSIS

5.0 DISASSEMBLY OF THE TRACTION MOTOR MOD. MP20X / MS12X

Motor securing bolts

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SERVICE

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MP20X / MS12X

SPECIAL TOOLS NEEDED • Wooden blocks 100x100x200 2 pieces • Hydraulic jack STANDARD TOOLS NEEDED

MEDIUM SIZE PHILIPS SCREWDRIVER

SOCKET WRENCH 13 mm

SWIVEL-HEAD BOX WRENCH 13 mm

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

3) PHILIPS SCREWDRIVER - Lower the platform, unscrew the bolts securing the motor hood (4 bolts).

4) BOX WRENCH 13 WITH EXTENSION - Unscrew the bolts (4, Pos. 3) securing the tiller to the motor, pull out the motor cable sheath support, the connector support and take away the complete tiller.

5) HYDRAULIC JACK - Lift the platform, put the jack centrally under the chassis and lift until the blocks can pass. Insert the blocks and lower the jack.

6) SOCKET WRENCH 13 - Unscrew the nuts fastening the cables to the motor.

7) SWIVEL-HEAD BOX WRENCH 13 - Unscrew the nuts (2) fastening the steering limit-switch bracket to allow greater rotation of the reducer so that the motor securing bolts may be identified.

8) SOCKET WRENCH 13 - Unscrew the (3) motor securing bolts from under the reducer (see figure on the opposite page).

Take the motor out by pulling it upwards, at the same time turning it left and right to facilitate removal.

Reassemble by inverting the steps of the disassembly procedure.

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CHASSIS

2) Lower the forks, turn the key switch to the OFF position, disconnect the battery.

Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

6.0

SERVICE

MP20X / MS12X

DISASSEMBLY OF THE REDUCER SPRING-MOUNTED GROUP MOD. MP20X

The reducer group is heavily stressed since it is supported by pins and bushings in continuous movement and subject to wear. Therefore, to keep the truck in perfect operating condition, the bushings must be replaced after every 600-700 hours’ work.

SPECIAL TOOLS NEEDED • Pin/bar Ø25 - length 300 mm • Pin/bar Ø20 - length 300 mm STANDARD TOOLS NEEDED

ALLEN WRENCH 4 mm

SOCKET WRENCH 9-11-13 mm

PLASTIC HAMMER 500 gr.

STEEL HAMMER 1000 gr.

CHASSIS

DISASSEMBLY PROCEDURE 1) Follow the disassembly procedure step 1 to step 8 in the Reducer Section - paragraph 1.0.

2) Disassemble the pump motor group (Section Hydraulic system paragraph 5.1) 4) Lift the movable chassis until the group support hinge pins can be seen (fig.2).

5) ALLEN WRENCH 4 - Unscrew the fastening stud of the upper anchor (lever) hinge pin (fig.2 ref. A).

6) STEEL HAMMER AND PIN/BAR Ø20 - Knock out the pin and remove Fig. 1 the upper anchor (lever) (fig.2 ref. B).

7) WRENCH 13 - Unscrew the lower lever hinge pin stop bolts (fig.3, ref. C).

8) STEEL HAMMER AND PIN/BAR Ø 20 - Knock out the pins. Take out the group support pantograph complete with the lower levers (fig.3, ref. D).

9) Replace the pins and bushings.

Reassemble by inverting the steps of the disassembly procedure.

C A D B

Fig. 2

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Part No: 272352200

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Fig. 3

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SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

6.1

MP20X / MS12X

DISASSEMBLY OF THE REDUCER SPRING-MOUNTED GROUP MOD. MS12X

The reducer spring-mounted group is hinge-mounted with pins and bushings; being constantly in movement and under stress in manoeuvring right and left with a full load, the bushings wear prematurely, resulting in play that could make the truck unstable. They must therefore be replaced after every 1000 - 1200 hours’ work.

SPECIAL TOOLS NEEDED • Wooden blocks 100x100x200 2 pieces • Oil drainage receptacle 2 kg • Jack and extension STANDARD TOOLS NEEDED

SWIVEL-HEAD BOX WRENCH 13 mm

LARGE SLOT SCREWDRIVER

MEDIUM SIZE PHILIPS SCREWDRIVER

BOX WRENCH 17-27-19 mm

ALLEN WRENCH 4 mm

HYDRAULIC JACK

PLASTIC HAMMER 500 gr.

CHASSIS

SOCKET WRENCH 13-17-19-27 mm

DISASSEMBLY PROCEDURE 1) Perform the complete reducer disassembly procedure (see paragraph 2.0).

2) BOX WRENCH 19 WITH JACK- Unscrew the pantograph support securing bolts (2 + 2) from the vertical chassis (Fig. 1).

3) SOCKET WRENCH 19 - 2 REQUIRED - Unscrew the bolts and self-locking nuts of the support on the base side; socket wrench on bolt head under the base, socket wrench on self-locking nut in the support under the base (Fig. 2 - Ref. A).

Securing bolts

Fig. 1

4) Take everything out from the top.

Reassemble by inverting the steps of the disassembly procedure.

A

Fig. 2

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Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

7.0 DISASSEMBLY OF THE SWIVEL WHEEL GROUP MOD. MP20X

CHASSIS

The swivel wheels are located at the sides of the reducer and have the purpose of keeping the truck stable during manoeuvring.

A

A Fig. 1

B

C Fig. 2

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SERVICE

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MP20X / MS12X

SPECIAL TOOLS NEEDED • Wooden blocks 100x100x200 2 pieces • Hydraulic jack STANDARD TOOLS NEEDED

BOX WRENCH 19 mm WITH JACK AND EXTENSION

SOCKET WRENCH 19 mm

DISASSEMBLY PROCEDURE

2) Lower the forks to the ground using the down push button. Turn the key switch to OFF, disconnect the battery.

3) HYDRAULIC JACK - Lift the platform, insert the jack under the fixed chassis local to the platform. Lift the truck until the wooden blocks can fit underneath. Insert the blocks on either side of the jack and lower the jack. Let the chassis rest on the blocks and take away the jack.

4) PHILIPS SCREWDRIVER - Lower the platform: loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

5) BOX WRENCH 19 WITH ACCESSORIES - Insert the segments in the box wrench, lie down with the wrench under the chassis (ref.A, fig.1), unscrew the 4 bolts securing the swivel wheel support (ref.B, fig.2) and remove the complete support.

6) BOX WRENCH 19 WITH JACK AND SOCKET WRENCH 19 - For disassembly of the wheel alone, hold the nut of the wheel bolt/pin (ref.C, fig.2) with the box wrench and unscrew the nut underneath using the socket wrench. Take out the pin and and take the wheel away for replacement.

Reassemble by inverting the steps of the disassembly procedure.

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CHASSIS

1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

8.0 DISASSEMBLY OF THE SWIVEL WHEEL GROUP MOD. MS12X The swivel wheels are located at the sides of the reducer and have the purpose of keeping the truck stable during manoeuvring.

SPECIAL TOOLS NEEDED • Wooden blocks 100x100x200 (2 pieces) • Hydraulic jack STANDARD TOOLS NEEDED

BOX WRENCH 19 mm

SOCKET WRENCH 19 mm

MEDIUM SIZE PHILIPS SCREWDRIVER

CHASSIS

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks to the ground using the down push button. Turn the key switch to OFF, disconnect the battery.

3) HYDRAULIC JACK - Lift the platform, insert the jack under the fixed chassis local to the platform. Lift the truck until the wooden blocks can fit underneath. Insert the blocks on either side of the jack and lower the jack. Let the chassis rest on the blocks and take away the jack.

Through bolts, seen from the motor compartment side

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SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

4) PHILIPS SCREWDRIVER - Lower the platform: loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part beside the instrument compartment) and take off the hood.

5) SOCKET WRENCH 19 - Hold the bolts located above the chassis at the wheel support (Fig. 1).

6) BOX WRENCH 19, JACK COMPLETE WITH EXTENSION- Put the wrench on the self-locking nut under the chassis, unscrew the nut and take out the complete support (Fig. 2).

7) SOCKET AND BOX WRENCH 19 - Unscrew the nut from the bolt/pin, take out the wheel (Fig. 2).

N.B. To replace the wheel only, follow the indications of steps 1-2-3-4-7.

CHASSIS

Reassemble by inverting the steps of the disassembly procedure.

Swivel wheel securing nuts seen from wheel side Fig. 2

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Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

9.0 DISASSEMBLY OF THE MOTOR PUMP MOD. MS12X The motor pump is attached to the oil tank and located between the chassis and the tank.

SPECIAL TOOLS NEEDED • Oil can 10 lt.

• Average-size funnel STANDARD TOOLS NEEDED

SOCKET WRENCH 13-17-19-22mm

MEDIUM SIZE PHILIPS SCREWDRIVER

SLOT SCREWDRIVER

CHASSIS

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks to the ground using the down push button. Turn the key switch to OFF, disconnect the battery.

3) HYDRAULIC JACK - Lift the platform, insert the jack under the fixed chassis local to the platform. Lift the truck until the wooden blocks can fit underneath. Insert the blocks on either side of the jack and lower the jack. Let the chassis rest on the blocks and take away the jack.

4) PHILIPS SCREWDRIVER - Lower the platform: loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

5) Socket wrench 13 - Unscrew the nuts locking the pump motor feed cables.

6) WRENCH 19 - Unscrew the hydraulic coupling for oil supply to the distributor.

7) WRENCH 17 - Unscrew the 1st bolt securing the tank at the base of the chassis (Fig. 2), lift the battery compartment, unscrew the 2nd tank securing bolt located above the battery compartment (Fig. 1), take out the tank with motor pump.

8) Put the tank in a raised position to let the oil drain off.

9) SLOT SCREWDRIVER - Unscrew the metal fastening strap of the pump suction pipe on the tank side.

10) Put the oil can with funnel underneath, loosen the pipe, drain off the oil, emptying the tank completely.

11) WRENCH 13 - Unscrew the bolts (2) securing the motor pump support bracket, take out the motor.

Reassemble by inverting the steps of the disassembly procedure.

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Section: MECHANICS-CHASSIS HOUSING

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

Fig.1

Oil tank securing bolt

Fig.2

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CHASSIS

Bolt securing oil tank located in the battery compartment

Section: MECHANICS-CHASSIS HOUSING Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

SERVICE

MP20X / MS12X

CHASSIS

NOTES:

Page: 26

Part No: 272352200

Date: July 98

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Section: MECHANICS-MASTS

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

MECHANICS

UPDATE

å

MAST TYPES ............................................................................................... page 2

å

COMPOSITION ............................................................................................ page 4

å

DISASSEMBLY ............................................................................................. page 6

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MASTS

MASTS

Page: 1

SERVICE

Section: MECHANICS-MASTS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

1.0 MAST TYPES MOD. MS12X

The figure that follows illustrates the different mast types that may be fitted on the MS12X type trucks.

Single Type

MASTS

SIMPLEX Type

(fig. 2)

(fig. 1)

TIPLEX Type

DUPLEX Type

(fig. 3) Page: 2

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Date: July 98

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Section: MECHANICS-MASTS

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

The masts are built in accirdance with the operating requirements.

DESIGNATION A) SINGLE MAST For low lifts, consists of a fixed mast, a central cylinder for lifting of the forks (fig. 1).

B) SIMPLEX MAST For medium low lifts, consists of a fixed mast, a movable mast, two lateral cylinders, the forks rise simultaneously with the movable mast (fig. 2).

C) TRIPLEX MAST For medium high lifts, consists of a fixed mast, two movable masts, two lateral cylinders and a central one to allow lifting of the forks before the draw-out units (free lift) (fig. 3).

For medium low lifts, consists of a fixed mast and a movable one, two lateral cylinders and a central one to allow lifting of the forks before the draw-out units. Hydraulically similar to the triplex (fig. 4).

E) The fork front unit is similar in shape for all masts. The only difference is the bearing supports which are of a width suitable for the sliding masts.

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MASTS

D) DUPLEX MAST

SERVICE

Section: MECHANICS-MASTS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

2.0 COMPOSITION OF THE SIMPLEX MAST MOD. MS12X

MP20X / MS12X

4

2 15

15

12

10

12

12 10 13

1

13

12

9

9

11 8

8 12

24

24 10

23 23

3

8

7

6 7

6

MASTS

5 5

2.1 COMPOSITION OF THE DUPLEX AND TRIPLEX MASTS MOD. MS12X

15 2 12 10

20

10

6

19 11

17 13

17 10

11

4

22

9

20 9

27

9 8

21

16

14

18

8

8

24

25

12 10

24

24

26

23

23 23

3 1

9 7

6

6

9

7

8

5

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Section: MECHANICS-MASTS

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

2.2 TABLE OF COMPOSITION OF THE DUPLEX AND SIMPLEX MASTS MOD. MS12X

The various components shown on the adjacent page are described in the table below.

Key to understanding: Reference of component on exploded view Function of component Presence of component on the model indicated

Ref.

Component description

Duplex

Simplex

1

Anti-shearing mesh

✓

✓

2

Movable intermediate mast

✓

✓

3

Front fork unit

✓

✓

4

Internal mast

✓

5

Mast bearing

✓

✓

6

Mast contrast roller

✓

✓

7

Roller shim

✓

✓

8

Chain pin

✓

✓

9

Lifting chain

✓

✓

10

Chain pulley bearing

✓

✓

11

Chain mounting pulley

✓

✓

12

Pulley shim washer

✓

✓

13

Circlip

✓

✓

14

Connecting bar

✓

15

Pulley pin

✓

16

Pulley pin

✓

17

Washer

✓

18

Pulley

✓

19

Pulley bearings

✓

20

Retaining plate

✓

21

Nut

✓

22

Pulley support

✓

23

Nuts

✓

✓

24

Chain tightener

✓

✓

25

Circlip

✓

26

Washer

✓

27

Hydraulic pipe

✓

28

Internal mast chain attachment

✓

MASTS

Exploded view ref.

Component description Duplex/Simplex

✓

Tab.01

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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SERVICE

Section: MECHANICS-MASTS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

3.1 DISASSEMBLY OF FORK FRONT UNIT FROM TRIPLEX, DUPLEX, SINGLE MASTS MOD. MS12X SPECIAL TOOLS NEEDED • Lifting slings of 2000 kg., length : 1400 with hooks at the ends.

• Lifting sling of 2000 kg., length : 1500 normal • Wooden beam 100x100x800 - 2 pieces • Wooden block 100x100x200 STANDARD TOOLS NEEDED

ALLEN WRENCH 6 mm

SOCKET WRENCH 13-19-22-24 mm

OVERHEAD CRANE OF SUITABLE HEIGHT FOR REMOVAL OF THE MASTS, CARRYING CAPACITY 2000 Kg

UNIVERSAL PLIERS

MASTS

PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) With the distributor lever, lift the forks by 300 mm and place the beam on the straddles of the truck, centrally with respect to the forks; lower the forks until they come to rest on the beam; discharge the cylinder completely and slacken the lifting chains (see figure).

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

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Part No: 272352200

Date: July 98

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Section: MECHANICS-MASTS

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

4) ALLEN WRENCH 6 - Unscrew the bolts (4) securing the top horizontal connecting member of the internal mast and take out the connecting member.

5) PLIERS - Remove the cotter pins from the chain pins on the tightener located behind the fork lift cylinder, take the pins out, take the chains off and place them on the forks.

6) CONNECTING SLING WITH HOOKS - Insert the hooks of the sling into the slots of the forks at the rollers facing the truck.

7) NORMAL LIFTING SLING - Fit the sling to the central vertical support of the load backrest, thread the ends into the “V” of the sling with the hooks, hook the ends of the sling to the hook of the overhead travelling crane and tighten the ropes (see figure).

MASTS

Horizontal connecting member

Normal sling

Sling with hooks

8) Lift the fork front unit carefully until it comes away completely.

Reassemble by inverting the steps of the disassembly procedure.

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SERVICE

Section: MECHANICS-MASTS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

3.2 DISASSEMBLY OF FORK FRONT UNIT FROM SIMPLEX MASTS MOD. MS12X DISASSEMBLY PROCEDURE 1) Perform the operations described for disassembly of the forks from the triplex, duplex and single masts (Paragraph 3.1 steps 1 - 2 - 3).

2) PLIERS - Remove the cotter pins from the chain pins on the tightener located on the fixed mast, take the pins out, take the chains off and place them on the forks.

3) Connect the battery, turn the key switch to the ON position.

4) Pull the lifting lever, lift the mast carefully until the front unit has come completely out of the bottom part of the internal mast.

3.3 DISASSEMBLY OF INTERNAL TRIPLEX MAST MOD. MS12X

MASTS

DISASSEMBLY PROCEDURE 1) Disassemble the fork front unit (see Paragraph 3.1).

2) WRENCH 22 - Unscrew the coupling of the hydraulic pipe of the cylinder at the by-pass block located at the base of the internal mast, unscrew the coupling of the hydraulic feed pipe from the pulley at the bypass block of the internal mast.

3) WRENCH 24 - Unscrew the coupling of the hydraulic pipe located on the fixed mast, remove the pipe, screw a plug in place of the coupling to prevent oil leaking out.

4) WRENCH 19 - Unscrew the bolts (4) securing the cylinder to the internal mast, remove the cylinder.

5) Connect the battery, turn the key switch to the ON position.

6) Pull the lifting lever, lift the internal mast 20 - 30 cm., put the 100 x 100 x 200 wooden block under the internal mast; lower the lever, discharge the hydraulic cylinders until the lifting chains slacken.

7) Turn the key switch to the OFF position, disconnect the battery.

8) PLIERS - The lifting chains of the internal mast are attached to the chain-tightener on the fixed mast and to the comb welded at 300 mm from the base of the mast. With the pliers, remove the cotter of the chain pins in the comb, remove the pins, take off the chains from the chassis side of the truck.

9) ALLEN WRENCH 6 - Unscrew the screws (2 + 2) securing the contrast rollers at the top part of the intermediate mast, take out the rollers.

10) LIFTING SLING - Put the sling around the mast horizontal member, hook the sling to the hook of the overhead crane, tighten the ropes and check that everything is perpendicular. Lift until removal is completed.

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Part No: 272352200

Date: July 98

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Section: MECHANICS-MASTS

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

3.4 DISASSEMBLY OF TRIPLEX INTERMEDIATE MAST AND DUPLEX INTERNAL MAST MOD. MS12X

DISASSEMBLY PROCEDURE 1) Connect the battery and turn the key to the ON position.

2) Pull the lifting lever, hydraulically lift the mast about 300 mm, put the 100 x 100 x 200 wooden block under the intermediate mast on the right or left side.

3) WRENCH 13 - Unscrew the bolts on the head of the rod of the cylinders located above the mast cross-slide.

4) Lower the distributor lever, causing the rods to enter all the way.

5) LIFTING SLING - Put the sling around the mast horizontal member, hook the sling to the hook of the overhead crane, tighten the ropes and check that everything is perpendicular.

6) SOCKET WRENCH 13 - Unscrew the bolts securing the contrast rollers in the top part of the fixed mast.

7) Lift the mast slowly until it is out completely.

MASTS

For reassembly of all the parts, invert the steps of the disassembly procedure.

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SERVICE

Section: MECHANICS-MASTS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

MASTS

NOTES:

Page: 10

Part No: 272352200

Date: July 98

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Section: MECHANICS - LEVER MECHANISMS

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

MECHANICS

UPDATE

å

COMPONENTS ................................................................................. page 2

å

DISASSEMBLY OF ROCKER ARMS AND ROLLERS ...................... page 4

å

COMPLETE DISASSEMBLY ............................................................. page 5

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LEVER MECHANISMS

LEVER MECHANISMS

Page: 1

SERVICE

Section: MECHANICS - LEVER MECHANISMS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

1.0 FRONT CHASSIS COMPONENTS MOD. MP20X

2 1 24

27 26 23 22

3 4

21

5

27

25 20

LEVER MECHANISMS

19 18 17 16 15

14

27

25 13

28

6 10 8

12 11

7

8 9 28

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Part No: 272352200

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Section: MECHANICS - LEVER MECHANISMS

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

1.1 TABEL OF FRONT CHASSIS COMPONENTS MOD. MP20X The various components shown on the adjacent page are described in the table below.

Key to understanding: Reference of component on exploded view Function of component Ref.

Component description

1

Fork chassis

2

Battery compartment cover

3

Cover with instrumentation

4

Rear cover

5

Lifting cylinder hinge pin

6

Bushes for levers

7

Rear tie rod lever

8

Bushes for levers

9

Rear lever pin

10

Rear lever pin

11

Rear lever tie rod fork

12

Nut

13

Lifting tie rod

14

Nut

15

Front fork attachment tie rod end

16

Front fork hinge pin

17

Bushes

18

Bushes

19

Front fork hinge pin

20

Front fork

21

Bush

22

Roller rocker arm

23

Roller pin

24

Roller complete with bearing

25

Grease cup

26

Washer

27

Elastic pin

28

Stud with tip dia. 6 MA

LEVER MECHANISMS

Exploded view ref.

Component description

Tab.01

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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SERVICE

Section: MECHANICS - LEVER MECHANISMS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

2.0 DISASSEMBLY OF THE ROLLER SUPPORTING ROCKER ARMS MOD. MP20X SPECIAL TOOLS NEEDED • Drift pin Ø 18 length : 200 mm • Wooden block 150x100x600 STANDARD TOOLS NEEDED

DRIFT BOLT Ø 5 mm

STEEL HAMMER 1000 gr.

LEVER MECHANISMS

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

2) Before commencing any repair work, put on suitable safety clothing.

3) Lift the forks to the maximum height, put the beam under the forks, as close to the front lever as possible (ref.A, fig.1).

4) Lower the forks with the down push button and let the forks rest on the beam.

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

C

A

B

6) Using the drift bolt and the hammer, force out the elastic pins blocking the roller pin (ref. D, fig.2).

Fig.1

D

7) Using the bar and hammer, force the pins out of the rollers and the two rocker arms from the lever (ref. E, fig.2).

F

8) Make all necessary replacements.

E

Reassemble the unit by inverting the steps of the disassembly procedure.

Page: 4

Part No: 272352200

Date: July 98

G

Fig.2

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Section: MECHANICS - LEVER MECHANISMS

SERVICE

Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

2.1 DISASSEMBLY OF THE COMPLETE LEVER MECHANISMS MOD. MP20X Description for complete disassembly of the lever mechanisms of the chassis to replace bushings and pins (due for replacement every 900÷1000 hours).

SPECIAL TOOLS NEEDED • Drift pin Ø 18 length : 200 mm • Wooden block 150x100x600 • Wooden beam 100x100x800 - 2 pieces • Wooden beam 100x100x200 • Sling with hooks, capacity 2000 Kg, length : 2 mt STANDARD TOOLS NEEDED

STEEL HAMMER 1000 gr.

ALLEN WRENCH 4-5 mm

HYDRAULIC JACK LEVER MECHANISMS

DRIFT BOLT Ø 5 mm

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

2) Before commencing any repair work, put on suitable safety clothing.

3) Push the lifting button to lift the forks to the maximum height.

4) HYDRAULIC JACK - Place the jack under the rear chassis. Put the two wooden beams 100x100x200 under the fixed chassis from the outside, lower the jack and let the chassis rest on the beams (ref. B, fig.1).

5) Put the long beam (150x100x600) under the tip of the forks (ref. A, fig.1).

6) Put the 200x100x100 beams under the battery compartment, keeping the hinge pins of the rear levers well in view (ref. C, fig.1).

7) Lower the forks with the down push button. Let the forks rest on the beams and make sure that they are all immobilised.

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

9) Open the battery compartment, take the sling with the hooks and insert the hooks into the lugs of the battery. Take a hoist and hook the sling wrapped around the battery into it; start pulling, disconnect the cables from the poles and take the battery out of its compartment.

10) DRIFT BOLT AND HAMMER - Drive out the elastic pins (ref. F, fig.2) blocking the hinge pin of the front levers and the elastic pin of the hinge pin of the rear lever tie rod head.

11) PIN/BAR AND HAMMER - Drive out the lever hinge pin, hammering from the outside towards the inside.

Let the strut fall to the ground complete with lever (ref. G, fig.2).

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SERVICE

Section: MECHANICS - LEVER MECHANISMS Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

12) DRIFT BOLT AND HAMMER - Drive the elastic pin blocking the lever hinge pin out of the battery compartment (ref. H, fig.3).

H

13) PIN/BAR AND HAMMER - Drive the movable chassis lever hinge pin out. Let the complete tie rod assembly fall to the ground (ref. I, fig.3).

I

14) ALLEN WRENCH, PIN/BAR, HAMMER - Use the Allen wrench to remove the securing stud of the fixed chassis lever pin located under the truck. Use the pin/bar and hammer to drive the pin out, definitively freeing the tie rod.

Fig.3

15) Take the tie rod and lever assembly and bring it to the work bench. Put the levers in the vice, first the front one and then the rear one, then with the pin/bar and hammer, drive out the hinge pins of the lever tie rod heads.

16) After replacing the various bushings, reassemble by inverting the steps of the disassembly procedure.

LEVER MECHANISMS

For reasons of safety, you are advised to disassemble and reassemble the tie rods subsequently one at a time.

N.B.: To adjust the height of the tie rods, unscrew the right and left counter-nuts from the head of the tie rod.

Tighten if the forks have to go up, loosen if they have to go down.

Perform the operation on the right and left simultaneously to obtain perfectly level forks.

Page: 6

Part No: 272352200

Date: July 98

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SERVICE

Section: REDUCER Truck Model / Tipo Carrello / Modèle Chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

UPDATE

å

DISASSEMBLY OF REDUCER ......................................................... page 3

å

COMPONENTS ................................................................................. page 8

å

DISASSEMBLY .................................................................................. page 10

å

TIGHTENING TORQUES .................................................................. page 14

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REDUCER

REDUCER

Page: 1

SERVICE

Section: REDUCER Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

REDUCER

NOTES:

Page: 2

Part No: 272352200

Date: July 98

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SERVICE

Section: REDUCER Truck Model / Tipo Carrello / Modèle Chariot / Staplertyp / Tipo de carretilla

1.0

MP20X - MS12X

DISASSEMBLY OF THE REDUCER FROM THE TRUCK MOD. MP20X

The reducer is attached to the lower pantograph of the spring-mounted system of the fixed chassis.

SPECIAL TOOLS NEEDED • Wooden blocks 100x100x200 • Waste oil receptacle

REDUCER

STANDARD TOOLS NEEDED

SOCKET WRENCH 11-13-17-19-27 mm

SWIVEL-HEAD BOX WRENCH 13 mm

BOX WRENCH 13-17-19-27 mm

PLASTIC HAMMER 500 gr

ALLEN WRENCH 5-6-7-14 mm

HYDRAULIC JACK

LARGE SLOT SCREWDRIVER

MEDIUM PHILIPS SCREWDRIVER

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks with the down push button. Turn the key switch to the OFF position and disconnect the battery.

3) HYDRAULIC JACK - Lift the platform and place the jack under it. Raise the truck until the wooden blocks can pass underneath and place them at the sides of the fixed chassis. Lower the jack, let the chassis rest on the blocks and remove the jack (fig. A).

4) Disassembly of the motor compartment hood (see paragraph 2.1 Section Chassis) 5) Disassembly of the operator platform (see paragraph 2.0 - Section Chassis) 6) Disassembly of the tiller group (see paragraph 4.0 - Section Chassis) 7) Disassembly of the operator protections (see paragraph 2.1 - Section Chassis) UPDATE

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SERVICE

Section: REDUCER Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

8) Disassembly of the traction motor (see paragraph 5.0 - Section Chassis) 9) Disassembly of the springs (see paragraph 3.0 - Section Chassis) 10) SOCKET WRENCH 19 - Unscrew the counter-nut of the upper trapezium limit-switch bolt (before taking it out, measure by how much it protrudes = 25 mm). Take the bolts out completely (fig.3, ref.A).

11) Turn the reducer, put the wheel horizontal with the bolts exposed (fig.2, ref. B).

REDUCER

12) BOX WRENCH 17 - Unscrew the 6 wheel locking bolts and take off the wheel.

13) ALLEN WRENCH 5 - Unscrew the 2 bolts securing the speed microswitch support from the pantograph (see figure at side).

14) ALLEN WRENCH 7 - Place the oil drainage receptacle under the reducer, unscrew the plug at the bottom (fig. 4), empty the oil from the reducer and put the plug back on, locking it tightly.

15) ALLEN WRENCH 19 - Unscrew the 6 bolts securing the reducer to the pantograph. Let the reducer fall on the floor (figure, ref. C).

16) SOCKET WRENCH 11 - Unscrew the grease cup from hinge pin of the lower pantograph and the upper anchor (figure 1, ref. E).

17) SOCKET WRENCH 27, BOX WRENCH 27 - Unscrew a nut of the anchor/pantograph hinge pin (figure 1, ref. G).

18) PLASTIC HAMMER - Drive the pin out and separate the two segments (figure 1, ref. G).

19) Pull the upper anchor upwards and secure it so that it remains in a safe position.

20) Rotate the lower pantograph 180° towards the outside : this will give you the space needed to take out the reducer.

Reassemble by inverting the steps of the disassembly procedure.

Page: 4

Part No: 272352200

Date: July 98

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SERVICE

Section: REDUCER

MP20X - MS12X

REDUCER

Truck Model / Tipo Carrello / Modèle Chariot / Staplertyp / Tipo de carretilla

G

F

Fig. 1

E

Microswitch A

C

B Fig. 3

Fig. 2

Fig.4

Plug UPDATE

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Part No: 272352200

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SERVICE

Section: REDUCER Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

2.0

MP20X - MS12X

DISASSEMBLY OF THE REDUCER FROM THE TRUCK MOD. MS12X

The traction group is anchored to the truck spring-mounted pantograph.

SPECIAL TOOLS NEEDED • Wooden blocks 100x100x200 2 pieces • Oil drainage receptacle 2 kg • Jack and extension

REDUCER

STANDARD TOOLS NEEDED

SOCKET WRENCH SWIVEL-HEAD BOX 13-17-19-27 mm WRENCH 13 mm

LARGE SLOT SCREWDRIVER

MEDIUM SIZE PHILIPS SCREWDRIVER

BOX WRENCH 17-27-19 mm

ALLEN WRENCH 4 mm

HYDRAULIC JACK

PLASTIC HAMMER 500 gr.

DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

Before commencing any repair work, put on suitable safety clothing.

2) Lower the forks to the ground using the down push button. Turn the key switch to OFF, disconnect the battery.

3) HYDRAULIC JACK - Lift the platform, insert the jack under the fixed chassis local to the platform. Lift the truck until the wooden blocks can fit underneath. Insert the blocks on either side of the jack and lower the jack. Let the chassis rest on the blocks and take away the jack.

4) PHILIPS SCREWDRIVER - Lower the platform: loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

5) Disassemble the platform (see paragraph 2.0 - Section Chassis) 6) Disassemble the lateral protections (see paragraph 2.2 - Section Chassis).

7) Disassemble the springs (see paragraph 3.1 - Section Chassis).

8) Disassemble the complete tiller (see paragraph 4.0 - Section Chassis.

9) Disassemble the traction motor (see paragraph 5.0 - Section Chassis) Page: 6

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SERVICE

Section: REDUCER Truck Model / Tipo Carrello / Modèle Chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

10) ALLEN WRENCH 7, OIL DRAINAGE RECEPTACLE - Place the oil drainage receptacle under the reducer, unscrew the plug located at the base of the reducer at the end opposite the wheel (Fig. 4), drain all the oil from the reducer, put the plug back on and lock it tightly.

11) ALLEN WRENCH 17 WITH JACK AND EXTENSION - Turn the reducer to the right, leaving the traction wheel bolts exposed, unscrew the bolts (6) and remove the wheel (Fig. 1).

13) SOCKET WRENCH 27, BOX WRENCH 27 - Unscrew the selflocking nut of the anchor/pantograph hinge pin (Fig. 3).

14) PLASTIC HAMMER - Take out the anchor hinge pin, lift the anchor upwards and secure it with a strap so that it stays in position.

Fig. 1

15) Move the end of the pantograph towards the chassis, rotate it 180° towards the outside. This will give you enough space to take out the reducer.

Reassemble by inverting the steps of the disassembly procedure.

Fig. 2

Reducer securing bolts

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Fig. 3

Fig. 4

Reducer securing bolts UPDATE

Self-locking nut of the hinge pin

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Part No: 272352200

Page: 7

REDUCER

12) SOCKET WRENCH 17 - Unscrew the bolts (6) securing the reducer to the pantograph, let the reducer fall on the ground (Fig. 2).

SERVICE

Section: REDUCER Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

3.0

MP20X - MS12X

REDUCER COMPONENTS MOD. MP20X - MS12X

18

REDUCER

20

19

21 27 22

17

23 27 24 27 2527

16 27 15 27 8 27

2627 27 27

14 27

8 7

4

1

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27

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13

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SERVICE

Section: REDUCER Truck Model / Tipo Carrello / Modèle Chariot / Staplertyp / Tipo de carretilla

3.1

MP20X - MS12X

TABLE OF REDUCER COMPONENTS MOD. MP20X - MS12X

The various components shown on the adjacent page are described in the table below.

Key to understanding: Ref. Component description

Reference of component on exploded view Function of component Component description

1

Screw

2

Wheel

3

Sealing ring

4

Elastic ring

5

Shim

6

Bearing

7

Elastic ring

8

Plug

9

Wheel hub

10

Washer

11

Screw

12

Washer

13

Screw

REDUCER

Ref.

14

Reducer box

15

Seal

16

Fifth wheel

17

Flange

18

Seal

19

Gearwheel on motor (R=1:13)

19

Gearwheel on motor (R=1:18)

19

Gearwheel on motor (R=1:21)

19

Gearwheel on motor (R=1:24)

20

Nut

21

Gearwheel on pinion (R=1:13)

21

Gearwheel on pinion (R=1:18)

21

Gearwheel on pinion (R=1:21)

21

Gearwheel on pinion (R=1:24)

22

Bearing

23

Spacer

24

Shim

25

Bearing

26

Tab

27

Pinion

Tab. 01

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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SERVICE

Section: REDUCER Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

4.0

MP20X - MS12X

DISASSEMBLY OF REDUCER MOD. MP20X - MS12X

REDUCER

Equipment for fastening unit to assembly bench using a vice

1 - Motor support

Equipment for replacement of shims

2 - Mallet for extraction

Hub extractor for replacement of shims

Clearance 0.1 - 0.15

Clearance adj. shims

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Date: July 98

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Section: REDUCER Truck Model / Tipo Carrello / Modèle Chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

REDUCER

Extraction and reassembly of pinion

Equipment for mounting outer rings of conical pinion bearings using impact wrench or ordinary wrench

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SERVICE

Section: REDUCER Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

Equipment for mounting pinion bearing using a hand press or hydraulic press

Equipment for mounting wheel hub bearings using a hand press or hydraulic press

REDUCER

Equipment for mounting steering fifth wheel using a hand press or hydraulic press

Equipment for mounting wheel hub oil baffle using an impact wrench or ordinary wrench

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SERVICE

Section: REDUCER Truck Model / Tipo Carrello / Modèle Chariot / Staplertyp / Tipo de carretilla

MP20X - MS12X

SPECIAL TOOLS NEEDED • Reducer support • Extraction tool for extractor • Large extractor for bearings • Medium size extractor for bearings

ALLEN WRENCH 4 mm

SOCKET WRENCH 13-17-19-27 mm

LARGE PLIERS FOR OPENING CIRCLIPS

LARGE PLIERS FOR TIGHTENING CIRCLIPS

PLASTIC HAMMER MEDIUM SIZE 500 gr.

SCREWDRIVER DISASSEMBLY PROCEDURE 1) Place the reducer support in a well tightened vice.

2) Insert the reducer in the support and make sure that it is secure.

3) SLOT SCREWDRIVER - Remove the oil baffle (item 3).

4) CIRCLIP TIGHTENING PLIERS - Take out the circlip (item 4).

5) ALLEN WRENCH 12 - Unscrew the wheel hub centre hole plug (item 8).

6) EXTRACTION TOOL - Screw the threaded part in the threaded hole, hammer outwards with the mallet, remove the wheel hub complete with bearings.

7) LARGE EXTRACTOR - ALLEN WRENCH 12 - Remove the extraction tool from the wheel hub, put the plug back in, with the extractor, remove the 1st bearing (item 6), remove the shims (item 5).

8) CIRCLIP OPENING PLIERS - Remove the circlip (item 7).

9) With the extractor, take out the 2nd bearing and the shims (items 5 and 6).

10) ALLEN WRENCH 8 - Unscrew the 9 fastening bolts of the upper flange (item 13), remove the flange.

11) SOCKET WRENCH 30 - Unlock the nut fastening the pinion to the crown (item 20), remove the crown (item 21).

12) PLASTIC MALLET - Using the mallet, hammer on the threaded part of the pinion, extract it from the reducer housing side (item 14).

13) MEDIUM SIZE EXTRACTOR - Remove the bearings from the pinion.

N.B. While taking out the various bearings, note the shims and the position they occupy in order to simplify reassembly. In reassembling the parts, use Loctite and lock the bolts according to the diagram on the next page.

Reassemble by inverting the steps of the disassembly procedure.

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REDUCER

STANDARD TOOLS NEEDED

SERVICE

Section: REDUCER Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

5.0

MP20X - MS12X

REDUCER TIGHTENING TORQUE DIAGRAM MOD. MP20X - MS12X

Continuous torque on wheel axle 181 Nm Max. torque at max. acc. on wheel axle during max. braking action 484 Nm Max. load on wheel in line with motor 1100 Kg Bearing underneath wheel with 1100 Kg torque/p ratio = 4.24 static

(Ø 14x1.5M class 8) cone Ø20 with 1:5 5.9 Kgm (58Nm) Loctite 242 Arexon 52A42

(cone Ø20) with 1:5

REDUCER

C40 58÷73 Kg/m 6 Kgm (59Nm) Ø 20x1.5M Loctite 242 Arexon 52A42

2

Loctite 542

2.24 Kgm (22Nm) Arexon 35A42

Loctite 542

Motorsil D Arexon

M 10x1.5 class 8.8 4.8 Kgm (47Nm) Loctite 242 Arexon 52A42

Ø8x1.25 class 8.8 2.4 Kgm (23.5Nm) Loctite 242 Arexon 52A42 2.24 Kgm (22Nm)

Loctite 542 Arexon 35A42

2.24 2.4 4.8 5.9 6 7.5÷8

Ø 10x 1.5 class 10.9 7.5÷8 Kgm (73÷78Nm) Loctite 242 Arexon 52A42

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4

5

Allen hex. hex. hex. hex. hex.

M14x1.5 conical M8x1.25 M10x1.5 M14x1.5 M 20x1.5 M10x1.5

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SERVICE

Section: BRAKING SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

UPDATE

å

COMPONENTS .................................................................................. page 2

å

BRAKING SYSTEMS .......................................................................... page 4

å

ELECTROMAGNETIC BRAKE ........................................................... page 5

å

DISK BRAKE ...................................................................................... page 7

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BRAKES

BRAKING SYSTEM

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SERVICE

Section: BRAKING SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

1.0

MP20X / MS12X

COMPONENTS OF THE ELECTROMAGNETIC BRAKE MODS. MP20X - MS12X

1

3 4

5

BRAKES

2

6

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Section: BRAKING SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

1.1

MP20X / MS12X

TABLE OF ELECTROMAGNETIC BRAKE COMPONENTS MODS. MP20X - MS12X

The various components shown on the adjacent page are described in the table below (Tab. 01).

Key to understanding: Ref. = Reference of component on exploded view; Component Description = Function of the component; MP20X - MS12X = Columns indicating whether the component is present on each model.

MS12X

MP20X

Ref.

Component description

1

Friction flange for brake disk

2

Electronic brake coil

3

Brake disk

4

Disk guide pinion

5

Coil feed connector

6

Complete electronic brake

MP20X

MS12X

✓ ✓ ✓ ✓ ✓ ✓

✓ ✓ ✓ ✓ ✓ ✓

Tab.01

BRAKES

NOTE: All Yale codes of the components may be looked up in the spare parts catalogue.

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SERVICE

Section: BRAKING SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

1.2

MP20X / MS12X

BRAKING SYSTEMS Mods. MP20X - MS12X

The MP20X and MS12X/D models are provided with 2 braking systems, one used as a service brake and the second one as an emergency or parking brake. On these trucks it is also possible to make use of a decelerating system, the intensity of which is easy to regulate in relation to the user’s requirements (see “regenerative braking” in the section Electrical System).

1.2.1

SERVICE BRAKE

Service braking, also known as “plugging braking”, consists in inverting the motor current, thus changing the direction of travel when the truck is moving. When the inversion occurs, the truck will start to decelerate with an intensity proportional to the current value set by means of the programming handset in the parameter INVERSION BRAKING. The braking current must be adjusted in such a way that the truck stops in a distance not less than the length of the truck itself.

Too great a reduction of the braking distance could jeopardise the proper functioning of some components of the truck as, during the plugging braking stage, the motor current reaches very high levels resulting in (if not properly adjusted) premature wear of the brushes, the traction motor collector and the drive wheel. We strongly advise you therefore to follow the instructions given in our manuals.

1.2.2

EMERGENCY AND PARKING BRAKE

The function of the emergency and parking brake is performed by the electromagnetic brake fitted on the traction motor.

OPERATING PRINCIPLE: The electromagnetic brake essentially comprises the following components: n a circular electromagnet to which a steel plate of the same shape and diameter is attached by means of appropriate screws, kept at a determined distance from the electromagnet by 4 springs;

BRAKES

n a brake disk attached to a pinion fixed in the rotor shaft part extending from the top part of the traction motor.

The electromagnet complete with plate must be secured by 3 screws to the traction motor in such a way that the centre of the magnet corresponds with the centre of the disk and the plate, forced by the springs, exerts pressure on the brake disk. The distance between plate and electromagnet must be adjusted to 0.4 mm as described in the next chapter.

When a 24V voltage is applied to the electromagnet, it will attract the plate through the effect of the electromagnetic field created, overcoming the force exerted by the springs on the plate and which caused it to block the brake disk against the upper flange of the motor, preventing it from rotating. This will allow the disk to rotate freely together with the rotor.

To obtain the braking effect, it will suffice to cut off the power supply to the electromagnet so that the plate will again press the brake disk against the motor flange, with a force proportional to the spring load. The spring load can be adjusted by means of the lock nut on the electromagnet, as described in the next chapter.

1.3

DISASSEMBLY AND ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE Mods. MP20X - MS12X

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SERVICE

Section: BRAKING SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

STANDARD TOOLS NEEDED

MEDIUM SIZE PHILIPS SCREWDRIVER

SOCKET WRENCH 13 mm

ALLEN WRENCH 5 mm

THICKNESS GAUGE

mm 0.2 - 0.3 - 0.4... mm 1

SMALL PLIERS FOR OPENING CIRCLIPS (Ø 20 mm) DISASSEMBLY PROCEDURE 1) Drive the truck to a safe place, far from the movement of other vehicles or passers-by.

2) Lower the forks to the ground. Turn the key switch to the OFF position and disconnect the battery.

3) PHILIPS SCREWDRIVER - Lower the platform, loosen the bolts securing the motor compartment hood (2 at the platform, 2 at the top part near the instrument compartment) and take off the hood.

4) Disconnect the brake power supply connector.

5) Disassemble the tiller (see Section: Chassis - paragraph 4.0)

BRAKES

6) WRENCH 13 - Loosen the 3 nuts (R) securing the bolts attached to the motor flange.

7) ALLEN WRENCH 5 - Unscrew the 3 bolts (V) securing the brake group. Remove the magnet complete with plate and take out the brake lining.

8) CIRCLIP PLIERS - Remove the circlip of the lining pinion inserted in the motor shaft and take out the pinion.

Reassemble by inverting the steps of the disassembly procedure.

11d

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SERVICE

Section: BRAKING SYSTEM Truck model / Tipo carrello / Modèle chariot / Staplertyp / Tipo de carretilla

MP20X / MS12X

INSPECTION AND MAINTENANCE • Check the state of wear of the lining disk “p”, it must not be less than 5 mm thick (dimension “S”) • Check the condition of the cup springs.

• Check the proper functioning of the locking and unlocking coil.

• Check the condition of the pinion/disk teeth.

REASSEMBLY OF THE PARKING BRAKE • Invert the procedure just described

1.4

ADJUSTMENT AND PUTTING INTO OPERATION Mods. MP20X - MS12X

1) After reassembling the brake group, before putting the tiller back in place, adjustment of the brake lining must be carried out.

2) To obtain a good braking performance, the distance between the lining and the plate of the electromagnet (S) must not be greater than 0.4 mm. The thickness gauge used must be suitable for this measurement.

3) Keep the three nuts R slackened, insert the thickness gauge near a bolt T and tighten the bolt V with the Allen wrench 5. Bring the plate closer to a distance that allows the thickness gauge to be taken out with a slight friction. Repeat the operation on all three bolts V. Lock the nuts R. 4) Put the tiller back in place and make the truck ready for operation by making all the necessary electrical connections.

BRAKES

5) Restoring stopping/braking progress: set the truck moving at maximum speed. Remove the current from the coil by stopping and releasing the tiller. The truck must come to a stop in a space neither less than or greater than the length of the truck. To optimize braking, turn the lock nut (G): locking shortens and unlocking increases the braking distance.

Page: 6

Part No: 272352200

Date: July 98

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