Download PDF: Service Manual for Yale B979 (MP20XV) Forklift

Part no.: 550063444

Revision:

0 (06/2013)

Technical information for Yale service centres

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

B979.....

MP20XV

INTRODUCTION

SERVICE

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

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

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

2

Product support group

SERVICE

INTRODUCTION

GUIDE TO USING THE MANUAL ATTACHED MANUALS Keypad (part n. 550072197) SECTIONS This handbook is composed of the following sections: Presentation Installation and settings Diagnostics and measurements Electrical system Hydraulic system Mechanics Reduction gear Braking system Standard maintenance

Section 1: Section 2: Section 3: Section 4: Section 5: Section 6: Section 7: Section 8: Section 9:

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

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

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

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

INSTALLATION PROCEDURES For the installation procedures, carry out the reverse procedure to disassembly, observing any notes and information given for the truck to function properly.

3

INTRODUCTION

SERVICE

GENERAL SAFETY RULES PERSONAL SAFETY •

Always wear the personal protective equipment in situations requiring it.

•

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

•

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

•

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

•

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

SAFETY AT THE WORKPLACE •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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

•

Avoid twisting chains or metal ropes.

•

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

•

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

•

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

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

•

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

4

SERVICE

INTRODUCTION

•

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

•

Do not short-circuit the terminals.

•

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

•

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

•

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

•

Always disconnect the battery before working on the electrical system.

•

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

•

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

•

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

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE •

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

•

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

•

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

•

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

•

Always rest the load in the race of the hook.

•

Never load the tip of the hook.

•

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

•

Never do any lifting with the ropes and belts twisted.

•

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

•

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

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

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

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

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

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

• When the sling shows signs of overloading.

5

SERVICE

INTRODUCTION Belt capacity table

Colour

Working load capacity (kg)

purple green yellow grey red brown blue

1000 2000 3000 4000 5000 6000 8000

2000 4000 6000 8000 10000 12000 16000

1400 2800 4200 5600 7000 8400 11200

800 1600 2400 3200 4000 4800 6400

orange

10000 12000

20000 24000

14000 16800

8000 9600

15000 20000 25000 30000

30000 40000 50000 60000

21000 28000 35000 42000

12000 16000 20000 24000

1

2

1.4

0.8

orange orange orange orange orange

Coefficient

Rope capacity table

Working load capacity (kg)

Coefficient

6

Colour

Track (mm)

black purple black green yellow grey red brown blue orange

35 50 50 60 75 120 150 180 240 300

500 1000 1500 2000 3000 4000 5000 6000 8000 10000

1000 2000 3000 4000 6000 8000 10000 12000 16000 20000

700 1400 2100 2800 4200 5600 7000 8400 11200 14000

400 800 1200 1600 2400 3200 4000 4800 6400 8000

1

2

1.4

0.8

SERVICE

INTRODUCTION

Suspension element capacity table

Colour

Working load capacity (kg) Coefficient

purple green yellow grey red

1000 2000 3000 4000 5000

1400 2800 3800 5600 6600

2100 4200 6300 8400 9800

2100 4200 6300 8400 10500

1

1.4

2.1

2.1

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

7

SERVICE

INTRODUCTION

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

To make the threaded matings secure, LOCTITE 270 is used for tightening the screws.

If it is not possible to unscrew the bolts because this product has been used, avoid applying extensions to the tools, instead slightly heat the area (at most 50°C) so as to eliminate the LOCTITE 270 effect.

In the cases described, reapply LOCTITE 270 during installation in a moderate quantity (30% of the mating surface).

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

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

TORQUE SETTING Nm

Nominal diameter

Class 8

Class 10

M3

4

5.2

M4

7

9.15

M5

12.14

14.8

M6

17.2

20.9

M8

31.8

38.1

M10

50.5

60.3

M12

74.2

88.5

M14

101.2

120.8

M16

138.2

164.9

M18

176.6

203.5

M20

225.4

259.7

M22

278.8

321.2

M24

324.8

374.2

M27

422.3

486.5

M30

516.1

594.7

TORQUE SETTING Nm Pre-load N

Class 8.8

Class 10.9

M4

0.7

7

3

2400

1.92

1.44

3.07

2.3

4.17

3.13

M5

0.8

8

4

3880

3.88

2.91

6.2

4.65

8.43

6.33

M6

1

10

5

5490

6.58

4.94

10.5

7.9

14.3

10.8

M8

1.25

13

6

9990

16

12

25.6

19.2

34.8

26.1

M8

1

13

6

10700

17.1

12.8

27.4

20.5

37.3

27.9

M10

1.5

16

8

15825

31.7

23.8

51

38

69

52

M10

1.25

16

8

16700

33.4

25.1

53

40.1

73

55

M12

1.75

18

10

23025

55

41.4

88

66

120

90

M12

1.25

18

10

25150

60

45.3

96

72

130

98

M14

2

21

12

31400

88

66

140

105

190

145

M14

1.5

21

12

34125

96

72

155

115

210

155

M16

2

24

14

42850

135

105

220

165

300

225

M16

1.5

24

14

45600

145

110

235

175

320

240

M20

2.5

30

17

66875

270

200

430

320

580

435

M20

1.5

30

17

74250

295

225

475

355

650

485

= with lubricant

8

Class 5.8

SERVICE

INTRODUCTION

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

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

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

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

TORQUE SETTINGS

UNF thread

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

UNF thread

REVOLVING FEMALE jic 37° Torque setting Nm Size

Nominal torque

min / max

M 12x1.5

6

20

15 -25

7/16-20

-4

15

9 - 21

M 14x1.5

8

38

30 - 45

1/2-20

-5

20

13 - 27

45

38 - 52

9/16-18

-6

30

18 - 42

3/4-16

-8

50

30 - 70

7/8-14

-10

69

44 - 94

1.1/16-12

-12

98

63 - 133

1.3/16-12

-14

118

73 - 163

1.5/16-12

-16

140

90 - 190

1.5/8-12

-20

210

135 - 285

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

8 10 10 12 12 14 15

51

43 - 85

58

50 - 65

74

60 - 88

M 24x1.5

16

74

60 - 88

1.7/8-12

-24

290

200 - 380

M 26x1.5

18

105

85 - 125

2.1/2-12

-32

450

300 - 600

135

115 - 155

166

140 - 192

30

240

210 - 270

35

290

255 - 325

330

280 - 380

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

UNF thread G1/4

20 22 25 28

38 42

REMOVING FEMALE BSP Torque setting Nm

UNF thread

REVOLVING FEMALE ORFS Torque setting Nm Size

Nominal torque

max.

Nominal torque

max

20

15 - 25

9/16-18

-4

14

16

-6

24

27 47

G3/8

34

27 - 41

11/16-16

G1/2

60

42 - 76

13/16-16

-8

43

G5/8

69

44 - 94

1-14

-10

60

68

G3/4

115

95 - 135

1.3/16-12

-12

90

95

G1

140

115 - 165

1.3/16-12

-14

90

95

G1.1/4

210

140 - 280

1.7/16-12

-16

125

135

G1.1/2

290

215 - 365

1.11/16-12

-20

170

190

G2

400

300 - 500

2-12

-24

200

225

2-1/2-20

-32

460

490

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

9

INTRODUCTION

SERVICE

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

• • • • • • •

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

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

Installation Avoid twisting the pipe, which could cause it to burst under pressure.

There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assembled pipe decreases considerably when below the minimum radius of curvature.

The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly greater length than the requirement in order to compensate for these changes.

10

SERVICE

INTRODUCTION

SECTION CONTENTS

Presentation

1

Installation and settings

2

Diagnostics and measurements

3

Electrical system

4

Hydraulic system

5

Truck base mechanics

6

Fork mechanics

6 7

Reduction gear

6 8

Braking system

7 9

Standard maintenance

10 8

11

INTRODUCTION

12

SERVICE

SERVICE

PRESENTATION

Presentation TRUCK PRESENTATION ������������������������������������������������������������������������������������������������������������������������������������������� 2 VIEWS OF THE TRUCK ��������������������������������������������������������������������������������������������������������������������������������������������� 2 TRUCK AND LOAD IDENTIFICATION DATA ������������������������������������������������������������������������������������������������������������ 3 TRUCK IDENTIFICATION DATA PLATE ��������������������������������������������������������������������������������������������������������������������� 3 TRUCK SERIAL NUMBER PUNCHING and location of documentation ���������������������������������������������������� 3 GENERAL SPECIFICATIONS ������������������������������������������������������������������������������������������������������������������������������������ 4

1

PRESENTATION

TRUCK PRESENTATION VIEWS OF THE TRUCK

2

SERVICE

SERVICE

PRESENTATION

TRUCK AND LOAD IDENTIFICATION DATA TRUCK IDENTIFICATION DATA PLATE

The truck identification data plate is located on the battery compartment cover .

• • • • •

Manufacturer's name.

Model Serial number Weight without battery Year of manufacture

• • • • •

Max. weight battery Min weight battery Battery voltage Nominal Load capacity Persons on board

Always refer to the nominal load capacity to be sure to lift only the permitted load.

TRUCK SERIAL NUMBER PUNCHING and location of documentation

The truck serial number is located inside the battery compartment.

The truck documentation is located inside the battery compartment.

3

PRESENTATION

GENERAL SPECIFICATIONS

4

SERVICE

SERVICE

PRESENTATION

MOTOR UNITS

PERFORMANCE

DIMENSIONS

WHEELS, FRAME

WEIGHT CHARACTERISTICS

GENERAL SPECIFICATIONS 1.2 1.3 1.4 1.5 1.6 1.8 1.9 2.1 2.2 2.3

manufacturer’s type designation power: electrical (battery or mains), diesel, petrol, gas operation: manual, pedestrian, standing, seated, order pickers rated capacity/rated load load centre (6) load distance, from wheel axle to fork shoulder (6) wheelbase (WB)(6) unladen weight in service axle loading, laden (front/rear) axle loading, unladen (front/rear)

3.1

wheels: polyurethane, vulkollan, topthane (front/rear)

3.2 front wheel size 3.3 rear wheel size 3.4 additional wheels (size) 3.5 no. of wheels (front/rear) (x = drive wheel) 3.6 front track width 3.7 rear track width 4.4 lifting height 4.9 height of tiller in operating position (min/max) 4.15 fully lowered forks height 4.19 overall length (driving on ground)(2) 4.19 overall length (driving standing) (2) 4.20 length at front of forks (driving on ground)(2) 4.20 length at front of forks (driving standing)(2) 4.21 total length 4.22 fork dimensions DIN ISO 2331 (6) 4.25 outside fork width 4.32 ground clearance, centre of wheelbase 4.33 load dimensions b12xI6 crossways (2) 4.34.1 aisle width for pallets 1000 x 1200 mm crossways (driving on ground) (2) 4.34.1 aisle width for pallets 1000 x 1200 mm crossways (driving standing) (2) 4.34.2 aisle width for pallets 1000 x 1200 mm lengthwise (driving on ground) (2) 4.34.2 aisle width for pallets 1000 x 1200 mm lengthwise (driving standing) (2) 4.35 radius of curvature (driving on ground)(2) 4.35 radius of curvature (driving standing)(2) 5.1 traverse speed, laden/unladen (driving on ground) 5.1 traverse speed, laden/unladen (driving standing) 5.1.1 traverse speed, laden/unladen, in reverse (driving on ground) 5.1.1 traverse speed, laden/unladen, in reverse (driving standing) 5.2 lift speed laden/unladen 5.3 lowering speed with/without load 5.7 grade ability with/without load 5.8 maximum gradeability with/without load 5.10 electromagnetic service 6.1 traction motor, power S2 60 minutes 6.2 lifting motor, power S3 15% (4) 6.3 battery in compliance with DIN 43531/35/36 A,B,C, no 6.4 K5 battery voltage/capacity 6.5 battery weight (6) 6.6 consumption per VDI cycle 8.1 type of drive control 10.7 noise level at operator position

Q (t) c (mm) x (mm) y (mm) kg kg kg ø (mm x mm) ø (mm x mm) ø (mm x mm) b 10 (mm) b 11 (mm) h3 (mm) h14 (mm) h13 (mm) l1 (mm) l1 (mm) l2 (mm) l2 (mm) b1/b2 (mm) s/e/l (mm) b5 (mm) m2 (mm) b12 x I6 Ast (mm) Ast (mm) Ast (mm) Ast (mm) Wa (mm) Wa (mm) km/h km/h km/h km/h m/s m/s % % kW kW V/Ah kg kWh/h dB (A)

(1)

batteries also available: 210Ah, 250Ah, 315Ah; see Table “A”. With battery 210Ah, 250Ah, unladen weight in service 661kg

(2)

see Table “A”

(3)

with side guards open: 8.5 / 8.5 km/h

(4)

value referred to S3 6%

(5)

all the values are with forks lowered; with forks raised 130mm all these sizes must be decreased by 100.6mm

(6)

+/- 5%

MP20XV battery on ground / standing 2.0 600 1012 (5) 1491 (5) 750 (1) 1159/1591 605/145 vulkollan-polyurethane/ vulkollan 230 x 75 85 x 115 100 x 40 1x+2/4 / 1x+2/2 480 390 130 1220 / 1460 85 1922 2368 730 1176 716 170/55/1191 560 30 1000 x 1200 2477 2923 2579 3025 1743 (5) 2189 (5) 4/4 6 / 6 (3) 4/4 6 / 6 (3) 0.03 / 0.04 0.05 / 0.04 5.5 / 20 9 / 20 brake 2 1.4 Din 43535 B 24/375 (1) 288 0.48 AC control < 70

These specifications are a guideline only and are subject to change without notice.

5

SERVICE

PRESENTATION

TABLE “A” 1.8

load distance, from wheel axle to fork shoulder

x (mm)

809

1012

1429

809

1012

1429

y (mm)

1288

1491

1908

1218

1421

1838

overall length (driving on ground) l1 (mm) overall length (driving standing) l1 (mm) length at front of forks (driving on ground) l2 (mm) length at front of forks (driving standing) l2 (mm) fork dimensions DIN ISO 2331 s/e/l (mm) aisle width for pallets 1000 x 1200 mm cros4.34.1 Ast (mm) sways (driving on ground) aisle width for pallets 1000 x 1200 mm cros4.34.1 Ast (mm) sways (driving standing) aisle width for pallets 1000 x 1200 mm lengthwi4.34.2 Ast (mm) se (driving on ground) aisle width for pallets 1000 x 1200 mm lengthwi4.34.2 Ast (mm) se (driving standing) (1) 4.35 radius of curvature (driving on ground) Wa (mm) 4.35 radius of curvature (driving standing)(1) Wa (mm)

1719 2165 730 1176 988

1922 2368 730 1176 1191

2339 2785 730 1176 1608

1649 2095 660 1106 988

1852 2298 660 1106 1191

2269 2715 660 1106 1608

2375

2477

2910

2305

2407

2840

2821

2923

3356

2751

2853

3286

2340

2579

3229

2270

2509

3159

2786

3025

3675

2716

2955

3605

1540 1986

1743 2189

2160 2606

1470 1916

1673 2119

2090 2536

1.9

(1)

wheelbase (WB)

(1)

4.19 4.19 4.20 4.20 4.22

6.4 (1)

6

K5 battery voltage/capacity

V/Ah

375/315

all the values are with forks lowered; with forks raised 130mm all these sizes must be decreased by 100.6mm

250/210

SERVICE

INSTALLATION AND SETTINGS

Installation and settings BEFORE INSTALLATION ������������������������������������������������������������������������������������������������������������������������������������������� 2 WEIGHT TABLE ���������������������������������������������������������������������������������������������������������������������������������������������������������� 2 TRUCK ASSEMBLY ��������������������������������������������������������������������������������������������������������������������������������������������������� 3 LIST OF MATERIALS RECEIVED FROM THE DEALER ������������������������������������������������������������������������������������������� 3 UNLOADING THE TRUCK ������������������������������������������������������������������������������������������������������������������������������������������ 5 TOPPING UP THE OIL RESERVOIR ������������������������������������������������������������������������������������������������������������������������� 6 INSTALLATION OF THE BATTERY ���������������������������������������������������������������������������������������������������������������������������� 7 List of the SETTINGS AND ADJUSTMENTS to be carried out ��������������������������������������������������������������� 10 SETTING THE BATTERY VOLTAGE ������������������������������������������������������������������������������������������������������������������������ 10 CHECK THE CONDITIONS OF USE OF THE TRUCK �������������������������������������������������������������������������������������������� 11

1

INSTALLATION AND SETTINGS

SERVICE

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

WEIGHT TABLE

Model

MP20XV

Weight (excluding battery)

Battery voltage/ capacity

Battery weight (min/max)

Overall weight (min/max)

kg

V/Ah

kg

kg

201÷223

862÷884

274÷302

1024÷1052

661 750

2

24/210 24/250 24/315

SERVICE

INSTALLATION AND SETTINGS

TRUCK ASSEMBLY LIST OF MATERIALS RECEIVED FROM THE DEALER CARRIAGE SOLD WITHOUT BATTERY

2

1

3 5 4

The materials received from the dealer may vary depending on the presence or absence of optional accessories.

Ref.

Description

1

Fork lift truck

2

Battery charge plug

3

Battery plug

4

Rollerway for lateral battery removal (on request)

5

Battery plug extension (for trucks with side battery removal)

3

SERVICE

INSTALLATION AND SETTINGS CARRIAGE SOLD WITH BATTERY

4

1 6

2 3 7 5

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

Ref.

4

Description

1

Fork lift truck

2

Battery

3

Battery plug

4

Rollerway for lateral battery removal (on request)

5

Top up bottle for battery electrolyte

6

Battery charge

7

Battery plug extension (for trucks with side battery removal)

SERVICE

INSTALLATION AND SETTINGS

UNLOADING THE TRUCK Equipment and tools

fork lift truck load capacity 3000 kg

bridge crane load capacity 2000 kg

double arm lift belt load capacity 2800 kg

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

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

Phase 2 BRIDGE CRANE - 2 LIFTING SLINGS Remove the packaging.

Hook the double arm lift belt to the bridge crane.

Hook the two hooks of the lift belt to the two side holes of the truck base made for lifting (ref.A fig.2).

Fig. 2

a

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

Slowly raise and carefully position the truck on the ground.

5

SERVICE

INSTALLATION AND SETTINGS TOPPING UP THE OIL RESERVOIR

Before topping up the oil in the hydraulic oil reservoir make sure that the forks are fully lowered.

Equipment and tools

funnel

oil resistant gloves

large flat blade screwdriver

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

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

A

A

A Phase 1 LARGE FLAT BLADE SCREWDRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Recover the washers.

Remove the cover.

Phase 2 OIL RESISTANT GLOVES - FUNNEL Unscrew the oil reservoir cap (ref.B fig.2), place the funnel in the filler hole and top up the oil level.

Do not overfill the reservoir.

After topping up the oil level, replace the screw on filler cap.

Fig. 1

B

Fig. 2 6

SERVICE

INSTALLATION AND SETTINGS

INSTALLATION OF THE BATTERY Equipment and tools Fig.1

A tackle load capacity 1000 kg

lift belt load capacity 1000 kg

spreader bar

open ended spanner 13 mm

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

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

Fig. 2

Phase 1 13 mm OPEN ENDED SPANNER Open the upper cover of the battery compartment (ref.A Fig.1).

Using the open ended spanner unscrew and remove the locking nuts and remove both battery fasteners located in the battery compartment (ref.B Fig.3).

Phase 2 HOIST - LIFT BELT - SPREADER BAR Hook the spreader bar to the hoist using the lift belt.

Attach the spreader bar to the battery, lift it with the tackle and position it over the battery compartment.

Make sure that the tackle is set at right-angles to the battery.

Lower the battery very carefully into the battery compartment (fig.2).

Fig. 3

B C

Phase 3 FIXED GAUGE 13 mm SPANNER Apply two battery retainers and, using the open ended spanner, screw on the lock nuts (ref.C Fig.3).

Phase 4 Connect the cables of the battery plug provided to the positive and negative poles of the battery.

Connect the battery plug (ref.D Fig.4) and lower the battery compartment cover.

Fig. 4

d

7

SERVICE

INSTALLATION AND SETTINGS WITH LATERAL REMOVAL Equipment and tools

Fig.1

hoist and lift belt load capacity 1000 kg

spreader bar

open ended spanner 30 mm

rollerway for lateral battery removal

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

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

Fig. 2

A Phase 1 Open the upper cover of the battery compartment (fig.1).

Raise the bracket locking the side door and turn it anticlockwise (ref.A fig.2).

Remove the side door (ref.B fig.3).

Raise and remove the handle retaining the battery (ref.C fig.3).

Phase 2 ROLLERWAY FOR SIDE BATTERY REMOVAL - HOIST - LIFT BELT SPREADER BAR - 30 mm OPEN ENDED SPANNER Position the rollerway for side battery removal next to the truck, by the opening to the battery compartment (fig.3).

Using the open ended spanner, loosen the lock nuts (ref.E fig.4) and adjust the height of the rollerway for side removal with the adjuster screws (ref.F fig.4).

Using the tackle and spreader bar, carefully position the battery on the rollerway (fig.5).

Unhook the spreader bar and push the battery into the battery compartment.

Phase 3 Put the battery retainer handle back into its seat (ref.C fig.3) and tighten the battery retainer plug (ref.D fig.3) to lock it.

Refit the side door and lock it by turning the locking bracket clockwise.

8

Fig. 3

D

C

B

Fig. 4

E

F

SERVICE

INSTALLATION AND SETTINGS

Phase 4 Connect the cables of the battery plug provided to the positive and negative poles of the battery. Connect the battery plug and lower the battery compartment cover.

Fig. 5

CONNECTION OF CABLES TO BATTERY The positive battery terminal is identified with the redmarking or the symbol + , while the negative pole is identified with bluemarking or the symbol .

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

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

_ +

BLUE tag Connection of the cable to the negative terminal RED tag Connect lead to positive terminal

BLUE negative terminal RED negative terminal

_

+

9

SERVICE

INSTALLATION AND SETTINGS

List of the SETTINGS AND ADJUSTMENTS to be carried out After assembling all the machine's components as described in the previous pages, the following operations must be carried out in the sequence given:

• Set the battery voltage • Check the conditions of use of the truck SETTING THE BATTERY VOLTAGE The battery charge indicator does not require any adjustments.

However, the preset value can be modified if necessary, i.e. if the fully charged or discharged indication on the battery display does not correspond to the actual status of the battery.

Equipment and tools

precision flat blade screwdriver

large flat head screw driver

Procedure Use the large flat head screwdriver to unscrew and remove the screws fastening the upper cover.

Remove the cover.

With the truck switched off, use the flat blade screwdriver to adjust the setting screw placed on the rear of the display (ref.A fig.2), increasing or diminishing the voltage value per cell (the voltage value beneath which the battery discharged indicator will be activated) in accordance with the following table: Setting

Volts/Battery cell discharged

K

1.57

L

1.63

M

1.68

N

1.73 (factory setting)

O

1.78

P

1.82

Q

1.84

R

1.86

S

1.89

T

1.91

U

1.93

Check and edit also the battery parameters (see "STANDARD CONFIGURATION OF MODULE PARAMETERS" section "ELECTRICAL SYSTEM").

10

Fig. 1

A

Fig. 2

SERVICE

INSTALLATION AND SETTINGS

CHECK THE CONDITIONS OF USE OF THE TRUCK In order to ensure the safety personnel and materials, before proceeding with the operations described below, it is important to assess the following:

• •

the type of load to be moved The general conditions of the warehouse, the aisles and the flooring

Having carried out these assessments, check whether the conditions encountered are compatible with the truck performance levels set: • • • •

maximum traction speed traction acceleration reduction of traction speed braking

If necessary, reduce truck performance by using the programmer to customise the truck configuration parameter (see "TRUCK FUNCTIONS" section "ELECTRICAL SYSTEM").

In order not to jeopardize the safety of the truck, the only way in which the truck configuration parameters may be modified is by reducing the factory-set values.

Parameter values that exceed the factory-set values are not permitted.

11

INSTALLATION AND SETTINGS

12

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

diagnostics and measurements DESCRIPTION OF MODULE CONNECTORS ����������������������������������������������������������������������������������������������������������� 2 COMBI MODULE �������������������������������������������������������������������������������������������������������������������������������������������������������� 2 MENU �������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 4 MONITOR menu �������������������������������������������������������������������������������������������������������������������������������������������������������� 4 faults menu ���������������������������������������������������������������������������������������������������������������������������������������������������������� 10 CONTROLLER INFORMATION MENU �������������������������������������������������������������������������������������������������������������������� 11 TROUBLESHOOTING: MODULE DIAGNOSIS SYSTEM ��������������������������������������������������������������������������������������� 12 ALARMS �������������������������������������������������������������������������������������������������������������������������������������������������������������������� 12 ELECTRICAL COMPONENT MEASUREMENTS ���������������������������������������������������������������������������������������������������� 24 SOLENOID VALVE COIL ������������������������������������������������������������������������������������������������������������������������������������������� 24 ELECTROMAGNETIC BRAKE COIL ������������������������������������������������������������������������������������������������������������������������ 24 MOTORS ������������������������������������������������������������������������������������������������������������������������������������������������������������������� 25

1

DIAGNOSTICS AND MEASUREMENTS

DESCRIPTION OF MODULE CONNECTORS COMBI MODULE

35 23 12

XA1-1 XA1-2 XA1-3 XA1-4 XA1-5 XA1-6 XA1-7 XA1-8 XA1-9 XA1-10 XA1-11

2

XA1

24 13 1

Key switch digital input (+24V) Digital output (+24V) for first auxiliary solenoid valve (forks) Lowering solenoid valve digital output (+24V) Hydraulic pump contactor coil digital output (+24V) Electromagnetic brake coil digital output (+24V) Main contactor coil digital output (+24V) Earth (GND) Traction motor temperature sensor analog input Tiller digital input (+24V) Digital input (+24V) for closed panels Digital input (+24V) mode

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

XA1-12 Digital input (+24V) for man on board XA1-13 Key switch digital output (+24V) XA1-14 Digital input (+24V) for raised platform XA1-15 Not used XA1-16 Steering sensor for speed reduction 1 XA1-17 Steering sensor for speed reduction 2 XA1-18 Not used XA1-19 Digital output (+24V) second auxiliary solenoid valve XA1-20 Horn relay digital output (+24V) XA1-21 CAN Term High XA1-22 Belly switch digital input (+24V) XA1-23 CAN High XA1-24 Redundant direction (wig wag 0-2.5-5V) XA1-25 Output (+12V) XA1-26 Output (+5V) XA1-27 Not used XA1-28 Serial line transmission XA1-29 Serial line reception XA1-30 Not used XA1-31 Encoder phase A XA1-32 Encoder phase B XA1-33 Digital input (+24V) for open panels XA1-34 CAN Term Low XA1-35 CAN Low

3

DIAGNOSTICS AND MEASUREMENTS

SERVICE

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

Certain of these menu parameters refer to functions whose status is received via Can bus, others refer to functions directly connected to the analog/digital inputs of the module. The following list shows the relative measurements: MONITOR menu MAIN MENU MONITOR  Throttle Inputs PARAMETER RAW CAN THROTTLE

measurement unit Number

Numeric status level of traction control butterfly rotation MAPPED CAN THROTTLE

%

Percentage status level of traction control butterfly rotation RAW REDUNDANT THROTTLE

Volts

Not used MAPPED REDUNDANT THROTTLE

%

Not used

MAIN MENU MONITOR  Tiller Switch Inputs PARAMETER NEUTRAL SWITCH

measurement unit ON/OFF

Traction control butterfly level: ON if in rest position EMER REV SWITCH

ON/OFF

Emergency reverse button selection SNAIL SWITCH

ON/OFF

"Snail" mode button selection HORN SWITCH

ON/OFF

Horn button selection FORK LIFT SWITCH

ON/OFF

Slow fork lifting button selection FORK LOWER SWITCH

ON/OFF

Slow fork lowering button selection MAST LIFT SWITCH Slow fork lifting button selection

4

ON/OFF

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER MAST LOWER SWITCH

measurement unit ON/OFF

Forks lowering button selection

MAIN MENU MONITOR  Maintenance Timers PARAMETER TOTAL HOURS LEFT

measurement unit h

Number of key-on operating hours remaining before servicing TRACTION HOURS LEFT

h

Number of traction hours remaining before servicing PUMP HOURS LEFT

h

Number of hydraulic pump operating hours remaining before servicing

MAIN MENU MONITOR  Inputs PARAMETER THROTTLE COMMAND

measurement unit %

Angular displacement of the traction control butterfly MAPPED THROTTLE

%

Angular displacement of the traction control butterfly evaluated after mapping THROTTLE POT Not used BRAKE COMMAND Not used MAPPED BRAKE Not used POT2 RAW Not used PD THROTTLE Not used INTERLOCK

ON/OFF

Tiller status level: ON during activation EMER REV

ON/OFF

Emergency direction reversal level: ON during direction reversal

5

DIAGNOSTICS AND MEASUREMENTS

PARAMETER

SERVICE measurement unit

ANALOG 1 Not used ANALOG 2

Volts

Thermal sensor voltage sensor measured on input A8 SWITCH 1 Not used SWITCH 2

ON/OFF

Not used SWITCH 3

ON/OFF

Status level of the tiller measured on input A9 SWITCH 4 Not used SWITCH 5 Not used SWITCH 6

ON/OFF

Battery discharge status level measured on input A12 SWITCH 7

ON/OFF

Belly switch status level measured on input A22 SWITCH 8 Not used DRIVER 1 INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver 1 PWM DRIVER 2 INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver 2 PWM DRIVER 3 INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver 3 PWM DRIVER 4 INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver 4 PWM PD INPUT

ON/OFF

See the parameter main menu monitor / Outputs / Driver PWM DIGOUT6 INPUT See the parameter main menu monitor / Outputs / Digital Out 6

6

ON/OFF

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER DIGOUT7 INPUT

measurement unit ON/OFF

See parameter main menu monitor / Outputs / Digital Out 7 SWITCH 16 Not used

MAIN MENU MONITOR  Outputs PARAMETER

measurement unit

ANALOG OUT Not used DIGITAL OUT 6

ON/OFF

Status level of the Q3 solenoid valve control signal on output A19 DIGITAL OUT 7

ON/OFF

Status level of the horn control signal on output A20 DRIVER 1 PWM

%

Percentage level of main contactor coil control on output A6 DRIVER 2 PWM

%

Percentage level of electromagnetic brake control on output A5 DRIVER 3 PWM

%

Percentage level of hydraulic pump contactor coil control on output A4 DRIVER 4 PWM

%

Percentage level of solenoid valve control on output A3 PD PWM

%

Percentage level of Q2 solenoid valve control on output A2 PD CURRENT

Amps

Current measured on output A2 5 VOLTS

Volts

Voltage measured on output A26 EXTERNAL SUPPLY CURRENT

mA

Current measured on outputs A25 - A26 POT LOW Not used BDI

%

Battery charge percentage level

7

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MAIN MENU MONITOR  Battery PARAMETER

measurement unit

CAPACITOR VOLTAGE

Volts

Voltage at internal capacitor bank, measured at terminal B+ of the controller KEYSWITCH VOLTAGE

Volts

Key switch voltage measured at input A1

MAIN MENU MONITOR  Motor PARAMETER MOTOR RPM

measurement unit RPM

Motor speed TEMPERATURE

°C

Motor temperature read by thermal sensor MOTOR SPEED A

RPM

Rpm of phase A of the motor encoder MOTOR SPEED B

RPM

Rpm of phase B of the motor encoder

MAIN MENU MONITOR  Controller PARAMETER CURRENT (RMS)

measurement unit Amps

Controller current draw MODULATION DEPTH

%

Voltage percentage applied to the motor FREQUENCY

Hz

Rotation frequency applied to the motor TEMPERATURE

°C

Controller internal temperature MAIN STATE Status of the main contactor

8

Number

0 = open 1 = precharge 2 = welding check 3 = closure delay 4 = missing check 5 = closed (with parameter Main Enable  ON) 6 = delay 7 = arc check 8 = opening delay 9 = error 10 = closed (with parameter Main Enable  OFF)

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER

measurement unit

REGEN

ON/OFF

ON during all phases of current regeneration VCL ERROR MODULE

Number

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

VCL ERROR

Number

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

MOTOR CHARACTERIZATION ERROR

Number

An error in the motor (code 87) will save information in the variable of this parameter: 0 = no error 1 = encoder detected but impossible to determine the encoder step size 2 = temperature sensor error 3 = high motor temperature cutback error 4 = controller over-temperature cutback error 5 = controller under-temperature cutback error 6 = undervoltage cutback error 7 = severe over-voltage error 8 = encoder signal not detected; one or both channels not found 9 = motor parameters out of range

MAIN MENU MONITOR  Controller  Cutbacks PARAMETER MOTOR TEMP CUTBACK

measurement unit %

Percentage of cutback during motor temperature reduction stage CONTROLLER TEMP CUTBACK

%

Percentage of cutback during controller temperature reduction stage UNDERVOLTAGE CUTBACK

%

Percentage of cutback during under-voltage reduction stage OVERVOLTAGE CUTBACK

%

Percentage of cutback during over-voltage reduction stage

MAIN MENU MONITOR  Controller  Motor Tuning PARAMETER BASE SPEED CAPTURED

measurement unit RPM

Highest speed reached by the motor during last stage of acceleration

9

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MAIN MENU MONITOR  Vehicle PARAMETER

measurement unit

VEHICLE SPEED

km/h

Speed of the truck VEHICLE ODOMETER

m

Distance travelled in forward drive VEHICLE ACCELERATION

g

Acceleration of the truck TIME TO SPEED 1

sec

Time required to reach 0 km/h from a speed value pre-defined in the software BRAKING DISTANCE CAPTURED

m

Distance travelled during all phases of the braking action DISTANCE SINCE STOP

m

Total distance travelled by the truck, calculated as the sum of distances travelled in both directions. This value is reset to zero each time the truck is stopped.

DISTANCE FINE

m

Net distance travelled by the truck calculated as the sum of the distances travelled in the direction the operator is facing (positive value) and in the opposite direction (negative value).

faults menu FAULTS MAIN MENU PARAMETER SYSTEM FAULTS List of current alarms on the truck FAULT HISTORY Log of all alarms previously detected on the truck CLEAR FAULT HISTORY Reset the alarms log.

10

SERVICE

DIAGNOSTICS AND MEASUREMENTS

CONTROLLER INFORMATION MENU CONTROLLER INFORMATION MAIN MENU PARAMETER MODEL NUMBER Controller model number PROTOCOL VERSION Protocol version SERIAL NUMBER Controller serial number MFG DATA CODE Date of manufacture of the controller The first two digits indicate the year, the last three digits indicate the day.

HARDWARE VERSION Hardware version OS VERSION Latest version of the operating system installed BUILD NUMBER First version of the operating system installed SM VERSION Version of the Start Manager installed on the controller PARAM BLK VERSION Version of the Parameter Block installed on the controller VCL APP VERSION Version of the programming language software installed

11

DIAGNOSTICS AND MEASUREMENTS

SERVICE

TROUBLESHOOTING: MODULE DIAGNOSIS SYSTEM The module is equipped with two LEDs (one red, one yellow) which, in the event of a fault, will flash the corresponding error code. The red LED flashes once to indicate that the system is about to signal first digit of the error code, then the yellow LED will emit the number of flashes corresponding to this first digit. The red LED now flashes twice to indicate that the system is about to signal second digit of the error code, then the yellow LED will emit the number of flashes corresponding to this second digit.

The two LEDs have four operating modes which are used to signal different type of information.

RED LED

YELLOW LED

STATUS

Off

Off

The controller is switched off or the truck battery is completely discharged.

Off

Flashing

On

On

The controller is in Flash Program mode.

On

Off

Watchdog error or software not installed.

Turn off and restart the truck or install the software.

Flashing

Flashing

The controller has detected an error. The two digit code is signalled by the flashing of the two LEDs in a cyclical sequence.

The controller is in operation.

ALARMS ALARM

troubleshooting

12 - “Controller Overcurrent” Possible causes: - External shortcircuit on connections of phases U, V or W to the motor - Motor parameters incorrect - Controller fault - Encoder problem

• • • •

Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

Turn off and restart the truck.

Check the wiring and for a short-circuit or low impedance on the phases U, V and W. Check the motor parameters are correct.

If no fault is found in the wiring or the parameters but the alarm persists, then the problem lies in the module.

13 - “Current Sensor Fault” Possible causes: - Dispersion of current from phases U, V or W to the truck • chassis (short circuit of motor stator) • - Controller fault • Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

12

Turn off and restart the truck.

Check motor insulation If no fault is found and the alarm persists, then the problem lies in the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

14 - “Precharge failed” Possible causes: • - External load on capacitor bank (connected to B+) pre• venting capacitors from charging Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

•

Release all the tiller controls.

Check value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage.

If no fault is found and the alarm persists, then the problem lies in the module.

15 - “Controller Severe Undertemp” • Possible causes: - The controller is operating in too low temperature condi• tions (below -40°C) Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

•

Check the value of the parameter MAIN MENU MONITOR / Controller / Temperature Bring the temperature to above the lower limit of -40°C, release all tiller controls, turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

16 - “Controller Severe Overtemp” Possible causes: • - The controller is operating in too high temperature conditions (above 95°C) • - Truck overloaded - Controller incorrectly installed • Effects: • - Main contactor open - All truck functions disabled - Electromagnetic brake activated

17 - “Severe Undervoltage” Possible causes: - Incorrect battery parameters - Battery resistance too high - Battery disconnected during truck operation - Loss of capacitor charge to below critical limit - Fuse on positive feed to key switch disconnected or blown - The main contactor did not close Effects: - Drive reduced

• • • • • • •

Check the value of the parameter MAIN MENU MONITOR / Controller / Temperature Return the temperature to below the maximum limit of 95°C, release all the tiller controls, remove all loads from the truck, turn off and restart the truck.

Check that the module is installed correctly.

If no fault is found and the alarm persists, then the problem lies in the module.

Check value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage.

Return the capacitor voltage to above the minimum critical value.

Check the battery parameters.

Check the battery wiring.

Check the fuses Check the status of the main contactor.

If no fault is found and the alarm persists, then the problem lies in the module.

13

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

18 - “Severe Overvoltage” Possible causes: • - Incorrect battery parameters - Battery resistance too high to supply regenerative cur• rent - Battery disconnected during regenerative braking • - Voltage at capacitors above critical limit • Effects: • - Main contactor open - All truck functions disabled - Electromagnetic brake activated

21 - “Controller Undertemp Cutback”

•

Possible causes: • - The controller is operating in low temperature conditions (below -30°C) Effects: - Reduced performance

•

22 - “Controller Overtemp Cutback”

• Possible causes: - The controller is operating in high temperature conditions • (above 85°C) - Truck overloaded - Controller incorrectly installed • Effects: • - Drive reduced - Braking effect reduced

Check value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage.

Return the capacitor voltage to below the maximum permitted value. Turn off and restart the truck.

Check the battery parameters.

Check the battery wiring.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Controller / Temperature Bring the temperature to above the lower limit of value -30°C, release all tiller controls, turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Controller / Temperature Return the temperature to below the maximum limit of 85°C, release all the tiller controls, remove all loads from the truck, switch off the truck, wait a few minutes, then switch it on again.

Check that the module is installed correctly.

If no fault is found and the alarm persists, then the problem lies in the module.

23 - “Undervoltage Cutback” Possible causes: - The battery is discharged and the controller has reduced truck performance.

- Incorrect battery parameters - Battery resistance too high - Battery disconnected during truck operation - Fuse on positive feed to key switch disconnected or blown - The main contactor did not close - Excessive loss of capacitor charge Effects: - Reduced drive

14

• • • • • • •

Check value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage.

Return the capacitor voltage to above the minimum permitted value.

Check the battery parameters.

Check the battery wiring.

Check the fuses Check the status of the main contactor.

If no fault is found and the alarm persists, then the problem lies in the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

24 - “Overvoltage Cutback” Possible causes: - Voltage at battery too high during regenerative braking - Incorrect battery parameters - Battery resistance too high to supply regenerative current - Battery disconnected during regenerative braking - Voltage at capacitors above maximum limit

• • • • •

Effects: - Braking action reduced

25 - “+5V Supply Failure”

• Possible causes: - The external charge impedance on the +5V output (pin • 26) is too low (outside range ±10%) • Effects: - None

Check value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage.

Return the capacitor voltage to below the maximum permitted limit. Turn off and restart the truck.

Check the battery parameters.

Check the battery wiring.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Outputs / 5 Volts Return the voltage on pin 26 to within the permitted range. Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

26 - “Digital Out 6 Overcurrent” Possible causes: • - The external charge impedance on Digital Output 6 (pin • 19) is too low (the current exceeds 15 mA) Effects: - The Digital Out 6 driver is not activated

Find the cause of the overcurrent.

If no fault is found and the alarm persists, then the problem lies in the module.

27 - “Digital Out 7 Overcurrent” Possible causes: • -The external charge impedance on the horn relay (pin 20) • is too low (the current exceeds the limit by 15 mA) Effects: - The Digital Out 7 driver is not activated

Find the cause of the overcurrent.

If no fault is found and the alarm persists, then the problem lies in the module.

28 - “Motor Temp Hot Cutback” Possible causes: - The temperature of the motor has reached or exceeded the limit value set in the parameter MAIN MENU PROGRAM / Motor / Temperature Control / Temperature Hot - Motor temperature parameters incorrect Effects: - Reduced drive

• • • •

Check values of the parameters MAIN MENU MONITOR / Motor / Temperature and Inputs / Analog2 Check the motor parameters.

Return the motor temperature to within the permitted limits.

If no fault is found and the alarm persists, then the problem lies in the module.

15

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

29 - “Motor Temp Sensor Fault”

• Possible causes: - The motor thermistor is not connected correctly or is • faulty.

- The analog input of the temperature sensor (pin 8) is • 0V or 10V Effects: - Reduced maximum speed - Motor temperature cutback disabled

SERVICE

•

Check values of the parameters MAIN MENU MONITOR / Motor / Temperature and Inputs / Analog2 Check the status of the temperature sensor thermistor.

Bring the thermistor voltage back to within the limits.

If no fault is found and the alarm persists, then the problem lies in the module.

31 - “Coil 1 Driver Open/Short” Possible causes: • - Driver of the main contactor coil open or short circuit (pin 6) • - Connector dirty • - Wiring damaged Effects: - Main contactor driver stopped

Check wiring of the main contactor, clean the connectors and check that the fastons are firmly connected.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

32 - “EM Brake Driver Open/Short” Possible causes: - Driver of the electromagnetic brake coil open or short • circuit (pin 5) • - Connector dirty • - Wiring damaged Effects: - Truck stops - Electromagnetic brake activated

Check the brake wiring, clean the contacts.

Switch the truck off and then back on.

If no fault is found and the alarm persists, then the problem lies in the module.

33 - “Coil 3 Driver Open/Short” Possible causes: • - Driver of the hydraulic pump coil open or short circuit (pin 4) • - Connector dirty • - Wiring damaged Effects: - Hydraulic pump contactor driver stopped

Check the wiring of the hydraulic pump contactor; clean the contacts.

Switch the truck off and then back on.

If no fault is found and the alarm persists, then the problem lies in the module.

34 - “Coil 4 Driver Open/Short” Possible causes: - Driver of solenoid valve Q1 open or short circuit (pin 3) - Connector dirty - Wiring damaged Effects: - Solenoid valve driver stopped

16

• • •

Check the solenoid valve wiring, clean the connectors Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

35 - “PD Open/Short” Possible causes: - Auxiliary function driver open or short circuit (pin 2) - Connector dirty - Wiring damaged

• • •

Check the wiring, clean the connectors Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

•

Check the value of the parameter MAIN MENU MONITOR / Motor / Motor RPM Check the motor wiring, clean the connectors.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

Effects: - Auxiliary function driver stopped

36 - “Encoder Fault” Possible causes: - Motor encoder phase error - Wiring damaged Effects: - Electromagnetic brake activated

• • •

37 - “Motor Open” Possible causes: - One the motor phases is open - Wiring damaged Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

• • • •

Check the wiring on phases U, V and W. Check continuity of the motor phases.

Switch the truck off and then back on.

If no fault is found and the alarm persists, then the problem lies in the module.

38 - “Main Contactor Welded” Possible causes: - Main contactor contacts soldered • - Phase U or V disconnected or open • - Just before closing the main contactor, the capacitor bank (connected to B+) is charged for a brief period but is not discharged • • Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

Check the wiring on phases U and V. Check the power wiring of the main contactor, clean the connectors and check that the fastons are firmly connected.

Switch the truck off and then back on.

If no fault is found and the alarm persists, then the problem lies in the module.

17

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

39 - “Main Contactor Did Not Close” Possible causes: - The main contactor did not close - The contacts of the main contactor are oxidised or burned or disconnected - External load on the capacitor bank (connected to B+) preventing capacitors from charging - Fuse on positive feed to keyswitch disconnected or blown Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

•

• • • •

41 - “Throttle Wiper High”

• Possible causes: - Voltage on steering sensor for speed reduction 1 (pin • 16) too high • Effects: - Butterfly drive control deactivated

42 - “Throttle Wiper Low”

• Possible causes: - Voltage on steering sensor for speed reduction 1 (pin • 16) too low • Effects: - Butterfly drive control deactivated

43 - “Brake Wiper High”

• Possible causes: - Voltage on steering sensor for speed reduction 2 (pin • 17) too high • Effects: - Electromagnetic brake activated

44 - “Brake Wiper Low”

• Possible causes: - Voltage on steering sensor for speed reduction 2 (pin • 17) too low • Effects: - Electromagnetic brake activated

18

Check the power wiring of the main contactor, clean the connectors and check that the fastons are firmly connected.

Check value of the parameter MAIN MENU MONITOR / Battery / Capacitor Voltage.

Check the fuses Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Inputs / Throttle Pot Check the voltage on the sensor and set to below the error threshold.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Inputs / Throttle Pot Check the voltage on the sensor and set to above the error threshold.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Inputs / Pot2 Raw Check the voltage on the sensor and set to below the error threshold.

If no fault is found and the alarm persists, then the problem lies in the module.

Check the value of the parameter MAIN MENU MONITOR / Inputs / Pot2 Raw Check the voltage on the sensor and set to above the error threshold.

If no fault is found and the alarm persists, then the problem lies in the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

45 - “Pot Low Overcurrent” Possible causes: - Voltage on pin 18 (not used) too high

•

This kind of failure is not connected to external components. When it appears persistently the module must be replaced.

• Possible causes: - Error writing to the Eeprom caused by programming language or the Can Bus or by incorrect parameter editing • with the console or installation of new software.

If this error occurs after editing parameters or installing new software, restore conditions existing prior to the error.

Download and install the correct software; use the standard parameter configuration.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

Effects: - Butterfly drive deactivated - Electromagnetic brake activated

46 - “EEPROM Failure”

Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

• •

47 - “HPD/Sequencing Fault”

• •

Possible causes: Incorrect start up sequence - Wiring or connectors or pushbuttons damaged Effects: - Butterfly drive control deactivated

• •

Follow the correct start up sequence Check the tiller wiring and the electrical panel wiring Check condition of pushbutton connectors, clean if necessary.

If no fault is found and the alarm persists, then the problem lies in the module.

47 - “Emer Rev HPD” • Possible causes: - After an emergency reversing manoeuvre, some of the • inputs may not have returned to neutral position.

• • Effects: - Butterfly drive deactivated - Electromagnetic brake activated

Release all the tiller controls.

Check that the belly button is released.

Switch the truck off and then back on.

If no fault is found and the alarm persists, then the problem lies in the module.

49 - “Parameter Change Fault” Possible causes: - The truck was not turned off and restarted after editing • one or more parameters • Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

19

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

51 - “CAN Startup Failure” Possible causes: - Communication with tiller failed - Short or open circuit on pins 35-23 Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

• • •

Check that there no faults on the line.

Check the wiring.

Check that the connectors are clean.

• • •

Check that there no faults on the line.

Check the wiring.

Check that the connectors are clean.

• • • •

Release all the tiller controls.

Check that the belly button is released.

Switch the truck off and then back on.

If no fault is found and the alarm persists, then the problem lies in the module.

• •

Release all the tiller controls.

Follow the correct startup sequence.

•

Check values of the parameters MAIN MENU MONITOR / Controller / VCL Error Module and VCL Error. This error can be compared with “VCL module ID” and the definition of the error code that can be found in the “information file” of the operating system.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

52 - “CAN PDO Timeout” Possible causes: - Failure to receive message via CAN within 50 ms - Short or open circuit on pins 35-23 Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

61 - “BB Sequence Fault” Possible causes: - Belly button activation request with tiller at rest - Short or open circuit on pin 22 Effects: - All truck functions disabled - Electromagnetic brake activated

62 - “Interlock SRO” Possible causes: - Startup with tiller in operating position - Short to power on pin 9 Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

68 - “VCL Runtime Error” Possible causes: - Error in the programming language code Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

20

• •

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

69 - “External Supply Out Of Range”

• Possible causes: - External supply current on 5V (pin 26) and 12V (pin 25) • outputs too high or too low • Effects: - None

Check value of the parameter MAIN MENU MONITOR / Outputs / External Supply Current Bring the external supply current to within the limits.

If no fault is found and the alarm persists, then the problem lies in the module.

71 - “OS General” Possible causes: - Controller internal fault Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

• •

Turn off and restart the truck.

If the alarm persists, replace the module.

• •

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

•

Identify valid signals at the encoder and check that the parameters MAIN MENU MONITOR / Motor / Motor RPM and Inputs / Throttle Command return to 0.

Check the general mechanical condition.

Check that the electromagnetic brake is released when energised.

Turn off and restart the truck.

If no fault is found and the alarm persists, then the problem lies in the module.

72 - “PDO Timeout” Possible causes: - Delay in reception of CAN PDO message Effects: - Tiller deactivated

73 - “Stall Detected” Possible causes: - Motor stalled - Motor encoder fault - Wiring damaged - Problems with the power supply to the motor encoder Effects: - Electromagnetic brake activated

87 - “Motor Characterization Fault” Possible causes: - Motor characterization process failed Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

• • • •

• • • • •

Identify fault from the parameter MAIN MENU MONITOR / Controller / Motor Characterization Error Switch the truck off and then back on.

Check the condition of the motor.

Check that the motor is in good condition.

If no fault is found and the alarm persists, then the problem lies in the module.

88 - “Encoder Characterization Fault” Possible causes: - Encoder characterization process failed Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

• •

Switch the truck off and then back on.

If no fault is found and the alarm persists, then the problem lies in the module.

21

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

troubleshooting

89 - “Motor Type Fault” Possible causes: - The Motor_type parameter is out of range

• •

Turn off and restart the truck.

If no fault is found and the alarm persists, the problem lies in the motor.

• Possible causes: - The electromagnetic brake is unable to block rotation of the motor so the truck continues to move • Effects: - Butterfly drive deactivated

This alarm is displayed for few seconds then disappears. If it is present in the Fault History, check the efficiency of the brake.

Turn the butterfly drive control a few times to restore brake operation.

Effects: - Main contactor open - All truck functions disabled - Electromagnetic brake activated

92 - “EM Brake Failed To Set”

93 - “LOS (Limited Operating Strategy)” Possible causes: - The LOS has been activated due to an error (code 36 or 73) • - Vehicle stalled • - Motor encoder fault - Wiring damaged

Turn off and restart the truck.

Follow the troubleshooting guide for the faults Stall Detected or Encoder Fault

Effects: - LOS mode activated

94 - “Emer Rev Timeout” Possible causes: - Emergency reverse time has elapsed and the emergency • reverse input remains ser to ON Effects: - Butterfly drive deactivated - Electromagnetic brake activated

Check the condition of the belly button and the internal microswitch.

x - “Side Sensor Fault” • Possible causes: - Conflict between the open and closed side panel signals. • Both sensors are on • Effects: • - All truck functions disabled - Electromagnetic brake activated

22

Release all tiller and hydraulic controls Check the open and closed side panel sensor wire harness assembly Check that the sensors are not covered in dirt Check signals on pins 10 and 33

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

troubleshooting

x - “Side Gate Uncorrect Position” Possible causes: • - Conflict between the open and closed side panel signals.

• Both sensors are off •

Release all tiller and hydraulic controls Check the open and closed side panel sensor wire harness assembly Check signals on pins 10 and 33

• Possible causes: - Conflict between the closed platform and man on board • signals. Both sensors are on • Effects: • - All truck functions disabled

Release all tiller and hydraulic controls Check the closed platform and man on board sensor wire harness assembly Check that the sensors are not covered in dirt Check signals on pins 12 and 14

Effects: - All truck functions disabled - Electromagnetic brake activated

x - “Platform Sensor Fault”

- Electromagnetic brake activated

x - “Platform Uncorrect Position” Possible causes: • - Conflict between the closed platform and man on board • signals. Both sensors are off Effects: - All truck functions disabled - Electromagnetic brake activated

•

Release all tiller and hydraulic controls Check the closed platform and man on board sensor wire harness assembly Check signals on pins 12 and 14

23

DIAGNOSTICS AND MEASUREMENTS

ELECTRICAL COMPONENT MEASUREMENTS SOLENOID VALVE COIL

Q1

ELECTROMAGNETIC BRAKE COIL

Drive wheel electromagnetic brake

24

SERVICE

SERVICE

DIAGNOSTICS AND MEASUREMENTS

MOTORS To measure the motor insulation resistance, disconnect the phase wires (U, V, W). Connect one of the tester probes to the U phase and the other probe to the bodywork. The resistance reading (Ω) on the tester should be infinity ( ). If not. the motor is not insulated and the module connected to the motor in question will diagnose the alarm "capacitor charge".

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

25

DIAGNOSTICS AND MEASUREMENTS

26

SERVICE

SERVICE

ELECTRICAL SYSTEM

electrical system ELECTRICAL WIRING DIAGRAMS �������������������������������������������������������������������������������������������������������������������������� 4 ELECTRICAL COMPONENTS ����������������������������������������������������������������������������������������������������������������������������������� 6 KEY TO ELECTRICAL COMPONENTS ���������������������������������������������������������������������������������������������������������������������� 6 TILLER BOARD ���������������������������������������������������������������������������������������������������������������������������������������������������������� 8 CONTROLS ������������������������������������������������������������������������������������������������������������������������������������������������������������ 10 KEY TO TILLER CONTROLS AND MAIN PANEL ����������������������������������������������������������������������������������������������������� 10 DISPLAY (battery charge level indicator) ���������������������������������������������������������������������������������������������� 12 BATTERY CHARGE LEVEL INDICATOR ����������������������������������������������������������������������������������������������������������������� 13 HOUR METER ���������������������������������������������������������������������������������������������������������������������������������������������������������� 13 MDI (OPTIONAL) ������������������������������������������������������������������������������������������������������������������������������������������������������ 14 BATTERY CHARGE LEVEL INDICATOR ����������������������������������������������������������������������������������������������������������������� 15 MAINTENANCE AND WARNINGS INDICATOR ����������������������������������������������������������������������������������������������������� 15 TRUCK FUNCTIONS ������������������������������������������������������������������������������������������������������������������������������������������������ 16 TRACTION ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 16 STEERING ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 22 FORK LIFTING/LOWERING ������������������������������������������������������������������������������������������������������������������������������������� 23 STANDARD CONFIGURATION OF MODULE PARAMETERS ������������������������������������������������������������������������������� 25 “TRACTION” MODULE ��������������������������������������������������������������������������������������������������������������������������������������������� 25 DESCRIPTION OF MODULE PARAMETERS ��������������������������������������������������������������������������������������������������������� 27 “TRACTION” MODULE ��������������������������������������������������������������������������������������������������������������������������������������������� 27 MODULE: INTRODUCTION ������������������������������������������������������������������������������������������������������������������������������������� 32 POSITIONING OF THE "PC TOOL" CONNECTOR ������������������������������������������������������������������������������������������������� 32 “TRACTION” MODULE ��������������������������������������������������������������������������������������������������������������������������������������������� 33 REPLACEMENT OF MODULES: INSTRUCTIONS ������������������������������������������������������������������������������������������������� 34 REPLACEMENT OF “TRACTION” AND "EPS" MODULES �������������������������������������������������������������������������������������� 34 REMOVAL OF ELECTRICAL COMPONENTS �������������������������������������������������������������������������������������������������������� 36 REPLACEMENT OF THE GENERAL EMERGENCY SWITCH �������������������������������������������������������������������������������� 36 REPLACEMENT OF THE DISPLAY �������������������������������������������������������������������������������������������������������������������������� 37 REPLACEMENT OF THE KEY SWITCH ������������������������������������������������������������������������������������������������������������������ 38 REPLACEMENT OF THE HORN ������������������������������������������������������������������������������������������������������������������������������ 39 REPLACING the raised platform sensor and man presence sensor �������������������������������������������� 40 ADJUSTMENT OF THE MAN PRESENCE SENSOR ���������������������������������������������������������������������������������������������� 41 PANEL SENSORS REPLACEMENT ������������������������������������������������������������������������������������������������������������������������� 42 1

ELECTRICAL SYSTEM

SERVICE

TILLER BOARD REPLACEMENT ����������������������������������������������������������������������������������������������������������������������������� 43 REPLACEMENT OF TILLER BUTTONS ������������������������������������������������������������������������������������������������������������������ 44 REPLACEMENT OF THE TILLER CONTROL SPRINGS ����������������������������������������������������������������������������������������� 45 REPLACEMENT OF THE TILLER ENABLES SENSOR ������������������������������������������������������������������������������������������ 47 REPLACEMENT of steering sensor �������������������������������������������������������������������������������������������������������������� 48

2

SERVICE

ELECTRICAL SYSTEM

3

SERVICE

ELECTRICAL SYSTEM

ELECTRICAL WIRING DIAGRAMS COMPONENTS Ref.

4

Description

Ref.

Description

A1

Type of drive control

M

Complete traction motor

A2

Tiller controller

M1

Traction motor

A3

Battery charge level indicator

M2

Pump motor

A4

Key Pad (optional)

P1

Horn

A5

MDI display (optional)

P2

Reversing buzzer (optional)

A6

Internal circuit charger T1 (optional)

P3

Battery charge phase indicator LED

B1

Encoder

Q1

Lowering solenoid valve

B2

Heat sensor

R1

Varistor

B4

Tiller sensor

R2

Electromagnetic brake

B5

Closed side panel sensor

R3

Varistor

B6

Open side panel sensor

S1

Emergency button

B7

Speed reduction sensor

S2

Keyswitch

B8

Raised platform sensor

S5

On-off lifting button

B9

Man presence sensor

S6

On-off lowering button

B13

Bimetallic thermostat (optional)

S7

On-off lifting button

C1

Battery 24V

S8

On-off lowering button

C2

Electrolyte condenser

S9

Horn button

F1

Power fuse 150 A

S10

Emergency reversing button (belly)

F2

Power fuse 100 A

S11

Low gear button (snail)

F3

Fuse 5 A

T1

Charger (optional)

F4

Fuse 3 A

F5

Fuse 1 A

F7

Fuse 5 A (optional)

G1

Fan (optional)

K1

Traction contactor coil

K2

Pump contactor coil

K3

Horn relay coil

K4

Recycling diode

K5

Reversing buzzer relay (optional)

K6

Fan relay (optional)

ELECTRICAL SYSTEM

(1) mmq equals mm2

NOTES

SERVICE

4a

SERVICE

ELECTRICAL SYSTEM

4b

SERVICE

ELECTRICAL SYSTEM

4c

SERVICE

ELECTRICAL SYSTEM

NOTES (2) As reference us the colour X of the individual wire (or the number printed on it, if the wire is black)

4d

SERVICE

ELECTRICAL SYSTEM application diagram - key pad (optional)

application diagram - REVERSE BUZZER (optional)

NOTES (2) As reference us the colour X of the individual wire (or the number printed on it, if the wire is black)

application diagram - mdi (optional)

application diagram - platform only (optional)

4e

SERVICE

ELECTRICAL SYSTEM

application diagram - FAN (optional)

application diagram - ON BOARD CHARGER (optional)

NOTES (2) As reference us the colour X of the individual wire (or the number printed on it, if the wire is black)

4f

SERVICE

ELECTRICAL SYSTEM

5

ELECTRICAL SYSTEM

SERVICE

ELECTRICAL COMPONENTS KEY TO ELECTRICAL COMPONENTS

Ref.

6

Description

Ref. wiring diagram

1

Traction motor

M1

2

Pump motor

M2

3

Tiller board

A2

4

Emergency button

S1

5

Keyswitch

S2

6

3-way connector for PC connection

X30

7

Thermostat (optional)

B13

8

Speed reduction sensor

B7

9

Man on the machine sensor

B9

10

Raised platform sensor

B8

11

Horn relay

K3

12

Power fuse 150 A

F1

13

Power fuse 100 A

F2

14

Fuse 5 A

F3

15

Fuse 3 A

F4

16

Fuse 1 A

F5

18

acoustic buzzer

P1

19

Type of drive control

A1

20

Main contactor

K1

21

Pump contactor

K2

22

Closed side panel sensor

B5

23

Open side panel sensor

B6

24

Fan fuse 5 A (optional)

F7

25

Fan (optional)

G1

26

Fan relay (optional)

K6

27

Tiller sensor

B4

28

Reversing buzzer relay (optional)

K5

29

Reversing buzzer (optional)

P2

SERVICE

ELECTRICAL SYSTEM

27 3

14

21

20

28

15 16

13 12

23

29 24

22

7 19 25

11

26

18 4 2 1

8

9

5 6 10

6a

SERVICE

ELECTRICAL SYSTEM

7

ELECTRICAL SYSTEM

SERVICE

TILLER BOARD

Ref.

8

Description

Ref. wiring diagram

1

Rapid reverse microswitch (belly)

S10

2

Low gear enabling microswitch (snail)

S11

3

Horn enabling microswitch

S9

4

Can Bus and tiller control cable connector

X1

5

Tiller sensor connector

X9

6

Connector not used

X8

7

Lifting button connector

X3

8

Lowering button connector

X4

9

Lifting button connector

X2

10

Lowering button connector

X5

11

Connector not used

X6

12

Connector not used

X7

13

Connector not used

X11

14

Connector not used

X12

SERVICE

ELECTRICAL SYSTEM

1

2

14 3

13 12 11 10 9 8 7 6

5

4

9

SERVICE

ELECTRICAL SYSTEM

CONTROLS KEY TO TILLER CONTROLS AND MAIN PANEL

4

5

6

2 1

8

10

3

7

SERVICE

ELECTRICAL SYSTEM

9

10

Ref.

Description

Ref. wiring diagram

1

Rapid reverse button

S10

2

Horn button

S9

3

Forward/reverse traction control butterfly

4

Lowering push button

S8

5

Lifting push button

S7

6

Lifting push button

S5

7

Lowering push button

S6

8

Slow progress enabling button with tiller in rest position

S11

9

Emergency button

S1

10

Keyswitch

S2

11

ELECTRICAL SYSTEM

DISPLAY (battery charge level indicator)

1

2

Ref.

12

Description

1

Battery charge level indicator

2

Total operating hours indicator

SERVICE

SERVICE

ELECTRICAL SYSTEM

BATTERY CHARGE LEVEL INDICATOR The battery charge level is indicated on display with 10 bars, each of which corresponds to 10%.

When the charge level falls 30% the third bar starts to flash.

When the charge level falls to 20%, the first two bars start to flash and lifting of the forks and the platform is inhibited, while speed is reduced.

To reset the low battery charge indicator recharge the battery. When the recharge reaches 100%% the low battery charge indicator is reset, and the fork lift system is restored.

If a battery is installed in the truck that is not provided by the factory, in order for the battery charge indicator to work correctly the "BATTERY VOLTAGE SETTING" procedure performed on installation must be performed following the values provided by the manufacturer (see “INSTALLATION AND SETTINGS” section).

HOUR METER When any function is active (traction, fork/platform lift/lowering) the hourglass symbol flashes, indicating that the battery level indicator is recording the operating hours.

If the battery charge level indicator is replaced the truck operating hours will be lost (the new indicator will start from 0 hours).

13

ELECTRICAL SYSTEM

SERVICE

MDI (OPTIONAL)

1

2

3

4

Ref.

Description

1

Total operating hours and alarms indicator

2

Green LED - hour meter ON

3

Yellow LED - battery low

4

Red LED - alarm and maintenance warning

On starting the truck (key-on) the MDI performs a number of tests, and each element will illuminate for one second. On completion of the tests, the display will show the total truck operating hours for a few seconds, followed by the battery charge status. The green operating LED will illuminate.

14

SERVICE

ELECTRICAL SYSTEM

When the tiller is lowered or a traction command is given, the total number of traction hours are displayed for a few seconds.

When a lifting or lowering command is given, the total operating hours of the truck pump appear on the display for a few seconds.

BATTERY CHARGE LEVEL INDICATOR The battery charge status is indicated on the display.

When the battery charge state reaches 20% clamp lifting is inhibited.

The "battery low" indicator LED illuminates.

To reset the "battery low" indicator recharge the battery. When the recharge reaches 75% the low battery charge indicator is reset, and the clamp lift system is restored.

MAINTENANCE AND WARNINGS INDICATOR The MDI provides an indication of the truck's warning status. When a warning is generated, the red LED starts blinking.

The display shows the error code that generated the warning identified by a number (see “DIAGNOSTICS” section).

On reaching the number of hours of operation after which maintenance is required, the red LED lights up. After carrying out the necessary maintenance, reset the parameters TRACTION / menu program / display functions / reset total maintenance - reset traction maintenance - reset pump maintenance (see “DESCRIPTION OF MODULE PARAMETERS”).

15

SERVICE

ELECTRICAL SYSTEM

TRUCK FUNCTIONS TRACTION CONTROLS

Forward travel (operator side)

Reverse travel (clamp side)

Devices involved

status

Symbol on diagram

Keyswitch

ON

S2

Emergency switch

ON

S1

Tiller tilt sensor

ON*

B4

Open side panel sensor

ON

OFF

B6

Closed side panel sensor

OFF

ON

B5

Raised platform sensor

OFF

ON

B8

Man presence sensor

ON

OFF

B14

Forward/reverse traction control butterfly

* OFF when the button (S11) "snail" is pressed

16

forward/reverse rotation

SERVICE

ELECTRICAL SYSTEM

CONFIGURATION PARAMETERS menu program TRACTION

snail speed speed reduction 1 speed reduction 2 speed reduction 3 speed reduction 4 right deadband left deadband

max accel max decel neutral braking max braking temperature hot temperature max

For the adjustment values of each individual parameter, see the paragraph "standard configuration of module parameters".

For a description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".

SPEED AND ACCELERATION The acceleration cannot be modified, while the maximum traction speed can be set with the programmer.

Maximum speed setting TRACTION / menu program / traction / speed reduction / max speed

SPEED REDUCTION There are four levels of speed reduction available on the machine:

• speed reduction 0 no traction speed reduction (value between 0% and 100% of the maximum speed).

On with side panels open, platform lowered and man on board.

• speed reduction 1 medium traction speed reduction (value between 0% and 70% of the maximum speed). On with side panels closed, platform lowered and man on board.

• speed reduction 2 maximum traction speed reduction (value between 0% and 47% of the maximum speed). On with side panels closed and platform raised.

• speed reduction 3 medium traction speed reduction (value between 0% and 75% of the maximum speed). On with steering angle > 15°.

Setting of the speed reduction levels TRACTION / menu program / traction / speed reduction / speed reduction 0 TRACTION / menu program / traction / speed reduction / speed reduction 1 TRACTION / menu program / traction / speed reduction / speed reduction 2 TRACTION / menu program / traction / speed reduction / speed reduction 3 The maximum traction speed is obtained with the platform lowered (sensor B8 ► OFF), man on machine (sensor B14 ► ON) and side panels open (sensors B6 ► ON, B5 ► OFF).

The minimum traction speed is obtained with the platform raised (sensors B8 ► ON, B14 ► OFF) and side panels closed (sensors B6 ► OFF, B5 ► ON).

If both side panel sensors are OFF (one panel open and one closed or both panels semiopen), there is a controlled truck stop.

17

SERVICE

ELECTRICAL SYSTEM speed reduction with traction wheel steered

This function reduces the maximum traction speed on exceeding a steering angle of 15°.

Above the steering angle the speed is reduced as set with the parameter "speed reduction 3".

With the tiller straight we have maximum speed.

With a steering angle of greater than 15° the speed is reduced as set with the parameter "speed reduction 3".

SPEED REDUCTION TABLE Sensor Reduction maximum speed speed reduction 0 speed reduction 1 speed reduction 2 speed reduction 3

18

Side panels open

Side panels closed

Platform raised

● ● ● ●

With the operator on the truck

Drive wheel > 15°

● ● ● ● ■

SERVICE

ELECTRICAL SYSTEM

SPEED REDUCTION AND TRACTION LOCKOUT AT HIGH TEMPERATURES If the traction motor temperature reaches 115°C the current supplied to the motor is limited, leading to a reduction in the truck speed. If the motor temperature reaches 140°C, the motor lockout is tripped. The temperature threshold values can be set via the programmer.

Setting the temperature threshold for motor speed reduction TRACTION / menu program / motor / temperature control / temperature hot Setting the temperature threshold for motor lockout TRACTION / menu program / motor / temperature control / temperature max

19

ELECTRICAL SYSTEM

SERVICE

BRAKING The truck is equipped with four braking systems:

• • • •

Release braking.

Braking on direction reversal.

Emergency braking.

Parking brake

Truck braking will be performed in different ways according to which of the above systems is implemented. For further information on the braking systems see "BRAKING SYSTEMS" “BRAKING SYSTEM” section.

BRAKING SYSTEMS

WHEN APPLIED

Release braking

Release of the butterfly traction control

Braking on direction reversal

Inversion of the direction of travel using the butterfly control Through operation of the emergency braking button

Emergency braking

Parking brake

An alarm has been generated that requires traction to be halted immediately.

The machine is stationary and no traction control is activated

With the programmer it is possible to set the deceleration ramps for release braking, emergency braking and direction reversal braking.

Setting the deceleration ramp for release braking TRACTION / menu program / traction / performance setup / neutral braking Setting the deceleration ramp for emergency braking TRACTION / menu program / traction / performance setup / max braking Setting the deceleration ramp for direction reversal braking TRACTION / menu program / traction / performance setup / max decel

EMERGENCY REVERSE MANOEUVRE The emergency reverse manoeuvre is a safety function that is applied in the event that the operator, when driving forwards (direction of the traction wheel), hits an object.

In this event, pressing the button (S10) causes the truck to immediately reverse, thereby preventing the operator from being crushed.

The emergency reverse procedure is activated with the truck in forward drive, will the tiller in driving position (tiller sensor B4 active) and the "BELLY SWITCH" button pressed.

20

emergency reverse function activation button

SERVICE

ELECTRICAL SYSTEM

SNAIL FUNCTION The "snail" function enables traction and fork and clamp lifting/lowering even when the tiller is in the rest position (tiller sensor B4 not active). This allows to operator to drive the truck even when there is not enough room to lower the tiller. The "snail" function is activated by pressing the button on the tiller head (S11).

Once the "snail" button is pressed, traction control is assigned to the butterfly control.

It is possible to set the traction speed in "snail" mode using the programmer.

Setting the traction speed in "snail" mode.

TRACTION / menu program / traction / snail speed tiller sensor

butterfly control potentiometer (accelerator)

snail function activation button

21

ELECTRICAL SYSTEM

SERVICE

STEERING CONTROLS

Implementors involved

status

Symbol on diagram

Keyswitch

ON

S2

Emergency switch

ON

S1

Tiller rotation

22

rotation right/left

SERVICE

ELECTRICAL SYSTEM

FORK LIFTING/LOWERING CONTROLS

D c

A B

To lift the clamps, press the on/off button “A” or “C”.

To lower the clamps, press the on/off button "B" or “D”.

Devices involved

status

Symbol on diagram

Keyswitch

ON

S2

Emergency switch

ON

S1

Clamp lifting/lowering

ON/OFF button for lifting/ lowering activated

S5-S6-S7-S8

ON*

B4

Tiller tilt sensor * OFF when the button (S11) "snail" is pressed

CONFIGURATION PARAMETERS

TRACTION

main menu program 803 lockout enable lift run time BDI warning enable lift delay time valve 1-2 lowering delay time valve 1-2

For the standard values of each individual parameter, see the paragraph "STANDARD CONFIGURATION OF MODULE PARAMETERS".

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

23

SERVICE

ELECTRICAL SYSTEM

When the tiller is in the rest position, to be able to perform lifting, press the first gear pushbutton simultaneously with the normal lifting buttons.

LIFTING LOCKOUT WITH LOW BATTERY When the level of the battery charge drops below 20% fork lifting is inhibited. To restore initial operating conditions the battery must be recharged.

When the battery charge reaches 75% the "battery low" indicator is reset and normal fork operation is restored.

Lifting lockout due to low battery may be disabled via the programmer.

Enabling/disabling lifting lockout with battery low TRACTION / menu program / hydraulic function / 803 lockout enable  0: disabled

1: enabled With the optional display this parameter must be set to 0, otherwise, depending on the battery charge level, only lowering of the forks will be permitted.

Enabling/disabling lifting lockout with battery low (with optional display) TRACTION / menu program / display functions / bdi warning enable 

0: disabled 1: enabled

If there is not the optional display, this parameter must be set to 0.

With the optional display, the level of battery charge at which the "battery low" condition is activated can be modified using the programmer.

Battery low level (with optional MDI) TRACTION / menu program / display functions / warning bdi

TIMED LIFTING LOCKOUT On pressing a lift button (S5/S7) the clamps start to rise and continue to rise for the maximum time that can be set using the programmer.

Setting the maximum fork lift run time.

TRACTION / menu program / hydraulic function / lift run time Once this time period has elapsed, to continue lifting, you must first press the "lower" button and then press the "lift" button again.

In this case the parameter "lift run time" is used solely to prevent the pump motor from continuing to turn too long even after reaching the clamp limit stop (if the operator keeps on pressing the lift button).

24

SERVICE

ELECTRICAL SYSTEM

STANDARD CONFIGURATION OF MODULE PARAMETERS It is advisable to retain the factory settings seeing as they have been designed to achieve the best compromise between performance and part wear and tear. It is however possible to customise the performance to suit the customer's requirements, the characteristics of the warehouse and the materials to be moved, but no parameters must be changed if this jeopardises the safety of the truck.

“TRACTION” MODULE Parameter

value

INTERLOCK TIMEOUT

120 sec

HPD/SRO TYPE

1

BUZZER OPTION

0

BUZZER DEADBAND

70 RPM

DIRECTION FAULT THRESHOLD

25%

EM TYPE

1

EM TIME LIMIT

10 sec

803 LOCKOUT ENABLE

1

LIFT RUN TIME

4.3 sec

LIFT DELAY TIME VALVE 1-2

0.3 sec

LOWERING DELAY TIME VALVE 1-2

0.3 sec

SNAIL SPEED

1327 RPM

MAX SPEED

4512 RPM

SPEED RED 0

100%

SPEED RED 1

70%

SPEED RED 2

47%

SPEED RED 3

75%

MAX ACCEL

5 sec

MAX DECEL

2.2 sec

NEUTRAL BRAKING

2.3 sec

MAX BRAKING

2.1 sec

MAX ACCEL

5.0 sec

MAX DECEL

1.5 sec

NEUTRAL BRAKING

2.2 sec

MAX BRAKING

1.8 sec

BDI WARNING ENABLE

0

BDI WARNING

20%

25

SERVICE

ELECTRICAL SYSTEM

26

Parameter

value

TOTAL MAINTENANCE ENABLE

1

TRACTION MAINTENANCE ENABLE

1

PUMP MAINTENANCE ENABLE

1

MAINTENANCE INTERVAL

2000 h

RESET TOTAL MAINTENANCE

0

RESET TRACTION MAINTENANCE

0

RESET PUMP MAINTENANCE

0

10S OF HOURS

0

REMAINING HRS IN MINS

0

PRESET TOTAL HOURMETERS

0

PRESET TRACTION HOURMETER

0

PRESET PUMP HOURMETER

0

DRIVER 3 CHECKS ENABLE

1

TEMPERATURE HOT

115°C

TEMPERATURE MAX

140°C

RESET VOLTS PER CELL

2.1 V

FULL VOLTS PER CELL

2V

EMPTY VOLTS PER CELL

1.73 V

BDI RESET PERCENT

75%

EMR SPEED

700 RPM

EMR ACCEL RATE

1.1 sec

EMR DECEL RATE

1.1 sec

SERVICE

ELECTRICAL SYSTEM

DESCRIPTION OF MODULE PARAMETERS “TRACTION” MODULE MENU PROGRAM  VEHICLE PARAMETER INTERLOCK TIMEOUT

min

max

0 sec

1000 sec

Maximum time period the truck may remain with the tiller in the operating position without any command being given.

MENU PROGRAM  DRIVER CONTROL PARAMETER HPD/SRO TYPE

min

max

0

2

0

3

0 rpm

1000 rpm

Identify the correct fire order.

0: disabled 1: key → tiller lowered → butterfly driver control on (>25%) 2: key and tiller lowered (in any order) → butterfly driver control on (>25%) BUZZER OPTION 0: reversing warning buzzer not present 1: reversing warning buzzer active only when reversing 2: reversing warning buzzer active in both directions of travel 3: reversing warning buzzer active in the direction of travel on the operator side BUZZER DEADBAND

Minimum motor rpm at which the buzzer can be activated (the buzzer only sounds when the motor is running at speeds equal to or greater than this rpm).

DIRECTION FAULT THRESHOLD

0%

30%

When the travel direction redundancy is checked, this value indicates the threshold within which there is no error.

EM TYPE

0

2

During emergency reversing, it identifies the actions to be done by the electromagnetic brake.

0: if the truck is travelling forwards (operator side), when the emergency reverse button is pressed the control is disabled, the engine speed is reduced to 0 RPM and the brake is enabled.

1: if the truck is travelling forwards (operator side), when the emergency reverse button is pressed the direction of travel is automatically reversed until the push button is released or until the time limit indicated in the parameter EM TIME LIMIT is reached.

2: if the truck is travelling in any direction, when the emergency reverse button is pressed the engine speed is reduced to 0 RPM and the brake is enabled.

EM TIME LIMIT

0.6 sec

30 sec

Time required to for emergency reversing after the push button is pressed.

803 LOCKOUT ENABLE

0: lockout disabled 1: lockout enabled

Enables/disables lifting lockout when battery low (with the optional display this parameter must be set to 0).

LIFT RUN TIME

0 sec

10 sec

Maximum time for which continuous lifting is enabled.

27

SERVICE

ELECTRICAL SYSTEM

MENU PROGRAM  DRIVER CONTROL PARAMETER LIFT DELAY TIME VALVE 1-2

min

max

0 sec

5 sec

After initial lift, the maximum time for which the optional auxiliary valves remain open after the hydraulic pump is stopped.

LOWERING DELAY TIME VALVE 1-2

0 sec

5 sec

When lowering the forks (or clamps), the maximum time for which the optional auxiliary valves remain open after the lowering valve is deactivated.

MENU PROGRAM  TRACTION PARAMETER SNAIL SPEED

min

max

0 rpm

1327 rpm

0 rpm

4512 rpm

0%

100%

Maximum rpm permitted in SNAIL mode (low gear).

MAX SPEED Maximum truck speed.

SPEED RED 0

Maximum permissible speed (expressed as a percentage of the general maximum speed) when the first speed reduction triggers (see under the heading “TRUCK FUNCTIONS - TRACTION”).

SPEED RED 1

0%

70%

Maximum permissible speed (expressed as a percentage of the general maximum speed) when the second speed reduction triggers (see under the heading “TRUCK FUNCTIONS - TRACTION”).

SPEED RED 2

0%

47%

Maximum permissible speed (expressed as a percentage of the general maximum speed) when the third speed reduction triggers (see under the heading “TRUCK FUNCTIONS - TRACTION”).

SPEED RED 3

0%

76%

Maximum permissible speed (expressed as a percentage of the general maximum speed) when the fourth speed reduction triggers (see under the heading “TRUCK FUNCTIONS - TRACTION”).

MAX ACCEL

0.1 sec

8 sec

Time required to accelerate from 0% to 100% of the maximum truck speed with the butterfly control fully rotated.

MAX DECEL

0.1 sec

8 sec

Braking time required when the traction direction is inverted using the butterfly control.

NEUTRAL BRAKING

0.1 sec

8 sec

0.1 sec

3 sec

Braking time required on releasing the butterfly control.

MAX BRAKING Braking time required on releasing the tiller.

28

SERVICE

ELECTRICAL SYSTEM

MENU PROGRAM  BATTERY PARAMETER

min

max

0: lockout disabled 1: lockout enabled

BDI WARNING ENABLE

With the optional MDI, it enables/disables blocking lifting and LED warnings with a low battery charge (if there is not the optional display, this parameter must be set to 0).

BDI WARNING

0%

100%

If the optional MDI is present, battery charge level percentage at which the "battery low" condition is activated.

MENU PROGRAM  HOUR METER FUNCTIONS PARAMETER TOTAL MAINTENANCE ENABLE

min

max

0: signalling disabled 1: signalling enabled

If the optional MDI is present, it enables/disables maintenance signalling when the truck's number of key-on operating hours reaches the preset value (parameter MENU MONITOR / Maintenance Timers / Total Hours Left = 0).

TRACTION MAINTENANCE ENABLE

0: signalling disabled 1: signalling enabled

If the optional MDI is present, it enables/disables maintenance signalling when the truck's number of traction operating hours reaches the preset value (parameter MENU MONITOR / Maintenance Timers / Traction Hours Left = 0).

PUMP MAINTENANCE ENABLE

0: signalling disabled 1: signalling enabled

If the optional MDI is present, it enables/disables maintenance signalling when the truck's number of pump operating hours reaches the preset value (parameter MENU MONITOR / Maintenance Timers / Pump Hours Left = 0).

MAINTENANCE INTERVAL

10 h

20000 h

Number of truck operating hours after which maintenance is required.

RESET TOTAL MAINTENANCE

0: maintenance not carried out 1: maintenance carried out

When set to 1, the remaining key-on operating hours before the next maintenance interval expires are reset to the value indicated by the parameter MENU PROGRAM / Display Functions / Maintenance Interval. After setting to 1 following maintenance, switch the truck off and then on again.

RESET TRACTION MAINTENANCE

0: maintenance not carried out 1: maintenance carried out

When set to 1, the remaining traction operating hours before the next maintenance interval expires are reset to the value indicated by the parameter MENU PROGRAM / Display Functions / Maintenance Interval. After setting to 1 following maintenance, switch the truck off and then on again.

RESET PUMP MAINTENANCE

0: maintenance not carried out 1: maintenance carried out

When set to 1, the remaining pump operating hours before the next maintenance interval expires are reset to the value indicated by the parameter MENU PROGRAM / Display Functions / Maintenance Interval. After setting to ON following maintenance, switch the truck off and then on again.

29

SERVICE

ELECTRICAL SYSTEM

MENU PROGRAM  HOUR METER FUNCTIONS PARAMETER

min

max

0

20000

10S OF HOURS

Value used to preset the operating hours count. Each unit corresponds to 10 hours (e.g. the value 23 corresponds to 230 hours).

REMAINING HRS IN MINS

0

600

Value used to preset the operating hour meter, expressed in minutes (the value 360 corresponds to 6 hours).

PRESET TOTAL HOURMETERS

0: presetting not performed 1: presetting performed

When set to 1, the number of truck operating hours (key-on) is preset to the value defined in the parameters MENU PROGRAM / Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10) + (“Remaining HRs in Mins” / 60) The value of the parameter MENU MONITOR / Maintenance Timers / Total Hours Left is updated.

PRESET TRACTION HOURMETERS

0: presetting not performed 1: presetting performed

When set to 1, the number of truck traction hours is preset to the value defined in the parameters MENU PROGRAM / Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10) + (“Remaining HRs in Mins” / 60) The value of the parameter MENU MONITOR / Maintenance Timers / Traction Hours Left is updated.

PRESET PUMP HOURMETERS

0: presetting not performed 1: presetting performed

When set to 1, the number of truck pump operating hours is preset to the value defined in the parameters MENU PROGRAM / Hour Meter Functions / 10s Of Hours and Remaining HRs In Mins, according to the formula: (“10s Of Hours” * 10) + (“Remaining HRs in Mins” / 60) The value of the parameter MENU MONITOR / Maintenance Timers / Pump Hours Left is updated.

MENU PROGRAM  DRIVER SETUP PARAMETER

min

max

0

1

min

max

0°C

150°C

DRIVER 3 CHECKS ENABLE Enable control on driver 3.

MENU PROGRAM  MOTOR PARAMETER TEMPERATURE HOT

Temperature limit above which the current supplied to the motor starts to be reduced.

TEMPERATURE MAX

0°C

Maximum temperature limit above which the amount of current supplied to the motor is cut to zero.

30

150°C

SERVICE

ELECTRICAL SYSTEM

MENU PROGRAM  BATTERY PARAMETER RESET VOLTS PER CELL

min

max

2V

3V

Volt/Cell value above which the charged battery status is reached at a given percentage indicated by the parameter BDI RESET PERCENT. FULL VOLTS PER CELL

1.8V

3V

1.57 V

1.93 V

70%

100 %

Volt/Cell value above which the 100% charged battery status is reached.

EMPTY VOLTS PER CELL Volt/Cell value below which the discharged battery status is reached.

BDI RESET PERCENT

Battery charge percentage above which the hydraulic functions of the truck are restored.

MENU PROGRAM  EMERGENCY REVERSE PARAMETER EMR SPEED

min

max

50 rpm

1000 rpm

0.1 sec

3 sec

0.1 sec

3 sec

Truck speed when the emergency reversing is enabled.

EMR ACCEL RATE Time required to accelerate from 0% to 100% of the emergency reversing speed.

EMR DECEL RATE

Time required to stop the truck during forward travel and enable the emergency reversing.

31

SERVICE

ELECTRICAL SYSTEM

MODULE: INTRODUCTION The module electronic system for AC motor control is composed of: •

“TRACTION” module to govern the AC traction motor and the common electrical functions on the machine.

The module is connected and communicates through the CANBUS network, which allows access to truck diagnostics or programming via PC or laptop.

The connector (X30) for the interface cable kit connection ("PC TOOL") is connected to the module and can be accessed from a compartment on the control panel.

The module is equipped with flash memory, which enables the software to be updated by connecting a PC to the CANBUS network (Can flash).

POSITIONING OF THE "PC TOOL" CONNECTOR

PC connector

interface cable kit cod.580039670

32

SERVICE

ELECTRICAL SYSTEM

“TRACTION” MODULE The module has been designed to perform all the electrical functions normally present on the truck: • control of the 2 kW AC traction motor • controlling the 1.4 kW hydraulic pump • CanBus interface • interface with the tiller Can Bus • alarms • performance Technical specifications: Inverter for asynchronous three phase AC motors and chopper for DC pump motors Regenerative braking functions Digital control via microcontroller Voltage: ........................................................................................24V Maximum inverter current (24V):...................................................200A (RMS) for 2’ PWM operating frequency.............................................................10 kHz Maximum encoder frequency........................................................10 kHz Maximum control output frequency...............................................300 Hz External temperature limits............................................................-40°C to 50°C

A

33

ELECTRICAL SYSTEM

SERVICE

REPLACEMENT OF MODULES: INSTRUCTIONS REPLACEMENT OF “TRACTION” AND "EPS" MODULES Equipment and tools

socket wrench 10 mm

resistor 100 Ohm 25w isolated

T handle hex key 5 mm

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

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

Fig. 1

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "MECHANICS" section).

Phase 2 100 Ohm 25 W RESISTOR Connect a resistor between the positive (B+) and negative (B-) of the module to replace (fig.1).

Wait approximately 10 seconds for the internal capacitors to discharge and then disconnect the resistor.

To avoid short circuits, it is important that the resistor is isolated.

If it is not possible to use an external resistor to run down the capacitors, it will be necessary to wait at least 90 seconds before disconnecting the power cables.

34

SERVICE

ELECTRICAL SYSTEM

Phase 3 10 mm SOCKET WRENCH Using the socket wrench loosen and remove the power cable retaining screws.

Disconnect the module wiring connector.

Label the power cables before disconnecting them.

Phase 4 5 mm T HANDLE HEX KEY Using the hexagonal "T" section spanner remove the 4 screws securing the module to the truck chassis (ref.A fig.2) and recover the washers.

Remove the module including the heat sink and proceed with replacement.

A

Fig. 2

ACQUISITION OF “TRACTION” MODULE OPERATING HOURS The truck operating hours are saved in the display memory.

After replacing the "Traction" controller, on switching on the truck make a note of the operating hours shown on the display (value H: e.g. 138.9). Divide the value H by 10. The result will be in the format XX.YY (e.g.

13.89).

Procedure With the machine switched off (key switch OFF) connect the PC with the interface cable and start the PC Tool program and select the "traction" module.

Switch on the truck (keyswitch ON) and select the parameter menu program / hour meter functions / 10s of hours.

Set the parameter to the value XX (e.g.13).

Select the parameter menu program / hour meter functions / remaining hrs in mins.

Set the parameter to the value YY·6 (e.g. 89·6=534).

Select the parameter menu program / hour meter functions / preset total hourmeters.

Set the parameter to “ON”.

Switch off the truck (Keyswitch OFF) and switch it back on again ( Keyswitch ON).

At this point the module will make the necessary modifications to the monitor menu parameters regarding maintenance hours and will reset the parameter preset total hourmeters to “OFF“.

35

SERVICE

ELECTRICAL SYSTEM

REMOVAL OF ELECTRICAL COMPONENTS

Fig. 1

REPLACEMENT OF THE GENERAL EMERGENCY SWITCH Equipment and tools

A T handle hex key 5 mm

pin punch ø 3 mm

open ended spanner 13 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

B

Fig. 2

Fig. 3 Phase 1 Remove the motor compartment cover and the upper cover (see "COVER REMOVAL" in the "MECHANICS" section).

Phase 2 HEXAGONAL 5 mm "T" SPANNER - 10 mm SOCKET WRENCH RATCHET Using the socket wrench and the ratchet hold the locking nut steady on the bracket (ref.A fig.1) using the hexagonal T spanner to unscrew and remove the screw (ref.B fig.2).

Disconnect the connector.

Phase 3 Unscrew and remove the nut securing the emergency switch (ref.C fig.3).

Rotate the switch and slide it off the bracket (fig.4).

36

C

Fig. 4

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE DISPLAY Equipment and tools

large flat head screw driver

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 1

A When the battery charge status indicator is replaced the truck operating hours cannot be transferred onto the new display.

Phase 1 Remove the upper cover (see ”REMOVAL OF THE COVER" in the "MECHANICS" section).

Phase 2 Disconnect the wiring connector(ref.A fig.1).

Loosen the nuts securing the retaining bracket (ref.B fig.1). Remove the bracket (ref.C fig.1).

Remove the display (fig.2) and proceed with replacement.

C B

Fig. 2

37

ELECTRICAL SYSTEM

SERVICE

REPLACEMENT OF THE KEY SWITCH Equipment and tools

large flat head screw driver

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Phase 1 Remove the upper cover (see ”REMOVAL OF THE COVER" in the "MECHANICS" section).

Phase 2 Remove the starter key(fig.1).

Unscrew the nut (ref. A fig.1), remove the switch block from the console (fig.2).

Disconnect the wiring connectors and proceed with the replacement.

INSTALLATION Before reconnecting the Faston connectors, check that they are firmly attached. If not, tighten the connectors with Faston pliers.

38

A

Fig. 1

Fig. 2

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE HORN Equipment and tools Fig. 1

open ended spanner 13 mm

Allen key 6 mm

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

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

Fig. 2

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "MECHANICS" section).

A

B

Phase 2 13 mm FIXED SPANNER - 6 mm ALLEN KEY Using the open ended spanner, counterhold the nut (ref.A fig.2), and with the Allen key loosen and remove the screw securing the horn (ref.B fig.2).

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

INSTALLATION Before reconnecting the Faston connectors, check that they are firmly attached. If not, tighten the connectors with Faston pliers.

39

SERVICE

ELECTRICAL SYSTEM REPLACING the raised platform sensor and man presence sensor Equipment and tools

Allen key 4 mm

small cross-head screwdriver

combination spanner 7 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Fig. 2

A Fig. 3

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "MECHANICS" section).

MAN PRESENCE SENSOR Phase 2 4 mm ALLEN WRENCH - SMALL PHILLIPS SCREWDRIVER - SCISSORS With the Allen wrench, unscrew and remove the screws securing the clamp (ref.B fig.2). Using the screwdriver, unscrew the screw fastening the sensor to the clamp (ref.D fig.5), extract the sensor (fig.5), with the scissors remove the straps retaining the sensor cable, retrieve the cable and make the replacement.

RAISED PLATFORM SENSOR Phase 3 4 mm ALLEN WRENCH - 7 mm COMBINATION SPANNER - SMALL PHILLIPS SCREWDRIVER Raise the platform. Using the open-ended spanner, keep the nuts securing the clamp (ref.B fig.4) locked while with the Allen wrench unscrew and remove the screws fastening the clamp (ref.C fig.4). With the screwdriver, unscrew the screw fastening the sensor to the clamp (ref.D fig.5), extract the sensor (fig.5), retrieve the cable and make the replacement.

Fig. 4

C

B

D Fig. 5

40

SERVICE

ELECTRICAL SYSTEM

ADJUSTMENT OF THE MAN PRESENCE SENSOR The two sensors B8 and B9 detect the position of the operator platform by reading a cam.

•

With the platform fully raised (fig.1) the sensor B8 is active (ON) and enables low gear. The sensor B9 is not active (OFF).

•

With the platform lowered and the operator on the ground (fig.2) neither sensor is active (OFF) and traction is disabled.

•

With the platform lowered and the operator on the machine (fig.3) the sensor B9 is active (ON) and enables low gear with the side gates open. The sensor B8 is not active (OFF). The platform has been designed so that the sensor B9 turns on with a weight of 40 kg at a distance of 400 mm from the platform support.

platform support

B9 cam

B8

400 mm

40 kg

Fig. 1 sensor B8: ON sensor B9: OFF

Fig. 2 sensor B8: OFF sensor B9: OFF

Fig. 3 sensor B8: OFF sensor B9: ON

41

SERVICE

ELECTRICAL SYSTEM PANEL SENSORS REPLACEMENT Equipment and tools

hex bit socket 17-28 mm

ratchet

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 1

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "MECHANICS" section).

Phase 2 17-28 mm HEXAGONAL SOCKET WRENCH - RATCHET Close the panels if you want to replace the closed panels sensor. Open the panels if you want to replace the open panels sensor.

Using the socket wrench and ratchet, unscrew and remove the lower ferrule fastening the sensor (ref.A fig.2) and extract upwards.

Recover the wire and proceed with replacement.

Fig. 2

A The optimal distance between the sensor and the cam is 4 mm.

42

SERVICE

ELECTRICAL SYSTEM

TILLER BOARD REPLACEMENT Equipment and tools

T handle hex key 2.5 - 4 mm

Fig. 1

A

small flat blade screwdriver

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 2

B CD E

F

Phase 1 4 mm T HANDLE HEX KEY Unscrew the bolts securing the upper casing (ref.A fig.1).

Phase 2 Lift the upper casing and detach it from the lower casing (fig.2). Disconnect the serial cable connector (ref.B fig.2) and place the cover on a clean work bench.

Fig. 3

Phase 3 2.5 mm T HANDLE HEX KEY Loosen the screw securing one of the two butterflies(ref.C fig.3) and recover the washer (ref.D fig.3). Slide the butterfly off the pin (ref.E fig.3). Remove the other butterfly control complete with the guide pin (ref.F fig.3).

Phase 4 SMALL FLAT BLADE SCREWDRIVER Unscrew the screw securing the tiller board retaining clip (ref.G fig.4).

Remove the retaining clip (ref.H fig.4) and the board from its slot (ref.I fig.4), disconnect the connectors of the various microswitches.

Proceed with replacement

I

H Fig. 4

G

43

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF TILLER BUTTONS

Fig. 1

Equipment and tools

T handle hex key 4 mm

A

small flat blade screwdriver

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 2

B Fig. 3

Phase 1 4 mm T HANDLE HEX KEY Unscrew the bolts securing the upper casing (ref.A fig.1).

Phase 2 Lift the upper casing and detach it from the lower casing (fig.2). Disconnect the serial cable connector (ref.B fig.2) and place the cover on a clean work bench.

Phase 3 SMALL FLAT BLADE SCREWDRIVER Using the screwdriver, prise open the clips (fig.4) and push the button its seat (fig.4,5).

Proceed with replacement.

Fig. 4

Fig. 5 44

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE TILLER CONTROL SPRINGS Equipment and tools

T handle hex key 2.5 - 4 mm

small flat blade screwdriver

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 1

A

Phase 1 4 mm T HANDLE HEX KEY Unscrew the bolts securing the upper casing (ref.A fig.1).

Phase 2 Lift the upper casing and detach it from the lower casing (fig.2). Disconnect the serial cable connector (ref.B fig.2) and place the cover on a clean work bench.

Fig. 2

B CD E

Fig. 3

F

Phase 3 2.5 mm T HANDLE HEX KEY Loosen the screw securing one of the two butterflies(ref.C fig.3) and recover the washer (ref.D fig.3). Slide the butterfly off the pin (ref.E fig.3). Remove the other butterfly control complete with the guide pin (ref.F fig.3).

45

SERVICE

ELECTRICAL SYSTEM BUTTERFLY CONTROL SPRING

Fig. 4

Phase 4 SMALL FLAT BLADE SCREWDRIVER With the screwdriver, prise out the butterfly control guide bush (ref.G fig.4).

In the same way, prise out the butterfly control spring (ref.H fig.4).

Proceed with the replacement.

H

G BELLY AND HORN BUTTON SPRINGS Fig. 5

Phase 4 SMALL FLAT BLADE SCREWDRIVER With the screwdriver, apply leverage under the belly switch in correspondence with the locking pin (fig.5). Remove the button (ref.I fig.6) and recover the spring (ref.J fig.6).

In the same way, apply leverage under the horn button in correspondence with the locking pin (fig.5). Remove the button (ref.K fig.6) and recover the spring (ref.L fig.6).

Proceed with replacement

Fig. 6

I J

L

K

46

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE TILLER ENABLES SENSOR

Fig. 1

Equipment and tools

small / medium T handle hex key Phillips screwdri4-5 mm ver

A

B

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Phase 1 5 mm HEXAGONAL "T" SECTION SPANNER Unscrew the bolts securing the upper casing (ref.A fig.1).

Fig. 2

C Fig. 3

D E

Phase 2 Lift the upper casing and detach it from the lower casing (fig.2). Disconnect the wiring connector of the tiller sensor cable (ref.C fig.2).

Fig. 4 Phase 3 MEDIUM PHILIPS SCREWDRIVER With the cross-head screwdriver, unscrew and remove the screws fastening the vibration damping buffer (ref.B fig.1). Lower the tiller and remove the buffer (ref.D fig.3) and the guard (ref.E fig.3).

Phase 4 4 mm HEXAGONAL "T" SECTION SPANNER - SMALL PHILIPS SCREWDRIVER With the hexagonal "T" section spanner, unscrew and remove the screws securing the clamp (ref.F fig.4). With the screwdriver, unscrew the screw fastening the sensor to the clamp (ref.G fig.5), extract the sensor (fig.5), retrieve the cable and make the replacement.

The optimal distance between the sensor and the cam is 4 mm.

F

G Fig. 5

47

ELECTRICAL SYSTEM

SERVICE

REPLACEMENT of steering sensor Equipment and tools Fig. 1

hex bit socket 28 mm

ratchet

open-ended spanner 28 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Phase 1 Remove the motor compartment cover and the upper cover (see "COVER REMOVAL" in the "MECHANICS" section).

Phase 2 28 MM HEX SOCKET WRENCH - RATCHET - 28 mm OPEN ENDED SPANNER Rotate the tiller to move the cam.

Using the open ended spanner hold the upper ferrule and using the socket wrench and ratchet, unscrew and remove the lower ferrule fastening the sensor (ref.A fig.2) and extract upwards.

Recover the wire and proceed with replacement.

The optimal distance between the sensor and the cam is 4 mm.

48

A

Fig. 2

SERVICE

HYDRAULIC SYSTEM

Hydraulic system HYDRAULIC FUNCTIONS ����������������������������������������������������������������������������������������������������������������������������������������� 2 OIL SUPPLY TO THE HYDRAULIC CIRCUIT ������������������������������������������������������������������������������������������������������������� 3 PRESSURE CONTROL VALVES �������������������������������������������������������������������������������������������������������������������������������� 3 DIRECTIONAL VALVES ���������������������������������������������������������������������������������������������������������������������������������������������� 3 pressure switches ��������������������������������������������������������������������������������������������������������������������������������������������� 3 HYDRAULIC DIAGRAMS ������������������������������������������������������������������������������������������������������������������������������������������� 4 symbols ������������������������������������������������������������������������������������������������������������������������������������������������������������������� 4 MAIN HYDRAULIC DIAGRAM ������������������������������������������������������������������������������������������������������������������������������������ 5 HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS ������������������������������������������������������������������������������������������� 6 SOLENOID VALVE OPERATION CHART ������������������������������������������������������������������������������������������������������������������� 6 HYDRAULIC DIAGRAM FOR LIFTING ���������������������������������������������������������������������������������������������������������������������� 7 HYDRAULIC DIAGRAM FOR LOWERING ����������������������������������������������������������������������������������������������������������������� 8 HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE ����������������������������� 9 hydraulic components ���������������������������������������������������������������������������������������������������������������������������������� 10 hydraulic component identification �������������������������������������������������������������������������������������������������������� 10 REMOVAL OF THE PRESSURE RELIEF VALVE ����������������������������������������������������������������������������������������������������� 11 CALIBRATION OF THE PRESSURE RELIEF VALVE ���������������������������������������������������������������������������������������������� 12 CARTRIDGE SOLENOID VALVE ��������������������������������������������������������������������������������������������������������������������������� 13 KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS ������������������������������������������������������������������������������������� 13 REMOVAL OF THE SOLENOID VALVE ������������������������������������������������������������������������������������������������������������������� 14 CYLINDERS �������������������������������������������������������������������������������������������������������������������������������������������������������������� 15 SINGLE ACTING CYLINDER ������������������������������������������������������������������������������������������������������������������������������������ 15 LIFTING CYLINDER �������������������������������������������������������������������������������������������������������������������������������������������������� 15 KEY TO CYLINDER COMPONENTS ����������������������������������������������������������������������������������������������������������������������� 16 CYLINDER REMOVAL ���������������������������������������������������������������������������������������������������������������������������������������������� 17 REPLACEMENT OF THE CYLINDER SEALS ���������������������������������������������������������������������������������������������������������� 19 lift pump ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 22 KEY TO LIFT PUMP COMPONENTS ����������������������������������������������������������������������������������������������������������������������� 22 REMOVAL OF THE LIFT PUMP ������������������������������������������������������������������������������������������������������������������������������� 24 REPLACEMENT OF THE PUMP ������������������������������������������������������������������������������������������������������������������������������ 26 REPLACEMENT OF THE CYLINDER SUPPLY PIPE ���������������������������������������������������������������������������������������������� 27

1

HYDRAULIC SYSTEM

SERVICE

HYDRAULIC FUNCTIONS • •

Clamp lifting Clamp lowering

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

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

2

SERVICE

HYDRAULIC SYSTEM

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

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

PRESSURE CONTROL VALVES Pressure limiting valves The "pressure limiting" or "pressure relief" valves are mainly used to guarantee the maximum pressure permitted in the system and to protect the pump from damaging pressure levels that exceed its own structural characteristics.

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

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

DIRECTIONAL VALVES One-way and check valves.

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

They are essentially comprised of a fixed part connected to the end of the pipe; the internal seat contains the moving element, which might be a ball or a conical plug.

Check valves instead have an opposing spring. In the direction of free flow, the oil pressure must overcome the force exerted by the spring. pressure switches Pressure switches with one threshold The function of the pressure switches with one threshold is to convert a certain hydraulic pressure signal into an electrical one, keeping the oil flow pressure under control.

They are basically composed of a piston with a counter spring connected to movable electric contacts. When the oil pressure reaches the highest setting, the movable contacts close the electric circuit; if the pressure decreases or is cancelled the electric circuit opens, signalling an error.

3

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS symbols

RESERVOIR

FILTER

PUMP

PRESSURE RELIEF VALVE

ONE-WAY VALVE

ON/OFF SOLENOID VALVE

ON/OFF SOLENOID VALVE WITH CHECK

LINE CONNECTION

CYLINDER

4

SERVICE

HYDRAULIC SYSTEM

MAIN HYDRAULIC DIAGRAM

C2 P

Q1 CH

SB

P F

5

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS •

Clamp lifting

•

Clamp lowering

•

Oil outlet through the pressure relief valve

SOLENOID VALVE OPERATION CHART Function

Pump

Straddle legs lifting

P +

Straddle legs lowering Oil drain through pressure relief valve

Q1

P

-

Q1

P = pump in operation + = solenoid valve coil energised relief valve

6

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM FOR LIFTING

C2 P

Q1 CH

SB

P F

7

SERVICE

HYDRAULIC SYSTEM HYDRAULIC DIAGRAM FOR LOWERING

C2 P

Q1 CH

P F

8

SB

SERVICE

HYDRAULIC SYSTEM

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

The pressure relief valve may intervene in the following cases: • • •

C2the truck load capacity.

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

Q1 CH

SB

P F

9

SERVICE

HYDRAULIC SYSTEM

hydraulic components hydraulic component identification

5 2

4 1

3

Ref.

10

Description

1

On/off solenoid valve Q1

2

Pump

3

Filter

4

Pressure relief valve

5

Clamp lifting cylinder

SERVICE

HYDRAULIC SYSTEM

REMOVAL OF THE PRESSURE RELIEF VALVE Malfunction of the pressure relief valve can be caused by the presence of dirt or weakening of the internal spring.

In the first case thorough cleaning is required, in the second case the valve needs to be replaced.

Equipment and tools

oil resistant gloves

medium flat blade screwdriver

open ended spanner 22 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the clamps to the ground, turn the keyswitch to OFF and disconnect the battery.

Fig. 1

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1 Remove the cover of the motor compartment (if you do not know how to proceed, see ”REMOVAL OF THE COVER" in the "TRUCK BASE MECHANICS" section).

Phase 2 22 mm OPEN ENDED SPANNER - OIL RESISTANT GLOVES - MEDIUM FLAT BLADE SCREWDRIVER Wear the oil resistant gloves.

Using the open ended spanner, unscrew and remove the valve cap (ref.A fig.2).

Using the socket wrench, unscrew and remove the complete valve (ref.B fig.2), recover the spring (ref.C fig.2) and proceed with the replacement.

Fig. 2

C A B

INSTALLATION On installation, tighten the valve with a torque wrench to 13 Nm. 11

SERVICE

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

Equipment and tools Fig. 1

medium flat blade screwdriver

open ended spanner 22 mm

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

Fig. 2 Phase 1 Connect the battery and switch on the truck (starter key to ON).

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

Phase 2 22 mm OPEN ENDED SPANNER - MEDIUM FLAT BLADE SCREWDRIVER Using the open ended spanner, unscrew and remove the valve cap (ref.A fig.2).

With the screwdriver turn the adjuster screw (ref.B fig.3) counter-clockwise until, while holding pressed the clamp lifting button on the tiller (fig.4), the pressure is reduced and the oil drains into the reservoir (lifting stops).

At this point, turn the adjuster screw in the opposite direction (clockwise) until the point where the clamps start to lift again.

Release the clamp lift button and screw in the adjuster screw by a further ¼ turn.

Carry out a few trial lifts and lowering manoeuvres with the load, checking that the pressure setting is sufficient to cope with the pressure surge during the initial lifting stage.

If not, tighten the screw by a further ¼ turn.

INSTALLATION On installation, tighten the valve cap to a torque of 20-22 Nm.

12

A Fig. 3

B

Fig. 4

SERVICE

HYDRAULIC SYSTEM

CARTRIDGE SOLENOID VALVE The distributor solenoid valve has a screwed-in cartridge.

This type of valve is comprised of a body with a fixed hex nut, a threaded part, a set of static seals; inside a moving element allows communication between the various chambers.

KEY TO CARTRIDGE SOLENOID VALVE COMPONENTS

1

3

2

Ref.

Description

1

Coil

2

Valve body

3

Coil retaining plug

13

HYDRAULIC SYSTEM

SERVICE

REMOVAL OF THE SOLENOID VALVE Equipment and tools

oil resistant gloves

small cross-head screwdriver

24 mm open ended spanner

Procedure

Fig. 1

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Fig. 2

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "TRUCK BASE MECHANICS" section).

B Phase 2 SMALL PHILIPS SCREWDRIVER Unscrew the retaining screws and disconnect the connector of the power supply to the solenoid valve coil (fig.2).

Phase 3 OIL RESISTANT GLOVES - 24mm OPEN ENDED SPANNER Unscrew and remove the coil retaining plug (ref.B fig.3) and recover the seal (ref.C fig.3).

Withdraw the coil (ref.D fig.3) and recover the seals.

Use the open ended spanner to unscrew the valve body from the hydraulic block and proceed with replacement.

INSTALLATION On installation, tighten the valve retaining screws to a torque of 39 to 51 Nm.

14

C

D

Fig. 3

SERVICE

HYDRAULIC SYSTEM

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

Single-acting plunger type cylinders In this type of cylinder the piston is replaced by the flat end face of the piston rod or plunger; these cylinders are usually mounted vertically or in other positions in which the force of gravity returns the plunger to the rest position. Usually the diameter of the lower end of the rod is increased by a few millimetres in order to avoid it slipping out at the end of it's upstroke; this gives rise to a hydraulic damping effect during the last stages of the stroke which helps the slowing of the rod and avoids recoil on the upper end cap. Static seals located in the end cap prevent oil leaking outside the cylinder.

To replace these seals it is necessary to unscrew the seal carrier bush.

Single acting cylinder with hollow rods differ in that before the lifting stroke begins the rod is also filled with oil. This solution is used on particularly tall truck masts to increase the resistance of the cylinders at the maximum height and make it possible to use smaller cylinder barrels and rods.

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

LIFTING CYLINDER Type of cylinder

Rod diameter mm

Height h3 mm

Type with single-acting plunger cylinder with solid rod

50

130

h3

15

SERVICE

HYDRAULIC SYSTEM KEY TO CYLINDER COMPONENTS

The cylinder is of the single-acting plunger type.

After replacing the cylinder, bleed the air through the bleed valve.

Replacement of the static and dynamic seals on the piston requires removing and disassembling the cylinder.

2

5

4

3

6

8

1

Ref.

16

Description

1

Barrel and end cap

2

Piston rod

3

Rod end cap

4

Bottom

5

Piston

6

Dynamic seals

7

Static seals

8

Bottom sealing gasket

7

SERVICE

HYDRAULIC SYSTEM

CYLINDER REMOVAL Equipment and tools

bridge crane load capacity 2000 kg

2 lifting slings load capacity 2000 kg

spreader bar

open ended spanner 13-18 mm

A oil resistant gloves

"Parker" service plug

T handle hex key 5 mm

pliers

Fig. 1 Procedure Before starting work, ensure that you are wearing suitable protective clothing.

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

Fig. 2

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "TRUCK BASE MECHANICS" section).

Phase 2 Remove the steering motor (see "STEERING MOTOR REMOVAL” in the "TRUCK BASE MECHANICS" section).

Phase 3 Remove the steering motor (see "TRACTION MOTOR REMOVAL” in the "TRUCK BASE MECHANICS" section).

17

SERVICE

HYDRAULIC SYSTEM Phase 4 BRIDGE CRANE - 13 mm OPEN ENDED SPANNER - SPREADER BAR Raise the upper cover of the battery compartment.

Using the open ended spanner, loosen the bolts securing the battery restraints (ref.A fig.1). Remove the battery restraints.

Hook the spreader bar to the bridge crane. Position the bridge crane above the battery compartment.

Attach the spreader bar to the battery; carefully lift the battery clear of the battery compartment with the bridge crane (fig.2).

Gently lower the battery to the ground and detach the spreader bar.

B

Fig. 3

Phase 5 BRIDGE CRANE - 2 LIFTING SLINGS Attach the two lifting slings to the lifting attachments on the truck base.

Attach the lifting slings to the hoist and take up the slack.

Phase 6 OIL RESISTANT GLOVES - 18 mm OPEN ENDED SPANNER - "PARKER" SERVICE PLUG Wear the oil resistant gloves.

Using the spanner, unscrew the hydraulic hose union (ref.B fig.3).

Fit the plug to the hydraulic hose.

C

Fig. 4 Phase 7 5 mm PIVOTING HEXAGONAL "T" SECTION SPANNER - PLIERS Using the pivoting hexagonal "T" section spanner, unscrew and remove the two cylinder retainer screws in the battery compartment (ref.C fig.4).

Using the pliers, remove the cotter pin of the cylinder (ref.D fig.5).

Using the hoist, lift the truck 150 mm from the ground and remove cylinder cap from its housing.

Extract the cylinder from the bottom upwards and rest it on a clean workbench fitted with a vice.

Dismantle or replace.

ASSEMBLY Before tightening the hydraulic connections, consult the table of reference (see "CORRECT METHOD OF APPLYING FEMALE CONNECTIONS” "PREMISES" section).

18

D

Fig. 5

SERVICE

HYDRAULIC SYSTEM

REPLACEMENT OF THE CYLINDER SEALS Equipment and tools

small flat blade screwdriver

oil resistant gloves

work bench

vice

C spanner

brush

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

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

Fig. 1

A

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Phase 1 Carry out the lifting cylinder removal procedure (see “REMOVAL OF THE CYLINDER”).

Phase 2 WORK BENCH - VICE - OIL RESISTANT GLOVES - C SPANNER Wear the oil resistant gloves.

Secure the cylinder in the vice, interposing a rubber protection between the vice jaws and the cylinder barrel.

Apply the C spanner at the notches on the seal carrier bush (ref.A fig.1).

Unscrew the bush from the cylinder and slide it off the rod (fig.1).

B

C Fig. 2 19

SERVICE

HYDRAULIC SYSTEM REPLACEMENT OF THE STATIC SEALS

Fig. 3

Phase 3 SMALL FLAT BLADE SCREWDRIVER Using the screwdriver, remove the internal seals (ref.B fig.2) and the seals external to the bush (ref.C fig.2) and proceed with replacement.

DYNAMIC SEAL REPLACEMENT Phase 4 SMALL FLAT BLADE SCREWDRIVER Remove the rod from the cylinder (fig.3).

Using the screwdriver, remove the dynamic seals on the piston (ref.D fig.4).

INSTALLATION Fitting the seals is a delicate stage in the lifting cylinder assembly procedure. Most cylinder maintenance operations can be attributed to defective seals.

Fig. 4

D

Clean the seal carrier bush and lubricate the seal contact faces in the bush and the seals themselves with clean hydraulic oil before installation.

The seal carrier bush should be tightened to a torque of 275 Nm. Apply Loctite 262 in the internal profile of the piston before assembling the cylinder.

20

D

SERVICE

HYDRAULIC SYSTEM

21

HYDRAULIC SYSTEM

lift pump KEY TO LIFT PUMP COMPONENTS

Ref.

22

Description

1

Pump motor

2

Directional control valve

3

Pump body

4

Reservoir

5

On/off solenoid valve Q1

6

Drive coupling

7

Pressure relief valve

8

Oil intake pipe

9

Oil outlet pipe

10

Oil flow control valve

11

Filter

SERVICE

SERVICE

HYDRAULIC SYSTEM

1

5

6

10

2

7 3

9

4

8

11

23

SERVICE

HYDRAULIC SYSTEM REMOVAL OF THE LIFT PUMP Equipment and tools Fig. 1

A open ended spanner 13-17-19 mm

small cross-head "Parker" service oil resistant gloves screwdriver plug

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Fig. 2

B

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "TRUCK BASE MECHANICS" section).

Fig. 3 Phase 2 13 mm OPEN ENDED SPANNER Remove the terminal protection caps, then use the open ended spanner to unscrew the nuts securing the pump motor power cables (ref.A fig.1).

Make a note of the cable positions. Extract the cables.

Phase 3 SMALL CROSS-HEAD SCREWDRIVER Unscrew the retaining screws and disconnect the power supply connector of the solenoid valve coil (ref.B fig.2).

24

C

SERVICE

HYDRAULIC SYSTEM

Phase 4 OIL RESISTANT GLOVES - 19 mm open ended spanner - "PARKER" PLUG Wear the oil resistant gloves.

Using the open ended spanner, unscrew the union of the hydraulic pipe (ref.C fig.3).

Apply the cap.

Fig. 4

D Phase 5 17 mm OPEN ENDED SPANNER Using the fixed gauge spanner unscrew and remove the screws fastening the assembly to the truck base (ref.D fig.4). Retrieve the washers and plugs.

Remove the pump assembly and proceed with its replacement or disassembly.

25

HYDRAULIC SYSTEM

SERVICE

REPLACEMENT OF THE PUMP Equipment and tools

T handle hex key 4 mm

small flat blade screwdriver

oil resistant gloves

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

Phase 1 Carry out the procedure to remove the lift pump (see "REMOVAL OF THE LIFT PUMP").

Fig. 1

A

Fig. 2

Phase 2 SMALL FLAT BLADE SCREWDRIVER Loosen the screw of the steel clip securing the reservoir to the flange (ref.A fig.2). Withdraw the pump complete with flange from the reservoir.

Phase 3 4 mm T HANDLE HEX KEY Unscrew and remove the nuts securing the pump body to the flange (ref.B fig.3), remove the pump and proceed with replacement.

B INSTALLATION On installation tighten the nuts securing the pump to the flange with a torque wrench to 5 Nm. Use medium Loctite.

26

Fig. 3

SERVICE

HYDRAULIC SYSTEM

REPLACEMENT OF THE CYLINDER SUPPLY PIPE Equipment and tools

open ended spanner 19 mm

"Parker" service oil resistant gloves plugs

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground. Turn the keyswitch to OFF and disconnect the battery.

The hydraulic fluid gets very hot during system operation and can cause burns. It is advisable to wear gloves that are resistant to oil and high temperatures.

Fig. 1

B

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "TRUCK BASE MECHANICS" section).

Phase 2 OIL RESISTANT GLOVES - 19 mm OPEN ENDED SPANNER - "PARKER" PLUGS Wear the oil resistant gloves.

Using the fixed spanner unscrew the coupling of the hydraulic pipe (ref.A-B fig.1).

Fit the service plugs to the unions. Recover the hydraulic pipe and proceed with replacement.

A

27

HYDRAULIC SYSTEM

28

SERVICE

SERVICE

MECHANICS

mechanics COVERS ��������������������������������������������������������������������������������������������������������������������������������������������������������������������� 3 COVER REMOVAL ����������������������������������������������������������������������������������������������������������������������������������������������������� 3 DRIVE WHEEL ������������������������������������������������������������������������������������������������������������������������������������������������������������ 5 KEY TO DRIVE WHEEL COMPONENTS ������������������������������������������������������������������������������������������������������������������� 5 REMOVAL OF THE DRIVE WHEEL ���������������������������������������������������������������������������������������������������������������������������� 6 PIVOTING WHEEL ASSEMBLY ��������������������������������������������������������������������������������������������������������������������������������� 7 KEY TO PIVOTING WHEEL ASSEMBLY COMPONENTS ���������������������������������������������������������������������������������������� 7 REMOVAL OF THE PIVOT WHEEL ASSEMBLY �������������������������������������������������������������������������������������������������������� 8 FOOTBOARD ����������������������������������������������������������������������������������������������������������������������������������������������������������� 10 KEY TO FOOTBOARD COMPONENTS ������������������������������������������������������������������������������������������������������������������� 10 REMOVAL OF THE FOOTBOARD ASSEMBLY ������������������������������������������������������������������������������������������������������� 12 FOOTBOARD GAS SPRING REPLACEMENT �������������������������������������������������������������������������������������������������������� 13 FOOTBOARD SPRING REPLACEMENT ����������������������������������������������������������������������������������������������������������������� 15 FOOTBOARD SPRINGS adjustment ������������������������������������������������������������������������������������������������������������������ 16 SIDE PANELS ����������������������������������������������������������������������������������������������������������������������������������������������������������� 17 KEY TO SIDE PANEL COMPONENTS �������������������������������������������������������������������������������������������������������������������� 17 SIDE PANEL ASSEMBLY REMOVAL ������������������������������������������������������������������������������������������������������������������������ 18 SIDE PANEL REPLACEMENT ���������������������������������������������������������������������������������������������������������������������������������� 19 SIDE PANEL GAS SPRING REPLACEMENT ���������������������������������������������������������������������������������������������������������� 20 LOAD WHEELS �������������������������������������������������������������������������������������������������������������������������������������������������������� 22 KEY TO LOAD WHEEL COMPONENTS ������������������������������������������������������������������������������������������������������������������ 22 REPLACEMENT OF THE LOAD WHEELS �������������������������������������������������������������������������������������������������������������� 24 LOAD WHEEL ASSEMBLY REPLACEMENT ����������������������������������������������������������������������������������������������������������� 25 LINKAGE ������������������������������������������������������������������������������������������������������������������������������������������������������������������ 26 KEY TO LINKAGE ASSEMBLY COMPONENTS ������������������������������������������������������������������������������������������������������ 26 REMOVAL OF THE LINKAGE ASSEMBLY ��������������������������������������������������������������������������������������������������������������� 28 LINKAGE ASSEMBLY GREASING POINTS ������������������������������������������������������������������������������������������������������������� 31 ADJUSTMENT OF THE LINKAGE ASSEMBLY (OPTIONAL) ���������������������������������������������������������������������������������� 32 TILLER ���������������������������������������������������������������������������������������������������������������������������������������������������������������������� 34 KEY TO TILLER COMPONENTS ������������������������������������������������������������������������������������������������������������������������������ 34 STEERING BAR REMOVAL ������������������������������������������������������������������������������������������������������������������������������������� 36 DISMANTLING THE TILLER ASSEMBLY ����������������������������������������������������������������������������������������������������������������� 37 REPLACEMENT OF THE TILLER GAS SPRING ����������������������������������������������������������������������������������������������������� 39 TILLER REPLACEMENT ������������������������������������������������������������������������������������������������������������������������������������������ 40 1

MECHANICS

SERVICE

traction motor �������������������������������������������������������������������������������������������������������������������������������������������������� 41 KEY TO TRACTION MOTOR COMPONENTS ��������������������������������������������������������������������������������������������������������� 41 REMOVAL OF THE TRACTION MOTOR ������������������������������������������������������������������������������������������������������������������ 42 Traction motor dismantlement ������������������������������������������������������������������������������������������������������������������ 43

2

SERVICE

MECHANICS

COVERS COVER REMOVAL Equipment and tools

Large flat head screwdriver

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

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

MOTOR COMPARTMENT COVER Phase 1 LARGE FLAT HEAD SCREWDRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Recover the washers.

Remove the cover.

A

A

A

Fig. 1 3

MECHANICS

SERVICE

UPPER COVER Phase 2 LARGE FLAT HEAD SCREWDRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the upper cover (ref.B fig.2).

Recover the washers.

Disconnect the connectors of the key switch and display (XFF9 - XFF10 - X28, and also the optional keypad or optional MDI when applicable).

Remove the cover.

Fig. 2

B

B

4

SERVICE

MECHANICS

DRIVE WHEEL KEY TO DRIVE WHEEL COMPONENTS

2

1

Ref.

Description

1

Wheel

2

Drive wheel retaining nut

5

SERVICE

MECHANICS REMOVAL OF THE DRIVE WHEEL Equipment and tools

bridge crane load capacity 2000 kg

double arm lift belt 2 wooden blocks load capacity 100x100x1000 mm 2000 kg

socket 15 -19 mm

ratchet

extension

Procedure

Fig. 1

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Raise the clamps to the maximum height, turn the tiller completely to the right, set the keyswitch onto OFF and disconnect the battery.

A Phase 1 BRIDGE CRANE - DOUBLE ARM LIFT BELT - 2 WOODEN BLOCKS Hook the two ends of the lift belt to the holes of the truck base made for lifting (ref.A fig.1). Using the bridge crane, raise the truck by 200 mm. Put the blocks under the truck, lower the bridge crane and set the truck on the blocks keeping the lift belt under tension (fig.1).

Phase 2 15 mm socket wrench - ratchet Unscrew and remove the nuts fastening the footboard support to the truck base (ref.B fig.2). Disconnect the connectors of the footboard sensors and remove the footboard support assembly.

B

Phase 3 19 mm socket - ratchet - extension bar - TORQUE WRENCH Unscrew and remove the nuts securing the drive wheel to the reduction unit (ref.C fig.3), recover the washers and remove the wheel.

Fig. 2

ASSEMBLY The traction wheel retaining nuts must be tightened using a torque wrench to a torque of 66÷80 Nm.

C Fig. 3

6

SERVICE

MECHANICS

PIVOTING WHEEL ASSEMBLY KEY TO PIVOTING WHEEL ASSEMBLY COMPONENTS 1 2

3

4

5

6 7

8 9

7

8

Ref.

Description

Ref.

10

Description

1

Closing circlip

6

Wheel screw

2

Shim

7

Brush

3

Upper plate

8

Cover

4

Pivot assembly rotation bearing

9

Wheel

5

Opening circlip

10

Nut 7

SERVICE

MECHANICS REMOVAL OF THE PIVOT WHEEL ASSEMBLY Equipment and tools

bridge crane load capacity 2000 kg

double arm lift belt load capacity 2000 kg

socket wrench 13 - 17 mm

ratchet

truck stand

open-ended spanner 13 - 17 mm

medium internal circlip pliers

small external circlip pliers

Procedure

Fig. 1

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Raise the clamps to the maximum height, turn the keyswitch to OFF and disconnect the battery.

A Phase 1 BRIDGE CRANE - DOUBLE ARM LIFT BELT - TRUCK STAND Hook the two ends of the lift belt to the holes of the truck base made for lifting (ref.A fig.1). Use the bridge crane to raise and position the truck on the stand. Tighten the crossbar of the stand and take up the slack of the lift belt (if you don't have a stand, rest the truck on two wooden blocks to keep it raised off the ground).

Remove the cover of the motor compartment (see previous page).

Phase 2 13 mm SOCKET WRENCH - ratchet - 13 mm open ended spanner Using the open-ended spanner, keep the nuts in the lower part (ref.B fig.2) locked while with the socket wrench unscrew and remove the screws fastening the castor wheel assembly to the bodywork (ref.C fig.3).

Remove the wheel assembly and proceed with its replacement or disassembly.

8

B

Fig. 2

SERVICE

MECHANICS

REMOVAL OF THE PIVOTING WHEEL Phase 4 17 mm socket wrench - ratchet - 17 mm open ended spanner Using the fixed gauge spanner hold the self-blocking nut of the castor wheel steady (ref.D fig.4), while with the socket wrench and the ratchet unscrew and remove the fastening screws of the castor wheel (ref.F. fig.4). Recover the screw and the self-locking nut and remove the wheel from its support.

Proceed with replacement.

C Fig. 3

DISASSEMBLY OF THE PIVOTING WHEEL

D

Phase 5 Recover the brushes (ref.F fig.4) and the covers (ref.G fig.4).

Proceed with replacement REMOVAL OF THE UNIT ROTATION BEARING Phase 7 EXTERNAL CIRCLIP PLIERS - INTERNAL CIRCLIP PLIERS Using the circlip pliers remove the upper retaining circlip (ref.H fig.5) e retrieve the washer. Remove the upper plate. Using the external circlip pliers remove the bearing retaining circlip (ref.I fig.5) and remove the bearing.

Proceed with replacement

INSTALLATION

F

G E

Fig. 4

H

The nut securing the castor wheel must be tightened using a torque to a torque of 30 Nm (±5 Nm).

The screws fastening the castor wheel assembly to the truck base must be tightened to a torque of 34 Nm.

I

Fig. 5 9

SERVICE

MECHANICS

FOOTBOARD KEY TO FOOTBOARD COMPONENTS 1

1

2

2

3

3

4

4

37 38

39

5

5

6

6

7

7

11

10

39

12

40

8 8

9

9

10

11

36

41

43

42

35

12

34 13

16

17

18 22 21

19 23

14 15

16

19

23 25

20 21

22 26

10

28

29

30

29

25 22 26 31 32

30 27

24

27 28

33

SERVICE

Ref.

MECHANICS

Description

Ref.

Description

1

Nut fastening spring runner pin

23

Bush

2

Spring adjuster bush

24

Lower screw fastening gas springs

3

Upper spring washer

25

Washer

4

Spring

26

Footboard closure adjuster screw

5

Lower spring washer

27

Grease nipple

6

Lower bush for spring runner pin

28

Bolt fastening footboard

7

Spring runner pin

29

Bush

8

Pin

30

Bushing

9

Bush

31

Nut fastening footboard

10

Roller

32

Footboard

11

Grease nipple

33

Clip

12

Clip

34

Rubber footboard

13

Screws fastening gas spring support

35

Screws fastening rubber footboard

14

Gas spring support

36

Man presence sensor support

15

Upper screw fastening gas spring

37

Screws fastening man presence sensor support

16

Bush

38

Man presence sensor

17

Washer

39

Screws fastening footboard to frame

18

Upper nut fastening gas spring

40

Closed footboard sensor

19

Gas spring

41

Nuts fastening closed footboard sensor support

20

Lower nut fastening gas springs

42

Closed footboard sensor support

21

Washer

43

Screws fastening closed footboard sensor

22

Spacer

11

MECHANICS

SERVICE

REMOVAL OF THE FOOTBOARD ASSEMBLY Equipment and tools

socket wrench 15 mm

ratchet

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the clamps to the ground, turn the keyswitch to OFF and disconnect the battery

A Fig. 1 Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER").

Phase 2 15 mm socket wrench - ratchet Unscrew and remove the nuts fastening the footboard support to the truck base (ref.A fig.1). Disconnect the connectors of the footboard sensors (X10) and remove the footboard support assembly.

Dismantle and replace.

12

SERVICE

MECHANICS

FOOTBOARD GAS SPRING REPLACEMENT Equipment and tools

socket wrench 15 mm

ratchet

2 open ended spanners 10 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the clamps to the ground, turn the keyswitch to OFF and disconnect the battery

Phase 1 Remove the footboard (see "FOOTBOARD ASSEMBLY REMOVAL”).

Phase 2 15 mm SOCKET WRENCH - RATCHET - 2 x 10 mm OPEN ENDED SPANNERS Unscrew and remove the screws fastening the gas spring support (ref.A fig.2). Using an open ended spanner, lock the screw fastening the stems of the gas springs (ref.B fig.4), while with the other spanner unscrew and remove the nut (ref.C fig.4).

Phase 3 N.2 FIXED GAUGE 10 mm SPANNERS Extract the gas spring support and then extract both springs downwards (fig.5). Using an open ended spanner, lock the gas spring pivoting screw (ref.D fig.6), while with the other spanner unscrew and remove the nut (ref.E fig.6). Retrieve the springs, washers, bushes and spacers and proceed with the replacement.

Fig. 1

A Fig. 2

13

SERVICE

MECHANICS ASSEMBLY At the gas spring pivoting points, use SHELL “ADVANCE TEFLON CHAIN” lubricant.

The gas spring fixing screws must be tightened to a torque setting of 5 Nm.

Fig. 3 Fig. 4

B

C

Fig. 5

E

D

Fig. 6 14

SERVICE

MECHANICS

FOOTBOARD SPRING REPLACEMENT

Fig. 1

Equipment and tools

fixed gauge spanner 18-24 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the clamps to the ground, turn the keyswitch to OFF and disconnect the battery

A

Phase 1 Remove the footboard (see "FOOTBOARD ASSEMBLY REMOVAL”).

Fig. 2

B

Phase 2 18 - 24 mm OPEN END SPANNER Using the 18 mm open ended spanner, unscrew and remove the selflocking nut of the spring pin (ref.A fig.2). Extract the pin from its seat (fig.3), with the 24 mm open ended spanner slightly unscrew the threaded adjustment bush (ref.B fig.3), retrieve the washers and the spring (ref.C fig.4) and replace.

Fig. 3 ASSEMBLY

Fig. 4

After assembly, carry out the spring firmness adjustment procedure (see "FOOTBOARD SPRING ADJUSTMENT”).

C

15

SERVICE

MECHANICS FOOTBOARD SPRINGS adjustment When is this adjustment needed?

- When replacing the operator footboard - When replacing the operator footboard suspension springs Equipment and tools

fixed gauge spanner 18-24 mm

caliper

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

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

Lower the clamps to the ground, turn the keyswitch to OFF and disconnect the battery

Phase 1 18 - 24 mm OPEN ENDED SPANNER - CALIPER Using the spanners, adjust both threaded bushes for spring adjustment (ref.A fig.1) and the self-locking nuts (ref.B fig.1), while with the caliper measure the compression of the springs as shown in the drawing (fig.1).

16 mm

B A

15 mm 20 mm

Fig. 1

16

SERVICE

MECHANICS

SIDE PANELS KEY TO SIDE PANEL COMPONENTS

9 10 2

7

11

4

3

1

6 5 2

1 3

8

8

7

15

12 6

12

16

13

13

14

Ref.

Description

Ref.

Description

1

Side panels

9

Connector plate retaining screws

2

O-ring

10

Connector plate

3

Bush

11

Connector plate retaining nut

4

Closed side panel sensor

12

Bush

5

Open side panel sensor

13

Side panel support pin

6

Split pin

14

Gas spring

7

Screw fastening side panel assembly to frame

15

Side panel support

8

Spacer

16

Clip

17

SERVICE

MECHANICS SIDE PANEL ASSEMBLY REMOVAL Equipment and tools

T handle hex key 6 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the clamps to the ground, turn the keyswitch to OFF and disconnect the battery

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER").

Phase 2 HEXAGONAL 6 mm "T" SECTION SPANNER Disconnect the connectors of both side panel sensors (X9). With the hexagonal "T" section spanner unscrew and remove the 6 screws fastening the side panel assembly to the truck base (ref.A fig.1).

Remove the side panel assembly and proceed with replacement or disassembly.

18

Fig. 1

A

SERVICE

MECHANICS

SIDE PANEL REPLACEMENT Equipment and tools Fig. 1

hammer

plastic hammer

pin punch Ø 5 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the clamps to the ground, turn the keyswitch to OFF and disconnect the battery

A

Phase 1 HAMMER - PIN EXTRACTOR - PLASTIC HAMMER Using the hammer and the pin punch, drive out the spring pin pivoting the side panel (ref.A fig.2).

With the aid of the plastic hammer, extract the side panel upwards (fig.3).

Proceed with replacement

Fig. 2

Fig. 3

19

MECHANICS

SERVICE

SIDE PANEL GAS SPRING REPLACEMENT Equipment and tools

plastic hammer

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

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

Lower the clamps to the ground, turn the keyswitch to OFF and disconnect the battery

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER").

Phase 2 PLASTIC HAMMER Close the panels.

Using the hammer, moderately strike the ends of the gas spring (ref.B,C fig.1) from the bottom upwards so as to extract them. Retrieve the gas spring and proceed with replacement.

ASSEMBLY When assembling, keep the side panels closed so as to help insert the gas spring into its seat.

20

SERVICE

MECHANICS

Fig. 1

B

C

21

SERVICE

MECHANICS

LOAD WHEELS KEY TO LOAD WHEEL COMPONENTS TANDEM

1 3

4

2

4

4

6

5

7 9 8

Ref.

22

7

6

Description

1

Spring pin

2

Tie-rod pivot pin

3

Spacer roller

4

Bush

5

Load wheel fastening screw

6

Dust cover

7

Bearing

8

Load wheel

9

Spacer

SERVICE

MECHANICS

SINGLE ROLLER

1 3

4

2

4

8 6

5 7

9

7

Ref.

6

Description

1

Spring pin

2

Tie-rod pivot pin

3

Roller

4

Bush

5

Load wheel screw

6

Dust cover

7

Bearing

8

Load wheel

9

Spacer sleeve

23

SERVICE

MECHANICS REPLACEMENT OF THE LOAD WHEELS Equipment and tools

Fig. 1

T handle hex key 8 mm

small flat blade screwdriver

2 wooden blocks 150x150x500 mm

grease gun

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

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

Fig. 2

B

Phase 1 2 WOODEN BLOCKS Raise the clamps to the maximum height. Position the wooden blocks under the clamps (fig.1). Lower the clamps so that they rest on the wooden blocks and continue lowering until the load wheels are raised off the ground by about 2 cm.

Turn the keyswitch to OFF and disconnect the battery.

A

C

D E

Phase 2 8 mm T HANDLE HEX KEY Fig. 5 Using the T handle hex key, unscrew and remove the load wheel retaining screw (ref.A fig.2). Withdraw the load wheel from its support (ref.B fig.2) and proceed with its disassembly or repalcement.

WHEEL DISMANTLING Phase 3 SMALL FLAT BLADE SCREWDRIVER Using the small flat blade screwdriver, prise off the dust cap (ref.C fig.3) and recover the bearings (ref.D fig.4) and the spacer (ref.E fig.4).

Proceed with replacement INSTALLATION When fitting new load wheels, use medium Loctite on the thread and grease the portion under the head of the fixing screws. Tighten the screws to a maximum torque setting of 70 Nm. 24

SERVICE

MECHANICS

LOAD WHEEL ASSEMBLY REPLACEMENT Equipment and tools Fig. 1

hammer

driving tool Ø 15 mm

2 wooden blocks 150 x 150 x 500 mm

pin punch Ø 4 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Raise the clamps to the maximum height.

Phase 1 2 WOODEN BLOCKS Position the wooden blocks under the clamps (fig.1). Lower the clamps so that they rest on the wooden blocks and continue lowering until the load wheels are raised off the ground by about 2 cm.

B

A Fig. 2

C

Fig. 3

Turn the keyswitch to OFF and disconnect the battery.

Phase 2 HAMMER - PIN PUNCH - DRIVING TOOL Using the hammer and the pin punch, drive out the spring pin securing the pivot pin (ref.A fig.2). Drive out the pivot pin (ref.B fig.2) using the driving tool and the hammer.

D

Phase 3 HAMMER - PIN PUNCH - DRIVING TOOL Using the hammer and the pin punch, drive out the spring pin securing the pivot pin (ref.C fig.3). Drive out the pivot pin (ref.D fig.3) using the driving tool and the hammer. Withdraw the load wheel assembly from its housing.

Proceed with replacement.

25

SERVICE

MECHANICS

LINKAGE KEY TO LINKAGE ASSEMBLY COMPONENTS

2

1 2

2

6

2 7 8

8

9

2 2

5

5

5

5

10 2

9

8

2

12

8

Ref.

26

4

6

11

2

3

Description

1

Load wheels assembly

2

Bush

3

Pivot pin for load wheels - clamp

4

Tie rod pivot pin - load wheels

5

Spring pin

6

Spacer roller

7

Tie rod

8

Grease nipple

9

Retaining plate

10

Truck base pivot pin

11

Tie-rod pivot pin

12

Linkage assembly pin

5

SERVICE

MECHANICS

ADJUSTABLE TIE RODS (OPTIONAL)

1

3

6

2

5

2

4

7

8

5 9

10 2

5

7

2

7

7

5 12

14 7

13

2

7

11

2

Ref.

5

Description

1

Load wheels assembly

2

Grease nipple

3

Tie rod pivot pin - load wheels

4

Pivot pin for load wheels - clamp

5

Spring pin

6

Adjustable tie rod end

7

Bush

8

Tie rod adjuster pin

9

Tie rod adjuster locknut

10

Tie rod

11

Linkage assembly pin

12

Truck base pivot pin

13

Retaining plate

14

Drive unit pivot pin

27

SERVICE

MECHANICS REMOVAL OF THE LINKAGE ASSEMBLY Equipment and tools

hoist load capacity 2000 kg

2 lifting slings load capacity 1500 kg

pliers

long driving tool Ø 15 mm

lifting rope load capacity 1500 kg

spreader bar

open ended span- n. 2 wood beams ner 100 x 800 x 100 13 mm mm

hammer

socket wrench with flexible handle 9 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the clamps to the ground. Turn the keyswitch to OFF and disconnect the battery.

pin punch Ø 4 mm

Fig. 1

A

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER").

Remove the footboard (see "FOOTBOARD ASSEMBLY REMOVAL”).

Fig. 2 Phase 2 HOIST - SPREADER BAR - 13 mm OPEN ENDED SPANNER Open the battery compartment. Using the open ended spanner, unscrew the nuts of the battery blocks (ref.A fig.1). Remove both blocks.

Hook the spreader bar to the tackle. Position the hoist above the battery compartment. Attach the spreader bar to the battery; carefully lift the battery clear of the battery compartment with the hoist (fig.2).

Gently lower the battery to the ground and detach the spreader bar.

28

SERVICE

MECHANICS

Phase 3 PLIERS Using the pliers, remove the cotter pin of the cylinder (ref.B fig.3).

Phase 4 HOIST - 2 LIFTING SLINGS - 2 WOODEN BEAMS Sling the movable bodywork with the two lifting slings by means of the special attachments (ref.C fig.4).

Hook the belts onto the hoist, raise the bodywork to the top, set the beams under the clamps (fig.5), lower the hoist and rest the clamps on the beams. Unhook the belts.

B

Fig. 3 Phase 5 HOIST - 2 LIFTING SLINGS Sling the fixed bodywork with the two lifting slings by means of the special attachments (ref.D fig.4).

Hook the belts onto the hoist, take up the slack without raising the truck.

Fig. 4

C

D

Phase 6 9 mm SOCKET WRENCH WITH FLEXIBLE HANDLE - HAMMER - LONG DRIVING TOOL Using the socket wrench with flexible handle, unscrew and remove the grease nipple from the truck base pivoting pin (ref.E fig.7). Extract the plate retaining the pin (ref.F fig.7). Using the hammer and driving tool, eject and retrieve the pin from its seat (ref.G Fig.8). Perform the same operation on the other pin and separate the two bodyworks.

Pay attention to your hands, when extracting the pins, the two bodyworks might move and cause damage.

Operate the bridge crane and move the fixed bodywork outside the working range.

Fig. 5

29

SERVICE

MECHANICS Phase 7 HOIST - LIFTING ROPE With the greatest care and safety, and with the aid of the hoist and rope, overturn the movable bodywork and set it in the optimal condition for disassembling the linkage (fig. 9).

Fig. 6

Phase 8 HAMMER - PIN PUNCH - DRIVING TOOL Using the pin punch and hammer, drive out the split pins securing the pivot pins to the clamps (ref.H fig.10) Drive out the pivot pins (ref.I fig.10) using the driving tool and the hammer.

Fig. 7 Phase 9 HAMMER - PIN PUNCH - DRIVING TOOL Using the pin punch and hammer, drive out the split pin securing the pivot pin to the truck base (ref.J fig.10). Extract the pivot pin (ref.K fig.10) using the driving tool and the hammer.

Raise and remove the linkage assembly from the bodywork and rest it on a workbench.

Dismantle or replace.

F

H

E

Fig. 8

G

I J H I

K

Fig. 10 30

Fig. 9

SERVICE

MECHANICS

LINKAGE ASSEMBLY GREASING POINTS

Access to the two grease nipples on the linkage pivot pins is through the battery compartment.

Remove the battery before proceeding.

Grease gun

Access to the two grease nipples of the truck base pivot pins via the movable bodywork.

Raise the clamps to their full height before proceeding.

31

SERVICE

MECHANICS ADJUSTMENT OF THE LINKAGE ASSEMBLY (OPTIONAL)

In order to adjust the linkage well, the truck must be equipped with a full set of new, drive, pivot and load wheels. It must be set on a perfectly level surface raised off the floor to permit screwing in and unscrewing the adjusters.

The tie rods must be adjusted when, with clamps fully lowered, the height of the clamps off the ground measured with a metre rule is greater or less than the optimal height (88 mm - fig.1). In addition, the adjustment must also be made when a pair of load wheels does not touch the ground (fig.2). This means that a tie rod has been incorrectly adjusted.

Equipment and tools Fig. 1 88 mm

rule

open ended spanner 36-41 mm

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

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

Fig. 2 36 - 41 mm OPEN END SPANNER Set the truck on a perfectly flat base plate so that, after adjustment, all the support points (wheels) adhere completely to the floor.

Raise the straddle legs to the cylinder stroke end.

Using the 41 mm open ended spanner, loosen the lock nuts of the adjusters (ref.A fig.3).

Using the 36 mm open ended spanner, lengthen or shorten the tie-rod adjusters (ref.B fig.3) to obtain the desired distance.

After adjusting the tie rods, use the 41 mm open ended spanner to tighten the lock nuts.

A

Fig. 3

32

B

SERVICE

MECHANICS

33

SERVICE

MECHANICS

TILLER KEY TO TILLER COMPONENTS 2

3 4

1

5 6

41

7

40

10

39

8 11

38 37

9

12

13 36

15

35

16

34 14

17

18

19 20

33 21 22 23

32

25

31

24

30

29

27 26

28

34

SERVICE

Ref.

MECHANICS

Description

Ref.

Description

1

Tiller head

22

Washer

2

Nut

23

Upper plate retaining screws

3

Tiller sensor retaining screws

24

Steering sensor

4

Tiller limit stop damping

25

Steering sensor cam

5

Tiller sensor guard

26

Steering sensor cam fixing nut

6

Screws fastening tiller sensor support

27

Spring pin

7

Sensor

28

Pin

8

Tiller sensor support

29

Lower plate

9

Plate

30

Lower plate fastening screws

10

Tiller support

31

Bush

11

Buffer fastening screw

32

Upper plate

12

Buffer

33

Tiller support flange

13

Buffer fastening nut

34

Central chassis

14

Bush

35

Gas spring bush

15

Washer

36

Tiller gas spring

16

Pin

37

E-ring seal

17

Ball bearing

38

Buffer fastening screw

18

Plate fastening nut

39

Tiller sensor guard fastening screws

19

Plate

40

Tiller head support fastening screws

20

Wire harness

41

Washer

21

Circlip

35

SERVICE

MECHANICS STEERING BAR REMOVAL Equipment and tools

socket wrench 15 mm

ratchet

hammer

pin punch Ø 5 mm

long driving tool Ø 15 mm

Procedure

A

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

T handle hex key 5 mm

Fig. 1

D

Phase 1 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER").

Phase 2 15 mm SOCKET WRENCH - RATCHET With the wrench and ratchet unscrew and remove the fastening screws of the lower steering push rod (ref.A fig.1).

Phase 3 HAMMER - PIN PUNCH - DRIVING TOOL Using the hammer and pin punch, drive out the circlips retaining the steering rod hinge pin (ref.B fig.2).

Using the hammer and the driving tool, drive out the pin from the steering rod hinging (ref.C Fig.2).

Remove the lower steering rod.

Phase 4 5mm T HANDLE HEX KEY Using the socket wrench, unscrew and remove the four screws securing the castor wheel assembly to the truck body (ref.D fig.1). Remove the push rod at the base of the steering column and proceed with the replacement of the two parts.

INSTALLATION The screws fastening the two brackets must be tightened using Loctite 222 with a torque setting of 25-30 Nm. 36

C B Fig. 2

SERVICE

MECHANICS

DISMANTLING THE TILLER ASSEMBLY Equipment and tools

T handle hex key medium external 5 mm circlip pliers

hammer

plastic hammer

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

long driving tool Ø 15 mm

Fig. 1

B A

Phase 1 Remove the motor compartment cover and the upper cover (see "COVER REMOVAL").

Remove the side panel assembly (see “SIDE PANEL ASSEMBLY REMOVAL”).

Phase 2 5mm T HANDLE HEX KEY With the Allen wrench, unscrew and remove the four screws securing the upper steering rod (ref.A fig.1).

With the Allen wrench, unscrew and remove the fastening screws of the steering sensor cam (ref.B fig. 1).

Fig. 2

C

Fig. 3

Phase 3 15 mm SOCKET WRENCH - RATCHET Using the socket wrench and the ratchet, unscrew and remove the screws securing the tiller assy to the chassis (ref.C fig.2).

Withdraw the tiller assy (fig.3) and proceed to dismantle.

37

MECHANICS

SERVICE

TILLER SUPPORT

Fig. 4

Phase 4 MEDIUM EXTERNAL CIRCLIP PLIERS - PLASTIC HAMMER Use the circlip pliers to remove the circlip blocking the tiller support (ref.D fig.4). Using the plastic hammer beat the flange and remove the tiller support from the lower casing.

BEARINGS Phase 5 HAMMER - CLAMP GUDGEON Using the hammer and the driving tool, extract the two bearings (ref.E-F fig.4) and replace them.

E

F D

38

SERVICE

MECHANICS

REPLACEMENT OF THE TILLER GAS SPRING Equipment and tools Fig. 1

medium Phillips screwdriver

T handle hex key round-nose pliers 4 mm

A

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Phase 1 4 mm T HANDLE HEX KEY Unscrew the bolts securing the upper casing (ref.A fig.1).

Phase 2 MEDIUM PHILIPS SCREWDRIVER With the screwdriver, unscrew and remove the screws fastening the tiller buffer (ref.B fig.2). Recover the buffer (ref.C fig.2).

Removing the buffer relieves the force of the tiller spring, thereby making it easier to remove and install the tiller.

Fig. 2

C B

Fig. 3

D

Phase 3 ROUND-NOSE PLIERS Using the pliers, remove the e-ring retaining the gas spring (ref. D fig.3).

Remove the spring and proceed with the replacement.

Fig. 4

39

SERVICE

MECHANICS TILLER REPLACEMENT Equipment and tools

medium Phillips screwdriver

hexagonal "T" section spanner 4-8 mm

round-nose pliers

open ended spanner 16-24 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

A

B Phase 1 Remove the tiller gas spring (see “REPLACEMENT OF THE TILLER GAS SPRING”).

Phase 2 FIXED 16 mm SPANNER - 8 mm HEXAGONAL "T"" SECTION SPANNER Using the open-ended spanner keep the locking nuts (ref.A fig.1) while with the hexagonal "T" section spanner unscrew and remove the screws fastening the tiller housing to the tiller (ref.B fig.1). Remove the tiller head and retrieve the washers.

Phase 3 24 mm OPEN ENDED SPANNER Using the open ended spanner unscrew and remove both pins pivoting the tiller to the support (ref.C Fig.2). Recover the washers.

Remove the tiller and proceed with the replacement.

40

Fig. 1

Fig. 2

C

C

SERVICE

MECHANICS

traction motor KEY TO TRACTION MOTOR COMPONENTS 1 2 4 7

5 3 8

6 9 11

10

13 12 14 15

Ref.

Description

Ref.

Description

1

Circlip

9

Upper-lower flange fastening screws

2

Circlip

10

Upper-lower flange fastening nuts

3

Upper bearing

11

Terminal board

4

Upper bearing circlip

12

Stator

5

Elastic ring

13

Lower bearing

6

Rotor

14

Lower flange

7

Upper flange

15

Oil seal

8

Heat sensor

41

SERVICE

MECHANICS REMOVAL OF THE TRACTION MOTOR Equipment and tools

Fig. 1

2 open ended spanners 13 mm

hexagonal "T" section spanner 6 mm

brush

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

Completed rotate the steering unit, turn the keyswitch to OFF and disconnect the battery.

Fig. 2 Phase 1 Carry out the electromagnetic brake removal procedure (see "REMOVAL OF THE ELECTROMAGNETIC BRAKE" in the "BRAKING SYSTEM" section).

Phase 2 2 x 13 mm OPEN ENDED SPANNERS Using the two spanners, unscrew the nuts securing the traction motor power supply cables. Note the position of the cables prior to removing them. Disconnect all the wiring connectors.

A

Phase 3 6 MM PIVOTING HEXAGONAL "T" SECTION SPANNER Unscrew and remove the screws fastening the traction motor to the reducer (ref.A fig.2).

Phase 4 Lift the motor until the shaft is completely clear of the reduction unit.

Remove it from the truck body and proceed with replacement or disassembly.

INSTALLATION Before installing the motor on the reduction unit, lubricate the drive shaft with a thin, even layer of special grease: "SHELL STAMINA GREASE RL 2" or "ALBIDA GREASE EP2".

During the coupling stage, carefully rotate the wheel shaft to help the motor shaft engage with the pinion.

The screws securing the reduction unit to the chassis must be tightened using a torque wrench to a torque of 25 Nm.

42

SERVICE

MECHANICS

Traction motor dismantlement Equipment and tools

T handle hex key 5 mm

adjustable pliers

medium internal circlip pliers

medium flat blade screwdriver

puller

plastic hammer

small external circlip pliers

open ended spanner 19 mm

small cross-head screwdriver

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

Fig. 1

A

F

Phase 1 Carry out the traction motor removal procedure (see “REMOVAL OF THE TRACTION MOTOR”).

REDUCTION UNIT COUPLING PINION REMOVAL Phase 2 ADJUSTABLE PLIERS - 19 mm OPEN ENDED SPANNER - EXTRACTOR Wrap the cloth around the brake lining guide pinion (ref.A fig.1) and using the pliers tighten it to hold the rotor still while unscrewing. Using the open ended spanner remove the nut (ref.B fig.1) securing the reduction unit drive pinion. Recover the washer.

c B

Phase 3 PULLER - ADJUSTABLE PLIERS Using the puller, remove the reduction unit coupling pinion (ref.C fig.1). Proceed with replacement Using the adjustable pliers, extract the pinion retaining key.

43

SERVICE

MECHANICS OIL SEAL REMOVAL

Fig. 2

Phase 4 MEDIUM FLAT BLADE SCREWDRIVER Using the flat blade screwdriver, prise the oil seal from its housing (ref.D fig.3). Proceed with replacement

BEARING REMOVAL Phase 5 SMALL CROSS-HEAD SCREWDRIVER With the screwdriver, unscrew and remove the screws fastening the terminal cover on the motor power cables (ref.E fig.2). Remove the cover to access the cables.

Phase 6 EXTERNAL CIRCLIP PLIERS - PULLER Use the pliers to remove the upper circlip securing the brake lining guide pinion (ref.G fig.4).

Using the puller, remove the pinion from the stator shaft.

Having removed the pinion, use the pliers to remove the lower circlip securing the brake lining sliding pinion fastener (ref.G fig.3).

Phase 7 5 mm HEXAGONAL "T" SECTION SPANNER - PLASTIC HAMMER With the hexagonal "T" section spanner unscrew and remove the three fastening screws holding the engine in place (ref.H fig.3).

Using the hammer beat the upper flange carefully and remove the rotor complete with the flange.

E

Fig. 3

G J I

H

K

Phase 8 EXTERNAL CIRCLIP PLIERS Using the circlip pliers remove the circlip holding the bearing to the flange (ref.I fig.3) and retrieve the bearing (ref.J fig.3) and replace.

Phase 9 CIRCLIP OPENING PLIERS - PLASTIC HAMMER - extractor Using the circlip pliers remove the circlip holding the rotor shaft to the flange (ref.K fig.3) and using the hammer slide the rotor shaft from the flange. Using the puller, extract the bearing from the rotor shaft (ref.L fig.3) and replace it.

L

D

44

F

SERVICE

REDUCTION UNIT

reduction unit KEY TO REDUCTION UNIT COMPONENTS ������������������������������������������������������������������������������������������������������������� 2 REMOVAL OF THE REDUCTION UNIT ��������������������������������������������������������������������������������������������������������������������� 4 DISASSEMBLY OF THE REDUCTION UNIT �������������������������������������������������������������������������������������������������������������� 6 CHANGING THE REDCUTION UNIT OIL ���������������������������������������������������������������������������������������������������������������� 10

1

SERVICE

REDUCTION UNIT

KEY TO REDUCTION UNIT COMPONENTS 1

2

3

31 30

4

29

5

28

6

27 7

26 25

8

24 9

15

14

23

10 11 13

12

22 21

16

20 14

15

17

18

32

19

gearbox type

supplier code TYP.

part number

CODE

production date

DATE

32

C.P.N.

2

NR

serial number

SERVICE

Ref.

REDUCTION UNIT

Description

Ref.

Description

1

Traction motor

17

Circlip

2

Reduction unit drive pinion

18

Circlip

3

Motor flange O-ring

19

Oil seal

4

Retaining ring

20

Drive wheel

5

Stud bolt and self-locking nut

21

Hex head screw

6

Breather plug

22

Washer

7

Flanged pivot bearing

23

Bevel gear pair

8

Tiller support retaining screw

24

Bevel pinion

9

Tiller support

25

Pinion retaining key

10

Oil filler plug

26

Lower taper roller bearing

11

Reduction unit housing

27

Shims

12

Oil drain plug

28

Spacer

13

Crown wheel

29

Upper taper roller bearing

14

O-ring

30

Helical gear

15

Spacer

31

Hex nut

16

Ball bearings

32

data plate

3

SERVICE

REDUCTION UNIT

REMOVAL OF THE REDUCTION UNIT Equipment and tools

T handle hex key 8 mm

hydraulic jack

2 wooden blocks

extension bar

ratchet

oil pan

socket 13 mm

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

A

Fig. 1

Phase 1 Carry out the drive wheel removal procedure (see “REMOVAL OF THE DRIVE WHEEL” in the “MECHANICS” section).

Phase 2 Perform the tiller steering bar dismantling procedure (see “DISMANTLING THE STEERING BAR” in the “MECHANICS” section).

B

Phase 3 Carry out the traction motor removal procedure (see “REMOVAL OF THE TRACTION MOTOR” in the “MECHANICS” section).

Fig. 2 4

SERVICE

REDUCTION UNIT

Phase 4 OIL PAN - 8 mm FLEXIBLE T HANDLE HEX KEY Position the oil pan under the reduction unit.

Using the hexagonal T section spanner, loosen and remove the oil filler cap (ref.A fig.1).

Using the same spanner, loosen and remove the oil drain plug (ref.B fig.2). Drain all the oil into the pan.

Clean the drain plug thoroughly to remove any impurities that may have accumulated during operation of the reduction unit and screw it back in place.

C

Fig. 3 Phase 5 HYDRAULIC JACK - 13 mm SOCKET - EXTENSION BAR - RATCHET Position the hydraulic jack beneath the reduction unit and lift until the jack is supporting the reduction unit.

Using the socket wrench, the extension bar and the ratchet, unscrew the screws securing the reduction unit to the chassis (ref.C fig.3).

Lower the jack completely, being careful to support the reduction unit.

Recover the reduction unit, place it on the clean workbench and proceed with replacement or disassembly.

INSTALLATION The screws securing the reduction to the chassis must be tightened using a torque wrench to a torque of 25 Nm.

5

SERVICE

REDUCTION UNIT DISASSEMBLY OF THE REDUCTION UNIT Equipment and tools

vice

medium/large bearing puller

8 mm hex socket wrench

ratchet

A

driving tool

hammer

slide hammer puller

open ended spanner 30 mm

B

Fig. 1

C

Fig. 2 oil resistant gloves

medium extrnal circlip pliers

large internal circlip pliers

medium flat blade screwdrivers

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

Phase 1 OIL RESISTANT GLOVES Wear the oil resistant gloves.

Carry out the reduction unit removal procedure (see “REMOVAL OF THE REDUCTION UNIT”).

D

Fig. 3

E

F

Fig. 4 6

SERVICE

REDUCTION UNIT

Phase 2 VICE - MEDIUM FLAT BLADE SCREWDRIVER Hold the reduction unit firmly in the vice.

Using the flat blade screwdriver, prise out the oil seal (ref.A fig.1).

G

Phase 3 LARGE INTERNAL CIRCLIP PLIERS Use the circlip pliers to remove the circlip securing the crown wheel of the bevel gear pair (ref.B fig.2). Recover the spacers (ref.C fig.2).

Fig. 5

H Phase 4 SLIDE HAMMER PULLER Screw the threaded part of the puller shaft into the hole in the hub (ref.D fig.3). Extract the complete crown wheel (fig.3).

I

Phase 5 MEDIUM EXTERNAL CIRCLIP PLIERS Use the circlip pliers to remove the circlip securing the bearings (ref.E fig.4). Recover the spacers (ref.F fig.4).

Phase 6 LARGE BEARING PULLER Use the bearing puller to remove the two hub bearings (ref.G fig.5).

Fig. 6 Phase 7 LARGE INTERNAL CIRCLIP PLIERS Use the circlip pliers to remove the circlip securing the flanged pivot bearing (ref.H fig.6). Remove the pivot bearing (ref.I fig.6).

J

Phase 8 6 mm HEX BIT SOCKET - RATCHET Using the hex bit socket and the ratchet, unscrew and remove the screws securing the steering pivot bearing (ref.J fig.7). Recover the complete pivot bearing assembly.

Fig. 7 7

SERVICE

REDUCTION UNIT Phase 9 30 mm OPEN ENDED SPANNER - HAMMER - DRVING TOOL Using the open ended spanner, loosen and remove the nuts securing the bevel pinion to the helical gear (ref.K fig.8). Using the hammer and the driving tool, drive out the the bevel pinion and withdraw it through the inside of the reduction unit (fig.8). Withdraw the helical gear (ref.L fig.9) and recover the pinion shaft retaining keys (ref.M fig.9).

K

Phase 10 MEDIUM BEARING PULLER Recover the upper bearing (ref.N fig.10) and the spacers (ref.O,P fig.10).

Using the bearing puller remove the bearing from the pinion (ref.Q fig.10) and recover the spacers (ref.R,S,T, fig.10).

Fig. 8

M

L

INSTALLATION To facilitate bearing installation, during removal make a note of the positioning of the spacers.

Use Loctite 243 when assembling the parts and tighten the bolts following the indications given in fig.11.

Fig. 9

R O N S Q

P

T

Fig. 10

8

SERVICE

REDUCTION UNIT

25 - 35 Nm 60 - 70 Nm

25 - 27 Nm

45 - 50 Nm

20 - 25 Nm

20 - 25 Nm 83 - 109 Nm

Fig. 11

9

SERVICE

REDUCTION UNIT

CHANGING THE REDCUTION UNIT OIL Equipment and tools

oil resistant gloves

oil pan

hydraulic jack

T handle hex key 6-8 mm

oil syringe

torque wrench

2 wooden blocks

Procedure

Fig. 1

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Use caution as the oil in the reduction unit will be hot after use of the truck. Wear oil resistant gloves capable of withstanding high temperatures.

Do not dispose of used oil in the ground or by pouring it down the drain. Contact a waste disposal company specialised in the disposal and recycling of industrial oils.

Phase 1 HYDRAULIC JACK - 2 WOODEN BLOCKS Position the hydraulic jack on the right-hand side of the truck body and raise the truck sufficiently to insert the wooden block underneath. Lower the jack so that the truck rests on the wooden block. Repeat the operation on the other side of the truck body (fig.1).

A

Fig. 2 10

SERVICE

REDUCTION UNIT

Phase 2 Remove the cover of the motor compartment (see ”REMOVAL OF THE COVER" in the "MECHANICS" section).

Phase 3 OIL RESISTANT GLOVES - OIL PAN Clean the area around the oil filler and drain plugs thoroughly. Place a suitably sized oil pan beneath the drain plug.

Phase 4 OIL RESISTANT GLOVES - OIL PAN - 8 mm FLEXIBLE T HANDLE HEX KEY - TORQUE WRENCH - OIL SYRINGE Using the flexible T handle hex key, loosen and remove the oil filler plug (ref.A fig.2).

Using the same key, loosen and remove the oil drain plug (ref.B fig.3).

Drain all the oil into the pan.

Clean the drain plug thoroughly to remove any impurities that may have accumulated during operation of the reduction unit and screw it back in place.

The oil drain plug must be tightened using a torque wrench to a torque of 22 Nm.

Use Standard Cold store

Oil type ESSO UNIFARM 15W - 40

B

Fig. 3

Fig. 4

L

OI

Quantity 1.4 litres

Using an oil syringe to fill the reduction unit (fig.4) makes for quick and easy oil changes.

The correct quantity of oil is achieved when the oil reaches the lower edge of the oil filler hole or, at most, overflows out of the filler hole.

The oil filler plug must be tightened using a torque wrench to a torque of 22 Nm.

11

REDUCTION UNIT

12

SERVICE

SERVICE

BRAKING SYSTEM

braking system KEY TO THE ELECTROMAGNETIC BRAKE COMPONENTS ��������������������������������������������������������������������������������� 2 OPERATION ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 3 BRAKING systems �������������������������������������������������������������������������������������������������������������������������������������������������� 3 REMOVAL OF THE ELECTROMAGNETIC BRAKE ������������������������������������������������������������������������������������������������� 4 ELECTROMAGNETIC BRAKE ADJUSTMENT ���������������������������������������������������������������������������������������������������������� 6

1

SERVICE

BRAKING SYSTEM

KEY TO THE ELECTROMAGNETIC BRAKE COMPONENTS

1

2 3 5

4 6

8

7

9

10

Ref.

2

Description

1

Retaining screw

2

Electromagnet

3

Brake plate

4

Circlip

5

Adjusting screw

6

Pinion

7

Rotor

8

Friction disc

9

Dust cover

10

Disc

SERVICE

BRAKING SYSTEM

OPERATION The electromagnetic brake mounted on the traction motor is a spring-operated brake.

When the electromagnet is powered, it attracts the brake plate and releases the friction disc, allowing the latter to rotate freely.

When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction disc, thus applying the brake.

BRAKING systems There are 4 braking systems used:

• • • •

drive control release

Release braking Braking on direction reversal Emergency braking Parking brake

A) Release braking Controls the deceleration ramp when the drive control is released.

B) Braking on direction reversal Controls the deceleration ramp when the travel direction is inverted.

“Braking on direction reversal", also know as counter current braking, consists of reversing the current supplied to the motor, thus changing the direction of travel when the truck is in motion.

The braking current must be adjusted so that the truck stops in a distance that is at least not less than the length of the truck itself.

direction reversal

C) Emergency braking Emergency braking occurs when an alarm is triggered that requires an immediate arrest of truck traction or when the tiller sensor is deactivated (tiller in rest position or fully lowered).

The braking action is performed by the electromagnetic brake mounted on the traction motor.

D) Parking brake The "parking brake" action is performed by the electromagnetic brake and is applied when the truck is stationary and the tiller is in the rest position.

3

SERVICE

BRAKING SYSTEM

REMOVAL OF THE ELECTROMAGNETIC BRAKE Equipment and tools Fig. 1

T handle hex key 5 mm

open ended spanner 15 mm

A scissors

external circlip pliers

B

large cross-head screwdriver

puller

C

Fig. 2

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

Move the truck to a safe place, away from areas of transit of other vehicles and pedestrians. Lower the forks to the ground, turn the key switch to OFF and disconnect the battery.

Fig. 3 When replacing the rotor, the pinion must also be replaced.

Phase 1 Remove the motor compartment cover, the wheel cover and the motor cover (see "REMOVAL OF THE COVERS” in the "MECHANICS" section).

D

Fig. 4

E F

4

SERVICE

BRAKING SYSTEM

Phase 2 open ended spanner - 5 mm T handle hex key - scissors Remove the dust cover (ref.A fig.1).

Using the open ended spanner, loosen the three adjustment nuts (ref.B fig.1).

Using the T handle hex key, unscrew the three screws securing the electromagnetic brake to the traction motor (ref.C fig.2).

Use the scissors to cut the cable ties to release the electromagnetic brake power cable. Disconnect the wiring connector and withdraw it from the tab.

Remove the electromagnetic brake from the motor (fig.2).

Phase 3 EXTERNAL CIRCLIP PLIERS - PULLER Withdraw the rotor (ref.D fig.3) from the pinion.

Using the circlip pliers, remove the circlip from the drive shaft (ref.F fig.4). Using the extractor remove the pinion (ref.E fig.4).

INSTALLATION After installation, proceed with the adjustment of the electromagnetic brake.

5

BRAKING SYSTEM

SERVICE

ELECTROMAGNETIC BRAKE ADJUSTMENT

C

A B

Fig. 1

After re-installing the electromagnetic brake assembly, before using the truck, the friction disc must be adjusted.

To obtain a good braking action, the distance between the friction disc and the brake plate (ref.A fig.1) must not be greater than 0.35 mm. A feeler gauge of this size is therefore required.

With the three nuts loose (ref.B fig.1), insert the feeler gauge near one of the bolts, tighten the retaining screw (ref.C fig.1) with the hex key and position the plate so the feeler gauge can be withdrawn with a little friction. Repeat the operation with all three bolts.

Tighten the nuts using the open ended spanner (ref.B fig.1).

6

SERVICE

STANDARD MAINTENANCE

standard maintenance OILS AND LUBRICANTS ������������������������������������������������������������������������������������������������������������������������������������������� 4 CLEANING PRODUCTS ��������������������������������������������������������������������������������������������������������������������������������������������� 4 SCHEDULED MAINTENANCE ����������������������������������������������������������������������������������������������������������������������������������� 5

1

STANDARD MAINTENANCE

SERVICE

WARNINGS •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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

•

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

•

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

•

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

•

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

•

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

•

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

2

SERVICE

STANDARD MAINTENANCE

•

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

•

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

•

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

•

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

•

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

Close the valves at the end of the maintenance work.

3

SERVICE

STANDARD MAINTENANCE

OILS AND LUBRICANTS Application OIL for lubrication of the HYDRAULIC CIRCUIT OIL for lubrication of the REDUCTION UNIT GREASE for lubrication OF MDU GEARS GREASE for lubrication of LEVERAGE TIE ROD PINS GREASE for lubrication of TILLER HEAD

Std

Cold store

Trademark

Type

Shell

TELLUS 32

Shell

AEROSHELL FLUID 41

 

     

 

Isolation of BATTERY PLI

Specifications DIN 51524 (part 2) HCE-80 MIL-H-5606G HCE-79

ESSO UNIFARM 15W-40

Shell

ADVANCE TEFLON CHAIN

Shell

ALBIDA GREASE EP2

MIL-G-24129A HCE-74

Shell

AEROSHELL GREASE 6

MIL-PRF-24139A

ITP SYNTHY GREASE 450/L ITP SYNTHY GREASE NYOGEL 760 G Pure Vaseline

CLEANING PRODUCTS Casing and plastic cover cleaning - Cleaning of painted truck parts For general cleaning of the truck, use only dry air, damp rags or degreasing detergents.

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

Motor and electronic system cleaning For general cleaning purposes use dry air at low pressure and a clean dry brush.

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

Mast profile and SMALL MAST cleaning Use degreasing solvents.

Do not use water jets, vapour, solvents or flammable products that may damage the small mast or be harmful to the operator.

4

SERVICE

STANDARD MAINTENANCE

SCHEDULED MAINTENANCE  = check and maintenance by specialist technician  = operator check x = replacement

Maintenance intervals Every 8 hours 1 day

Operation description

Every Every Every 1000 hours 2000 hours 3000 hours 12 months 24 months 36 months

Welding check



BRAKING SYSTEM

MOTORS

HYDRAULIC SYSTEM

TRUCK BASE

General cleaning



Dynamic braking action check





Reverse braking action check





Normal braking action check





Emergency braking action check





Electromagnetic brake and coil efficiency check





Brake lining check

(1)



General cleaning



Oil leak check





Valve operation check





Tank oil level check



General cleaning Flexible pipe check

 (2)



Tank oil change

x

Oil filter change

x

Motor insulation check



Cable connection check



Fixing nut condition check



Bearing noise check

 

Oil leak check





Check general condition of reducer



General cleaning



Reducer oil change

x

Check condition and wear of drive wheel WHEELS & TYRES

FORKS

REDUCTION UNIT

General cleaning

(1)





Check condition and wear of load wheels (1)













Check condition and wear of castor wheels

(1)

Check condition of castor wheel swinging support bearings (1) Check drive wheel fixing nut tightness



Load wheel bearing check (1



Check the castor wheel fixing nut tightening



Check the drive wheel-tiller alignment Check fork condition

 



General cleaning CAB



Check the side guard conditions and operation



Check the platform conditions and operation



TILLER

Check the platform suspension spring efficiency



Check the tiller conditions and operation



Check the gas tank efficiency



Check the tiller screw tightening



Check the tiller head screw tightening



Steering thrust bearing check



(1

5

SERVICE

STANDARD MAINTENANCE

 = check and maintenance by specialist technician  = operator check x = replacement

Operation description

GREASING POINTS

BATTERY

ELECTRICAL SYSTEM

Battery plug/socket integrity check

LINKAGE

(1)

Every 8 hours 1 day

Every Every Every 1000 hours 2000 hours 3000 hours 12 months 24 months 36 months



Electrical connection check



Fixing nut condition check



Electrical wiring check



Sensor efficiency check



General cleaning of electrical panel



Battery charge check



Cable connection check



Liquid leaks check



Electrolyte density check



Electrolyte level check



(3)

Battery insulation check



General cleaning



Greasing the pins and bushings



Lubrication of platform suspension springs Linkage check

  

Check the tightening of the screws and bolts



CONTROLS

Check all load bearing elements

Check machine functions with actuating controls



SAFETY DECALS

CHASSIS

Maintenance intervals

Check safety labels and decals



replace if necessary

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

(3)

6

fill up whenever the electrolyte levels falls to 5 - 10 mm (0.19-0.39 in) from the plate unit

SERVICE

STANDARD MAINTENANCE

7

Codice: 550063444

Revision: 0 (06/2013)

Part no.: 550072197

Revision:

0 (12/2012)

KEYPAD

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

MULTIFUNCTION KEYPAD

KEYPAD

SERVICE

IMPORTANT We recommend you read this manual carefully in order to avoid accidents with personnel or damage and keep it in a good condition so it is always decipherable and complete.

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

2

Product support group

SERVICE

KEYPAD

Contents INTRODUCTION.......................................................................................................................................................... 4 CONNECTIONS........................................................................................................................................................... 4 KEYPAD....................................................................................................................................................................... 5 SWITCHING ON AND ENABLING THE TRUCK FOR USE....................................................................................... 5 Entering the password..................................................................................................................................... 6 user changeover................................................................................................................................................. 7 supervisor menu.................................................................................................................................................. 8 create a new user................................................................................................................................................ 9

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INTRODUCTION The Keypad is a multifunction instrument comprised of a keypad, display and internal memory.

This device allows truck operation to be enabled on entry of an identification code.

SPECIFICATIONS •

Required length of the identification code: 5 characters

•

Maximum number of permitted users: 256 (plus an administrator user)

CONNECTIONS

4-pin connector: 1) +VBatt 24 Vdc (max 30 Vdc) 2) GND 3) No Relay 4) No Relay

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KEYPAD The keypad is composed of 10 numeric keys (from 0 to 9) and two alphanumeric keys “*“ and “#”.

Keys "2" and "0" have a double function as they allow the administrator user to move within the supervisor menu.

The "#" key is used to confirm an operation.

The “*“ key is used to delete a value entered or to go back to the previous menu.

SWITCHING ON AND ENABLING THE TRUCK FOR USE Turn the key switch to ON (1).

The display will light up and show the version of the firmware.

After approximately 2 seconds the welcome message will appear.

It is now possible to enter the identification code (PIN).

There are two levels of identification: •

User -The PINs of the various users are created by the administrator (Master) or by the specialist technician (Service). Enter the five-digit user code with the numeric keypad and confirm with “#” to enable use of the truck by the user.

•

Administrator - Enter the administrator code 56789 (default value) with the numeric keypad and confirm with “#” to access the supervisor menu where you can: - Create a new user - Block or unblock a user - Read and change the password of a user - Read and change the administrator's password

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Entering the password On pressing a numerical key the display shows the screen for entering the password,

where the "+" symbol indicates the digits already entered and "-" those still to be entered.

Any digit entered after the maximum number allowed (five) is not considered by the system.

To delete an incorrect digit, press To confirm the password entered press

. .

If the password entered is correct, the display will show the enabled user's number (for example user 3):

All the truck's functions are now enabled.

On the contrary, if the password entered is not correct (or the user has been blocked by the administrator), the display will show this message:

If instead confirmation is given with "#" before entering all the digits forming the password,

the display will show this message:

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user changeover The device can be controlled by one user at a time. In the case of access by an enabled user, if another one tries to obtain access by entering his own password, no operations are carried out.

User 3 switches on the truck and enters the password.

The password is correct and user 3 can begin using the truck.

User 1 enters his own password.

Use of the truck remains enabled for user 3.

To allow another user to be able to access and use the truck, the user that has it in use must first disconnect by entering the password.

User 3 switches on the truck and enters the password.

The password is correct and user 3 can begin using the truck.

User 3 enters the password again to be disconnected.

The password is correct and the device is ready to accept a new user.

If the key switch is turned OFF (0), the device automatically disconnects the user.

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KEYPAD

supervisor menu To access this menu it is necessary to enter the Master password (56789 by default).

On entering the Master password, at any time, all active functions are switched off to permit access to the supervisor menu.

The display shows a guide to the enabled keys,

which have the following functions: • "0": scrolls through the list of registered users in ascending order, passing from the first item of "New User" to the last one of "Master".

• "2": scrolls through the list of registered users in descending order, passing from the last item of "Master" to the first one of "New User".

• “#”: select.

• “*”: exit.

... ...

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create a new user To create a new user, go onto "New User" using keys "0" and "2" and confirm your choice with the "#" key.

The display will request the password for the new user:

It is now possible to enter the password and confirm with the "#" key or go back to the previous menu without creating a user by pressing the "*" key.

If an existing password is entered, the user is still created but he will not be able to access the truck functions since, for the same password, the first user in the list takes priority over the others.

If the same password is wrongly entered by the administrator user (Master), the user is in any case created but the password remains associated with the administrator.

If you try to create a user when the maximum limit on the number of users that can be registered (256) has already been reached, the following message will appear on the display:

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Code: 550072197

Revision: 0 (12/2012)