Yale C852 (MS14-MS16) Service Manual - PDF DOWNLOAD by www.heydownloads.com

Part No.: 524301698

Revision:

1 (03/2010)

Technical information for Yale customer care centres

This manual is addressed to the skilled technicians of Yale service network

C846.....

MS10 - MS12 C852..... MS14 - MS16 MS14 I.L.- MS16 I.L.

PREFACE

SERVICE

IMPORTANT This manual contains detailed information about the routine and preventive maintenance, troubleshooting, disassembly/assembly of components, adjustment procedures for the following Hyster models: MS10 - MS12 - MS14 - MS16 - MS14 IL - MS16 IL. These procedures require specific technical knwoledge and they must be carried out only by qualified and trained staff. Please read this manual carefully in order to prevent damage or accidents to people; it must be kept in good conditions so that it is always readable and complete in all its parts. This manual is an integral part of the use and maintenance manual and it does not replace it.

Product support group

SERVICE

PREFACE

HOW TO USE THE MANUAL SECTIONS This manual is divided in the following sections: Section1: Introduction Section 2: Installation and settings Section 3: Diagnostics and measurements Section 4: Electrical system Secttion 5: Hydraulic system Sezione 6: Frame mechanics Sezione 7: Mast assembly mechanics Sezione 8: Reduction gear Sezione 9: Braking system Sezione 10: Ordinary maintenance

Always refer to the index with the numbered black bands in order to go to the desired section. SYMBOLS It indicates the presence of a danger that can cause accidents to people or damage to the truck. It indicates a danger due to high temperatures.

It indicates notes or important information to be taken into consideration. It indicates that, in the electronic version of the manual, by clicking on this symbol it is possible to display a filmed sequence.

ASSEMBLY PROCEDURE For the assembly carry out the disassembly procedure in the reverse order complying with the information and the notes concerning the correct operation of the truck.

PREFACE

SERVICE

GENERAL SAFETY STANDARDS PERSONAL SAFETY •

Always use the personal protective equipment when it is required.

•

Pay attention to the squashing risks due to moving parts, oscillations, not correctly fastened materials when lifting operations are carried out or when the loads are moved.

•

Do not wear rings, watches, jewels, unbuttoned or hanging clothes such as scarves, unbuttoned jackets or smocks with open zips that can get entangled in the moving parts.

•

Never carry out cleaning, lubrication or maintenance operations when the battery is connected.

•

IIf you use compressed air to clean the parts, wear glasses with lateral guards. The air pressure must not be higher than 1 bar.

SAFETY IN THE WORKPLACE •

Make sure that all working tools are perfectly efficient and ready to use. Keep the working surfaces clean and free from the deposits that settle on the truck parts and cause damage.

•

Keep sparks, free flames and cigarettes at a distance from fuels or flammable materials such as the gas of the batteries.

•

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

•

Make sure that the lifting equipment, devices or machines can bear the load.

•

ver use petrol, gas oil or other flammable liquids as detergents: use commercial non-toxic and nonflammable solvents.

•

In case the interventions are carried out of the workshop, lay the truck flat and block it. If it is necessary to carry out the work on slopes, block the truck and bring it in a flat area as soon as possible within a certain safety limit.

•

Disconnect the batteries and label all controls in order to indicate that an intervention is in progress. Block the truck and any equipment to be lifted.

•

Do not carry out any intervention on the truck when the operators are controlling it, except that they are qualified operators and help to carry out the intervention.

•

During towing operations use only the prescribed attachment points and make sure that the pins and/or bolts are tightly secured. Lift and move all heavy components by means of a lifting device of proper carrying capacity. Use the proper eyebolts. Make sure that nobody stays near the load to be lifted.

•

Do not twist chains or metal ropes.

•

Do not use damaged or bent chains or ropes: do not use them during lifting or towing operations. While handling them always wear safety gloves.

•

Do not accumulate cloths soaked with grease or oil: they represent a risk of fire. Always put them in a closed metal container.

•

The oil must be collected and not be let off in the drain pipes; the industrial oils must be disposed of by specialized companies under the protection of the law in force in every Country.

•

When welding operations are carried out, it is necessary to use proper accident-prevention protections: protective glasses, helmet, overalls, shoes. The protective glasses must be worn also by the people who do not carry out the works if they stay near a welding area.

SERVICE

PREFACE

•

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

•

Do not short-circuit the terminals.

•

The gas emanated during a recharge is higly flammable. During the recharge of the battery leave the battery compartment uncovered in order to use a more efficient ventilation and remove the plugs.

•

Do not check the condition of the battery charge by means of “jumpers” obtained by placing metal objects on the terminals.

•

Before any intervention check if there are no short-circuit elements.

•

Disconnect the batteries before acting on the electric system.

•

For the battery chargers and similar equipment, use only auxiliary electric power supply sources in order to avoid any electric shocks.

•

A fluid passing through a very small hole can be almost invisible but strong enough to penetrate into the skin; in these cases check the fluid by means of a card or a piece of wood.

•

To chek the pressure of the plant use the proper devices.

•

BANDS, ROPES AND HANGING ROPES: SUGGESTIONS FOR THE USE

•

Do not use bands, ropes or hanging ropes, whose identification plate has been lost.

•

Always use bands, ropes or hanging ropes of proper dimensions. As far as the hanging ropes are concerned, take into consideration the lifting angle and the unbalance of the load.

•

The hooks of the hanging ropes must have a proper size according to the hook of the bridge crane and they must move freely.

•

Position the load in the hook mouth.

•

Do not place the load on the point of the hook.

•

During lifting, do not carry out sudden operations that could tear the ropes and the bands.

•

Do not carry out lifting operations with twisted ropes and bands.

•

Knots are forbidden.Always protect the ropes and the bands when they are near sharp edges.

•

During the movements without load in order to avoid unintentional collisions or hooking, fasten the hooks to the proper seats and lock them.

Use of hanging ropes with unbalanced load If unbalanced loads must be lifted it is advisable to reduce the carrying capacity of the hanging ropes: • Slings with 2 arms, consider them as the slings with 1 arm. • Slings with 3 and 4 arms, consider them as the slings with 2 arms. Suggestions for maintenance Check the bands, the ropes and the hanging ropes according to the law in force in order to determine their working conditions. Carry out the replacement in the following cases: • When the components are deformed, cut or when there are cracks, hollows, notches or abrasions on them. • When the wear of the components is higher than 10% of the initial dimensions. • When the sling is overloaded.

SERVICE

PREFACE Rope capacity table

Colour

Working capacity (kg)

violet 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

1,4

0,8

orange orange orange orange orange

Coefficient

Band capacity table

Working capacity (kg)

Coefficient

Colour

Width (mm)

black violet black green yellow grey red browm 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

1,4

0,8

SERVICE

PREFACE

Hanging rope capacity table

Colour

Working capacity (kg) Coefficient

violet green yellow grey red

1000 2000 3000 4000 5000

1400 2800 3800 5600 6600

2100 4200 6300 8400 9800

2100 4200 6300 8400 10500

1,4

2,1

Working capacity: the working capacity is calculated with an angle in the centre of 90°.

SERVICE

PREFACE

DRIVING TORQUE OF SCREWS, NUTS AND CONNECTORS Before the disassembly of the various parts and of the bolts and screws, read carefully the instructions below. To tighten the screws use the product LOCTITE 270 in order to ensure the safety of the threaded couplings. If it is not possible to loosen the screws because this product is used, do not add extensions to the tools, but heat the area (maximum 50°C) in oder to eliminate the effect of LOCTITE 270. In the above-mentioned cases use a small quantity of LOCTITE 270 in the assembly phase (30% of the connection surface). The driving torque with which the threaded couplings are tightened is very important to ensure the safety of the truck connection. The bolts and nuts and the corresponding driving torques are shown in the tables on this page.

Preloading N

Class 8

Class 10

5,2

9,15

12,14

14,8

17,2

20,9

31,8

38,1

M 10

50,5

60,3

M 12

74,2

88,5

M 14

101,2

120,8

M 16

138,2

164,9

M 18

176,6

203,5

M 20

225,4

259,7

M 22

278,8

321,2

M 24

324,8

374,2

M 27

422,3

486,5

M 30

516,1

594,7

DRIVING TORQUE Nm Class 5.8

Class 8.8

Class 10.9

0,7

2400

1,92

1,44

3,07

2,3

4,17

3,13

0,8

3880

3,88

2,91

6,2

4,65

8,43

6,33

5490

6,58

4,94

10,5

7,9

14,3

10,8

1,25

9990

25,6

19,2

34,8

26,1

10700

17,1

12,8

27,4

20,5

37,3

27,9

M 10

1,5

15825

31,7

23,8

M 10

1,25

16700

33,4

25,1

40,1

M 12

1,75

23025

41,4

120

M 12

1,25

25150

45,3

130

M 14

31400

140

105

190

145

M 14

1,5

34125

155

115

210

155

M 16

42850

135

105

220

165

300

225

M 16

1,5

45600

145

110

235

175

320

240

M 20

2,5

66875

270

200

430

320

580

435

M 20

1,5

74250

295

225

475

355

650

485

= with lubricant

DRIVING TORQUE Nm

Nominal diameter

SERVICE

PREFACE

CORRECT METHOD TO APPLY THE FEMALE CONNECTORS To ensure an optimum connection between the female connectors and the adapters mentioned in this manual, it is necessary to carry out the following procedure, which is different from the one for the assembly of the rigid pipes. Female connectors without gasket (metal/metal connection) Screw the nut manually and then tigthen 1/4 turn by means of a spanner. Female connectors with O-RING Screw the nut manually and then tighten 1/4 turn by means of a spanner. In any case make sure that the pipe is correctly aligned before tightening the nut to the adapter. DRIVING TORQUE

Thread UNF

ROTARY METRIC FEMALE CONNECTOR Driving torque Nm External diameter Nominal torque min / max of the pipe

M 12x1,5

15 -25

M 14x1,5

30 - 45

M 16x1,5 M 18x1,5 M 20x1,5 M 22x1,5

10 10 12 12 14 15

38 - 52

43 - 85

50 - 65

60 - 88

Thread UNF

ROTARY METRIC FEMALE CONNECTOR jic 37° Driving torque Nm Dimension

Nominal torque

min / max

7/16-20

-4

9 - 21

1/2-20

-5

13 - 27

9/16-18

-6

18 - 42

3/4-16

-8

30 - 70

7/8-14

-10

44 - 94

1.1/16-12

-12

63 - 133 73 - 163

1.3/16-12

-14

118

1.5/16-12

-16

140

90 - 190

-20

210

135 - 285

M 24x1,5

60 - 88

1.5/8-12

M 26x1,5

105

85 - 125

1.7/8-12

-24

290

200 - 380

2.1/2-12

-32

450

300 - 600

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

135

115 - 155

166

140 - 192

240

210 - 270

290

255 - 325

330

280 - 380

22 25 28

38 42

ROTARY FEMALE CONNECTOR BSP Driving torque Nm

Thread UNF

ROTARY FEMALE CONNECTOR ORFS Driving torque Nm Dimension

Thread UNF

Nominal torque

max

9/16-18

-4

G1/4

15 - 25

11/16-16

-6

G3/8

27 - 41

13/16-16

-8

G1/2

42 - 76

1-14

-10

G5/8

44 - 94

1.3/16-12

-12

Nominal torque

max.

G3/4

115

95 - 135

1.3/16-12

-14

140

115 - 165

1.7/16-12

-16

125

135

G1.1/4

210

140 - 280

1.11/16-12

-20

170

190

G1.1/2

290

215 - 365

2-12

-24

200

225

400

300 - 500

2-1/2-20

-32

460

490

The values shown in the tables refer to to galvanized steel connectors. Different values correspond to connectors of different materials. 9

PREFACE

SERVICE

HYDRAULIC SYSTEM MAINTENANCE INSTRUCTIONS Before servicing the hydraulic system you must eliminate any residual circuit pressure. Using the Allen key provided, open valve “A” to discharge any residual pressure from the fork lifting circuit. Close the valve on completion of the maintenance operations.

SERVICE

PREFACE

INSTRUCTIONS FOR THE INSTALLATION OF HOSES AND CONNECTORS Visual check of hoses and connectors: if one of the following conditions occurs, the hose must be immediately disconnected and replaced:

• • • • • • •

movement of the connector on the hose; there are damage, cuts or abrasions on the surface; hardening or stiffness of the hose, burned parts or cracks due to heat; cracks, damage or corroded parts on the connector; leakages from the hose or connector; the hose has permanent folds, squashed or twisted parts; presence of bubbles, softening and wear of the external surface.

Pre-installation inspection: before installing a hose it is necessary to check the conditions of the pipes. First of all check if the type, the size, the reference code and the length are correct and then make sure that there are no impurities, obstructions, bubbles, external layer peeling-off or other visible defects. Installation: Do not twist the hose, otherwise it could break due to pressure. Consider a proper radius of curvature in order to avoid the bending or breaking. If the radius of curvature is lower than the minimum radius of curvature allowed, the life of the hose is considerably reduced. The pressure can change the length of the hose, up to + 2%. Therefore it is advisable to consider a length which is higher than the required one in order to compensate for such changes.

PREFACE

SERVICE

PREFACE

SECTION INDEX

Introduction

Installation and settings

Diagnostics and measurements

Electrical system

Hydraulic system

Frame mechanics

Mast assembly mechanics

Reduction gear

Braking system

Routine maintenance

10 13

PREFACE

SERVICE

PRESENTATION

presentation TRUCK PRESENTATION �� 2 TRUCK VIEWS �� 3 TRUCK AND LOAD IDENTIFICATION DATA �� 4 TRUCK IDENTIFICATION DATA PLATE �� 4 RESIDUAL LOAD PLATE �� 4 TRUCK AND MAST SERIAL NUMBER STAMP �� 5 DATA LOCATION �� 5 GENERAL SPECIFICATIONS �� 6

PRESENTATION

SERVICE

TRUCK PRESENTATION The new range of tiller lift trucks is made up of four models, with nominal loads of 1000kg - 1200kg - 1400kg - 1600kg: • • • • • •

MS10 MS12 MS14 MS16 MS14 IL MS16 IL

Electrical system The traction motor benefits from the use of alternate current three phase AC technology. The high battery efficiency is guaranteed by the regenerative nature of the breaking system and the energy retrieval achieved during the cab lowering stage with the forks loaded. The Combi AcO electronic control system communicates via the CAN-Bus system (Controller Area Network Bus). Hydraulic system The 2 kW and 3 kW pump motors guarantee excellent performance thanks to the technology with ON/OFF or proportional solenoid valves for the fork lifting/lowering operations with fluid movements of the actuators. Guidance system These are lift systems with ground operators. The tiller is mounted on the traction assembly. The low anchor point of the tiller enables no effort steering. Thanks to the SNAIL function one can also operate in tight corners. Mast The masts can be in one, two or three stages. The rigidity and stability characteristics of the masts allow the forks to reach heights of over 4 meters. The lift cylinders are of the type with a simple lift effect with an end point slowing system and a simple plunger effect with a full shaft.

SERVICE

PRESENTATION

TRUCK VIEWS

PRESENTATION

SERVICE

TRUCK AND LOAD IDENTIFICATION DATA TRUCK IDENTIFICATION DATA PLATE

The truck identification data plate is located on the truck base.

• • • • •

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

RESIDUAL LOAD PLATE

The load plate is located on the mast crossbar The load plate bears the following data:

• Model • Liftable load values up to varying heights up to the maximum load with different distances from the load centre of gravity of the forks.

SERVICE

PRESENTATION

Always refer to the load plate to be sure to lift an admissible load to an appropriate height. TRUCK AND MAST SERIAL NUMBER STAMP

The truck Serial number is located in side the engine compartment.

The mast serial number is located on the side of the external mast.

DATA LOCATION

The truck documentation located in the battery compartment.

PRESENTATION

GENERAL SPECIFICATIONS MS10 - MS12

SERVICE

PRESENTATION

WHEELS AND CHASSIS

WEIGHTS

CHARACTERISTICS

GENERAL SPECIFICATIONS 1.2

model

MS10

MS12

1.3

power: battery, diesel, LPG, petrol, electic

Battery

1.4

steering: tiller, accompanied, standing, sitting

tiller

1.5

load capacity, load

Q (t)

1.2

1.6

centre of gravity

c (mm)

600

1.8

load distance from the load bearing wheel axle

x (mm)

714

744 (1)

1.9

distance between the axles (WB)

y (mm)

1225

1315

2.1

unladen weight

880

960 (3)

2.2

load per axle when loaded (front/back)

660 / 1220

740 / 1420

2.3

load per axle when unladen (front/back)

610 / 270

670 / 290

3.1

covering: full rubber, polyurethane, vulkollan, (front/back)

polyur. / polyur.

3.2

front wheel size

ø 230 x 75

3.3

rear wheel size

ø 85 x 100

3.4

additional wheels (size)

ø 150 x 50

3.5

wheels: quantity, (x= traction) (front/back)

1x/2

3.6

front wheel tread

b 10 (mm)

515

3.7

rear wheel tread

b 11 (mm)

400

4.2

height of the upright assembly when closed

h1 (mm)

4.3

free lift

h2 (mm)

See upright assembly cutaway diagram

4.4

lifting

h3 (mm)

See upright assembly cutaway diagram

4.5

height of the upright assembly when removed

h4 (mm)

See upright assembly cutaway diagram

4.9

height of tiller in operating position (min/max)

h14 (mm)

695 / 1196

h13 (mm)

4.19 total length

l1 (mm)

1852

1912 (6)

4.20 length of the forks at the heel

l2 (mm)

692

752 (6)

ELECTICAL MOTORS

PERFORMANCE

DIMENSIONS

4.15 height of lowered forks

(1) (3) (6)

See upright assembly cutaway diagram

4.21 total length 4.22 fork size

b1/b2 (mm)

800/800

s/e/l (mm)

65 / 180 / 1160

4.24 fork bearing front assembly width

b3 (mm)

675

4.25 outer fork gauge

b5 (mm)

570

4.31 free space beneath the loading assembly

m1 (mm)

4.32 free space beneath the centre of the wheelbase

m2 (mm)

4.33 pallet work channel 1000 x 1200

Ast (mm)

2405

2478 (8)

4.34 pallet work channel 800 x 1200

Ast (mm)

2369

2433 (9)

4.35 turning radius

Wa (mm)

1540

1626

5.1

transfer speed with/without load

km/h

5.5 / 6

5.2

fork lifting speed with/without load

m/s

0.13 / 0.18

0.12 / 0.18 (12)

5.3

fork lowering speed with/without load

m/s

0.3 / 0.25

5.8

maximum grade ability with/without load

7 / 10

electromagnetic

1.2

5.10 service breaks 6.1

traction motor, S2 60 minutes

6.2

lifting motor, S3 15%%

6.3

BS battery, DIN 43531/35/36 A,B,C, no

6.4

battery voltage/nominal capacity

6.5

battery weight (+/- 5%)

6.6

consomption under VDI cyclus

8.1

type of controls

- 50 mm with 3 stage mast assembly +175 kg with three stage mast assembly + 50 mm with 3 stage mast assembly

DIN 43535 B

V/Ah

24 / 150 (150-200)

24 / 220 (210-250)

150 (144-185)

222 (212)

kWh/h

1,0

1,1

AC ~ Mosfet

(8)

+ 22 mm with 3 stage mast assembly

(9)

+ 38 mm with 3 stage mast assembly

(12)

0.10 / 0.18 with 3 stage mast assembly

PRESENTATION

MS14 - MS16

SERVICE

PRESENTATION

WHEELS AND CHASSIS

WEIGHTS

CHARACTERISTICS

GENERAL SPECIFICATIONS 1.2

model

MS14

MS16

1.3

power: battery, diesel, LPG, petrol, electic

Battery

tiller

1.4

1.6

1.4

steering: tiller, accompanied, standing, sitting

1.5

load capacity, load

Q (t)

1.6

centre of gravity

c (mm)

600

1.8

load distance from the load bearing wheel axle

x (mm)

712 (2)

1.9

distance between the axles (WB)

y (mm)

1315

1385

2.1

unladen weight

1000 (4)

1120 (4)

2.2

load per axle when loaded (front/back)

570 / 1830

810 / 1710

875 / 1845

2.3

load per axle when unladen (front/back)

695 / 305

760 / 360

3.1

covering: full rubber, polyurethane, vulkollan, (front/back)

3.2

front wheel size

ø 230 x 75

DIMENSIONS PERFORMANCE

ø 230 x 75

3.3

rear wheel size

ø 85 x 70

3.4

additional wheels (size)

ø 150 x 50

3.5

wheels: quantity, (x= traction) (front/back)

1x+1 / 4

3.6

front wheel tread

b 10 (mm)

515

3.7

rear wheel tread

b 11 (mm)

400

4.2

height of the upright assembly when closed

h1 (mm)

See upright assembly cutaway diagram

4.3

free lift

h2 (mm)

See upright assembly cutaway diagram

4.4

lifting

h3 (mm)

See upright assembly cutaway diagram

4.5

height of the upright assembly when removed

h4 (mm)

See upright assembly cutaway diagram

4.9

height of tiller in operating position (min/max)

h14 (mm)

695 / 1196

h13 (mm)

4.15 height of lowered forks

ELECTICAL MOTORS

polyur. / polyur.polyur. / polyur.polyur. / polyur.

4.19 total length

l1 (mm)

1944

4.20 length of the forks at the heel

l2 (mm)

784 (7)

4.21 total length 4.22 fork size

(7)

2013

(7)

853 (7)

2013 (7) 853 (7)

b1/b2 (mm)

800/800

s/e/l (mm)

65/180/1160

4.24 fork bearing front assembly width

b3 (mm)

675

4.25 outer fork gauge

b5 (mm)

570

4.31 free space beneath the loading assembly

m1 (mm)

4.32 free space beneath the centre of the wheelbase

m2 (mm)

4.33 pallet work channel 1000 x 1200

Ast (mm)

4.34 pallet work channel 800 x 1200

Ast (mm)

4.35 turning radius

Wa (mm)

1626

1692

km/h

5.5 / 6

5.1

transfer speed with/without load

2492

(10)

2457

(11)

2558

(10)

2558 (10)

2523

(11)

2523 (11)

5.2

fork lifting speed with/without load

m/s

0.15 / 0.22

5.3

fork lowering speed with/without load

m/s

0.3 / 0.25

5.8

maximum grade ability with/without load

7 / 10

5.10 service breaks

electromagnetic

6.1

traction motor, S2 60 minutes

1.2

6.2

lifting motor, S3 15%%

6.3

BS battery, DIN 43531/35/36 A,B,C, no

DIN 43535 B

6.4

battery voltage/nominal capacity

V/Ah

24 / 220 (210-250)

24 / 330 (315-375)

6.5

battery weight (+/- 5%)

222 (212)

288

6.6

consomption under VDI cyclus

8.1

type of controls

kWh/h

1.2

1,3

1.4

AC ~ Mosfet

(2)

- 18 mm with three stage mast assembly

(10)

+ 8 mm with three stage mast assembly

(4)

+115 kg with three stage mast assembly

(11)

+ 14 mm with three stage mast assembly

(7)

+ 18 mm with three stage mast assembly

SERVICE

PRESENTATION

MS14 I.L. - MS16 I.L.

(0) (0)

h14

l2 181

h13

(0)

X X2

Y l1

l l6 a/2

a/2 Ast

b12

SERVICE

PRESENTATION

WHEELS AND CHASSIS

WEIGHTS

CHARACTERISTICS

GENERAL SPECIFICATIONS 1.2

model

1.3

power: battery, diesel, LPG, petrol, electric

Battery

steering: tiller, pedestrian, standing, sitting

tiller

1.5

load capacity, load

1.4

1.6

Q (t)

1.6

centre of gravity

c (mm)

600

1.8

load distance from load wheel axle

x (mm)

818 (2)

1.9

wheelbase (WB)

y (mm)

1529

2.1

unladen weight

1200 (4)

2.2

load per axle when loaded (front/rear)

900 / 1700

950 / 1850

2.3

load per axle when unladen (front/rear)

3.1

tyres: full rubber, polyurethane, vulkollan (front/rear)

3.2 3.3 3.4

800 / 400

polyur. / polyur.

front wheel size

ø 230 x 75

rear wheel size

ø 85 x 70

additional wheels (size)

ø 150 x 50

3.5

wheels: quantity, (x= traction) (front/rear)

1x+1 / 4

3.6

front track width

b 10 (mm)

515

3.7

rear track width

b 11 (mm)

375

4.2

height of closed mast

h1 (mm)

See mast section

4.3

free lift

h2 (mm)

See mast section

4.4

lifting

h3 (mm)

See mast section

4.5

height of extended mast

h4 (mm)

See mast section

4.6

initial lift

4.9

height of tiller in operating position (min/max)

DIMENSIONS

375

h5 (mm)

130

h14 (mm)

695 / 1196

h13 (mm)

4.19 total length

l1 (mm)

2052

4.20 length to fork heel

l2 (mm)

892 (7)

4.21 total length 4.22 fork size 4.24 fork arm carriage width

PERFORMANCE

MS16 IL

1.4

4.15 fully lowered forks height

ELECTRIC MOTORS

MS14 IL

(7)

2052 (7) 892 (7)

b1/b2 (mm)

860/860

s/e/l (mm)

65/195/1160

b3 (mm)

675

4.25 width over forks

b5 (mm)

570

4.31 ground clearance under mast

m1 (mm)

30+130

4.32 ground clearance at wheelbase centre

m2 (mm)

30+130

4.33 working aisle width with 1000 x 1200 pallet

Ast (mm)

2587 (10)

4.34 working aisle width with 800 x 1200 pallet

Ast (mm)

2513 (11)

4.35 turning radius

Wa (mm)

1760

km/h

5.0 / 5.0

5.1

travel speed with/without load

5.2

fork lifting speed with/without load

m/s

0.15 / 0.22

5.3

fork lowering speed with/without load

m/s

0.3 / 0.25

5.8

maximum gradeability with/without load

7 / 10

5.10 service brakes

electromagnetic

6.1

traction motor, S2 60 minutes

1.2

6.2

lift motor, S3 15%%

V/Ah

24 / 315-375

267-291

kWh/h

1.3

1,4

AC ~ Mosfet

6.3

battery BS, DIN 43531/35/36 A,B,C, no

6.4

battery voltage/nominal capacity

6.5

battery weight (+/- 5%)

6.6

consumption per VDI cycle

8.1

type of control

(2)

- 18 mm with three stage mast assembly

(10)

+ 8 mm with three stage mast assembly

(4)

+115 kg with three stage mast assembly

(11)

+ 14 mm with three stage mast assembly

(7)

+ 18 mm with three stage mast assembly

PRESENTATION

SERVICE

INSTALLATION AND SETTINGS

installation and settings BEFORE INSTALLATION �� 2 WEIGHT TABLE �� 2 MACHINE ASSEMBLY �� 3 LIST OF MATERIALS RECEIVED FROM THE DEALER �� 3 TRUCK UNLOADING �� 4 TOPPING UP THE OIL SUMP �� 5 BATTERY INSTALLATION �� 6 List of the SETTINGS AND ADJUSTMENTS to be carried out �� 9 BATTERY VOLTAGE SETTING �� 9 VERIFY THE TRUCK USE CONDITIONS �� 11

SERVICE

INSTALLATION AND SETTINGS

BEFORE INSTALLATION Make sure in advance that all the tools required to unload the battery are readily available (bridge crane, lift truck, lift belts etc.). Before delivering to the client it is very important to check the suitability of the place where the carriage is to be installed. WEIGHT TABLE

Model

Weight (excluding battery)

Battery voltage/ capacity

kg MS10

730

MS12

738 (1) 778 (2)

MS14 832 (2)

(1) (1)

MS16

832 (2)

MS14 I.L.

933 (2)

MS16 I.L.

933 (2)

+175 Kg for a three stage mast assembly +115 Kg for a three stage mast assembly

Battery weight min

max

V/Ah

24/150

135

153

24/200

174

196

24/210

201

223

24/250

201

223

24/210

201

223

24/250

201

223

24/315

274

302

24/375

274

302

24/315

274

302

24/375

274

302

24/315

254

280

24/375

276

306

24/315

254

280

24/375

276

306

SERVICE

INSTALLATION AND SETTINGS

MACHINE ASSEMBLY LIST OF MATERIALS RECEIVED FROM THE DEALER

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

Ref.

Description

Base truck, assembled mast and forks.

Batter extension plug (with lateral extraction)

External battery charger

Rollerway for lateral battery removal (on request)

SERVICE

INSTALLATION AND SETTINGS TRUCK UNLOADING Equipment and tools

fork lift truck load capacity 3000 kg

bridge crane load capacity 3000 kg

lift belt load capacity 3200 kg

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing.

Phase 1 ELEVATOR TRUCK WITH 3000 kg load Load the pallet using the lift truck, raise it and carry it to a safe place, far from the passage of other vehicles and pedestrian traffic.

Phase 2 BRIDGE CRANE - LIFT BELT Remove the packaging. Harness the column with the lift belt (fig.1).

Ensure that the bridge crane is positioned at right angles to the truck to be lifted. Hook the belt to the bridge crane, lift and position the truck gradually off the ground.

Fig. 1

SERVICE

INSTALLATION AND SETTINGS

TOPPING UP THE OIL SUMP Before topping up the oil in the hydraulic fluid tank make sure that the forks are completely lowered. Equipment and tools

funnel

oil protecting gloves

large Philips screw driver

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Phase 2 OIL PROTECTING GLOVES - FUNNEL Unscrew the oil sump cap (ref.B fig.2), place the funnel in the filler hole and top up the oil level. Make sure the tank is not too full. At the end of the operation screw the tank cap back on.

Fig. 1

Fig. 2

SERVICE

INSTALLATION AND SETTINGS BATTERY INSTALLATION

Fig. 1

Equipment and tools

bridge crane load capacity 1000 kg

spacer bar

hexagonal "T" section spanner 5 mm

fixed spanner 10 mm

Procedure

Fig. 2

Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

Phase 1 5 MM HEXAGONAL "T" SECTION SPANNER - FIXED 10 mm SPANNER Open the battery compartment (fig.1) Using the fixed gauge spanner hold the nut firm (ref.A fig.2), with the hexagonal "T" section spanner loosen and remove the fastening screw of the battery compartment (ref.B fig.2). Perform the same operation on the other compartment screw. Remove the battery compartment cover.

Fig. 3

Phase 2 BRIDGE CRANE - SPACER BAR Hook the spacer bar to the bridge crane. Hook up the spacer bar to the battery, lift by means of the bridge crane and position on the battery compartment. Lower the battery very cautiously into the truck compartment (fig.3). Unhook the spacer bar from the battery. Phase 3 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.C fig.4). Open the engine cover. Insert and tighten the battery catch. On the initial lift version, before securing the battery in position, connect the battery and raise the straddle legs to the maximum height so that they clear the slots located on the truck base. 6

Fig. 4

SERVICE

INSTALLATION AND SETTINGS

WITH SIDE EXTRACTION Equipment and tools

bridge crane load capacity 1000 kg

spacer bar

rollerway

Fig. 1

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

Phase 1 ROLLERWAY Position the rollerway alongside the battery compartment and adjust the height from the ground to align with the compartment surface. Lift the cover over the battery compartment (ref.A fig.1).

Phase 2 BRIDGE CRANE - SPACER BAR With the key provided unblock the side panel (fig.2).. Remove the truck base panel (fig.3). Hook the spacer bar to the bridge crane. Hook the spacer bar to the battery, lift by means of the bridge crane and position on the rollerway (fig.4). Detach the spacer bar from the battery and push carefully into the truck compartment until the battery stop is reached (fig.5).

Fig. 2

Fig. 3

Phase 3 Reposition the side panel in its seat and fasten it using the key provided. Connect the battery cables to the plug and lower the battery compartment cover.

INSTALLATION AND SETTINGS

SERVICE

CABLE CONNECTION TO BATTERY

Fig. 4

The battery poles are marked with the colour red or a symbol + to identify the positive pole, and with the colour blue or the symbol to identify the negative pole. The battery connector cables are in turn marked with a stripe in red for the connection to the positive pole and a stripe in blue for the connection to the negative pole. After connecting the clamps to the battery poles, apply some Vaseline grease to prevent the risk of oxidation.

Fig. 5

_ +

Clip colour BLUE Connection of the cable to the positive pole Clip colour RED Connection of the cable to the positive pole

Negative pole colour BLUE Positive pole colour RED

SERVICE

INSTALLATION AND SETTINGS

List of the SETTINGS AND ADJUSTMENTS to be carried out Having assembled all the machine's components as described in the preceding pages, one must then perform the following operations in sequence:

• Battery voltage setting • Verification of the carriage utilisation conditions BATTERY VOLTAGE SETTING BATTERY CHARGE LEVEL INDICATOR The battery charge indicator does not need adjusting. The preset value can in any case be modified, but only if strictly necessary, or in other words if the indication on the battery display of battery fully charged or flat does not correspond to the actual state of the battery. Equipment and tools

precision flat head screwdriver

large Philips screw driver

Procedure Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover. With the machine off, using the flat head screw adjust the setting screw placed on the rear of the display (ref.B fig.3), increasing or diminishing the volt value per cell (beneath which the display shows the uncharged state of the battery) according to the following table: Setting

Volt/ cell uncharged battery

1.57

1.63

1.68

1.73 (factory setting)

1.78

1.82

1.84

1.86

1.89

1.91

1.93

Fig. 1 Fig. 2

Fig. 3 9

INSTALLATION AND SETTINGS

SERVICE

WITH "MDI" MODULE OPTIONAL If a battery that is not provided by the factory is installed on the carriage, the battery voltage on the COMBI model must be set. To carry out this regulation, it is good practice to proceed with an additional charging period for the battery used on the carriage in order that it may provide the maximum voltage. Equipment and tools

programmer

tester

Procedure With the engine turned off connect the programmer Turn on the machine (ON switch) and select the following parameter: COMBI /config. menu adjustment / adjust battery With the tester check the exact tension of the battery on the Combi between the negative pole (-Batt) and the positive pole as shown on "pin 10" of the connector A (fig.3). The parameter "adjust battery" must be set with the value of this tension. Turn the machine off (switch key OFF) and disconnect the programmer. Turn the machine back on (ON switch). It may happen that by using the truck and running down the battery, after the first complete recharge the battery charge level indicator may show a value below 100%. If this happens, with the machine off connect the programmer. Turn the machine on (ON switch) and select the following parameter: COMBI / config menu adjustment / bat. max adj. Increase the regulating level to adapt the charge algorithm to the kind of battery.

SERVICE

INSTALLATION AND SETTINGS

- BATT

A 24 13 1

35 23 12

Fig. 3

VERIFY THE TRUCK USE CONDITIONS In order to safeguard the safety of people and goods, before undertaking the following operations, one should first check:

• the kind of loads that are to moved • the overall conditions of the warehouse, the aisles and the flooring Having carried out these assessments verify whether the conditions given are compatible with the performance levels set:

• • • • • •

maximum traction speed traction acceleration reduction of traction speed maximum speed of fork lifting/lowering acceleration slopes for cab lifting/lowering breaking

If necessary reduce the performance by personalising the configuration parameters via the programmer (see "FUNCTIONS OF A TRUCK " section "ELECTRICAL SYSTEM").

In order not to jeopardize the carriage's safety, the configuration parameter customisation can only be carried out by exclusively reducing factory values. Parameter values in excess of those introduced at the factory are not allowed.

INSTALLATION AND SETTINGS

SERVICE

DIAGNOSTICS AND MEASUREMENTS

diagnostics and measurements DESCRIPTION OF MODULE CONNECTORS �� 2 COMBI MODULE �� 2 MENU TESTER �� 4 COMBI MODULE �� 4 BREAKDOWN SEARCH: DIAGNOSIS SYSTEM FOR COMBI MODULE �� 8 ALARMS �� 8 ANALYSIS AND BREAKDOWN SEARCH FOR ALARMS �� 16 WARNINGS �� 24 ANALYSIS AND BREAKDOWN SEARCH WARNINGS �� 28 ELECTRICAL COMPONENT MEASUREMENTS �� 32 SOLENOID VALVE COILS �� 32 ELECTROMAGNETIC BRAKE COILS �� 32 MOTORS �� 33 INDUCTIVE SENSORS �� 33

DIAGNOSTICS AND MEASUREMENTS

DESCRIPTION OF MODULE CONNECTORS COMBI MODULE

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11

Tiller digital input Positive (+24V) - electromagnetic brake coil power supply Positive (+24V) - auxiliary functions power supply Negative (-BATT) - electromagnetic brake coil power supply Negative (GND) - encoder Lifting lock removal digital input Belly switch digital input Unused Negative (-BATT) - fork lowering solenoid valve Q2 Positive (+ BATT) Negative (-BATT) - straddle legs lifting/lowering solenoid valve Q3

SERVICE

SERVICE A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35

DIAGNOSTICS AND MEASUREMENTS

Main remote control switch coil digital output Phase B encoder Phase A encoder Not used Mode selector digital input Forks lifting below 1500 mm sensor digital input Not used Not used ENABLE TRUCK digital input Not used Traction motor heat sensor digital input Not used Negative (-BATT) - proportional lowering solenoid valve Q1 Positive (+12V) - encoder Acoustic buzzer digital output Can Low Can High Lifting lock sensor digital input Not used Fork lifting below 500 mm sensor digital input Straddle legs down sensor digital input Negative (-BATT) - forks lifting solenoid valve Q4 Not used Lifting lock digital input

DIAGNOSTICS AND MEASUREMENTS

SERVICE

MENU TESTER The main input and output signals can be measured in real time using the TESTER function of the programmer. The programmer acts as a multimeter capable of reading voltage, current and temperature. Certain of these menu parameters refer to functions whose status is received via Can bus, other refer to functions directly connected to the Analog/digital module inputs. The following list shows the relative measurements:

COMBI MODULE MAIN TESTER MENU PARAMETER BATTERY VOLTAGE

unit measure Volt

Level of battery voltage measured at the F10 input (key) BATTERY CURRENT

Ampére

Current battery level MOTOR VOLTAGE

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

Level of voltage booster supplied to the motor per load; is expressed as a percentage of the maximum voltage (which depends on the battery voltage) FREQUENCY

Current and voltage frequency supplied to the motor ENCODER

Motor speed, expressed in the same unit as the frequency; this information comes from the motor encoder (feedback frequency) SLIP VALUE

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

Ampére

Actual effective motor current BATTERY CHARGE

Battery charge percentage level TEMPERATURE

°C

Temperature of the inverter measured on the aluminium heat sink MOTOR TEMPERATURE

°C

Motor temperature PUMP CURRENT Level of continuous current supplied to the pump motor 4

Ampére

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER pump vmn

unit measure %

Voltage supplied to the pump motor by the inverter; it is expressed as a percentage of the maximum voltage (which depends on the battery voltage) set point evp

Starting value for the EV1 electrovalve ACCELERATOR

Volt - %

Voltage/percentage shift of the traction manipulator TILLER SWITCH

ON/OFF

Lowered tiller sensor digital input level FORWARD SWITCH

ON/OFF

Level of the forward motion input BACKWARD SWITCH

ON/OFF

Level of the reverse motion input lifting control

Volt

Value of the proportional lifting and lowering potentiometer LIFTING SWITCH

ON/OFF

Fast fork lifting selection button DESCENDENT SWITCH

ON/OFF

Fast fork descent selection button INITIAL LIFT SWITCH

ON/OFF

Slow fork lifting selector button (or straddle leg lifting) INITIAL LOW SWITCH

ON/OFF

Slow fork lowering selector button (or straddle leg lowering) AUX SWITCH FWD

ON/OFF

Forward auxiliary traction selection button AUX SWITCH REV

ON/OFF

Reverse auxiliary traction selection button BELLY SWITCH

ON/OFF

Emergency reverse selection button SNAIL SWITCH

ON/OFF

"Snail" mode selection button HORN SWITCH

ON/OFF

Acoustic buzzer selection button 5

DIAGNOSTICS AND MEASUREMENTS

PARAMETER truck enable

SERVICE unit measure ON/OFF

Truck operation enabling input level. LEGS DOWN SENSOR

ON/OFF

Straddle legs down sensor digital input level FORK UNDER 500

ON/OFF

Fork lift digital sensor input level below 500 mm FORK UNDER 1500

ON/OFF

Fork lift digital sensor input level below 1500 mm TOP MAST SENSOR

ON/OFF

Maximum height digital sensor input level UNLOCK LIFT

ON/OFF

Lift unblock input level BDI LOCK LIFTING

ON/OFF

Lift block input level with battery charge dropped below 20% MODE INPUT

ON/OFF

Traction mode input level SELECT INPUT 1 COMBI

ON/OFF

Unused SELECT INPUT 2 COMBI

ON/OFF

Unused EMERGENCY

ON/OFF ON = contacted closed OFF = contact open

Emergency button digital input DIGITAL INPUT FREE

ON/OFF

Unused PWM EVP

Ampére

Inverter value with which the proportional valve is piloted. OUTPUT EV2 - OUTPUT EV6

ON/OFF

EVn electrovalve pilot output state MAIN CONT VOLT

The voltage supplied to the electromagnetic break by the inverter; is expressed as a percentage of the maximum voltage.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

PARAMETER ELECT. BRAKE VOLT

unit measure %

The voltage supplied to the electromagnetic break by the inverter; is expressed as a percentage of the maximum voltage. CAN BYTE 0/7 Byte value relative to Can Bus - Tiller communication

DIAGNOSTICS AND MEASUREMENTS

SERVICE

BREAKDOWN SEARCH: DIAGNOSIS SYSTEM FOR COMBI MODULE The diagnosis system is divided into two main groups: Alarms When an alarm is detected, the current to the motors of the modules involved is cut off. The remote-control switch opens and the electromagnetic break is activated. These alarms are connected to:

• breakdowns in the motors/modules, the power system is no longer able to supply current to the motors. • breakdowns connected with safety.

Warnings When a warning takes place, the module is working properly but it has detected conditions that lead it to reduce performance or stock the truck, without affecting the power systems. These warnings are connected to:

• incorrect starting sequences by the operator. • conditions that require a reduction of performance (as for example high temperatures, ...) ALARMS keyboard message

WATCHDOG (8)

WATCHDOG 2 (8)

description

effect

state of the truck

The general K2 remote-control The auto diagnosis system within the • Start up switch, open power bridge, machine's logic system has been trig• Stand-by electromagnetic break activagered. • During traction ted. Re-start procedure: Re-start up of the key. The main K2 remote-control The auto diagnosis system within the • Start up switch, open power bridge, machine's logic system has been trig• Stand-by electromagnetic break activagered. • During traction ted. Re-start procedure: Re-start up of the key.

The main K2 remote-control This fault in the hardware section of switch open, open power bridthe logic card that manages the curge, electromagnetic break actirent hardware protection. vated. LOGIC FAILURE #3 (17) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

On start up, immediately after the closing of the K2 main remote control switch.

Smart driver open, cannot supply the The main K2 remote-control • Start up positive input to the electric brake on switch open, open power brid- • Stand-by pin 2. ge • During traction

SMARTDRIVER KO Re-start procedure: (22) Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

SERVICE keyboard message

PUMP VMN LOW (28)

PUMP VMN HIGH (29)

VMN HIGH (31)

AUX DRIV. SHRT. (40)

WRONG BATTERY (41)

AUX DRIV. OPEN (42)

DIAGNOSTICS AND MEASUREMENTS

description

effect

state of the truck

The main K2 remote-control • Start up Low voltage on the pump motor po- switch open, open power brid- • Stand-by wer capacitors. ge, electromagnetic break acti- • During lifting/ vated. lowering Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control High voltage on the pump motor po- switch open, open power brid- • During lifting/ wer capacitors. ge, electromagnetic break acti- lowering vated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both Incorrect voltage on one of the outputs of the 3 power phases, a fault in the power section or in the motor coils/connections.

The main K2 remote-control switch open, open power brid- • Start up ge, electromagnetic break acti- • During traction vated.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control • Start up The electromagnetic break semicon- switch open, open power brid• Stand-by ductor has shorted out. ge, electromagnetic break acti• During traction vated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The battery voltage is not correct: - Vbatt < 80% Vbatt nom - Vbatt > 120% Vbatt nom

• Start up The main K2 remote-control • Stand-by (immeswitch open, open power brid- diately after the ge, electromagnetic break acti- closing of the K2 vated. main remote control switch)

DIAGNOSTICS AND MEASUREMENTS

keyboard message

description -

EVP2 NOT OK (47)

EVP1 NOT OK (48)

effect

SERVICE state of the truck

The main K2 remote-control • Start up switch open, open power bridge, • Stand-by electromagnetic break activated.

The main K2 remote-control • Start up switch open, open power bridge, • Stand-by electromagnetic break activated. • During traction

EVP1 COIL OPEN Re-start procedure: (50) Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both -

The main K2 remote-control • Start up switch open, open power bridge, • Stand-by electromagnetic break activated. • During traction

EVP2 COIL OPEN Re-start procedure: (51) Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

STBY I HIGH (53)

WRONG ZERO (53)

The main K2 remote-control Incorrect output voltage of the "hall • Start up switch open, open power bridge, effect" sensor. • Stand-by electromagnetic break activated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control The motor voltage is not correct ( > 3 switch open, open power bridge, • Initialisation Volt or < 2 Volt) electromagnetic break activated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The overvoltage detected by the mo- The main K2 remote-control dule, appears on the power capaci- switch open, open power bridge, • Start up tors. electromagnetic break activated.

LOGIC FAILURE #1 Re-start procedure: (54) Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both 10

SERVICE keyboard message

DIAGNOSTICS AND MEASUREMENTS

description

effect

state of the truck

• Stand-by The main K2 remote-control Fault in the hardware section of the • Immediately after switch open, open power bridlogic card that manages the retroacthe closing of the ge, electromagnetic break actition of the U,V,W phase voltages. K2 main remote vated. LOGIC FAILURE #2 control switch. (55) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

CAPACITOR CHARGE (60)

VMN LOW (72)

The capacitor voltage does not increase on start up: a fault in the power section, in the logic card or in the motor.

The main K2 remote-control switch open, open power brid• Start up ge, electromagnetic break activated.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both Incorrect voltage on one of the outputs of the 3 power phases, a fault in the power section or in the motor coils/connections.

The main K2 remote-control switch open, open power brid- • Start up ge, electromagnetic break acti- • During traction vated.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

The main K2 remote-control The driver of the main remote-control switch open, open power brid• Start up switch coil has shorted out. ge, electromagnetic break activated. DRIVER SHORTED (74) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

CONTACTOR DRIVER (75)

CONTACTOR CLOSED (75)

The main K2 remote-control The main remote-control switch coil switch open, open power brid- • Stand-by is open, not capable of commanding ge, electromagnetic break acti- • During traction the remote-control switch coil. vated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The power contact of the remote-control switch is closed on start up, probably a block of the remote-control switch's power contact.

The main K2 remote-control switch open, open power brid• Start up ge, electromagnetic break activated.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

DIAGNOSTICS AND MEASUREMENTS

keyboard message KEY OFF SHORTED (76)

COIL SHOR. MC-EB (76)

COIL SHOR. EV. (76)

CONTACTOR OPEN (77)

description The key-off signal is always low

EMERGENCY (80)

state of the truck

The main K2 remote-control • Start up switch open, open power bridge.

Re-start procedure: Re-start up of the key. Either the main remote-control switch The main K2 remote-control • Stand-by or the electromagnetic break coils switch open, open power bridge, • During traction has shorted out. electromagnetic break activated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control The electromagnetic break driver has • Stand-by switch open, open power bridge, shorted out • During traction electromagnetic break activated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The remote-control switch doesn't close.

The main K2 remote-control switch open, open power bridge, • Start up electromagnetic break activated.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both Tiller breakdown

TILLER ERROR (77)

effect

SERVICE

The main K2 remote-control • Start up switch open, open power bridge, • Stand-by electromagnetic break activated. • During traction

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The positive of the main K2 remoteThe main K2 remote-control • Start up control switch is missing due to the switch open, open power bridge, • Stand-by opening of the contact of the emerelectromagnetic break activated. • During traction gency button. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

A fault in the encoder or in the conThe main K2 remote-control nection between the encoder and switch open, open power bridge, • During traction module, or in the module input circuelectromagnetic break activated. ENCODER ERROR its. (82) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

SERVICE

DIAGNOSTICS AND MEASUREMENTS

keyboard message

POS. EB. SHORTED (86)

POWER MOS SHORT (89)

ANALOG INPUT (96)

description

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control The driver of the main remote-control switch open, open power brid• Start up switch coil has shorted out. ge, electromagnetic break activated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control Problem with the analog/digital signal switch open, open power brid• During traction conversion. ge, electromagnetic break activated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

The main K2 remote-control switch, open power bridge, • Start up electromagnetic break activa- • Stand-by ted.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both -

END TEACH OK (0)

The main K2 remote-control switch, open power bridge, • Start up electromagnetic break activa- • Stand-by ted.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both -

END TEACH ERROR (0)

state of the truck

The main K2 remote-control The smart driver output that supplies switch open, open power bridthe positive input to the electric brake • Start up ge, electromagnetic break actiis high when the tiller sensor is open. vated.

TEACH ERROR (0)

effect

The main K2 remote-control switch, open power bridge, • Start up electromagnetic break activa- • Stand-by ted.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

DIAGNOSTICS AND MEASUREMENTS

keyboard message FLASH CHECKSUM (8)

WRONG RAM (10)

description

state of the truck

The main K2 remote-control Test on firmware not carried out corswitch, open power bridge, elec- • Start up rectly. tromagnetic break activated. Re-start procedure: Re-start up of the key. Problem in accessing RAM.

The main K2 remote-control switch, open power bridge, elec- • Start up tromagnetic break activated.

Re-start procedure: Re-start up of the key. A motor phase is disconnected.

PHASE KO (27)

effect

SERVICE

The main K2 remote-control • Start up switch, open power bridge, elec- • Stand-by tromagnetic break activated. • During traction

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

The main K2 remote-control Potentiometer pump out of set range switch open, power bridge • Always when in rest mode. open, electromagnetic activaPUMP VACC. NOT ted. OK Re-start procedure: (45) Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both High chopper temperature alarm.

The main K2 remote-control switch open, power bridge • Always open, electromagnetic brake activated.

TH. PROTECTION (62) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

The main K2 remote-control Hardware/software error for snail re- switch, open power bridge, • Start up quest from tiller. electromagnetic break activa- • Stand-by ted. HS-TIL MISMATCH (64) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both General CAN alarm. NO CAN MSG. (67)

The main K2 remote-control switch open, power bridge • Always open, electromagnetic brake activated.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

SERVICE keyboard message

DIAGNOSTICS AND MEASUREMENTS

description

effect

state of the truck

The main K2 remote-control Positive output of electric brake has switch, open power bridge, • Start up short-circuited. electromagnetic break activa- • Stand-by ted. AUX BATT. SHORT. (74) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

INCONS. TILLER (93)

BELLY ERROR 2 (96)

BELLY ERROR 1 (97)

BELLY ERROR 3 (98)

The main K2 remote-control Tiller released for more than two mi- switch closed, power bridge • Stand-by nutes. closed, electromagnetic brake activated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control Inconsistency between the belly si• Start up switch, open power bridge, gnal to the combi and what is com• Stand-by electromagnetic break activamunicated by the tiller card. • During traction ted. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control Inconsistency between the belly si• Start up switch, open power bridge, gnal to the combi and what is com• Stand-by electromagnetic break activamunicated by the tiller card. • During traction ted. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The main K2 remote-control Belly activated with tiller in rest switch open, power bridge • Stand-by mode. open, electromagnetic brake activated. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

DIAGNOSTICS AND MEASUREMENTS

SERVICE

ANALYSIS AND BREAKDOWN SEARCH FOR ALARMS ALARM

breakdown search

“Watchdog” Cause: The system is provided with a self-diagnosis circuit. A microchip tests the self-testing circuit to verify its correct operation. This circuit's output changes state if the microchip does not perform the test correctly. In this case the general This is a failure inside the module, it needs to be replaremote-control switch K2 is disabled together with the ced. power section. The electromagnetic break is activated. The alarm appears when: • the circuit output does not correspond to the input during the initial test on the self-testing circuit (start up diagnosis - START-UP). • the circuit's output changes during the stand-by or during the hydraulic functions (STANDBY AND MOTOR RUNNING diagnosis).

“Logic failure #3”

This type of failure is not connected to external comCause: ponents, so when it manifests itself the module needs A hardware problem pertaining to the logic card as a pro- replacing. tection against high current values (overload).

“Smartdriver ko”

• Check the cabling and verify that there is a connection between the PIN (A2) and the brake. Cause: • If, even when disconnecting the PIN from the conWith the Smart driver open, no signal reaches the PIN nector, the output maintains a high value then the (A2) of the electromagnetic brake. problem is inside the module. Replace the module.

“Pump vmn low”

If the problem appears on start up (the remote-control switch doesn't close at all), check: • the internal motor connections (ohm continuity). • The motor's power cabling. • If the motor cabling is okay, then the problem rest with the module. If the problem appears after having closed the remotecontrol switch (the remote-control switch closes and opens immediately after), check: • The motor cabling. • If the coil-winding/cables of the motor phases show Cause: losses towards the trucks bodywork. The motor pump output is lower than expectred, conside- • If no problem connected with the motors is detected, ring the PWM applied. then the problem lies inside the module. If the alarm takes place while the motor is operating, check: • The motor cabling. • If the coil-winding/cables of the motor phases show losses towards the trucks bodywork. • That the power contact of the remote-control switch closes correctly, with a good contact. • If no problem connected with the motors is detected, then the problem lies inside the module.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

breakdown search

“Pump vmn high”

It is advisable to check: • The motor cabling. Cause: • If the coil-winding/cables of the motor phases show This test is carried out when the motor pump is activated. losses towards the trucks bodywork. The motor pump output is higher than expected, conside- • If no problem connected with the motors is detected, ring the PWM applied. then the problem lies inside the module.

“Vmn high” Cause 1: Before closing the remote-control switch, the software check the power section: it turns on the Mosfets alternatively and waits until the phase voltage drops down to -BATT. If the voltage of the phases does not drop, this alarm appears. Cause 2: This alarm may appear even when the start-up diagnosis has been completed and the remote-control switch is closed. In this situation, the phase voltage should be Vbatt/2. If it is over this value, an error status is recorded.

If the problem appears on start up (the remote-control switch doesn't close at all), check: • The internal motor connections (ohm continuity). • The motor power cable connections • If the motor cabling is okay, then the problem rests with the module. If the problem appears after having closed the remotecontrol switch (the remote-control switch closes and opens immediately after), check: • The motor cabling. • If the coil-winding/cables of the motor phases show losses towards the truck's bodywork. • If no problem connected with the motors is detected, then the problem lies inside the module.

“Wrong battery”

• Ensure that the value of the COMBI/ config adjustment menu / set battery type corresponds to the nominal battery voltage. • Verify that the COMBI /main tester menu / battery Cause: voltage parameter is the same as the battery volOn start up, the module check the battery voltage and tage measured using the multimeter. If they do not ensures that it is within a specific range of the nominal correspond, carry out the battery voltage setting value. procedure (see "BATTERY VOLTAGE SETTING” in the "INSTALLATION AND SETTINGS" section”). • Replace the battery.

“Aux driv. open” Cause: Replace the module. The electromagnetic break driver is not capable of supplying the load.

“Aux driv. shrt.” Cause: The electromagnetic break driver has shorted out

“Evp2 not ok” Even if this alarm is present, it should never appear.

•

Check if there is a short circuit or a low pull-down impedance between the PIN (A4) and -BATT. • The circuit driver is damaged inside the module, which must be replaced. If the alarm shows, then the problem is inside the module. Replace the module.

DIAGNOSTICS AND MEASUREMENTS

SERVICE

ALARM

breakdown search

Cause 1: The EV1 electrovalve driver has shorted out. Cause 2: The microcontroller detects an incongruence between the EV1 electrovalve setpoint and the driver voltage measured at the output (A24).

Check if there is a short circuit or a low pull-down impedance between the electrovalve coil negative and -BATT. If this is not the case the driver circuit is damaged. Replace the module.

“Evp1 coil open”

• Check the cabling and verify that the EV1 electrovalve coil is connected to the right connector and that there are no interuptions. • If, even connecting the wire to the correct connector PIN or replacing the wire itself, the alarm persists, the problem is inside the module. Replace the module.

“Evp1 not ok”

Cause: The EV1 proportional electrovalve coil is open.

“Evp2 coil open” Even if this alarm is present, it should never appear.

If the alarm shows, then the problem is inside the module. Replace the module.

"Stby i high” This kind of failure is not connected to external compoCause: nents. When it appears the module must be replaced. The current transducer (hall effect sensor) or the current power supply circuit are damaged inside the module.

“Logic failure #1”

If the alarm appears on start up or in standby, it is very likely that the problem is due to a voltage drop. In this case the following checks are advisable: • Diminishing pulsations of the key input signal (beneath the undervoltage level) due to an external load, such as the start up of a DC/DC converter, the start up of a relay or a contactor, charging/discharging of coils. • If no change in the voltage is detected on the power supply line and the alarm is present every time the Cause: key is placed on ON, then the fault probably lies with the module hardware. In this case the module needs This alarm appears when the module detects over or under to be replaced. voltage conditions. The overvoltage limit is 35V, the limit for undervoltage is 9,5V. If the fault appears while in motion, then it could be due to over or undervoltage. • If the alarm appears during acceleration while in traction, it is most likely due to undervoltage; check the batter charge and the cabling to the power supply. • If the alarm appears when the break is released, in all probability it is due to undervoltage: check the remote-control switch contacts and the cabling to the power supply.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

breakdown search

“Wrong zero” Cause: This kind of failure is not connected to external compoThe voltage during the amplifier output intitialisation stage nents. When it appears the module must be replaced. (used to measure the traction motor voltage) is greater than 3 volts or lower than 2 volts.

“Logic failure #2”

This type of failure is not connected to external comCause: ponents, so when it manifests itself the module needs A fault in the hardware section of the logic card that over- replacing. sees the retroaction of the phase voltage.

“Capacitor charge” Cause: To get a better understanding of the significance of this alarm, take a look at the following diagram:

• There's an external load in parallel with the capacitors,

that lowers the module pre-charge circuit current, preventing its charging. Check if a lamp or a dc/dc converter or an auxiliary load is connected. • The charge resistance is open; add a power resistance over the remote-control switch terminals; if the alarm goes off it means that the module's internal charge resistance is damaged. Replace the module. • The charging circuit is faulty inside the module. Replace the module. When the key is turned on at ON, the inverter tries to load • There's a problem in the module's power section. Replace the module. the condenser through the power resistance and check if the condenser has charged within a certain time frame. If this doesn't happen, the alarm appears; the main K2 remote-control switch is not closed.

“Vmn low”

Cause 1: start up testing Before closing the remote-control switch, the software check the power section: it turns on the Mosfets alternatively and waits until the phase voltage rises up to the condenser values. If the voltage of the phases does not increase, this alarm appears. Cause 2: test in stand-by This alarm may appear even when the start-up diagnosis has been completed and the remote-control switch is closed. In this situation, the phase voltages should be Vbatt/2. If they are below this value, an error status is recorded. Cause 3: motor running test When the motor is operating, the power bridge is ON and the motor power supply voltage is monitored; if it is below the set value, an error status is recorded.

If the problem appears on start up (the remote-control switch doesn't close at all), check: • the internal motor connections (ohm continuity). • The motor's power cabling. • If the motor cabling is okay, then the problem rest with the module. If the problem appears after having closed the remotecontrol switch (the remote-control switch closes and opens immediately after), check: • The motor cabling. • If the coil-winding/cables of the motor phases show losses towards the trucks bodywork. • If no problem connected with the motors is detected, then the problem lies inside the module. If the alarm takes place while the motor is operating, check: • The motor cabling. • If the coil-winding/cables of the motor phases show losses towards the trucks bodywork. • That the power contact of the remote-control switch closes correctly, with a good contact. • If no problem connected with the motors is detected, then the problem lies inside the module.

DIAGNOSTICS AND MEASUREMENTS

ALARM

SERVICE

breakdown search

“Driver shorted”

• Check if there is a short circuit or a low pull-down impedance between the PIN (A12) and -BATT. Cause: • The circuit driver is damaged inside the module, The driver of the main K2 remote-control switch coil has which must be replaced. shorted out.

“Contactor driver” Cause: This kind of failure is not connected to external compoThe remote-control switch coil driver is not capable of nents; replace the module. piloting the load. This same device of the piloting circuit is damaged.

“Contactor closed” Cause: Before activating the remote-control switch coil, the module Check the remote-control switch power contacts; reverifies if the remote-control switch is blocked. The module place the remote-control switch if necessary. activates the power section for a few milliseconds trying to discharge the remote-control switch capacitors If this doesn't happen an error status is recorded.

“Key off shorted”

It is very likely that the problem is due to an undervoltage. In this case the following checks are advisable: • Diminishing pulsations of the key input signal (beneath the undervoltage level) due to an external load, such as the start up of a DC/DC converter, the start up of a relay or a contactor, charging/discharging of coils. Cause: • Check the cabling of the positive and negative batThe controller identifies a low logic level of the Key-off tery terminals, of the motor and the module. Ensure signal during the start up diagnosis stage. that the fastening nuts are secured with a torque of between 5.6 Nm and 8.4 Nm. • If no voltage is detected on the power supply line and the alarm appears at every activation, the problem is in the module hardware. The module needs replacing.

“Coil shor. mc-eb” Cause: This alarm appears when there is a short circuit on one of the coils connected to the combi outputs (remote-control switch or electromagnetic break coils). Having removed the cause of the overload, the alarm disappears automatically after having released and enabled a traction request.

“Coil shor. ev.” Cause: This alarm appears when there is a short circuit on one of the coils connected to the combi outputs (remote-control switch or electromagnetic break coils). Having removed the cause of the overload, the alarm disappears automatically after having released and enabled a traction request.

If the fault occurs on truck start-up, it is likely that the hardware of the overload protective circuit is damaged; in this case the model needs replacing. If the fault occurs when the module manages the remotecontrol switch (immediately after start-up) or the electromagnetic break (traction request), the problem should be sought in the cabling and with the coils. If the fault occurs on truck start-up, it is likely that the hardware of the overload protective circuit is damaged; in this case the model needs replacing. If the fault occurs when the module manages the remotecontrol switch (immediately after start-up) or the electromagnetic break (traction request), the problem should be sought in the cabling and with the coils.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

breakdown search

“Contactor open”

• The cables of the remote-control switch coil are interrupted or not connected, check the coil cabling. Cause: • The problem could also be connected to a remoteThe main remote-control switch coil is activated by the control switch contact that doesn't work. Try replacing module, but the remote-control switch doesn't close. the remote-control switch.

“Tiller error” Cause: Incongruent signals between the PIN (A1) and (A29).

Using a voltmeter check the voltage between the two PIN's If the state of one of the inputs is correct, it could be a problem internal to the module. Replace the module.

“Emergency”

If the alarm appears when the contact of the EMERGENCY BUTTON is shut. • Ensure that the emergency button is functioning Cause: correctly. The state of the emergency button is diagnosed by the • Check the cabling of the emergency button. input (A3) of the COMBI module; if these inputs are not • Using a multimeter measure the input of the COMBI +BATT but higher, then an error condition is detected. (A3) module; if it exceeds +BATT and, despite this, the alarm is present, replace the faulty module.

“Encoder error” Cause: This alarm is triggered by the following conditions: the frequency supplied to the motor is greater than 50Hz and the encoder's feedback signal shows leaps of more than 40 hz in just a few mSec. This behaviour is linked to an encoder malfunction.

• Check both the electrical and mechanical efficiency of the encoder and of the cabling. • Verify the encoder's installation, if the encoder slides inside its housing, causing an alarm condition. • Even an electromagnetic sound on the sensor bearing can cause the alarm. In these cases, replace the encoder. • If the problem persists after the replacement of the encoder, the fault lies in the module.

“Pos. eb. shorted”

• Check the cabling and verify that there is a connection between the PIN (A2) and the brake. Cause: • If, even when disconnecting the PIN from the conThe output voltage of the smart driver that powers the nector, the output maintains a high value then the electromagnetic brake coil is high when the tiller sensor problem is inside the module. Replace the module. is open.

“Power mos short” Cause: Before closing the remote-control switch, the software This kind of failure is not connected to external compochecks the power section: it turns on the Mosfets alter- nents; replace the module. natively and waits until the phase voltage drops down to -BATT. If the voltage of the phases does not follow the commands, this alarm appears.

“Analog input” Cause: The analog/digital conversion has returned a negative • If the problem appears regularly, the module needs value on all the signals converted for more than 400 msec. replacing. The aim of this diagnosis is to find a fault in the A//D converter or a problem in the code that omits the updating of the conversion of the analog signal.

DIAGNOSTICS AND MEASUREMENTS

ALARM "Teach error" Even if this alarm is present, it should never appear.

"End teach error" Even if this alarm is present, it should never appear.

"End teach OK" Even if this alarm is present, it should never appear.

"Flash checksum" Cause: Problem with the internal testing of the control code

SERVICE

breakdown search If the alarm shows, then the problem is inside the module. Replace the module. If the alarm shows, then the problem is inside the module. Replace the module. If the alarm appears, then the problem is inside the module. Replace the module.

Turn off and restart the truck. If the alarm persists, replace the control.

"Wrong RAM" Turn off and restart the truck. If the alarm persists, reCause: place the control. The control microprocessor has a problem accessing the RAM.

"Phase ko" Cause: A motor phase is disconnected.

Check the cabling and the connections inside the traction motor. If no problem related to the motor is detected, then the problem lies inside the module.

"Pump vacc. not OK"

Check that the proportional buttons are not damaged or faulty. Cause: If everything is as it should be, the problem lies inside Value of proportional raising or lowering potentioameter the module. Replace. out of range

"Th. protection" Cause: Temperature of the control higher than 85°.

Check the temperature of the control. If it is low, the problem lies in the control. Replace the control.

"Hs-til. mismatch"

Check the cabling of the tiller signal. Cause: If everything is as it should be, the problem lies in the There is a snail request from tiller without there being a tiller card. Replace. matching tiller input (pin A8).

"No Can msg."

Check the High CAN - Low CAN cabling and check that the resistance is 60Ω. Cause: If no anomaly is detected, then the problem is related Missing communication via CAN between the tiller cylinto the tiller cylinder head or to the control. der hear and the electronic control.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

ALARM

breakdown search

"Aux. batt. short."

With the electromagnetic brake disconnected, check Cause: that the signal has not short-circuited. The positive output of the electromagnetic brake has Replace the control. short-circuited.

"Incons. tiller"

If the allarm shows again within two minutes of turning Cause: the truck off and starting it up again, the problem is The tiller is active without any function being requested inside the control. Replace it. for over two minutes.

"Belly error 2"

Check the tiller cylinder head cabling using a tester Cause: and the control panel. Inconsistency between the belly signal to the combi and If no problem with the wire harness is detected, then what is communicated by the tiller card: input ON while the problem lies inside the cylinder head. Replace it. tiller states OFF.

"Belly error 1"

Check the tiller cylinder head wire harness using a teCause: ster and the control panel. Inconsistency between the belly signal to the combi and If no problem with the wire harness is detected, then what is communicated by the tiller card: input ON while the problem lies inside the cylinder head. Replace it. tiller states OFF.

"Belly error 3" Cause: Belly request with tiller in rest position

Check the tiller cylinder head wire harness using a tester and the control panel. If no problem with the wire harness is detected, then the problem lies inside the cylinder head. Replace it.

DIAGNOSTICS AND MEASUREMENTS

SERVICE

WARNINGS keyboard message BATTERY LOW (0) CHECK UP NEEDED (0) DATA ACQUISITION (0)

CURRENT SENS. KO (25)

LIFT + LOWER (49)

TILLER OPEN (51)

PUMP I=0 EVER (52)

description The battery is flat

effect

The maximum current is redu• Always ced by a half.

Truck maintenance must be perfor- Speed reduction or traction med. block The alarm appears during data acquiThe truck is not operational sition.

• Stand-by

Current sensor not working.

• Start up • Stand-by • During operation

The pump motor stops

Re-start procedure: Re-synchronisation of the system: • release all hydraulic requests • carry out a hydraulic request Lifting/lowering requests are present The pump motor stops at the same time.

• Always

Re-start procedure: Release the controls and apply the correct sequence. The truck is in stand-by with the tiller K2 main remote-control switch sensor active for more than 30 se• Stand-by open. conds. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The pump return current is always 0 Ampére, even when the pump motor The pump motor stops is operating.

• During operation

Re-start procedure: Re-synchronisation of the system: • release all hydraulic requests • carry out a hydraulic request Pump boost capacitor current is high The pump motor stops when at rest.

PUMP I NO ZERO (56)

state of the truck

Re-start procedure: Re-synchronisation of the system: • release all hydraulic requests • carry out a hydraulic request

• Start up • Stand-by

SERVICE keyboard message

ENCODER LOCKED (57)

DIAGNOSTICS AND MEASUREMENTS

description

effect

The alarm appears when the module detects a rotor block condition, caused by a mechanical blockage or a fault in the motor encoder retroaction. The truck stops When this condition is detected for more than 5 seconds, an error condition is signalled.

state of the truck

• During traction

Re-start procedure: Release and reapply the traction request. WAITING FOR NODE (58)

The module receives a message from the CAN that another node in the network is faulty; consequently Depends on the kind of fault the module itself cannot be operated but has to wait for the other module to exit from its error condition.

• Always

THERMIC SENS. KO (61)

The maximum current is reduThe heat sensor control output is be- ced by one half and the trucks • Always yond the limits. traction performance diminishes.

MOTOR TEMPERATURE (65)

The maximum current is reduHigh temperature in the traction ced by one half and the trucks • Always motor traction performance diminishes.

SENS. MOT TEMP The motor temperature sensor is KO The truck stops faulty. (67) EEPROM KO (71)

Error in eeprom diagnosis on the mo- The module works using de• Always dule logic fault parameters. The Evn electrovalve coil is absent.

CONT. DRV. EV2 (74)

DRV. SHOR. EV3/EV4/EV5 (74)

• Start up • Stand-by • During traction

Blocked solenoid valve

• During operation.

Re-start procedure: Re-synchronisation of the system: • release all hydraulic requests • carry out a hydraulic request The solenoid valve drive On/Off EV3 Blocked On/Off solenoid val- • Start up or EV4 orEV5 has shorted out (alves. • Stand-by ways ON). Re-start procedure: Re-synchronisation of the system: • release all hydraulic requests • carry out a hydraulic request The solenoid valve drive On/Off EV2 Blocked On/Off solenoid val- • Start up or EV6 has shorted out (always ON). ves. • Stand-by

DRV. SHOR. EV26 Re-start procedure: (74) Re-synchronisation of the system: • release all hydraulic requests • carry out a hydraulic request

DIAGNOSTICS AND MEASUREMENTS

keyboard message

description The Evn electrovalve coil is absent.

effect

SERVICE state of the truck

Blocked solenoid valve

• During operation.

The truck stops

• Start up • Stand-by • During traction

CONT. DRV. Re-start procedure: EV3/EV4/EV5/EV6 Re-synchronisation of the system: (75) • release all hydraulic requests • carry out a hydraulic request INCORRECT START (79)

FORW + BACK (80)

Incorrect start up sequence

Re-start procedure: Release the controls and apply the correct sequence. Forward/backward motions requests The truck stops are present at the same time. Re-start procedure: Release the controls and apply the correct sequence.

The truck is not operational VACC OUT RANGE (85) Re-start procedure: Release the controls and apply the correct sequence. CURRENT GAIN (92)

SLIP PROFILE (99)

K2 main remote-control switch • Stand-by open.

Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both The value of the traction motor "slip" parameters are not correct. This alarm is unlikely to appear seeing as The truck stops these parameters are set by the producer and cannot be modified. The truck enabling input is missing.

• Start up • Stand-by • During traction

The main K2 remote-control • Start up switch, open power bridge, • Stand-by electromagnetic break activa• During traction ted.

TRUCK DISABLED (/) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

• Start up • Stand-by

The maximum current adjustment The module works, but with a • Start up procedure has not yet been carried lower maximum current. • Stand-by out. -

DEAD MAN ABSENT (98)

• Start up • Stand-by • During traction

SERVICE keyboard message

DIAGNOSTICS AND MEASUREMENTS

description

effect

state of the truck

The main K2 remote-control switch closed, power bridge • Start up Wrong pump initialisation sequence. open, electromagnetic brake • Stand-by activated. PUMP INC. START (79) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

KEY ON INC. ST. P. (94)

Pump control state error at start up.

The main K2 remote-control switch, open power bridge, • Start up electromagnetic break activa- • Stand-by ted.

Re-start procedure: Release the controls and apply the correct sequence.

The main K2 remote-control Traction control state error at start switch, open power bridge, • Start up electromagnetic break activa- • Stand-by KEY ON INC. ST. T. up. ted. (95) Re-start procedure: Release the controls and apply the correct sequence. The main K2 remote-control • Start up Cabling error: fork position not pos- switch closed, power bridge • Stand-by sible. open, electromagnetic activa• During traction ted. WIRING INCON. #1 (95) Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

LIFTING STOP (99)

The main K2 remote-control There is a lift request lasting a longer switch open, power bridge time than set by the max lift time pa• Always open, electromagnetic activarameter. ted. Re-start procedure: Re-synchronisation of the system: • release all requests (traction and hydraulic) • forward a traction or a hydraulic request or both

DIAGNOSTICS AND MEASUREMENTS

SERVICE

ANALYSIS AND BREAKDOWN SEARCH WARNINGS WARNING

breakdown search

“Battery low”

Recharge the battery. If it doesn't work, measure the battery voltage using a multimeter and compare it with the COMBI / main tester menu/ battery voltage parameter. Cause: If they are different, carry out the battery voltage setting It appears when the battery charge is calculated beneath procedure (see "BATTERY VOLTAGE SETTING” in the 20% of full charge. "INSTALLATION AND SETTINGS" section”).

“Check up needed”

After having carried out the maintenance, set the COMBI Cause: / main adjustment menu / check up done parameter This message is only a warning that the time has come to to ON. carry out the maintenance program.

“Data acquisition” Cause: Acquisition of current gains.

The alarm disappears when the acquisition is completed.

“Current sens. ko” This kind of failure is not connected to external compoCause: nents; replace the module. The diagnosis on the current sensor reveals there is a fault.

“Lift + lower”

Check the cabling of the "lifting" and "lowering" requests (use the MAIN TESTER MENU” to facilitate the breakdown search). • COMBI / main tester menu / lifting switch • COMBI / main tester menu / descent switch Cause: • COMBI / main menu tester / initial lift switch This alarm only appears when both the fork lifting and • COMBI / main menu tester / initial low switch lowering requests are activated at the same time. Check the microswitches. A fault in the card could be possible. Having checked that the lifting and lowering request switches are working correctly and the cabling is correct, replace the module.

“Tiller open” Cause: The traction warning disappears with the next request. The tiller is at rest, after a set stand-by period (30 seconds) the remote control switch opens.

“Pump i=0 ever”

• Check that there are no interruptions in the pump motor connections. If the connection is open, the Cause: current can't flow and the test fails. The test carried out on the pump motor during operation • If everything is in good condition with the motor, the verifies if the current on the boost capacitors is not fixed problem could lie with the current sensor or the relaat 0. tive circuit.

“Pump i no zero” Cause: This kind of failure is not connected to external compoIn stand-by conditions (pump motor stationary), the return nents; replace the module. value provided by the current sensor returns a value outside allowed limits, because the pump current is not 0.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

WARNING

breakdown search

“Encoder locked” Cause: See the breakdown search referred to the ENCODER The error message appears when the module detects a ERROR alarm. motor block due to mechanical blockage of the rotor or a failure in the encoder feedback.

“Waiting for node”

The AC2 TRACTION module cannot be activated, but Cause: it has to wait until the other module exits from the error The module receives the message from the CAN that condition. another network module is in a breakdown condition.

“Thermic sens. ko” Cause: This alarm is not connected to external components, the The interval of the inverter thermal sensor is always module must be replaced. checked and an alarm is generated if it's beyond the interval.

“Motor temperature”

Check the heat sensor inside the motor ( COMBI parameter/main tester menu / motor temperature; check the value in ohms of the sensor and the cabling. If the Cause: sensor is OK, improve motor ventilation. If the alarm is This is a warning that appears when the motor temperature present when the motor is cold, the problem is located exceeds 150 °C. inside the module.

“Sens. mot temp ko”

Check the sensor cabling or that it it has not shorted out Cause: to the ground. The diagnosis (undervoltage and overvoltage) on the ther- Replace the sensor. mal sensor of the motor detects that it is broken.

“Eeprom ko”

Try to carry out a reset of the EEPROM (clear eeprom) using the programming console. Turn off the key "keyCause: OFF" and then restart "key-ON" and check the result. It is due to a defect in the hardware or in the non volatile If the alarm persists, replace the module. If the alarm memory software that supports the module parameters. goes off, the parameters previously memorized will be This alarm does not block machine operation, but the truck replaced by default parameters. operates under default values.

“Cont. drv. EV2/EV3/EV4/EV5/EV6” The device of its power supply circuit are damaged. Cause: Replace the module. The EVn elettrovalve driver is not able to supply the load (it can't close).

“Drv. shor. EV3/EV4/EV5”

Cause: There is a short circuit in the EVn elettrovalve driver.

•

Check if there is a short circuit or a low pull-down impedance between the coil negative and -BATT. • This warning appears even if an external laod is not present but a parameter of the Set Option menu relative to the valve has the PRESENT value, in this case the warning disappears and the parameter is set to ABSENT. • The circuit driver is damaged inside the module, which must be replaced.

DIAGNOSTICS AND MEASUREMENTS

WARNING “Drv. shor. EV26” Cause: The EV2 or EV6 electrovalve driver has shorted out.

“Incorrect start” Cause: It's an incorrect start sequence alarm.

SERVICE

breakdown search •

Check if there is a short circuit or a low pull-down impedance between the coil negative and -BATT. • The circuit driver is damaged inside the module, which must be replaced. The possible causes for this are (use the "MAIN TESTER MENU" to make fault detection easier): • An active traction request on start up. Check cabling. Check the microswitches. It could even be ascribed to an operator sequence error. A fault in the card could be possible; if no malfunction is detected, replace the module.

“Forw+back”

Check the cabling of the "forward" and "backwards" (use the MAIN TESTER MENU” to facilitate the breakdown search). • COMBI / main tester menu / forward switch Cause: • COMBI / main tester menu / backward switch This alarm only appears when both the (forward and back- Check the microswitches. ward) motion requests are activated at the same time. A fault in the card could be possible. Having checked that the traction request switches are working correctly and the cabling is correct, replace the module.

“Vacc out range” Even if this alarm is present, it should never appear.

If the alarm shows, then the problem is inside the module. Replace the module.

“Current gain” Contact the Zapi service unit to carry out the correct Cause: adjustment procedure for the current gain parameters, The gain parameters of maximum current have default vaor replace the module. lues, therefore the adjustment procedure of the maximum current has not yet been performed.

“Dead man absent” Even if this alarm is present, it should never appear.

“Slip profile”

If the alarm shows, then the problem is inside the module. Replace the module.

Contact the Zapi service unit to carry out a check on Cause: the deviation parameter values of the current gain, or The deviation parameters of the hardware setting menu replace the module. are not correct.

SERVICE

DIAGNOSTICS AND MEASUREMENTS

WARNING "Truck disabled" Cause: Input on A20 pin open

breakdown search Check the cabling using a tester and the control panel. If no problem with the cabling is detected, then the problem lies inside the module. Replace it.

"Pump inc. start" Check there are no problems with the potentiometer Cause: and that it is secured correctly. Any request for hydraulic function has been pressed before the tiller has been lowered.

"Key on inc. st. p”

Check cabling. Check buttons. If no problems can be found and if the operator performs the correct sequenCause: ce, the breakdown is inside the tiller cylinder head. There is some kind of hydraulic function request at start Replace it. up.

"Key on inc. st. t" Cause: There is a gear request at start up.

Check cabling. Check the throttle traction control. If no problems are found and if the operator has performed the correct sequence, the breakdown is inside the tiller cylinder head. Replace it.

"Wiring incon. #1" Cause: Check the cable connections. The input corresponding to forks below 500 mm is pre- If the problem persists, replace the control. sent and the input corresponding to forks below 1500 mm is absent.

"Lifting stop" Cause: If the lowering button is pressed the truck functions are There is a request to lift the forks for a longer time than restored. established by the max lift time parameter (this function is only active if the lifting block parameter is ON).

DIAGNOSTICS AND MEASUREMENTS

ELECTRICAL COMPONENT MEASUREMENTS SOLENOID VALVE COILS

Q3 Q4

Q2 Q1

ELECTROMAGNETIC BRAKE COILS

Traction wheel electromagnetic break

Coil

Value measured (Ohm)

Electromagnetic break

17,7

SERVICE

DIAGNOSTICS AND MEASUREMENTS

MOTORS To measure the motor insulation disconnect the cables from the phases (U, V, W). Connect the tester ferrule to the U phase and the other ferrule to the bodywork. The resistance value ( ) shown on the tester must be infinite ( ). Otherwise the motor is not insulated and the module connected to the motor involved diagnoses the alarm "capacitor charge". Repeat the operation with the other two phases (V, W).

INDUCTIVE SENSORS The inductive sensors are powered by a 24V current. They are all of the PNP type with a positive output signal (10mA). Nominal Load capacity: Optimal load capacity:

8 mm 4 mm

Inductive sensor PNP

Inductive sensor NPN

DIAGNOSTICS AND MEASUREMENTS

SERVICE

ELECTRICAL SYSTEM

electrical system WIRING DIAGRAMS �� 4 models without initial lift �� 4 models with initial lift �� 6 ELECTRICAL COMPONENTS �� 8 IDENTIFICATION OF ELECTRICAL COMPONENTS �� 8 TILLER DIAGRAM �� 10 CONTROLS �� 12 IDENTIFICATION OF TILLER CONTROLS AND MAIN PANEL �� 12 DISPLAY (battery charge level indicator) �� 14 BATTERY CHARGE LEVEL INDICATOR �� 15 HOUR METER �� 15 MDI (OPTIONAL) �� 16 BATTERY CHARGE LEVEL INDICATOR �� 17 SPEED REDUCTION INDICATOR �� 17 HOUR METER �� 17 WARNINGS INDICATOR �� 17 TRUCK FUNCTIONS �� 18 TRACTION FORWARD/REVERSE �� 18 BREAKING �� 21 STEERING WHEEL �� 24 LIFTING/LOWERING �� 25 CONFIGURATION PARAMETER ACCESS PROCEDURE �� 29 Menu RESEACH PROCEDURE and parameter modification �� 29 STANDARD CONFIGURATION OF MODULE PARAMETERS �� 32 "COMBI AC0" Module �� 32 MODULE PARAMETER DESCRIPTION �� 34 "COMBI AC0" Module �� 34 COMBI AC0 MODULE: INTRODUCTION �� 42 POSITIONING OF THE "PC CONSOLE" CONNECTOR AND CONSOLE �� 43 REPLACEMENT MODULE: INSTRUCTIONS �� 44 REPLACEMENT OF THE COMBI AC0 MODULE �� 44 ELECTRICAL COMPONENT DISMANTLING �� 46 REPLACEMENT OF THE GENERAL EMERGENCY SWITCH �� 46 DISPLAY REPLACEMENT �� 48 1

ELECTRICAL SYSTEM

SERVICE

REPLACEMENT OF THE KEY SWITCH �� 49 REPLACEMENT OF THE WARNING BUZZER �� 50 FUSE REPLACEMENT �� 51 tiller diagram: configuration and calibration �� 52 TILLER CARD REPLACEMENT �� 55 REPLACEMENT OF tiller BUTTONS �� 56 REPLACEMENT OF THE TILLER CONTROL SPRINGS �� 57 REPLACEMENT OF THE TILLER ASSENT SENSOR �� 59 RENEWAL OF 'FORKS ABOVE 1500 mm' SENSOR (OPTIONAL) FOR INITIAL LIFT VERSION ONLY �� 60 RENEWAL OF 'FORKS ABOVE 500 mm' SENSOR (OPTIONAL) FOR INITIAL LIFT VERSION ONLY �� 61 RENEWAL OF THE 'FORKS LOWERED' SENSOR FOR INITIAL LIFT VERSION ONLY �� 62

SERVICE

ELECTRICAL SYSTEM

SERVICE

ELECTRICAL SYSTEM

WIRING DIAGRAMS models without initial lift COMPONENTS Ref.

Description

Ref.

Description

Combi controller

Tiller controller

X28

XCJ2

Battery charge level indicator

XAJ2

Encoder

Heat sensor

Tiller sensor

Battery

Power fuse - 300 A

5A fuse for 24V power supply to keyswitch

XA1

35 pin male connector

XJP1 XJP2

8 pin male connectors 6 pin male connectors

XJP10 4 pin male connectors

XJP12

X30

3 pin male connector

X31

XJP11

10 A fuse for 24 V power supply to solenoid coils

XJP13

XJP14

3 A fuse for 24 V power supply to horn relay

XJP15

XJP16 2 pin male connectors

3 A fuse for 24 V power supply to battery charge level indicator

XJP17

Horn relay

X14

Main remote control switch coil

XFF7

XFF20

Recycling diode

XFF8

XFF9

Complete traction motor

XFF10

XFF11

Traction motor

XFF15

XFF16

Pump motor

XFF18

XFF19

Horn

XTF22

XTF23 female terminals

Solenoid valve 1

XTF24

XTF25

Varistor

XTF26

XTF27

Electromagnetic brake

XTF28

XTF29

Resistor 120 Ω

XFF2

XFF3

Button not used

XFF12

XFF13

Emergency button

XTR1

XTR4

Battery charger socket-plug microswitch

XTR14

XTR17

Keyswitch

Proportional lift button

Proportional lowering button

On-off lift button

On-off lowering button

Horn button

S10

Belly switch

S11

Snail button

S12

Auxiliary function forward button

S13

Auxiliary function reverse button

CONNECTORS

Battery charger

ring terminals

SERVICE

ELECTRICAL SYSTEM 24V +Batt. 24V +Batt.

240

24V +Valv.

5-A

24V +Aux.

24V +Key

-B1

24V +Key

280-B

12V +Enc.

-X6

5-D

10-Q

10-P

10 G 101

** As reference use the colour X of the individual wire (or the number printed on it, if the wire is black)

Y 280-A

W 578

2 -XTF27

-XFF15

2.1

-S2

-F4

-XTR14

2.1

* When T1 and S2 are not present (no load on board) connect XFF19 to terminal 30 of S3.

-XTR17

-K2 /2.8

2.1

-X4

-XTF26

-XFF16

2.1

-B2

M 3

-XFF19

-M

1 -XTF22

-M1

-F2 5A

-XTF28 -XTF24

24V +Valv.

2 1

-F3 10A

-S1

-XTF23

-XTF29 -XTF25

-F5 3A

24V +Batt.

367

102-B

L+

577

-XFF8

-M2

201

15.54

-S3

-XFF9

-C1

87a

-K1 /2.7

-XFF10

10-A

XFF18

-P1

-XTR4

280-B

DI2

Remove lift block

DI9

S.top mast level

DI3

S.legs down

DI8

S.<1500mm forks

+KEY

DI4

280-B

S.<500mm forks

THMOT

NENC

GND Encoder

25 +12V

PENC

ENC A

ENC B

Encoder B

/.7

Thermal sensor in

-B

-A1

-T1

-P

L-

-XA1

Encoder A

-XFF11

280-B

10-E

-R1

-XTR1

/.7

0V -Batt.

0V -Batt. 0V -Batt.

102-B 102-A

0V -Batt.

13-B

0V -Batt.

13-U

0V -Batt.

13-H

0V -Batt.

2.1 2.1 2.1 2.1

SERVICE

ELECTRICAL SYSTEM 1.12

24V +Batt.

1.12

24V +Valv.

1.12

24V +Key

280-B

24V +Key

10-C

24V +Aux.

280-B

12V +Enc.

-XFF3

-XFF12

3.1

3.1 3.1 3.1

-X14

10-B

-X7

5-E

280-B

1.12

12V +Enc.

24V +Batt.

240

-Q1

-K3

-K1

-K2 85

-R2

CPOTL

Optional in

DI12

Optional in

DI5

Optional in

DI11

Optional in

CPOTTR

Optional in

EV5

- Q6

EV4

- Q5

EV3

- Q4

EV2

- Q3

EVP2

Flash diagnosis

843 12

DI10

Mode In

721

NMC

- main cont. coil

- Q1

- horn

HORN OUT

800 24

LOWER EVP1

EV1

2 4

NEB

* As reference use the colour X of the individual wire (or the number printed on it, if the wire is black)

4 840

3 200-A

200-B 2

PEB

- Brake

-A1

+ Brake

5-B

PAUX

+ Aux.

-XA1

-XFF13

-XFF2

- Q2

-X14

-X7

1.12

0V -Batt.

102-A

0V -Batt.

1.12

0V -Batt.

13-B

0V -Batt.

1.12

0V -Batt.

13-U

0V -Batt.

1.12

0V -Batt.

13-H

0V -Batt.

3.1 3.1 3.1 3.1

SERVICE

ELECTRICAL SYSTEM

280-B -X31

-XFF20

GND +24 in

Data out

GND

UNUSED

GND 8

Sel 2 7

GND 4

-XAJ2

-X3

TO PC TOOLS

UNUSED

CAN-L G 1

-XCJ2

G 2

-X30

GND

Tiller in

+24V (out)

-R3 Can High

901-B

Can Low

900-B

-XFF7

/.3

2.12 2.12 2.12 2.12

0V -Batt. 0V -Batt.

13-H

13-U

CANH

CANL

Tiller switch

13-B

Belly switch

DI0 Snail + Tiller in

-A1

/.5

DI1 Enable truck

-XA1

DI6 Belly in

/.3

DI7 Lift block

10-F

900-A

-B4 901-A

-XJP2

-XJP13

-XJP11

GND

+5V

+5V Sel 1

-XJP17 D

-S

-S 1

2 D

Sel 0

-S13

-XJP16

+5V

-XJP15

CAN-H

-XJP14

-S12

+24V

-S8

+5V

-S7

Data out

+24V 3

Snail + tiller

-P10

Belly out NO

GND

-XJP12

540-A

4 4 541

5 5 13-B

+5V Belly out NC 5

GND 2 2

+24V 1

1 6 6 540-B

-X3

519

102-A

+5V

GND

-S9

-A2

-XJP1

540-B

10-C

10-F

10-I

- Hours meter

+ Key switch

-XJP10

+ Relay

- Relay (out)

-B

- Hours meter

240

-X28

UNUSED

-S6

-A3

-S5

UNUSED

10-H

TO CONSOLE/ TO OPTIONAL MDI

Belly out NC

280-B

12V +Enc.

Clock in

10-C

24V +Aux.

2.12

24V +Key

10-D

2.12

* As reference use the colour X of the individual wire (or the number printed on it, if the wire is black) 10-M

2.12

24V +Batt.

2.12

/.5

102-A 13-B

0V -Batt.

13-U

0V -Batt.

13-H

SERVICE

ELECTRICAL SYSTEM

SERVICE

ELECTRICAL SYSTEM models with initial lift COMPONENTS Ref.

Description

Ref.

Description

Combi controller

On-off lowering button

Tiller controller

Horn button

Battery charge level indicator

S10

Belly switch

Encoder

S11

Snail button

Heat sensor

S12

Auxiliary function forward button

Tiller sensor

S13

Auxiliary function reverse button

'Forks above 500mm' position sensor

S14

Lifting release button

'Forks above 1500mm' position sensor

S15

Mode selector button

Lift lock sensor

'Straddle legs down' sensor

Battery

Power fuse - 300 A

5A fuse for 24V power supply to keyswitch

10 A fuse for 24 V power supply to solenoid coils

3 A fuse for 24 V power supply to horn relay

3 A fuse for 24 V power supply to battery charge level indicator

Horn relay

Battery charger

CONNECTORS Ref.

Description

XA1

35 pin male connector

X28

XCJ2

X19

8 pin male connectors

XAJ2

XJP1

Main contactor coil

X18

Recycling diode

X24

XJP2

Complete traction motor

XJP10

XJP12

Traction motor

Pump motor

X18A

X18B

Horn

X19A

X24A

Solenoid valve 1

X23

X30

Solenoid valve 2

Solenoid valve 3

X10

Solenoid valve 4

X11

X12

Solenoid valve 5

X14

Solenoid valve 6

X31

XJP11

Varistor

XJP13

XJP14

Electromagnetic brake

XJP15

XJP16

Resistor 120 Ω

XJP17

Button not used

X19B

Emergency button

X18C

X24C

4-way female connector

Battery charger socket-plug microswitch

X33B

X23A

3-way female connector

Keyswitch

Proportional lift button

Proportional lowering button

On-off lift button

6 pin male connectors 4 pin male connectors

X33

X24B

3-way male connectors

2 pin male connectors

6-way female connector

2-way female connector

SERVICE

ELECTRICAL SYSTEM 24V +Batt. 24V +Batt.

240

24V +Valv.

5-A

24V +Valv.

2.1 2.1

24V +Key

2.1

-X19 -X19B

10-P

11-B

1 -X24A

-X19A

-X24B

-B5

-B6

-B7

-B8

-S14

+ Fe

2 2

-X24C -X24

-X18C -X18

-X19B -X19

87a

* When T1 and S2 are not present (no load on board) connect XFF19 to terminal 30 of S3.

-S3 M

515

13-E

517

516

13-N

-XFF10

514

13-M

15.54

-M2

513

-X18C -X18

-XFF9

201

-X19A

2 2 2

3 4

-X24B

2 2 2

3 4 4

-X24A

102-B

367

101

280-A

578

577

-X18B

-X18A

30 L+

-X18B

-S2

-K1 /2.10

XFF18

10-A -XTR1

/.8

/.6

0V -Batt.

0V -Batt. 0V -Batt.

DI3 S.legs down

DI2

DI8

DI4

DI9 /.9

/.11

102-A 13-B 13-A

0V -Batt.

13-E

0V -Batt.

/.11

102-B

13-N

0V -Batt.

/.9

S.<1500mm forks

-XTR4

0V -Batt.

/.8

+KEY

THMOT

PENC +12V NENC GND Encoder

ENC B Encoder B ENC A Encoder A

/.6

** As reference use the colour X of the individual wire (or the number printed on it, if the wire is black)

280-B

-B

-A1

-P

L-

-XA1

-XFF11

10-E

-R1 U

13-M

-P1

-T1

2.1

-XTF27

-XFF8

-C1

2.1

-XTR14 -XFF15

12V +Enc.

-X24 -X24C

-X18A

-F4 3A

-K2 /2.11

24V +Valv.

-X6

-X4

-F1 300A

-XTF26

11-A

280-B

-X18 -X18C

-M

280-B

-B2

10-Q

2 35

-XTR17

-B1

-XFF19

-XFF16

-S1

-M1

12V +Enc.

-XTF22

-XTF24

-XTF28

-F2 5A

-F3 10A

-F5 3A

-XTF23

5-D

24V +Aux.

-XTF29 -XTF25

24V +Batt.

0V -Batt. 0V -Batt.

2.1 2.1 2.1

6a 4d

SERVICE 1.12

24V +Batt.

240

24V +Batt. 24V +Valv.

24V +Key

3.1

1.12

5-F

5-E

1.12

ELECTRICAL SYSTEM

11-A

12V +Enc.

280-B

-X33 -X33B

24V +Valv. 280-B

10-C

280-B

24V +Aux. 12V +Enc.

3.1 3.1

200-B

10-L

1.12

11-A

1.12

24V +Valv.

11-E

-X11

-XFF3

-X12

-XFF12

-X10

-X9

-X8

-X14

-X7

-XFF6

11-D

11-C

10-B

200-A

-S15 -Q1

-K3

-Q2

-Q3

-Q4

-Q5

-Q6

-K2

-K1

1.12 1.12

-X12

-XFF2

-XFF13

3 -X33B -X33

-X33B -X33

18 5

4 4

-X19B -X19

* As reference use the colour X of the individual wire (or the number printed on it, if the wire is black)

843 12

NMC - main cont. coil

721 26

HORN OUT - horn

806 8

EV5 - Q6

805 34

EV4 - Q5

804 33

EV3 - Q4

803 11

EV2 - Q3

EV1 - Q2

NEB - Brake

PEB + Brake

LOWER EVP1 - Q1

PAUX + Aux.

EVP2 Flash diagnosis

16 3

-X19B -X19

802 1.12

DI10 Mode In

-A1

-X11

800

840

200-A

200-B

5-B

801

530

-X19B -X19

-XA1

-X10

-X9

-X8

-X14

-X7

-XFF21

-XFF5

-R2

0V -Batt.

102-A

0V -Batt.

13-B

0V -Batt.

13-A

0V -Batt.

3.1 3.1 3.1

6b 4e

2.12

2.12 0V -Batt.

0V -Batt.

0V -Batt. /.3

102-A 13-B 13-U

DI6 Belly in 7

/.5

/.4 /.5

13-A Can High 901-B

Can Low 900-B 2

-X30

+24 in

GND

Belly out NC

Clock in

-XJP13 2

-S

Data out

GND

+5V

-XJP11

-XAJ2

GND

UNUSED

GND

-S13

Sel 2

GND

-XJP17

+5V

-S12

+5V

Sel 1

GND

Sel 0

CAN-H

CAN-L

-XJP16

-XJP15

-S8

CPOTTR Optional in DI11 Optional in DI5 Optional in DI12 Optional in CPOTL Optional in

-X3

901-A

-XCJ2

-B4

CANH

UNUSED

D +5V

-XJP14

GND

-S7

-XJP2 2

+5V

Tiller in

+24V

+24V (out)

GND

900-A

-XJP1

Belly out NO

-S9

-S11 Data out

Snail + tiller

+5V

-XJP12

Belly out NC

+5V

GND

-S5

CANL

GND

10-C

10-F

10-I

10-H

-X31

13-H

/.4 540-A

-X23 -X23A

Tiller switching

540-B 4

+24V

540-B

-X3

541

* 1

10-I

10-H

-A2

DI0

Belly switching

2 1

- Hours meter

-XJP10

13-B

-X23A -X23

10-D

10-M

280-B

+ Key switch

12V +Enc.

+ Relay

10-C

- Relay (out)

24V +Aux.

-B

- Hours meter

13-C

518

519

+ Battery sense (24V)

24V +Key

13-C

-A1 DI1 Enable truck

-XA1 35

/.3

DI7 Lift block

-X28 6

-A3

102-A

540-B

2.12

+ battery sense (>24V)

2.12

240

2.12

SERVICE ELECTRICAL SYSTEM

24V +Batt.

* As reference use the colour X of the individual wire (or the number printed on it, if the wire is black)

280-B -XFF20

TO CONSOLE/ TO OPTIONAL MDI UNUSED UNUSED

-S6 -S

TO PC TOOLS

XFF7

-R3

13-B 13

6c 4f

SERVICE

ELECTRICAL SYSTEM

SERVICE

ELECTRICAL COMPONENTS IDENTIFICATION OF ELECTRICAL COMPONENTS

Ref.

Description

Ref. wiring diagram

Traction motor

Pump motor

Electromagnetic break

Tiller control sensor

Battery

Tiller diagram

acoustic buzzer

Horn relay

Key fuse switch - 5 A

Solenoid valve coil fuse - 10 A

horn relay fuse - 3 A

Battery charge level indicator fuse - 3 A

Power fuse - 300 A

COMBI AC0 Module

Battery charger

General remote control switch - emergency button

General remote control coil contacts

Auxiliary general remote control connector contacts

Battery charge level indicator

3 way connector for control panel connection

X30

2 wayconnector for control panel connection

X31

'Straddle legs down' sensor (initial lift only)

'Forks above 500 mm' position sensor ( initial lift only)

'Forks above 1500 mm' position sensor ( initial lift only)

SERVICE

ELECTRICAL SYSTEM

24 6

18 17

3 1

13 14

5 21 8 12

SERVICE

ELECTRICAL SYSTEM

SERVICE

TILLER DIAGRAM

Ref.

Description

Ref. wiring diagram

LED display for traction throttle calibration

Micro quick reverse mode

Micro slow progress enabling with vertical tiller

Tiller control cable connection connector

XJP1

Tiller enabling sensor connection connector

XJP2

Unused connector

XAJ2

Configuration selector bridge

Proportional fork lifting button connection connector

S10 S11

XJP10

Can Bus Connection connector

XCJ2

Proportional fork lowering button connection connector

XJP12

ON/OFF slow lifting button connection connector Straddle leg lifting ON/OFF button wiring connector (initial lift only)

XJP14

ON/OFF slow lowering button connection connector Straddle leg lowering ON/OFF button wiring connector (initial lift only)

XJP15

ON/OFF button connection connector for auxiliary functions

XJP16

ON/OFF button connection connector for auxiliary functions

XJP17

Unused connector

XJP11

Unused connector

XJP13

Micro enabling acoustic buzzer

SERVICE

ELECTRICAL SYSTEM

17 3 16 15 14 13 12 11 10 9 8 7

SERVICE

ELECTRICAL SYSTEM

CONTROLS IDENTIFICATION OF TILLER CONTROLS AND MAIN PANEL

2 3 1

SERVICE

ELECTRICAL SYSTEM

Ref.

Description

Ref. wiring diagram

Quick reverse button

S10

acoustic buzzer button

Forward reverse traction throttle

Slow fork lowering button Straddle leg lowering button (initial lift only)

Slow fork lifting button Straddle leg lifting button (initial lift only)

Proportional* fork lifting button

Proportional* fork lowering button

Slow progress enabling button with tiller in rest position

S11

Emergency button

Key switch

* The buttons are of the ON/OFF variety for trucks with nominal load capacity of 1000/1200 kg

ELECTRICAL SYSTEM

DISPLAY (battery charge level indicator)

Ref.

Description

Battery charge level indicator

Total work hour indicator

SERVICE

ELECTRICAL SYSTEM

BATTERY CHARGE LEVEL INDICATOR The battery charge level is indicated by the display with ten notches, each of which corresponds to 10%. When the charge reaches 30% the third notch starts to flash. When the charge reaches 20% the first two notches start to flash and the fork lift system is immediately inhibited. 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 (see “INSTALLATION AND SETTINGS” section).

HOUR METER When any function is active (lowered tiller, traction, lift/lowering) the hour meter flashes, indicating that the battery level indicator is recording the hours of work. When the battery charge level display is replaced the truck working hours will be lost.

ELECTRICAL SYSTEM

MDI (OPTIONAL)

4 5

Ref.

Description

Total work hour indicator and warnings

Battery charge level indicator

Light emitting diode - LED in warning state

Hour meter

Speed reduction status indicator

Programmed maintenance and warning status indicator

SERVICE

ELECTRICAL SYSTEM

BATTERY CHARGE LEVEL INDICATOR The battery charge level is indicated by the display with ten notches, each of which corresponds to 10%. When the battery charge state reaches 30% the battery symbol placed beneath the notches starts to flash. When the battery charge state reaches 20% the fork lifting is inhibited. 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 (see “INSTALLATION AND SETTINGS” section).

SPEED REDUCTION INDICATOR indicates that the speed reduction function is active The symbol (for speed reduction see “TRUCK FUNCTIONS”). HOUR METER When any function is active (lowered tiller, traction, lift/lowering) the hour meter flashes, indicating that the MDI is recording the hours of work. When the MDI or COMBI modules are replaced, one can maintain the truck operating hours and memorize them on the new modules (see "replacement module: INSTRUCTIONS").

WARNINGS INDICATOR The MDI provides an indication of the truck's warning status. When a warning in generated, the light emitting diode - LED starts to flash and the spanner symbol appears. The error code that has generated the warning appears on the display (XXAYY), comprised of a number that identifies the module (XX) and one (YY) that identifies the kind of error (see “DIAGNOSTICS" section). The error code 16A06 corresponds to the NO COMMUNICATION warning. Indicates that there is a communication problem between the MDI and the COMBI. Verify the cable connections.

SERVICE

ELECTRICAL SYSTEM

TRUCK FUNCTIONS TRACTION FORWARD/REVERSE IMPLEMENTATION CONTROLS

Forward travel (operator side)

Implementors involved

state

Initials on diagram

Key switch

Emergency switch

Tilted tiller sensor

ON*

Forward reverse traction throttle * OFF when the button (S11) "snail" is pressed

Reverse travel (fork side)

forward/reverse rotation

SERVICE

ELECTRICAL SYSTEM

CONFIGURATION PARAMETERS

COMBI

Main menu parameter change acceleration delay release braking invers braking decel braking speed limit braking max speed forwd max speed back cutback speed 1 cutback speed 2 snail speed frequency creep acc smooth inv smooth stop smooth brk smooth stop brk smooth auxiliary time emb insertion delay

Main menu tester battery voltage battery current motor voltage voltage booster frequency encoder slip value current rms battery charge temperature motor temperature accelerator tiller switch forward switch backward switch snail switch fork under 500 fork under 1500 elct. brake voltage

Config menu set options stop on ramp quick inversion motor selection auxiliary function buzzer function flash beacon brake on release

Config menu adjustment adjust battery throttle 0 zone throttle x point throttle y point

For the regulation values of each individual parameter see the paragraph "standard configuration of MODULE parameters". For the description of each individual parameters see "MODULE PARAMETER DESCRIPTION". The maximum traction speed and acceleration are settable through the programmer. Maximum forward and backward traction speed setting. COMBI / main menu parameter change / max speed forwd COMBI / main menu parameter change / max speed back Acceleration setting COMBI / main menu parameter change / acceleration delay

ELECTRICAL SYSTEM

SERVICE

SPEED REDUCTIONS There are two levels of speed reduction available on the machine. • cutback speed 1 Average traction speed reduction(between 50% AND 100 % of the maximum spe-

ed)

• cutback speed 2 Average traction speed reduction(between 5% AND 50% of the maximum speed)

Setting of the speed reductionlevels COMBI / main menu parameter change / cutback speed 1 COMBI / main menu parameter change / cutback speed 2 In the presence of fork height sensors, when the forks exceed a height of 500 mm a first speed reduction cuts in cutback speed 1. When the forks exceed a height of 1500 mm a second speed reduction cuts in cutback speed 2

cutback speed 2 1500 mm

cutback speed 1 500 mm

maximum speed

SPEED REDUCTIONS AND TRACTION BLOCK WITH “CHECK UP NEEDED” WARNING When the programmed maintenance control is enabled, if it is not performed, depending on the parameter values it is possible that the truck may first be subject to a reduction in speed and then to a traction block. One can set what actions will occur to the truck via the programmer. Setting the action that follows a maintenance warning. COMBI / config menu adjustment / check up type NONE: no alarm OPTION #1: the warning appears after 300 hours OPTION #2: the warning appears after 300 hours and a reduction in speed takes place after 340 hours. OPTION #3: the warning appears after 300 hours, a speed reduction takes place after 340 hours and the traction is blocked after 380 hours. Once the programmed maintenance is performed, to reset the "check up needed" warming, one must set the parameter: Reset the hourmeter of the maintenance hours COMBI / config menu adjustment / check up done

SERVICE

ELECTRICAL SYSTEM

BREAKING The truck is equipped with four breaking systems: • • • •

Release breaking. Breaking on direction reversal. Emergency breaking. Stationary handbrake.

The truck breaks in a different way depending on which of the above listed systems comes into play. For further information on the breaking systems see "BREAKING SYSTEMS" “BREAKING SYSTEM” section.

BREAKING SYSTEMS

WHEN DOES IT COME INTO OPERATION?

Release breaking

Traction control throttle release

Breaking on direction reversal

Inversion of the direction of motion through the traction control throttle Through operation of the emergency breaking button

Emergency breaking

Stationary handbrake

A warning has been triggered that requires immediate traction stoppage. The machine is stationary and no traction control is activated

Through the programmer one can set the deceleration slope of the release breaking, of the partial release breaking and of the reverse breaking. Setting the release breaking deceleration slope COMBI / main menu parameter change / release braking Setting the partial release breaking deceleration slope COMBI / main menu parameter change / decel braking Setting the reverse breaking deceleration slope COMBI / main menu parameter change / inverse braking SPEED REDUCTIONS AND BREAKING When the truck speed is reduced this causes a gradual deceleration of the truck through a breaking process that can be set by the programmer. Setting the deceleration slope for speed reduction COMBI / main menu parameter change / speed limit braking

SERVICE

ELECTRICAL SYSTEM EMERGENCY REVERSE MANOEUVRE The emergency reverse manoeuvre is a safety function in the event that the operator, when driving forwards (direction of the traction wheel), hits an object. If this happens, by pressing the S10 button, the truck goes into immediate reverse, with the aim of avoiding the operator being crushed. The emergency reverse procedure is activated with the truck in forward gear, in driving position (tiller sensor B4 active) and the "BELLY SWITCH" button pressed. It is possible to program the "emergency reverse" function so that it is possible to go into reverse mode on continuous basis, with a time delay (approx. 5 seconds) or disabled. Enabling/disabling of the emergency reverse mode COMBI / config menu set options / quick inversion

emergency reverse function activation button

none: disabled belly: active and operated by pressing on the belly switch button timed: active and delayed with operation through the belly switch button

It is possible to program the Belly button function in such a way that the truck performs the direction reversal or stops. Enabling/disabling of the emergency reverse mode COMBI / config menu set options / belly with inv.

BELLY WITH INV.

OFF

forward movement

"Belly Switch" button pressure

direction reversal

on: by exerting pressure on the S10 button a reverse manoeuvre is performed off: by exerting pressure on the S10 button the truck is stopped.

Stopping the truck

SERVICE

ELECTRICAL SYSTEM

SNAIL FUNCTION The "snail" function enables the traction even when the tiller is in the rest position (tiller sensor B4 is 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, the traction request is performed by the potentiometric throttle. Thanks to the programmer it is possible to set the traction speed in the "snail" mode. Setting of the traction speed in "snail" mode. COMBI / main menu parameter change / snail speed

tiller sensor

potentiometric throttle (accelerator)

snail function activation button

SERVICE

ELECTRICAL SYSTEM

STEERING WHEEL IMPLEMENTATION CONTROLS

To steer to the right or to the left rotate the steering tiller to the right or to the left Implementors involved

state

Initials on diagram

Key switch

Emergency switch

Tilted tiller sensor

Tiller

rotation right/left

SERVICE

ELECTRICAL SYSTEM

LIFTING/LOWERING IMPLEMENTATION CONTROLS

D c

A B

To lift the forks quickly press the potentiometric button“A”. To lower the forks slowly press the pontentiometric button “B”. To lift the forks slowly press the on/off button “C”. To lower the forks slowsly press the on/off button “D”. VERSION WITH INITIAL LIFT To lift the straddle legs, press the on/off button “C”. To lower the straddle legs, press the on/off button “D”.

Implementors involved

state

Initials on diagram

Key switch

Emergency switch

Quick fork lifting/lowering

proportional* lifting/lowering button active

S5 - S6

Slow fork lifting/lowering or Straddle leg lifting/lowering (with initial lift only)

ON/OFF button for lifting/ lowering activated

S7 - S8

ON**

Tilted tiller sensor

* The buttons are of the ON/OFF variety for trucks with nominal load capacity of 1000/1200 kg ** Only where the forks are being lowered (OFF if the (S11) “snail” button is pressed)

SERVICE

ELECTRICAL SYSTEM CONFIGURATION PARAMETERS

COMBI

Main menu parameter change pu. acceler delay pu. deceler delay speed limit initial lift initial lower creep speed compensation min evp max evp evp open delay evp close delay lift max time

Main menu tester battery voltage battery current pump current pump vmn set point evp lifting control lifting switch descent switch initial lift switch initial low switch truck enable fork under 500 fork under 1500 top mast sensor unlock lift bdi block lifting emergency pwm evp output ev2 output ev3 output ev4 output ev5 output ev6 output ev6

Config menu set options auxiliary function lifting block ev2 ev3 ev4

Config menu adjustment adjust battery

For the regulation values of each individual parameter see the paragraph "standard configuration of MODULE parameters". For the description of each individual parameters see "MODULE PARAMETER DESCRIPTION". When the tiller is in the rest position, to enable lifting, press the ‘slow’ drive push-button simultaneously with the normal lifting buttons. Via the programmer it is possible to set the maximum fork lifting/lowering speed. Setting the maximum proportional fork lifting speed. COMBI / main menu parameter change / speed limit Setting the maximum proportional fork lowering speed COMBI / main menu parameter change / min evp COMBI / main menu parameter change / max evp Setting the maximum on/off lifting/lowering speed for the forks/straddle legs COMBI / main menu parameter change / initial lift COMBI / main menu parameter change / initial lower

SERVICE

ELECTRICAL SYSTEM

ACCELERATION/DECELERATION SLOPES By activating the proportional lift button (S5), the forks begin to rise with an acceleration slope that can be set via the programmer. Setting the fork lift acceleration slope COMBI / main menu parameter change / pu. acceler delay By releasing the proportional lift button (S5), the forks start to stop with a deceleration slope that can be set via the programmer. Setting the proportional fork lift button release deceleration slope COMBI / main menu parameter change / pu. deceler delay By activating the proportional descent button (S6), the forks begin to descend with an acceleration slope that depends on the opening slope of the solenoid valve Q1. Setting the fork lowering acceleration slope COMBI / main menu parameter change / evp open delay By releasing the proportional descent button (S6), the forks begin to stop with a deceleration slope that depends on the closing slope of the solenoid valve Q1. Setting the proportional fork lowering button release deceleration slope COMBI / main menu parameter change / evp close delay

FORK LOWERING AND BUTTON RELEASE

FORK LIFT AND BUTTON RELEASE

button “ “ON””

stop

settable acceleration slope: “evp open delay”

settable deceleration slope: “pu. deceler delay" button release

maximum lowering speed settable: “min evp” “max evp”

maximum lift speed settable: “speed limit”

button release

settable deceleration slope: “evp close delay”

settable deceleration slope: “pu. acceler delay”

stop

button “ “ON””

SERVICE

ELECTRICAL SYSTEM LIFT BLOCK WITH FLAT BATTERY

When the level of the battery charge drops below 20% the fork lifting is disabled. To restore initial operating conditions one must recharge the batttery. When the battery charge reaches 100% the flat battery indicator resets itself and the normal fork operation is restored.

TIMER LIFT BLOCK BY activating the lift button (S5/S7) the forks start to rise for a maximum time that may be set with the programmer. Setting the maximum proportional fork lift time. SICOS / main menu parameter change / lift max time Once this time is elapsed, to continue lifting, one must first press the lowering button and then the lift button once more. It is possible to enable/disable the timed fork lift block. Enabling/disabling of the timer fork lift block COMBI / config menu set options / lifting block

off: disabled on: enabled

END POINT SLOWDOWN lifting/LOWERING FORKS In the lifting stage the forks reach the maximum height without any slowdown effect coming into play, the halt is determined by the mechanical end point of the cylinders. In the lowering stage the forks reach their descent end point without any slowdown effect, the halt is determined by the mechanical end point.

VERSION WITH INITIAL LIFT: ‘STRADDLE LEGS DOWN’ AND ‘FORKS ABOVE 1500 mm’ SENSORS On versions with initial lift, if the straddle legs are in a raised position (‘straddle legs down’ sensor B8 not activated), and the forks are lifted above 1500 mm (‘forks above 1500 mm’ sensor B6 not activated), the straddle legs will be lowered to the ground automatically. If automatic straddle leg lowering is not enabled, when the forks are raised above 1500 mm (‘forks above 1500 mm’ sensor B6 not activated), truck traction will be inhibited until the operator lowers the straddle legs to the ground (‘straddle legs down’ sensor B8 activated). Various truck operating parameters can be set via the programmer. Setting automatic straddle leg lowering COMBI / config menu set options / autolo. straddle legs

off: disabled on: enabled

SERVICE

ELECTRICAL SYSTEM

CONFIGURATION PARAMETER ACCESS PROCEDURE Thanks to the CAN BUS connection one may configure the module parameters by connecting the console to the 3 pin (X30) and 2 pin (X31) connectors proceding with the search of the required menu. Before connecting the console to the module, position the key switch on “OFF”. If the optional MDI is installed, disconnect it from the connector X31 before connecting the console. Menu RESEACH PROCEDURE and parameter modification To access the config menu one must press the two buttons top left and top right, then scrol until the desired menu appears and press "Enter". To access a main menu one must press "Enter", then scroll until the desired menu appears then press "Enter".

CA0Z2A 24V

ZP1.00 200A

00000

Opening heading

Press the keys "Roll h" and “Set h” at the same time

*CONFIG. MENU* SET MODEL

The SET MODEL menu heading appears.

Press the "Roll h” or “Roll i” keys until the desired config menu appears.

*CONFIG. MENU* SET OPTION

The SET OPTION menu heading appears.

Press the "Enter" key

ELECTRICAL SYSTEM

HOUR COUNTER RUNNING

SERVICE

The heading of the first parameter with its current value appears. To scroll through the parameters press the keys "Roll h” or “Roll i”

Press the keys "Set h” or “Set i” to modify the value.

HOUR COUNTER KEY ON

The new value appears.

Press the key "Out" to exit the selection.

ARE YOU SURE? YES=ENTER NO=OUT

The modification confirmation request appears

Press the key "Enter" to confirm. If one doesn't want to confirm the choice press the "Out" key.

*CONFIG. MENU* SET OPTION

After having pressed the enter key the heading of the SET OPTION menu reappears.

Press the "Out" key to return to the opening heading

CA0Z2A 24V

ZP1.00 200A

00000

Opening heading

SERVICE

ELECTRICAL SYSTEM

CA0Z2A 24V

ZP1.00 200A

00000

Opening heading

Press the "Enter"key to enter the main menu

*MAIN MENU* PARAMETER CHANGE

The PARAMETER CHANGE menu heading appears. If another menu is displayed, press the "Roll h” or “Roll i” keys until the PARAMETER CHANGE menu appears.

Press the "Enter" key

ACCELERATION DELAY LEVEL = 3

The heading of the first parameter with its current value appears. To scroll through the parameters press the keys "Roll h” or “Roll i” Press the keys "Set h” or “Set i” to modify the value.

ACCELERATION DELAY LEVEL = 5

The new value appears.

Press the key "Out" to exit the selection.

ARE YOU SURE? YES=ENTER NO=OUT

The modification confirmation request appears

Press the key "Enter"to confirm. If one doesn't want to confirm the choice press the "Out" key.

ELECTRICAL SYSTEM

SERVICE

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 based on the client's request, the characteristics of the warehouse and the materials to be moved, but no parameter must be changed if this jeopardises the safety of the truck.

"COMBI AC0" Module COMBI / main menu parameter change / COMBI / config menu set options / COMBI / config menu adjustment / MAIN MENU PARAMETER CHANGE

PARAMETER

std

initial lift

PARAMETER

std

initial lift

ACCELERATION DELAY

1,8

INITIAL LOWER

30%

RELEASE BRAKING

1,1

AUX SPEED FWD

30%

INVERS BRAKING

0,9

AUX SPEED REV

30%

DECEL BRAKING

CREEP SPEED

10%

SPEED LIMIT BRAKING

2,8

COMPENSATION

10%

MAX SPEED FORWD

100%

MIN EVP

5,8%

MAX SPEED BACK

100%

MAX EVP

43,9%

46,2%

CUTBACK SPEED 1

100%

EVP OPEN DELAY

0,5

CUTBACK SPEED 2

25%

EVP CLOSE DELAY

0,0

SNAIL SPEED

15%

LIFT MAX TIME

FREQUENCY CREEP

0,6

ACC SMOOTH

INV SMOOTH

STOP SMOOTH

BRK SMOOTH

STOP BRK SMOOTH

AUXILIARY TIME

0,4

EMB INSERTION DELAY

1,6

PU. ACCELER DELAY

0,5

PU. DECELER DELAY

0,4

SPEED LIMIT

100%

INITIAL LIFT

30%

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU SET OPTIONS PARAMETER

std

initial lift

HOUR COUNTER

Running

BATTERY CHECK

Off

STOP ON RAMP

QUICK INVERSION

Belly

BELLY WITH INV.

DRIVE MODE

Off

AUTOLO. BASE ARMS

Off

AUXILIARY FUNCTION

Off

BUZZER FUNCTION

Option #2

FLASH BEACON

Option #2

LIFTING BLOCK

Off

BRAKE ON RELEASE

Off

EV2

Absent

Present

EV3

Absent

Present

EV4

Absent

Present

MOTOR SELECTION

REDUNDANCY

Off

PARAMETER

std

initial lift

ADJUST BATTERY

25,03 V

THROTTLE 0 ZONE

10%

THROTTLE X POINT

50%

THROTTLE Y POINT

35%

THROTTLE 0 PROP

THROTTLE X PROP

10%

THROTTLE Y PROP

40%

THROTTLE X1 PROP

30%

THROTTLE Y1 PROP

70%

BAT. MIN ADJ.

BAT. MAX ADJ.

LOAD HM FROM MDI

Off

CHECK UP DONE

Off

CHECK UP TYPE

None

CONFIG MENU ADJUSTMENT

SERVICE

ELECTRICAL SYSTEM

MODULE PARAMETER DESCRIPTION "COMBI AC0" Module COMBI / main menu parameter change / COMBI / config menu set options / COMBI / config menu adjustments / MAIN MENU PARAMETER CHANGE PARAMETER ACCELERATION DELAY

level = 0

level = 9

0.3 sec

10 sec

0.3 sec

5 sec

0.3 sec

5 sec

0.3 sec

5 sec

0.3 sec

10 sec

10%

100%

10%

100%

50%

100%

50%

30%

0.6 Hz

5 Hz

traction acceleration slope RELEASE BRAKING Release breaking deceleration slope INVERS BRAKING Direction reversal breaking deceleration slope DECEL BRAKING Deceleration slope with throttle released but not completely. SPEED LIMIT BRAKING Deceleration slope when a speed limit is active MAX SPEED FORWD Maximum forward traction speed MAX SPEED BACK Maximum backward traction speed CUTBACK SPEED 1 Average traction reduction speed (a percentage of the maximum speed) CUTBACK SPEED 2 Maximum traction reduction speed (a percentage of the maximum speed) SNAIL SPEED Traction speed in SNAIL mode (percentage of maximum speed) FREQUENCY CREEP

Minimum frequency applied with a forward or backward motion request is present but the traction control throttle is in the minimum position. ACC SMOOTH Associates a parabolic shape to the acceleration slope

1 sec

5 sec

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PARAMETER CHANGE PARAMETER INV SMOOTH

level = 0

level = 9

1 sec

5 sec

3 Hz

20Hz

Associates a parabolic shape to the acceleration slope for reverse breaking STOP SMOOTH

Sets the frequency level at which the effect of the parabolic shape of the acceleration slope ceases to have any effect BRK SMOOTH

1 sec

5 sec

3 Hz

20Hz

Associates a parabolic shape to the deceleration slope STOP BRK SMOOTH

Sets the frequency level at which the effect of the parabolic shape of the deceleration slope ceases to have any effect AUXILIARY TIME

0 sec

10 sec

If the COMBI / config menu set options / stop on ramp ON, indicates the time that elapses before disactivating the truck's electrical stop positioned on the ramp when the traction control throttle is released. EMB INSERTION DELAY

0.2 sec

10 sec

If the parameter COMBI / config menu set options / brake on release ON, indicates the time that elapses before the electromagnetic break is triggered when the tiller and the traction control throttle are released. PU. ACCELER DELAY

0.1 sec

10 sec

0.1 sec

10 sec

100%

Fork lifting/lowering acceleration slope (acceleration time) PU. DECELER DELAY Fork lifting/lowering deceleration slope (deceleration time) SPEED LIMIT Limits the maximum fork lifting/lowering speed INITIAL LIFT

Limits maximum lifting speed for slow fork lifting (or straddle leg lifting on versions with initial lift) INITIAL LOWER

100%

Limits maximum lowering speed for slow fork lowering (or straddle leg lowering on versions with initial lift) AUX SPEED FWD

100%

Unused AUX SPEED REV Unused CREEP SPEED

Minimun speed of the pump connected to the value of the COMBI / main menu parameter change / frequency creep parameter 35

SERVICE

ELECTRICAL SYSTEM

MAIN MENU PARAMETER CHANGE PARAMETER COMPENSATION

level = 0

level = 9

100%

Estabilshes the compensation voltage (∆V) applied to the engine when the proportional lift is active. The value of this compensation applied to the engine is a function of the engine current. The purpose of this function is to reduce the difference in speed between laden and unladen. MIN EVP

100%

10%

100%

0 sec

12.75 sec

0 sec

12.75 sec

3 sec

100 sec

Minimum current present on the solenoid valve coil EV1. MAX EVP Maximum current present on the solenoid valve coil EV1. EVP OPEN DELAY Solenoid valve EV1 opening slope EVP CLOSE DELAY Solenoid valve EV1 closing slope LIFT MAX TIME

If the COMBI / config menu set options / lifting block ON, indicates the duration of the fork lift before these are blocked. After the block, one has to press one of the descent buttons before being able to proceed with another lift.

CONFIG MENU SET OPTIONS PARAMETER

level KEY ON: record of truck start up

HOUR COUNTER

RUNNING: record of an active request

Select the hourmeter mode BATTERY CHECK

ON = test performed OFF = test not performed

Enables/disables the test of the battery level charge loss. If battery check ON, when the battery level reaches 20%, the fork lifting function is disabled and traction speed is reduced. STOP ON RAMP

ON: the stop is enabled OFF: the stop is disabled

Enables/disables the electric stop on the truck on a tilted ramp when the traction control throttle is released but the tiller sensor remains active. The duration of the electrical stop can be set using the parameter COMBI / main menu parameter change / auxiliary time. At the end of the electrical stop time the 3-phase bridge is released and the electromagnetic break is activated.

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU SET OPTIONS PARAMETER

level NONE: inversion disabled

QUICK INVERSION

TIMED: inversion enabled for 5 seconds BELLY: inversion always enabled

Select the emergency reverse mode if the parameter COMBI / config menu set options / belly with inv. ON. BELLY WITH INV.

ON: reverse enabled OFF: reverse disabled

Enabling/disabling of the direction reversal with the Belly button pressed. If the parameter is OFF, by pressing the Belly button the truck stops. DRIVE MODE Unused AUTOLO. STRADDLE LEGS

ON: lowering enabled OFF: lowering disabled

For initial lift version only. Enabling/disabling of automatic lowering of the straddle legs when the fork lifting height exceeds 1500 mm ON: outputs managed respectively like valves EV5 and EV6 AUXILIARY FUNCTION

OFF: outputs managed respectively as acoustic buzzer buzzer and warning light.

Setting of the control designed to manage the ouputs 34 and 8

BUZZER FUNCTION

OPTION#1: active with forward gear OPTION#2: active with backward gear

If the parameter COMBI / config menu set options / auxiliary function OFF, sets the buzzer operation mode.

FLASH BEACON

OPTION#1: active with tiller lowered OPTION#2: active with any truck functions active

If the parameter COMBI / config menu set options / auxiliary function OFF, sets the flash beacon operation mode. LIFTING BLOCK

ON: enabled OFF: disabled

Enabled/disabled fork lifting after a time established by the parameter COMBI / main menu parameter change / lift max time

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU SET OPTIONS PARAMETER BRAKE ON RELEASE

level ON: enabled OFF: disabled

ON: the electromagnetic brake is activated after a delay depandant on the parameter COMBI / main menu parameter change / emb insertion delay OFF: the electromagnetic break is activated at the end of the electrical breaking when the speed is nil EV2

PRESENT: checks performed ABSENT: checks not performed

Presence/absence of the solenoid valve EV2 EV3

PRESENT: checks performed ABSENT: checks not performed

Presence/absence of the solenoid valve EV3 EV4

PRESENT: checks performed ABSENT: checks not performed

Presence/absence of the solenoid valve EV4 MOTOR SELECTION

0 = Shabmüller 1 = ABM

Motor traction present (it is advisable not to modify this parameter) REDUNDANCY

ON: enabled OFF: disabled

Enabling/disabling of the checks on the A15 input of the controller so that there is an analog signal that varies between 5 V and 10 V (5 V and 0 V) when the traction command throttle has a value of between 2.5 V and 5 V (2.5 V and 0 V). If this does not take place, then the controller signals an alarm.

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU ADJUSTMENT PARAMETER ADJUST BATTERY

level Value expressed in Volts

Exact value of battery charged measured at the inverter This value is not altered by a CLEAR EEPROM THROTTLE 0 ZONE

Value expressed in percentage

Sets the breadth of the initial dead zone of the throttle pontentiometer.1 THROTTLE X POINT

Value expressed in percentage

Together with the parameter throttle y pointmodifices the charcteristics of the acceleration curve: when the traction control throttle is rotate by x% the corresponding truck speed will be y% of the maximum speed. The relationship between the position of the throttle and the truck speed is linear between the e throttle 0 zoneand X and between X and the position of maximum accelaration of the throttle, but with a different slope (fig.1). THROTTLE Y POINT

Value expressed in percentage

Together with the parameter throttle X pointmodifices the charcteristics of the acceleration curve: when the traction control throttle is rotate by x% the corresponding truck speed will be y% of the maximum speed. The relationship between the position of the throttle and the truck speed is linear between the e throttle 0 zoneand X and between X and the position of maximum accelaration of the throttle, but with a different slope(fig.1).

Fig. 1

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU ADJUSTMENT PARAMETER THROTTLE 0 PROP

level Value expressed in percentage

Sets the breadth of the initial dead zone of the throttle potentiometer (fig.2) THROTTLE X PROP

Value expressed in percentage

Establishes the coordinates on the X axis of the first point of the cross-section on which we approximate the curve of the proportional valve (fig.2) THROTTLE Y PROP

Value expressed in percentage

Establishes the coordinates on the y axis of the first point of the cross-section on which we approximate the curve of the proportional valve (fig.2) THROTTLE X1 PROP

Value expressed in percentage

Establishes the axis X of the second point of the cross-section on which we approximate the curve of the proportional valve (fig.2) THROTTLE Y1 PROP

Value expressed in percentage

Establishes the coordinates on the y axis of the second point of the cross-section on which we approximate the curve of the proportional valve (fig.2)

Fig. 2

A: percentage of the maximum value of the current in the proportional valve B: percentage of the maximum value of the travel distance of the proportional button

SERVICE

ELECTRICAL SYSTEM

CONFIG MENU ADJUSTMENT PARAMETER BAT. MIN. ADJ.

level 0 = minimum value 9 = maximum value

Adjusts the lower value of the battery charge state table. BAT. MAX. ADJ.

0 = minimum value 9 = maximum value

Adjusts the upper value of the battery charge state table. LOAD HM FROM MDI

ON: saving enabled OFF: saving disabled

Enable/disable the saving of the operating hours from the MDI module (optional) to the COMBI.

CHECK UP DONE

ON =programmed maintenance performed OFF = programmed maintenance not performed

Maintenance programme performed when enabled. When set to ON at the end of the maintenance it resets the maintenance hourmeter and the “CHECK UP NEEDED” warning

CHECK UP TYPE

NONE: disabled OPTION#1: warning after 300 hours OPTION#2: like option#1 plus speed reduction after 340 hours OPTION#3: like option#2 plus truck block after 380 hours

Enables/disables the programmed maintenance mode and warning At the end the maintenance set the parameter COMBI / config menu adjustment / check up done ON

SERVICE

ELECTRICAL SYSTEM

COMBI AC0 MODULE: INTRODUCTION The “COMBI AC0 INVERTER" has been developed to carry out all the electrical functions normally present on the truck: • controlling the 1.2 Kw AC motor • controlling the 2Kw hydraulic pump • driver for the porportional solenoid valve • CanBus interface • Interface with the tiller Can Bus • Warnings • performances Technical specifications: Asynchronous three phase inverter for AC motors and chopper for DC pump motors Regenerative breaking functions Digital control via microcontroller Voltage: ........................................................................................24V - 36V - 48V Maximum inverter current (24V):...................................................200A (RMS) for 2’ Continuous current output (24V)...................................................70A (RMS) for 2’ Operating inverter frequency: .......................................................8 kHz Maximum chopper current (24 V):.................................................270A (RMS) for 2’ Chopper operating frequency: ......................................................16 kHz External temperature limit.............................................................-40°C ÷ 40°C Maxmum inverter temperature (at maximum power):...................85°C

SERVICE

ELECTRICAL SYSTEM

The module is connected and communicates via the CANBUS network, which allows access to the diagnostics or programming of the truck via PC (or laptop) or console. The connector for the cable kit interface connection "PC CONSOLE") is connected to the “COMBI AC0" module and can be accessed from the engine compartment. The module is equipped with a flash memory, which enables the software to be updated by connecting a PC to the CANBUS netowork (Can flash).

POSITIONING OF THE "PC CONSOLE" CONNECTOR AND CONSOLE

pc console connector and console additional console connector

pc interface cable kit cod.580039670

console cable kit cod.582000044

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT MODULE: INSTRUCTIONS REPLACEMENT OF THE COMBI AC0 MODULE Equipment and tools

hexagonal pipe wrench 10 mm

resistence 100 Ohm 25w isolated

large philips screwdrivers

Fig. 1

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Phase 2 RESISTENCE 100 Ohm 25 W Connect the resistence betwen the positive (B+) and negative (B-) of the module (fig.2). Wait approximately 10 seconds for the internal capacitors to lose their charge and then disconnect the resistence. To avoid short circuit, it is important that the resistence by isolated. If it is not possible to have an external resistence to run down the capacitors, it will be necessary to wait at least 90 seconds before disconnecting the power cables.

Volt

Fig. 2

SERVICE

ELECTRICAL SYSTEM

Phase 3 HEXAGONAL 10 mm "T" SECTION SOCKET WRENCH Using the hexagonal pipe wrench loosen and remove the power cable fastening screws. Disconnect the module connection connector. Earmark the power cables for reassembly and disconnect them.

C C

B Phase 4 HEXAGONAL 10 mm "T" SECTION PIPE WRENCH Fig. 3 Usint the hexagonal pipe wrench loosen and remove the screws fastening the module to the truck chassis (ref.B fig.3), recover the washers and remove the cable fasteners (ref.C fig.3). Remove the module including the heat sink and procede with the replacement.

CONFIGURATION ADAPTER - PROGRAMMER Connect the adaptor to the “PC CONSOLE" connector. Connect the USB connector of the interface cable to the USB port on the PC. Connect the battery and turn on the machine (ignition key to ON). Start the PC Console program. Create a new configuration and copy the factory configuration or a customised configuration.

ACQUISITION OF WORK HOURS (with MDI optional) The hours of operation of the truck are memorised on the “COMBI” module and on the “MDI” module. On ignition the system assesses the hours recorded on the two modules. If the difference is greater than 20 hours the warning “98” appears and traction is disabled. In this case there are 5 minutes available to load the operating hours on the new “COMBI” by loading them up from the “MDI” module. Procedure With the machine off (key switch OFF) connect the programmer. Turn the machine on (Key switch ON) and select the parameter COMBI / config menu adjustment / load hm from mdi. Set the parameter on “ON” and save the information. Turn off the truck (Key switch OFF) and turn it back on again ( Key switch ON). At this point the new module will receive the operating hours recorded on the “MDI” module. If when turning the truck on the ”98” warning appears and the operating hour acquisition procedure is not performed, after 5 minutes the “MDI” module will load the hours recorded on the “COMBI” module (0 if the controller is new).

SERVICE

ELECTRICAL SYSTEM

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

medium/ large Phillips screwdriver

pin extractor Ø 3 mm

fixed spanner 13 mm

Procedure

Fig. 1

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Phase 2 PIN EXTRACTOR Slip the end of the pin extractor into the hole beneath the red general emergency knob (ref.B fig.2). Rotate the knob until the pin extractor fits into the inner knob shaft . Unscrew and remove the knob.

Phase 3 FIXED 13 mm spanner Using the fixed spanner loosen the nuts fastening the remote-control switch power cable (ref.C fig.3).

Fig. 2

Fig. 3

SERVICE

ELECTRICAL SYSTEM

Phase 4 MEDIUM PHILIPS SCREWDRIVER Unscrew the fastening screws of the general emergency switch (ref.D fig.4), retrieve the washers(ref.E fig.4). Pull downwards towards the remote control switch (fig.4).

Phase 5 Disconnect the connectors and proceed with the replacement.

Fig. 4

ASSEMBLY Before connecting them again, make sure the fastons are suitably tight. If this is not the case tighten the connectors with faston pliers.

SERVICE

ELECTRICAL SYSTEM DISPLAY REPLACEMENT Equipment and tools

large Philips screw driver

Fig. 1 Fig. 2

When the battery charge state display is replaced the truck working hours will be lost.

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Fig. 3

Phase 2 Disconnect the connector of the electrical connection (ref.B fig.2). Loosen the stop nuts of the blocking bracket (ref.C fig.3). Remove the bracket (ref.D fig.3). Remove the display (Fig.4) and proceed with the replacement.

Fig. 4 ACQUISITION OF WORK HOURS (with MDI optional) On turning on the truck the “98” warning appears and traction is disabled, after 5 minutes the “MDI” module will automatically acquire the operating hours recorded on the “COMBI” module (0 if the controller is new). 48

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE KEY SWITCH Equipment and tools

large Philips screw driver

Fig. 1 Fig. 2

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Fig. 3

Phase 2 Remove the ignition key (fig.2). Unscrew the ferrule (ref.B fig.2), remove the switch block from the dashboard (fig.3). Disconnect the connectors and proceed with the replacement.

ASSEMBLY Before connecting them again, make sure the fastons are suitably tight. If this is not the case tighten the connectors with faston plyers.

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF THE WARNING BUZZER Equipment and tools

large Philips screw driver

n..2 fixed gauge spanners 10 mm

A Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Set the key switch to OFF and disconnect the battery.

Fig. 1

Fig. 2

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Phase 2 N.2 FIXED GAUGE 10 mm SPANNERS With a fixed gauge spanner block the nut (ref.C fig.3), while with the other key you loosen and remove the warning buzzer fastening screws (ref.B fig.3). Disconnect the connectors, remove the buzzer and proceed with the replacement.

C ASSEMBLY Before connecting them again, make sure the fastons are suitably tight. If this is not the case tighten the connectors with faston plyers.

B Fig. 3

SERVICE

ELECTRICAL SYSTEM

FUSE REPLACEMENT • • • •

24V solenoid valve coils (F3) power supply fuse 24V Horn relay (F4) power supply fuse 24V Battery charge level indicator (F5) power supply fuse key switch ( F2) fuse

Equipment and tools

small flat head screwdriver

large Philips screw driver

Procedure

Fig. 1

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Phase 2 SMALL FLAT HEAD SCREWDRIVER Using the small flat head screwdriver press the flaps (ref.B Fig.3) and remove the fuse holder cover. Remove the fuse and procede with the replacement.

Fig. 2

B F5 F4 F3 F2 Fig. 3

SERVICE

ELECTRICAL SYSTEM

tiller diagram: configuration and calibration configuration When should one carry out this procedure? - When I replace the tiller card. In order to avoid accidentally triggering the horn micro during configuration, it is advisable to carry out the procedure before inserting the card into the tiller housing.

C A Fig. 1 Procedure Set the key switch to OFF and disconnect the battery. Phase 1 Move the configuration bridge of the tiller card from the position P (Parking) to the position C (Configuration) (fig.1).

Fig. 2

Connect the battery and position the ignition key on ON.

Fig. 3 Phase 2 The LED display will show the letter (trucks with on-off type lifting and lowering buttons) identifying the configuration type that has been saved on the board (fig.2). Press the Snail microswitch (ref.A fig.1) to increase the value until the LED display shows the configuration letter D (trucks with proportional lifting and lowering buttons). To decrease the value, press the horn microswitch (ref.B fig.1). Phase 3 Confirm the configuration by pressing the Bellyswitch microswitch (ref.C fig.1). On the LED display, a decimal point appears after the configuration letter (fig.3).

SERVICE

ELECTRICAL SYSTEM

Phase 4 Turn off the truck. Move the configuration bridge of the tiller card from the position C (Configuration) to the position P (Parking) (fig.1). Phase 5 Insert the card into its proper position in the tiller housing.

Fig. 4

Fig. 5

Calibration When should one carry out this procedure? - When I replace the tiller card. - When at top speed the truck does not proceed at a uniform speed. - When the traction stops at the end point of the throttle valve. - When there is a considerable difference in speed between the forward gear and the reverse gear. Procedure Before starting work check that all the lifting and lowering buttons are connected to the tiller card and that it is well lodged in its case. Position the key switch on OFF. Phase 1 Move the configuration bridge of the tiller card from the position P (Parking) to the position T (Teaching) (fig.1). Position the key switch on ON. Phase 2 The LED display shows zero. Press and release the lift button located on the left-hand side of the tiller casing (JP14, ref.D fig.5) to save the neutral position of the butterfly control.

Fig. 6

Fig. 7

If the LED display shows the value 8, indicating that at the moment the position was saved, the butterfly control was not in neutral position (at exactly 90° relative to the axis of rotation). Phase 3 The LED display will show a dash (fig.4). Rotate the butterfly control fully to the right and hold it in this position (fig.5). Press and release the lift button located on the left-hand side of the tiller casing (JP14, ref.D fig.5). The LED display will show another dash, indicating that the butterfly position has been successfully saved (fig.6). 53

SERVICE

ELECTRICAL SYSTEM Phase 4 Release the butterfly control. Rotate the butterfly control fully to the right and hold it in this position (fig.7). Press and release the lowering button located on the left-hand side of the tiller casing (JP15, ref.E fig.7). The LED display will show another dash, indicating that the butterfly position has been successfully saved (fig.8).

Fig. 8

Phase 5 Release the traction throttle. Move the configuration bridge of the tiller card from the position T (Teaching) to the position P (Parking) (fig.1). A decimal point appears on the LED display (fig.9). Fig. 9 Position the key switch on OFF. If the truck is turned off before having moved the configuration bridge onto the position P (parking), the calibration values will be lost and the procedure will have to be repeated.

SERVICE

ELECTRICAL SYSTEM

TILLER CARD REPLACEMENT Equipment and tools

hexagonal "T" section spanner 2.5 - 5 mm

small flat head screwdriver

A Fig. 1

D Fig. 2

Phase 1 HEXAGONAL 5mm "T" SECTION SPANNER Unscrew the nuts holding the upper frame housing in place (ref.A,B,C fig.1).

EF G

Phase 2 Lift the upper chassis housing and remove it from the lower frame housing (fig.2). Disconnect the connector connecting the serial cable (ref.D fig.2) and place the cover on a clean work bench.

Fig. 3

Phase 3 HEXAGONAL 2,5 mm "T" SECTION SPANNER Loosen the screw holding one of the two throttle valves (ref.E fig.3) and retrieve the washer (ref.F fig.3). Slip the throttle valve away from the gudgeon(ref.G fig.3). Remove the other throttle valve complete with guide pivot (ref.H fig.3). Phase 4 SMALL FLAT HEAD SCREWDRIVER Unscrew the tiller card latch fastening nut (ref.I fig.4). Remove the latch (ref.J fig.4) and the card from its seat (ref.K fig.4), disconnect the connectors of the various micro commands. Proceed with the replacement. After the assembly carry out the new card configuration and calibration procedure (see "TILLER DIAGRAM: CONFIGURATION AND CALIBRATION").

J Fig. 4

SERVICE

ELECTRICAL SYSTEM REPLACEMENT OF tiller BUTTONS Equipment and tools

A hexagonal "T" section spanner 5 mm

small flat head screwdriver

Fig. 1

D Fig. 2

Fig. 3

Phase 1 HEXAGONAL 5 mm "T" SECTION SPANNER Unscrew the nuts holding the upper chassis housing in place (ref.A,B,C fig.1).

Phase 2 Lift the frame of the upper housing and remove it from the lower frame housing (fig.2). Disconnect the connector connecting the serial cable (ref.D fig.2) and place the cover on a clean work bench.

Phase 3 SMALL FLAT HEAD SCREWDRIVER Using the screwdriver prise open the stop catches (fig.4) and apply pressure to the button to prise it out of its seat (fig.4,5). Proceed with the replacement

Fig. 4

Fig. 5 56

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE TILLER CONTROL SPRINGS Equipment and tools

T handle hex key 2.5 - 4 mm

small flat blade screwdriver

A Fig. 1

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

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

Fig. 2

EF G

Fig. 3

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

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.I fig.4). In the same way, prise out the butterfly control spring (ref.J fig.4). Proceed with the replacement.

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

Fig. 6

K L

SERVICE

ELECTRICAL SYSTEM

REPLACEMENT OF THE TILLER ASSENT SENSOR Equipment and tools

A hexagonal "T" section spanner 3 - 5 mm

small philips screwdriver

Fig. 1

D Fig. 2

Fig. 3

Phase 1 HEXAGONAL 5 mm "T" SECTION SPANNER Unscrew the nuts holding the upper chassis housing in place (ref.A,B,C fig.1).

Fig. 4

Phase 2 Lift the frame of the upper housing and remove it from the lower frame housing (fig.2). Disconnect the connector of the tiller sensor cable connection (ref.D fig.2).

Phase 3 HEXAGONAL 3 mm “T” SHAPED SPANNER - SMALL PHILIPS SCREWDRIVER Keeping the tiller lowered, using the hexagonal "T" section spanner unscrew and remove the sensor holder bridle (ref.E fig.4). Using the small philips screwdriver loosen the sensor fastening screw (ref.F fig.5). Remove the sensor from the bridle (fig.5), retrieve the cable and procede with the replacement. The optimal sensor sensitivity distance from the cam is 4 mm.

F Fig. 5 59

SERVICE

ELECTRICAL SYSTEM RENEWAL OF 'FORKS ABOVE 1500 mm' SENSOR (OPTIONAL) FOR INITIAL LIFT VERSION ONLY Equipment and tools

large flat blade screwdriver

open ended spanner 24 mm

scissors

Phase 1 LARGE FLAT BLADE SCREWDRIVER Using the screwdriver, loosen and remove the screws securing the wire mesh guard (ref.A fig.1) and recover the washers. Remove the wire mesh guard.

Phase 2 24 mm OPEN ENDED SPANNER - SCISSORS With the spanner, unscrew and remove the nut securing the sensor to the bracket (ref.B fig.2). With the scissors, cut the straps securing the sensor wire, then disconnect the connector. Remove the old sensor, recover the wire and fit the new sensor.

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

Fig. 1 Fig. 2

SERVICE

ELECTRICAL SYSTEM

RENEWAL OF 'FORKS ABOVE 500 mm' SENSOR (OPTIONAL) FOR INITIAL LIFT VERSION ONLY Equipment and tools Fig. 1

T handle hex key wooden beam 3-5 mm 100x100x1000 mm

scissors

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. 1

Phase 1 WOODEN BEAM Raise the forks by 1500 mm. Position the beam under the forks (ref.A fig.1), and lower the forks so that they rest on the beam.

Turn the keyswitch to OFF and disconnect the battery.

Phase 2 4 mm T HANDLE HEX KEY - SCISSORS With the T handle hex key, unscrew and remove the screws securing the sensor support clamp (ref.B fig.2). With the scissors, cut the straps securing the sensor wire, then disconnect the connector. Remove the clamp complete with the sensor and recover the wire. Extract the old sensor and fit the new one.

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

SERVICE

ELECTRICAL SYSTEM RENEWAL OF THE 'FORKS LOWERED' SENSOR FOR INITIAL LIFT VERSION ONLY Equipment and tools

large cross-head screwdriver

open ended spanner 24 mm

scissors

Procedure

Fig. 1

Phase 1 LARGE CROSS-HEAD SCREWDRIVER Use the cross-head screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the motor compartment cover. Fig. 2 Phase 2 24 mm OPEN ENDED SPANNER - SCISSORS With the spanner, unscrew and remove the nut securing the sensor to the bracket (ref.B fig.3). With the scissors, cut the straps securing the sensor wire, then disconnect the connector. Remove the sensor, recover the wire and proceed with the replacement.

Fig. 3

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

SERVICE

HYDRAULIC SYSTEM

hydraulic system HYDRAULIC FUNCTIONS �� 3 HYDRAULIC CIRCUIT POWER SUPPLY �� 4 PRESSURE REGULATING VALVES �� 4 DIRECTIONAL VALVES �� 5 HYDRAULIC PLANS �� 6 symbols �� 6 COMPLETE HYDRAULIC BLUEPRINT version without initial lift �� 7 MAIN HYDRAULIC DIAGRAMversion with initial lift �� 10 HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS �� 11 OPERATION TABLES - SOLENOID VALVES �� 11 HYDRAULIC DIAGRAM - forks lifting (without initial lift) �� 12 HYDRAULIC DIAGRAM - forks lifting (with initial lift) �� 13 HYDRAULIC DIAGRAM - forks lowering (without initial lift) �� 14 HYDRAULIC DIAGRAM - forks lowering (with initial lift) �� 15 HYDRAULIC DIAGRAM - straddle legs lifting (with initial lift) �� 16 HYDRAULIC DIAGRAM - straddle legs lowering (with initial lift) �� 17 HYDRAULIC DIAGRAM - emergency forks lowering (with initial lift) �� 18 HYDRAULIC PLAN FOR OIL RELEASE INTO THE TANK THROUGH THE PRESSURE RELIEF VALVE �� 19 HYDRAULIC COMPONENT �� 20 RELIEF VALVE DISMANTLING (all models) �� 20 PRESSURE RELIEF VALVE CALIBRATION (all models) �� 21 REMOVAL OF THE PRESSURE RELIEF VALVE (initial lift version only) �� 22 CALIBRATION OF THE PRESSURE RELIEF VALVE (initial lift version only) �� 23 REMOVAL OF THE LOWERING FLOW RATE CONTROL VALVE (for initial lift version only) �� 24 calibration of the lowering oil flow rate control valve (for initial lift version only) �� 25 CARTRIDGE SOLENOID VALVES �� 26 IDENTIFICATION OF THE COMPONENTS OF A CARTRIDGE SOLENOID VALVE �� 26 SOLENOID VALVE DISMANTLING �� 27 CYLINDERS �� 29 SINGLE ACTING CYLINDER �� 29 LIFTING CYLINDERS: COMBINATIONS �� 29 KEY TO INITIAL LIFT CYLINDER COMPONENTS �� 30 IDENTIFICATION OF THE LATERAL LIFT CYLINDER COMPONENTS �� 31 IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS �� 32 1

HYDRAULIC SYSTEM

SERVICE

DISMANTLING OF LATERAL LIFT CYLINDER �� 34 CENTRAL LIFT CYLINDER DISMANTLING �� 37 REMOVAL OF THE "INITIAL LIFT" CYLINDER �� 40 LIFT CYLINDERS: AIR BLEEDING �� 44 BLEEDING THE INITIAL LIFT CYLINDER �� 45 REPLACEMENT OF STATIC GASKETS ON LATERAL LIFT CYLINDERS �� 46 REPLACEMENT OF STATIC GASKETS ON THE CENTRAL LIFT CYLINDER �� 48 SMALL MAST LIFT CYLINDER SEPARATION INTO PARTS �� 51 lift pump �� 54 IDENTIFICATION OF THE LIFT PUMP COMPONENTS all models excluding initial lift models �� 54 IDENTIFICATION OF THE LIFT PUMP COMPONENTSmodels with initial lift �� 56 LIFT PUMP DISMANTLING all models excluding initial lift models �� 58 LIFT PUMP DISMANTLINGmodels with initial lift �� 60 PUMP REPLACEMENT �� 62 HYDRAULIC PIPES �� 64 PIPE PLACEMENT FOR HYDRAULIC CIRCUIT �� 64 REPLACEMENT OF CYLINDER FEED PIPES �� 67 REPLACEMENT OF THE HYDRAULIC PIPE HOSE SHEAVE �� 69 RENEWAL OF THE OIL SUPPLY PIPE TO THE INITIAL LIFT CYLINDER �� 70

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC FUNCTIONS • • • •

Fork Lifting Fork Lowering Straddle legs lifting (initial lift version only) Straddle legs lowering (initial lift version only)

INITIAL LIFT

FORK LIFTING/LOWERING The fork lifting speed is determined by the revs that the pump motor transmits to the pump drive shaft. In the descent stage the one-directional stops the flow of the fluid through the pump and the oil flows into the tank through the flow regulator valve. The proportionality of the lowering phase is handled by the Q1 proportional solenoid valve.

SERVICE

HYDRAULIC SYSTEM HYDRAULIC CIRCUIT POWER SUPPLY Fixed cylinder capacity pumps With fixed capacity cylinders, the oil flow is constant, providing the speed of crank shaft rotation remains unchanged. A reduction in the drive shaft revs lowers the load capacity: if the revs are reduced so is the flow and vice versa; the pressure, providing the load is unchanged, remains constant. PRESSURE REGULATING VALVES

Pressure limiting valves The "pressure limiting" or "pressure relief" valves are mainly used to guarantee the maximum pressure admitted into the system and to protect the pump from experiencing pressure that might exceed its own structural specifications. The use of pressure limitators does not only cover the functions mentioned above, but they are commonly used in many devices for which it is crucial to avoid pressure build ups. An example are Pump anti-shock and anti-knock valves. So long as the circuit is not affected by excess pressure conditions, the limiting valve remains in the closed position: the force exerted by the pressurized oil is lower than that exerted by the opposing spring. With the piston at its maximum extension or if an abnormal situation may arise which requires an effort in excess of the set level (for example with a load in excess of the load capacity), the over pressured oil overcomes the force of the spring and flows towards the oil outlet. Parachute valves (LB) These are blocking valves fixed directly onto the lift cylinders and are designed to stop an uncontrolled lowering of the load in the event of a pipe subject to high pressure should break. If the pressure exceeds the set value (80 litres/min) a plate, which is lifted through elastic reaction from the seat of the valve, is pressed by the electrodynamic forces involved, against the valve chassis, leading to the closure of the valve itself. They are equipped with a draining hole. Oil flow control valves (SB) Parachute valve The flow control valves act as 'brakes' on the cylinders during lowering manoeuvres to ensure a constant lowering speed, regardless of the weight of the load. The valves are comprised of a sliding cylinder, (B), complete with spool (C) and spring (D), and diaphragm bushing (A).

A B

oil inlet

C D

Oil flow control valve 4

SERVICE

HYDRAULIC SYSTEM

DIRECTIONAL VALVES One-directional and restraining valves. The function of "one-directional" or "non-return" valves is to allow the oil to flow in one direction only, while the flow in the opposite direction is not permitted. They are essentially comprised of a fixed part connected to the end of the pipe; in the appropriate inner housing runs the moving element which might be a bearing or a conical plug. The "restraining" valves, as opposed to the latter ones are equipped with an opposing spring mechanism. In the direction of free flow, the oil pressure must exceed the force exerted by the spring.

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC PLANS symbols

TWO POSITION SOLENOID VALVE

THREE POSITION SOLENOID VALVE

FILTER

ONE-DIRECTIONAL VALVE

DOUBLE ACTING CYLINDER

PROPORTIONAL VALVE

SINGLE ACTING CYLINDER

PUMP

TANK

HYDRAULIC MOTOR

LINE CONNECTION

ELECTRIC MOTOR

SAFETY VALVE

FLOW VALVE

MANUAL TAP

BY-PASS VALVE

SERVICE

HYDRAULIC SYSTEM

COMPLETE HYDRAULIC BLUEPRINT version without initial lift SINGLE STAGE MAST

C2 T

CH Q1 (Evp)

RELIEF 1 CH P

SERVICE

HYDRAULIC SYSTEM TWO STAGE MAST

C2 T

CH Q1 (Evp)

RELIEF 1 CH P

SERVICE

HYDRAULIC SYSTEM

THREE STAGE MAST

C2 T

CH Q1 (Evp)

RELIEF 1 CH P

SERVICE

HYDRAULIC SYSTEM MAIN HYDRAULIC DIAGRAM version with initial lift

INITIAL LIFT

Q2 RV2

Q4 P Q1 (evp) T

CV1 RV1 SB

TANK

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS FOR VARIOUS FUNCTIONS •

Forks lifting

•

Forks lowering

•

Straddle legs lifting (version with initial lift)

•

Straddle legs lowering (version with initial lift)

•

Emergency forks lowering (version with initial lift) The hydraulic control valve in the motor compartment is equipped with a 5 mm Allen key, which is required to open the emergency forks lowering valve. Open the valve gradually, so that the forks are lowered slowly. Once the forks have been lowered, close the valve.

•

Oil drain through the pressure relief valve

Version without initial lift

pressure relief valve

OPERATION TABLES - SOLENOID VALVES VERSION WITHOUT INITIAL LIFT Function Slow fork lifting

Pump

Q2 Q1

Emergency lowering valve

Proportional fork lowering Oil drain through pressure relief valve

Slow fork lowering Proportional fork lifting

Version with initial lift

relief valve

VERSION WITH INITIAL LIFT Function Straddle legs lifting

Pump

Forks lowering

- + -

+ - + -

Straddle legs lowering Forks lifting

- +

+ + -

P = pump in operation + = solenoid valve coil energised 11

SERVICE

HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - forks lifting (without initial lift)

C2 P

CH Q1 (Evp)

RELIEF 1 P

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM - forks lifting (with initial lift)

INITIAL LIFT

Q2 RV2

Q4 P Q1 (evp) T

CV1 RV1 SB

TANK

SERVICE

HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - forks lowering (without initial lift)

C2 P

CH Q1 (Evp)

RELIEF 1 P

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM - forks lowering (with initial lift)

INITIAL LIFT

Q2 RV2

Q4 P Q1 (evp) T

CV1 RV1 SB

TANK

SERVICE

HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - straddle legs lifting (with initial lift)

INITIAL LIFT

Q2 RV2

Q4 P Q1 (evp) T

CV1 RV1 SB

TANK

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM - straddle legs lowering (with initial lift)

INITIAL LIFT

Q2 RV2

Q4 P Q1 (evp) T

CV1 RV1 SB

TANK

SERVICE

HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - emergency forks lowering (with initial lift)

INITIAL LIFT

Q2 RV2

Q4 P Q1 (evp) T

CV1 RV1 SB

TANK

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC PLAN FOR OIL RELEASE INTO THE TANK THROUGH THE PRESSURE RELIEF VALVE The pressure relief or pressure limiting valves are used in hydraulic systems in order to guarantee the extreme pressures introduced into the system and to protect and safeguard the system against sudden pressure increases that could seriously damage the components. The pressure relief valve may come into operation in the following instances: • • •

Pressure regulation not suitable for the truck load capacity. Attempts to lift a load in excess of the truck's load capacity Blocked or faulty valve

CV1 RV1

Fork pressure relief valve (initial lift)

Q2 RV2

Q4 P Q1 (evp) T

RV1

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC COMPONENT RELIEF VALVE DISMANTLING (all models) The relief valve malfunction can be caused by the presence of dirt or a weakening of the inner spring. In the first case a thorough cleaning is required, in the second case the valve needs to be replaced. Equipment and tools

large Philips screw driver

oil protecting gloves

socket wrench int. 22 mm ext. Ø 26.5 mm

ratchet

Procedure

Fig. 1

The hydraulic fluid, after system operation, is very hot may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Fig. 2 Fig. 3

Phase 2 RATCHET - 22 mm SOCKET WRENCH - OIL PROTECTING GLOVES Put the oil proof gloves on. Use the wrench to remove the complete valve (ref.B fig.3) and proceed with the replacement. ASSEMBLY During the assembly stage tighten the valve with a dynamometric wrench set to 10 Nm. 20

SERVICE

HYDRAULIC SYSTEM

PRESSURE RELIEF VALVE CALIBRATION (all models) The calibration of pressure relief valve is required following replacement. Equipment and tools

socket wrench int. 10 mm ext. Ø 13.5 mm

ratchet

hexagonal "T" section spanner 4 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing.

Fig. 1 Fig. 2

A Phase 1 Connect the battery and turn on the machine (ignition key to ON). Position a load equivalent to the truck's load capacity, printed on the truck's specification nameplate, on the truck's forks. Phase 2 RATCHET - 10 MM SOCKET WRENCH - 4 mm T HANDLE HEX KEY Using the socket wrench, loosen the lock nut (ref.A fig.2). Using the T handle hex key, loosen the adjusting screw (ref.B fig.3) turning it counter-clockwise until, while pressing the fork lifting button on the tiller (fig.4), the pressure decreases and the oil drains back to tank (the lifting action ceases). At this point, turn the adjuster screw in the opposite direction (clockwise) to the point where the forks (or the straddle legs on the initial lift version) start to lift again. Release the lifting button and tighten the screw by a further 1/4 turn. Carry out a few trial lifts and lowering manoeuvres with the load on the forks, checking that the pressure setting is sufficient to cope with the pressure surge during the initial lifting stage. If this is not the case, tighten the screw by a further 1/4 turn. Use the socket wrench to tighten the lock nut (ref.A fig.2) to lock the adjusting screw in position.

Fig. 3

Fig. 4

SERVICE

HYDRAULIC SYSTEM REMOVAL OF THE PRESSURE RELIEF VALVE (initial lift version only) Equipment and tools

large cross-head oil resistant gloves screwdriver

open ended spanner 19 mm

Procedure

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 LARGE CROSS-HEAD SCREWDRIVER Use the screwdriver to unscrew and remove the screws securing the motor compartment cover (ref.A fig.1). Open the motor compartment cover. Phase 2 RATCHET - 19 mm SPANNER - OIL RESISTANT GLOVES Wear the oil resistant gloves. Use the spanner to remove the complete valve assembly (ref.B fig.3) and proceed with the replacement. INSTALLATION Install the valve and tighten with a torque wrench to 12 Nm.

Fig. 2 Fig. 3

SERVICE

HYDRAULIC SYSTEM

CALIBRATION OF THE PRESSURE RELIEF VALVE (initial lift version only) The pressure relief valve must be calibrated following replacement. Equipment and tools

open ended spanner 17 mm

T handle hex key 5 mm

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

Fig. 1 Fig. 2

Phase 1 Connect the battery and switch on the truck (starter key to ON). Place on the forks a load equivalent to the truck's load capacity, as indicated on the truck's dataplate. Phase 2 17 mm OPEN ENDED SPANNER - 5 mm T HANDLE HEX KEY Loosen the lock nut with the spanner (ref.A fig.2). Using the hexagonal "T" section spanner loosen the adjusting screw (ref.B fig.3) turning it counter-clockwise until, while pressing the fork lifting button on the tiller (fig.4), the pressure decreases and the oil drains back to tank (the lifting action ceases). At this point, turn the adjuster screw in the opposite direction (clockwise) to the point where the forks start to lift again. Release the lifting button and tighten the screw by a further 1/4 turn. Carry out a few trial lifts and lowering manoeuvres with the load on the forks, checking that the pressure setting is sufficient to cope with the pressure surge during the initial lifting stage. If this is not the case, tighten the screw by a further 1/4 turn. Use the spanner to tighten the lock nut (ref.A fig.2), to lock the adjusting screw in position.

Fig. 3

Fig. 4

HYDRAULIC SYSTEM

SERVICE

REMOVAL OF THE LOWERING FLOW RATE CONTROL VALVE (for initial lift version only) Malfunction of the flow rate control valve can be caused by dirt causing the spool to stick or by weakening of the spring. In the first case thorough cleaning is required, in the second case the valve needs to be replaced. Equipment and tools

large flat blade screw driver

oil resistant gloves

T handle hex key 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 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

Phase 1 Carry out the procedure to remove the lift pump (see "REMOVAL OF THE LIFT PUMP (INITIAL LIFT "). Phase 2 OIL RESISTANT GLOVES - 10 mm T HANDLE HEX KEY - FLAT BLADE SCREWDRIVER Wear the oil resistant gloves. Using the T handle hex key, unscrew and remove the blanking plug (ref.A fig.2). With the flat blade screwdriver, unscrew and remove the valve from its seat (ref.B fig.2) and proceed with the replacement.

Fig. 2

INSTALLATION Before installing the new valve, carry out the adjustment procedure On installation, tighten the valve to a torque of 12 Nm and the plug to 29 Nm.

B 24

SERVICE

HYDRAULIC SYSTEM

calibration of the lowering oil flow rate control valve (for initial lift version only) The oil flow rate can be varied between 20 and 30 litres by adjusting the spring preload by way of the adjuster nuts. Increasing spring compression increases the resistance of the slide to the diaphragm and therbey increases the clyinder stroke on lowering. Reducing spring preload reduces the resistance of the valve slide to the diaphragm and thereby reduces the speed at which the cylinder performs the lowering stroke. Before installing the valve on the hydraulic unit, measure the length of the spring. If the measured spring length is the same as that of the previously removed valve, proceed with the installation of the new valve on the hydraulic unit. If the measured spring length is greater or less than that of the old valve, adjust the length of the spring accordingly. Equipment and tools Fig. 1

open ended spanner 6-7 mm

pliers

caliper

A Fig. 2

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

B Phase 1 6-7 mm OPEN ENDED SPANNER - CALIPER Using the pliers and a small piece of cloth, restrain the valve on the screw (ref.A fig.1). Using the 6 mm spanner, loosen the locknut (ref.B fig.2). Using the 7 mm spanner, loosen or tighten the spring adjuster nut (ref.C fig.3). With the caliper, measure the length of the spring (fig.4) and turn the adjuster nut as necessary to obtain the correct measurement. Using the 6 mm spanner, tighten the locknut (ref.B fig.2).

Fig. 3

C Fig. 4

SERVICE

HYDRAULIC SYSTEM

CARTRIDGE SOLENOID VALVES The distributor solenoid valves are of the screw on cartridge type. This kind of valve is comprised of a chassis with a hexagon nut attached to the chassis, a threaded part, a range of static seal gaskets; inside a mobile element allows communication between the various holes.

IDENTIFICATION OF THE COMPONENTS OF A CARTRIDGE SOLENOID VALVE

INITIAL LIFT

Ref.

Description

Coil

Chassis valve

Washer

Elastic ring

SERVICE

HYDRAULIC SYSTEM

SOLENOID VALVE DISMANTLING Equipment and tools

oil protecting gloves

large/small Philips medium sized flat fixed spanner screw driver head screwdriver 14-19-22-26 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground, position the key switch on OFF and disconnect the battery. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

SOLENOID VALVE Q1 Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Fig. 1

Phase 2 SMALL PHILIPS SCREWDRIVER Unscrew the fastening screws and disconnect the energy supply connector of the solenoid valve coil (fig.2). Phase 3 OIL PROTECTING GLOVES - MEDIUM SIZES FLAT HEAD SCREWDRIVER - FIXED 14 mm SPANNER Use the screwdriver to lift up the elastic ring (ref.B fig.3) and remove it. Slip the washer off (ref.C fig.3), the coil (ref.D fig.3) and retrieve the gaskets.

Fig. 2

SERVICE

HYDRAULIC SYSTEM Use the fixed gauge spanner to unscrew the chassis valve from the hydraulic block and proceed with the replacement. ASSEMBLY

B C D

During the assembly stage tighten the valve fastening screws with a torque of 40 Nm.

Fig. 3 INITIAL LIFT: SOLENOID VALVES Q2 AND Q4 Phase 4 SMALL CROSS-HEAD SCREWDRIVER Unscrew the retaining screw and disconnect the connector of the power supply to the solenoid coil.

Phase 5 OIL RESISTANT GLOVES - 19-22 mm OPEN ENDED SPANNER With the 19 mm spanner, unscrew the nut securing the coil (ref.E fig.4). Withdraw the coil. Using the 22 mm spanner, unscrew the nut securing the valve body to the hydraulic unit (ref.F fig.5. Proceed with replacement

Fig. 4

Fig. 5

On installation, tighten the nut securing the valve body to a torque of 35 Nm. Tighten the coil retaining nut to a torque of 6 Nm.

INITIAL LIFT: SOLENOID VALVE Q3 Phase 6 SMALL CROSS-HEAD SCREWDRIVER Unscrew the retaining screw and disconnect the connector of the power supply to the solenoid coil. Phase 7 OIL RESISTANT GLOVES - 26mm OPEN ENDED SPANNER Unscrew the coil retaining nut (ref.G fig.6). Withdraw the coil. Using the spanner, unscrew the nut securing the valve body to the hydraulic unit (ref.F fig. Proceed with replacement On refitting the valve body, tighten the retaining nut to a torque of 29 Nm.

Fig. 6

SERVICE

HYDRAULIC SYSTEM

CYLINDERS SINGLE ACTING CYLINDER The single acting cylinders receive and discharge the oil from a single pipe and the pressurised oil acts on a single piston face (single action cylinders during the thrust stage) or on the plane face of the shaft for plunging cylinders. Single plunge action cylinders With these cylinders it is the same flat side of the shaft that replaces the piston and is usually positioned vertically or in other positions in which in any case it is the force of gravity that returns it to the rest position. Usually the diameter of the bottom of the shaft is increased by a few millimetres in order to avoid it slipping out at the top of it's upstroke; this gives rise to a hydraulic damping effect during the last stages of it's stroke which helps the slowing of the shaft and avoids recoils on the upper cylinder head. Place in the latter, the necessary static sealing gaskets which avoid seepage of oil to the exterior. In order to replace these gaskets one must unscrew the gasket case bushing. The hollow shaft simple action cylinders differ in that before beginning the lift stroke even the shaft is filled with oil. This solution is used on particularly tall masts to increase the resistance of the cylinders at the greater heights and make it possible to use smaller barrels and shafts. Static and dynamic gaskets The dynamic gaskets, assembled on the piston, avoid the seepage of the fluid from one barrel chamber to the next, the static gaskets, placed in the points where the parts meet (gasket case bushing - barrel) or between the sliding parts (shaft- chamber), avoid oil seepage from inside to outside.

LIFTING CYLINDERS: COMBINATIONS

Type of cylinder

Shaft diameter mm

Type “A” with simple plunging effect and solid shaft

Type “B” with a simple push effect

Single-acting plunger type “C” with solid rod (initial lift only)

Mast 1 stage

Mast 2 stages

Mast 3 stages

Height H3 mm

2603 - 4627

1260 - 4627

h5 130

SERVICE

HYDRAULIC SYSTEM KEY TO INITIAL LIFT CYLINDER COMPONENTS The cylinder is of the single-acting plunger type. After replacing the cylinder, bleed the air through the bleed valve.

Ref.

Description

Barrel and end cap

Piston rod

Rod end cap

Piston

Guide ring

Seal kit

Air bleed screw

SERVICE

HYDRAULIC SYSTEM

IDENTIFICATION OF THE LATERAL LIFT CYLINDER COMPONENTS It is a simple action plunging cylinder. After the replacement of the entire cylinder one must carry out the bleeding of the air through the bleeding valve. The static gaskets are replaced with the cylinder mounted in the machine.

Ref.

Description

Barrel

Shaft

Guide bushing

"LB" Parachute valve

Air bleeding valve

Gasket set

Gasket housing bushing

SERVICE

HYDRAULIC SYSTEM IDENTIFICATION OF THE CENTRAL LIFT CYLINDER COMPONENTS

It is a simple action thrusting cylinder with a slowing system on the upstroke before the end point. The static gaskets contained in the gasket case bushing are replaced with the cylinder mounted in the machine, while the replacement of the dynamic gaskets on the piston require the cylinder to be removed from the machine and dismantled.

Ref.

Description

Barrel

Shaft

Chamber

Check valve

"LB" Parachute valve

Elastic ring

Guide ring

Dynamic gasket

Air bleeding valve

Gasket housing bushing

Gasket set

Piston

SERVICE

HYDRAULIC SYSTEM

OPERATION During the lifting stage the air contained in the cylinder barrel enters into the shaft inner chamber through a hole (ref.A). When the piston approaches the stroke end point it presses the oil against the gasket housing bushing, the increase in pressure forces the oil into the chamber through a second hole (ref.B). The oil is thus compressed in the chamber together with the air generating a "cushioning" effect that slows the cylinder stroke over the last 40/50 mm, thus ensuring that the piston does not knock against the mechanical end point stop.

inner shaft chamber shaft

piston

SERVICE

HYDRAULIC SYSTEM DISMANTLING OF LATERAL LIFT CYLINDER Equipment and tools

A lifting belt load capacity 1000 kg

tackle load capacity 1000 kg

pliers to open medium size elastic rings

fixed spanner 19 mm

Fig. 1

n. 2 wood beams

n. 2 iron trestles

hammer

ladder

oil protecting gloves

"Parker" cap

Size of wood beams width 100 mm depth: 100 mm The lengths vary based on the mast elevation.

Fig. 2

SERVICE

HYDRAULIC SYSTEM

Procedure

Fig. 3

Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

Phase 1 Wood BEAMS Raise the mast using one of the buttons on the rudder. Place the wooden beam beneath the inner mast upright (rif.B fig.2). Move the mast downwards until it rests on the beams.

Phase 2 LADDER - pliers TO OPEN ELASTIC RINGS MEDIUM Climb up the ladder with the tools. Using the pliers remove the elastic ring from the top of the cylinder to be dismantled (ref.A fig.1). Activate the fork descent command, continue the descent until the shaft is once again housed completely inside the cylinder (fig.3).

Position the key switch to OFF and disconnect the battery.

Fig. 4 Fig. 5

Phase 3 fixed spanner 19mm - pliers FOR ELASTIC RING OPENING MEDIUM SIZE- OIL PROOF GLOVES - PARKER CAP Put the oil proof gloves on. Unscrew the coupling on the cylinder feed pipe (ref.C fig.5) and apply the cap. Using the elastic ring pliers remove the ring at the cylinder base (ref.D fig.5).

D C

HYDRAULIC SYSTEM Phase 4 TACKLE - LIFT BELT - LADDER Place the tackle above the mast, beside the cylinder to be removed. Climb up the ladder with the lift belt. Make a slipknot at one end of the rope and tie the cylinder beneath the air bleeding valve (fig.6). Tighten the slipknot. Hook the other end of the rope to the tackle hook and make taught.

SERVICE Fig. 6

Phase 5 LADDER - HAMMER Use the hammer to remove the cylinder stop ring (ref.E fig.7). Remove the ring.

Phase 6 TACKLE - TRESTLES Lift the cylinder upwards using the tackle until the bottom comes away from the base of the mast (fig.8). Extract the cylinder, place it on the two trestles and proceed with the separation into parts or replacement.

E Fig. 7

ASSEMBLY Before tightening the hydraulic connections, consult the table of reference (see "CORRECT METHOD TO APPLY THE FEMALE CONNECTORS” "PREFACE" section). After the assembly perform the air bleeding procedure from the cylinder (see “LIFT CYLINDERS: AIR BLEEDING”).

Fig. 8

SERVICE

HYDRAULIC SYSTEM

CENTRAL LIFT CYLINDER DISMANTLING The central cylinder is mounted on trucks with one and three stage masts and, depending on the time of column, it performs the following functions: • •

3-stage mast: lift the forks followed by the fork extensions single stage mast: lift the forks

Equipment and tools

tackle load capacity 1000 kg

N. 2 lift belts

n. 2 wooden beams 100x100x500 mm

fixed spanner 13 -19 - 22 mm

oil protecting gloves

taper end pliers

pliers to open medium size elastic rings

hexagonal "T" section spanner 5 mm

Fig. 1 "Parker" cap

"Parker" cap

Fig. 2

B B

The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

SERVICE

HYDRAULIC SYSTEM Phase 1 Wooden beams 100x100x500 mm Raise the mast using one of the buttons on the tiller. Position the wooden beams beneath the forks (ref.A fig.1). Move the mast downwards until the forms rest on the beams. Continue the descent in order to loosen the chains.

Position the key switch to OFF and disconnect the battery.

Phase 2 FIXED GAUGE 13 mm SPANNER Unscrew and remove the bracket fastening screws (ref.B fig.2), retrieve the elastic washers and remove the bracket (ref.C fig.2).

Fig. 3

Phase 3 TAPER END PLIERS Using the pliers remove the safety pin and the hinge pins (ref.D fig.3) that secure the chains to the chain tensioner positioned on the truck bulkhead. Remove the chains from the guide way pulleys and rest them on the forks.

f Fig. 4 Fig. 5

Phase 4 MEDIUM SIZE PLIERS TO OPEN ELASTIC RINGS Use the elastic ring pliers to remove the elastic ring blocking the pulley base plate (ref.E fig.4). Slip the complete pulley base plate away from the cylinder shaft (ref.F fig.4), retrieving the spreaders (ref.G fig.4).

Connect the battery and position the ignition key on ON

Phase 5 Activate the fork descent command, continue the descent until the shaft is once again housed completely inside the cylinder (fig.5).

SERVICE

HYDRAULIC SYSTEM

Fig. 6

Position the key switch to OFF and disconnect the battery.

Phase 6 TACKLE - N° 2 LIFT BELTS Secure the fork carrying plate with the two lift belts. Hook the belts on the tackle and lift 1000 mm (fig.6). Remove the wooden beams.

Phase 7 OIL PROTECTION GLOVES - FIXED 19-22 mm SPANNER - "PARKER" CAPS - MEDIUM SIZE PLIERS TO OPEN ELASTIC RINGS Put the oil proof gloves on. Unscrew the cylinder hydraulic feed tube connector positioned at the base of the cylinder itself (ref.H fig.7). Apply the caps to the connectors. Use the elastic ring pliers to remove the elastic ring blocking the cylinder (ref.I fig.7).

Phase 8 HEXAGONAL 5 mm "T" SECTION SPANNER Using the hexagonal "T" section spanner remove the screws from the cylinder stop bracket (ref.J fig.8) and retrieve the washers. Slip the bracket away and remove it (fig.8). Remove the cylinder and proceed with the replacement or the separation into parts.

ASSEMBLY Do not reuse the chain anchoring safety pins, use new safety pins, ensuring they are the correct size.

Fig. 7

Before tightening the hydraulic connections, consult the table of reference (see "CORRECT METHOD TO APPLY THE FEMALE CONNECTORS” "PREFACE" section). After the assembly perform the cylinder air bleeding procedure (see “LIFT CYLINDERS: AIR BLEEDING”).

Fig. 8 39

SERVICE

HYDRAULIC SYSTEM REMOVAL OF THE "INITIAL LIFT" CYLINDER Equipment and tools

hoist load capacity 2000 kg

2 lifting slings load capacity 1500 kg

wooden pallet

Allen key 5 mm

"Parker" cap

socket 9 mm

ratchet

long cable ties

hammer

slide hammer puller

open ended spanner 18-19 mm

medium cross- T handle hex key battery extension head screwdriver 4 mm lead

extension

long driving tool Ø 15 mm

Phase 1 LARGE CROSS HEAD SCREW DRIVER Use the cross head screwdriver to unscrew and remove the screws securing the motor compartment cover (ref.A fig.1). Open the motor compartment cover.

Fig. 1 40

SERVICE

HYDRAULIC SYSTEM

Phase 2 "Parker" service plug Carry out the mast removal procedure (see “REMOVAL OF THE MAST ASSEMBLY” in the “MAST MECHANICS” section). Fit a “Parker”plug to the connection fitting of the hydraulic pipe on the truck base (ref.B fig.2).

Phase 3 BATTERY EXTENSION LEAD Remove the battery (reverse the installation procedure, see “BATTERY INSTALLATION, “INSTALLATION AND SETTINGS” section). After removing the battery, place it near the truck so that it can be used with the aid of the extension lead.

Fig. 2

Fig. 3

Connect the battery and turn the keyswitch to ON. Phase 4 Wooden pallet - long cable ties Using the straddle leg lifting button located under the tiller (fig.3), raise the straddle legs to the maximum height. Position the wooden pallet under the straddle legs (fig.4). Lower the straddle legs so that they rest on the pallet. Fasten the straddle legs to the pallet with the ties.

Phase 5 hoist - lifting sling Pass the lifting sling between the front and rear bodies, using the hole to the left of the motor compartment (fig.5). Attach the lifting sling to the hoist positioned directly above the truck and take up the slack.

Fig. 4

Fig. 5

Phase 6 4 mm T HANDLE HEX WRENCH - HAMMER - SLIDE HAMMER PULLER Using the T handle hex key, unscrew and remove the screw securing the cylinder pin (ref.C fig.6). Using the hammer and the slide hammer puller, remove the initial lift cylinder pin (ref.D fig.6) Using the straddle legs lowering button on the tiller (fig.7), retract the cylinder to its stroke end.

SERVICE

HYDRAULIC SYSTEM

Turn the ignition key to OFF and disconnect the battery.

Fig. 6

Phase 7 Remove the lift pump (see “LIFT PUMP REMOVAL- MODELS WITH INITIAL LIFT”).

Phase 8 hoist - lifting sling Pass the second lifting sling between the front and rear body assemblies, using the hole to the right of the motor compartment (fig.8). Attach the lifting sling to the hoist and take up the slack in both the slings attached to the rear body.

Fig. 7

Phase 9 19 mm open ended spanner Using the spanner, unscrew the connection fitting of the hydraulic pipe (ref.E fig.9). Fig. 8 Phase 10 9 mm SOCKET WRENCH - RATCHET - EXTENSION Using the socket wrench, ratchet and extension, unscrew and remove the grease nipples from the two pins securing the tie-rods to the frame (ref.F fig.10). Phase 11 5 mm ALLEN KEY With the Allen key, unscrew and remove the grub screws securing the tie-rod/frame pivot pins (ref.G fig.11). Phase 12 HAMMER - LONG DRIVING TOOL Using the hammer and the driving tool, remove the tie-rod/frame pivot pins (ref.H fig.12). Phase 13 HOIST - 2 WOODEN BLOCKS With the aid of the hoist, separate the rear body from the front body, (fig.13) taking care to withdraw the battery cable. Place the rear body on two wooden blocks in a safe place, keeping the lifting slings under tension (fig.14).

Fig. 9

SERVICE

HYDRAULIC SYSTEM

Phase 14 18 mm OPEN ENDED SPANNER Using the spanner, unscrew the four bolts securing the cylinder (ref.F fig.15) and recover the washers. Remove the cylinder and proceed with replacement or disassembly.

Fig. 10

INSTALLATION Before tightening the hydraulic connection fittings, consult the reference table, (see "CORRECT METHOD FOR APPLYING FEMALE FITTINGS”, "FOREWORD" section). After installing the cylinder, carry out the air bleeding procedure (see “BLEEDING THE INITIAL LIFT CYLINDER”).

Fig. 11

Fig. 12

Fig. 14

F Fig. 13

Fig. 15 43

SERVICE

HYDRAULIC SYSTEM LIFT CYLINDERS: AIR BLEEDING Equipment and tools

oil protecting gloves

hexagonal "T" section spanner 3 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Set the key switch to OFF and disconnect the battery. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

Phase 1 OIL PROTECTING GLOVES - 3 mm HEXAGONAL "T" SECTION SPANNER Put the oil proof gloves on. With the hexagonal "T" section spanner loosen the air bleeding valve (ref.B fig.1).

Connect the battery and position the ignition key on ON. Phase 2 3 mm HEXAGONAL "T" SECTION SPANNER Lift the forks using the button placed on the tiller, continue lifting until oil pours out of the air bleeding valve (ref.A fig.1). Stop lifting and tighten the screw (ref.B fig.1). Wipe the cylinder with a clean cloth.

Fig. 1

A B

SERVICE

HYDRAULIC SYSTEM

BLEEDING THE INITIAL LIFT CYLINDER Equipment and tools

oil resistant gloves

open ended spanner 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. 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

Phase 1 OIL RESISTANT GLOVES - 10mm OPEN ENDED SPANNER Wear the oil resistant gloves. Using the spanner, loosen the air bleed screw (ref.B fig.1).

Connect the battery and turn the starter key to ON.

A B

Phase 2 10mm OPEN ENDED SPANNER Lift the straddle legs using the button located on the tiller; continue lifting until oil flows out of the bleed valve (ref.A fig.1). Stop lifting and tighten the bleed screw (ref.B fig.1). Wipe the cylinder with a clean cloth.

SERVICE

HYDRAULIC SYSTEM REPLACEMENT OF STATIC GASKETS ON LATERAL LIFT CYLINDERS Equipment and tools

A small sized flat head screwdriver

ladder

pliers to open medium size elastic rings

oil protecting gloves

Fig. 1

n. 2 wood beams

brush

hook wrench

chain pipe wrench

Size of wood beams width 100 mm depth: 100 mm The lengths vary based on the mast elevation.

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

Fig. 2

SERVICE

HYDRAULIC SYSTEM

Phase 1 Wood BEAMS Raise the mast using one of the buttons on the tiller. Place the wooden beam beneath the inner mast upright (rif.B fig.2). Move the mast downwards until it rests on the beams.

Fig. 3

Phase 2 LADDER - MEDIUM SIZED pliers TO OPEN ELASTIC RINGS Climb up the ladder with the tools. Using the pliers remove the elastic ring from the top of the cylinder to be dismantled (ref.A fig.1). Activate the fork descent command, continue the descent until the shaft is once again housed completely inside the cylinder (fig.3).

Position the key switch to OFF and disconnect the battery. Fig. 4

Phase 3 LADDER - OIL PROTECTION GLOVES - HOOK WRENCH - CHAIN PIPE WRENCH Apply the hook wrench in conjunction with the pin hole in the gasket case bushing and the pipe wrench on the cylinder barrel. Unscrew the casing from the cylinder (ref.C fig.4) slip it away from the shaft and place it on the workbench.

Phase 4 SMALL FLAT HEAD SCREWDRIVER - BRUSH Remove the external gaskets using the screwdriver (ref.D fig.5), the gaskets external to the bushing (ref.E fig.5) and proceed with the substitution.

ASSEMBLY The fitting of the sealing gaskets is a delicate stage of the lift cylinder assembly procedure. Most maintenance operations are to be ascribed to gasket leakage.

Clean the gasket housing bushing and lubricate the gasket seats with clean hydraulic oil as well as the gaskets themselves before assembling them. During the assembly stage tighten the bush to 340 Nm.

Fig. 10 Fig. 5

SERVICE

HYDRAULIC SYSTEM REPLACEMENT OF STATIC GASKETS ON THE CENTRAL LIFT CYLINDER Equipment and tools

workbench

wooden beam 100x100x500 mm

tackle load capacity 1000 kg

N. 2 lift belts

hook wrench

chain pipe wrench

small flat head screwdriver

brush

pliers to open medium size elastic rings

Fig. 1 oil protecting gloves

fixed spanner 13 mm

taper end pliers

Fig. 2

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

B B

SERVICE

HYDRAULIC SYSTEM

Phase 1 Wooden beams 100x100x500 mm Raise the mast using one of the buttons on the tiller. Position the wooden beams beneath the forks (ref.A fig.1). Move the mast downwards until the forks rest on the beams. Continue the descent in order to loosen the chains.

Position the key switch to OFF and disconnect the battery.

Phase 2 FIXED GAUGE 13 mm SPANNER Unscrew and remove the bracket fastening screws (ref.B fig.2), retrieve the elastic washers and remove the bracket (ref.C fig.2).

Fig. 3

g f

Fig. 4 Fig. 5

Connect the battery and position the ignition key on ON

Phase 5 Activate the fork descent command, continue the descent until the shaft is once again housed completely inside the cylinder (fig.5).

SERVICE

HYDRAULIC SYSTEM

Fig. 6

Position the key switch to OFF and disconnect the battery.

Phase 6 TACKLE - N° 2 LIFT BELTS Secure the fork carrying plate with the two lift belts. Hook the belts on the tackle and lift 1000 mm (fig.6). Remove the wooden beams.

Phase 7 OIL PROTECTION GLOVES - HOOK WRENCH - CHAIN PIPE WRENCH Apply the hook wrench in conjunction with the pin on the gasket case bushing and the pipe wrench on the cylinder barrel. Unscrew the bushing from the cylinder (ref.H fig.7) slip it away from the shaft and place it on the workbench.

Phase 8 SMALL FLAT HEAD SCREWDRIVER - BRUSH Remove the internal gaskets using the screwdriver (ref.I fig.8), the gaskets external to the bushing (ref.E fig.8) and proceed with the substitution.

Fig. 7

ASSEMBLY The fitting of the sealing gaskets is a delicate stage of the lift cylinder assembly procedure. Most maintenance operations are to be ascribed to gasket leakage. Clean the gasket housing bushing and lubricate the gasket seats with clean hydraulic oil as well as the gaskets themselves before assembling them.

Do not reuse the chain anchoring safety pins, use new safety pins, ensuring they are the correct size. During the assembly stage tighten the bush to 340 Nm.

Fig. 10 Fig. 8

SERVICE

HYDRAULIC SYSTEM

SMALL MAST LIFT CYLINDER SEPARATION INTO PARTS • • •

Dismantling of the parachute valve replacement of the dynamic gasket Replacement of the check valve

Equipment and tools

workbench

vice

oil protecting gloves

fixed spanner 22 mm

medium size taper end pliers

chain pipe wrench

medium elastic ring closing pliers

small flat head screwdriver

oil syringe

brush

hook wrench

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing.

Phase 1 Carry out the central lift cylinder dismantling procedure (see “CENTRAL LIFT CYLINDER DISMANTLING”).

Fig. 1

Fig. 2

Phase 2 FIXED GAUGE 22 mm SPANNER Unscrew and remove the cylinder connector (ref.A fig.1).

SERVICE

HYDRAULIC SYSTEM DISMANTLING OF THE PARACHUTE VALVE Phase 3 WORKBENCH - OIL PROTECTION GLOVES - MEDIUM SIZE TAPER END PLIERS Using the medium size taper end pliers unscrew from the seat and extract the parachute valve (ref.B fig.2). Proceed with the cleaning and elimination of any dirt residue or the adjustment of the spring load. Replace if broken.

REPLACEMENT OF THE DYNAMIC GASKET

Fig. 3

Phase 4 WORKBENCH - VICE - OIL PROTECTING GLOVES - HOOK WRENCH - PIPE WRENCH - SMALL FLAT HEAD SCREWDRIVERS Secure the cylinder in the vice, placing a rubber protection between the clamp jaws and the cylinder barrel. Apply the hook wrench in conjunction with the pin on the gasket housing bushing (ref.D fig.3) and the pipe wrench on the cylinder barrel (ref.E fig.3). Unscrew the bushing from the cylinder and slide it away from the shaft (fig.3). Remove the shaft from the cylinder (fig.4). Using the flat head screwdrivers remove the piston gasket (ref.F fig.5). Fig. 4 REPLACEMENT OF THE CHECK VALVE Phase 5 WORKBENCH - OIL PROTECTING GLOVES Using the elastic ring pliers remove the valve stop elastic ring (ref.G fig.6) e retrieve the spreader (ref.H fig.6). Extract the valve (ref.I fig.6). Proceed with the replacement

Fig. 5 ASSEMBLY The fitting of the sealing gaskets is a delicate stage of the lift cylinder assembly procedure. Most maintenance operations are to be ascribed to gasket leakage. Do not damage the parts during assembly. Lubricate all the inner parts of the cylinder with clean hydraulic oil. Use new gaskets.

G H I

Ensure that the arrow placed on the check valve is directed towards the piston base. During the assembly stage tighten the bush to 340 Nm. 52

Fig. 6

SERVICE

HYDRAULIC SYSTEM

lift pump IDENTIFICATION OF THE LIFT PUMP COMPONENTS all models excluding initial lift models

Ref.

Description

Pump motor

Distributor

Pump chassis

Tank

Proportional Q1 solenoid valve

Motor brushes

Safety valve

Oil extractor pipe

Oil drainage pipe

Check valve

Filter

SERVICE

HYDRAULIC SYSTEM

10 2 7 5

3 9

HYDRAULIC SYSTEM IDENTIFICATION OF THE LIFT PUMP COMPONENTS models with initial lift

Ref.

Description

Pump motor

check valve

Coupling

Oil flow control valve

Adapter

Directional control valve gaskets

Reservoir gasket

Pressure relief valve

Pump chassis

Oil drainage pipe

Oil intake pipe

Filter

Reservoir

Solenoid operated proportional valve Q1

Fork pressure relief valve

Directional control valve

Fork lowering solenoid valve Q2

Fork lifting solenoid valve Q4

Straddle legs lifting/lowering solenoid valve Q3

SERVICE

HYDRAULIC SYSTEM

1 19

18 3

17 5 16

15 6

14 9 10

11 13

SERVICE

HYDRAULIC SYSTEM LIFT PUMP DISMANTLING all models excluding initial lift models

They hydraulic unit is the same on all the different lift truck series. The only difference lies in the pump engine which on the trucks with a load capacity of 1000/1200 kg has a power rating of 2000 W and on the trucks with a load capacity of 1400/1600 kg has a power rating of 3000 W. All the other components are the same and are dismantled in the same way. Equipment and tools

workbench

fixed spanner 13-17-22 mm

large - small Philips screw driver

oil protecting gloves

Procedure

Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground. Position the key switch to OFF and disconnect the battery. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Phase 2 FIXED GAUGE 13 mm SPANNER Having removed the lug protection caps, use the fixed spanner to unscrew the fastening nuts of the pump motor energy feed cables (ref.B fig.2). Take note of the cable positions. Slide the cables out and disconnect the connectors.

Fig. 1

Fig. 2

Fig. 3

SERVICE

HYDRAULIC SYSTEM

Phase 3 SMALL PHILIPS SCREWDRIVER Unscrew the fastening screws and disconnect the energy supply connector of the solenoid valve coil (Ref.C fig.3).

Fig. 4

Phase 4 OIL PROTECTING GLOVES - fixed spanner 22mm Using the fixed spanner unscrew the connector of the hydraulic pipe (ref.D fig.4). Fig. 5 Phase 4 fixed gauge 17 mm spanner Using the fixed spanner unfasten the bolts that secure the motor to the truck base (ref.E fig.5), retrieve the washers, extract the pump chassis and place it on a workbench.

SERVICE

HYDRAULIC SYSTEM LIFT PUMP DISMANTLING models with initial lift Equipment and tools

workbench

open ended spanlarge - small ner cross-head screw oil resistant gloves 13-17-18 mm drivers

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.

Phase 1 LARGE CROSS-HEAD SCREW DRIVER Use the screwdriver to unscrew and remove the screws securing the motor compartment cover (ref.A fig.1). Open the motor compartment cover.

Phase 2 13 mm OPEN-ENDED SPANNER Having removed the terminal covers, use the spanner to unscrew the fastening nuts of the pump motor power supply cables (ref.B fig.2). Make a note of the cable positions. Remove the cables and disconnect the connectors.

Fig. 1

Fig. 2

Fig. 3

SERVICE

HYDRAULIC SYSTEM

Phase 3 SMALL CROSS-HEAD SCREWDRIVER Unscrew the fastening screws and disconnect the power supply connectors of the four solenoid coils (ref.C fig.3).

Fig. 4

Phase 4 OIL RESISTANT GLOVES -18mm OPEN ENDED SPANNER Using the spanner, unscrew the hydraulic pipe connection fittings (ref.D,E fig.4). Fig. 5 Phase 4 17 mm open-ended spanner Using the spanner, unfasten the bolts that secure the motor to the truck base (ref.F fig.5), recover the washers, extract the pump body and place it on a workbench.

HYDRAULIC SYSTEM

SERVICE

PUMP REPLACEMENT Equipment and tools

hexagonal "T" section spanner 5 mm

fixed spanner 10 mm

small flat head screwdriver

oil protecting gloves

Phase 1 Carry out the lift pump dismantling procedure (see "LIFT PUMP DISMANTLING").

Fig. 1

A Fig. 2

Phase 2 FIXED 10 mm SPANNER - A SMALL FLAT HEAD SCREWDRIVER Loosen the screw that holds the steel clip that fastens the tank to the flange (ref.A fig.2). Unscrew and remove the four screws that fasten the tank to the flange using the fixed spanner (ref.B fig.3), and slip away the solenoid pump complete with flange from the tank.

Phase 3 HEXAGONAL 5 mm "T" SECTION SPANNER Lower the thin fastening plate of the pipe together with the filter (ref.C fig.4) and slip the pipe away from the pump chassis. Unscrew and remove the nuts that fasten the pump chassis to the flange (ref.D fig.4), remove the pump and proceed with the replacement.

Fig. 3

SERVICE

HYDRAULIC SYSTEM

ASSEMBLY During the assembly stage tighten the nuts that fasten the pump to the flange with a torque wrench set at 29 Nm. Use medium size Loctite

D Fig. 4

SERVICE

HYDRAULIC SYSTEM

HYDRAULIC PIPES PIPE PLACEMENT FOR HYDRAULIC CIRCUIT

2 STAGES

1 STAGE

SERVICE

HYDRAULIC SYSTEM

3 STAGE FFL

2 STAGE FFL

HYDRAULIC SYSTEM

INITIAL LIFT

SERVICE

HYDRAULIC SYSTEM

REPLACEMENT OF CYLINDER FEED PIPES 3 STAGE MAST Equipment and tools Fig. 1

bridge crane load capacity 2000 kg

lifting belt load capacity 2000 kg

fixed spanner 19 - 22 mm

oil protecting gloves

large flat head screw driver

n. 2 wood beams 100x100x1500 mm

ladder

"Parker" caps

Fig. 2 Procedure

Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground. Position the key switch to OFF and disconnect the battery. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

A DISMANTLING FLEXIBLE HYDRAULIC PIPE Phase 1 BRIDGE CRANE - LIFT BELT Harness the two inner moving struts with the lift belt (fig.1). Lift the moving struts to loosen the hydraulic pipe that feeds the fork lift cylinder.

SERVICE

HYDRAULIC SYSTEM Phase 2 OIL PROTECTING GLOVES - FIXED 19 mm GAUGE SPANNER - "PARKER" CAPS Wear the oil proof gloves. Using the fixed spanner unscrew the connector of the hydraulic pipe (ref.A-B fig.2). Apply the caps to the connectors. Retrieve the hydraulic pipe and proceed with the replacement.

C DISMANTLING OF RIGID HYDRAULIC PIPE

Fig. 3

Phase 3 LARGE FLAT HEAD SCREWDRIVER Using the screwdriver unscrew and remove the fastening screws of the lexan protective cover (ref.C fig.3) and retrieve the washers. Retrieve the protective panel.

Phase 4 BRIDGE CRANE - LIFT BELT - N.2 WOODEN BEAMS MEASURING 100x100x1500 mm Use the bridge crane to lift the inner moving struts by around 1600 mm Position the wooden beams beneath the intermediate upright assembly channel (ref.E fig.5). Move the mast downwards until it rests on the beams.

Fig. 5

Phase 5 LADDER - FIXED 22 mm GAUGE SPANNER - "PARKER" CAPS Using the fixed spanner unscrew the hydraulic pipe coupling connecting it to the upright assembly base (ref.F fig.6). Apply the connector cap. Climb the ladder. Using the fixed spanner unscrew the coupling of the hydraulic pipe on the outer upright (ref.D fig.4). Apply the connector cap. Extract the hydraulic pipe from the moving strut and proceed with replacement.

F Fig. 5 68

SERVICE

HYDRAULIC SYSTEM

REPLACEMENT OF THE HYDRAULIC PIPE HOSE SHEAVE 3 STAGE MAST Equipment and tools Fig. 1

taper end pliers

oil protecting gloves

fixed spanner 19 - 20 mm

"Parker" cap

Fig. 2

Phase 1 OIL PROTECTING GLOVES - FIXED 19 mm GAUGE SPANNER - "PARKER" CAP Wear the oil proof gloves. Using the fixed spanner unscrew the coupling of the hydraulic pipe (ref.A fig.1). Apply the cap to the coupling, and rest the hydraulic pipe on the forks.

Phase 2 TAPER END PLIERS Using the pliers remove the cotter pins of the chain tensioner placed on the outer upright. Remove the pins (ref.B fig.2). Lower the chains onto the forks. Phase 3 FIXED GAUGE 20 mm SPANNER Using the fixed spanner loosen and remove the fastening screws of the hydraulic pipe hose sheave pin (ref.C fig.3). Extract the pin (ref.D fig.3) and retrieve the hose sheave (ref.E fig.3). Proceed with the replacement

Fig. 3

ASSEMBLY After assembly grease the hose sheave bearings by using a cartridge greasing nipple. 69

SERVICE

HYDRAULIC SYSTEM RENEWAL OF THE OIL SUPPLY PIPE TO THE INITIAL LIFT CYLINDER Equipment and tools

bridge crane load capacity 2000 kg

lifting sling load capacity 2000 kg

open-ended spanner 19 -22 mm

oil resistant gloves

Fig. 1

Fig. 2

large flat blade screw driver

2 wooden beams 100x100x1500 mm

ladder

"Parker" cap

Fig. 3

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. 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 LARGE CROSS-HEAD SCREW DRIVER Use the cross-head screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the motor compartment cover.

Fig. 4

Phase 2 wooden beam Using the straddle leg lifting button on the tiller (fig.2), raise the straddle legs to the maximum height. Position the beams under the straddle legs (fig.3). Lower the straddle legs so they rest on the beam.

B 70

SERVICE

HYDRAULIC SYSTEM

Phase 3 OIL RESISTANT GLOVES - 18 mm OPEN ENDED SPANNER - "PARKER" PLUG Wear the oil resistant gloves. With the spanner, unscrew the hydraulic pipe connection fitting from the base of the frame (ref.B fig.4). Fit the Parker plug to the connection fitting. Using the straddle legs lifting button the tiller (fig.2), raise the straddle legs, remove the wooden beam and lower the legs to the ground.

Set the key switch to OFF and disconnect the battery.

C Phase 4 Remove the lift pump (see “LIFT PUMP REMOVAL- MODELS WITH INITIAL LIFT”).

Fig. 5

Phase 5 5 mm T HANDLE HEX KEY Using the T handle hex key through the opening in the motor compartment, unscrew and remove the screws of the plate securing the hydraulic hose (ref.C fig.5). Recover the plate. Fig. 6 Phase 6 19 mm open ended spanner Using the open ended spanner, unscrew the connection fitting of the hydraulic pipe (ref.D fig.6). Recover the hydraulic pipe and proceed with replacement.

INSTALLATION Before tightening the hydraulic connection fittings, consult the reference table, (see "CORRECT METHOD FOR APPLYING FEMALE FITTINGS”, "FOREWORD" section).

HYDRAULIC SYSTEM

SERVICE

FRAME MECHANICS

frame mechanics TRACTION WHEEL �� 2 IDENTIFICATION OF TRACTION WHEEL COMPONENTS �� 2 DISMANTLING THE TRACTION WHEEL �� 3 PIVOTING WHEEL ASSEMBLY �� 5 IDENTIFICATION OF PIVOTING WHEEL ASSEMBLY COMPONENTS �� 5 DISMANTLING OF PIVOT WHEEL ASSEMBLY �� 6 LOAD WHEELS �� 8 IDENTIFICATION OF LOAD WHEEL COMPONENTS (all models excluding initial lift models) �� 8 KEY TO LOAD WHEEL COMPONENTS (models with initial lift) �� 9 LOAD WHEEL REPLACEMENT (all models excluding initial lift models) �� 10 REPLACEMENT OF THE LOAD WHEELS (models with initial lift) �� 12 LOAD WHEEL ASSEMBLY REPLACEMENT (models with initial lift) �� 14 LINKAGE ASSEMBLY (models with initial lift only) �� 15 KEY TO LINKAGE ASSEMBLY COMPONENTS �� 15 REMOVAL OF THE LINKAGE ASSEMBLY �� 16 ADJUSTMENT OF THE LINKAGE ASSEMBLY �� 20 TIE-RODS ASSEMBLY GREASING POINTS �� 21 TILLER �� 22 IDENTIFICATION OF TILLER COMPONENTS �� 22 TILLER DISMANTLING �� 23 TILLER SPRING REPLACEMENT �� 25 traction motor �� 27 IDENTIFICATION OF TRACTION motor COMPONENTS �� 27 TRACTION MOTOR DISMANTLING �� 28 OIL SEAL REPLACEMENT �� 30 BEARING REPLACEMENT �� 32

FRAME MECHANICS

TRACTION WHEEL IDENTIFICATION OF TRACTION WHEEL COMPONENTS

Ref.

Description

Vulkollan ring complete with hub

Traction wheel fastening nut

SERVICE

FRAME MECHANICS

DISMANTLING THE TRACTION WHEEL Equipment and tools

hydraulic jack

n. 2 wood stocks

large Philips screw driver

ratchet with extension

extension

torque wrench

socket wrench 19 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground, push the forks against an obstacle in order to keep the truck blocked when it is lifted using the hydraulic jack , position the ignition key on OFF and disconnect the battery.

On versions with initial lift, before disconnecting the battery, raise the straddle legs to the maximum height.

Fig. 1

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover. Phase 2 HYDRAULIC JACK - N. 2 WOODEN STOCKS Position the hydraulic jack at the centre of the bodywork (fig.2) and lift until the wooden stocks can slip beneath. Position the wooden stocks at the side of the truck (fig.2), lower the jack and lower the truck onto the stocks.

Fig. 2 3

SERVICE

FRAME MECHANICS Phase 3 19 mm socket wrench - ratchet - extension - TORQUE WRENCH Through the hole in the side of the bodywork (ref.B fig.3) unscrew and remove the traction wheel fastening nuts (ref.C fig.4), retrieve the washers and extract the wheel.

ASSEMBLY The traction wheel fastening nut must be tightened using a torque wrench with a torque power of 85 Nm.

B Fig. 3

Fig. 4

SERVICE

FRAME MECHANICS

PIVOTING WHEEL ASSEMBLY IDENTIFICATION OF PIVOTING WHEEL ASSEMBLY COMPONENTS

3 3

4 1

Ref.

Description

Ref.

Description

Wheel

Self-locking nut

Bush

Forks

Wheel bearing

Spacers

Bush

Flanged screwssecuring the pivoting wheel assembly to the bodywork

Pivoting wheel fastening screws 5

SERVICE

FRAME MECHANICS DISMANTLING OF PIVOT WHEEL ASSEMBLY Equipment and tools

hydraulic jack

n. 2 wood stocks

large Philips screw driver

socket wrench 19 mm

ratchet with extension

extension

Fig. 1

torque wrench

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground, push the forks against an obstacle in order to keep the truck blocked when it is lifted using the hydraulic jack , position the ignition key on OFF and disconnect the battery. Fig. 2

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Phase 2 HYDRAULIC JACK - N. 2 WOODEN STOCKS Position the hydraulic jack at the centre of the bodywork (fig.2) and lift until the wooden stocks can slip beneath. Position the wooden stocks at the side of the truck (fig.2), lower the jack and lower the truck onto the stocks. 6

B Fig. 3

SERVICE

FRAME MECHANICS

Phase 3 15 mm socket wrench - ratchet Using the socket wrench unscrew and remove the two screws fastening the pivoting wheel assembly to the bodywork (ref.B fig.3) and loosen the other two screws (ref.C fig.3). Retrieve the shims (fig.4) and extract the wheel assembly making the fastening screws pass through the holes in the bodywork (ref.D fig.5). Proceed with the replacement DISMANTLING OF PIVOTING WHEEL Phase 4 socket wrench 19 mm- ratchet - 19 mm FIXED gauge spanner Using the fixed gauge spanner hold the self-blocking nut of the pivoting wheel steady (ref.E fig.6), while with the socket wrench and the ratchet unscrew and remove the fastening screws of the pivoting wheel (ref.F. fig.6). Retrieve the screws and the self-blocking nut and extract the wheel from its lodging. Proceed with the replacement

Fig. 4

D ASSEMBLY The fastening nut of the pivoting wheel must be tightened using a torque wrench with a torque power of 85 Nm.

Fig. 5

Fig. 6

SERVICE

FRAME MECHANICS

LOAD WHEELS IDENTIFICATION OF LOAD WHEEL COMPONENTS (all models excluding initial lift models)

3 2 1

Ref.

Description

Load wheel

Elastic dowel

Dust cap

Spacer

Bearing

Bushing

Grease nipple

SERVICE

FRAME MECHANICS

KEY TO LOAD WHEEL COMPONENTS (models with initial lift)

2 13 4

3 4

4 10 9 7 5

Ref.

Description

Ref.

Description

Spring pin

Spacer

Bush

bearing

Tie-rod pivot pin

Load wheel bush

Grease nipple

Load wheel

Wheel pin locking screw

Load wheel screw

Wheel pin

Straddle leg pivot pin

Dust cover

Wheel

FRAME MECHANICS

SERVICE

LOAD WHEEL REPLACEMENT (all models excluding initial lift models) Equipment and tools

tackle load capacity 1000 kg

lift belt load capacity 1000 kg

wooden beam 100x100x1500 mm

wooden stock

hydraulic jack

pin extractor 5 mm in diameter

clamp gudgeon 15 mm in diameter

steel hammer

small flat head screwdriver

cartridge grease nipple

Phase 1 TACKLE - LIFT BELT Lift the forks by 1500 mm using the lift button. Harness the inner upright using the lift belt (fig.1). Attach the belts to the tackle and raise until taught.

Fig. 1 10

SERVICE

FRAME MECHANICS

Position the key switch to OFF and disconnect the battery.

Phase 2 HYDRAULIC JACK - WOODEN STOCK - WOODEN BEAM Position the hydraulic jack beside the load wheel and lift until the wooden stock can pass beneath. Position the wooden stock beneath the clamp and rest the truck on the stock (ref.A fig.2).

b a

Fig. 2

Place the wooden beam beneath the forks for greater safety when working (ref.B fig.2).

D Phase 3 5 mm PIN EXTRACTOR - CLAMP GUDGEON - STEEL HAMMER Using the hammer and the pin extractor expel the elastic dowel of the pivot (ref.C fig.3). Extract the pivot (ref.D fig.3) using the clamp gudgeon and the hammer. Extract the load wheel assembly from its lodging, retrieve the spacers and proceed with the disassembly or replacement.

Fig. 3

F E

LOAD WHEEL DISASSEMBLY Phase 4 PIN EXTRACTOR - CLAMP GUDGEON - STEEL HAMMER - SMALL FLAT HEAD SCREWDRIVER Using the hammer and the pin extractor expel the elastic dowel of the pivot (ref.E fig.4). Extract the pivot (ref.F fig.4) using the clamp gudgeon and the hammer. Extract the load wheel from its lodging. Using the small sized flat head screwdriver extract the dust cap (ref.G fig.4) retrieve the spacers (ref.H fig.4)and the bearings (ref.I fig.4). Proceed with the replacement

ASSEMBLY

I Fig. 4

Fig. 5

Following the assembly of the new load wheels grease the bearings using the grease nipple cartridge (ref.J fig.5).

SERVICE

FRAME MECHANICS REPLACEMENT OF THE LOAD WHEELS (models with initial lift) Equipment and tools

T handle hex key 8 mm

driving tool Ø 12 mm

small flat blade wooden block screwdriver 100x100x1000 mm

hammer

grease gun

Fig. 1

Phase 1 WOODEN BLOCK Place the wooden block under the straddle legs (fig.1). Lower the straddle legs so that they rest on the wooden block 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.

B Fig. 2

SERVICE

FRAME MECHANICS

Phase 2 8 mm "T" HANDLE HEX KEY - HAMMER - DRIVING TOOL Using the T handle hex key, unscrew and remove the wheel pin retaining screw (ref.A fig.2). Using the hammer and the driving tool, drive out the pin of the load wheel (ref.B Fig.2). Withdraw the load wheel from its support (ref.C fig.2) and proceed with its disassembly or replacement. Phase 3 SMALL FLAT BLADE SCREWDRIVER Using the small flat blade screwdriver, extract the dust cap (ref.D fig.3), remove the bearings (ref.E fig.3), spacers (ref.F fig.3) and bush (ref.G fig.3). Proceed with replacement

D F E

G E

F D

INSTALLATION

Fig. 3

Following installation of new load wheels, grease the bearings using a grease gun.

SERVICE

FRAME MECHANICS LOAD WHEEL ASSEMBLY REPLACEMENT (models with initial lift) Equipment and tools

hammer

driving tool Ø 15 mm

wooden block 100x100x1000 mm

pin punch Ø 4 mm

Fig. 1

Turn the keyswitch to OFF and disconnect the battery.

A 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.

Fig. 2

C 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. 14

Fig. 3

SERVICE

FRAME MECHANICS

LINKAGE ASSEMBLY (models with initial lift only) KEY TO LINKAGE ASSEMBLY COMPONENTS 4

3 2 1

3 5

7 2

2 3

5 2

14 2

Ref.

Description

Ref.

Description

Load wheels assembly

Tie rod adjuster pin

Bush

Tie rod adjuster locknut

Spring pin

Tie rod

Pivot pin for load wheels - straddle leg

Truck base pivot pin

Grease nipple

Linkage assembly pin

Tie rod pivot pin - load wheels

Drive unit pivot pin

Adjustable tie rod end

Pin locking screw

SERVICE

FRAME MECHANICS REMOVAL OF THE LINKAGE ASSEMBLY Equipment and tools

hoist load capacity 2000 kg

2 lifting slings load capacity 1500 kg

wooden pallet

Allen key 5 mm

"Parker" cap

socket 9 mm

ratchet

extension

long driving tool Ø 15 mm

pin punch

hammer

slide hammer puller

open ended spanner 19 mm

scissors

long cable ties

medium cross- T handle hex key battery extension head screwdriver 4 mm lead

Phase 1 LARGE CROSS-HEAD SCREW DRIVER Use the cross-head screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the motor compartment cover.

Fig. 1 16

SERVICE

FRAME MECHANICS

Phase 3 BATTERY EXTENSION LEAD Remove the battery (reverse the installation procedure, see “BATTERY INSTALLATION, “INSTALLATION AND SETTINGS” section). When the battery has been removed, place it near the truck so that it can be used with the aid of the extension lead.

Fig. 2

Fig. 3

Connect the battery and turn the ignition key to ON. Phase 4 Wooden pallet - long ties Using the straddle leg lifting button located under the tiller (fig.3), raise the straddle legs to the maximum height. Position the wooden pallet under the straddle legs (fig.4). Lower the straddle legs so that they rest on the pallet. Fasten the straddle legs to the pallet with the ties.

Fig. 4

Fig. 5

Phase 6 4 mm T HANDLE HEX KEY - HAMMER - SLIDE HAMMER PULLER Using the T handle hex key, unscrew and remove the screw securing the cylinder pin (ref.C fig.6). Using the hammer and the slide hammer puller, remove the initial lift cylinder pin (ref.D fig.6) Using the straddle legs lowering button on the tiller (fig.7), retract the cylinder to its stroke end.

SERVICE

FRAME MECHANICS

Turn the ignition key to OFF and disconnect the battery.

Fig. 6

Phase 7 Remove the lift pump (see “LIFT PUMP REMOVAL- MODELS WITH INITIAL LIFT”, in the section “ “HYDRAULIC SYSTEM”).

Fig. 7

Phase 9 19 mm open ended spanner Using the spanner, unscrew the connection fitting of the hydraulic pipe (ref.E fig.9). Fig. 8 Phase 10 9 mm SOCKET WRENCH - RATCHET - EXTENSION Using the socket wrench, ratchet and extension, unscrew and remove the grease nipples from the two tie-rod/frame pivot pins (ref.F fig.10). Phase 11 5 mm ALLEN KEY With the Allen key, unscrew and remove the grub screws securing the tie-rod/frame pivot pins (ref.G fig.11). Phase 12 HAMMER - LONG DRIVING TOOL Using the hammer and the driving tool, remove the tie-rod/frame pivot pins (ref.H fig.12). Phase 13 HOIST With the aid of the hoist, separate the rear body from the front body, (fig.13) taking care to withdraw the battery cable. Rest the rear body in a safe place and detach the lifting slings.

Fig. 9

SERVICE

FRAME MECHANICS

Phase 14 HOIST - LIFTING SLING - SCISSORS Taking great care, with the aid of the hoist and lifting sling, turn over the front bodywork and place it in the optimal position for disassembling the linkage (fig.14).

Fig. 10

Phase 15 HAMMER - PIN PUNCH - DRIVING TOOL Using the pin punch and hammer, drive out the split pins securing the pivot pins to the straddle legs (ref.I fig.14) Drive out the pivot pins (ref.J fig.14) using the driving tool and the hammer. Phase 16 HAMMER - PIN PUNCH - DRIVING TOOL Using the pin punch and hammer, drive out the split pin securing the pivot pins to the truck base (ref.K fig.14) Drive out the pivot pin (ref.L fig.14) 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.

Fig. 11

INSTALLATION

Fig. 12

Before tightening the hydraulic connection fittings, consult the reference table, (see "CORRECT METHOD FOR APPLYING FEMALE FITTINGS”, "FOREWORD" section).

I J K I

Fig. 13

Fig. 14 19

SERVICE

FRAME MECHANICS ADJUSTMENT OF THE LINKAGE ASSEMBLY

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 forks and straddle legs fully lowered, the height of the forks 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.

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 forks by 500 mm. 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.

Fig. 2

Fig. 3

SERVICE

FRAME MECHANICS

TIE-RODS 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

Raise the straddle legs.

SERVICE

FRAME MECHANICS

TILLER IDENTIFICATION OF TILLER COMPONENTS

2 8

9 10 11

Ref.

5 8

Description

Tiller casing

Spring

Tiller spring stop

Tiller spring screw

Buffer

Bushing

Tiller fastening screw

Spacer

Washer

Cap

SERVICE

FRAME MECHANICS

TILLER DISMANTLING Equipment and tools

large Philips screw driver

hexagonal "T" section spanner 5 mm

hexagonal socket wrench 6 mm

extension

ratchet

A Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Phase 2 5 MM HEXAGONAL "T" SECTION SPANNER With the hexagonal "T" section spanner unscrew and remove the engine cover fastening screws (ref.B fig.2). Remove the motor cover (ref.C fig.2).

Fig. 1 Fig. 2

B C

SERVICE

FRAME MECHANICS Phase 3 HEXAGONAL 6 mm SOCKET WRENCH - EXTENSION - RATCHET Disconnect the tiller connector (ref.D fig.3). Using the hexagonal socket wrench, the extension and the ratchet unscrew the screws fastening the tiller to the steering motor (ref.E fig.4). Remove the tiller frame tiller and proceed with its dismantling or replacement.

Fig. 3

Fig. 4

SERVICE

FRAME MECHANICS

TILLER SPRING REPLACEMENT Equipment and tools

large Philips screw driver

pliers

hammer

pin extractor 6 mm in diameter

hexagonal "T" section spanner 6 mm

A Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Fig. 1 Fig. 2

B Phase 2 PLIERS Lower the tiller and unscrew and remove the tiller buffers using the pliers (ref.B fig.2). Retrieve the washers.

The removal of the buffers helps to release the pressure of the tiller spring so that it is easier to dismantle and assemble.

SERVICE

FRAME MECHANICS Phase 3 HAMMER - PIN EXTRACTOR Bring the tiller back to the rest position Insert the pin extractor into the hole through which the spring catch pin fits (ref.D fig.3). With the help of the hammer extract the pin and free the lower part of the spring (ref.D fig.3).

Phase 4 HEXAGONAL 6 mm "T" SECTION SPANNER With the hexagonal "T" section spanner unscrew the fastening screw holding the upper part of the spring (ref.E fig.4). Extract the spring from the tiller (fig.4) and proceed with the replacement.

Fig. 3

Fig. 4

SERVICE

FRAME MECHANICS

traction motor IDENTIFICATION OF TRACTION motor COMPONENTS

19 18

3 4 5 6 7 17

16 9

14 13 12 11

10 Ref.

Description

Ref.

Description

upper flange fastening screws

lower flange

Speed sensor

Elastic ring

Upper flange

Lower bearing

corrugated washer

Elastic ring

Upper bearing

Reducer coupling pinion key

Tolerance ring

Rotor

cogwheel

Break rail coupling ring

Elastic ring

Cable fastening nut

Stator

Washer

Oil seal 27

FRAME MECHANICS

SERVICE

TRACTION MOTOR DISMANTLING Equipment and tools

fixed spanner 10 mm

hexagonal "T" section spanner 6 mm

brush

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Set the key switch to OFF and disconnect the battery.

Phase 1 Carry out the tiller group dismantling procedure (see "TILLER DISMANTLING").

Phase 2 Carry out the electromagnetic break dismantling procedure (see "DISMANTLING OF THE ELECTROMAGNETIC BREAK", "BRAKING SYSTEM" section).

Fig. 1

Phase 3 FIXED GAUGE 10 mm SPANNER Remove the cable end protection caps. Unscrew the traction motor power cable fastening nuts(fig.1). Note the position of the cables and then slip then out. Disconnect the encoder and thermal sensor cables.

A Phase 4 6 MM PIVOTING HEXAGONAL "T" SECTION SPANNER Unscrew and remove the screws fastening the traction motor to the reducer (ref.A fig.2). Fig. 2

SERVICE

FRAME MECHANICS

Phase 5 Lift the motor until the drive shaft is completely free of the reducer. Remove it from the bodywork and proceed with it's replacement or dismantling.

ASSEMBLY Before assembling the motor to the reducer, grease the drive shaft with a thin and uniform layer of special lubricant grease "SHELL STAMINA GREASE RL 2" or "ALBIDA GREASE EP2". During the coupling stage, rotate the wheel shaft, until the drive shaft engages with the pinion cog (fig.3). Before screwing the traction motor power cable nuts back on ensure that the nuts behind the cable ends are not loose.

Fig. 3

SERVICE

FRAME MECHANICS OIL SEAL REPLACEMENT Equipment and tools

fixed spanner 13 mm

medium adjustable pliers

extractor

plastic hammer

bushing

torque wrench

medium flat head screwdriver

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing.

Phase 1 Perform the traction motor dismantling procedure (see “TRACTION MOTOR DISMANTLING”).

B A

Fig. 1

Phase 2 FIXED 13 mm SPANNER - MEDIUM ADJUSTABLE PLIERS - CLOTH Wrap the upper part of the rotor in the cloth and use the adjustable pliers to held the rotor still. Using the fixed gauge spanner remove the fastening nut (ref.A fig.1) of the reducer coupling pinion. Retrieve the washer.

C 30

Fig. 2

SERVICE

FRAME MECHANICS

Phase 3 EXTRACTOR - MEDIUM ADJUSTABLE PLIERS Using the extractor remove the reducer coupling pinion (ref.B fig.1). Using the adjustable pliers extract the pinion stop key (ref.C fig.2).

Phase 4 MEDIUM FLAT HEAD SCREWDRIVER Using the flat head screwdriver remove the oil seal from its lodging (ref.D fig.3). Proceed with the replacement

Fig. 3

ASSEMBLY Assemble the new oil seal using the plastic hammer and the bushing. The fastening of the reducer coupling pinion fastening nuts must be carried out using a torque wrench with a torque power of 35 Nm.

SERVICE

FRAME MECHANICS BEARING REPLACEMENT Equipment and tools

Fig. 1

A hexagonal "T" section spanner 5 mm

medium adjustable pliers

plastic hammer

bushing

extractor

medium elastic ring opening pliers

Procedure

Before starting work, ensure that you are equipped with all suitable safety clothing.

Phase 1 Carry out the oil seal replacement procedure (see "OIL SEAL REPLACEMENT").

Phase 2 MEDIUM ADJUSTABLE PLIERS Using the adjustable pliers extract the break rail coupling key (ref.A fig.1).

Phase 2 5 MM HEXAGONAL "T" SECTION SPANNER With the hexagonal "T" section spanner unscrew and remove the two fastening screws that connects the upper to the lower flange (ref.B fig.2). Retrieve both flanges.

Fig. 2

SERVICE

FRAME MECHANICS

Phase 2 BEARING EXTRACTOR - MEDIUM SIZE ELASTIC RING OPENING PLIERS Use the elastic ring pliers to remove the elastic ring securing the lower bearing (ref.E fig.3). Remove the corrugated washer (ref.C fig.3). Use the extractor to remove the bearings from their seats (ref.D fig.3). Proceed with the replacement

Fig. 3

ASSEMBLY During the assembly stage replace all the gaskets with new gaskets. Assemble the new bearings using a plastic hammer and a bushing.

D E

FRAME MECHANICS

SERVICE

MAST ASSEMBLY MECHANICS

mast assembly mechanics MAST CHARACTERISTICS �� 2 mast elevation �� 4 SINGLE STAGE MAST ASSEMBLY �� 5 2 STAGE MAST ASSEMBLY - "C" PROFILE �� 5 2 STAGE MAST ASSEMBLY - "J" PROFILE �� 5 TWO STAGE FFL MAST �� 6 THREE STAGE FFL MAST �� 6 MAST ASSEMBLY COMPONENTS �� 8 IDENTIFICATION OF THE 2 STAGE MAST ASSEMBLY COMPONENTS �� 8 IDENTIFICATION OF THE 2 STAGE FFL MAST ASSEMBLY COMPONENTS �� 8 IDENTIFICATION OF THE 3 STAGE FFL MAST ASSEMBLY COMPONENTS �� 10 DISMANTLING INNER Upright �� 12 DISMANTLING INTERMEDIATE UPRIGHT: THREE STAGE FFL MAST �� 18 DISMANTLING COMPLETE SUPPORT COLUMN �� 20 BEARING REPLACEMENT �� 22 REPLACEMENT OF CHAINS AND CHAIN TENSIONER �� 23 REPLACEMENT OF CHAIN GUIDEWAY PULLEYS �� 27 SMALL MAST �� 30 IDENTIFICATION SMALL MAST COMPONENTS �� 30 DISMANTLING OF THE SMALL MAST LIFT CHAINS �� 32 SMALL MAST DISMANTLING: 2 stage upright assembly with a “c” or “j” channel profile �� 34 SMALL MAST DISMANTLING: 2 stage and 3 stage FFL mast assembly �� 36 SMALL MAST DISMANTLING: single stage mast �� 38 BEARING AND SLIDING SKID REPLACEMENT �� 39 SMALL MAST PULLEY ASSEMBLY �� 40 IDENTIFICATION OF THE SMALL MAST PULLEY ASSEMBLY COMPONENTS �� 40 REPLACEMENT OF SMALL MAST CHAIN GUIDEWAY PULLEYS �� 41

MAST ASSEMBLY MECHANICS

SERVICE

MAST CHARACTERISTICS SINGLE STAGE MAST For lifts up to a maximum height of 1760 mm, comprised of a fixed mast assembly, a central cylinder which lifts the forks and a plate compete with forks supported by 4 radial rollers (70 mm). TWO STAGE MAST For lifts up to a maximum height of 4230 mm (up to 4165 mm with a J channel) comprised of a fixed mast assembly, an movable inner mast supported by 6 radial rollers (4 with the J profile), to side cylinders and a place complete with the forks supported by 6 radial rollers mm (70 mm). The forks are raised at the same time as the mast. TWO STAGE FFL MAST For lifts of up to 4003 mm, comprised of a fixed mast assembly, a movable inner mast supported by 4 radial rollers (83 mm), two side cylinders and one central one and a plate compete with forks supported by 4 radial rollers (83 mm). This type of mast assembly allows the forks to be lifted freely, which means the forks can be lifted before the masts are lifted. THREE STAGE FFL MAST For lifts of up 5397 mm, comprised of a fixed mast assembly, an intermediate moving mast supported by 4 radial rollers (83 mm), an inner moving mast supported by 2 radial rollers (83 mm), one plate complete with forks supported by 4 radial rollers (83 mm), two side cylinders and one central one. This type of mast assembly allows the forks to be lifted freely, which means the forks can be lifted before the masts are lifted.

1 stage

SERVICE

MAST ASSEMBLY MECHANICS

2 stage "J" channel

2 stage "C" channel

2 stage FFL

3 stage FFL

MAST ASSEMBLY MECHANICS

mast elevation

SERVICE

MAST ASSEMBLY MECHANICS

SINGLE STAGE MAST ASSEMBLY

Model

MS10 MS12

Lifting

Maximum fork lift

height of the mast assembly when closed

Free lift

Height of mast assembly when open

h3 + h13

1260

1350

1820

1260

1830

1360

1450

1920

1360

1930

1460

1550

2020

1460

2030

1560

1650

2120

1560

2130

1760

1850

2320

1760

2330

2 STAGE MAST ASSEMBLY - "C" PROFILE

Model

MS10

MS12

Lifting

Maximum fork lift

height of the mast assembly when closed

Free lift

Height of mast assembly when open

h3 + h13

2830

2920

1870 *

100

3383

3030

3120

1970 *

100

3583

3230

3320

2070 *

100

3783

3430

3520

2170 *

100

3983

3830

3920

2370 *

100

4383

2830

2920

1870 *

100

3383

3030

3120

1970 *

100

3583

3230

3320

2070 *

100

3783

3430

3520

2170 *

100

3983

3830

3920

2370 *

100

4383

4230

4320

2570 *

100

4785

* forks lifted by 100 mm

2 STAGE MAST ASSEMBLY - "J" PROFILE

Model

MS14 MS16 MS14 IL MS16 IL

Lifting

Maximum fork lift

height of the mast assembly when closed

Free lift

Height of mast assembly when open

h3 + h13

2765

2855

1870 *

100

3335

2965

3055

1970 *

100

3535

3165

3255

2070 *

100

3735

3365

3455

2170 *

100

3935

3765

3855

2370 *

100

4335

4165

4255

2570 *

100

4735

* forks lifted by 100 mm

SERVICE

MAST ASSEMBLY MECHANICS TWO STAGE FFL MAST

Model

MS12 MS14 MS16 MS14 IL MS16 IL

Lifting

Maximum fork lift

height of the mast assembly when closed

Free lift

Height of mast assembly when open

h3 + h13

2603

2693

1820

1260

3164

2803

2893

1920

1360

3364

3003

3093

2020

1460

3564

3203

3293

2120

1560

3764

3403

3493

2220

1660

3964

3603

3693

2320

1760

4164

4003

4093

2520

1960

4564

Lifting

Maximum fork lift

height of the mast assembly when closed

Free lift

Height of mast assembly when open

h3 + h13

4027

4117

1820

1260

1588

4327

4417

1920

1360

4888

4027

4117

1820

1260

1588

4327

4417

1920

1360

4888

4627

4717

2020

1460

5188

4797

4887

2120

1560

5358

5097

5187

2220

1660

5658

5397

5487

2320

1760

5958

THREE STAGE FFL MAST

Model MS12 MS14 MS14 IL

MS16 MS16 IL

SERVICE

MAST ASSEMBLY MECHANICS

MAST ASSEMBLY COMPONENTS IDENTIFICATION OF THE 2 STAGE MAST ASSEMBLY COMPONENTS

Ref.

Description

Outer upright

Inner upright

Bearing

Spacer

Elastic ring

Lift cylinder

Chain guideway pulley

Pulley chain hinge pin

Chain

Truck chassis chain fastening buffer

Chain tensioner

Buffer

Mechanical stop point screw

Sliding skid

IDENTIFICATION OF THE 2 STAGE FFL MAST ASSEMBLY COMPONENTS

Ref.

Description

Outer upright

Inner upright

Bearing

Spacer

Elastic ring

Lift cylinder

Chain tensioner

Cylinder stop bracket

Fork lift cylinder

Chain tensioner

SERVICE

MAST ASSEMBLY MECHANICS

TWO STAGE MAST

TWO STAGE FFL MAST

13 11

8 7

1 1

7 2

9 14 4 10

10 3

5 3

SERVICE

MAST ASSEMBLY MECHANICS

MAST ASSEMBLY MECHANICS IDENTIFICATION OF THE 3 STAGE FFL MAST ASSEMBLY COMPONENTS

Ref.

Description

Outer upright

Intermediate upright

Inner upright

Lift cylinder

Lift chain

Chain tensioner

Hose sheave

Pulley chain hinge pin

Chain guideway pulley

bearing

Spacer

Elastic ring

Chain tensioner

Cylinder stop bracket

Fork lift cylinder

Fork lift chain

Chain tensioner

Buffer

SERVICE

MAST ASSEMBLY MECHANICS

7 5

9 1 4

2 13

3 14 11 15 16 10

10a

SERVICE

MAST ASSEMBLY MECHANICS

SERVICE

MAST ASSEMBLY MECHANICS DISMANTLING INNER Upright TWO STAGE MAST Equipment and tools

bridge crane load capacity 2000 kg

lifting belt load capacity 2000 kg

Fig. 1

wooden beam n. 2 iron trestles 100x100x1000 mm

A taper end pliers

bent hexagonal wrench 8 mm

medium elastic ring opening pliers

ladder

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

Phase 1 WOODEN BEAM Using the controls on the tiller lift the forks 500 mm off the ground. Position the wooden beam beneath the forks (ref.A fig.1). Lower the forks until they rest on the beam (fig.1), continue the descent until the chains are loose.

Position the key switch to OFF and disconnect the battery.

Phase 2 TAPER END PLIERS Using the pliers remove the cotter pins of the chain tensioner placed on the outer upright. Extract the pins (ref.B fig.2) and lower the chains onto the forks.

Fig. 2 Fig. 3

SERVICE

MAST ASSEMBLY MECHANICS

Phase 3 LADDER - MEDIUM SIZED pliers TO OPEN ELASTIC RINGS Climb up the ladder with the tools. Using the pliers remove the elastic rings at the ends of the side cylinders (ref.C Fig.4) and retrieve the washers.

Fig. 4

Phase 4 BENT HEXAGONAL 8 mm SPANNER If the upright is provided with a “C” channel, loosen and remove the mechanical end point bolt on the inner upright (ref.D fig.4).

Phase 5 BRIDGE CRANE - LIFT BELT - N.2 trestles Secure the inner upright using the lift belt (fig.5). Hook the belt onto the bridge crane and lift until it comes away completely. Lower the upright onto the trestles.

D Fig. 5

SERVICE

MAST ASSEMBLY MECHANICS TWO STAGE FFL MAST Equipment and tools

bridge crane load capacity 2000 kg

"Parker" cap

lifting belt load capacity 2000 kg

fixed spanner 22 mm

n. 2 iron trestles

oil protecting gloves

ladder

hexagonal "T" medium elastic section spanner ring opening pliers 5 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

Phase 1 Carry out the central lift cylinder dismantling procedure (see “CENTRAL LIFT CYLINDER DISMANTLING” in the "HYDRAULIC SYSTEM" section).

Phase 2 OIL PROOF GLOVES - FIXED SPANNER 22 mm - 5 mm HEXAGONAL "T"" SECTION SPANNER - "PARKER" PLUG Wear the oil proof gloves. Using the hexagonal "T" section spanner loosen and remove the pipe stop screw on the inner upright (ref.A fig.1). Using the fixed gauge spanner unscrew the hydraulic pipe connector (ref.B fig.1) and apply the plug. Retrieve the hydraulic pipe.

A Fig. 1

SERVICE

MAST ASSEMBLY MECHANICS

Phase 3 LADDER - MEDIUM SIZED pliers TO OPEN ELASTIC RINGS Climb up the ladder with the tools. Using the pliers remove the elastic rings at the ends of the side cylinders (ref.C Fig.2) and retrieve the washers.

Fig. 2

Phase 4 BRIDGE CRANE - LIFT BELT - N.2 trestles Secure the inner upright using the lift belt (fig.3). Hook the belt to the bridge crane and lift until you reach the bearing passage eyelets (ref.D fig.3), move the upright outwards. Lower the upright onto the trestles. Fig. 3

SERVICE

MAST ASSEMBLY MECHANICS THREE STAGE FFL MAST Equipment and tools Fig. 1

B bridge crane load capacity 2000 kg

lifting belt load capacity 2000 kg

fixed spanner 15 mm

n. 2 iron trestles

large flat head screw driver

taper end pliers

oil protecting gloves

"Parker" caps

A Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians. The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used.

Phase 1 Carry out the central lift cylinder dismantling procedure (see “CENTRAL LIFT CYLINDER DISMANTLING” in the "HYDRAULIC SYSTEM" section).

Phase 2 OIL PROTECTING GLOVES - FIXED 15mm GAUGE SPANNER - "PARKER" CAPS Wear the oil proof gloves. Using the fixed spanner unscrew the coupling of the hydraulic pipe (ref.A-B fig.1). Apply the caps to the couplings and retrieve the hydraulic pipe.

C Fig. 2

SERVICE

MAST ASSEMBLY MECHANICS

Phase 3 LARGE FLAT HEAD SCREWDRIVER Using the screwdriver loosen and remove the screws fastening the lexan protective panel (ref.C fig.2) and retrieve the washers. Retrieve the protective panel.

Fig. 3

Phase 4 BRIDGE CRANE - LIFT BELT Secure the inner upright using the lift belt (fig.3). Hook the lift belt to the bridge crane, watching out for the chain, lift until the chain fastening buffers on top of the mast become visible (ref.D fig.3).

Phase 5 TAPER END PLIERS Using the pliers remove the cotter pins of the chain fastening buffers positioned on the upright. Remove the pins (ref.D fig.3).

Phase 6 BRIDGE CRANE - LIFT BELT - N.2 trestles Lift the upright assembly until the chain passage eyelets are reached, then move the upright outwards. Lower the upright onto the trestles.

SERVICE

MAST ASSEMBLY MECHANICS DISMANTLING INTERMEDIATE UPRIGHT: THREE STAGE FFL MAST Equipment and tools

Fig. 1

A bridge crane load capacity 2000 kg

lifting belt load capacity 2000 kg

ladder

n. 2 iron trestles

medium elastic taper end pliers ring opening pliers

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

The hydraulic fluid, after system operation, is very hot and may cause scalding. It is recommended that oil protecting gloves resistant to high temperatures be used. Fig. 2

Fig. 3 Phase 1 Carry out the internal mast assembly dismantling procedure (see "DISMANTLING INNER UPRIGHT: 3 STAGE FFL MAST").

Phase 2 LADDER - MEDIUM SIZED pliers TO OPEN ELASTIC RINGS Climb up the ladder with the tools. Using the pliers remove the elastic rings at the ends of the side cylinders (ref.A fig.1) and retrieve the washers.

SERVICE

MAST ASSEMBLY MECHANICS

Phase 3 TAPE END PLIERS Using the pliers remove the cotter pins of the chain fastening buffers positioned on the upright. Remove the pins (ref.B fig.2).

Phase 4 BRIDGE CRANE - LIFT BELT - N.2 trestles Secure the intermediate upright using the lift belt (fig.3). Hook the belt to the bridge crane and lift until you reach the bearing passage eyelets (ref.C fig.3), move the upright outwards. Lower the upright onto the trestles.

SERVICE

MAST ASSEMBLY MECHANICS DISMANTLING COMPLETE SUPPORT COLUMN Equipment and tools

bridge crane load capacity 2000 kg

lifting belt load capacity 2000 kg

large Philips screw driver

"Parker" cap

fixed spanner 15 -22 mm

A hexagonal "T" section spanner 14 mm

Fig. 1

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover. Phase 2 OIL RESISTANT GLOVES - 15mm OPEN ENDED SPANNER - “PARKER” PLUG Wear the oil resistant gloves. VERSION WITHOUT INITIAL LIFT Using the open ended spanner, unscrew the union of the hydraulic pipe (ref.B fig.3). Fit the plug to the connection fitting and move the pipe aside. VERSION WITH INITIAL LIFT Raise the straddle legs to the maximum height. Using the spanner, unscrew the connection fitting of the hydraulic pipe (ref.B fig.3). Fit the plug to the connection fitting. Disconnect the forks sensor wire located on the mast. 20

Fig. 2

Fig. 3

Fig. 3bis

SERVICE

MAST ASSEMBLY MECHANICS

Phase 3 BRIDGE CRANE - LIFT BELTS - HEXAGONAL 14 mm "T" SECTION SPANNER Harness the two inner uprights with the lift belt (fig.4). Hook the belt to the bridge crane and lift to around 1500 mm. With the hexagonal "T" section spanner unscrew and remove the two support fastening screws that connect it to the truck base (ref.C fig.5). Lower the uprights to the ground.

Fig. 4

All caution must be exercised at this stage. Do not stand in front of the forks. Phase 4 BRIDGE CRANE - LIFT BELT Harness the complete support with the lift belt. Hook the lift belt to the bridge crane, position it so that it is slightly shifted away from the support and take up the slack (fig.6). Phase 5 Lever up on the forks so as to detach the lower crossbar of the mast upright from the seat of the truck base. Bring the bridge crane back into the upright position relative to the support column, lift and move the support column making sure to retrieve the hydraulic pipe (fig.7). ASSEMBLY The traction wheel fastening nut of the truck base column must be tightened using a torque wrench with a torque power of 175 Nm. Use Loctite 222 on the nut thread before tightening.

Fig. 5

Fig. 6

Fig. 7

SERVICE

MAST ASSEMBLY MECHANICS BEARING REPLACEMENT Equipment and tools

medium elastic ring opening pliers

Fig. 1

Phase 1 Depending on the bearings that need replacing, carry out the appropriate mast dismantling procedure (see "INNER/INTERMEDIATE MAST ASSEMBLY DISMANTLING").

Phase 2 MEDIUM SIZE ELASTIC RING OPENING PLIERS Use the elastic ring pliers to remove the elastic ring securing the bearing (ref.A fig.1). Extract the bearing (ref.B fig.1), retrieve the spacers (ref.C-D fig.1) and proceed with the replacement. Repeat the procedure for the other bearings.

The new bearings do not need to be greased.

ASSEMBLY After assembly ensure that the bearings slide correctly in the channel. In the event that there is play or chafing move the spacers from the "C" position to the "D" position (fig.1) or vice versa.

SERVICE

MAST ASSEMBLY MECHANICS

REPLACEMENT OF CHAINS AND CHAIN TENSIONER 2 STAGE MAST Never just replace the worn part of a chain. Replace the entire chain. Similarly, never replace just one chain of a couple, always replace both. Equipment and tools Fig. 1

wooden beam taper end pliers 100x100x1000 mm

fixed spanner 24 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

Position the key switch to OFF and disconnect the battery.

Phase 2 TAPER END PLIERS Using the pliers remove the cotter pins of the chain fastening buffers positioned on the fork support plate. Remove the pins (ref.B fig.2).

B Fig. 2

SERVICE

MAST ASSEMBLY MECHANICS Phase 3 TAPER END PLIERS Using the pliers remove the cotter pins of the chain tensioner placed on the outer upright. Remove the pins (ref.C fig.3). Retrieve the chains and proceed with the replacement.

Phase 4 TAPER END PLIERS- FIXED GAUGE 24 mm SPANNER Using the taper end pliers remove the cotter pin at the base of the chain tensioner (ref.D fig.4). Using the fixed gauge spanner loosen and remove the chain tensioner fastening nut (ref.E fig.4). Extract the chain tensioner.

Fig. 3 Fig. 4

ASSEMBLY Do not reuse the chain anchoring safety pins, use new cotter pins, ensuring they are the correct size. The chain tensioners should be adjusted so that, when unladen, the forks should not rest on the ground.

Fig. 4

SERVICE

MAST ASSEMBLY MECHANICS

3 STAGE MAST Equipment and tools Fig. 1

B bridge crane load capacity 2000 kg

lifting belt load capacity 2000 kg

fixed spanner 15 - 24 mm

large flat head screw driver

taper end pliers

"Parker" caps

oil protecting gloves

A Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

Phase 1 OIL PROTECTING GLOVES - FIXED 15mm GAUGE SPANNER - "PARKER" CAPS Wear the oil proof gloves. Using the fixed spanner unscrew the coupling of the hydraulic pipe (ref.A-B fig.1). Apply the caps to the couplings and retrieve the hydraulic pipe.

Phase 2 LARGE FLAT HEAD SCREWDRIVER Using the screwdriver loosen and remove the screws fastening the lexan protective panel (ref.C fig.2) and retrieve the washers. Retrieve the protective panel.

C Fig. 2

SERVICE

MAST ASSEMBLY MECHANICS Phase 3 BRIDGE CRANE - LIFT BELT Secure the inner upright using the lift belt (fig.3). Hook the belt to the bridge crane and minding the chain, lift until the chain fastening buffers are visible positioned on the upright.

Fig. 3

Phase 4 TAPER END PLIERS Using the pliers remove the cotter pins of the chain fastening buffers positioned on the upright. Remove the pins (ref.D fig.3). Lower the upright assembly.

Phase 5 TAPER END PLIERS Using the pliers remove the cotter pins of the chain tensioner placed on the outer upright. Remove the pins (ref.E fig.4). Retrieve the chains and proceed with the replacement.

Phase 6 TAPER END PLIERS- FIXED GAUGE 24 mm SPANNER Using the taper end pliers remove the cotter pin at the base of the chain tensioner (ref.F fig.4). Using the fixed gauge spanner loosen and remove the fastening nut of the chain tensioner (ref.G fig.4). Extract the chain tensioner.

ASSEMBLY Fig. 4

Do not reuse the chain anchoring safety pins, use new cotter pins, ensuring they are the correct size. The chain tensioners should be adjusted so that, when unladen, the forks should not rest on the ground.

F 26

SERVICE

MAST ASSEMBLY MECHANICS

REPLACEMENT OF CHAIN GUIDEWAY PULLEYS 2 STAGE MAST Equipment and tools

hexagonal "T" section spanner 5 mm

taper end pliers

hammer

clamp gudgeon

cartridge grease nipple

c a b

Phase 1 Carry out the chain dismantling procedure (see "CHAIN AND CHAIN TENSIONER REPLACEMENT").

Fig. 1

Phase 2 HEXAGONAL 5 mm "T" SECTION SPANNER - TAPER END PLIERS - HAMMER - GUDGEON HEAD With the hexagonal "T" section spanner unscrew and remove the lynch pin fastening screw of the chain hose pulley (ref.A fig.1). Using the taper end pliers remove the cotter pin of the chain pulley pin (ref.B fig.1). Using the clamp gudgeon and the hammer extract the pulley pin (ref.C fig.1), extract the pulley and proceed with the replacement.

ASSEMBLY Do not reuse the chain anchoring safety pins, use new cotter pins, ensuring they are the correct size. After assembly grease the pulley bearings by using a cartridge greasing nipple.

MAST ASSEMBLY MECHANICS

SERVICE

3 STAGE MAST Equipment and tools

hexagonal "T" section spanner 5 mm

taper end pliers

oil protecting gloves

fixed spanner 15 -19 mm

hammer

clamp gudgeon

cartridge grease nipple

"Parker" cap

Procedure

Fig. 1

A Phase 1 OIL PROTECTING GLOVES - FIXED 15mm GAUGE SPANNER - "PARKER" CAP Wear the oil proof gloves. Using the fixed spanner unscrew the coupling of the hydraulic pipe (ref.A fig.1). Apply the cap to the coupling, and rest the hydraulic pipe on the forks.

Fig. 2

B Phase 2 TAPER END PLIERS Using the pliers remove the cotter pins of the chain tensioner placed on the outer upright. Remove the pins (ref.B fig.2). Lower the chains onto the forks.

SERVICE

MAST ASSEMBLY MECHANICS

Phase 3 FIXED GAUGE 19 mm SPANNER Using the fixed spanner loosen and remove the fastening screws of the hydraulic pipe hose sheave pin (ref.C fig.3). Extract the pin (ref.D fig.3) and retrieve the hose sheave (ref.E fig.3).

Fig. 3

Phase 4 HEXAGONAL 5 mm "T" SECTION SPANNER - TAPER END PLIERS HAMMER - GUDGEON HEAD With the hexagonal "T" section spanner unscrew and remove the pin fastening the chain pulley (ref.F fig.4). Using the taper end pliers remove the cotter pin of the chain pulley pin (ref.G fig.4). Using the clamp gudgeon and the hammer extract the pulley pin (ref.H fig.4), extract the pulley and proceed with the replacement.

ASSEMBLY Do not reuse the chain anchoring safety pins, use new cotter pins, ensuring they are the correct size. After assembly grease the pulley bearings by using a cartridge greasing nipple.

H F G

Fig. 4

MAST ASSEMBLY MECHANICS

SERVICE

SMALL MAST IDENTIFICATION SMALL MAST COMPONENTS

2 11 4 10

1 5 6

Ref.

Description

Load support plate

Fixed fork

Chain tensioner

Cotter pin

Nut

Bearing

Sliding skid

Spacers

Sliding skid fastening screws

Mechanical stop point screws

SERVICE

MAST ASSEMBLY MECHANICS

Ref.

Description

Load support plate

Fixed fork

Chain fastening buffer

bearing

Sliding skid

Spacers

Sliding skid fastening screws

Mechanical stop point screws

SERVICE

MAST ASSEMBLY MECHANICS DISMANTLING OF THE SMALL MAST LIFT CHAINS Never replace just one chain, always replace both chains. When the chains are replaced the chain tensioner must also be replaced. Equipment and tools

wooden beam 100x100x1000 mm

fixed gauge spanner 13 -24 mm

taper end pliers

ratchet

hexagonal socket wrench 24 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

A Fig. 1 Fig. 2

Position the key switch to OFF and disconnect the battery.

C Phase 2 FIXED GAUGE 13 mm SPANNER Unscrew and remove the bracket fastening screws (ref.B fig.2), retrieve the elastic washers and remove the bracket (ref.C fig.2).

SERVICE

MAST ASSEMBLY MECHANICS

Phase 3 TAPER END PLIERS- FIXED GAUGE 24 mm SPANNER Using the pliers remove the cotter pins on the chain tensioner positioned on the cab backrest (ref.D fig.3). Using the 24 mm fixed gauge spanner unscrew and remove the nuts of the chain tensioner block (ref.E fig.4).

Phase 4 TAPER END PLIERS - RATCHET - 24 mm HEXAGONAL SOCKET WRENCH Using the pliers remove the cotter pins on the chain tensioner positioned on the fork support plate (ref.F fig.3). Using the ratchet and the hexagonal socket wrench unscrew and remove the chain tensioner blocking nuts (ref.G fig.4). Slip off the chains including the chain tensioners and proceed with the replacement.

D E

Fig. 3

ASSEMBLY Do not reuse the chain anchoring safety pins, use new cotter pins, ensuring they are the correct size. After assembly adjust the chain tensioners so that, in the completely lowered position, the chains remain taught. For a correct sliding of the bearings along the backrest guide rails it is essential that the chains have the same tension, otherwise the guide rails could be damaged.

G F

Fig. 4

SERVICE

MAST ASSEMBLY MECHANICS SMALL MAST DISMANTLING: 2 stage upright assembly with a “c” or “j” channel profile Equipment and tools

workbench

tackle load capacity 1000 kg

N° 2 lifting cables

bent hexagonal wrench 10 mm

Fig. 1

taper end pliers

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Set the key switch to OFF and disconnect the battery.

Fig. 2

Phase 1 BENT HEXAGONAL 10 mm SPANNER Unscrew and remove the small mast mechanical lift stop screw (ref.A fig.1).

Phase 2 TACKLE - N° 2 LIFT BELTS Secure the fork base plate with the two lift belts. Hook the belts to the tackle and pick up the slack until the chains are loose (fig.2).

B Fig. 3 34

SERVICE

MAST ASSEMBLY MECHANICS

Phase 3 TAPE END PLIERS Using the pliers remove the cotter pins of the chain fastening buffers positioned on the fork support plate. Remove the pins (ref.B fig.3).

Fig. 4

Connect the battery and position the ignition key on ON.

Phase 4 Using the button on the tiller begin lifting until the small mast extends completely beyond the mast assembly rail (fig.4).

Position the key switch to OFF and disconnect the battery.

Phase 5 Using the tackle move the small mast away from the truck and place it on a workbench.

SERVICE

MAST ASSEMBLY MECHANICS SMALL MAST DISMANTLING: 2 stage and 3 stage FFL mast assembly Equipment and tools

workbench

tackle load capacity 1000 kg

N° 2 lifting cables

bent hexagonal wrench 10 mm

Fig. 1

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Set the key switch to OFF and disconnect the battery.

Phase 1 Carry out the inverse procedure to the dismantling of the small mast lift chains (see "DISMANTLING OF THE SMALL MAST LIFT CHAINS"). Fig. 2 Phase 2 BENT HEXAGONAL 10 mm SPANNER Unscrew and remove the small mast mechanical lift stop screw (ref.A fig.1).

Phase 3 TACKLE - N° 2 LIFT BELTS Secure the fork base plate with the two lift belts. Attach the belts to the tackle and raise until taught (fig.2).

Connect the battery and position the ignition key on ON.

Fig. 3

SERVICE

MAST ASSEMBLY MECHANICS

Phase 4 Using the button on the tiller begin lifting until the small mast extends completely beyond the small mast assembly rail (fig.3).

Position the key switch to OFF and disconnect the battery.

Phase 5 Using the tackle move the small mast away from the truck and place it on a workbench.

SERVICE

MAST ASSEMBLY MECHANICS SMALL MAST DISMANTLING: single stage mast Equipment and tools

workbench

tackle load capacity 1000 kg

N° 2 lifting cables

bent hexagonal wrench 10 mm

Fig. 1

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing.

Phase 1 Carry out the inverse procedure to the dismantling of the small mast lift chains (see "DISMANTLING OF THE SMALL MAST LIFT CHAINS").

Phase 2 BENT HEXAGONAL 10 mm SPANNER Unscrew and remove the small mast mechanical lift stop screw (ref.A fig.1).

Fig. 2 Fig. 3

Phase 3 TACKLE - N° 2 LIFT BELTS Secure the fork base plate with the two lift belts. Hook the belts to the tackle and lift the small mast upwards until it extends completely beyond the mast assembly rail (fig.3).

Phase 4 Using the tackle move the small mast away from the truck and place it on a workbench.

SERVICE

MAST ASSEMBLY MECHANICS

BEARING AND SLIDING SKID REPLACEMENT Equipment and tools

hexagonal "T" medium elastic section spanner ring opening pliers 4 mm

fixed spanner 10 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing.

BEARING REPLACEMENT Phase 1 WORKBENCH - MEDIUM SIZE PLIERS TO OPEN ELASTIC RINGS Using the elastic ring opening pliers remove the elastic ring (ref.A fig.1), slip away the bearing (ref.B fig.1) and retrieve the spacer (ref.C fig.1). Repeat the operation for the other bearings and proceed with the replacement.

C B

REPLACEMENT OF SLIDING SKIDS Phase 2 WORKBENCH - HEXAGONAL “T” SECTION SPANNER 4 mm - FIXED GAUGE SPANNER 10 mm Using the fixed spanner block the sliding skid block nut (ref.D fig.2), while with the hexagonal "T" section spanner loosen and remove the fastening screws (ref.E fig.2). Retrieve the skid (ref.F fig.2) and the spacers (ref.G fig.2). Repeat the operation for the other skid and proceed with the replacement.

Fig. 1

Fig. 2

F G D

MAST ASSEMBLY MECHANICS

SMALL MAST PULLEY ASSEMBLY IDENTIFICATION OF THE SMALL MAST PULLEY ASSEMBLY COMPONENTS

3 5

Ref.

Description

Pulley base plate

Chain guideway pulley

Bracket

Spacer

Elastic ring

Flat washer

Screw

Elastic washer

SERVICE

MAST ASSEMBLY MECHANICS

REPLACEMENT OF SMALL MAST CHAIN GUIDEWAY PULLEYS Equipment and tools

workbench

vice

n. 2 wood beams 100x100x500 mm

taper end pliers

medium elastic ring opening pliers

extractor

fixed gauge spanner 13 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians.

Fig. 1 Phase 1 Wooden beams 100x100x500 mm Raise the mast using one of the buttons on the tiller. Position the wooden beams beneath the forks (ref.A fig.1). Move the mast downwards until the forks rest on the beams. Continue the descent in order to loosen the chains.

Position the key switch to OFF and disconnect the battery.

Fig. 2

B B

Phase 2 FIXED GAUGE 13 mm SPANNER Unscrew and remove the bracket fastening screws (ref.B fig.2), retrieve the elastic washers and remove the bracket (ref.C fig.2).

SERVICE

MAST ASSEMBLY MECHANICS Phase 3 TAPER END PLIERS Using the pliers remove the safety pin and the hinge pins (ref.D fig.3) that secure the chains to the chain tensioner positioned on the truck bulkhead. Remove the chains from the guide way pulleys and rest them on the forks.

Phase 4 MEDIUM SIZE ELASTIC RING OPENING PLIERS Use the elastic ring pliers to remove the elastic ring blocking the pulley base plate (ref.E fig.4). Slip the complete pulley base plate away from the cylinder shaft (ref.F fig.4), retrieving the spreaders (ref.G fig.4).

Fig. 3

Phase 5 MEDIUM SIZE ELASTIC RING OPENING PLIERS - EXTRACTOR Use the elastic ring pliers to remove the elastic ring blocking the pulley (ref.H fig.5). Retrieve the spacer (ref.I fig.5). Using the extractor slip off the pulley from the base hose sheave baseboard (ref.L fig.5) and retrieve the spacer (ref.M fig.5). Repeat the operation for the other pulley and proceed with the replacement.

g f

Fig. 4

ASSEMBLY Do not reuse the chain anchoring safety pins, use new cotter pins, ensuring they are the correct size.

LM Fig. 5

SERVICE

REDUCTION GEAR

reduction gear IDENTIFICATION OF REDUCER COMPONENTS �� 2 REDUCER DISMANTLING �� 4 REDUCER DISassembly �� 6 REPLACEMENT OF REDUCER OIL �� 9

SERVICE

REDUCTION GEAR

IDENTIFICATION OF REDUCER COMPONENTS 1

2 3

24 5

23 22 21 19

6 7 9

8 18 17

16 10

14 15

type gearbox

supplier code TYP.

part code

COD. C.P.N.

production date

DATE

Serial number

SERVICE

Ref.

REDUCTION GEAR

Description

Ref.

Description

Traction motor

Traction wheel

O-Ring motor flange

Hexagonal head screw

Steering pinion

Washer

Fifth wheel fastening screws

Bevel gear pair

Grease nipple

Bevel gear pair pinion

Oil filling screw cap

Pinion blocking tab

Reducer casing

Lower conical roller bearing

Oil emptying screw on cap

Shims

Bevel gear ring

Spacer

O-ring

Upper conical roller bearing

Spacer

Cylindrical bevel gear

Ball bearings

Hexagonal nut

Seeger safety ring

Reducer cover, steering fifth wheel

Seeger ring

Identification nameplate

Oil seal

SERVICE

REDUCTION GEAR

REDUCER DISMANTLING Equipment and tools

bridge crane load capacity 2000 kg

hydraulic jack

n. 2 wood stocks

lifting belt load capacity 2000 kg

Fig. 1 Fig. 2 ladder

oil recovery sump

hexagonal "T" section spanner 8 mm

fixed gauge spanner 17 mm

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground, push the forks against an obstacle in order to keep the truck blocked when it is lifted using the hydraulic jack. Set the key switch to OFF and disconnect the battery.

Phase 1 HYDRAULIC JACK - N. 2 WOODEN STOCKS Position the hydraulic jack at the centre of the bodywork (fig.1) and lift until the wooden stocks can slip beneath. Position the wooden stocks at the side of the truck (fig.1), lower the jack and rest the truck on the stocks.

Phase 2 BRIDGE CRANE - LIFT BELT - LADDER Climb up the ladder with the lift belt. Harness the complete support with the lift belt (fig.2). Attach the belt to the bridge crane and raise until taught. Fig. 3 4

SERVICE

REDUCTION GEAR

Phase 3 Perform the traction wheel dismantling procedure (see “DISMANTLING THE TRACTION WHEEL” in the “FRAME MECHANICS” section).

Phase 4 Perform the tiller dismantling procedure (see “TILLER DISMANTLING” in the “FRAME MECHANICS” section).

Fig. 4

Phase 5 Perform the traction motor dismantling procedure (see “TRACTION MOTOR DISMANTLING” in the “FRAME MECHANICS” section).

Phase 6 OIL RECOVERY SUMP - 8 mm PIVOTING HEXAGONAL "T" SECTION SPANNER Place the sump beneath the reducer. Using the pivoting hexagonal "T" section spanner unscrew and remove the oil drain plug (ref.A fig.3), remove the cap. Empty the oil into the sump completely. Clean the drain plug thoroughly from accumulated impurities that may have collected during reducer operation and screw it back in place.

B B

B Fig. 5

Phase 7 HYDRAULIC JACK - FIXED GAUGE 17 mm SPANNER Position the hydraulic jack beneath the reducer (fig.4) and lift until it is resting against it. Using the fixed gauge spanner unscrew the screws fastening the reducer to the chassis (ref.B fig.5). Retrieve the washers. Watching out for the reducer, lower the jack completely.

Phase 8 BRIDGE CRANE - WORKBENCH Use the bridge crane to lift the truck so that the reducer can be completely extracted (fig.6). Retrieve the reducer, place it on the clean workbench and proceed with replacement or dismantling.

Fig. 6

ASSEMBLY The screws securing the reducer to the chassis must be tightened using a torque wrench with a tightening torque of 45 Nm.

SERVICE

REDUCTION GEAR REDUCER DISassembly Equipment and tools

vice

medium/large bearing extractor

hexagonal socket wrench 8 mm

ratchet

A clamp gudgeon

hammer

percussion extractor

fixed spanner 30 mm

B oil protecting gloves

medium elastic large elastic ring ring opening pliers closing pliers

Fig. 1

medium flat head screwdrivers

Procedure

Fig. 2

Before starting work, ensure that you are equipped with all suitable safety clothing.

Phase 1 OIL PROTECTING GLOVES Wear the oil proof gloves. Carry out the reducer dismantling procedure (see “REDUCER DISMANTLING”).

Fig. 3

SERVICE

REDUCTION GEAR

Phase 2 VICE - MEDIUM SIZE FLAT HEAD SCREWDRIVER Position the reducer in the vice and clamp firmly. Using the flat head screwdriver lever up and remove the oil seal (ref.A fig.1).

Phase 3 LARGE ELASTIC RING CLOSING PLIERS Use the elastic ring pliers to remove the elastic ring blocking the bevel ring gear pair (ref.B fig.2). Retrieve the spacers (ref.C fig.2).

Fig. 4

Phase 4 PERCUSSION EXTRACTOR Screw the threaded part of the extractor shaft into the hub hole (ref.D fig.3). Extract the complete bevel gear pair (fig.3).

Fig. 5

H Phase 5 MEDIUM SIZE ELASTIC RING OPENING PLIERS Use the elastic ring pliers to remove the elastic ring blocking the bearings (ref.E fig.4). Retrieve the spacers (ref.F fig.4).

Phase 6 LARGE BEARING EXTRACTOR Use the bearing extractor to remove the two hub bearings (ref.G fig.5).

Phase 7 HEXAGONAL 6 mm SOCKET WRENCH - RATCHET Using the hexagonal socket wrench and the ratchet unscrew and remove the fastening screws of the steering fifth wheel (ref.H fig.6). Retrieve the complete fifth wheel.

Fig. 6

Phase 8 FIXED GAUGE 30 mm SPANNER - HAMMER - CLAMP GUDGEON Using the fixed gauge spanner loosen and remove the nuts fastening the bevel pinion to the upper bevel gear (ref.I fig.7). Using the hammer and the clamp gudgeon extract the bevel pinion by slipping it through inside the reducer (fig.7). Extract the bevel gear (ref.J fig.8) and retrieve the pinion blocking tabs (ref.K fig.8). Fig. 7 7

SERVICE

REDUCTION GEAR Phase 9 MEDIUM SIZE BEARING EXTRACTOR Retrieve the upper bearing (ref.L fig.9) and the spacers (ref.M,N fig.9). Using the bearing extractor remove the bearing from the pinion (ref.O fig.9) and retrieve the spacers (ref.P,Q,R fig.9).

ASSEMBLY To facilitate bearing assembly, during the dismantling please take care to note spacer positioning. During assembly of the specific elements use Loctite 243 and tighten the bolts according to the diagram provided in fig.10.

Fig. 8

P M L Q O

Fig. 9

shaft Ø20 - 59 Nm shaft Ø17 - 32 ÷ 35 Nm

60 ÷ 70 Nm

45 ÷ 50 Nm

silicone 20 ÷ 25 Nm

85 ÷ 109 Nm

20 ÷ 25 Nm

Fig. 10

SERVICE

REDUCTION GEAR

REPLACEMENT OF REDUCER OIL Equipment and tools

oil protecting gloves

oil recovery sump

hydraulic jack

hexagonal "T" section spanner 8 mm

oil syringe

torque wrench

n. 2 wood stocks

Procedure Before starting work, ensure that you are equipped with all suitable safety clothing. Move the carriage to a safe place, away from areas of transit of other vehicles and the pedestrian route. Lower the forks to the ground, push the forks against an obstacle in order to keep the truck blocked when it is lifted using the hydraulic jack , position the ignition key on OFF and disconnect the battery.

After using the reducer, beware of the high oil temperature. It is recommended that oil protecting gloves resistant to high temperatures be used. Do not get rid of the spent oil in the ground or by pouring down the drain. Special companies must be charged with disposal or the recycling of industrial oils.

Fig. 1

Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover. Fig. 2 9

SERVICE

REDUCTION GEAR Phase 2 HYDRAULIC JACK - N. 2 WOODEN STOCKS Position the hydraulic jack at the centre of the bodywork (fig.2) and lift until the wooden stocks can slip beneath. Position the wooden stocks at the side of the truck (fig.2), lower the jack and lower the truck onto the stocks.

Phase 3 OIL PROTECTIVE GLOVES - OIL RECOVERY SUMP Clean the area around the filler neck and oil drain thoroughly. Place a suitably sized oil pan beneath the drain plug.

Phase 4 OIL PROOF GLOVES - OIL RECOVERY SUMP - PIVOTING HEXAGONAL "T" SECTION SPANNER 8 mm - TORQUE WRENCH - OIL SYRINGE Using the pivoting hexagonal "T" section spanner loosen the oil filler cap (ref.B fig.3), remove the cap. Using the same spanner loosen and remove the oil drain plug (ref.C fig.4), remove the cap. Empty the oil into the sump completely. Clean the drain plug thoroughly from accumulated impurities that may have collected during reducer operation and screw it back in place.

Fig. 3

The tightening of the oil drain cap must be done using a torque wrench with a torque tightening power of 22 Nm.

Use Standard Cold store

Oil type

Quantity

ESSO UNIFARM 15W - 40

1 litres

SHELL TRANSAXLE 75 W 90

1 litres

Fig. 4

To top up use a pressure aspiration syringe (fig.5), that will easily enable the gearbox to be topped up with oil. The correct level and quantity of oil is achieved when the oil surface reaches the lower lip of the oil filler neck or at worst when the oil pours out of the oil filler neck. The tightening of the oil filler cap must be done using a torque wrench with a torque tightening power of 22 Nm.

Fig. 5 10

SERVICE

BRAKING SYSTEM

braking system IDENTIFICATION of the electromagnetic brake components �� 2 OPERATION �� 3 BrakING systems �� 3 DISMANTLING OF THE electromagnetic Brake �� 4 ELECTROMAGNETIC Brake ADJUSTMENT �� 6

SERVICE

BRAKING SYSTEM

IDENTIFICATION of the electromagnetic brakE components

2 3 5

4 6

Ref.

Description

Fastening screw

Electromagnet

Brake plate

Elastic ring

Adjusting screw

Pinion

Rotor

Ferode

Dust cap

Disc

SERVICE

BRAKING SYSTEM

OPERATION The electromagnetic brake attached to the traction motor is a spring brake. When the electromagnet is powered it attracts the brake plate and unblocks the ferode allowing to turn freely. As soon as the power to the electromagnet is cut, the springs push downwards on the brake plate above the ferode triggering the braking.

BRAKING systems 4 braking systems are envisaged:

• • • •

gear request release

Release braking Braking on direction reversal Emergency braking Stationary handbrake

A) Release braking Checks the deceleration ramp when the gear request is released. B) Braking on direction reversal Checks the deceleration ramp when the gear request is inverted. The “braking on direction reversal" also know as counter current braking, consists in a current reversal on the motor which changes the direction of travel when the truck is in motion. The braking current must be adjusted so that the truck stop in a space that is at least not less than the length of the machine itself.

direction reversal

C) Emergency braking Emergency braking takes place when an alarm is triggered that requires immediate traction arrest of when the tiller sensor is disactivated (tiller in rest position or completely lowered). The braking is performed by the electromagnetic brake attached to the traction motor. D) Stationary brake The "stationary brake" is performed by the electromagnetic brake and takes place when the machine is stationary and the tiller is in the rest position.

SERVICE

BRAKING SYSTEM

DISMANTLING OF THE electromagnetic Brake Equipment and tools

hexagonal "T" section spanner 5 mm

fixed spanner 15 mm

scissors

elastic ring opening pliers

large Philips screw driver

extractor

When replacing the rotor, the pinion must also be replaced. Fig. 1 Phase 1 LARGE PHILIPS SCREW DRIVER Use the Philips screwdriver to unscrew and remove the fastening screws on the motor compartment cover (ref.A fig.1). Open the engine cover.

Fig. 2

B Phase 2 fixed gauge spanner - hexagonal 5 mm "t" section spannerscissors Remove the dust cap (ref.B fig.2) Use the fixed gauge spanner to loosen the three adjustment nuts (ref.C fig.2). Using the hexagonal "T" section spanner unscrew the three screws fastening the electromagnetic brake to the traction motor (ref.D fig.3). Use the scissors to cut the electrical cable tie to free the solenoid brake power cable. Disconnect the connector and slip it out from the tongue. Remove the solenoid brake from the motor (fig.3).

SERVICE

BRAKING SYSTEM

Phase 3 ELASTIC RING OPENING PLIERS - EXTRACTOR Extract the rotor (ref.E fig.4) from the pinion. Using the elastic ring pliers remove the elastic ring from the drive shaft (ref.F fig.5). Using the extractor remove the pinion (ref.F fig.5).

Fig. 3

ASSEMBLY After assembly proceed with the adjustment of the electromagnetic brake.

Fig. 4

Fig. 5

F G

BRAKING SYSTEM

SERVICE

ELECTROMAGNETIC Brake ADJUSTMENT

A B

Fig. 1

After having reassembled the electromagnetic brake assembly, before using the truck, one must see to the adjustment of the ferode. In order to obtain good braking, the distance between the ferode and brake plate (ref.A fig.1) must not be greater than 0.35 mm. For this purpose one must use a feeler gauge of this size. With the three nuts loose (ref.B fig.1), insert the feeler gauge close to one of the bolts, tighten the fastening screw (ref.C fig.1) with the Allen key and place the plate at such a distance that enables the feeler gauge to be slipped out with a little friction. Repeat the operation with all three bolts. Tighten the nuts using the fixed gauge spanner (ref.B fig.1).

SERVICE

ORDINARY MAINTENANCE

ordinary maintenance OILS AND LUBRICANTS �� 4 PRODUCTS FOR THE CLEANING �� 4 PLANNED MAINTENANCE �� 5

ORDINARY MAINTENANCE

SERVICE

WARNINGS •

If maintenance operations are carried out immediately after the truck stop, some parts of the motor or of the hydraulic system may be hot. Always wear the individual protection devices, if it is required.

•

Do not wear rings, watches, jewells, untied clothes such as scarfs, undone shoes, unbuttoned coats or blouse with the opened zip that may get stuck in the moving parts.

•

Never carry out cleaning, lubrication or maintenance operations if the battery is connected.

•

Do not carry out any operation on the truck if there are operators working with it, unless they are authorized and are assisting the operation to be carried out.

•

To clean the components use compressed air and during this operation wear proper goggles with lateral protections. The maximum air pressure must not exceed 1 bar.

•

Never use petrol, oil or other inflammable liquids as detergents: we recommend using not inflammable and not toxic solvents.

•

Do not accumulate rags soaked in grease or oil: they may cause fire risk. Always put them in a closed metallic container.

•

The capacitors located in the transitor gearcase may keep an electric charge also after the battery has been disconnected. To avoid electrical shock and personal injuries, discharge the capacitors before checking or repairing any component of the electric compartment. Wear goggles. Make sure that the battery has been disconnected.

•

Do not file or lubricate the remote control switch contacts. This may cause the union of the contacts and therefore the loss of control, damage to things or personal injuries.

•

Drain oil must be gathered. Avoid letting it off in the common discharge ducts. Qualified companies must dispose of or recycle the industrial oils, according to the laws in force in each Country.

•

An apparently invisible fluid might come out of a small hole and have enough force to pass through the skin In such cases we recommend checking the penetration force by means of a piece of card or a piece of wood.

•

During the fluid check or the filter replacement prevent dirt from contaminating the hydraulic system.

•

Never enable the pump if the fluid in the hydraulic system is not enough. If the hydraulic fluid levels are low, the hydraulic pump will be damaged.

•

Do not put tools on the battery. Metall objects on the battery may cause short circuits and possible damages or injuries.

•

The batteries produce explosive gases. Keep the air outlets always clean. Keep sparks and flames away from the battery compartment. Do not produce sparks when disconnecting the battery cables. Disconnect the battery during the maintenance operations.

•

Always use a space bar and slings to lift the battery vertically by means of the proper eyelets. Do not use chains or slings without using the space bar, because this might damage the battery case. Check that the battery compartment is clean and dry. When the battery is in operation, the aeration plugs must be installed. If the plugs are not installed, the electrolyte, might come out and corrode the battery case and compartment.

SERVICE

ORDINARY MAINTENANCE

•

The acid contained in the electrolyte may cause damage. If the electrolyte is accidentally released, clean carefully with water. Neutralize the acid with a sodium bicarbonate solution (baking soda). In case of contact with the skin, immediately flush the skin with water. In case of contact with the eyes, wash the eyes thoroughly with water for at least 10 minutes, then seek medical advice.

•

The batteries are a part of the truck counterweight system. By installing a too small battery, the truck might not weigh enough to reach the rated capacity. When replacing the battery, check that the rated capacity and dimensions of the battery comply with the data indicated on the plate. Refer to the “ TRUCK AND LOAD IDENTIFICATION DATA” of the section “PRESENTATION”, in order to know the correct battery specifications for the truck in object.

•

Do not work under the lifted roller plate. Lower the roller plate or use a safety chain in order to avoid that the roller plate lowers during the maintenance operations on the mast and on the lifting chains.

•

Never repair damaged forks by heating or welding them. The forks are made up of tempered steel.. Replace the damaged forks.

•

Before proceeding with the maintenance of the hydraulic system, it is necessary to remove any possible residual pressures inside it. At the end of the maintenance operations, close the valves.

SERVICE

ORDINARY MAINTENANCE

OILS AND LUBRICANTS Application

Std

OIL for the lubrication of the HYDRAULIC CIRCUIT



OIL for the lubrication of the GEARBOX





GREASE for the lubrication of the MUST PROFILES and PULLEY PINS GREASE for the lubrication of MAST BEARINGS (1) and CABIN BEARINGS (1) SPRAY for the lubrication of the CHAINS (2) (1) (2)

Cold store

  

 

Trademark

Type

Specifications

Shell

TELLUS T32

DIN 51524

Shell

AEROSHELL FLUID 41

MIL-H-5606G

Shell

SPIRAX A 80W-90

API GL-5 MIL-L-2105D

Shell

TRANSAXLE OIL 75W-90

API GL-4 API GL-5

Shell

ALVANIA EP0

Shell

ALBIDA GREASE EP2

Shell

AEROSHELL GREASE 6

Shell

ADVANCE TEFLON CHAIN

MIL-G-24139A

The lubrication is not necessary; the bearings are already screened and greased for life. New chains are already lubricated.

PRODUCTS FOR THE CLEANING GUARD AND PLASTIC COVER CLEANING - TRUCK PAINTED PART CLEANING For the truck general cleaning use only dry water, wet rags or degreasing solvents. Do not use water jets, vapours, solvents or inflammable products that may damage the truck or that can be dangerous for the operator. motor and electronic system cleaning For the general cleaning use only dry water at low pressure and a clean dry brush. Do not use wet rags, water jets, vapour, solvents or products that may damage the truck or that may be dangerous for the operator. MAST PROFILE AND MAST CLEANING Use degreasing solvents. Do not use water jets, vapour, solvents or inflammable products that may damage the mast or that may be dangerous for the operator. 4

SERVICE

ORDINARY MAINTENANCE

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

REDUCER

HYDRAULIC SYSTEM

MOTORS

BRAKING SYSTEM

TRUCK BASE

Operation description Check welded joints Lubrification of tiller gudgeon Grease tie rod pins Lubrication of linkage pivot pins-forks-carriage (3) Check efficiency of tiller gas spring Check tiller control housing Check steering thrust block bearing Lubrification of steering thrust block General cleaning Check the efficiency of the electromagnetic brake coil Check brake lining wear (1) Check release braking Check reverse braking Check emergency braking Check parking mode braking General cleaning Check motor insulation Check cable connections Check fastening bolts General cleaning with compressed air Check for oil leaks at pump connections Check for oil leaks at cylinder head connections Check for oil leaks at motor housing distributor connections Check for oil leaks in pipe connections on mast Check hydraulic pipes Check flexible pipes (2) Replace oil in hydraulic tank Oil filter cleaning Check valve operation Reducer oil replacement Visual oil leak check Check general condition of reducer Check steering crown gear and steering pinion wear General cleaning Check lifting chain link and pin wear (2) Check chain elongation (2) Check chain tensioner (2)

Maintenance intervals every 8 hours 1 day

every every every every 500 h 1000 h 2000 h 3000 h 6 months 12 months 24 months 36 months    

  

  





















     













   x 

 x 

     





Clean chains (3) MAST

Lubricate chains

 (3)

Lubricate mast profiles Check chain slip bearings Check cable slip bearings Lubrification of chain and pipe bearing pins Check guide bearing wear Check mast bearings Check tightening of mast fastening bolts General cleaning

       

 

SERVICE

ORDINARY MAINTENANCE

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

Maintenance intervals

Operation description

every 8 hours 1 day

every every every every 500 h 1000 h 2000 h 3000 h 6 months 12 months 24 months 36 months

Check link and pin wear on lift chains (4) Check chain elongation



Check chain tensioner (4) SMALL MAST AND FORK BASE PLATE



(4)





Clean chains (3)



Chain lubrification

(3)



Bearing check



Check state of forks (7)





Check fork heel wear

(8)





Check fork point alignment (9)





Check that forks are parallel





Check aperture angle (10)





WHEELS

PLANT ELECTRICAL

General cleaning



Check all electrical connections



Check the condition of electric cables



Sensor check General cleaning of electrical panel, remote-control switches and contacts using dry air at low pressure Check traction wheel wear (1)



Check the tightening of traction wheel fastening nuts



Check tightening of pivoting wheel fastening nuts



Check load bearing wheel wear (1)



BATTERY

Check load bearing wheel bearings



(1)



Check cable connections



Check for liquid leakage



Check battery insulation



Check electrolyte density



Check electrolyte level (5)



General cleaning

(6)

Check all machine functions using activation controls

(1)



 

replace if it is necessary

replace in the following situations: • movement of the pipe fittings; • damage, cuts, or abrasions on the surface layer; • hardening or stiffness of the pipe, presence of burnings or cracks due to heat; • cracks, damage or corrosion on the pipe fitting; • leaks on the pipe or on the pipe fitting; • permanent folds, squashings, flattenings or twists on the pipe; • blisters, softening or wear of the external layer. (2)

the chains must be cleaned with paraffin, petrol, gas oil or oil of turpentine. Lubricate with spray can (see oil and lubricants table) Usually a universal grease layer is applied on the chains for the cold room or in wet environments.

(3)

SERVICE

ORDINARY MAINTENANCE

Replace, if chains have undergone a stretching which is higher than 3% or if the links, the hinge pins or the chain tightener are worn and they need to be replaced. Measure the extension with a callipers (fig.1) on many sections 10 steps apart taken in the more stressed sections. (4)

A) B) C) D) E) F) G) H) I)

Pin wear Pin damage Link damage Link edge wear Wear and ovalization of the links Too much play between the links Oxidization check Wear and ovalization of the chain tensioner Wear of the chain hinge gudgeon

c h

b G

Fig. 1

f d

Fig. 3

Fig. 2

If the chains do not seem to be worn or stretched, replace them anyway every 3 years (6000 hours) in case of normal operation conditions. Replace them every 2 years (4000 hours) in case of operation in cold room or in corrosive environments. (5)

top up whenever the electrolyte level decreases to 5-10 mm with respect to the plate unit

(6)

keep the battery clean and dry by using, if possible, antistatic clothes

the forks must not have cracks in the structure and especially in the welded joints (ref.A fig.4). If there are visible cracks, replace the fork. Do not carry out repairs by welding the fork; (7)

measure the bead thickness (ref.B fig.4). If the the thickness is lower than 90% of the vertical bracket thickness (ref.C fig.4) replace the fork.

(8)

(9) during the installation on the carriage the fork ends must be aligned within 3% of the fork length (ref.D fig.4). Do not correct the alignment by modifying the bending or the connection between the carriage and the forks. The alignment can be improved by moving the forks along the sides of the carriage or by choosing forks of the same length;

in case of permanent deviation between the vertical bracket (ref.E fig.4) and the blade (ref.F fig.4), the maximum angle allowed is equal to 93 degrees. If the angle (ref.G fig.4) exceeds 93 degrees, the forks must be replaced.

(10)

ORDINARY MAINTENANCE

SERVICE

C A

E A

Fig. 4

SERVICE

ORDINARY MAINTENANCE

Code: 524301698

Revision: 1 (03/2010)