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Part N° 524259539

Technical information for Yale customer care centres

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

B845

MS10E

SERVICE

PREFACE

IMPORTANT This manual contains detailed information about the routine and preventive maintenance, troubleshooting, disassembly/assembly of components, adjustment procedures for the following Yale model: MS10E. These procedures require specific technical knowledge 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

NOTES:

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PREFACE

HOW TO USE THE MANUAL ENCLOSED MANUALS “MPB” control Reduction gears

Cod. 524181955 Cod. 272490600

SECTIONS This manual is divided into the following sections: Section 1: Section 2: Section 3: Section 4: Section 5: Section 6: Section 7: Section 8: Section 9:

Introduction Installation and settings Diagnostics Electric system Hydraulic system Frame mechanics Mast mechanics Reduction gear Braking system

Always refer to the index with the numbered black bands in order to go to the desired section.

WORDS AND SYMBOLS It indicates the presence of a danger that can cause accidents to people or damage to the truck. 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.

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SERVICE

PREFACE

GENERAL SAFETY STANDARDS PERSONAL SAFETY n

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.

If you use compressed air to clean the parts, wear glasses with lateral guards.

SAFETY IN THE WORKPLACE n

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.

Never use petrol, gas oil or other flammable liquids as detergents: use commercial non-toxic and non-flammable 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.

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n n n n n n n n n

PREFACE

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. 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 check the pressure of the plant use the proper devices.

BANDS, ROPES AND HANGING ROPES: SUGGESTIONS FOR THE USE n n n n n n n n n n n

Register all used hanging ropes, whose features and data are shown on the identification plate. 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: n Slings with 2 arms, consider them as the slings with 1 arm. n 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: n When the components are deformed, cut or when there are cracks, hollows, notches or abrasions on them. n When the wear of the components is higher than 10% of the initial dimensions. n When the sling is overloaded.

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SERVICE

PREFACE

Band capacity table

Colour

violet green yellow grey red brown blue orange orange orange orange orange orange

Working capacity (kg.)

Coefficient

1000

2000

1400

800

2000

4000

2800

1600

3000

6000

4200

2400

4000

8000

5600

3200

5000

10000

7000

4000

6000

12000

8400

4800

8000

16000

11200

6400

10000

20000

14000

8000

12000

24000

16800

9600

15000

30000

21000

12000

20000

40000

28000

16000

25000 30000

50000 60000

35000 42000

20000 24000

1.04

0.08

Rope capacity table

Colour

black violet black green yellow grey red brown blue orange

Working capacity (kg.)

Width (mm.) 35

500

1000

700

400

1000

2000

1400

800

1500

3000

2100

1200

2000

4000

2800

1600

3000

6000

4200

2400

120

4000

8000

5600

3200

150

5000

10000

7000

4000

180

6000

12000

8400

4800

240

8000 10000

16000 20000

11200 14000

6400 8000

1.04

0.08

300

Coefficient

Hanging rope capacity table

Colour

Working capacity (kg.)

violet green yellow grey red

Coefficient

1000

1400

2100

2000

2800

4200

3000

3800

6300

4000 5000

5600 6600

8400 9800

8400 10500

1.04

2.01

W orking ca pa city: the w orking ca pa city is ca lcula te d w ith a n a ngle of 90° in the ce ntre

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Hanging rope capacity table

Colour

Working capacity (kg.)

violet green yellow grey red

Coefficient

1000

1400

2100

2000

2800

4200

3000

3800

6300

4000 5000

5600 6600

8400 9800

8400 10500

1.04

2.01

W orking ca pa city: the working capacity is calculated with an angle of 90° in the centre

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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.

DRIVING TORQUE Nm

Nominal diameter

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° - XXX farehnheit degrees) 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.

Class 8

Class 10

5.02

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 Preloading N

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

= con lubrificante

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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 TORQUES ROTARY FEMALE CONNECTOR jic 37°

ROTARY METRIC FEMALE CONNECTOR Thread UNF

Driving torque Nm Outside diameter of Nominal torque min. / max. the pipe

Driving torque Nm Thread UNF

Dimension

Nominal torque

min. / max.

M 12x1.5

15 -25

7/16-20

-4

9 - 21

M 14x1.5

30 - 45

1/2-20

-5

13 - 27

38 - 52

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

1.3/16-12

-14

118

73 - 163

1.5/16-12

-16

140

90 - 190

1.5/8-12

-20

210

135 - 285

M 16x1.5

M 18x1.5

8 10 10

43 - 85

50 - 65

60 - 88

12 M 20x1.5 M 22x1.5

12 14 15

M 24x1.5

60 - 88

1.7/8-12

-24

290

200 - 380

M 26x1.5

105

85 - 125

2.1/2-12

-32

450

300 - 600

135

115 - 155

166

140 - 192

M 30x2

22 25

M 36x2

28 M 42x2

240

210 - 270

M 45x2

290

255 - 325

330

280 - 380

M 52x2

ROTARY FEMALE CONNECTOR ORFS ROTARY FEMALE CONNECTOR BSP Driving torque Nm Thread UNF

Nominal torque 20

G1/4

G3/8

Driving torque Nm Thread UNF

max. 15 - 25 27 - 41

Dimensions

Nominal torque

max.

9/16-18

-4

11/16-16

-6

13/16-16

-8

68 95

G1/2

42 - 76

1-14

-10

G5/8

44 - 94

1.3/16-12

-12

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 galvanized steel connectors. Different values correspond to connectors of different materials.

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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.

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INTRODUCTION

INTRODUCTION 1.00

PRESENTATION OF THE VARIOUS MODELS.....................................................................................................................2

2.00

IDENTIFICATION DATA AND RESIDUAL CAPACITY...................................................................................................................3

3.00

PLATE POSITIONING ......................................................................................................................................................................................4

4.00

STAMPING OF THE TRUCK SERIAL NUMBER............................................................................................................................5

5.00

CONFIGURATION .............................................................................................................................................................................6

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INTRODUCTION

1.00

PRESENTATION OF THE VARIOUS MODELS

VIEWS OF THE TRUCKS MS10E SIMPLEX

MS10E DUPLEX

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INTRODUCTION

IDENTIFICATION DATA AND RESIDUAL CAPACITY

IDENTIFICATION DATA PLATE

The identification plate provides the following data:

• • • • • • • • • •

Manufacturer’s trade name Model Serial number Weight without battery Year of manufacture Max battery weight Min battery weight Battery voltage Nominal capacity Persons on board

RESIDUAL CAPACITY PLATE

The residual capacity plate provides the following data:

• Model • Values of load which may be lifted to various heights up to the maximum height and with different distances between the centre of gravity of the load and the forks. Always refer to the carrying capacity plate to ensure that the load is lifted to the suitable height.

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INTRODUCTION

3.00

PLATE POSITIONING

MS10E simplex

MS10E duplex

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INTRODUCTION

STAMPING OF THE TRUCK SERIAL NUMBER

matricola carrello

serial number

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5.00

CONFIGURATION

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INTRODUCTION

GENERAL SPECIFICATIONS

MS10E

CHARACTERISTICS

Load centre

c (mm)

600

1.8

Load distance

x (mm)

1.9

Wheelbase

y (mm)

677 1225

2.1

Unladen weight (battery included)

745

2.2

Axle loading laden, front/rear

2.3

Axle loading unladen, front/rear

555 / 1190 515 / 230

3.1

Tyres: rubber, polyurethane, vulkollan, front/rear

3.2

Tyre size - front

3.3

Tyre size - back

3.4

Additional wheels (dimensions)

3.5

Number of wheels, front/rear (x = drive wheel)

3.6

Truck width - front

b 10 (mm)

3.7

Truck width - rear

b 11 (mm)

515 420

4.2

Hight of mast, lowered

h1 (mm)

see mast table

4.3

Free lift

h2 (mm)

see mast table

4.4

Lift height

h3 (mm)

see mast table

4.5

Height of the mast extended

h4 (mm)

see mast table

4.6

Outrigger lifting

h5 (mm)

see mast table

4.9

Height of the tiller arm in working position min/max

h14 (mm)

695 / 1196

OTHER POWER UNIT PERFORMANCE

DIMENSIONS

1.6

WHEELS AND TYREWHEIGHTS

Yale

1.1

Manufacturer

1.2

Model

1.3

Power: battery, diesel, LPG, electric mains

1.4

Operation: manual, pedestrian, stand on, seated

1.5

Load capacity

Battery pedestrian 1

Q (t)

(1)

polyurethane/ polyurethane

ø 230 x 75 ø 85 x 74,5 ø 150 x 50 1x + 1 / 2

4.15 Height of the forks lowered

h13 (mm)

4.19 Overall length

l1 (mm)

1892

4.20 Length to the front face of the forks

(2)

l2 (mm)

4.21 Overall width

b1/b2 (mm)

732 800

4.22 Fork dimensions

s/e/l (mm)

65 / 180 / 1160

4.24 Fork carriage width

b3 (mm)

675

4.25 Outside fork width

b5 (mm)

570

4.31 Ground clearance beneath mast, laden

m1 (mm)

4.32 Ground clearance, centre of wheelbase

m2 (mm)

4.33 Aisle width for pallets 1000x1200 wide

Ast (mm)

2242

4.34 Aisle width for pallets 1000x1200 long

Ast (mm)

4.35 Turning radius

Wa (mm)

2386 1528

(3) (3)

5.1

Travel speed laden/unladen

km/h

5,6 / 6

5.2

Lift speed, laden/unladen

m/s

0.1 / 0.2

5.3

Lowering speed laden/unladen

m/s

0.2 / 0.25

5.8

Max gradeability laden/unladen

8 / 10 electromagnetic

5.10 Service brake 6.1

Drive motor, rating S2 60 min.

2 24/150 180

6.2

Lift motor, rating S3 15%

6.3

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

6.4

Battery voltage/capacity (5 hour rate)

V/Ah

6.5

Battery weight

8.1

Drive control

8.4

Average noise level at the operator's ear

(1)

+ 37 mm simplex mast

(1)

- 37 mm simplex mast

(1) -

MS10E

Mosfet dB (A)

29 mm simplex mast

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INTRODUCTION

NOTES

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INSTALLATION AND SETTINGS

1.00

TRUCK ASSEMBLY..............................................................................................................................................2

2.00

W EIGHT TABLE......................................................................................................................................................4

2.01

UNLOADING FROM THE LORRY W ITH TRUCK ON THE PALLET.........................................................................4

3.00

TRUCK LIFTING MOD. SIMPLEX MAST........................................................................................................................5

3.01

TRUCK LIFTING MOD. DUPLEX MAST........................................................................................................5

4.00

CABLE CONNECTION TO THE BATTERY.......................................................................................................................6

4.01

BATTERY INSTALLATION...................................................................................................................................7

5.00

DELIVERY OF THE TRUCKS.............................................................................................................................9

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INSTALLATION AND SETTINGS 1.00

TRUCK ASSEMBLY

LIST OF THE MATERIALS RECEIVED BY THE DEALER TRUCK SUPPLIED WITHOUT BATTERY

Re f.

De scription

Lift truck

Battery charger plug

4 4

Battery plug Roller track for battery side extraction (on request)

Battery plug extension (for trucks with battery side extraction)

The materials received by the dealer can vary according to the presence or absence of optional equipment.

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INSTALLATION AND SETTINGS

TRUCK SUPPLIED WITH BATTERY

1 3

Re f.

De scription

Lift truck

Battery

3 4

Battery plug Roller track for battery side extraction (on request)

Can for the electrolyte level topping up in the batteries

Battery charger

Battery plug extension (for trucks with battery side extraction)

The materials received by the dealer can vary according to the presence or absence of optional equipment.

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INSTALLATION AND SETTINGS 2.00 WEIGHT TABLE WEIGHT VOLTAGE/BATTERY (without battery) CAPACITYA

M S10E

BATTERY WEIGHT

TOTAL WEIGHT

V/Ah

565

24/150

180

745

2.01 UNLOADING FROM THE LORRY WITH TRUCK ON THE PALLET Necessary special tool

lift truck with 3 t. carrying capacity

Procedure Position the truck forks under the pallet, lift it and place it in a safe area supplied with hoist with a carrying capacity of 3t and far from the transit of other motor vehicles and from the passage of pedestrians.

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INSTALLATION AND SETTINGS

TRUCK LIFTING MOD. SIMPLEX MAST

Necessary special tools

hoist with 3000 kg carrying capacity

lifting band with 3000 Kg carrying capacity

Procedure Remove the packing. Insert the lifting band into the hole located on the mast crosspiece. Hook the band to the hoist.

Fig. 1

Make sure the hoist is perpendicular to the truck to be lifted. Lift slowly and position the truck on the floor with care. Fig. 2

3.01

TRUCK LIFTING MOD. DUPLEX MAST

Necessary special tools

hoist with 3000 kg carrying capacity

lifting band with 3000 Kg carrying capacity

Procedure

Fig. 1

Remove the packing. Insert the lifting band into the hole located on the mast crosspiece. Hook the band to the hoist.

Make sure the hoist is perpendicular to the truck to be lifted. Lift slowly and position the truck on the floor with care. Fig. 2

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INSTALLATION AND SETTINGS 4.00

CABLE CONNECTION TO THE BATTERY

The battery poles are marked with a red colour or with the symbol “+” to identify the positive pole, and with a blue colour or with the symbol “-” to identify the negative pole. The battery plug cables are marked as well: the first one with a red clamp for the connection to the positive pole and the second one with a blue clamp for the connection to the negative pole. After connecting the cable terminals to the battery poles, lubricate with some vaseline grease to prevent oxidation. Before assembling the battery on the truck recharge it by means of a suitable charger.

RED clamp for cable connection to the positive pole

BLUE clamp for cable connection to the negative pole

Negative pole BLUE

Positive pole RED

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INSTALLATION AND SETTINGS

BATTERY INSTALLATION

Necessary special tools

hoist with 1000 kg carrying capacity

lifting rope with two arms carrying capacity 1400 kg

lever

Necessary tools

A large slotted screwdriver

17 mm socket wrench

ratchet

17 mm open ended spanner

Procedure Before starting to work wear the proper accident prevention clothes. Park the truck in a safe area, far from the transit of other motor vehicles and from the passage of pedestrians.

Fig. 1

Step 1 SLOTTED SCREWDRIVER Loosen the screws fastening the motor bonnet. Remove the bonnet (ref.A fig.1). Open the upper bonnet of the battery compartment (ref.B fig.1). Step 2 SOCKET WRENCH - RATCHET - OPEN ENDED SPANNER By means of the socket wrench, the ratchet and the open ended spanner, remove the battery retainer (ref.C fig.2).

Fig. 2

Step 3 HOIST - LIFTING ROPE WITH TWO ARMS - LEVER Hook the hanging rope with two arms to the hoist. Fasten the two hooks of the hanging rope to the two battery side holes suitable for lifting. Make sure the hoist is perpendicular to the battery. Lift the battery, position it over the battery compartment and insert it with care by keeping it as close as possible to the left side (tiller side) (fig.3). Release the hooks of the lifting rope from the battery, move the hoist and by means of the lever push the battery against the left side (tiller side). Fig. 3

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INSTALLATION AND SETTINGS Step 4 SOCKET WRENCH - RATCHET - OPEN ENDED SPANNER Assemble the battery retainer (ref.D fig.4). Step 5 SLOTTED SCREWDRIVER Connect the battery plug cables supplied to the positive and negative pole of the battery (see “CABLE CONNECTION TO THE BATTERY” on page 6). Connect the battery plug (ref.E fig.5) and lower the bonnet over the battery compartment. Reassemble the motor compartment bonnet.

D Fig. 4

Fig. 5

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INSTALLATION AND SETTINGS

DELIVERY OF THE TRUCKS MOD. ALL MODELS

Before delivering the truck, the battery on the control (COMBI and/or MPB) must be set. Before carrying out this operation, we recommend charging the battery so that it can be used at the maximum voltage. SETTING PROCEDURE A) When the truck is off, remove the MDI connector (if any) from the control and connect the console adapter on the same connector (B) of control MPB. Turn on the truck and select “CONFIG MENU ADJUSTMENT “ and then parameter “ADJUST BATTERY”. B) Lower the tiller to disable the main remote control switch and by using the “MULTIMETER” detect the battery voltage on the control by positioning the multimeter prods on the battery cable clamps (B+ - B-). Set the value detected on the “MULTIMETER” (example 25,2V) on the console on parameter “ADJUST BATTERY”. Turn off the key and turn it on to store the value. To check if the value of the voltage has been stored, select “MAIN MENU’ TESTER” and then parameter “BATTERY VOLTAGE”, if the value does not correspond, repeat the procedure above-described. NOTE: If the battery is not completely charged, the battery indicator (MDI) does not reset showing the actual charge value, until the battery is completely recharged.

B+ B-

C/B

MULTIMETER

ADAPTER

CONSOLE

Fig. 7

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INSTALLATION AND SETTINGS

NOTES:

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ELECTRIC SYSTEM 1.00

WIRING DIAGRAM KEYS TO SYMBOL MOD. MS10E...........................................................................................................................2

2.00

ELECTRIC COMPONENTS MOD. MS10E...............................................................................................................................4

2.01

REFERENCE TABLE FOR THE COMPONENTS OF THE TILLER BOX MOD. MS10E....................................................................5

2.02

ELECTRIC COMPONENTS OF THE TILLER BOX MOD. MS10E..................................................................................6

2.03

REFERENCE TABLE FOR THE ELECTRONIC COMPONENTS OF THE TILLER BOX MOD. MS10E......................................6

2.04

ELECTRIC COMPONENTS OF THE TILLER BOARD MOD. MS10E...........................................................................................7

2.05

REFERENCE TABLE FOR THE ELECTRIC COMPONENTS OF THE TILLER BOARD MOD. MS10E.......................................7

2.06

CONNECTION OF THE POWER CABLES TO THE “MPB” CONTROL MOD. MS10E................................................8

2.07

ON BOARD BATTERY CHARGER CONNECTION MOD MS10E.........................................................................................9

3.00

START SEQUENCE FOR DRIVE LIFTING AND LOW ERING MOD. MS10E.......................................................10

3.01

REFERENCE TABLE FOR THE PARAMETERS OF MPB CONTROL “MPB” MOD. MS10E..........................................................11

4.00

DISASSEMBLY OF THE TILLER CONTROL BOX MOD. MS10E..........................................................................12

4.01

DISASSEMBLY OF THE TILLER BOX BOARD............................................................................................................12

4.02

DRIVE POTENTIOMETER ACQUISITION MOD. MS10E....................................................................................13

5.00

PROCEDURE FOR THE “MPB” CONTROL REPLACEMENT MOD. MS10E.....................................................................................14

5.01

DATA TRANSFER TO THE CONTROL MOD. MS10E......................................................................................................16

6.00

PROCEDURE TO REPLACE THE BATTERY CHARGER....................................................................................................17

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1.00 WIRING DIAGRAM KEYS TO SYMBOLS MOD. MS10E

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Ref.

Description of the component function

AC MAINS S E T1 FU1 FU2 PM MTR P1 P2 P3 P4 P5 BELLY SWITCH TILLER SENSOR PILOT LAMP KEY SWITCH EV1 HORN EMB M.D.I.

On board charger Plug connecting the system to the battery Emergency push button Main remote control switch 175A fuse of power line 5A fuse of auxiliary line 2000 W pump motor 1000 W drive motor ON-OFF push button for the quick fork lifting ON-OFF push button for the quick lowering Push button for "SNAIL" control inching with tiller in upright position ON-OFF push button for the fork slow lifting ON-OFF push button for the fork slow lowering Push button for the emergency reverse Tiller sensor Lamp signalling the turning on of the truck Key switch ON-OFF controlled lowering solenoid valve Horn Electromagnetic brake Diagnostic display, signal for the battery charge/discharge (Options)

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ELECTRIC SYSTEM WIRING DIAGRAM MOD. MS10E +

6 7

0 7

% , 7

0 , 7

7 7

,% 7

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4544

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1 ' "

, 2 *

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ELECTRIC SYSTEM SHEATH CONNECTION DIAGRAM MOD. MS10E

OPTIONS

M.D.I.

HORN AUXILIARY UPDATE

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2.00 ELECTRIC COMPONENTS MOD. MS10E

2 10

11 12 1

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2.01 REFERENCE TABLE FOR COMPONENTS OF THE TILLER BOX MOD. MS10E The following table contains the description of the functions of the components shown in the following page. Symbol description Ref. Wiring diagram ref. Description of the component

Reference for the component on the exploded view Reference for the component on the wiring diagram Description of the component function

8 9 10 11

Diagram Description of the component reference MTR 2.00Kw drive motor PM 2.00Kw pump motor MPB Drive electronic control AC MAINS 15A on board battery charger TILLER Control tiller box CONTROL BOX HORN Horn EMERGENCY Immediate stop PUSH BUTTON PILOT LAMP Pilot lamp KEY SWITCH Key switch EV1 Fork lowering solenoid valve EMB Electromagnetic brake

TILLER SENSOR Tiller sensor

Ref. 1 2 3 4 5 6 7

NOTE: All Yale codes are contained in the spar part list.

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2.02 ELECTRIC COMPONENTS OF THE TILLER BOX MOD. MS10E 2

Fig. 29

5 LOWER BOX BODY

Fig. 30

UPPER BOX BODY

TILLER BOARD

Fig. 31

2.03 REFERENCE TABLE FOR THE ELECTRIC COMPONENTS OF THE TILLER BOX MOD. MS10E Re f. 1 2 3 4 5 6 7 8 9 10

Dia gra m re fe re nce TILLER CONTROL BOX SPEED CONTROL HORN PUSHBUTTON P1 P2 P4 P5 BELLY SW ITCH P3 ELECTRONIC TILLER BOARD

De scription of the com pone nt Complete control tiller box Speed control Horn push button Push button for the quick lifting of the forks Push button for the quick lowering of the forks Push button for the slow lifting of the forks Push button for the slow lowering of the forks Push button for the quick reverse Push button for travel with tiller in upright position Electronic tiller board

NOTE: All Yale spare parts are contained in the spare part list.

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2.04 ELECTRIC COMPONENTS OF THE TILLER BOARD MOD. MS10E 1

5 6

15 14 13

12 11 10 16 8 9

2.05 REFERENCE TABLE FOR THE ELECTRIC COMPONENTS OF THE TILLER BOARD MOD. ALL MODELS Ref. 1 2 3 4 5 6 7 8 9

Diagram ref. Description of the component ELECTRONIC TILLER Tiller box electronic board BOARD POT1 Potentiometer for the inductive speed Eprom BELLY SWITCH Quick reverse microswitch O - CONTROL Forward/reverse speed microswitch HORN PUSHBUTTON Horn microswitch P3 Microswitch enabling the travel with tiller in upright position Connector for the connection between serial cable and control Connector for the connection of the cable of the sensor enabling the tiller Connector for the connection of the push button for the fork quick lifting

Connector for the connection of the push button for the fork quick lowering Connector for the connection of the push button for the slow fork lifting Connector for the connection of the push button for the slow forl lowering Connector of the push button for other hydraulic functions Connector of the push button for other hydraulic functions Jumper to be used for the potentiometer programming

11 12 13 14 15 16

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2.06

CONNECTION OF THE POWER CABLES TO THE “MPB” CONTROL MOD. MS10E

2 B-

B+

5 6

ATTENTION THE REVERSAL OF THE CABLES CAUSES IRREPARABLE DAMAGES. WE RECOMMEND RESPECTING THE CONNECTIONS DESCRIBED IN THIS PAGE.

Re f. 1 2 3 3 4 5 6 7

No. Ca ble 5 4 7 11 6 8 9 10

Page: 8

Ba tte ry te rm ina l

Ma in sw itch B+

B-

Control te rm ina l Fuse - B+ Negative - BFuse - B+ Fuse - B+ Negative - T Connector - F1 Connector - F2 Negative - P

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Drive m otor te rm ina l

Pum p m otor te rm ina l

Terminal A1 Red terminal Terminal A2 Terminal F1 Terminal F2 Blue terminal

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2.07 ON BOARD BATTERY CHARGER CONNECTION MOD. MS10E

1 B+

2 B-

WARNING While connecting the supply cables, follow the description of the table enclosed

Ref.

Cable

1 2 3 4 5

Red Black

Loading charge

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Terminal Connect to MPB control terminal 1 "B+" Connect to MPB control terminal 2 "B-" Shuko outlet for shuko plug Microswitch enabling the travel when the plug is plugged in Trimmer selecting the voltage of the alternated current Red led showing the beginning of the charge Yellow led showing the intermediate charge Green led showing that the battery is charged Shuko plug for 220 V supply to the battery charge Alternative plug for the UK market

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3.00 START SEQUENCE FOR DRIVE, LIFTING AND LOWERING MOD. MS10E Before starting the truck, follow the instructions below:

1) By keeping the tiller at rest, activate the main switch by moving upwards the red push button “A”.

A C

2) Turn the key switch “B” to position 1 (ON).

3) The lamp “C” showing that the truck is on lights up. Fig. 1

2 4) Move the tiller downward to working position disabling the tiller sensor “D”.

FORWARD

5) Enable the speed controls in the desired direction (forward or backward) “E”

LIFTING AND LOWERING

The lifting and the lowering of the forks, after turning on the key, can be enabled with the tiller in every position.

BACKWARD

A) For a quick lifting press the right internal push button (1) B) For a quick lowering press the right external push button (2) C) For a slow lifting press the left internal push button (3)

Fig. 2

D) For a slow lowering press the left external push button (4)

TILLER

SENSOR

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3.01 REFERENCE TABLE FOR THE PARAMETERS OF “MPB” CONTROL MOD. MS10E

SET OPTIONS

BATTERY CHECK HOUR COUNTER AUX FUNCTION 2 LIFTING BLOCK QUICK INVERSION AUX FUNCTION 1 CHECK UP DONE CHECK UP ENABLE DRIVES MODE BRAKE IN RELEASE

ADJUSTMENT

PARAMETER "MPB 150+150"

CONFIG MENU'

To display the different programming menu through the console (Handset) use the procedure contained in the Service Manual “MPB” P/ N 1533761. The control adjusting parameters for each models are contained in the table below. We suggest always respecting the adjusting values set by the manufacturer in order to obtain an optimum compromise between performance and component “life”.

ADJUST BATTERY MIN VALVE VOLT MAX VALVE VOLT AUX VOLTARE # 1 ADJUSTMENT 1 ADJUSTMENT 2 THROTTLE 0 ZONE THROTTLE X POINT THROTTLE Y POINT

NOTES:

LEVEL ON RUNNING ABSENT ABSENT BELLY OFF OFF OFF OFF ON

25.5 (Volt Battria) 16 186 143 5 5 0 5 5

P1.6

LEVEL P1.8

P2.0-P2.0L

5 5 6 6 7 9 5 9 9 2 5 9 9 5 8 9 5 5 9 9 5 5 5 5

5 5 6 6 7 9 5 9 9 6 5 9 5 5 9 8 5 5 9 9 5 5 5 5

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PARAMETER CHARGE

"MAIN MENU' "

PARAMETER "MPB 150+150A" ACCELERATION DELAY FLD ACCELERATION DECELERATION DELAY RELEASE BRAKING INVERS. BRAKING CUTBACK SPEED 1 SOFT W ORKING LEVEL MAX SPEED FORW . MAX SPEED BACK CREEP SPEED EMB INSERTION DELAY TRACTION IMAX ARMA NOM CURR W EAK DROPOUT FIELD NOM CURRENT FIELD CURR. MAX PU ACC. DELAY PU DECELERATION DELAY 1ST SPEED COARSE FORK LIFT SPEED PUMP CREEP EVP ACC. DELAY EVP DEC. DELAY LIFT MAX TIME

3 4

5 6

OFF KEYON PRESENT PRESENT TIMER ON ON ON ON OFF

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ELECTRIC SYSTEM

4.00

DISASSEMBLY OF THE TILLER CONTROL BOX MOD. MS10E

When one of the function such as forward/reverse, horn does not work, the complete board must be replaced. The procedure to replace the board is described below. Necessary standard tools

2.5-5mm Allen wrench

Fig. 1

Fig. 2

4.01

DISASSEMBLY OF THE TILLER BOX BOARD

Step 1 5mm ALLEN WRENCH Loosen the 3 bolts fastening the upper box body (ref. A fig. 1). Lift the upper box body and separate it from the lower box body (ref. B fig. 2). Disconnect the connector of the serial cable and position the cover on a clean workbench. Step 2 2.5mm ALLEN WRENCH Loosen the fastening screw (right or left) of the speed control (ref. C fig. 3), extract the speed control from the pin (ref. D fig. 4), remove the other control complete with guide pin (ref. E fig. 4).

Fig. 3

Extract the board from its seat, disconnect the connectors of the various control microswitches, (NOTE: before disconnecting the connectors mark their position to make the connection on the new board easier), replace it (Fig. 5). Fig. 4 Reassemble the new board by carrying out the procedure in the reverse order. Pay attention to insert the board into the proper seat. This allows keeping the potentiometer centered and making the assembly of the various components easier. After the assembly of the board, carry out the procedure for the drive potentiometer acquisition (see on page 13).

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4.02 DRIVE POTENTIOMETER ACQUISITION MOD. MS10E When must this procedure be followed? • When the tiller box board must be replaced • When the proportional push buttons for the lifting and lowering must be replaced (when they are installed)

PROCEDURE Step 1 Move the jumper from position “A” (fig. 1) to position“B” (fig. 3). During the acquisition procedure the jumper must be inserted in the external pins of the board. Step 2 Turn on the truck (Key ON): the CONTROLLER is in acquisition mode. Step 3 Rotate slowly the speed control forward up to its end of stroke and then release it slowly by letting it come back to the centre. Rotate slowly the speed control backward up to its end of stroke and release it slowly by letting it come back to the centre. Step 4 Remove the JUMPER from position “B” and iinsert it into position “A” (travel condition). Turn off the truck (Key OFF). Wait 30 seconds before restarting the truck (Key ON). The controls has now acquired the potentiometer new values. Close the tiller box and carry out the test by moving the truck. If the acquisition is not successful, repeat the procedure.

NOTE: A new acquisition is required when “ALARM 78” (Vacc not ok) is activated. Refer to the table for failure search on page ........of the electric system section. Fig. 1

B Fig. 2

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5.00

PROCEDURE FOR THE “MPB” CONTROL REPLACEMENT MOD. MS10E

Necessary standard tools

large slotted screwdriver (2x12mm)

10-13mm articulated socket wrench

Console

control console adapter

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground, turn the key OFF and disconnect the battery. Before disassembling the control load on the main menu “SAVE PARAMETER” console storage the configuration data and the related parameters by carrying out the procedure described below. Then transfer the data on the new control.

MPB-EU NA V 1.27 DISPLAY 24V 180A 00058

KEYBOARD MAIN MENU PARAM. CHARGE

MAIN MENU SAVE PARAMETER

SELECT: Mod. 00 FREE

SELECT: Mod. 01 MPB-EU NA

RENDING... ACCEL. DELAY (ECC)

Heading

Press ENTER to display the main menu

The first entry of the list is displayed

Scroll the list by using the ROLL UP or ROLL DOWN key, select SAVE PARAM.

The entry selected is displayed (SAVE PARAM.)

Press ENTER to display function SAVE.

The code of the selected model is displayed in the upper line. FREE is displayed in the lower line if the module box is free, otherwise the name of the model is displayed.

By means of the ROLL UP and ROLL DOWN keys the model code can be selected

The new code selected and the related conditions (FREE / “Name of the model”) are displayed.

10)

Press ENTER to cofirm the reading.

11)

The entries of the parameters stored are displayed on the second line.

12)

At the end of the procedure SAVE PARAM is displayed again.

MAIN MENU

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Step 1 SLOTTED SCREWDRIVER Loosen and remove the screws fastening the motor compartment bonnet, remove the bonnet. Step 2 13mm ARTICULATED SOCKET WRENCH After removing the protections loosen and remove the bolts fastening the power cables to the control (ref. A fig. 2), extract the connector (ref. B fig. 2) supplying the motor fields and the auxiliary supply connectors (ref. C fig. 2), remove all the cables from the control. Step 3 10mm ARTICULATED “T” SOCKET WRENCH Loosen and remove the nuts fastening the control to the chassis (ref. D fig. 2), remove the control and replace it. Reassemble the new control by carrying out the procedure in the reverse order

Fig. 1

WITH WARNING LAMP ON THE DASHBOARD When turning on the truck the working hours stored on the control recovered are lost; therefore the count starts from 0 hours. WITH “MDI” TOOL The working hours of the control recovered can be loaded automatically on the new control. For the storage carry out the procedure described below. After the replacement of the control the working hours stored are different from the ones of the MDI since the new control has “0” hours whereas the MDI has stored the hours of the old control. When the truck is started 60sec All. 94 is displayed on MDI and the drive is blocked. The MDI warns the operator that the working hours stored will be deleted. To avoid the deletion carry out the procedure to transfer the data.

Fig. 2

PROCEDURE TO TRANSFER THE WORKING HOURS FROM “MDI” TO “MPB”. When the truck is off, before connecting the MDI to the control connect the console complete with adapter, turn on the truck and enter menu “CONFIG MENU’ SET OPTIONS”, select paragraph “AUX FUNCTION 1 ”and set “ON” (OFF is generally set), confirm the datum and turn off the truck. Remove the console, connect the MDI and start again. The working hours stored on MDI are overwritten on the control. After overwriting the working hours parameter “AUX FUNCTION 1” turn to “OFF” automatically.

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5.01 DATA TRANSFER TO THE CONTROL MOD. MS10E After connecting the control carry out the transfer of the data saved previously by using the console in the function “RESTORE PARAMETER” by carrying out the procedure described below.

MPB-EU NA V 1.27 24V 180A 00058

DISPLAY KEYBOARD

MAIN MENU PARAM. CHARGE

MAIN MENU RESTORE PARAMETER

SELECT: Mod. 01 MPB

Heading.

Press ENTER to display the main menu.

The first entry of the list is displayed.

4) 5)

Scroll the list by using the ROLL UP or ROLL DOWN keys, selezionare RESTORE PARAM. The entry selected is displayed (RESTORE PARAM.)

Press ENTER to display the function RESTORE PARAM.

The code of the model selected is displayed.

Press ENTER to confirm the loading procedure.

ARE YOU SURE?

STORING ACCEL. DELAY (ECC.)

MAIN MENU

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The request to confirm the procedure is displayed ENTER = YES, OUT = NO. 10) Press ENTER to confirm the loading procedure (OUT to cancel). 11) The list of the parameters is displayed during the loading. 12) At the end of the procedure the name of the submenu is displayed.

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ELECTRIC SYSTEM

PROCEDURE TO REPLACE THE BATTERY CHARGER

Necessary standard tools

large slotted screwdriver

10mm articulated 13mm open ended socket wrench wrench

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground, turn the key OFF and disconnect the battery. Fig. 1 Step 1 LARGE SCREWDRIVER Loosen and remove the screws fastening the motor compartment bonnet, remove the bonnet to reach the motor compartment. Step 2 13mm OPEN ENDED WRENCH Remove the rubber protections of the terminal connecting the negative pole on the control coming from the battery (ref. A fig. 2). By using the spanner loosen the fixing screw of the positive pole of the battery charger connected to the main switch (red push button) (ref. B fig. 2). Disconnect the supply plug from the drive enabling outlet (ref. C fig. 2)

B A

Step 3 10mm “T” ARTICULATED SOCKET WRENCH Loosen and remove the nuts fastening the battery charger to the control support (ref. D fig. 3). Remove the battery charger and replace it.

Fig. 2

Fig. 3

Reassemble the battery charger by carrying out the procedure in the reverse order. After the assembly no ajustment is required.

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ELECTRIC SYSTEM DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE, PAGE 1/3 MODEL ALL MODELS

MDI

Alarms Codes

Console Display Alarms Description

AL01

EVP NOT OK

AL02

BRAKE DRIVER KO

AL03

V FIELD NOT OK

AL04

PUMP VACC NOT OK

AL06

SERIAL ERROR #1

Alarms Description

Possible Causes

Solutions

a) No power on control circuit cables a) Check and, if necessary, renew the 10A fuse b) Proportional valve open at rest b) Renew proportional valve The alarm is generated by the failed operation of c) Valve short-circuiting c) Renew proportional valve the proportional lowering valve d) Power cable connection incorrect d) Connect cables correctly e) Renew controller e) Controller driver faulty a) No power on control circuit cables a) Check and, if necessary, renew the 10A fuse b) Electromagnetic brake driver on controller faulty b) Renew controller This alarm occurs in the presence of problems on c) Driver faulty, incapable of driving the electromagnetic brake c) Renew controller the electromagnetic brake driver d) No power on electromagnetic brake coil d) Check cable connections e) Renew electromagnetic brake e) Electromagnetic brake coil short circuiting a) Traction motor ground fault due to carbon powder from a) Clean and blow with compressed air to remove dust b) Traction motor short circuit b) Renew motor Alarm generated by traction fault c) Incorrect cable connections from motor to controller c) Remake connections as per the electrical schematic d) Renew controller d) Field driver controller section fault a) Reconnect the interrupted cable a) Interrupted potentiometer connection cable This alarm appears when the potentiometer b) Faulty potentiometer c) Renew potentiometer button value is out of calibration or faulty c) Potentiometer incorrect programming d) Reprogram correctly (the same fault also gives rise to alarm AL78) d) After turning on the truck with the ON/OFF buttons, pressing e) Release the button, the alarm will be cleared and all the the fast lowering button truck functions will be restored This alarm is caused by a communication error a) Main contactor control contacts not closing a) Renew the main contactor between the MDI and the controller b) Bad contacts on the controller to MDI connector c) Renew connection cable a) Controller/Tiller serial cable interrupted

AL07

SERIAL ERROR #2

a) Renew the serial cable

b) The controller fails to respond to signals transmitted from the b) Renew controller This alarm is caused by a communication error tiller between the controller and the tiller box c) Tiller board faulty c) Renew tiller board d) Main contactor control contacts not closing

AL08

WATCHDOG

AL13

EEPROM KO

AL30

FORW + BACK

AL32

VMN NOT OK

d) Renew the main contactor

This alarm is generated because the watchdog a) Watchdog hardware circuit not OK circuit has tripped b) Software not OK Alarm appears in the presence of an EEPROM a) Loss of saved parameters memory error a) Incorrect wiring Alarm appears when the forward and reverse b) Travel microswitch sticking travel commands are active simultaneously c) Incorrect operator manoeuvre a) Traction motor ground fault due to carbon powder from brushes Alarm appears when motor field voltage falls b) Traction motor short circuit below battery value c) Incorrect cable connections from motor to controller d) Field driver controller section fault

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a) Renew controller b) Renew controller a) Switch the truck off and then on again; if the alarm persists renew the controller a) Wire correctly in accordance with the electrical schematic b) Renew Tiller board c) Perform correct travel requires procedure a) Clean and blow with compressed air to remove dust b) Renew motor c) Remake connections as per the electrical schematic d) Renew controller

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DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE, PAGE 2/3 MODEL ALL MODELS

MDI Alarms Codes

Console Display Alarms Description

Alarms Description

AL37

CONTACTOR CLOSED

The alarm appears before closing of the main contactor

a) Contactor contact sticking b) Power unit fault

a) Renew the main contactor b) Renew controller

AL49

I = 0 EVER

Alarm appears when traction current is always lower than a given threshold value

a) Faulty controller current sensor

a) Renew controller

c) Logic feedback circuits fault

c) Renew controller

AL53

STBY I HIGH

Alarm appears during diagnosis in rest conditions a) Faulty controller sensor if current is above a certain threshold c) Logic feedback circuits fault

a) Renew controller

AL57

HIGH FIELD CURRENT

AL58

NO FIELD CURRENT

AL60

CAPACITOR CHARGE

AL66

BATTERY LOW

AL67

THER. PROTECTION

AL68

CHARGING BATTERY

AL73

POWER FAILURE #1

AL74

DRIVER SHORTED

AL75

CONTACTOR DRIVER

Possible Causes

Solutions

a) Renew controller

a) Motor field short circuit a) Renew motor c) Current transducer fault b) Renew controller c) Power unit fault b) Renew controller This alarm appears in the presence of a field a) Controller current sensor fault a) Renew controller b) Field power unit fault b) Renew controller current anomaly a) Main contactor fault a) Renew the main contactor The alarm is signalled if the capacitors have not b) Brushes cable shorting against motor casing b) Change brushes and clean motor with compressed air started charging 500 ms after KEY-ON c) Logic unit fault b) Renew controller a) Charge the battery a) If the alarm appears with a flat battery b) If the alarm appears with a charged battery b) Perform the battery power configuration procedure on the BATTERY ADJUSTMENT CALIBRATION: With the truck switched off connect the programming console to the controller on This alarm appears when the battery is at 20% the MDI connector. Switch on the truck and select "Config Menu ADJUSTMENT" followed by "ADJUST BATTERY". Lower the with lift function inhibit; when the lift button is tiller and close the main contactor. Using a multimeter check battery voltage directly on the controller across terminals B+ and pressed the horn sounds three times signalling B-. Program the value read on the Multimeter on the console in the "ADJUST BATTERY" parameter. Switch the truck off and that the battery power is low then on again to save the data. WARNING: To check the voltage value you have just saved, select "Main Menu TESTER" on the console, followed by the parameter "BATTERY VOLTAGE". If the value does not correspond, repeat the procedure described above. This alarm appears in the presence of a field current anomaly

This alarm appears when the controller temperature exceeds 80°C

a) Renew controller

a) Controller thermal sensor driver fault

This alarm is generated at key-on: if the controller detects a signal of 21,3V after closing the a) This fault must be sought on the battery contactor, it inhibits operation of the truck

a) Check that all the battery elements are in good condition; if you find damaged elements or if the battery is sulphated (i.e. as been standing for a long time without being charged or used), it must be renewed

a) ON/OFF solenoid valve short-circuiting This alarm appears in the presence of short b) Main contactor coil short-circuiting circuits on components external to the controller c) Electromagnetic brake coil short-circuiting This alarm appears with the main contactor open a) Controller driver short-circuited and it checks that the contactor driver is not short- b) Contactor coil wiring error circuited. c) Fault in contactor coil voltage feedback circuit This alarm appears with the main contactor a) Contactor coil driver open closed and it checks that the contactor driver is b) Fault in contactor coil voltage feedback circuit

a) Renew solenoid valve b) Renew main contactor c) Renew electromagnetic brake a) Renew controller b) Wire correctly in accordance with the electrical schematic c) Renew controller a) Renew controller b) Renew controller

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ELECTRIC SYSTEM

DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE, PAGE 3/3 MODEL ALL MODELS MDI Alarms Codes

Console Display Alarms Description

Alarms Description

Possible Causes

Solutions

a) Potentiometer incorrect connection b) Faulty potentiometer c) Potentiometer incorrect programming

AL78

AL79

VACC NOT OK

ICORRECT START

b) Restore connection as per electrical schematic c) Renew potentiometer d) Reprogram correctly

PROGRAMMING: With the truck switched off, shift the jumper from "A" to "B". Switch on the truck and slowly turn the butterfly control in the forward travel direction This alarm appears in the presence of a fault on as far as it will go then release it gradually so that it returns to its rest position; perform the accelerator inductive potentiometer. the same operation for the reverse travel direction. Perform the signal acquisition procedure for the potentiometric pushbuttons, if present. Slowly press the lifting pushbutton fully down and release it gradually; repeat the same operation for the lowering pushbutton. Move the jumper from "B" to "A". Switch off the truck and then switch it on again after 30 seconds. This alarm is generated by an incorrect traction start sequence.

a) When the truck is switched on the controller detects a command on the tiller board

a) Renew the tiller board

b) Incorrect start sequence

b) Release the butterfly control; the alarm disappears; perform the start sequence correctly

After replacing the controller the duty hours in the memory of the MDI and COMBI are in conflict; when the truck is switched on the MDI will display AL 94 for sixty seconds (with traction inhibit); this alarm message warns the operator of the imminent erasure of the hour meter memory. To prevent this from happening the data transfer procedure must be executed.

This alarm is generated when the Display (MDI) or Combi controller are renewed. It signals incongruence between the hours memorised on PROCEDURE: with the truck switched off, before connecting the MDI to the Combi controller, connect the console; now switch on the truck the display and the hours stored in the Combi and enter the "CONFIG MENU SET OPTIONS" menu, select the option "AUX FUNCTION 1" and select ON (default is OFF), confirm the controller. new setting and then switch off the truck. Remove the console connector, connect the MDI, and then switch on again; at this point the hour

AL94

meter count of the previous system will be saved on the newly installed controller.

AL98

IMPUT ERROR 2

This alarm is generated when the rapid inversion a) Rapid inversion input not present on controller function (belly switch) is not functioning. b) If the problem persists

AL99

IMPUT ERROR 1

This alarm is generated when the rapid inversion a) Rapid inversion input not present on tiller board function (belly switch) is not functioning.

ORE 250

CHECK UP ENABLE

a) Renew controller b) Check connection of the serial cable a) Renew the tiller board

PROCEDURE: with the truck switched off disconnect the MDI connector from the controller and connect the console in its place. Switch on the truck, enter "CONFIG MENU SET OPTIONS", select the option "CHECK UP ENABLE" and set "ON" This alarm is generated when 250 operating (default is "OFF"). In this condition the display of the maintenance request occurs automatically by flashing of the wrench hours have been reached; it informs the user that symbol every 250 hours of duty (the 250 maintenance time interval is fixed and cannot be altered). After performing the service a "maintenance service" (when programmed) is work the maintenance hour meter must be reset. Again in Config Menu "Set Options" select the option "CHECK UP DONE" needed. and set to "ON". When you switch the truck off and then on again the function will have automatically reset to "OFF" (consult Service Manual P/N 2795674). Display situation when the truck is switched on. Also the EEPROM version installed on the truck is displayed for a few seconds.. This symbol indicates activation of the travel speed cut-back function.

A flashing hourglass means that the hour meter is running.

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FRAME MECHANICS

1.00

MECHANICAL COMPONENTS OF THE FRAME ..........................................................................................................2

2.00

REMOVAL

3.00

REMOVAL AND REPLACEMENT OF THE PIVOTING W HEEL UNIT ............................................ 4

3.01

REMOVAL AND REPLACEMENT OF THE PIVOTING WHEEL.................................................................. 5

4.00

REMOVAL AND REPLACEMENT OF THE LOAD ROLLERS

5.00

REMOVAL AND REPLACEMENT OF THE DRIVE MOTOR MOD. MS10E.............................................7

5.01

COMPONENTS OF THE 800W DRIVE MOTOR MOD. MS10E.........................................................................................8

5.02

REFERENCE TABLE FOR THE 800W DRIVE MOTOR MOD. MS10E................................................................9

5.03

REMOVAL AND REPLACEMETN OF THE MOTOR BEARINGS MOD. MS10E..................................................10

5.04

REMOVAL AND REPLACEMENT OF THE LOWER FLANGE OIL SEAL BEARING...........................................................................10

5.05

REMOVAL AND REPLACEMENT OF THE FAN...................................................................................11

5.06 5.07

REMOVAL AND REPLACEMENT OF THE UPPER FLANGE BEARING..................................................11 REMOVAL AND REPLACEMENT OF THE DRIVE MOTOR BRUSHES MOD. MS10E.....................................................12

6.00

REMOVAL AND REPLACEMENT OF THE HYDRAULIC POWER UNIT MOD. MS10E...................................................................13

6.01

REMOVAL AND REPLACEMENT OF THE PUMP MOD. MS10E......................................................................14

6.02

REMOVAL AND REPLACEMENT OF THE PUMO MOTOR BRUSHES MOD. MS10E..........................................15

6.03

DRIVING TORQUES OF THE BOLTS AND NUTS OF THE HYDRAULIC POW ER UNIT.........................16

7.00

REMOVAL AND REPLACEMENT OF THE TILLER SPRING MOD. MS10E ...................................................17

7.01

REMOVAL AND REPLACEMENT OF THE TILLER FROM THE SUPPORT MOD. MS10E ...............................................18

7.02

REMOVAL AND REPLACEMENT OF THE TILLER COMPLETE W ITH SUPPORT MOD. MS10E......................19

AND

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THE

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DRIVE

W HEEL........................................................3

MOD. MS10E...........................................6

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FRAME MECHANICS 1.00

MECHANICAL COMPONENTS OF THE FRAME

Reference 1 2 3 4 5 6 7

Page: 2

Component description Drive wheel unit Pivoting wheel unit Load roller unit Drive motor unit Hydraulic power unit Pump motot unit Tiller unit

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2.00 REMOVAL AND REPLACEMENT OF THE DRIVE WHEEL MOD. MS10E The new design of the truck provides a wheel bumper incorporated in the main chassis. To make the loosening of the wheel fixing screws easier, a hole by the screws has been carried out (fig.2). To reach the wheels and replace them, lift the truck to allow removing the wheel from the bottom of the chassis. Necessary special tools

Hoist

Lifting rope with two hooks

Necessary standard tools

Ratchet and extension for socket wrench

19mm socket wrench

Fig. 1

Large slotted screwdriver

Fig. 2

Fig. 3

Step 2 HOIST, LIFTING ROPE WITH TWO HOOKS Position the hoist by the truck. Position the hooks of the lifting rope in the proper eyebolts on the chassis and the lifting rope end ring to the hoist hook (fig. 1). Tension the hoist and lift the truck until the wheel are about 300mm from the ground. Step 3 SOCKET WRENCH, RATCHET WITH EXTENSION Rotate the wheel and position the fixing screw heads next to the hole (ref. A fig. 2). Insert the wrench and loosen the screws one at time, until the wheel is released. Remove the wheel and replace it. Reassemble the new wheel by carrying out the procedure in the reverse order

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FRAME MECHANICS 3.00 REMOVAL AND REPLACEMENT OF THE PIVOTING WHEEL UNIT MOD. MS10E Necessary special tools

Hoist

Lifting rope with two hooks

Fig. 1

Necessary standard tools

Ratchet for socket wrench

Extension for socket wrench

15mm socket wrench

Large slotted screwdriver (2x12mm)

CACCIAVITE A Fig. 2

Step 2 HOIST, LIFTING ROPE WITH TWO HOOKS Position the hoist next to the truck. Hook the lifting rope hooks to the proper eyebolts on the chassis and connect the lifting rope end ring to the hoist hook (fig. 2). Tension the hoist and lift the truck, until the wheels are about 300mm from the ground. Step 3 SOCKET WRENCH, RATCHET, EXTENSION By using the tools loosen and remove the screws fastening the pivoting unit (rif. A fig. 1). Remove the unit and replace it. Reassemble the new pivoting wheel unit by carrying out the procedure in the reverse order. Fig. 3

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3.01 REMOVAL AND REPLACEMENT OF THE PIVOTING WHEEL MOD. MS10E Necessary special tools

Hoist

Necessary standard tools

Lifting rope with two hooks

No.2 22mm open ended spanners

Large slotted screwdriver

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground, turn the key OFF and disconnect the battery. Step 1 LARGE SCREWDRIVER Loosen and remove the screws fastening the motor bonnet. Remove the bonnet. Step 2 HOIST, LIFTING ROPE WITH TWO HOOKS Position the hoist next to the truck. Hook the lifting rope hooks in the proper eyebolts on the chassis and connect the lifting rope end ring to the hoist hook (fig. 2). Tension the hoist and lift the truck until the wheels are about 300mm from the ground. Step 3 OPEN ENDED SPANNERS Put a spanner on the stop nut (ref. A fig. 2) and the other one on the bolt hexagonal head (ref. B fig. 2). Loosen the nut, extract the bolt and remove the wheel (fig. 3), then replace it.

CACCIAVITE A Fig. 1

Fig. 2

Reassemble the new wheel by carrying out the procedure in the reverse order.

Fig. 3

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FRAME MECHANICS 4.00 REMOVAL AND REPLACEMENT OF THE LOAD ROLLERS MOD. MS10E Necessary standard tools

Hydraulic jack

100x100x150mm wooden block

500g steel hammer

pin extractor with 5mm diameter

drift with 18mm diameter

Fig. 1

Step 2 HAMMER, PIN EXTRACTOR, DRIFT By using the hammer and the pin extractor remove the lockpin of the roller hinge pin (ref. C fig. 2).

Step 3 HAMMER, DRIFT By using the hammer and the drift remove the hinge pin of the roller (ref. D fig. 2), extract the roller and replace it. Repeat the same procedure to remove the roller located on the opposite side.

Reassemble the new rollers by carrying out the procedure in the reverse order. Fig. 2

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5.00 REMOVAL AND REPLACEMENT OF THE DRIVE MOTOR MOD. MS10E Necessary standard tools

10mm open ended spanner

Scissors

Medium cross 6mm articulated Tslotted screwdriver shaped Allen wrench

Step 1 CROSS SLOTTED SCREWDRIVER Loosen and remove the screws fastening the motor bonnet. Remove the bonnet to reach the motors.

Step 2 Remove the tiller complete with its support (see paragraph ... on page...) Step 3 SCISSORS, 10mm OPEN ENDED SPANNER By using the scissors cut the cable clamps. By using the open ended spanner loosen and remove the stop nuts of the motor supply cables (ref. A fig. 1), remove the cables from the motor. Disconnect the electromagnetic brake connector.

Fig. 1

Step 4 ARTICULATED ALLEN WRENCH Loosen and remove the three screws fastening the drive motor to the reduction gear (ref. B fig. 2). Lift the motor about 100mm and remove it from the reduction unit. Position it on a workbench and replace or disassemble it to replace the damaged components. Reassemble the new motor by carrying out the procedure in the reverse order.

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FRAME MECHANICS 5.01 COMPONENTS OF THE 800W DRIVE MOTOR MOD. MS10E 15

7 5

2 10

4 18

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5.02 REFERENCE TABLE FOR THE DRIVE MOTOR 800W MOD. MS10E The table below contains the description of the various components of the drive motor shown in the previous page: Re f. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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De scription of the com pone nts Complete 1000W drive motor Stator outer casing Rotor Lower flange for coupling with the reduction gear Cooling fans Upper brush holder flange Lower flange rotor bearing Rotor bearing of the upper brush holder flange Snap ring of the bearing on the brush holder flange Lower flange rotor shaft oil seal Snap ring of the fan on the rotor shaft Snap ring of the electronic brake lining guiding pinion Snap ring of the upper flange on the rotor Motor brushes Brush pressing spring Brush covering metallic band Bolts fastening the upper flange to the casing Bolts fastening the lower flange to the casing

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FRAME MECHANICS 5.03 REMOVAL AND REPLACEMENT OF THE MOTOR BEARINGS MOD. MS10E

Necessary standard tools

Medium slotted screwdriver

22 mm open ended spanner

Medium cross slotted screwdriver

Drift with 18mm diameter

Fig. 1

L D External circlip pliers

Internal circlip pliers

Puller

Hammer

Procedure Before starting to work wear suitable safety clothes.

5.04 REMOVAL AND REPLACEMENT OF THE LOWER FLANGE OIL SEAL BEARING Step 1 OPEN ENDED SPANNER, PROPER PULLER After disassembling the motor from the truck, position it in a vice and tighten so that you can easily disassemble it. By using the spanner loosen and remove the motor pinion stop nut (ref. A fig. 2), extract the washer. By using the puller extract the pinion from the motor shaft (ref. B fig. 2). Remove the pinion retainer (ref. C fig. 2) Step 2 CROSS SLOTTED SCREWDRIVER, PROPER PULLER. By using a screwdriver loosen and remove the screws fastening the motor lower flange (ref. D fig. 2-3). By using the puller remove the lower flange from the rotor (ref. E fig. 3) and position it on a workbench. Step 3 SLOTTED SCREWDRIVER, HAMMER, DRIFT By using a screwdriver remove the oil seal from the flange seat (ref. F fig. 3). By using the hammer and the drift remove the bearing from the flange (ref. G fig. 3) and replace it. Reassemble the oil seal and the bearing by carrying out the procedure in the reverse order.

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H G

E Fig. 3

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SERVICE

FRAME MECHANICS

5.05 REMOVAL AND REPLACEMENT OF THE FAN Step 4 EXTERNAL CIRCLIP PLIERS After extracting the lower flange, you can remove the fan following the instructions below. By using the pliers remove the fan snap ring (ref. H fig. 3), extract the fan and replace it. Reassemble the fan by carrying out the procedure in the reverse order.

5.06 REMOVAL AND REPLACEMENT OF THE UPPER FLANGE BEARING Step 5 EXTERNAL CIRCLIP PLIERS Remove the electromagnetic brake unit (see section: braking system, paragraph No., on page). By using the pliers remove the snap rings from the motor shaft (ref. L fig. 1-2). Step 6 PULLER, CROSS SLOTTED SCREWDRIVER By using the screwdriver loosen and remove the upper flange fixing screws (ref. M fig. 1-2). By using the puller remove the flange from the rotor shaft (ref. P fig. 1). Position the flange on the workbench. Step 7 INTERNAL CIRCLIP PLIERS, HAMMER, DRIFT By using the circlip pliers remove the snap ring locking the bearing (ref. Q fig. 1). By means of the hammer and of the pin extractor remove the bearing from the flange (ref. R fig. 1) and replace it. Reassemble the bearing by carrying out the procedure in the reverse order Reassemble the complete motor by carrying out the procedure in the reverse order.

NOTE: For the driving torques of the motor screws see table (fig. 4) 2 5 Nm

5 Nm

5 Loctite 242

Re f. 1 2 3 4 5

UPDATE

24 Nm

1 4 Nm

5 Nm

4 Loctite 242

De scription of the compone nt Locking bolts of the motor supply cables Locking bolts of the lower flange Locking bolts of the upper flange Bolts fastening the motor to the reduction gear Nut fastening the pinio to the motor shaft

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Driving torque 4 Nm 5 Nm 5 Nm 24 Nm 13 Nm

Fig. 2

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SERVICE

FRAME MECHANICS 5.07 REMOVAL AND REPLACEMENT OF THE DRIVE MOTOR BRUSHES MOD. MS10E

Medium cross slotted screwdriver

Spring tightener

Fig. 2

B C D

Step 1 CROSS SLOTTED SCREWDRIVER Loosen and remove the screws fastening the motor compartment bonnet. Remove the bonnet to reach the motors. Step 2 CROSS SLOTTED SCREWDRIVER, SPRING TIGHTENER By using the screwdriver loosen and remove the screw fastening the clamp protecting the brushes (ref. A fig. 1) and remove the clamp to reach the brushes. By using the same screwdriver loosen and remove the screws fastening the final part of the brush to the brush holder (ref. B fig. 2). By means of the spring tightener lift the brush pressing spring (ref. C fig. 2), extract the brush. Repeat the same procedure to remove the other three brushes and replace them. Reassemble the brushes by carrying out the procedure in the reverse order.

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FRAME MECHANICS

REMOVAL AND REPLACEMENT OF THE HYDRAULIC POWER UNIT MOD. MS10E

Necessary standard tools

Medium cross slotted screwdriver

Small slotted screwdriver

13-17-19mm open ¾” male hydraulic ended spanner plug

Fig. 1

Step 2 19mm OPEN ENDED SPANNER, HYDRAULIC PLUG By means of the spanner loosen the hydraulic fitting connecting the power unit (ref. A fig. 2). By using the same spanner plug the hose to avoid oil leakages. Step 3 SLOTTED SCREWDRIVER, 13-17mm OPEN ENDED SPANNER. By means of the screwdriver loosen the screw fastening the solenoid valve connector (ref. B fig. 2), disconnect the connector from the solenoid valve. By using the 13mm spanner loosen and remove the nut fastening the supply cables of the motor (ref. C fig. 2). By means of the 17mm spanner loosen and remove the two bolts fastening the power unit to the support (ref D fig.2). Remove the power unit and replace or disassemble it to replace the damaged components. Reassemble the complete power unit by carryin g out the procedure in the reverse order.

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A B C D

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SERVICE

FRAME MECHANICS 6.01 REMOVAL AND REPLACEMENT OF THE PUMP MOTOR MOD. MS10E The pump motor must be removed to replace the power unit assembled on the truck. Necessary standard tools

Fig. 1 11-13mm open ended spanner

Medium cross 5mm Allen wrench slotted screwdriver

Fig. 2

Step 2 13mm OPEN ENDED SPANNER By using the spanner loosen and remove the locknuts of the motor supply cables (ref. A fig. 2) and extract the cables from the terminals. Step 3 11mm OPEN ENDED SPANNER By using the spanner loosen and remove the screws fastening the motor to the power unit (ref. A fig. 1). Remove the motor by lifting it upwards and replace it. The connection coupling between the motor and the pump must be used again and positioned correctly.

Fig. 3

Install the new motor by carrying out the procedure in the reverse order

Fig. 4

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6.02 REMOVAL AND REPLACEMENT OF THE PUMP MOTOR BRUSHES MOD. MS10E Necessary standard tools

large slotted screwdriver

11 mm open ended spanner

medium cross slotted screwdriver

spring tightener

Fig. 1

Step 2 11 mm OPEN ENDED SPANNER Loosen and remove the bolts locking the motor to the flange (ref.A fig.1), lift the cover (ref.B fig.1) by keeping the motor on the flange so that the brush holder can be seen (fig.2). Step 3 CROSS SLOTTED SCREWDRIVER - SPRING TIGHTNER By using the screwdriver loosen and remove the screws fastening the brushes to the brush holder (ref.C fig.3) and by means of the spring tightner lift the spring pressing the brush on the rotor (ref.D fig.3), extract the brushes and replace them.

Fig. 2

Install the new brushes by carrying out the procedure in the reverse order.

After the assembly no adjustment is required.

C Fig. 3

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FRAME MECHANICS

6.03 DRIVING TORQUES OF THE BOLTS AND NUTS OF THE HYDRAULIC POWER UNIT After the assembly of the components and of the motors, we recommend observing the driving torques of the bolts and nuts as shown in the figure below.

5 3

Ref. 1 2 3 4 5 6

Page: 16

Driving torque 12 Nm 5 Nm 4 Nm 22 Nm 10 Nm 30 Nm

Description of the component No. 2 locknuts M8 of the supply cables No. 3 locknuts M8 of the motor to the power unit No. 4 locking bolts M6 of the tank to the power unit No. 2 locking bolts M6 of the pump boy to the power unit Body of the relief valve RV1 Body of the propertional solenoid valve EV1

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7.00 REMOVAL AND REPLACEMENT OF THE TILLER SPRING MOD. MS10E Necessary standard tools

Allen wrench

100x100x150mm wooden block

500g steel hammer

Pin extractor with 5mm

Procedure

Fig. 1

Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground, turn the key OFF and disconnect the battery.

Step 1 NORMAL PLIERS Lower the tiller and by means of the pliers loosen and remove the tiller rubber pads (ref. A fig.1).

Fig. 2

Step 2 HAMMER, PIN EXTRACTOR By means of the hammer and the pin extractor remove the hinge pin securing the tiller to the support (ref.B fig. 2). Step 3 ALLEN WRENCH By using the Allen wrench loosen and remove the screw fastening the upper part of the spring to the tiller (ref. C fig. 3). Extract the spring from the lower part of the tiller (ref. D fig. 4) and replace it.

Fig. 3

Reassemble the new spring by carrying out the procedure in the reverse order.

Fig. 2

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FRAME MECHANICS

7.01 REMOVAL AND REPLACEMENT OF THE TILLER FROM THE SUPPORT MOD. MS10E Necessary standard tools

5mm Allen wrench

Medium slotted screwdriver

24mm socket wrench

Ratchet for socket wrench

Fig. 1

Step 2 Remove the tiller spring (see procedure “REMOVAL OF THE TILLER SPRING” on page 18). Step 3 24mm SOCKET WRENCH, RATCHET Disconnect the connector of the tiller cable and of the tiller sensor (ref. B fig. 2). By using the socket wrench complete with ratchet loosen and remove the two pins fastening the tiller (ref. C fig, 2), remove the tiller and replace it. Reassemble the new tiller by carrying out the procedure in the reverse order.

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FRAME MECHANICS

7.02 REMOVAL AND REPLACEMENT OF THE TILLER COMPLETE WITH SUPPORT MOD. MS10E Necessary standard tools

5-6mm Allen wrench

Medium slotted screwdriver

Fig. 1

Step 2 6mm ALLEN WRENCH By using the Allen wrench loosen and remove the four screws fastening the support of the tiller (ref. B fig. 2), remove the complete tiller and replace it. Reassemble the complete tiller by carrying out the procedure in the reverse order.

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NOTES:

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MAST MECHANICS

1.00

TYPE OF MASTS....................................................................................................................................................2

1.01

COMPONENTS OF THE SIMPLEX MAST...............................................................................................................................4

1.02

REFERENCE TABLE FOR THE COMPONENTS OF THE SIMPLEX MAST.....................................................................................5

2.00

REMOVAL PF THE MAST FROM THE FRAME MOD. MS10E SIMPLEX MAST..............................................................................6

2.01

DISASSEMBLY OF THE MAST MOD. MS10E SIMPLEX MAST.................................................................................................8

2.02

REPLACEMENT OF THE CHAINS MOD. MS10E SIMPLEX MAST...........................................................................................10

2.03

REPLACEMENT OF THE CHAIN TIGHTENERS MOD. MS10E SIMPLEX MAST.........................................................................11

2.04

REPLACEMENT OF THE CHAIN TIGHTENER ON THE MAST MOD. MS10E SIMPLEX MAST........................................................11

2.05

REPLACEMENT

2.06

ADJUSTEMENT OF THE LIFTING CHAINS........................................................................................................................13

2.07

REMOVAL AND REPLACEMENT OF THE CHAIN PULLEYS MOD. MS10E SIMPLEX MAST.....................14

3.00

COMPONENTS OF THE DUPLEX MAST.............................................................................................................................16

3.01

REFERENCE COMPONENTS OF THE DUPLEX MAST.................................................................................................................17

3.02

REMOVAL AND REPLACEMENT OF THE MAST FROM THE FRAME MOD. MS10E DUPLEX MAST.........................18

OF THE CHAIN TIGHTENER ON THE FORK CARRIAGE............................................12

3.03

DESASSEMBLY OF THE MAST MOD. MS10E DUPLEX MAST..........................................................................................20

3.04

REMOVAL AND REPLACEMENT OF THE SLIDING BLOCKS......................................................................................23

3.05

REMOVAL OF THE FORK CARRIAGE SLIDING BLOCKS............................................................................23

3.06

REMOVAL OF THE INTERNAL STAFE SLIDING BLOCKS...................................................................................................23

3.07

DISASSEMBLY OF THE EXTERNAL STAGE SLIDING BLOCKS..................................................................................................24

3.08

CHAIN REPLACEMENT MOD. MS10E DUPLEX MAST...................................................................................................................25

3.09

REPACEMENT OF THE CHAIN TIGHTENER ON THE CYLINDER MOD. MS10E DUPLEX MAST.............................................26

3.10

REPLACEMENT OF THE FORK CARRIAGE CHAIN TIGHTENER.................................................................27

3.11

ADJUSTEMENT OF THE LIFTING CHAINS MOD. MS10E DUPLEX MAST...............................................................................28

3.12

DISASSEMBLY OF THE CHAIN PULLEY MOD. MS10E DUPLEX MAST.......................................................................29

4.00

CHAIN GREASING................................................................................................................................................................30

4.01

CHAIN ELONGATION............................................................................................................................................................30

4.02

CHAIN MEASURE........................................................................................................................................................................30

4.03

CHECK OF LINKS, PINS AND CHAIN TIGHTENERS....................................................................................................................30

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MAST MECHANICS 1.00

TYPE OF MASTS SIMPLEX MAST

DUPLEX MAST

DESCRIPTION SIMPLEX MAST One stage mast for liftings up to max.1845 mm. The mast is made up of channel sections. It consists of a fixed mast, a central cylinder for the lifting of the forks and of a plate complete with forks, on which 4 radial roller having 70mm diameter are assembled. The central cylinder is a single-acting one with shock absorption in the last 50 mm. DUPLEX MAST Two stage mast for liftings up to max. 3460 mm. The mast is made up of channel sections. It consists of a fixed mast, a mobile internal mast borned by 4 radial roller having 70mm diameter, a central cylinder for the lifting of the forks and by a plate complete with forks, on which 4 radial rollers having 70mm diameter are assembled. The central cylinder is single-acting one.

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DAT A OF T HE M AST

Fork m a x . he ight (h3+h13) mm

He ight of the m a st low e re d h1 mm

1260

1345

1260

1820

1830

Simplex FFL

1360

1445

1360

1920

1930

1460 1560 1760

1545 1645 1845

1460 1560 1760

2020 2120 2320

2030 2130 2330

2660

100

1835

3115

Duplex LFL

2860

100

1935

3315

Channel section

T ype of the mast

Lifting stroke h3

Fre e lift stroke h2

He igth of the m a st e x te nde d h4 * mm

3060

100

2035

3515

3260 3460

100 100

2135 2235

3715 3915

h4 add 525 mm with backrest

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MAST MECHANICS 1.01

COMPONENTS OF THE SIMPLEX MAST

9 8 7

3 4

11 12

13 14

18 16

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MAST MECHANICS

REFERENCE TABLE FOR THE COMPONENTS OF THE SIMPLEX MAST

Re f. 1

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De scription

Fixed stage Fixed fork carriage

Protection grid

Screw

5 6

W asher Snap ring

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Shim Chain pulley Chain covering bracket Pulley support Chain Chain tightener W asher Screw Cylinder locking collar Chain tightener Sliding block Retainer screw Radial roller of the internal stage with 70 mm diameter Shim Snap ring Fork lifting/lowering cylinder

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MAST MECHANICS 2.00

REMOVAL OF THE MAST FROM THE FRAME MOD. MS10E SIMPLEX MAST

Necessary special tools

lifting band

hoist

oil proof gloves

3/4” female plug

3/4” male plug

Necessary standard tools

19 mm open ended spanner

14 mm Allen wrench with extension

torque wrench

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians, lower the forks to the ground, turn the key switch OFF, disconnect the battery. Step 1 HOIST - LIFTING BAND Hook one end of the band to the fork carriage backrest and the other end to the hoist hook (fig.1). Enable the hoist and lift the forks up to 800 mm. Step 2 OIL PROOF GLOVES - 19 mm OPEN ENDED SPANNER - MALE AND FEMALE PLUGS Wear the oil proof gloves and by means of the open ended spanner loosen the hose fitting to the cylinder (ref.A fig.2). Plug the fitting by means of the female plug and the cylinder supply hose by means of the male plug.

Fig. 1

Step 1 HOIST - LIFTING BAND Release the lifting band, hook one end of the band to the mast and the other end to the hoist hook (fig.3). Enable the hoist and tension the band.

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Step 4 14 mm ALLEN WRENCH - EXTENSION - TORQUE WRENCH Loosen and remove the two screws fastening the mast to the frame (ref.B fig.4). Enable the hoist until the central crosspiece of the mast (ref.C fig.5) is out of its seat. Remove the mast and replace or disassemble it.

Fig. 3

For the assemply carry out the procedure in the reverse order. During the assembly apply some Loctite of average texture to the screws fastening the mast and tighten with 140 Nm driving torque.

B Fig. 4 Fig. 5

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MAST MECHANICS 2.01 DISASSEMBLY OF THE MAST MOD. MS10E SIMPLEX MAST DISASSEMBLY OF THE ROLLERS AND THE SLIDING BLOCKS Necessary special tools

hoist

No. 3 lifting bands with suitable length

100x100x200mm wooden beam

medium external circlip pliers

nosed pliers

Necessary tools

17 mm open ended spanner

4 - 8 mm Allen wrench

bearing puller

Procedure Before starting to work wear suitable safety clothes.

Fig. 1

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Step 1 WOODEN BEAM Enable the pump and lift the forks until the beam can pass under the them (ref.A fig.1). Position the beam under the forks and lower them until the beam lean against the forks. Keep on lowering till the lifting chains are loosened.

Turn the key switch OFF, disconnect the battery.

Step 2 NOSED PLIERS By using the pliers remove the split pins (ref.B fig.2) of the hinge pins securing the chains to the chain tighteners. By u8sing the same tool remove the pins (ref.C fig.2) and separate the chains from the chain tighteners. Remove the chains from the pulleys.

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Fase 3 17 mm OPEN ENDED SPANNER - EXTERNAL CIRCLIP PLIERS By using the open ended spanner loosen the setscrews (ref.D fig.3) and remove the bracket preventing the chains from fleeting (ref.E fig.3). By using the circlip pliers remove the snap rings locking the pulley support (ref.F fig.3). Remove the pulley support and the pulleys (ref.G fig.3) from the cylinder rod.

E F G D Fig. 3

Step 4 8 mm ALLEN WRENCH By using the Allen wrench loosen and remove the mechanical stop screw on the fork carriage (ref.H fig.5). Step 5 HOIST - LIFTING BAND Position the hoist in the centre of the mast next to the forks. Hook two bands to the forks and one band to the backrest; hook the other ends to the hoist hooks. Lift the hoist and remove the fork carriage from the top (fig.4). Position the fork carriage on the ground or on two stands and replace the rollers and/or the sliding blocks.

REPLACEMENT OF THE ROLLERS

Fig. 4

Step 6 CIRCLIP PLIERS - PULLER Remove the snap rings locking the roller (ref.I fig.5), remove the distance washer (ref.L fig.5). By means of the puller extract the roller from the pin (ref.M fig.5) e replace it.

REPLACEMENT OF THE SLIDING BLOCKS Step 7 4 mm ALLEN WRENCH Remove the sliding block fastening screws (ref.N fig.5) and replace the sliding blocks.

L Fig. 5

For the assembly carry out the procedure in the reverse order.

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MAST MECHANICS 2.02

REPLACEMENT OF THE CHAINS MOD. MS10E SIMPLEX MAST

Necessary special tools

100x100x400mm wooden beam

Necessary standard tools

nosed pliers

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Step 1 WOODEN BEAM Enable the pump and lift the forks until the beam can pass under them (ref.C fig.2). Position the beam under the forks and lower them until they lean against the beam. Keep on lowering until the lifting chains are loosened.

Fig. 1

Turn the key switch OFF, disconnect the battery. Fig. 2 Step 2 NOSED PLIERS By using the pliers remove the split pins (ref.A fig.3) of the hinge pins securing the chains to the chain tighteners. By means of the same tool extract the pins (ref.B fig.3) and separate the chains from the chain tighteners.

Step 3 NOSED PLIERS By using the pliers remove the split pins (ref.D fig.3) of the hinge pins securing the chains to the chain tightners. By using the same tool extract the pins (ref.E fig.3) and separate the chains from the chain tighteners.

E D

For the assembly carry out the procedure in the reverse order. After the assembly adjust the lifting chains (see “ADJUSTMENT OF THE LIFTING CHAINS” on page XX).

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SERVICE 2.03

MAST MECHANICS

REPLACEMENT OF THE CHAIN TIGHTENERS MOD. MS10E SIMPLEX MAST

Necessary special tools

Necessary standard tools

nosed pliers

100x100x200mm 100x100x1500mm wooden beam

24 mm open ended spanner

4 mm Allen wrench

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Fig. 1

2.04 REPLACEMENT OF THE CHAIN TIGHTENER ON THE MAST Step 1 100x100x200mm WOODEN BEAM Enable the pump and lift the forks until the beam can pass under them (ref.A fig.1). Position the beam under the forks and lower them until they lean against the beam. Keep on lowering until the lifting chains are loosened.

A C

Turn the key switch OFF and disconnect the battery. Step 2 NOSED PLIERS By means of the pliers remove the split pin (ref.B fig.2) of the hinge pin securing the chain to the chain tightener. By using the same pliers extract the pin (ref.C fig.2) and separate the chain from the chain tightener. Remove the split pin (ref.D fig.3).

Fig. 2

Step 3 OPEN ENDED SPANNER Loosen and remove the nut locking the chain tightener (ref.E fig.3), remove the chain tightener and replace it. For the assembly carry out th procedure in the reverse order. After the assembly adjust the lifting chains (see “ADJUSTMENT OF THE LIFTING CHAINS” on page XX).

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2.05 REPLACEMENT OF THE CHAIN TIGHTENER ON THE FORK CARRIAGE Step 1 100x100x1500mm WOODEN BEAM Enable the emergency push button and turn the key switch “ON”. Enable the pump and lift the forks until the beam can pass under them (ref.F fig.5). Position the beam under the forks and lower them until they lean against the beam. Keep on lowering until the lifting chains are loosened. Turn the key switch OFF and disconnect the battery.

Step 2 4 mm ALLEN WRENCH Loosen the fastening screws and remove the protection grid on the mast (fig.4). Fig. 4

Step 3 NOSED PLIERS By using the pliers remove the split pin (ref.G fig.6) of the hinge pin securing the chainto the chain tightener. By means of the same tool extract the pin (ref.H fig.6) and separate the chain from the chain tightener. Extract the split pin on the chain tightener (rif.I fig.7). Step 4 OPEN ENDED SPANNER Loosen and remove the nut locking the chain tightener (ref.L fig.7), remove the chain tightener and replace it.

F Fig. 5

For the assembly carry out the procedure in the reverse order. After the assembly adjust the lifting chains (see “ADJUSTMENT OF THE LIFTING CHAINS” on page 13).

Fig. 6

I L Fig. 7

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MAST MECHANICS

ADJUSTMENT OF THE LIFTING CHAINS

The surface of the forks must be not higher than 90mm from the ground and the forks must not come in contact with the outrigger base (fig.3). Necessary standard tools

A Fig. 1

24 mm open ended spanner

90 mm Fig. 3

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MAST MECHANICS

2.07 REMOVAL AND REPLACEMENT OF THE CHAIN PULLEYS MOD. MS10E SIMPLEX MAST Necessary special tools

100x100x200mm wooden beam

vice

Necessary standard tools

nosed pliers

17 mm open ended spanner

medium circlip pliers

puller

Procedure

Fig. 1

Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Step 1 WOODEN BEAM Enable the pump and lift the forks until the beam can pass under the forks (ref.A fig.1). Position the beam under the forks and lower them until they lean against the beam. Keep on lowering until the lifting chains are loosened.

A C B

Turn the key switch OFF and disconnect the battery.

Step 2 NOSED PLIERS By using the pliers remove the split pins (ref.B fig.2) of the hinge pins securing the chain to the chain tighteners. By means of the same tool extract the pins (ref.C fig.2) and separate the chains from the chain tighteners. Remove the chains from the pulleys. Step 3 17 mm OPEN ENDED SPANNER - EXTERNAL CIRCLIP PLIERS By means of the open ended spanner loosen the setscrews (ref.D fig.3) and remove the bracket preventing the chains from fleeting (ref. E fig. 3). By using the circlip pliers remove the snap ring locking the pulley support (ref. F fig. 3). Extract the support complete with pulleys from the cylinder rod (ref. G fig. 3) and position it on a clean workbench.

Fig. 2

F E

G Fig. 3

Step 4 VICE - PULLER Block the pulley support in the vice. By using the puller remove the pulleys (fig.4) and replace them. Reassemble the complete support by carrying out the procedure in the reverse order.

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MAST MECHANICS

NOTES

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MAST MECHANICS 3.00

COMPONENTS OF THE DUPLEX MAST

12 5 6

10 9

2 13

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SERVICE 3.01

MAST MECHANICS

REFERENCE TABLE FOR THE DUPLEX MAST

Re f 1 2

UPDATE

De scription Fixed external stage Mobile internal stage

Fixed fork carriage

Protection grid

5 6

Sliding block Screw

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Sliding block Chain tightener Pin Bearing Chain Chain pulley Sliding block Radial roller with 70mm diameter for the fork carriage Distance washer Snap ring Snap ring Distance washer Radial roller with 70mm diameter for the internal stage Sliding block Fork lifting/lowering cylinder

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MAST MECHANICS 3.02

REMOVAL AND REPLACEMENT OF THE MAST FROM THE FRAME MOD. MS10E DUPLEX MAST

Necessary special tools

lifting band

hoist

oil proof gloves

No.2 3/4” male plug

Necessary standard tools

19 mm open ended wrench

14 mm Allen wrench with extension

torque wrench

Procedure Before starting to work wear suitable safety clothes.

Fig. 1

Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians, lower the forks to the ground, turn the key switch OFF, disconnect the battery. Step 1 HOIST - LIFTING BAND Hook an end of the band to the backrest of the fork carriage and the other end to the hoist hook (fig.1). Enable the hoist and lift the fork 800 mm. Step 2 OIL PROOF GLOVES - 19 mm OPEN ENDED SPANNER - MALE PLUGS Wear the oil proof gloves and by using the open ended spanner loosen the cylinder fitting (ref.A fig.2). Put a male plug on the fitting and the other male plug to the cylinder hose. Enable the hoist and lower the forks completely. Step 3 HOIST - LIFTING BAND Release the lifting band, hook one end of the band to the mast and the other end to the hoist hook (fig.3). Enable the hoist and tension the band.

A Fig. 2

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Step 4 14 mm ALLEN WRENCH - EXTENSION - TORQUE WRENCH Loosen and remove the two screws fastening the mast to the frame (ref.B fig.4). Enable the hoist, lift the mast until the central crosspiece of the mast (ref.C fig.5) is out of its seat. Remove the mast and replace it.

Fig. 3

For the assembly carry out the procedure in the reverse order. During the assembly apply some loctite of average texture on the screws fastening the mast and tighten with 140 Nm driving torque.

B Fig. 4

Fig. 5

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MAST MECHANICS 3.03

DISASSEMBLY OF THE MAST MOD. MS10E DUPLEX MAST

Fig. 1

ROLLER DISASSEMBLY Necessary special tools

No. 3 lifting band of suitable length

hoist

No. 2 stands

Necessary standard tools

B A medium external circlip pliers

nosed pliers

bearing puller

4 - 8 mm Allen wrench

Procedure

Fig. 2

Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians, lower the forks to the ground, turn the key switch OFF, disconnect the battery.

DISASSEMBLY OF THE FORK CARRIAGE ROLLERS Step 1 HOIST - LIFTING BAND Hook an end of the band to the fork carriage backrest and the other end to the hoist hook (fig.1). Enable the hoist and lift the forks 400 mm.

Fig. 3

Fig. 4

Step 2 NOSED PLIERS By using the pliers remove the split pin (ref.A fig.2) of the hinge pin securing the cahin to the chain tightener on the mast. By means of the same tool extract the pin (ref.B fig.2) and remove the chain from the chain tightener. Enable the hoist and lowered the forks completely. Step 3 Enable the pump and lift the internal mast to an height allowing the removal of the fork carriage (ref.C fig.3).

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Step 4 HOIST - LIFTING BAND Position the hoist in the centre of the mast next to the forks. Hook the two bands to the forks and one band to the backrest; hook the other ends to the hoist hook. Lift the hoist and remove the fork carriage (fig.4). Position the fork carriage on the ground or on two stands.

Fig. 5

G Step 5 CIRCLIP PLIERS - PULLER Remove the snap ring locking the roller (ref.E fig.6), extract the distance washer (ref.F fig.6). With the help of the puller remove the roller from the pin (ref.G fig.6) and replace it.

For the assembly carry out the procedure in the reverse order. During the assembly position the fork carriage on the mast base and lower the internal stage carefully in order not to damage the sliding blocks on the fork carriage (ref.D fig.3).

Fig. 6

DISASSEMBLY OF THE INTERNAL STAGE ROLLERS Before disassembling the internal stage rollers the fork carriage must be removed (see procedure “DISASSEMBLY OF THE FORK CARRIAGE” steps 1,2,3 and 4). Step 5 4 mm ALLEN WRENCH Loosen the fastening screws and remove the mast protection grid. Enable the pump and lower completely the internal stage (fig.7).

Fig. 7

Step 6 Disassemble the complete cylinder (see “DISASSEMBLY OF THE CYLINDER” on page16 section: “HYDRAULIC SYSTEM” steps 4,5,6 Step 7 8 mm ALLEN WRENCH By using the Allen wrench loosen and remove the mechanical stop screw (ref.H fig.8).

H Fig. 8

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MAST MECHANICS Step 8 HOIST - No. 2 LIFTING BANDS Position the hoist in the centre of the mast next to the internal stage. Hook the band to the upper part of the stage and to the hoist. Lift the hoist and extract the internal stage (fig.9). Position the internal stage horizontally on the ground. Hook the other band to the crosspiece located on the opposite side of the internal stage and to the hoist. Lift the hoist and position the internal stage on two stands (fig.11).

Step 9 CIRCLIP PLIERS - PULLER Remove the snap ring blocking the roller (ref.I fig.10), remove the distance washer (ref.L fig.10). With the help of the puller extract the roller from the pin (ref.M fig.10) and replace it. For the assembly proceed as follows: 1) Insert the internal stage 2) Assemble the cylinder 3) Assemble the pulley 4) Assemble the chain on the chain tightener of the lifting cylinder 5) Enable the pump and lift the internal stage 600 mm 6) Sling the fork carriage and position it on the mast base. 7) Enable the pump and lower the internal stage Lower the internal stage carefully in order not to damage the sliding blocks on the fork carriage (ref.D fig.3). 8) Hook the backrest of the fork carriage by means of a band and lift 800 mm by means of the hoist. 9) Assemble the chain on the chain tightener of the fork carriage.

I Fig. 10

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Fig. 11

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MAST MECHANICS

REMOVAL AND REPLACEMENT OF THE SLIDING BLOCKS

The sliding blocks on the fork carriage and on the two stages of the mast can be removed easily without disassembling the mast. Necessary standard tools

4mm long Allen wrench

large slotted screwdriver

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

3.05 REMOVAL OF THE FORK CARRIAGE SLIDING BLOCKS Step 1 Enable the pump and lift the forks 1200 mm (fig.1). Turn the key switch OFF and disconnect the battery.

Step 2 ALLEN WRENCH - SCREWDRIVER Remove the sliding block fastening screws (ref.A fig.2) and extract the sliding blocks by acting between the fork carriage and the internal stage by means of the screwdriver and replace them.

Fig. 1

3.06 REMOVAL OF THE INTERNAL STAGE SLIDING BLOCKS

Step 1 Enable the pump and lift the forks until the sliding blocks fixed at the internal stage base are positioned over the frame (fig.3).

Fig. 2

Turn the key switch OFF and disconnect the battery. Step 2 ALLEN WRENCH - SCREWDRIVER By using the Allen wrench remove the mast protection grid (ref.B fig.3). By using the same wrench remove the screws fastening the sliding blocks (ref.C fig.3) and extract the sliding blocks by acting between the external and the internal stage profile by means of the screwdriver and replace them.

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MAST MECHANICS 3.07 DISASSEMBLY OF THE EXTERNAL STAGE SLIDING BLOCKS Step 2 ALLEN WRENCH - SCREWDRIVER Remove the screws fastening the sliding blocks (ref.D fig.4) and extract the sliding blocks by acting between the external and the internal stage profile by means of the screwdriver and replace them.

Fig. 4

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3.08 CHAIN REPLACEMENT MOD. MS10E DUPLEX MAST Necessary special tools

Necessary standard tools

nosed pliers

100x100x400mm wooden beam

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Step 1 WOODEN BEAM Enable the pump and lift the forks until the beam can pass under them (ref.F fig.2). Position the beam under the forks and lower them until they lean against the beam and keep on lowering until the lifting chain is loosened.

Turn the key switch OFF and disconnect the battery.

Fig. 1 Fig. 2

Step 2 NOSED PLIERS By using the pliers remove the split pin (ref.G fig.3) of the mast chain tightener hinge pin. By means of the same tool extract the pin (ref.H fig.3) and remove the chain from the chain tightner.

Step 3 NOSED PLIERS By using the pliers remove the split pin (ref.A fig.1) of hinge pin of the chain tightener fixed on the cylinder. By means of the same tool extract the pin (ref.B fig.1) and remove the chain from the chain tightener. Remove the chain from the pulley and replace it.

F H G

For the assembly carry out the procedure in the reverse order. After the assembly adjust the lifting chains (see “ADJUSTMENT OF THE LIFTING CHAINS” on page 28). Fig. 3

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SERVICE

MAST MECHANICS 3.09

REPLACEMENT OF THE CHAIN TIGHTENER ON THE CYLINDER MOD. MS10E DUPLEX MAST

Necessary special tools

Necessary standard tools

100x100x200mm 100x100x1200mm wooden beam

nosed pliers

24 mm open ended spanner

4 mm Allen wrench

ratchet

24 mm socket wrench

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Step 1 100x100x200 WOODEN BEAM Enable the pump and lift the forks until the beam can pass under them (ref.A fig.2). Position the beam under the forks and lower them until they lean against the beam. Keep on lowering until the lifting chains are loosened.

Fig. 1 Fig. 2

Turn the key switch OFF and disconnect the battery.

Step 2 4 mm ALLEN WRENCH Loosen the fastening screws and remove the mast protection grid (fig.1).

Step 3 NOSED PLIERS By using pliers remove the spit pin (ref.B fig.3) of the hinge pin securing the chain to the chain tightener. By means of the same tool extract the pin (ref.C fig.3) and separate the chain from the chain tightener.

C B

Step 4 OPEN ENDED SPANNER Loosen and remove the chain tightener stop nut (ref.E fig.3). Remove the chain tightener and replace it.

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For the assembly carry out the procedure in the reverse order. After the assembly adjust the lifting chains (see “ADJUSTMENT OF THE LIFTING CHAINS” on page 28).

3.10

REPLACEMENT OF THE CHAIN TIGHTENER ON THE FORK CARRIAGE

Step 1 100x100x1200mm WOODEN BEAM Enable the pump and lift the forks until the beam can pass under them (ref.A fig.2). Position the beam under the forks and lower them until they lean against the beam. Keep on lowering until the lifting chains are loosened. Turn the key switch OFF and disconnect the battery.

Step 2 4 mm ALLEN WRENCH Loosen the fastening screws and remove the mast protection grid (fig.1).

Fig. 1 Fig. 2

Step 3 NOSED PLIERS By using the pliers remove the split pin (ref.B fig.3) securing the chain to the chain tightener. By means of the same tool remove the pin (ref.C fig.3) and separate the chain from the chain tightener. Remove the chain tightener split pin (ref.D fig.3). Step 4 RATCHET - 24 mm SOCKET WRENCH Loosen and remove the chain tightener stop nut (ref.E fig.3), extract the chain tightner and replace it.

A C

For the assembly carry out the procedure in the reverse order. After the assembly adjust the lifting chains (see “ADJUSTMENT OF THE LIFTING CHAINS” on page 28).

B D E

Fig. 3

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MAST MECHANICS 3.11 ADJUSTMENT OF THE LIFTING CHAINS MOD. MS10E DUPLEX MAST

The surface of the forks must not be higher than 90 mm from the ground and the forks do not come in contact with the outrigger base (fig.4). Necessary standard tools

4 mm Allen wrench

24 mm open ended spanner

Procedure Before starting to work wear suitable safety clothes.

Fig. 1

A Fig. 2

Step 2 OPEN ENDED SPANNER By using the open ended spanner screw or loosen the chain tightener nuts (ref.A fig.2) until the height of the forks (90mm from the ground) is reached.

Fig. 3

90 mm Fig. 4

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MAST MECHANICS

3.12 DISASSEMBLY OF THE CHAIN PULLEY MOD. MS10E DUPLEX MAST Necessary special tools

Necessary standard tools

100x100x200mm wooden beam

4 - 12 mm Allen wrench

nosed pliers

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians.

Fig. 1

Step 1 WOODEN BEAM Enable the pump and lift the forks until the beam can pass under them (ref.C fig.3). Position the beam under the forks and lower them until they lean against the beam. Keep on lowering until the lifting chain is loosened.

Turn the key switch OFF and disconnect the battery.

Fig. 2 Fig. 3

Step 2 4 mm ALLEN WRENCH Loosen the fastening screws and remove the mast grid protection (fig.1). Step 3 NOSED PLIERS By using the pliers remove the split pin (ref.A fig.2) securing the chain hinge pin to the chain tightener. By using the same tool extract the pin (ref.B fig.2) and separate the chain from the chain tightener. Extract the chain from the pulley. Step 4 12 mm ALLEN WRENCH Loosen and remove the hinge screws of the pulley support (ref.C fig.4). Remove the sliding blocks (ref.D fig.4) and remove the pulley support togheter with the pulley (ref.E fig.4). Remove the pulley from the support and replace it.

Fig. 4

For the assembly carry out the procedure in the reverse order.

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MAST MECHANICS 4.00

CHAIN GREASING

The element that gives a long life to the chains is their lubrication. Therefore a periodical lubrication with a proper oil must be performed by means of a brush or by means of aerosol cans.The frequency with which this operation must be repeated depends much on the type of work and the environmental conditions, but usually every 500 working hours.

4.01 CHAIN ELONGATION

With the use, the chains tend to stretch.Such elongation can be reduced by acting on the chain tightener. The maximum reduction of the chain elongation is equal to 2%. When this value is exceeded, the chain must be replaced.

4.02

CHAIN MEASURE

Measure the elongation on more sections of 10 pitches, measured on the most stressed sections. This control must be performed about every 1500/2000 working hours. The measure of the 10 pitches is represented in the table below with also an indication of the corresponding chain. If, before the control, the chains have undergone negligible elongations, lower than 2%, this does not mean the chain has remained intact and without any defect.On the contrary, you can have deformations caused by the stress; therefore it is better to carefully check the whole chain in order to control the wear state of the links, the hinge pins, the chain tightener and the chain tightener pin. CHECK O F T HE L IF T ING CHAIN EL O NG AT IO N

S am p le len g th 10 "P"

1"P"

T yp e o f ch ain

M ast

Pitch len g th "P"

S am p le len g th 10"P"

M axim u m elo n g atio n allo w ed A m m esso 2% referred to sam p le len g th mm

LL 1244

S im p le x

19.05

190.5

194.31

B L 534

Du p le x

15.86

158.75

162.00

4.03 CHECK OF LINKS, PINS AND CHAIN TIGHTENERS

Before checking, clean the chain enough by using paraffin or a paraffin derivative. It is possible to check the chain when it is positioned. Check the chain and its associated components (fig. beside):

A) Worn pin B) Damaged pin C) Crack of the links D) Wear of the link borders E) Wear and ovalization of the link hole F) Excessive play between the links G) Oxidation check H) Wear and ovalization of the chain tightener hole I) Worn chain hinge pin

F H

If the chains show one or more of the above-mentioned wear problems, they must be replaced.

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SERVICE

REDUCTION GEAR

1.00 IDENTIFICATION OF THE REDUCTION GEAR COMPONENTS....................................................................2 1.01 COMPONENT TABLE...............................................................................................................................3 2.00 REMOVAL OF THE REDUCTION GEAR: REPLACEMENT OF THE COMPLETE REDUCTION GEAR.............4 3.00 OIL DRAIN FROM THE REDUCTION GEAR.......................................................................................6 3.01 OIL FILLING IN THE REDUCTION GEAR .........................................................................................6 4.00 DRIVING TORQUES OF THE REDUCTION GEAR......................................................................................7

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REDUCTION GEAR 1.00 IDENTIFICATION OF THE REDUCTION GEAR COMPONENTS

19 23

10 11 9

20 12 22

5 16 24

14 15

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REDUCTION GEAR

COMPONENT TABLE

Re f. 1

De scription

Reduction gear box Reduction gear cover, steering gear fifth wheel

Drive wheel

Drive motor

5 6

Pinion and ring bevel gear Gear

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Pinion gear Upper taper roller bearing of the pinion Lower taper roller bearing of the pinion Spacer Shims Pinion retainer Drive wheel hub Shims Shims W heel hub bearings Snap ring Oil seal Motor flange grommet Greaser Oil drain plug of the reduction gear Oil filling plug of the reduction gear Ring nut for the pin Snap ring Reduction gear cover fastening screws

Use Standard Cold store

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SHELL SPIRAX 80 W 90 SHELL TRANSAXLE 75 W 90

1.4 Liters

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REDUCTION GEAR 2.00 REMOVAL OF THE REDUCTION GEAR : REPLACEMENT OF THE COMPLETE REDUCTION GEAR Necessary special tools

lifting band with No. 2 wooden blocks with proper bearing capacity of 2000 kg dimensions

hydraulic jack

hoist

tray to collect oil

7 mm Allen wrench

torque wrench

support for reduction gear

Necessary tools

large screwdriver

ratchet

17 mm socket wrench

Procedure Before starting to work wear suitable safety clothes. Park the truck in a safe area, away from the transit of other motor vehicles and from the passage of pedestrians. Lower the forks to the ground, turn the key OFF and disconnect the battery. Step 1 HYDRAULIC JACK - WOODEN BLOCKS Position the hydraulic jack in the centre of the chassis, lift the truck so that the wooden blocks can pass under it and position them under the chassis. Lower the hydraulic jack and lean the chassis against the blocks; remove the hydraulic jack (fig.1). Step 2 LARGE CROSS SCREWDRIVER Loosen the fixing screws of the motor bonnet. Remove the bonnet. Step 3 Remove the drive wheel (see “REMOVAL OF THE DRIVE WHEEL” page 3 steps 1,2 section: “FRAME MECHANICS”).

Fig. 1

Step 4 Remove the complete tiller (see “REMOVAL OF THE TILLER UNIT” page 19 steps 1,2 section: “FRAME MECHANICS”).

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Step 5 Remove the drive motor (see “REMOVAL OF THE DRIVE MOTOR” page 7 steps1,2 section “FRAME MECHANICS”).

Fig. 3

Step 6 7 mm ALLEN WRENCH - TRAY TO COLLECT THE OIL Position the tray under the reduction gear and by means of the Allen wrench, remove the plug from the reduction gear (ref.A fig.2), empty the reduction gear and reposition the plug. Step 7 SUPPORT FOR REDUCTION GEAR - 17 mm SOCKET WRENCH RATCHET - LIFTING BAND - HOIST Insert the tool in the reduction gear motor coupling hole (fig.6), hook an end of the band into the tool and the other end to the bridge crane. Lift and tension the band; by using the socket wrench loosen the bolts fastening the reduction gear to the chassis (ref.B fig.6). Lower the bridge crane, position the reduction gear on the floor and remove the band.

Step 8 LIFTING BAND - HOIST Hook the band to the column crosspiece (fig.3) and lift the truck to allow the reduction gear to be removed. Position the reduction gear on a workbench and replace or disassemble it. Fig. 4 To assemble carry out the procedure in the reverse order.

Fig. 5

Fig. 6

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REDUCTION GEAR 3.00 OIL DRAIN FROM THE REDUCTION GEAR Necessary special tools

oil proof gloves

tray to collect oil

Necessary standard tools

7 mm Allen wrench

Procedure After using the reduction gear, pay attention to the high temperature of the oil. Heat resistant gloves are recommended. Clean carefully the area near the filling and drain screws. Position a tray for the oil with proper dimensions under the drain screw. By means of the Allen wrench loosen the oil filling screw (ref.A fig.1), remove the filling screw. By means of the same Allen wrench loosen the oil drain screw (ref.B fig.1), remove the screw. Drain completely the oil in the tray. Clean carefully the drain screw from the dirtiness accumulated by the reduction gear during its working.

Fig. 1

Put some sealant “AREXON 35A42” on the filling and drain screws and screw with a 22 Nm driving torque.

3.01 OIL FILLING IN THE REDUCTION GEAR Necessary special tools

Necessary standard tools

B oil proof gloves funnel with hose

7 mm Allen wrench

Fig. 2 Procedure For what concerns the amount of oil and the viscosity classes refer to table on page 3 in this section. Loosen and remove the upper filling screw. For the filling use a funnel equipped with a hose with proper outside diameter. The correct amount of oil is reached when the oil level is near the lower edge of the oil filling hole or when the oil comes out from the oil filling hole. Put some sealant “AREXON 35A42” on the filling screw and screw with a 22 Nm driving torque.

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4.00 DRIVING TORQUES OF THE REDUCTION GEAR Continuous torque axis wheel 181 Nm Torque during acc. max. braking max. axis wheel 484 Nm Max. load on the wheel in axis with the motor 1100 Kg The bearing under the wheel with 1100 Kg Ratio Co/p= 4.24 static

(Ø 14x1,5M class 8) Ø20 cone with 1:5 5.9 Kgm (58Nm) Loctite 242 Arexon 52A42

(cone Ø20) with 1:5 C40 58÷73 Kg/m 6 Kgm (59Nm) Ø 20x1,5M Loctite 242 Arexon 52A42

Loctite 542

2.24 Kgm (22Nm) Arexon 35A42

Loctite 542

Motorsil D Arexon

Ø8x1,25 class 8.8 2,4 Kgm (23,5Nm) Loctite 242 Arexon 52A42

M 10x1,5 class 8.8 4,8 Kgm (47Nm) Loctite 242 Arexon 52A42

2.24 Kgm (22Nm)

Loctite 542 Arexon 35A42

Ø 10x 1,5 class 10.9 7.5÷8 Kgm (73÷78Nm) Loctite 242 Arexon 52A42

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2.24 7 Allen WRENCH M14x1,5 conic 2.4 13 hexag. WRENCH M8x1.25 4.8 17 hexag. WRENCH M10x1.5 5.9 22 hexag. WRENCH M14x1.5 6 30 hexag. WRENCH M20x1.5 7.5÷8 17 hexag. WRENCH M10x1.5

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NOTES

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BRAKING SYSTEM

BRAKING SYSTEM 1.00

ELECTROMAGNETIC BRAKE COMPONENTS OF THE DRIVE MOTOR............................................................................2

2.00

BRAKING SYSTEMS...........................................................................................................................................3

3.00

REMOVAL OF THE ELECTROMAGNETIC BRAKE....................................................................................................................4

3.01

REMPLACEMENT

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BRAKING SYSTEM

1.00 ELECTROMAGNETIC BRAKE COMPONENTS OF THE DRIVE MOTOR MODEL: ALL MODELS

5 6 7

Re f. 1

De scription

Complete electromagnetic brake Unit fixing bolts

Electromagnet

Braking plate

5 6

Lining adjusting nut Snap ring

7 8

Lining guide pinion Lining

OPERATION The electromagnetic brake, which is fixed on the drive motor, is only a parking brake with STOP or EMERGENCY function and it is a spring-loaded brake. When the electromagnet is supplied, it attracts the braking plate (ref.4) and releases the brake lining making it rotate freely. When the electromagnet is no more supplied, the springs push the plate downward on the brake lining enabling the braking.

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BRAKING SYSTEM

2.00 BRAKING SYSTEMS There are 3 braking systems:

• Release breaking. • Inversion braking. • Emergency and parking braking. A) RELEASE BRAKING It controls the deceleration ramp when the drive control is released. B) INVERSION BRAKING It controls the deceleration ramp when the drive control is inverted. The “inversion braking” called also reverse current braking is consists in reversing the current on the motor by changing the direction of travel when the truck is driving. The braking current must be adjusted so that the truck can stop within a distance not smaller than the length of the truck. C) EMERGENCY AND PARKING BRAKING The “emergency and parking braking” is obtained by the electromagnetic brake fixed on the drive motor.

The excessive decreasing of the braking space may compromise the good operation of some components of the truck, since during the braking the current on the motor reaches very high values thus causing (in case of wrong adjustment) an early wear of the brushes, the drive motor manifold and the drive wheel.

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BRAKING SYSTEM

3.00 REMOVAL OF THE ELECTROMAGNETIC BRAKE: REPLACEMENT OF THE COMPLETE BRAKE, REPLACEMENT OF THE BRAKE LINING Necessary standard tools

large slotted screwdriver

5 mm Allen wrench

external circlip pliers

feeler gauge

13 mm open ended spanner

scissors

Fig. 1

Step 1 LARGE SCREWDRIVER Loosen the screws fastening the motor bonner. Remove the bonnet.

Step 2 OPEN ENDED SPANNER - “T” SHAPED WRENCH - SCISSORS By using the open ended spanner loosen the three stop nuts (ref.A fig.1). By using the “T-shaped” wrench loosen the three screws fastening the electromagnetic brake to the drive motor (ref.B fig.1). By using the scissor cut the cable clamp to release the electromagnetic brake supply cable. Disconnect the connector and extract it from the retainer. Remove the brake from the motor.

Fig. 2

Fig. 3

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BRAKING SYSTEM

Step 3 EXTERNAL CIRCLIP PLIERS Extract the brake lining (ref.C fig.2) from the guide pinion. By using the circlip pliers remove the snap ring from the motor shaft (ref.D fig.4) and extract the guide pinion (ref.E fig.4).

D E

Replace the brake lining and the guide pinion. For the assembly carry out the operation in the reverse order. After the assembly carry out the adjustment

Fig. 4

3.01 ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE

H G Fig. 5 After assembling the electromagnetic brake unit, it is necessary to adjust the brake lining before using the truck. For a good braking the distance between the brake lining and the electromagnet (ref.F fig.5) must be not higher than 0.35 mm. Therefore a feeler gauge of that measure is required. Keep the three nuts loosened (ref.G fig.5), insert the feeler gauge near a bolt (ref.H fig.5), tighten the fastening screw by means of the Allen wrench (ref.I fig.5) Allen wrench and bring the plate nearer at a distance that allows extracting the feeler gauge with a little friction. Repeat the operation on all three bolts. Tighten the nuts by means of the open ended spanner (ref.G fig.5).

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NOTES

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