524159096.pdf

Technical Information for YALE Service Centres

Part No 524159096

This manual is addressed exclusively to the specialised technicians of the Yale service network

C849...........

MR14 MR14H MR16 MR16H MR16N MR20 MR2OH MR20W MR25

AC..

SERVICE

CONTENTS

Section: CONTENTS

GENERAL SAFETY PRESCRIPTIONS NEVER DO ANY CLEANING, LUBRICATING OR SERVICING WITH THE BATTERY CONNECTED. DO NOT WEAR RINGS, WATCHES, JEWELLERY, LOOSE CLOTHING SUCH AS SCARVES, UNBUTTONED OR UNZIPPED JACKETS OR SHIRTS THAT COULD GET CAUGHT UP IN MOVING PARTS. WE RECOMMEND INSTEAD THAT THE OPERATOR WEAR APPROVED SAFETY CAPS CLOTHING: HARD HAT, NON-SLIP FOOTWEAR, GLOVES, SAFETY GLASSES. DO NOT USE PETROL, DIESEL FUEL OR OTHER FLAMMABLE LIQUIDS AS DETERGENTS: USE INSTEAD NON-FLAMMABLE, NON-TOXIC COMMERCIAL SOLVENTS. DO NOT SMOKE, USE NAKED FLAMES OR CAUSE ANY SPARKS NEARBY WHEN HANDLING EASILY FLAMMABLE MATERIALS. When working on the truck outside the workshop, park on a level surface, if possible, and chock the wheels. If working on a gradient is unavoidable, chock the wheels to prevent the truck moving and transfer it to a level area as soon as it is safe to do so. Disconnect the batteries and label all the controls to warn of the work in progress. Immobilize the machine and all equipment that has to be lifted. When towing, use solely the prescribed towing points and make sure the pins and/or bolts are firmly secured before starting to pull. Lift and handle all heavy parts with lifting equipment of suitable capacity. Use the lifting eyes provided. Beware of persons in the vicinity of the load to lift. Do not get chains or steel ropes tangled up. Do not use damaged chains or kinked ropes for lifting or pulling. Always wear safety gloves when handling ropes or chains. Handle all parts carefully, do not put your hands or fingers between one part and another. Wear approved safety clothing such as safety goggles, gloves and footwear. The area where maintenance work is performed must be kept clean and dry. Clean up any spilt water or oil immediately. Do not pile up greasy or oily rags: they constitute a serious fire risk. Always store these materials in a closed metal container. Do not carry out any servicing on the machine with persons at the controls, unless they are qualified operators helping in the work to be done. When using compressed air to clean parts, protect your eyes with goggles that have side shields. Welding When welding, always wear the prescribed safety gear: welding goggles, helmet, overalls, gloves and footwear. Dark goggles should also be worn by anyone working in the vicinity of the welding operation. Never look at the welding arc without appropriate eye protection. Batteries When using batteries, remember that the both ends of cables must be connected to the terminals as prescribed: (+) to (+) and (-) to (-). Take care not short the terminals. The gas given off during battery recharging is highly flammable. When recharging, leave the battery compartment open for better ventilation and remove the caps.

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NEVER CAUSE SPARKS OR ALLOW ANY NAKED FLAMES NEAR THE BATTERY! Do not check the battery charge level by placing metal objects across the terminals. Before carrying any operations, check the electrical system for short-circuits. Always disconnect the batteries before working on the electrical system. For battery chargers and similar equipment, use only auxiliary power supplies with an efficient earth connection in order to avoid the risk of electric shock. Hydraulic system Pressurised fluid escaping through a tiny hole may be virtually invisible although projected with sufficient force to penetrate the skin; when checking for possible leaks, always use a piece of card or wood. Never use your hands. Always use the appropriate instruments when checking system pressure. NOTE: THIS MANUAL IS NOT INTENDED AS A SUBSTITUTE FOR THE USE AND MAINTENANCE MANUAL BUT AS A SUPPLEMENT TO IT

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CONTENTS

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SERVICE

CONTENTS

Section: CONTENTS

Section: 1.0 2.0 1.0 2.0 3.0 4.0 5.0 5.1 5.2 6.0 6.3 7.0 8.0 8.1 8.2 8.3 8.4 8.5 9.0 9.1 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.8 10.9 11.0 11.3 11.4 11.5 11.6 11.8 12.0 13.0 13.1

ELECTRICAL SYSTEM

INTRODUCTION TO THE TRUCK ............................................................................................................... 10 INSTALLING THE TRUCK .......................................................................................................................... 11 KEY TO ELECTRICAL DIAGRAMS ............................................................................................................ 14 KEY TO LOCATION OF ELECTRICAL COMPONENTS .............................................................................. 16 TABLE OF FUNCTION INPUTS .................................................................................................................. 18 PARAMETER TABLES .............................................................................................................................. 20 PROCEDURE FOR ACCESSING THE CALIBRATION FUNCTION FOR THE VARIOUS MODULES ................................................................................................................................................. 24 MODULE SEARCH PROCEDURE ............................................................................................................. 25 AC2 TRACTION INVERTER BATTERY VOLTAGE SETTING ...................................................................... 26 TRACTION START SEQUENCE ................................................................................................................. 27 HYDRAULIC FUNCTIONS START SEQUENCE ......................................................................................... 28 SPEED CUTBACK ..................................................................................................................................... 29 MODULES REPLACEMENT PROCEDURE ............................................................................................... 30 REPLACING MODULES 2 OR 5 - AC2 TRACTION INVERTER ................................................................. 30 REPLACING MODULE 1 - I/O CAN ........................................................................................................... 32 REPLACING MODULE 16 - SICOS (DISPLAY) .......................................................................................... 33 REPLACING MODULE 9 - MHYRIO ........................................................................................................... 34 REPLACING MODULE 6 - EPS-AC .......................................................................................................... 34 SICOS (DISPLAY) ...................................................................................................................................... 36 GENERAL DESCRIPTION OF CONTROL COMPONENTS AND INSTRUMENTS ....................................... 36 BATTERY CHARGE STATUS INDICATOR .................................................................................................. 37 SPEED CUTBACK INDICATOR .................................................................................................................. 37 TRAVEL DIRECTION AND WHEEL ROTATION INDICATOR ....................................................................... 38 SELECTED HYDRAULIC FUNCTION INDICATOR ...................................................................................... 38 TRACTION OPERATING MODE INDICATOR .............................................................................................. 39 HOUR METER ACTIVE INDICATOR ........................................................................................................... 39 TRUCK SPEED, TRUCK HOUR METER, FORKS HEIGHT, MODULE ALARM INDICATOR ....................... 40 PARKING BRAKE SELECTOR BUTTON ................................................................................................... 41 AUXILIARY HYDRAULIC FUNCTION SELECTOR BUTTON ....................................................................... 41 DRIVE PERMISSIVE FUNCTION SELECTOR BUTTON ............................................................................. 42 DISPLAY MENUS ...................................................................................................................................... 42 MAIN MENU 1 ........................................................................................................................................... 42 TESTER MENU ......................................................................................................................................... 43 ALARMS MENU ........................................................................................................................................ 43 PROGRAM OFFSET ................................................................................................................................. 44 INSERT PASSWORD ................................................................................................................................ 44 MAIN MENU 2 ........................................................................................................................................... 44 PROGRAM PASSWORD ........................................................................................................................... 46 READ USERS MENU ............................................................................................................................... 47 PRE-HEIGHT SELECTOR .......................................................................................................................... 48 OPERATION WITHOUT REACH CARRIAGE IN SEQUENCE ..................................................................... 49 OPERATION WITH REACH CARRIAGE IN SEQUENCE ........................................................................... 50 ADJUSTING THE PRE-HEIGHT SELECTOR .............................................................................................. 51 PROGRAMMING IN SELF-TEACH MODE ................................................................................................. 51 USING THE PRE-HEIGHT SELECTOR ...................................................................................................... 53 ALARMS .................................................................................................................................................... 54 DIAGNOSTICS ........................................................................................................................................... 55 TROUBLESHOOTING GUIDE .................................................................................................................... 55

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ADDITIONAL FUNCTIONS

OPTION SHEET No. 1 - Setting of the steering for a turn of “360° and 90°”...........................................................4 OPTION SHEET No. 2 - DC_DC converter installation.........................................................................................6 OPTION SHEET No. 3 - Flashing rotating light installation...................................................................................8 OPTION SHEET No. 4 - Working light installation.............................................................................................10 OPTION SHEET No. 5 - Reverse motion audible alarm installation......................................................................12 OPTION SHEET No. 6 - Height preselector installation .....................................................................................14 OPTION SHEET No. 7 - Installation and enabling of the 5. function ....................................................................16 OPTION SHEET No. 8 - Deceleration of the “HE” mast lifting limit switches........................................................19 OPTION SHEET No. 9 - Electric block of the lowering forks with 1200mm pallet....................................................21 OPTION SHEET No. 10 - Warmed seat installation ..........................................................................................23 OPTION SHEET No. 11 - Cab for -30° refrigerating room ...................................................................................27 OPTION SHEET No. 12 - Seat belt installation...................................................................................................35

Section:

HYDRAULIC SYSTEM

1.01 KEY TO HYDRAULIC SYSTEM SYMBOLS ................................................................................................ 2 HYDRAULIC DIAGRAMS ........................................................................................................................... 2a 1.02 CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS ......................................................................... 3 1.03 HYDRAULIC UNIT COMPONENTS ............................................................................................................. 4 1.04 TABLE OF HYDRAULIC UNIT COMPONENTS ........................................................................................... 5 1.05 BASIC TRUCK HYDRAULIC SYSTEM ........................................................................................................ 6 1.06 TABLE OF BASIC TRUCK HYDRAULIC SYSTEM COMPONENTS ............................................................ 6 1.07 MAST HYDRAULIC SYSTEM ..................................................................................................................... 7 1.08 TABLE OF MAST HYDRAULIC SYSTEM COMPONENTS .......................................................................... 7 1.09 SINGLE-ACTING LATERAL LIFT CYLINDER ............................................................................................... 8 1.10 TABLE OF SINGLE-ACTING LATERAL LIFT CYLINDER COMPONENTS .................................................. 8 1.11 SINGLE-ACTING CENTRAL LIFT CYLINDER .............................................................................................. 9 1.12 TABLE OF SINGLE-ACTING CENTRAL LIFT CYLINDER COMPONENTS................................................... 9 1.13 SINGLE-ACTING LIFT CYLINDERS WITH HYDRAULIC CUSHIONING AT DOWN AND UP STROKE LIMITS .......................................................................................................................... 10 1.14 PLUNGER TYPE LATERAL LIFT CYLINDER ............................................................................................. 11 1.15 TABLE OF PLUNGER TYPE LATERAL LIFT CYLINDER COMPONENTS .................................................. 11 1.16 PLUNGER TYPE CENTRAL LIFT CYLINDER ............................................................................................ 12 1.17 TABLE OF PLUNGER TYPE CENTRAL LIFT CYLINDER COMPONENTS ................................................. 12 1.18 PLUNGER TYPE LIFT CYLINDERS ........................................................................................................... 13 1.19 REACH CARRIAGE CYLINDER ................................................................................................................. 14 1.20 TABLE OF REACH CARRIAGE CYLINDER COMPONENTS ..................................................................... 14 1.21 FORKS TILT CYLINDER............................................................................................................................. 15 1.22 TABLE OF FORKS TILT CYLINDER COMPONENTS ................................................................................. 15 1.23 FORKS SIDESHIFTER CYLINDER ............................................................................................................ 16 1.24 TABLE OF FORKS SIDESHIFTER CYLINDER COMPONENTS ................................................................. 16 2.00 REMOVING THE LATERAL LIFT CYLINDERS FROM THE MAST ............................................................. 17 2.01 REPLACEMENT OF THE LATERAL SINGLE-ACTING CYLINDER SEALS ................................................ 19 2.02 REMOVING THE CENTRAL LIFT CYLINDERS FROM THE MAST ............................................................ 20 2.03 REPLACEMENT OF THE SINGLE-ACTING CENTRAL LIFT CYLINDER SEALS ........................................ 22 2.04 REPLACEMENT OF THE LATERAL PLUNGER CYLINDER SEALS .......................................................... 23 2.05 REPLACEMENT OF THE CENTRAL PLUNGER CYLINDER SEALS ......................................................... 25

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2.06 2.07 2.08 2.09 2.10 2.11

REMOVING THE FORKS TILT CYLINDER ................................................................................................. 27 REPLACING THE SEALS .......................................................................................................................... 29 REPLACEMENT OF THE SIDESHIFTER CYLINDER SEALS .................................................................... 30 REMOVING THE REACH CYLINDER ........................................................................................................ 31 REPLACEMENT OF THE REACH CYLINDER SEALS .............................................................................. 32 REPLACEMENT OF HYDRAULIC HOSES OF THE TILT CYLINDER AND SIDESHIFTER CYLINDER ................................................................................................................................................. 33 2.12 REMOVING THE CENTRAL CYLINDER HYDRAULIC SUPPLY HOSE ...................................................... 34

Section: 1.00 1.01 1.02 1.03 1.04 1.05 1.06 2.00 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10

MAST TYPES ............................................................................................................................................. 3 SIDESHIFTER COMPONENTS ................................................................................................................... 3 TABLE OF SIDESHIFTER COMPONENTS ................................................................................................. 3 BETA MAST ................................................................................................................................................ 4 HE 140L MAST ........................................................................................................................................... 5 HE 140 MAST ............................................................................................................................................. 6 HE 140R MAST .......................................................................................................................................... 7 PROCEDURE FOR REMOVING THE MAST .............................................................................................. 8 DIAGRAM WITH MAST ASSEMBLY DIRECTIONS .................................................................................... 10 MAST INCLINATION TABLE ....................................................................................................................... 11 FORK ARM CARRIAGE REMOVAL PROCEDURE .................................................................................... 12 BEARING REPLACEMENT PROCEDURE ................................................................................................ 14 GREASING THE BEARING ....................................................................................................................... 15 PROCEDURE FOR REPLACING THE MAST BEARINGS ......................................................................... 16 LIFTING CHAIN .......................................................................................................................................... 17 CHAIN MEASUREMENT ........................................................................................................................... 18 REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT) .............................................................................. 19 REPLACING THE LATERAL LIFT CHAINS ................................................................................................. 20

Section: 1.00 1.01 1.02 1.03 2.00 2.01 2.02 2.02 3.00 3.01 3.01 3.02 4.00 4.01 4.02 4.03

MASTS

MECHANICS

TABLE OF SCREW TIGHTENING TORQUES ............................................................................................. 2 DRIVE WHEEL REPLACEMENT PROCEDURE ......................................................................................... 3 LOAD WHEELS REPLACEMENT PROCEDURE (MODELS R1.4-R1.6-R1.6N) .......................................... 4 LOAD WHEELS REPLACEMENT PROCEDURE (MODELS R1.6 OPT.-R2.0-R2.0H-R2.0W-R2.5) ............. 5 FORKS SIDESHIFTER SLIDING SHOES REPLACEMENT PROCEDURE ................................................. 7 BATTERY BLOCK FUNCTION .................................................................................................................... 9 BATTERY BLOCK REMOVAL PROCEDURE ............................................................................................. 10 REPLACING THE LATCH AND SPRING .................................................................................................... 11 TRACTION MOTOR REPLACEMENT PROCEDURE ................................................................................. 12 TRACTION MOTOR COMPONENTS .......................................................................................................... 13 TABLE OF TRACTION MOTOR COMPONENTS ........................................................................................ 13 REPLACING THE ENCODER BEARING .................................................................................................... 14 PUMP MOTOR REMOVAL PROCEDURE ................................................................................................. 16 REPLACING THE PUMP CONNECTING FLANGE OIL SEAL .................................................................... 17 PUMP MOTOR COMPONENTS ................................................................................................................ 18 REPLACING THE ENCODER BEARING .................................................................................................... 19

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STEERING GEARED MOTOR REMOVAL PROCEDURE .......................................................................... 20 STEERING MOTOR COMPONENTS ......................................................................................................... 21 REPLACING THE ENCODER BEARING .................................................................................................... 22 STEERING UNIT ........................................................... ...................................................................... 23 STEERING UNIT LINKAGE COMPONENTS .............................................................................................. 24 TABLE OF STEERING UNIT LINKAGE COMPONENTS ............................................................................. 25 REPLACING THE STEERING UNIT GAS SPRING ..................................................................................... 26 ADJUSTING STEERING HANDWHEEL ROTATION RESISTANCE ............................................................. 27 DISASSEMBLING THE HANDWHEEL - DISPLAY UNIT ............................................................................ 28

Section: 1.00 1.01 1.02 1.03 2.00 2.01 2.02

REACH CARRIAGE

REACH CARRIAGES UTILISED ................................................................................................................. REACH CARRIAGE COMPONENTS .......................................................................................................... TABLE OF REACH CARRIAGE - TRUCK COMBINATIONS ........................................................................ TABLE OF REACH CARRIAGE COMPONENTS ......................................................................................... REACH CARRIAGE DISASSEMBLY PROCEDURE ................................................................................... BEARING REPLACEMENT ........................................................................................................................ REPLACING THE REACH CARRIAGE GUIDE SHOES ..............................................................................

Section: 1.00 1.01 2.00 2.01 2.02

1.00 1.01 1.02 1.03 1.04 1.05 1.06 2.00 2.01 3.00 3.01 3.02

REDUCTION GEAR

REDUCTION GEAR COMPONENTS .......................................................................................................... TABLE OF REDUCTION GEAR COMPONENTS ......................................................................................... REDUCTION GEAR REMOVAL PROCEDURE ........................................................................................... REPLACING THE MOTOR SHAFT OIL SEAL ............................................................................................ REPLACING THE DRIVE WHEEL AXLE OIL SEAL ....................................................................................

Section:

2 2 3 4 5 6 6

2 2 3 5 6

BRAKING SYSTEM

ELECTROMAGNETIC BRAKE COMPONENTS .......................................................................................... 2 TABLE OF ELECTROMAGNETIC BRAKE COMPONENTS ........................................................................ 2 LOAD WHEEL BRAKING SYSTEM COMPONENTS .................................................................................. 3 TABLE OF BRAKING SYSTEM COMPONENTS ....................................................................................... 3 LOAD WHEELS BRAKE COMPONENTS ................................................................................................... 4 TABLE OF LOAD WHEELS BRAKE COMPONENTS ................................................................................. 4 BRAKING SYSTEM .................................................................................................................................... 5 REMOVAL AND ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE ..................................................... 6 ADJUSTING AND PUTTING INTO SERVICE THE ELECTROMAGNETIC BRAKE ....................................... 7 REMOVING THE BRAKE MASTER CYLINDER .......................................................................................... 8 REPLACING THE LOAD WHEEL BRAKES ................................................................................................ 9 BLEEDING AIR FROM THE BRAKE CIRCUIT ............................................................................................ 11

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5.00 5.01 5.02 6.00 6.01 6.02 6.03 6.04 6.05

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Section: ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

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INTRODUCTION INSTALLING THE TRUCK D INTRODUCTION TO THE TRUCK ......................................................... 8 D INSTALLING THE TRUCK .................................................................... 9

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ELECTRICAL SYSTEM

1.0 INTRODUCTION TO THE TRUCK The reach trucks of the new range differ from the previous models because of a series of innovations in terms of ergonomics and performance. The truck is equipped with AC motors driven by the latest generation of controllers, and an electronic system composed of 6 modules that communicate and interact via a CAN BUS. This system has made it possible to achieve significant improvements in the truck’s hydraulic and traction performance characteristics. The hydraulic system is managed by a group of proportional solenoid valves that can be driven by three different control systems all of which are equipped with potentiometric joysticks. The current range is composed of seven chassis models and four mast models that can be combined in various configurations in accordance with the required lift heights and capacities The trucks are equipped with dataplates showing the serial number and located on the motor compartment hood next to the operator seat, the serial number of the mast punch marked on the right-hand external mast channel at a height of 1500 mm and a residual capacity dataplate located under the overhead guard in the centre of the external cross-member as shown in the following figure. The following sections of the manual contain detailed descriptions of truck components, functions, and performance specifications. The service manual is completed by the “AC MOTORS MODULAR CONTROL SYSTEMS” manual and the “EPS-AC” steering motor management system manual.

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TRUCK RESIDUAL CAPACITY RATING PLATE Fig.

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MAST SERIAL NUMBER PUNCH MARKING

Fig. 4

TRUCK SERIAL NUMBER DATAPLATE

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2.0 INSTALLING THE TRUCK MODEL ALL MODELS Trucks are delivered after testing and checking of all the factory parameters. Certain truck models are delivered with the mast removed because the overall height exceeds the maximum permissible height for transportation purposes. All functions of the trucks are tested, after which the mast is removed and the fork arm carriage is secured to its base in such a way that it does not tend to slide along the internal mast section. All hydraulic connections are suitably plugged to prevent the egress of oil during transportation. When the truck arrives at its destination the mast must be installed and all the various functions must be tested. To refit the mast, use a crane of suitable height or an overhead crane and a lifting sling of suitable capacity to lift the mast from the ground and install it on the basic truck (see figure below) There is a bag secured to the mast containing the fixing screws and shims to be inserted behind the mast base to impart the required inclination in accordance with the height. For directions on mast installation and positioning of the shims, refer to the section “masts, heading 2.01-2.02 page 10-11”. Set the battery voltage (Adjust Battery) on AC2 Traction inverter and AC2 Pump inverter (see procedure on pag. 26)

Fig. 5

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ELECTRICAL SYSTEM


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ELECTRICAL SYSTEM

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ELECTRICAL SYSTEM


ELECTRICAL SYSTEM D KEY TO ELECTRICAL DIAGRAMS ...................................................14 D KEY TO POSITION OF ELECTRICAL COMPONENTS ........................16 D FUNCTION INPUTS TABLE ................................................................ 18 D PARAMETER TABLES....................................................................... 20 D ACCESS PROCEDURE FOR CALIBRATION OF THE VARIOUS M ... 24 D TRACTION START SEQUENCE ......................................................... 27 D SPEED CUTBACK ............................................................................. 29 D MODULES REPLACEMENT PROCEDURE ....................................... 30 D SICOS DISPLAY ................................................................................ 36 D DISPLAY MENUS .............................................................................. 42 D PRE-HEIGHT SELECTOR .................................................................. 48 D ALARMS ............................................................................................ 54 D DIAGNOSTICS ................................................................................... 55 D TROUBLESHOOTING GUIDE ............................................................ 55

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1.0 KEY TO ELECTRICAL DIAGRAMS MODEL ALL MODELS D i a g ra m S y m b o l R e f. SW 1 SW 2 SW 3 SW 4 SW 5 SW 6 SW 7 SW 8 SW 9 S W 10 S W 11 S W 12 S W 13 S W 14 S W 15 S W 16 S W 17 S W 18 S W 19 S W 20 S W 21 S W 22 S W 23 S W 24 S W 25 S W 26 FU1 FU2 FU3 FU4 FU5 FU6 FU7 EM B ENC. M T R EN C . M S EN C . M P EN C . H .I EV I EV 2 EV 3 EV 4 EV 5 EV 6 EV 7 EV 8 OPT. 1 OPT. 2 H1 H2 H3 H4 M1 M2 L O A D C EL L M TR MP MS POT. 1 S S .S . T. M TR T. M P T. M S J 1 (2 a x i x ) J 2 (2 a x i x ) J1 J2 J3 J4

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D ia g r a m P a g e R e f. 1/7 1/7 2/7 2/7 3/7 3/7 3/7 3/7 3/7 3/7 3/7 4/7 4/7 4/7 4/7 4/7 4/7 5/7 5/7 5/7 4/7 5/7 5/7 4/7 4c /7 4c /7 1/7 1/7 1/7 1/7 2/7 2/7 2/7 2/7 2/7 2/7 3/7 3/7 3/7 3/7 3/7 3/7 3/7 3/7 3/7 3/7 3/7 3/7 4/7 4/7 4/7 3/7 2/7 3/7 3/7 1/7 1/7 1/7 4/7 1/7 2/7 2/7 3/7 2/7 4 -4 c / 7 4 -4 c / 7 4 a -4 d /7 4 a -4 d /7 4 a -4 d /7 4 a -4 d /7

D e sc ri p ti o n o f C o m p o n e n t E m e rg e n c y p u s h b u t t o n K e y s w it c h O p e ra t o r p re s e n c e in d u c t ive s e n s o r S t e e r w h e e l c e n t re d in d u c t ive s e n s o r S p e e d re d u c t io n a n d h e ig h t in d ic a t o r z e ro in d u c t ive s e n s o r S p e e d re d u c t io n in h e ig h t in d u c t ive s e n s o r In d u c t ive s e n s o r - R e a c h c a rria g e fo rw a rd s t o p - R e a c h c a rria g e re tra c t d e c e le ra t io n In d u c t ive s e n s o r - R e a c h c a rria g e re tra c tio n s to p - R e a c h c a rria g e fo rw a rd d e c e le ra t io n F o rk s lo w e rin g d e c e le ra t io n in d u c t ive s e n s o r F o rk s lo w e rin g in t e rlo c k in d u c t ive s e n s o r L o a d p re s e n c e o n fo rk s in d u c t ive s e n s o r F o rw a rd t ra ve l c o m m a n d o n p e d a l in d u c tive s e n s o r R e ve rs e t ra ve l c o m m a n d o n p e d a l in d u c tive s e n s o r F o rw a rd /re ve rs e t ra ve l S t a rt in d u c t ive s e n s o r P e d a l b ra k e c o n tro l in d u c t ive b ra k in g s e n s o r B a t te ry o u t o f p o s it io n in d u c tive s e n s o r O p e ra t o r p re s e n c e m ic ro s w itc h lo c a t e d u n d e r s e a t (o p tio n a l) Tra c t io n p e rm is s ive p u s h b u t t o n w it h b a t t e ry o u t P a rk in g p e rm is s ive p u s h b u tt o n L o w s p e e d t ra ve l p e rm is s ive b u t t o n a n d p e rfo rm a n c e c h a n g e (S L O W - S TD - H A R D H o rn b u t to n F ifth h y d ra u lic c irc u it c o n t ro l p u s h b u t to n A u t o m a t ic s c a le s c o n tro l p u s h b u t to n W o rk lig h t s p o w e r O N p u s h b u t t o n F o rw a rd t ra ve l s e le c t o r b u t to n o n d a s h b o a rd R e ve rs e t ra ve l s e le c t o r b u t to n o n d a s h b o a rd A C 2 t ra c t io n c o n tro lle r 3 0 0 A p o w e r fu s e A C 2 p u m p c o n t ro lle r 3 0 0 A p o w e r fu s e E P S A C c o n t ro lle r 3 2 A p o w e r fu s e A u x ilia ry lin e 1 0 A fu s e A u x ilia ry lin e 1 0 A fu s e A u x ilia ry lin e 1 0 A fu s e A u x ilia ry lin e 6 A fu s e E le c t ro m a g n e t ic b ra k e Tra c t io n m o t o r e n c o d e r S t e e rin g m o t o r e n c o d e r P um p m otor enc oder H e ig h t in d ic a tio n e n c o d e r P ro p o rt io n a l lo w e rin g s o le n o id va lve P ro p o rt io n a l lift in g s o le n o id va lve R e a c h c a rria g e re t ra c t io n p ro p o rt io n a l s o le n o id va lve R e a c h c a rria g e e x t e n s io n p ro p o rt io n a l s o le n o id va lve Tilt B a c k s o le n o id va lve Tilt F W D s o le n o id va lve F o rk s rig h t -h a n d s id e s h ift s o le n o id va lve F o rk s le ft -h a n d s id e s h ift s o le n o id va lve O p tio n s s o le n o id va lve w irin g c o n n e c t o r O p tio n s s o le n o id va lve w irin g c o n n e c t o r H o rn R e ve rs e t ra ve l w a rn in g s o u n d e r W o rk lig h t s Tru c k in m o t io n fla s h in g w a rn in g b e a c o n M o t o r c o m p a rt m e n t c o o lin g fa n M o t o r c o m p a rt m e n t c o o lin g fa n L o a d c e ll fo r d e te c t in g w e ig h t o f lo a d o n fo rk s A C t ra c t io n m o t o r A C pum p m otor A C s t e e rin g m o t o r Tra c t io n s p e e d va ria t io n p o t e n t io m e t e r B a t te ry to m a c h in e e le c t ric a l s y s te m c o n n e c t o r p lu g S t e e rin g s te p p e r m o to r Tra c t io n m o t o r t e m p e ra t u re p ro b e P u m p m o t o r te m p e ra t u re p ro b e S t e e rin g m o t o r t e m p e ra tu re p ro b e F o rk s lift/ lo w e r c o n t ro l a n d re a c h c a rria g e e x t e n d /re t ra c t c o n t ro l jo y s tic k F o rk s B a c k / F w d t ilt a n d rig h t / le ft s id e s h ift c o n t ro l jo y s t ic k F o rk s lift/ lo w e r c o n t ro l jo y s tic k R e a c h c a rria g e e x t e n d / re t ra c t c o n t ro l jo y s tic k F o rk s b a c k /fw d t ilt c o n t ro l jo y s t ic k F o rk s rig h t /le ft s id e s h ift c o n t ro l jo y s t ic k

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Sezione: ELECTRICAL SYSTEM

FUNCTIONAL ELECTRICAL DIAGRAM 1/7 MOTORS AND CONTROLLERS CONNECTION CONTROL CIRCUITS POWER SUPPLY

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Fuse after keyswitch

Solenoid valves power supply fuse

Auxiliary services power supply fuse

FUNCTIONAL ELECTRICAL DIAGRAM 2/7 AC TRACTION MODULE CONNECTION EPS AC MODULE CONNECTION

Reference to diagram number at top right 4a -4d,/7 joysticks R1 power supply positive. (Resistor for cold store version)

DC-DC CONVERTER FOR 12/24V POWER SUPPLY (OPTIONAL

1

M

1

2

1

24V ALL’INSERZIONE - 19V DI ALIMENTAZIONE 24V ON THE START UP - 19V TO KEEP EMB OPEN

2

1B - 2B PONTE CONFIGURAZIONE INVERTER PRESENTE = POMPA / NON PRESENTE = TRAZIONE 1B - 2B INVERTER JUMPER CONFIGURATION CLOSED = PUMP / OPEN = TRACTION

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FUNCTIONAL ELECTRICAL DIAGRAM 3/7 AC PUMP MODULE CONNECTION MHYRIO MODULE CONNECTION

3 1

2

1

1B - 2B PONTE CONFIGURAZIONE INVERTER PRESENTE = POMPA / NON PRESENTE = TRAZIONE 1B - 2B INVERTER JUMPER CONFIGURATION CLOSED = PUMP / OPEN = TRACTION

2

24V ALL’INSERZIONE - 19V DI ALIMENTAZIONE 24V ON THE START UP - 19V TO KEEP EMB OPEN

3

SE SW5 NON E’ PRESENTE PONTICELLARE 15A CON 12A IF SW5 IS NOT MOUNTED JUMPER 15A WITH 12A 1501469-3

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Sezione: ELECTRICAL SYSTEM FUNCTIONAL ELECTRICAL DIAGRAM 4/7 CAN I/O MODULE CONNECTION 2-JOYSTICK HYDRAULIC CONTROL FWD/REV TRAVEL CONTROL ON PEDALS

POT. J1

Function Lift Low Forw. Carr. Rev. Carr.

Range 2,6V - 4,5V 2,4V - 0.5V 2,4V - 0,5V 2,6V - 4.5V

POT. J2

Function Tilt Up Tilt Down Side Shift rh. Side Shift sh

Ra nge 2,6V - 4,5V 2,4V - 0.5V 2,6V - 4,5V 2,4V - 0.5V

SW13

SW12

DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FORW/REV AND TWO JOYSTICKS HYDRAULIC CONTROL

NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS NOT PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE PEDALS IS UTILIZED

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Sezione: ELECTRICAL SYSTEM FUNCTIONAL ELECTRICAL DIAGRAM 4a/7 CAN I/O MODULE CONNECTION 4-JOYSTICK HYDRAULIC CONTROL FWD/REV TRAVEL CONTROL ON PEDALS

C

D

B

POT. J1 POT. J2


Range 2,6V - 4,5V 2,4V - 0.5V 2,4V - 0,5V 2,6V - 4.5V

POT. J3 POT. J4


Ra nge 2,6V - 4,5V 2,4V - 0.5V 2,6V - 4,5V 2,4V - 0.5V

SW13

SW12

DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FORW/REV AND FOUR JOYSTICKS HYDRAULIC CONTROL


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R1

3

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RESITOR FOR COLD STORE VERSION

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Sezione: ELECTRICAL SYSTEM FUNCTIONAL ELECTRICAL DIAGRAM 4b/7 CAN I/O MODULE CONNECTION SINGLE JOYSTICK HYDRAULIC CONTROL FWD/REV TRAVEL CONTROL ON PEDALS

SW13

SW12

CON PEDALIERA DOPPIA IN FUNZIONE, IL COMANDO SUL JOYSTICK E’ DISATTIVATO WITH DUAL FUNCTION PEDAL, THE SPEED CONTROL IS DISABILITY DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FORW/REV AND ONLY ONE JOYSTICKS HYDRAULIC CONTROL


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Sezione: ELECTRICAL SYSTEM FUNCTIONAL ELECTRICAL DIAGRAM 4c/7 CAN I/O MODULE CONNECTION 2-JOYSTICK HYDRAULIC CONTROL FWD/REV TRAVEL CONTROL ON INSTRUMENT PANEL

POT. J1


Range 2,6V - 4,5V 2,4V - 0.5V 2,4V - 0,5V 2,6V - 4.5V

POT. J2

SW26

FORWARD BACKWARD WITH SWITCH AND TWO JOYSTICKS FOR IDRAULIC CONTROL


Range 2,6V - 4,5V 2,4V - 0.5V 2,6V - 4,5V 2,4V - 0.5V

SW25

NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE INSTRUMENT PANEL IS UTILIZED

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Sezione: ELECTRICAL SYSTEM FUNCTIONAL ELECTRICAL DIAGRAM 4d/7 CAN I/O MODULE CONNECTION 4-JOYSTICK HYDRAULIC CONTROL TRAVEL CONTROL ON INSTRUMENT PANEL

POT. J1

B

POT. J2


Range 2,6V - 4,5V 2,4V - 0.5V 2,4V - 0,5V 2,6V - 4.5V

POT. J3 POT. J4

SW26

FORWARD BACKWARD WITH SWITCH AND FOUR JOYSTICKS FOR IDRAULIC CONTROL

0 1

2

3

Ra nge 2,6V - 4,5V 2,4V - 0.5V 2,6V - 4,5V 2,4V - 0.5V

SW25

NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE INSTRUMENT PANEL IS UTILIZED

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4

R1 RESITOR FOR COLD STORE VERSION

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Sezione: ELECTRICAL SYSTEM FUNCTIONAL ELECTRICAL DIAGRAM 4e/7 CAN I/O MODULE CONNECTION SINGLE JOYSTICK HYDRAULIC CONTROL TRAVEL CONTROL ON JOYSTICK

SW25

SW26

FORWARD BACKWARD AND HYDRAULIC CONTROL WITH ONLY JOYSTICK

NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS PRESENT WHEN THE ITT JOYSTICK IS UTILIZED WITH INTEGRAL TRAVEL CONTROL

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FUNCTIONAL ELECTRICAL DIAGRAM 5/7 SICOS MODULE CONNECTIONS

1501469 - 10

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FUNCTIONAL ELECTRICAL DIAGRAM 6/7 CAN BUS MODULES CONNECTION

1501469 - 11

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FUNCTIONAL ELECTRICAL DIAGRAM 7/7 CONNECTION DIAGRAM POWER CABLES

1501486

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INPUT / OUTPUT CONNECTORS MODULES AC2 T, AC2 P

Input / output connectors module AC2 POMPA

Input / output connectors module AC2 TRAZIONE

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INPUT / OUTPUT CONNECTORS MODULES EPS AC, MHYRIO

Input / output connectors module EPS AC

Input / output connectors module MHYRIO

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INPUT / OUTPUT CONNECTORS MODULES CAN I/O, SICOS (display)

Input / output connectors module CAN I/O

Input / output connectors module SICOS

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ELECTRICAL SYSTEM

NOTES:

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ELECTRICAL SYSTEM


2.0 KEY TO POSITION OF ELECTRICAL COMPONENTS MODEL ALL MODELS Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Diagram Diagram Symbol Ref. Page Ref.

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

MTR MP MS SW3 Pot 1 SW14 SW12 SW13 SW15 H1 SW16 SW4 SW8 SW7 M1 S.S. EPS AC Logic SW25 SW26 SW21 AC2 Traction Logic AC2 Pump Logic CAN I/O Mhyrio Sicos M2 Enc Height Ind SW5 SW1 SW2 FU7 FU6 FU5 FU4 J1 (2axix) J2 (2axix) J1 J2 J3 J4

41

J ITT

21 22

42 43 44 45

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1/7 1/7 1/7 2/7 4/7 4/7 4/7 4/7 4/7 4/7 4/7 2/7 3/7 3/7 2/7 2/7 2/7 4c/7 4c/7 4/7

Description of Component AC traction motor - 6.4 kW 70 Hz AC pump motor - 11 kW 8 Hz AC steering motor - 0.4 kW 95 Hz Operator presence inductive sensor Acceleration traction potentiometer Forward/reverse travel start inductive sensor Forward travel selection inductive sensor on pedal Reverse travel selection inductive sensor on pedal Brake pedal control braking inductive sensor Horn Battery out of position inductive sensor Steer wheel centred inductive sensor Inductive sensor - reach carriage forward deceleration and retraction stop Inductive sensor - reach carriage retraction deceleration and forward stop Motor compartment cooling fan Steering stepper motor AC steering motor control module Forward travel selection switch on dashboard Reverse travel selection switch on dashboard Horn button

2/7

AC traction motor control module

3/7

AC pump motor control module

4/7 3/7 5/7 3/7 3/7 3/7 1/7 1/7 2/7 2/7 2/7 1/7 4-4c/7 4-4c/7 4a-4d/7 4a-4d/7 4a-4d/7 4a-4d/7

CAN I/O control module Mhyrio control module for valves bank management Sicos (display) control module for alarms and test information Panels cooling fan Height indication encoder Height encoder, speed reduction inductive zero sensor Emergency circuit breaker Keyswitch Auxiliary line fuse Auxiliary line fuse Auxiliary line fuse Auxiliary line fuse Joystick - forks Up/Down control, reach carriage extend/retract Joystick - forks tilt back/fwd control and forks left/right sideshift control Joystick - forks lift/lower Joystick - reach carriage forward/back control Joystick - forks tilt Fwd/Back control Joystick - forks left/right sideshift control Multifunction Joystick. Displace lever up and down for lift and lower, displace right 4b-4e/7 and left for reach carriage movements Travel forward / reverse control pushbutton Forks tilt Fwd / Back control pushbutton Forks right and left sideshift control pushbutton Horn button

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MOTORS COMPARTMENT ELECTRICAL COMPONENTS WITH FORWARD/REVERSE TRAVEL PUSHBUTTONS ON PEDALS MODEL ALL MODELS

16

15 2 3 17

1 4 5 6

8 7

9

5

12

11

13

14

6 10

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Section: ELECTRICAL SYSTEM MOTORS COMPARTMENT ELECTRICAL COMPONENTS FORWARD/REVERSE TRAVEL CONTROL WITH DIRECTION CHANGE CONTROL ON INSTRUMENT PANEL MODEL ALL MODELS

16

15 2 3 17

1

19

18

4

20

9

5

12

11

13

14

6 10

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4

ELECTRICAL COMPONENTS AND POSITION OF CONTROL MODULES MODEL ALL MODELS

25

43

44

30

30

29

42

30 37

35

36

45

28

29 38

39

29 40

41

19

27

18

19 20

18 20

23 22 21 30 26

32

24

31

33

34

29

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POSITIONING OF DECELERATION SENSORS ON REACH CARRIAGE MODEL ALL MODELS

140-150mm

1 2 3

1 2 3

4 STANDARD AND PLUS REACH CARRIAGE WITH SENSOR POSITIONING ACCORDING TO BASIC TRUCK BATTERY SIZE

4

BASIC TRUCK WITH THREE BASIC TRUCK WITH THREE

STANDARD AND PLUS REACH CARRIAGE WITH FOUR SENSOR HOLDER SLOTS

1

2 BASIC TRUCK WITH TWO SENSOR READING CAMS

NARROW REACH CARRIAGE WITH TWO SENSOR HOLDER SLOTS

POSITIONS OF SENSORS WITH REFERENCE TO BASIC TRUCK AND BATTERY DIMENSIONS MR14 MR14H MR16 MR16H MR16N MR20 MR20H MR20W MR25 Slot Ref. Battery Dimensions "A" "A" "A" "A" "A" "A" "A" "A" "A" Read distance between the two sensors 140-150mm Din C 420A (1220x280x784) 127 109 39 1 Din C 560A (1220x352x784) 127 109 39 39 51 2 Din C 700A (1220x424x784) 127 109 39 39 51 51 22 23 3 Din C 840A (1220x496x784) 51 51 22 23 4 1 2

Din B 420A (1032x350x784) Din B 560A (1032x440x784)

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ELECTRICAL SYSTEM

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ELECTRICAL SYSTEM


3.0 TABLE OF FUNCTION INPUTS MODEL ALL MODELS The tables show all the sensors and microswitches that are activated in accordance with the requested functions. Key

Input = Description of Functions =

List of sensor inputs in the modules with specification of pins and access connector. Description of the function to be executed

Enabled function =

Description of the requested enabled function

Control =

Controller involved

Pin =

Pin corresponding to signal output

Status =

State of the sensor at the time of the function request

SW4 - SW23 =

Sensors activated on the basis of the requested function

NOTES:

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Sezione: IMPIANTO ELETTRICO INPUT TABLE OF THE FUNCTIONS (Sheet 1/3) Inputs

TRACTION MAX SPEED

FORWARD SPEED

AC2-TR

ELECTROMAGNETIC BRAKE

AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

l

l

l l

l

l

l

l l

l

l

l

l l

l

l

l

SW1

J1/J1

J1/J2

J3

J4

SW21

AUTOMATIC WEIGHT BUTTON

l

SW3

SICOS 15/A

OPTIONAL 1-2 IDR.VALVE BUTTON

l l

SW17

SICOS 3/A

PARKING BUTTON

l

SW16

SICOS 2/A

SLOW SPEED BUTTON

l

SW15

SICOS 6/A

BATTERY OUT BUTTON

l

SW14

PEDAL MODE

l l

CLACSON BUTTON

l

ENABLE SIDE SHIFT

l

ENABLE TILT

l

ENABLE CARRIAGE

l l

ENABLE LIFT/LOW

l

l

EMERGENCY

l

SW12/25 SW13/26

DEAD MAN

l

SW11

SEAT SWITC (OPTIONAL)

l l

SW10

BATTERY OUT

ON

SW9

BRAKE

l

ENABLE

SW8

l

CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS 1/C 4/C 13/A 8/A 1/A 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B BACKWARD

SW7

l

FORWARD

SW4

l

LOAD PRESENCE

SW3

ON

INTERLOCK LOW FORKS

SW6

STATU S

REDUCTION SPEED LOW

SW5

CARRIAGE CUT OUT FORW. FOR. STOP CARRIAGE REV. SLOW D. CARRIAGE CUT OUT REVERSE FOR. SLOW D. CARRIAGE REV. STOP

REDUCTION SPEED LIFT

PIN

REDUCTION SPEED AND RESET ENCODER

FUNCTION OPERATED CONTROL

STEER POSITION

FUNCTION DESCRIPTION

DEAD MAN

= INPUT ACTIVITY

PUMP MODE

AC2-TR EPS-AC AC2-PU MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO CAN-I/O 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G

SW18

SW20

SW19

SW22

SW23

l

l

l

l

l

l l

l

l l

l l

l l

l l

l l

l l

l l

l l

l

l l

l l

l l

l l

l l

l l

l l

l l

l l

l l

l l

l

l l

l

l l

l l

l l

l l

l l

l l

l l

l l

l

l

l l

l l

l l

l l

l l

l l

l

l l

l l

l l

l l

l l

l

l l

l l

l l

l l

l l

l l

l l

l l

l l

l l

l

l l

l l

l l

l l

l l

l l

l l

l l

l l

l l

l l

l

l l

l l

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DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION MAX SPEED

9/F

ON

l

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DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION MAX SPEED

9/F

ON ON

l

l

FORWARD/BACKWARD WITH SWITCH TRACTION MAX SPEED

9/F

ON ON

l

l

FORWARD/BACKWARD WITH SWITCH TRACTION REDUCTION SPEED

9/F

ON ON

l

l

l

WITH SLOW DOWN BUTTON ACTIVITY DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED

9/F

ON ON

l

l

l

WITH SLOW DOWN BUTTON ACTIVITY DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED

9/F

ON ON

l

l

WITH SLOW DOWN BUTTON ACTIVITY FORWARD/BACKWARD WITH SWITCH TRACTION REDUCTION SPEED

9/F

ON ON

l

l

WITH SLOW DOWN BUTTON ACTIVITY FORWARD/BACKWARD WITH SWITCH TRACTION REDUCTION SPEED

9/F

ON ON

l l

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l

l

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WITH FORKS OVER FREE LIFT DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED

9/F

ON ON

l

l

WITH FORKS OVER FREE LIFT DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED

9/F

ON ON

l

l

WITH FORKS OVER FREE LIFT FORWARD/BACKWARD WITH SWITCH TRACTION REDUCTION SPEED

9/F

ON ON

l

l

WITH FORKS OVER FREE LIFT FORWARD/BACKWARD WITH SWITCH TRACTION SPEED REDUCTION

9/F

l l

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ON

l l

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ON

l

ON ON

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WITH CARRIAGE ALL OUT DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED

9/F

ON ON

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l

WITH CARRIAGE ALL OUT DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED

9/F

ON ON

l

l

WITH CARRIAGE ALL OUT FORWARD/BACKWARD WITH SWITCH TRACTION REDUCTION SPEED

9/F

ON

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WITH CARRIAGE ALL OUT FORWARD/BACKWARD WITH SWITCH

9/F

AGGIORNAMENTO

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5 6 Data: Marzo 2002 Part No: 524159096

Pag. 18a

SERVICE

Sezione: IMPIANTO ELETTRICO INPUT TABLE OF THE FUNCTIONS (Sheet 2/3) Inputs

TRACTION REDUCTION SPEED

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR


AC2-TR

BACKWARD SPEED

AC2-TR


AC2-TR

FORWARD SPEED

AC2-TR

l

J1/J1

J1/J2

J3

J4

SW21

PEDAL MODE

ENABLE

BACKWARD

FORWARD

SW1


l

SW3

OPTIONAL 1-2 IDR.VALVE BUTTON

l

SW17

PARKING BUTTON

l l

SW16

SLOW SPEED BUTTON

l

SW15

BATTERY OUT BUTTON

l

CLACSON BUTTON

l

ENABLE SIDE SHIFT

l l

ENABLE TILT

l

ENABLE CARRIAGE

l

ENABLE LIFT/LOW

l

EMERGENCY

l l

l

DEAD MAN

l

SW11 SW12/25 SW13/26 SW14


l

SW10

BATTERY OUT

l

SW9

BRAKE

SW8

LOAD PRESENCE

ON

SW7

INTERLOCK LOW FORKS

l

SW6

REDUCTION SPEED LOW

ON

SW5

REV. SLOW D. CARRIAGE CUT OUT FOR. SLOW D. REVERSE CARRIAGE REV. STOP

SW4

CARRIAGE

SW3

CUT OUT FORW. FOR. STOP CARRIAGE

STATUS


PIN


FUNCTION OPERATED CONTROL

STEER POSITION

FUNCTION DESCRIPTION

DEAD MAN

= INPUT ACTIVITY

PUMP MODE

AC2-TR EPS-AC AC2-PU MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO MHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B 1/C 4/C 13/A 8/A 1/A 6/A 2/A 3/A 15/A

SW18

SW20

SW19

SW22

SW23

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WITH BATTERY OUT DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED

9/F

ON

l

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WITH BATTERY OUT DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED

9/F

ON ON

l

l

WITH BATTERY OUT FORWARD/BACKWARD WITH SWITCH TRACTION REDUCTION SPEED

9/F

ON ON

l

l

WITH BATTERY OUT FORWARD/BACKWARD WITH SWITCH PARKING BRAKE ACTIVITY

9/F

ON OFF

l l

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l

DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW OR SWITCH PARKING BRAKE ACTIVITY


AC2-TR

BACKWARD SPEED

AC2-TR

9/F

OFF

l l

OFF

l

OFF

l

DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW OR SWITCH STRIGHT WELL LIFT FORKS MAX SPEED LIFT FORKS REDUCTION SPEED LOWER FORKS MAX SPEED LOWER FORKS REDUCTION SPEED CARRIAGE FORWARD MAX SPEED CARRIAGE FORWARD REDUCTION SPEED CARRIAGE FORWARD STOP CARRIAGE REVERSE MAX SPEED CARRIAGE REVERSE REDUCTION SPEED CARRIAGE REVERSE STOP TILT UP TILT DOWN SIDE SHIFT RIGHT SIDE SHIFT LEFT OPTIONAL 1


AC2-TR

ELECTIRC STEERING

EPS-AC AC2-PU MHYRIO AC2-PU MHYRIO MHYRIO MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO

MOTOR PUMP EV2 MOTOR PUMP EV2 EV1 EV1 MOTOR PUMP EV4 MOTOR PUMP EV4 MOTOR PUMP EV4 MOTOR PUMP EV3 MOTOR PUMP EV3 MOTOR PUMP EV3 MOTOR PUMP EV5 MOTOR PUMP EV6 MOTOR PUMP EV7 MOTOR PUMP EV8 MOTOR PUMP OPT.1

9/F

ON

l

ON

7/G

ON

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ON

7/G 8/G 8/G

ON ON ON

l l

ON

5/G

ON

l

ON

5/G

ON OFF

5/G

OFF ON

6/G

ON

l

ON ON OFF

6/G

OFF ON

4/G

ON ON ON ON

2/G

ON ON

1/G

ON ON

3/F

ON

AGGIORNAMENTO

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Pag. 18b

SERVICE

Sezione: IMPIANTO ELETTRICO INPUT TABLE OF THE FUNCTIONS (Sheet 3/3)

Inputs

LOWERANDCARRIAGEREVERSEMAXSPEED LOWERANDCARRIAGEREVERSE REDUCTION SPEED LOWERANDCARRIAGEREVERSESTOP LOWERANDSIDESHIFTRIGHT

LOWERANDSIDESHIFTLEFT LOWERWITHCARRIAGEALLREVERSE ANDINTERLOKFORKSDEVICEACTIVITY CARRIAGEREVERSEWITHFORKSALLDOWN ANDINTERLOKFORKSDEVICEACTIVITY AUTOMATICWEIGHTLOAD CLACSON

EV8-EV1 EV1

MHYRIO

MOTORPUMP

AC2-PU MHYRIO AC2-PU MHYRIO

MOTORPUMP EV2-EV4-EV1 MOTORPUMP EV2-EV4-EV1 MOTORPUMP EV2-EV4-EV1 MOTORPUMP EV2-EV3-EV1 MOTORPUMP EV2-EV3-EV1 MOTORPUMP EV2-EV3-EV1 MOTORPUMP EV7-EV1 MOTORPUMP

EV3 MOTORPUMP EV2 H2

BACKUPALARMDUALFUNCTIONPEDAL

REVERSESPEED

WITHDIRECTIONALCONTROLFW/BACKW

H3

BACKUPALARMFORWARDBACWARD WITHSWITH FLSHINGBEACON

REVERSESPEED H3 H1

CANI/O AC2-TR CANI/O AC2-TR CANI/O AC2-PU

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OPTIONAL 1-2 IDR .VALVE BUTTON

SW21

PARKING BUTTON

J4

SLOW SPEED BUTTON

J3

SW11 SW12/25 SW13/26 SW14

BATTERY OUT BUTTON

J1/J2

ENABLE

J1/J1

BACKWARD

SW1

SW10

FORWARD

SW3

SW9

LOAD PRESENCE

SW17

INTERLOCK LOW FORKS

SW16

REDUCTION SPEED LOW

SW15

SW8

PEDAL MODE

CARRIAGE CUT OUT FORW. FOR. STOP CARRIAGE REV. SLOW D. CARRIAGE CUT OUT FOR. SLOW D. REVERSE CARRIAGE REV. STOP


CLACSON BUTTON

LOWERANDCARRIGAFORWARDSTOP

EV2-EV3

ENABLE SIDE SHIFT

LOWERANDCARRIAGEFORWARDREDUCTION SPEED

EV2-EV3 MOTORPUMP

ENABLE TILT

LOWERANDCARRIAGEFORWARDMAXSPEED

EV2-EV3 MOTORPUMP

ENABLE CARRIAGE

LIFTANDCARRIAGEREVERSESTOP

EV2-EV4 MOTORPUMP

SW7

ENABLE LIFT/LOW

LIFTANDCARRIAGEREVERSEREDUCTION SPEED

EV2-EV4 MOTORPUMP

SW6

EMERGENCY

LIFTANDCARRIAGEREVERSEMAXSPEED

EV2-EV4 MOTORPUMP

SW5

DEAD MAN

LIFTANDCARRIAGEFORWARDSTOP

MOTORPUMP

SW4


LIFTANDCARRIAGEFORWARDREDUCTION SPEED

OPT.2

STATUS SW3

BATTERY OUT

LIFTANDCARRIAGEFORWARDMAXSPEED

AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO AC2-PU MHYRIO

MOTORPUMP

PIN

BRAKE

OPTIONAL 2

FUNCTIONOPERATED CONTROL


FUNCTIONDESCRIPTION

PUMP MODE

DEAD MAN

= INPUTACTIVITY

STEER POSITION

AC2-TR EPS-AC AC2-PU MHYRIOMHYRIOMHYRIOMHYRIOMHYRIOMHYRIOMHYRIO CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O CAN-I/O SICOS SICOS SICOS SICOS SICOS 1/C 4/C 13/A 8/A 1/A 6/A 2/A 3/A 15/A 4/F 12/B 2/B 12/A 1/A 2/A 3/A 5/A 7/A 8/A 3/G 4/G 1/G 2/G 9/A 14/A 5/G 6/G 1/B 4/B

SW18 SW20 SW19 SW22 SW23

ON

2/F

ON

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ON

7/G-5/G

ON

l

ON

7/G-5/G

ON OFF

7/G-5/G

OFF ON

7/G-6/G

ON

l

ON

7/G-6/G

ON OFF

7/G-6/G

OFF ON

7/G-5/G-8/G

ON

l

ON

7/G-5/G-8/G

ON OFF

7/G-5/G-8/G

OFF ON

7/G-6/G-8/G

ON

l

ON

7/G-6/G-8/G

ON OFF

7/G-6/G-8/G

OFF ON

2/G-8/G

ON

l

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1/G-8/G

ON

l

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8/G

OFF

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OFF

6/G

OFF

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ON

7/G

ON

8/G

ON

l

l

ON

7/G

ON

l

ON

7/G 8/F

ON ON

l l

OR

OR

l

l

AGGIORNAMENTO

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2

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3

4

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l OR

OR

OR

OR

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Pag. 18c

SERVICE


ELECTRICAL SYSTEM

NOTES:

UPDATE

0

1

2

3

4

5

6

Date: Mar. 2002

Part No.: 524159096

Page: 19

SERVICE

4.0 PARAMETERS TABLE MODULE 2 AC2 TRACTION The values of certain levels programmed in the “PARAMETER CHANGE” main menu are displayed in different ways depending on how the “PERFORMANCE TYPE” parameter in the config. menu “SET OPTIONS” is set on the SICOS display module. “PERFORMANCE TYPE” can be set in four different modes by means of the console (see following on the display (see description): numbers) or directly by means of the button 0) “SLOW” = Cutback speed 1 activation 1) “SOFT” = Reduction of parameters “ACCELERATION DELAY”, “RELEASE BRAKING”, “INVERSION BRAKING” and “MAX SPEED” by one level. 2) “STDN” = Parameters programmed from the console 3) “HARD” = Increase of parameters “ACCELERATION DELAY”, “RELEASE BRAKING”, “INVERSION BRAKING” and “MAX SPEED” by one level. NOTE: In order to change the value of the parameters in the “PARAMETER CHANGE” of the AC2 traction inverter you must have the parameter “PERFORMANCE TYPE” of the SICOS 2 (the display must indicate the letters STDN).

Page: 20

SET OPTIONS ADJUST

RUNNING ON ON Brake Digital

HOUR COUNTER BATTERY CHECK STOP ON RAMP AUX OUTPUT PEDAL BRAKING SET BATTERY TYPE ADJUST BATTERY ADJUSTMENT # 1 ADJUSTMENT # 2

PARAMETER CHANGE

CONFIG MENU'

MODULE (DISPLAY) PARAMETERS AC2 TRACTION

MAIN MENU'

ELECTRICAL SYSTEM


ACCELER. DELAY RELEASE BRAKING INVERS. BRAKING PEDAL BRAKING MAX SPEED FORW . MAX SPEED BACK CURVE CUTBACK STEER DEAD ANGLE FREQUENCY CREEP MAXIMUN CURRENT AUXILIARY TIME

Part No.: 524159096

KEYON OFF OFF Analog 48V 51,6V LEVEL 3 LEVEL 5

1 7 8 9 105 Hz 105 Hz 44% 6% 1,20 Hz 7 1.5

Date: Mar. 2002

Max Max Max Max Min 95Hz Min 95Hz -

= 9 = 9 = 9 = 9 Mx 114Hz Mx 114Hz

Max = 9 Min 0sec - Max 5sec

0

1

2

3

4

5

6

UPDATE

SERVICE


ELECTRICAL SYSTEM

4.1 PARAMETER TABLES MODULE 5 AC2 PUMP

SET OPTIONS ADJUST

HO UR CO UNTE R

RUNNING

S E T B A TTE RY TY P E

KE YON

48V

A DJUS T B A TTE RY

PARAMETER CHANGE

MAIN MENU'

CONFIG MENU'

M O DULE (DIS P L AY) P ARAM ET ERS AC2 P UM P

51,6V

M A XIM UN CURRE NT

7

M ax 9

4.2 PARAMETERS TABLE MODULO 6 EPS-AC

UPDATE

0

SET OPTIONS

HOUR COUNTE R

ADJUST

SET SET SET SET

PARAMETER CHANGE

MAIN MENU'

CONFIG MENU'

M ODULE (DIS P LA Y ) P A RA M E TE RS E P S -A C S TE E RING

S P E E D LIM IT A UX FUNCTION 3

7 5

M ax = 9 M ax = 9

S E NS IB ILITY

0

M ax = 9

5 5 2 2 40%

M ax = 9 M ax = 9 M ax = 9 M ax = 9 M in 0% M ax 70%

RUNNING

A UTO IM P UT A CTIV E RA NGE 360

2

1 ON

3

4

5

6

OFF 5.000V 2,5V 7,2V 10.0V

S TE E R 0-P OS . M IN. E NCODE R M A X E NCODE R 180 E NCODE R

A UX FUNCTION 2 CRE E P S P E E D COM P E NS A TION A UXILIA RY TIM E A NTIROLLB A CK

1

K E Y ON

Date: Mar. 2002

Part No.: 524159096

Page: 21

SERVICE

4.3 PARAMETERS TABLE MHYRIO MODULE 9

# # # # # # # #

2 2 2 2 1 1 1 1

ADJUST

SET OPTIONS

OP TION OP TION OP TION OP TION OP TION OP TION OP TION OP TION 48V

E V 2 TY P E E V 1 TY P E E V 3 TY P E E V 4 TY P E E V 5TY P E E V 6 TY P E E V 7 TY P E E V 8 TY P E S E T B A TTE RY TY P E

Not available

Not available

PARAMETER CHANGE

MAIN MENU'

CONFIG MENU'

M ODULE (DIS P LAY) P ARAM ETERS M HYRIO

Not available

Not available

4.4 SICOS MODULE 16 PARAMETERS TABLE

Page: 22

SET OPTIONS PARAMETER CHANGE ADJUST

CONFIG MENU

S ICOS M ODULE (DIS P LA Y ) P A RA M E TE RS

MAIN MENU

ELECTRICAL SYSTEM


P E RFORM A NCE TY P E HOUR COUNTE R E NCODE R TY P E LOA D S E NS OR P RE -HE IGHT S E LE CTOR P A S S W ORD A UX FUNCTION 1 OP TIONA L 1-2 HY D A UTOM A TIC W E IGHT

0 RUNNING 0 ON ON ON ON ON ON

K E Y ON 1 OFF OFF OFF OFF OFF OFF

E NCODE R A DJUS TM E NT

127

M in 1 M ax 255

Not available

Part No.: 524159096

Not available

Date: Mar. 2002

0

1

2

3

4

5

6

UPDATE

SERVICE 4.4.1

Section: ELECTRIC SYSTEM

MODULE 16 “SICOS” PARAMETER TABLE

SET OPTIONS

MODULE 16 "SICOS" PARAMETER PERFORMANCE TYPE HOUR COUNTER ENCODER TYPE AUX INPUT 1 PRE-HEIGHT SELECTOR PASSWORD AUX FUNCTION OPTIONAL 1-2 HYD AUTOMATIC WEIGHT ENCODER ADJUSTMENT ADJ 2000 KG POIN ADJ 1500 KG POIN ADJ 1000 KG POIN ADJ 0 KG POIN

PARAMETER CHANGE

MAIN MENU

ADJUST

CONFIG MENU

Not available

ELECTRIC

This table does not substitute the previous one, but it is an integral part of it. The update refers to the weighing function enabling The update begins from the serial number of Module 16 “SICOS” P/N 300206213

PARAMETERS LEVEL 0 1-2-3 RUNNING KEY ON 0 1 0 1-2 ON OFF ON OFF ON OFF ON OFF ON OFF 127 Min. 1 Max 255 2000 Kg value to be stored 1500 Kg value to be stored 1000 Kg value to be stored 0 Kg value to be stored

Not available

UPDATES TO BE INSERTED IN THE SERVICE MANUAL MR1.4/2.5 SECTION "ELECTRIC SYSTEM" Release Update description 1 4.4.1 New Module 16 "SICOS" parameter table 4.5.1 New Modul 1 "CAN I/O" parameter table 2

UPDATE

0 1

2 3

4

Page 22 23

5 6 Date: March 2004 Comp. No.:524159096 Page: 22a

SERVICE

ELECTRIC


Page: 22b Comp. No.:524159096 Date: March 2004 0

1

2

3 4

5 6

UPDATE

SERVICE


ELECTRICAL SYSTEM

4.5 PARAMETERS TABLE CAN I/O MODULE 1

SET OPTIONS

0 RUNNING ON ON ON ON ON ON ON

1 KEYON OFF OFF OFF OFF OFF OFF OFF

THROTTLE 0 ZONE

0%

Max 17%

THROTTLE X ZONE THROTTLE Y ZONE

45%

Min 18% Max 100%

47%

Min 4% Max 100%

CUTBACK SPEED 1 CUTBACK SPEED 2 1 ST SPEED COARSE 2 ST SPEED COARSE 3 ST SPEED COARSE 4 ST SPEED COARSE 5 ST SPEED COARSE PUMP CREEP # 1 PUMP CREEP # 2-3 PUMP CREEP # 4 PUMP CREEP # 5 LIFT SPEDD CTB LOW SPEED CTB SPEED 2 CUTBACK PUMP ACC. # 1 PUMP ACC. # 2-3 PUMP ACC. # 4-5 PUMP DEC DELAY PU DEC DEL # 2-3 ADJUST # 2 PRE-H. LIFT CTB PRE-H. LOW CTB OPTION 03 OPTION 04 OPTION 05 OPTION 06

3 3 9 6 7 6 6% 0 0 0 0 8 8 3 0 3 2 1 5 4 5 5 5 5 5 5

0

1

ADJUST MAIN MENU'

UPDATE

CHECK UP TYPE HOUR COUNTER BATTERY CHECK CHECK UP DONE SEAT SWITC SINGLE FUNCTION AUX FUNCTION 1 AUX FUNCTION 2 AUX FUNCTION 3

PARAMETER CHANGE

CONFIG MENU'

MODULE (DISPLAY) PARAMETERS CAN I/O

2

3

4

5

6

Date: Mar. 2002

Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max Max

= = = = = = = = = = = = = = = = = = = = = = = = = =

9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9

Part No.: 524159096

Page: 23

SERVICE


MODULE CAN I/O PARAMETER TABLE

SET OPTIONS

MODULE 1 "CAN I/O" PARAMETERS LEVEL PARAMETER CHECK UP TYPE HOUR COUNTER BATTERY CHECK CHECK UP DONE SEAT SWITCH SINGLE FUNCTION AUX FUNCTION 1 AUX FUNCTION 2 AUX FUNCTION 3 SPEED LIMIT

PARAMETER CHANGE

ADJUSTMENT

CONFIG MENU

This table does not substitute the previous one, but it an integral part of it. The updates concern the possibility of disabling the reduction speed function with the carriage completely extended. The update begins from the serial number of Module 1 “CAN I/O” P/N 300208628

MAIN MENU

ELECTRIC

4.5.1

Not available

CUTBACK SPEED 1 CUTBACK SPEED 2 1ST SPEED COARSE 2ND SPEED COARSE 3RD SPEED COARSE 4TH SPEED COARSE 5TH SPEED COARSE PUMP CREEP # 1 PUMP CREEP # 2-3 PUMP CREEP # 4 PUMP CREEP # 5 LIFT SPEED CTB LOW SPEED CTB SPEED 2 COT BACK PUMP ACC # 1 PUMP ACC # 2-3 PUMP ACC # 4-5 PUMP DEC DELAY PUMP DEC # 2-3 ADJUST # 1 PRE-H. LIFT CTB PRE-H. LOW CTB OPTION 03 OPTION 04 OPTION 05 OPTION 06

3 3 9 6 7 6 6 0 0 0 0 8 8 3 0 3 2 1 5 4 3 3 5 7 5 5

Page: 23a Comp. No.:524159096 Date: March 2004 0

Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9 Min = 0 Max = 9

1

2

3 4

5 6

UPDATE

SERVICE

ELECTRIC


UPDATE

0 1

2 3

4

5 6 Date: March 2004 Comp. No.:524159096 Page: 23b

SERVICE

ELECTRICAL SYSTEM


5.0 ACCESS PROCEDURE FOR CALIBRATION OF THE VARIOUS MODULES MODEL ALL MODELS

MODULES CAN BUS CONNECTION DIAGRAM Fig. 6 Each module (controller) is identified by a number. Thanks to the CAN BUS connection you can access programming of each module by means of the “SET MODEL MENU”, using the console to connect to any module by typing the relevant address. When a module assumes alarm status it inhibits all the other module by means of a signal transmitted on the CAN BUS. The display shows a description of the alarm and an indication of the module concerned. The most accessible module on the reach truck for connection of the programming console is the “EPS” which is accommodated behind the seat. To access this module simply move the seat forward and remove the “EPS” connector cover working through the opening in the truck body panel (Ref. A Fig. 9); now insert the console connector. For the access procedure to find the module required, refer to the sequence of operations described on the next page. NOTE: Before connecting the console to the module, set the keyswitch to OFF.

Fig. 8

A

Fig. 7

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5.1 MODULE SEARCH PROCEDURE MODEL ALL MODELS

CONFIG. MENU / SET MODEL

EPS-AC NA 0.15 48V 300 A 0000

DISPLAY

1)

Initial display

2)

Press ROLLUP+SETUP simultaneously

3)

The heading of the SET MODEL menu is displayed

4)

Press ENTER

5)

A number is displayed corresponding to the connected module

6)

Use SET UP or SET DOWN to select a different connected module

7)

The newly selected module is displayed

8)

Press OUT to quit the selection procedure

9)

A prompt asking you to confirm the change is displayed

KEYPAD CONFIG MENU SET MODEL

CONNECTED TO 1

CONNECTED TO 5

ARE YOU SURE? YES=ENTER NO=OUT

10) Press ENTER to confirm or OUT to cancel the change 11) The heading of the SET MODEL menu is displayed CONFIG MENU SET MODEL

12) Press ROLL DOWN, ENTER, and SET DOWN simultaneously 13) The display will show the screen relative to the selected module from which you can view/edit all the associated menus

AC2P 2B NA 0.21 48V 300 A 0000 Fig. 10

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5.2 AC2 TRACTION INVERTER BATTERY VOLTAGE SETTING MODEL ALL MODELS Before handing over the truck to the end customer, it is indispensable to set the battery voltage on the “AC2 Traction” inverter and on the “AC2 Pump” inverter. Before making these settings it is advisable to execute a supplementary charge of the truck battery to ensure that it is able to deliver the maximum voltage. With the truck switched off connect the programming console to the “EPS-AC” module (see procedure on page 17) and execute the procedure for selection of the “AC2 Traction” inverter “module 2” (see procedure on page 18); now select “MAIN - MENU - ADJUSTMENT” and select the “ADJUST BATTERY” parameter. Use a tester to check the exact battery voltage on the “AC2 Traction” inverter between -Batt. (negative power connection to the inverter) and the positive as present on pin 1 of connector F keyswitch input (Fig. 11); this value must be entered in the “ADJUST BATTERY” parameter. Select “AC2 Pump” inverter module 5 and set the same value in the “ADJUST BATTERY” parameter of the main menu “ADJUSTMENT”. Switch off the keyswitch and then power on again to store the new settings. If when the truck is switched on with the battery fully charged the display should indicate a battery charge of 90%, increase the value of the “ADJUSTMENTS # 1” parameter in the “CONFIG MENU’”. This setting is indispensable to obtain the correct battery charge reading on the display.

“AC2 TRACTION” INVERTER

+

-

Fig. 11

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6.0 TRACTION START SEQUENCE MODEL ALL MODELS When you board the truck, before starting observe the sequence described below.

6.1 TRUCK WITH TRAVEL DIRECTION REVERSAL PEDAL CONTROL 1) Set the keyswitch to ON and activate the main circuit breaker. 2) Press the deadman button (SW3 Fig. 15). 3) Select forward or reverse travel buy pressing the relevant button (SW12 or SW13 Fig. 15). 4) Press the accelerator. NOTE: If this sequence is not executed, the alarm “INCORRECT START” will appear on the display. If you release the deadman control the truck hydraulic functions will remain enabled for 1 minute. At the end of the function the “INCORRECT START” alarm will be shown on the display.

Fig. 12 SW13 SW12

SW3

6.2 TRUCK WITH TRAVEL DIRECTION REVERSAL CONTROL ON THE INSTRUMENT PANEL

Fig. 15

1) Set the keyswitch to ON and activate the main circuit breaker. 2) Press the deadman button (SW3 Fig. 20). 3) Select forward or reverse travel by pressing the relevant button (SW25 or SW26 Fig. 19-21). 4) Press the accelerator. NOTE : If this sequence of operations is not observed the “INCORRECT START” alarm will appear on the display. If the deadman control is released the truck hydraulic functions will remain enabled for 1 minute. At the end of the function the “INCORRECT START” alarm will appear on the display. SW26

Fig. 13

SW25

SW3

Fig. 20

Fig. 21 SW26

Fig. 19 Fig. 14

SW25

Fig. 17

Fig. 18

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6.3 HYDRAULIC FUNCTIONS START SEQUENCE MODEL ALL MODELS For the hydraulic functions perform the following sequence: 1) Set the keyswitch to ON and activate the main circuit breaker. 2) Press the deadman button (SW3 Fig. 23). 3) Select the required hydraulic function (depending on the group of joysticks installed on the truck (Fig. 24) NOTE: If you release the deadman control the hydraulic functions will remain enabled for 1 minute, after which the “INCORRECT START” alarm will be shown on the display.

1 JOYSTICK

4 JOYSTICKS

2 JOYSTICKS

Fig. 24

SW3

Fig. 22

Fig. 23

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This heading describes all the speed cutback options available on the truck.

7.1 BATTERY TROLLEY OUT OF POSITION (BATTERY EXTRACTED In these circumstances the truck travel controls are inhibited and the only available hydraulic function is reach carriage extend/retract. It is still possible however to move the truck by pressing the button on the display.

7.2 BATTERY DISCHARGED BY MORE THAN 80% In these circumstances the “BATTERY LOW” alarm is shown on the display. In addition to inhibiting the forks lift function, the truck traction function is reduced to 50% of the maximum available current. This parameter cannot be modified from the programming console.

7.3 FAULTY STEER WHEEL CENTRED SENSOR In this case the steering function remains active but truck travel speed is reduced by 50% of the maximum available current (Alarm “EPS NOT ALIGNED”). This parameter cannot be modified from the programming console.

7.4 SPEED CUTBACK WITH FORKS LIFTED BEYOND THE FREE LIFT HEIGHT This function is possible only in the presence of (SW5 Fig. 25) connected to Mhyrio Module 9 (see electrical diagram). Function adjustable with the programming console by means of the parameter “CUTBACK SPEED 2” of the CAN I/O Module 1 parameter change menu. It is advisable to maintain this parameter as per the factory setting.

7.5 SPEED CUTBACK WITH PUSHBUTTON

(SLOW)

SW5 Fig. 25

Function adjustable from the programming console by means of the parameter “CUTBACK SPEED 1” of the CAN I/O Module 1 parameter change menu. It is advisable to maintain this parameter as per the factory setting.

7.6 SPEED CUTBACK WITH DRIVE WHEEL IN STEERING TURN This function provides speed reduction that increases progressively to the maximum value, which corresponds to the value entered in the “CURVE CUTBACK” parameter (Parameter Change menu of AC2 Traction Inverter Module 2). When the wheel is steered through an angle of 90°, the angle percentage with respect to the centred wheel within which maximum speed is still available can be defined by means of the parameter “STEER DEAD ANGLE” (AC2 Traction Inverter Module 2 Parameter Change menu). It is advisable to maintain the parameters recommended by the manufacturer.

7.7 SPEED CUTBACK WITH REACH CARRIAGE EXTENDED In these circumstances with the reach carriage fully extended the truck travels with a speed reduction corresponding to 50% of the maximum available current. This parameter cannot be modified from the programming console.

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7.0 SPEED CUTBACK

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The following headings contain a description of the procedure for replacing each individual module in such a way that at the end of the operation the truck operates in exactly the same way as with the original modules. Note: Ensure you perform this procedure without skipping any of the steps in the sequence. Incorrect operations could damage the new module. Before replacing any of the modules check the table of settings relative to the module as shown in the manual and compare them with the parameters stored on the module in the PARAMETER CHANGE and SET OPTIONS submenus. The values could be different depending on the options enabled. At the end of the replacement operation always check that the new module is programmed in exactly the same way as the original module.

8.1 REPLACING MODULES 2 OR 5 - TRACTION OR PUMP INVERTER AC2 Before starting the replacement procedure save the controller settings on the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more details refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual). 1) Switch off the keyswitch an press the emergency pushbutton. 2) Disconnect the battery. 3) Only when the battery is disconnected: connect a resistor of between 33 and 100 Ohm 50W across the inverter positive B+ and negative B-. Wait for approximately 8 seconds while for the controller internal capacitors to discharge and then disconnect the resistor. Note: To avoid short-circuits ensure that the resistor is insulated. If it is impractical to use an external resistor to discharge the capacitors you must wait at least 90 seconds before disconnecting any of the power cables.

60 Ohm 50W RESISTOR

ELECTRICAL SYSTEM

8.0 MODULES REPLACEMENT PROCEDURE

1234 1234 1234 1234 1234 1234 1234 1234

Fig. 26

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4) Disconnect the power cables, ensuring that they are still marked in relation to the corresponding connectors; if the cables are not marked, mark them before disconnecting. 5) Disconnect auxiliary connectors C,D,F. In the case of the PUMP inverter, remember to disconnect the jumper on connector B to apply it to the new controller. Without this jumper the system is unable to operate. This jumper is not present on the TRACTION inverter.

BATTERY CABLES

TRACTION MOTOR POWER CABLES

D2 A2

B2 C2

F2

E2

Fig. 27

BATTERY CABLES

PUMP MOTOR POWER CABLES

D5 A5

B5 C5

F5

E5

Fig. 28

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6)

Unscrew the screws that secure the controller to the truck and remove the inverter.

7)

Install the new module fitting the screws, connectors and cables in accordance with a reverse sequence of operations with respect to the removal procedure. Remember that connector B of the PUMP inverter must be equipped with a jumper.

8)

Connect the console to the inverter

9)

After having checked the correct connection of the cables, connect the battery, reset the emergency switch and set the keyswitch to ON.

10) By means of the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller the module settings previously saved to the console by means of the SAVE PARAMETERS procedure. 11) With the assistance of the table in the manual check that all the PARAMETER CHANGE and SET OPTIONS submenu settings correspond. 12) Test all the truck functions.

8.2 REPLACING MODULE 1 - CAN I/O Note: the CAN I/O module is identical in terms of size, shape, and connector positions, to the MHYRIO module. Therefore, when replacing this module pay special attention to the identification label on the outer case. The truck duty hours are stored on the CAN I/O and SICOS (display) modules. If it should become necessary to renew the CAN I/O module you must first execute a procedure that makes it possible to transfer the duty hours value stored in the display to the new CAN I/O module. 1) With the keyswitch set to OFF connect the console to the SICOS module (display). Set the keyswitch to ON. 2) In the CONFIG MENU>SET OPTIONS submenu set the AUX FUNCTION 1>parameter to OFF. This allows the CAN I/O module to set up to receive the truck duty hour data stored on the DISPLAY. Before starting the replacement procedure remember to save the controller settings to the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual). 3) Switch off the keyswitch and press the emergency pushbutton. 4) Disconnect the battery. 5) Disconnect all the connectors after checking that their positions are clearly identified. 6) Unscrew the screws that secure the module to the truck and remove the module. 7) Install the new module, fitting the screws and connectors by following the removal steps in reverse order. 8) After having checked that the connectors are correctly inserted, connect the console to the CAN I/O module by means of the adapter that you removed from the faulty module and then inserted on the relative connector of the new CAN I/O module. 9) Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.

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10) With the console, via the RESTORE PARAMETERS submenu present in the MAIN MENU upload to the controller the settings of the module previously saved on the console by means of the SAVE PARAMETERS procedure. 11) Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE and SET OPTIONS submenus correspond, including any option settings. 12) Test all the truck functions.

8.3 REPLACING SICOS MODULE 16 (display) The truck duty hours are stored on the SICOS module and CAN I/O bus. If you need to replace the SICOS module you must perform a procedure that makes it possible to transfer the duty hours memorized on the CAN I/O to the SICOS. 1)

With the keyswitch set to OFF connect the console to the SICOS module. Set the keyswitch to ON.

2)

In CONFIG MENU>SET OPTIONS set the parameter AUX FUNCTION 1>to OFF. In this manner the SICOS module sets up to accept the truck operating hours stored on the CAN I/ O bus.

Before starting the replacement procedure remember to save the controller settings to the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual). 3)

Switch off the keyswitch and press the emergency pushbutton.

4)

Disconnect the battery.

5)

Disconnect all the connectors after checking that their positions are clearly identified.

6)

Unscrew the screws that secure the module to the truck and remove the module.

7)

Install the new module, fitting the screws and connectors by following the removal steps in reverse order.

8)

After having checked that the connectors are correctly inserted, connect the console to the SICOS module by means of the adapter that you removed from the faulty module and then inserted on the relative connector of the new SICOS module.

9)

Connect the battery, reset the emergency pushbutton and set the keyswitch to ON.

10) Using the console, by means of the RESTORE PARAMETERS submenu located in the MAIN MENU, download to the controller the settings of the original module saved on the console by means of the SAVE PARAMETERS procedure. 11) With the assistance of the table in the manual check that all the adjustments relative to the PARAMETER CHANGE and SET OPTIONS submenus correspond, including possible changes relative to the option settings. 12) Test all the truck functions. Note: If the options “PASSWORD” or “PRE-HEIGHT SELECTOR” were enabled on the previous display, these functions must be completely reset by means of the new display (see relative heading).

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8.4 REPLACING MODULE 9 - MHYRIO Before starting the replacement procedure remember to save the controller settings to the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual). 1)

Set the keyswitch to OFF and press the emergency pushbutton.

2)


3)


4)

Unscrew the screws that secure the controller to the truck and remove the module.

5)


6)

After having checked that the connectors are correctly inserted, connect the console to the MHYRIO module by means of the adapter that you removed from the faulty module and then inserted on the relative connector of the new MHYRIO module.

7)

Connect the battery, activate the emergency switch and set the keyswitch to ON.

8)

With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller the module settings previously saved to the console by means of the SAVE PARAMETERS procedure.

9)

Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE and SET OPTIONS submenus correspond, including any option settings.

10) Test all the truck functions.

8.5 REPLACING MODULE 6 - EPS-AC Before starting the replacement procedure remember to save the controller settings to the console by means of the SAVE PARAMETERS submenu present in the MAIN MENU (for more information refer to the “AC MOTORS MODULAR CONTROL SYSTEM” manual). 1)

Set the keyswitch to OFF and press the emergency pushbutton.

2)


3)


4)

Unscrew the screws that secure the controller to the truck and remove the module.

5)


6)

After having checked that the connectors are correctly inserted, connect the console to the EPS-AC module by means of the adapter that you removed from the faulty module and then inserted on the relative connector of the new EPS-AC module.

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Connect the battery, activate the emergency switch and set the keyswitch to ON.

8)

With the programming console, via the RESTORE PARAMETERS submenu in the MAIN MENU, download to the controller the module settings previously saved to the console by means of theSAVE PARAMETERS procedure.

9)

Use the table in the manual to check that all the adjustments relative to the PARAMETER CHANGE and SET OPTIONS submenus correspond, including any option settings.

10) Perform the most appropriate EPS-AC setup procedure depending whether or not the 360° steering or +90° -90° steering option is enabled (see “EPS-AC” manual). 11) Test all the truck functions.

NOTES:

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9.0 SICOS (DISPLAY) 9.1 GENERAL DESCRIPTION OF CONTROL COMPONENTS AND INSTRUMENTS The following section contains a description of the controls indicated on the display, the position of the controls, and their method of use. 1

17

+

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50

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14

16

2

S OP F T

13

3

Kmh

12 11

4

15

00 01

5

6

10

7

8

9 Fig. 29

9.2 TABLE OF DISPLAY SYMBOLS WITH DESCRIPTIONS Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

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Description Auxiliary hydraulic function (5th function) selector button Traction permissive selection button with battery out Parking brake function selector button Traction mode selector button LCD screen Numerical keypad for altimeter / pre-height selector settings (when installed) ENTER' key to use during reading of the various display menus UP and DOWN keys to use during reading of the display menus Out key to use during reading of the display menus Indicator for truck speed, hour meter, forks height, alarms on module Travel direction and drive wheel rotation indicator Hour meter running indicator Parking brake indicator Battery charge status indicator Selected hydraulic function indicator Speed cutback indicator Selected traction functional mode indicator

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Provides a proportional reading of battery charge status. The AC2 traction inverter reads the battery voltage and transmits the information to the display. Battery charge status is shown on the display by means of ten lines, each of which corresponds to 10%. When the battery charge falls to 30%, the corresponding three lines start flashing. At this point it is advisable to charge the battery. When battery charge reaches 20%, Traction inverter AC2 transmits a message to the display to give a 20% charge reading, and another message to the AC2 pump controller instructing it to inhibit the lift function, leaving only the reach carriage operational. Furthermore, the available traction current is reduced by 50% (this precaution serves to allow the truck to proceed to the charging station) (Fig. 30). NOTE: The battery charge indicator can operate correctly only if the ADJUST BATTERY procedure has been performed correctly prior to delivery of the truck (see the section of the manual regarding the electrical system).

+

-

100

Battery charge indicator

50

20

S O F T

Kmh

00 01 Fig. 30

9.4 SPEED CUTBACK INDICATOR This indicator is activated when ‘SLOW’ traction mode is selected (Fig. 31) pressing the button with , (the display presents the same symbol). Or when the following speed reduction the symbol speed states are tripped: - Reach carriage extended (50% current supplied to traction motor, not adjustable). - Forks height above free lift height (SW5 mast sensor connected to MHYRIO unit; speed cutback intensity is adjustable by means of CUTBACK SPEED 2 in CAN I/O).

Speed cutback selector button

+

100

-

50

Speed cutback indicator

20

S O F T

P Kmh

00 01 Fig. 31

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9.3 BATTERY CHARGE STATUS INDICATOR

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ELECTRICAL SYSTEM

9.5 TRAVEL DIRECTION AND DRIVE WHEEL ROTATION INDICATOR This indicator performs the following three functions: indication of truck forward travel direction, reverse travel direction and drive wheel rotation (in 45° steps). The drive wheel angular position and truck travel direction are shown by the arrow positioned inside the truck logo. When the truck is in use the arrow illuminates in accordance with the forward/reverse travel selector when the operator presses the accelerator pedal. The arrow shows the travel direction of the truck with respect to the seated operator; the right hand arrow illuminates when the truck proceeds in reverse, while the left hand arrow indicates that the truck is travelling forward (Fig. 32)

+

100

50

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-

S O F T

Kmh

00 01 Travel direction and drive wheel rotation indicator Fig. 32

9.6 SELECTED HYDRAULIC FUNCTION INDICATOR An arrow on the display indicates the type of hydraulic movement being performed: reach carriage extend/ retract, lift/lower, tilt back/forward (Fig. 33).

+

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Selected hydraulic function indicator Fig. 33

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Indicates the traction mode selected by means of the relevant pushbutton ; this function allows the operator to personalize truck traction functions without requiring the intervention of a skilled technician. There are four different preset levels that are shown on the display: SLOW / STND / SOFT / HARD SLOW - Maximum speed settable by means of the console connected to the CAN I/O module, edit the CUTBACK SPEED 1 parameter. STND - The acceleration, release braking, and top speed parameters programmed in the AC2 Traction Inverter module are applied. SOFT - The acceleration, release braking, and top speed functions are executed at a level below the levels programmed in the AC2 Traction Inverter module 2. HARD - The acceleration, braking, release braking, and top speed functions are executed at a level above the levels programmed in AC2 Traction Inverter module 2 (Fig. 34).

+

-

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50

20

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Kmh

00 01

Selected traction mode indicator Fig. 34

9.8 HOUR METER RUNNING INDICATOR Flashes during execution of any of the truck functions, thereby indicating that the hour meter is running (Fig. 35).

+

-

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50

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S O F T

Kmh

00 01

Hour meter running indicator

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Fig. 35

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9.7 SELECTED TRACTION OPERATING MODE INDICATOR

SERVICE

ELECTRICAL SYSTEM


9.9 INDICATOR FOR TRUCK SPEED, TRUCK HOUR METER, FORKS HEIGHT, MODULE ALARM HOUR METER / SPEEDOMETER For two seconds after the truck is switched on this meter indicates the total truck duty hours, reading the value stored on the CAN I/O module; the indication is subsequently replaced by a display of the truck speed. To display the truck duty hours without turning off the keyswitch press the ENTER key to access the main menu and then the OUT key to exit. This action will generate a two-second display of truck duty hours. NOTE:When the SICOS or CAN I/O module is replaced the truck duty hours can be retained (see below). PROCEDURE FOR RETAINING DUTY HOURS WHEN RENEWING THE CAN I/O MODULE Before renewing the CAN I/O module use the console to check that AUX FUNCTION 1 in SICOS is set to OFF, and then change the CAN I/O module by following the directions on page 30. When the truck is switched on the RESET HOUR METER alarm is displayed. After 1 minute the alarm message will be cleared and the duty hours memorized in SICOS will be transferred to the CAN I/O module and shown on the display. PROCEDURE FOR RETAINING DUTY HOURS WHEN RENEWING THE SICOS MODULE Change the SICOS module in accordance with the directions on page 31. When the truck is switched on the RESET HOUR METER alarm will be displayed; at this point you have one minute to connect the console to the SICOS module and change AUX FUNCTION 1 from OFF to ON. This done, the RESET HOUR METER alarm will be cleared and the duty hours memorized on the CAN I/O module will be shown on the display. We recommend resetting AUX FUNCTION 1 in SICOS from ON to OFF (default value) when the operation is terminated. SPEED/MODULE ALARM If an alarm is generated, the relevant name and the module on which the alarm is present will be shown in place of the truck speed display. To perform additional diagnostics the programming console must be connected to the faulty module. SPEED/FORKS HEIGHT INDICATION When a forks height indicator is installed with the relative correctly calibrated encoder, the height of the forks is displayed in place of the truck speed (Fig. 36).

+

100

50

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S O F T

Fig. 36

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Indicator of truck speed, hour meter, module alarm forks height

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The parking brake must be applied by pressing the relevant button with the “P” symbol; at this point the display will shown the letter “P” and all drive functions are inhibited, although the truck’s hydraulic functions remain active. When the button is pressed again the parking brake is released and truck drive functions are re-enabled (Fig. 37). ATTENTION The parking brake selector can be activated only when the keyswitch is set to 1 (ON). Do not use the parking brake as a service brake during normal operation of the truck.

Parking brake selector button

+

-

100

Parking brake indicator

50

20

S O F T

P Kmh

00 01

Fig. 37

9.11 AUXILIARY HYDRAULIC FUNCTION SELECTION BUTTON (5th FUNCTION) Enables an auxiliary hydraulic function (5th function). The function must be set initially with the programming console connected to the SICOS module, selecting “CONFIG MENU’ - SET OPTIONS”, and subsequently selecting the parameter “OPTIONAL 1-2 HYDRAUL VALVE ON/OFF”. When level OFF is selected the pushbutton has no effect. When level ON is selected the function is shown in place of the forks down indicator by means of an icon representing a hydraulic gripper (Fig. 38).

Auxiliary hydraulic function selection button (5th function) +

-

100

50

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S O F T

P Kmh

00 01

Fig. 38

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The fork logo changes and is replaced with a hydraulic gripper icon

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9.10 PARKING BRAKE SELECTOR BUTTON PARKING BRAKE INDICATOR

SERVICE


ELECTRICAL SYSTEM

9.12 TRACTION PERMISSIVE WITH BATTERY OUT FUNCTION SELECTOR BUTTON This button serves to allow limited truck traction mobility in order to facilitate a battery change. When, during loading and unloading of a battery to and from the battery change rollerway, it becomes necessary to move the truck slightly backwards or forwards, the truck safety systems prevent the normal travel controls from being used. In these circumstances, to move the truck the operator, seated at the controls, must press the relevant permissive button and then press the accelerator pedal. The resulting travel speed corresponds to 50% of the current available at Vmax. This value cannot be adjusted by means of the console (Fig. 39). ATTENTION This control must not be used during normal working procedures. Pressing this button at any speed would result in intensive deceleration. Traction with battery out permissive function selector button +

100

50

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Kmh

00 01

Fig. 39

10.0 DISPLAY MENU 10.1 MAIN MENU 1 Press the ENTER key to access the main menu 1 (Fig. 40). Pressing the ENTER key from a given position of the cursor arrow opens the page relative to the selected option. The MAIN MENU 1 submenus are described in the following headings.

main menu 1 TESTER SLAVES ALARMS PROGRAM OFFSET INSERT PASWORD

Fig. 40

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When you enter the TESTER menu you will be presented with the most important information relative to the traction motor inverter and pump motor inverter status and the operating hours of the various modules (Fig. 41). To go from tester screen 1 to tester screen 2 and then tester screen 3, press the DOWN ARROW KEY (Fig. 41). tester 1 CURRENT TRACTION VOLTAGE TRACTION FREQUENCY TRAC. TEMPERATURE TR.

= = = =

004 AMP. 009 % 000 HERZ 025 GRADI

tester 2 CURRENT PUMP VOLTAGE PUMP FREQUENCY PUMP TEMPERATURE PU.

= = = =

004 AMP. 009 % 000 HERZ 026 GRADI

tester 3 TR.HOUR COUNTER PU. HOUR COUNTER EPS HOUR COUNTER EV HOUR COUNTER

= = = =

00011 00006 00003 00129

Fig. 41

10.3 ALARMS MENU When you open the ALARMS menu you will be presented with the last 5 alarms stored with the information regarding the module concerned, the number of times the alarm has occurred, the temperature, and the time of the alarm (Fig. 42). Press OUT to display the message CLEAR ALARMS, at this point press OUT to leave the alarms in the memory, or press ENTER to erase them.

ALARMS 1)BATTERY OUT 2)HEIGHT ENC. ERROR 3)CAN BUS KO 4)BATTERY OUT 5)NULL

HOURS

NUM

NTC

0001 0003 0003 0003

01 04 01 01

17 29 29 27

MOD 1 1 2 1

Fig. 42

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10.2 TESTER MENU

SERVICE


ELECTRICAL SYSTEM

10.4 PROGRAM OFFSET To be set exclusively when either the forks height indicator or the vertical pre-height selector is present. The height indicator encoder installed on the mast starts reading at the end of the free lift. The PROGRAM OFFSET parameter makes it possible to program the free lift height in millimetres. This value will be added by the display module to the height indicator encoder count value. 1. KEY ON 2. Lift the forks up to the free lift before the mast sections begin to extend. Measure the distance of the forks from the ground in millimetres. 3. Press ENTER on the display to enter MAIN MENU 1. 4. Select the PROGRAM OFFSET menu using the up arrow / down arrow keys. 5. Press the ENTER key on the display to enter PROGRAM OFFSET . 6. Set the forks height from the ground value in millimetres using the display numerical keypad. 7. Press ENTER on the display: the message ‘MEMO’ will appear to confirm that the settings have been saved. 8. KEY OFF and then KEY ON to save all settings (Fig. 43).

ADJUSTMENT OFFSET VALUE

02150

Fig. 43

10.5 INSERT PASSWORD This submenu serves to input the password that provides access to use of the truck when this option is programmed (see PROGRAM PASSWORD heading). If the option is not set, selecting this function will automatically return you to the main menu.

10.6 MAIN MENU 2 In addition to MAIN MENU 1, there is a second menu designated MAIN MENU 2. This menu is ‘concealed’ from the operator and can be accessed by holding down the OUT key while setting the keyswitch to ON. In this case MAIN MENU 1 will appear and MAIN MENU 2 can be accessed by means of the down arrow key. main menu 1

ENTER

TESTER SLAVES ALARMS PROGRAM OFFSET INSERT PASWORD main menu 2

DOWN ARROW

PROGRAM BLOCK PROGRAM PASSWORD READ USERS

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By pressing the ENTER key with the cursor arrow positioned on a given option, you will automatically open the page relative to the option in question. The MAIN MENU 2 submenus are described in the following headings (Fig. 44).

10.7 PROGRAM BLOCK Serves to set an electrical lifting limit stop. This function is available solely when the pre-height selector or height indicator is installed. CALIBRATION PROCEDURE

1. KEY ON pressing the OUT key simultaneously, the MAIN DISPLAY appears.

+

S O F T

-

100

50

20

Kmh

00 01 Fig. 45

2. Press the ENTER key on the display to enter MAIN MENU 1. 3. Select the PROGRAM OFFSET menu with the down arrow / up arrow and check that the programmed free lift value is correct. 4. Press the OUT key on the display twice in succession to return to the MAIN DISPLAY. 5. Lift the forks until you reach the desired height. 6. Press ENTER on the display to enter MAIN MENU 1. 7. Enter MAIN MENU 2 by pressing the DOWN ARROW key. 8. Press the ENTER key on the display to enter the PROGRAM BLOCK function.

autoteaching HEIGHT VALUE = 04814 ENCODER VALUE = 05900

Fig. 46 9. Press the ENTER key on the display to save the value shown on the display; the message ‘MEMO’ will appear to confirm that the value has been effectively saved. 8. KEY OFF then KEY ON to save all settings (Fig. 45 - 46).

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SERVICE


ELECTRICAL SYSTEM

10.8 PASSWORD PROGRAM The password program serves to set up to 5 passwords to allow the truck to be used by 5 different operators. To store the 5 passwords in this menu enable the PASSWORD function as described in the following procedure. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Connect the programming console to the SICOS (module 16), see AC Motors Modular Control System service manual (Programming Section). KEY ON With the console enter the SICOS CONFIG MENU/SET OPTIONS submenu. Select the PASSWORD menu and set to ON to configure SICOS (Display) at the password function press OUT and then ENTER on the console to save the setting. KEY OFF, you can now disconnect the console from the SICOS module. KEY ON pressing the OUT key. Press ENTER on the display to enter MAIN MENU 1. Enter MAIN MENU 2 using the DOWN ARROW key Select PASSWORD PROGRAM with the UP ARROW key and then press ENTER on the display to enter the program.

set password PASS1 = 1986 PASS2 = 0000 PASS3 = 0000 PASS4 = 0000 PASS5 = 0000

Fig. 47

10. Select the password to be set using the DOWN ARROW and UP ARROW keys. 11. Press ENTER and set the password with the numerical keypad. 12. Press ENTER; the message ‘MEMO’ will be displayed to confirm that the data have been saved. The same procedure applies to all five passwords. 13. KEY OFF then KEY ON to save all your changes (Fig. 47). From this time on in order to use the truck functions it is necessary to enter one of the preset passwords. With the PASSWORD function enabled, when the truck is powered on the message ‘ALARM ON MOD 16 PASSWORD NEEDED’ is displayed (Fig. 48).

+

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-

S O F T

ALARM ON MOD 16 PASSWORD NEEDED Fig. 48

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1. Press ENTER to enter MAIN MENU 1 of the main display. 2. Select INSERT PASSWORD with the DOWN ARROW and open the function by pressing ENTER

INSERT YOUR PASSWORD !

1986

Fig. 49 3. Type the password on the numerical keypad. 4. Press ENTER to return to the main display; the truck functions will have been enabled (Fig. 49).

10.9 MENU READ USERS By entering the READ USERS menu of MAIN MENU 2 It is possiple to visualize the work hours at the end of each shift of each operator.

users logbook USERS = 1986 HOURS = 0006

Fig. 50

NOTE:

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ELECTRICAL SYSTEM

To input the access password:

SERVICE


ELECTRICAL SYSTEM

11.0 PRE-HEIGHT SELECTOR 11.1 COMPONENTS NEEDED The essential components for the correct operation of the pre-height selector are the encoder, installed on the mast to measure forks height from the ground, and the zero sensor (SW5).

HEIGHT INDICATOR ENCODER

ZERO SENSOR

Fig. 51 A microswitch or sensor to indicate the presence of a load on the forks can be used together with the preheight selector although it is not indispensable. This component is used to indicate whether or not the operator intends to perform a picking cycle (forks not loaded) or a put away cycle (forks loaded). If the indicator is not installed this definition is specified manually.

11.2 OPERATING MODES The pre-height selector gives the operator the opportunity to perform picking and put-away cycles on shelves on 21 programmable levels (00-20) in a semi-automatic manner. The various heights to perform these operations on various levels of shelving are programmed on the display beforehand. The programming procedures are described in the following headings. When the pre-height selector function is selected, the operator must indicate whether he intends to perform a put away (load) cycle or a picking (unload) cycle. If the forks load sensor (load cell) is installed, the display provides an indication of forks with or without load and the consequent put away or picking cycle is executed. If the load indicator is not present, the put-away (load) or picking (unload) selection is performed manually by the operator by means of the up arrow/down arrow keys shown on the display; the pre-height selector informs the operator with regard to the hydraulic functions necessary to complete the mission. These functions can be either lifting or lowering depending on the position of the forks at the time of the level request. Lifting hydraulic deceleration and stroke end cushioning are performed automatically. There are two types of possible programming. 1) Consider automatic movements of the reach carriage. 2) Do not consider automatic movements of the reach carriage. Both types of programming are illustrated below.

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A) UNLOAD SEQUENCE - EXAMPLE STARTING FROM GROUND 5. Lifting - UNLOADING OFFSET value defined with console in CANI/O PARAMETER CHANGE - OPTION 06 (see USING THE PRE-HEIGHT SELECTOR) 4. Reach carriage retract (sequence end) 3. Lifting end - height programmed by means of the display (see point 1).

PALLET

2. Deceleration phase - value defined with console in CAN I/O - PARAMETER CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see USING THE PREHEIGHT SELECTOR

1. Lifting (sequence start) - height programmed on display.

At points 1, 3 and 5 this symbol is presented on the display to indicate that a lift movement is required to reach the selected level. (indicated at point 3 because in this case extraction of the truck is not considered and the symbol is the same symbol as referred to in point 5).

Fig. 52

B) LOAD SEQUENCE - EXAMPLE STARTING FROM GROUND 5. Lowering - LOAD OFFSET value defined with the console in CANIO PARAMETER CHANGE - OPTION 05 (see USING THE PRE-HEIGHT SELECTOR) 4. Reach carriage extension. 3. Lifting end. 2. Deceleration phase - value defined with the console in CAN I/O PARAMETER CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see USING THE PRE-HEIGHT SELECTOR

1. Lifting (sequence start) - height programmed on display plus DEPOSIT OFFSET value (OPTION 5), see USING THE PRE-HEIGHT SELECTOR heading At point 5 this symbol is presented on the display to indicate that a lowering movement is required to reach the selected level. At point 1 this symbol is presented on the display to indicate that a lift movement is required to reach the selected level.

PALLET

Fig. 53

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11.3 OPERATION WITHOUT REACH CARRIAGE IN SEQUENCE

SERVICE


ELECTRICAL SYSTEM

11.4 OPERATION WITH REACH CARRIAGE IN SEQUENCE C) UNLOAD SEQUENCE - EXAMPLE STARTING FROM GROUND 5. Lifting - UNLOADING OFFSET value defined with console in CANI/O PARAMETER CHANGE - OPTION 06 (see USING THE PRE-HEIGHT SELECTOR) 6. Reach carriage retract (sequence end)

PALLET

3. Lifting end - height programmed by means of the display (see point 1). 4.Reach carriage extension.

2. Deceleration phase - value defined with console in CAN I/O - PARAMETER CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see USING THE PREHEIGHT SELECTOR 1. Lifting (sequence start) - height programmed on display. At point 6 this symbol is presented on the display to indicate that the reach carriage must be retracted. At point 4 this symbol is presented on the display to indicate that the reach carriage must be extended. At points 1 and 5 this symbol is presented on the display to indicate that a lift movement is required to reach the selected level.

Fig. 54

D) LOAD SEQUENCE - EXAMPLE STARTING FROM GROUND 5. Lowering - LOAD OFFSET value defined with the console in CANIO PARAMETER CHANGE - OPTION 05 (see USING THE PRE-HEIGHT SELECTOR) 4. Reach carriage extension. 3. Lifting end.

6. Reach carriage retract (sequence end)

2. Deceleration phase - value defined with the console in CAN I/O PARAMETER CHANGE - OPTION 03 (lifting) OPTION 04 (lowering) see USING THE PRE-HEIGHT SELECTOR 1. Lifting (sequence start) - height programmed on display plus DEPOSIT OFFSET value (OPTION 5), see USING THE PRE-HEIGHT SELECTOR heading At point 6 this symbol is presented on the display to indicate that the reach carriage must be retracted. At point 5 this symbol is presented on the display to indicate that a lowering movement is required to reach the selected level. At point 4 this symbol is presented on the display to indicate that the reach carriage must be extended. At point 1 this symbol is presented on the display to indicate that a lift movement is required to reach the selected level. Fig. 55

PALLET

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Before programming the various values relative to the required heights remember to enable the pre-heights selector function (trucks configured with the necessary components). The enable procedure is as follows: A) PRE-HEIGHT SELECTOR FUNCTION ENABLE WITHOUT REACH CARRIAGE IN SEQUENCE 1. Connect the programming console to the SICOS module 16, see AC Motors Modular Control System service manual (Programming Section). 2. KEY ON. 3. With the console enter the CONFIG MENU/SET OPTIONS submenu. 4. Select the PRE-HEIGHT SELECTOR parameter and set to ON to configure SICOS (Display) at the PRE-HEIGHT SELECTOR function; this done, press ENTER to save your settings. 5. KEY OFF to save all data; now the console can be disconnected from the SICOS module. B) PRE-HEIGHT SELECTOR FUNCTION ENABLE WITH REACH CARRIAGE IN SEQUENCE 1. Connect the programming console to the CAN I/O module 1, see AC Motors Modular Control System service manual (Programming Section). 2. KEY ON. 3. With the console enter the CONFIG MENU/SET OPTIONS submenu. 4. Select the AUX FUNCTION 2 parameter and set to ON to configure CAN I/O at the PRE-HEIGHT SELECTOR function; this done, press ENTER to save your settings. 5. KEY OFF to save all data; now the console can be disconnected from the CAN I/O module. After having enabled the function there are two methods to program the pre-height selector, one AUTOTEACHING (recommended) and the other in manual mode. Before performing the programming procedure (in both AUTOTEACHING and manual mode) you will need to check that the PROGRAM OFFSET value has been set correctly (see heading PROGRAM OFFSET in MAIN MENU1, DISPLAY MENU).

11.6 PROGRAMMING IN AUTOTEACHING MODE (RECOMMENDED METHOD) 1. KEY ON, the MAIN DISPLAY appears (Fig. 56).

+

-

100

50

20

S T N D

Mm

5025 Fig. 56

2. Lift the forks to the required height (the lowest programmable level must be higher than the value of (PROGRAM OFFSET). 3. Type the number of the level to be programmed (e.g. 03) on the display numerical keypad. The pre-height selector working screen is displayed (Fig. 57). PRE-HEIGHT SEL LEVEL NUMBER = 03 HEIGHT VALUE = 00000 ENCODER VALUE = 05025 LOAD PROGRAM = ENTER

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11.5 PRE-HEIGHT SELECTOR ADJUSTMENT

SERVICE


ELECTRICAL SYSTEM

4. Press ENTER to enter the pre-height selector programming screen. Autoteaching LEVEL NUMBER = 03 HEIGHT VALUE = 00000 ENCODER VALUE = 05025

Fig. 58

5. Press ENTER again to save the value acquired in AUTOTEACHING (value shown under the heading ENCODER VALUE). 6. Press OUT to return to the pre-height selector working screen and the press OUT again to return to the MAIN DISPLAY. 7. Programming of additional levels in AUTOTEACHING must always start from the MAIN DISPLAY with manual lifting. 8. KEY OFF to save all your data (Fig. 58).

11.7 MANUAL PROGRAMMING FROM THE DISPLAY 1. KEY ON, the MAIN DISPLAY appears (Fig. 59). +

100

-

50

20

S O F T

Kmh

00 01 Fig. 59

2. Type the number of the level you wish to program (e.g. 03) with the display numerical keypad. The preheight selector working screen is displayed (Fig. 60). PRE-HEIGHT SEL LEVEL NUMBER = 03 HIEGHT VALUE = 00000 ENCODER VALUE = 00000 LOAD PROGRAM = ENTER

Fig. 60

3. Press ENTER to enter the pre-height selector programming screen (Fig. 61). Autoteaching LEVEL NUMBER = 03 HEIGHT VALUE = 00000 ENCODER VALUE = 00000

Fig. 61

4. Specify the desired height in millimetres using the numerical keypad next to the item HEIGHT VALUE and then strike ENTER to save the value; use the UP ARROW and DOWN ARROW keys to move on to programming of further levels. Press OUT OUT to return to the main display. 5. KEY OFF to save all your data.

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From the main menu select the required level (e.g. 03) using the display numerical keypad. If the forks load sensor is not installed, the pre-height selector working screen is displayed in LOAD mode by default; if, however, the forks are empty and you intend execute an UNLOAD cycle, press the UP ARROW or DOWN ARROW to set UNLOAD. Function requested to follow the programmed sequence

Screen heading Selected level

PRE-HEIGHT SEL LEVEL NUMBER = 03 HEIGHT VALUE = 05025 ENCODER VALUE = 00000 LOAD PROGRAM = ENTER

Level preset height Current forks height To go to the level programming screen

UP ARROW

DOWN ARROW

Sequence to execute LOAD/UNLOAD

Fig. 62

IMPORTANT: If the forks load sensor is not installed, the LOAD/UNLOAD sequence must be set correctly before starting the sequence, otherwise there is a risk of damaging the shelving and/or the material stored on the shelves. ATTENTION: If the pre-height selector is set with the reach carriage movement option included, lift (or lower) the forks with the reach carriage retracted, extend the carriage, pick up the load, and then retract the carriage (sequence end). The pre-height selector working display (above) shows, with the forks symbol, the inputs required to complete each phase of the selected sequence; the operator must activate the appropriate joystick in relation to the requested function and maintain the function enabled until it stops automatically on the preset value. At this point the operator will be prompted for the next input required, and so forth until the end of the sequence. To modify (when necessary) the deceleration phase at the end of the lift/lower movement in such a way as to reach the selected level compensating for inertia and ensuring that the forks stop at the programmed height: Connect the console to the CAN I/O module 1. Connect the programming console to the CAN I/O module, see AC Motors Modular Control System service manual (Programming Section). 2. KEY ON 3. With the console enter the MAIN MENU/PARAMETER CHANGE submenu 4. Select the parameter OPTION 03 to modify deceleration during upward movement (default value is 5) Select the parameter OPTION 04 to modify deceleration during downward movement (default value 5) Increase the value to increase the deceleration distance. 5. Press OUT and then ENTER on the console to save the new setting. 6. KEY OFF to save all your changes; you can now disconnect the console.

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11.8 USING THE PRE-HEIGHT SELECTOR

SERVICE

ELECTRICAL SYSTEM


For reasons of headroom available above the load and the shelving, it may prove necessary to adjust the lifting distance to lift the pallet from the shelf or the lowering distance to deposit the pallet on the shelf(LOAD OFFSET and UNLOAD OFFSET) see operating examples in the headings OPERATION WITHOUT REACH TRUCK and OPERATION WITH REACH TRUCK IN SEQUENCE. To edit these values: 1. Connect the programming console to the CAN IOO module, see AC Motors Modular Control System service manual (Programming Section). 2. KEY ON 3. With the console enter the MAIN MENU/PARAMETER CHANGE submenu 4. Select the OPTION 05 parameter to modify the LOAD OFFSET (default value is 5) Select parameter OPTION 06 to edit the UNLOAD OFFSET (default value 5) Increasing the value of OPTION 05 corresponds to an increase in the loading stroke Increasing the value of OPTION 06 corresponds to an increase in the unloading stroke 5. Press ENTER, followed by OUT and then ENTER again on the console to save the modified value. 6. KEY OFF to save all data; at this point the programming console can be disconnected from the SICOS module.

12.0 ALARMS All the alarms are shown on the display together with an indication of the module on which the fault has occurred. Connect the console to the most accessible module (Module 6 EPS-AC) and perform the procedure indicated on page 23 in order to address the required module.

Every 200msec messages arrive from the MHYRIO, CAN I/O, PUMP, TRACTION and EPS modules as they confirm their connected status.

CAN BUS KO:

If within this interval one of the modules should fail to transmit the message to the DISPLAY, an alarm status results: CAN BUS KO MHYRIO: the mhyrio module has not transmitted its message CAN BUS KO CAN I/O: the can i/o module has not transmitted its message CAN BUS KO PUMP: the pump module has not transmitted its message CAN BUS KO TRACTION: the traction module has not transmitted its message CAN BUS KO EPS: the eps module has not transmitted its message -Connect to the specified module to identify the alarm condition. NO CAN MESAGE:

If no message reaches the display via the CAN BUS, the display assumes alarm status. Possible causes: - Interrupted communication due to a missing connection - Restore the connection. - Faulty display - Renew the SICOS module 16

NOTE: CAN BUS alarms on the display assume priority with respect to all other alarms.

12.1 ALARMS CONCERNING THE DISPLAY PASSWORD NEEDED

This alarm is generated when the truck access Passwords are requested. - Enter the access Password

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SERVICE EEPROM KO:

This alarm appears in the presence of a fault in the memory area in which the setup parameters are stored; the EEPROM KO alarm inhibits operation of the truck. Set the keyswitch to OFF and then to ON again; if the alarm is cleared note that the parameters stored previously have been erased and replaced by the factory default parameters. If the alarm persists - Renew the controller.

ENCODER RESET:

This alarm is generated when the truck is equipped with pre-height selector and zero sensor. When the keyswitch is set to ON the forks are above the zero level Possible causes: - Zero sensor faulty - Renew sensor - Sensor not reading - Reduce the sensor gap for more positive reading This alarm appears when the display hour meter count and the CAN I/O count are different. The differences are eliminated after 1 minute with the transfer of the hours value from the display to the CAN I/O module. Refer to the procedure for transferring the hours value from the display module to the CAN I/O module and vice versa - page 38.

RESET HOUR METER:

13.0

DIAGNOSTICS

13.1 TROUBLESHOOTING GUIDE The tables shown below are provided to complete the “diagnostics” section of the modules manual entitled “AC Motors Modular Control System”. For more rapid troubleshooting we recommend consulting both manuals.

NOTE:

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#NA ME?

Keysw itch

CA N-BUS

SW2

SW3

T.MTR

Traction motor thermal ov erload cutout

Operator presence sensor

EMB

ENEC-MTR

Electromagnetic brake

Permis sive f rom electric steering

Traction motor encoder f eedback

COM PONENT

SYM BOL ON DIAGRAM

1F

1C-4C

4F

6F, 12F

3F, 9F

3F, 9F

11F, 5F

3D, 5D

3D, 5D

3D, 5D

2D

1D

CONNECT. the truck travels w ithout alarms until it exceeds a speed of 2 km/h. A t this point the traction f unction is inhibited and the alarm is tripped

TRUCK REACTION

open

open

open c ircuit

s ensor output in short c ircuit (+V bat f ixed)

s ensor output interrupted

open c ircuit

c oil or w ires short-circuited

c oil or w ires in open circuit

inputs open, negativ e permis sive signal transmitted by EPS-A C is missing

Check enc oder connections and renew enc oder if neces sary

02 ENCODER ERROR

5

6

check pow er f uses and pow er connection

TROUBLESHOOTING GUIDE (AC2 TRACTION MODULE 2)

02 V MN LOW

alarm activ e if tripped at start-up. No alarm if tripped during traction

check keys w itc h and relative connections

check CA N-BUSS lines connections. Renew the module if necess ary

16 NO CA N MESSA GE; 01 CA N BUS KO EPS or 01 CA N BUS KO TR in the c ase of intermittent connections 01 CA N BUS KO TR immediately; 05 CA N BUS KO later,

renew operator presenc e sensor (lef thand pedal)

renew operator presenc e sensor (lef thand pedal)

check thermal c utout connec tions and general condition. A naly ze reasons f or motor temperature rise

02 INCORRECT STA RT

02 INCORRECT STA RT only af ter having pressed the acc elerator

02 MOTOR TEMPERA TURE

02 COIL SHORTED, if this f ault occurs check elec tromagnetic brake during trac tion; 02 INCORRECT STA RT connection or renew the brake if the f ault trips during s tartup

renew elec tromagnetic brake

06 MA IN CONT. OPEN, if occ urs f ault to be f ound on elec tric s teering during trac tion; 02 INCORRECT STA RT sy stem. Check alarms on EPS-A C during startup



ACTIONS REQUIRED

None

02 ENCODER ERROR

ALARM

no f unction. A larm activ e

f unctions blocked. A larm ac tive

f unctions blocked. A larm ac tive only af ter having pressed the ac celerator pedal f unctions blocked. A larm ac tive w hen keysw itch is s et to ON

alarm activ e

f unctions blocked and alarm activ e

no active alarms. Brake engaged. The motor tends to run w ith braking applied

traction inhibited and alarm active

encoder phases A and B are the truck travels at reduced speed No s horting alarm displayed the truck travels w ithout alarms until it exceeds a speed of 2 km/h. A t this the encoder phases are at point the traction f unction is inhibited B and the alarm is tripped

one of the w ires is not c onnected

FAULT TYPE

AC2-TRACTION (MODULE 2)

ELECTRICAL SYSTEM


SERVICE

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#NAME?

Keysw itch

SW2

T.MS

Steering motor thermal cutout

CAN-BUS

STEPPER MOTOR

SW4

ECN-MS

Stepping motor (steering transducer)

Wheel centred sensor

Steering motor encoder feedback

COMPONENT

SYMBOL ON DIAGRAM

open

open

open circuit

3A, 4A, 13A, 14A

channels A/B open

common open

sensor output short-circuited

sensor output open circuit

open circuit

11B

TRUCK REACTION

16 NO CAN MESSAGE

06 MOTORE TEMPERATURE

06 D LINE SENSOR KO

06 NOT ALIGNED

06 MOTOR LOCKED

ALARM

check connection and general condition of thermal cutout. Analyze reasons for motor temperature rise check CAN-BUS lines connection. If necessary renew the module

check stepper motor connections. Renew if necessary

check w heel centred sensor and relative connections. Renew if necessary

Check encoder connections and renew encoder if necessary

ACTIONS REQUESTED

no function. Alarm active

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ELECTRICAL SYSTEM

TROUBLESHOOTING GUIDE (EPS-AC TRACTION MODULE 6)

01 CAN BUS KO EPS starting to steer; check keysw itch and relative 16 CAN BUS KO EPS at keysw itch connections pow er-on alarm active if tripped at pow er up. No check pow er fuse and pow er 06 POWER FAILURE #2 alarm if tripped during traction connections

functions inhibited. Alarm active

traction speed reduction and alarm active


the drive w heel steers clockw ise for 5 seconds and then the alarm trips and the truck travels at reduced speed

Brief steering turn f ollow ed by functions inhibit w ith alarm active Brief steering turn f ollow ed by B- open functions inhibit w ith alarm active encoder phases A and B are Brief steering turn f ollow ed by short-circuited functions inhibit w ith alarm active

+5V open

FAULT TYPE

11A, 7A

3B, 9B

4B

12B

16A, 17A

8A

6A

CONNECT.

EPS-AC (MODULE 6):

SERVICE Section: ELECTRICAL SYSTEM

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#NAME?

Keyswitch

SW2

1F

1C-4C

CAN-BUS

open

open

open circuit

open

open

encoder phases are at -B

5D

6F, 12F

encoder phases A and B are short-circuited

one of the wires is not connected

FAULT TYPE

3D

1B, 2B

T.MP

ENC-MP

2D

1D

SYMBOL ON CONNECT. DIAGRAM

Pump inverter configuration jumper

Thermal cutout

Pump motor encoder feedback

COMPONENT

alarm active




alarm active

the pump rotates slowly without alarms until the rotation speed increases. At this point the functions are inhibited and the alarm is tripped

TRUCK REACTION

AC2-PUMP (MODULE 5)

check for presence of jumper on connector B.

check connection and general condition of thermal cutout. Analyze reasons for motor temperature rise

check encoder connections and renew encoder if necessary

ACTIONS REQUIRED

05 VMN LOW

16 CAN BUS KO PU

2

TROUBLESHOOTING GUIDE (AC2 PUMP MODULE 5)

check power fuse and power connection

check keyswitch and relative connections

16 NO CAN MESSAGE; if connection is intermittent or open during operation: 01 check CAN-BUS lines connection. If CAN BUS KO EPS& 01 CAN BUS KO necessary, renew the module TR

16 CAN BUS KO PU

05 MOTOR TEMPERATURE

05 ENCODER ERROR

ALARM

ELECTRICAL SYSTEM


SERVICE

3

4

5

6

UPDATE

UPDATE

0

1

2

3

4

5

6

Date: Mar. 2002

Reac h c arriage bac k limit s ens or

Reac h c arriage f orw ard limit s ens or

Lif ting s peed reduc tion s ens or

Height indic ator/trac tion s peed c utbac k af ter

Height indic ator enc oder

COM PONENT

SW8

SW7

SW6

SW5

ECN-HEIGHT IND

SYM BOL ON DIAGRAM

3A

2A

1A

12A

4D, 2D CUTBA CK SPEED 2 ac tiv e. If open at the time of pow er-on, alarm ac tiv e

the v alue of the height indic ator remains f ix ed on the dis play

T RUCK REACTION

s ens or output

s ens or output

s ens or output

s ens or output

in s hort c irc uit

lif ting s peed reduc tion not ac tiv e

lif ting s peed reduc tion alw ay s ac tiv e No c arriage retrac ted s top if output opens w hile f unc tion is ac tiv e; no c arriage f orw ard f unc tion if already c ompletely at retrac ted s troke limit. interrupted Res etting the key s w itc h it is pos s ible to ac tiv ate the c arriage f orw ard mov ement w ith reduc ed pump s peed until the oppos ite s troke limits w itc h trips c arriage retrac ted s troke limit not s hort-c irc uited f unc tioning; c arriage ex tended s peed reduc tion not f unc tioning No c arriage f orw ard s top if output opens w hile f unc tion is ac tiv e; no c arriage retrac ted f unc tion if already c ompletely at f orw ard s troke limit. interrupted Res etting the key s w itc h it is pos s ible to ac tiv ate the c arriage bac k mov ement w ith reduc ed pump s peed until the oppos ite s troke limits w itc h trips c arriage f orw ard s troke limit not s hort-c irc uited f unc tioning; c arriage retrac ted s peed reduc tion not f unc tioning

s ens or output interrupted

output in s hort c irc uit (alw ay s No alarm. The v alue of the height at +V bat) indic ator remains f ix ed on the dis play

output not ac tiv ated

enc oder phas es A and B are s hort-c irc uiting

one of the w ires is not c onnec ted

3D

1D

FAULT TYPE

CONNECT .

M HYRIO (M ODULE 9) - (1°)

none

none

none

none

none

16 RESET ENCODER

none

ALARM

Part No.: 524159096

Page: 59

ELECTRICAL SYSTEM

TROUBLESHOOTING GUIDE (MHYRIO MODULE 9)

renew f aulty s ens or

renew f aulty s ens or

renew s ens or

none

f irs t c hec k c orrec t adjus tment of induc tiv e s ens or. Renew if nec es s ary

c hec k the enc oder c onnec tions and replac e if nec es s ary

ACTIONS REQUIRED


Page: 60

Part No.: 524159096

CAN-BUS

4B, 1B

2B

Keysw itch

SW2

6B

TRUCK REACTION

MHYRIO (MODULO 9) - (2°)

open circuit

open

open

none

none

ALARM

no f unction. Alarm active

no f unction. Alarm active

b) 09

check keysw itch and relative connections

check connection

In the case of FF VA LVES identif y the short-circuiting coil and renew ; in the case of DRIV ER SHORTED, renew the module

check coil of solenoid valve 8 and renew if necessary

renew f aulty sensor

ACTIONS REQUIRED

Date: Mar. 2002

TROUBLESHOOTING GUIDE (MHYRIO MODULE 9)

01 CAN BUS KO EPS at pow er on; 16 check CA N-BUS lines connection. If NO CAN MESSAGE if tripped during necessary, renew the module operation

16 CAN BUS KO V ALVE

09 DRIV ER OPEN, also 16 RESET ENCODER on start

a) soneoid valve coils shorted: hydraulic f unctions disabled and alarm a) 09 FF VA LV ES active; b) coil control driver shorted: DRIV ER SHORTED hydraulic f unctions inhibited and alarm active

low ering speed reeduction not low ering speed reduction alw ays renew short-circuiting sensor enabled solenoid valve coil open no f unction. No active alarm circuit

FAULT TYPE

sensor output interrupted

3B-8G;11G6G;16G5G;15GShorted 2G;12G1G;13G4G;9G-3G

10G-7G;

5A

CONNECT.

Coils pow er supply +Batt

Solenodi valves connection inputs

Solenoid valves *8

Low ering speed

COM PONENT

SYM BOL ON DIAGRAM SW9

ELECTRICAL SYSTEM


0

1

SERVICE

2

3

4

5

6

UPDATE

UPDATE

0

1

2

3

4

5

6

Date: Mar. 2002

SW17

SW21 SW3

Horn sw itch Operator presence

POT1

Traction

Seat sensor

SW16

SW15

SW14

SW13

Battery out sensor

Brake pedal sensor

Start sensor

Reverse travel

Forw ard travel

COM PONENT


13A 5G

14A

no traction, alarm activated traction normal operation not operational alarm as soon as f unction is selected alarm at keysw itch pow er-on

sensor output short-circuit open sensor output interrupted sensor output short-circuit

no traction, alarm activated

pedal braking not f unctioning no traction only reach carriage f unction available. Reduced speed traction possible w ith "battery out" button same f unctions as w hen battery is in position alarm at keysw itch pow er-on, af ter 1

alarm active

no f orw ard travel at time of reverse travel enable, f unctions are inhibited and alarm is tripped no reverse travel at time of f orw ard travel enable, f unctions are inhibited and alarm is tripped no traction. A larm w hen almost at accelerator stroke limit

TRUCK REACTION

sensor outupt interrupted

negative open

central open

5A

7A

positive open

sensor output short-circuit


sensor output interrupted sensor output short-circuit

closed circuit

open circuit





FAULT TYPE

4A

9A

2G

1G

4G

3G

CONNECT.

CANIO (MODULE 1) - (1°)

none none 01 INCORRECT START

01 INCORRECT START

Part No.: 524159096

check seat sensor and renew if necessary none none check operator presence sensor (lef t-

perf orm PROGRA M V ACC procedure

renew battery out sensor

renew brake pedal sensor

renew start sensor

renew f orw ard travel sensor

renew f orw ard travel sensor

ACTIONS REQUIRED

Page: 61

ELECTRICAL SYSTEM

TROUBLESHOOTING GUIDE (CAN I/O MODULE 1)

01 V ACC NOT OK, pedal dow n 01 PEDAL WIRE KO

01 V ACC NOT OK

none

01 BATTERY OUT

none

01 INCORRECT START

01 V ACC NOT OK

01 FORW & REV

none

01 FORW & REV

none

ALARM


Page: 62

Part No.: 524159096

Date: Mar. 2002

0

Tilt bac k/f orw ards enable s w itc h

Tilt Potentiometer

J2

J2/POT1

J1

J1/POT2

Reac h c arriage potentiometre

Reac h c arriage f w d/bac k enable

J1

J1/POT1

SW 1

Lif t/low er enable s w itc h

Lif t/low er potentiometer

Emergenc y c irc uit breaker

C OM PONENT

SYM BOL ON DIA GRA M

1

2

3

1C

6C

2C

3C

4B

4 ac tiv e alarm alarm at key s w itc h pow er-on

c los ed c irc uit

alarm pres ent at key s w itc h pow er-on and f unc tions ac tiv ation

open c irc uit

negativ e open

c entral open

pos itiv e open

alarm at key s w itc h pow er-on

if the alarm is generated at the time of key s w itc h pow er-on: f unc tion unav ailable. For alarm during operations tilt mov ement bac kw ards , or return to neutral f rom f orw ard (dow n) pos ition. f unc tion not av ailable, no alarm

alarm ac tiv e

c los ed c irc uit

alarm pres ent at key s w itc h pow er-on and f unc tions ac tiv ation

immediate alarm at pow er-on, all hy draulic f unc tions inhibited. f unc tion av ailable - no alarm

open c irc uit

negativ e open

c entral open

5B

6B

pos itiv e open

alarm at key s w itc h pow er-on

3B

alarm ac tiv e

c los ed c irc uit

alarm ac tiv e if c ontac ts are opened f ollow ing pow er-on. if the alarm appears at the time of pow er-on: f unc tion bloc ked. If this alarm trips during operations , only low ering mov ements are allow ed. f unc tion not av ailable, no alarm f unc tion not av ailable, alarm pres ent

T RUC K REA C T ION

open c irc uit

c entral open negativ e open

2B 6B

1B

pos itiv e open

open c irc uit

FA UL T T YPE

3B

6G

C ONNEC T .

CANIO (M O DULE 1) - (2°)

5

01 INCORRECT STA RT

01 POT #3 NOT OK

01 POT #1 NOT OK

01 POT #1 NOT OK

01 INCORRECT STA RT

01 POT #2 NOT OK

01 POT #1 NOT OK

01 POT #1 NOT OK

01 INCORRECT STA RT

01 POT #1 NOT OK

01 POT #1 NOT OK

01 POT #1 NOT OK

05 LOGIC FA ILURE #2, 01 EMERGENCY

A L A RM


none

c hec k potentiometer c onnec tions and renew the joy s tic k if nec es s ary .

none

c hec k potentiometer c onnec tions and renew joy s tic k if nec es s ary .

none

c hec k potentiometer c onnec tions and renew the joy s tic k if nec es s ary .

c hec k emergenc y c irc uit breaker c ontac ts and c irc uit breaker.

A C T IONS REQUIRED

ELECTRICAL SYSTEM


SERVICE

6

UPDATE

UPDATE

0

1

2

3

4

5

6

Date: Mar. 2002

J7

J7

J7

Joystic k pow er supply positive

A ll sw itches except f orw ard/reverse and horn

J7

E3-A 1

B-

J2

J2/POT2

Joystic k pow er supply negative

CAN joys tick : Connec tion betw een Joy stick and CA N I/O

BUS connec tion w ith SICOS module

Keysw itch

Battery negative

Rh/lh sideshif t enable sw itc h

Sideshif t potentiometer

COM PONENT

SYM BOL ON DIAGRAM

1D

4D

2D, 3D

to CA NIO

1F, 2F

9F

18A , 14G, 10F

4C

6C

5C

3C

CONNECT.

open or closed c ircuit

open circuit

open circuit

01 INCORRECT STA RT

01 CA N BUS KO JOY

no alarm at pow er-on, alarm present af ter s hort interv al or w ith f unctions activation alarm active

16 NO CA N MESSA GE

01 CA N BUS KO JOY

16 NO CA N MESSA GE

16 CA N BUS KO IO

16 CA N BUS KO IO

Part No.: 524159096

none

check +12v, connections, joystick and CA N I/O; renew if nec essary.

check pow er supply negative, connections and CA N I/O; renew if neces sary .

Chec k connections, joystic k and CA N I/O; renew joystick if necessary .

check battery negativ e, connec tions and CA N I/O; renew if nec essary Chec k key sw itc h, connections and CA N I/O; renew if nec essary Chec k connection betw een CA N I/O and SICOS and renew modules if neces sary .

none

check potentiometer c onnections and renew joys tick if nec essary.

ACTIONS REQUIRED

Page: 63

ELECTRICAL SYSTEM


16 CA N BUS KO EPS, 16 NO CA N MESSA GE

01 INCORRECT STA RT

01 POT #4 NOT OK

01 POT #1 NOT OK

01 POT #1 NOT OK

ALARM

immediate alarm at key sw itch pow eron; all hydraulic operations inhibited

No alarm at keys w itch pow er-on, alarm present and no f unction at activation of f irst action.

alarm at key sw itch pow er-on

c losed circ uit

open circuit



open circuit

open circuit

alarm af ter slight delay

alarm present at keys w itch pow er-on

c losed circ uit

open circuit

alarm active

alarm present at keys w itch pow er on and f unctions ac tivation

f unction not available, no alarm.

if the alarm is present at pow er-on: f unction not available. If the alarm is tripped during operations s ideshif t to

TRUCK REACTION

open circuit

negative open

c entral open

positiv e open

FAULT TYPE

CANIO (MODULE 1) - (3°)


Page: 64

Part No.: 524159096

Date: Mar. 2002

0

1

Bus connection w ith CAN I/O module

Keysw itch

E4-A1

C4

SW23

Automatic capacity detector

Battery negative

SW22

SW20

Low speed travel sw itch

Optional Valves

SW19

Holding or parking sw itch

Traction permissive

COM PONENT


1F, 2F

9F

10F, 18A

15A

3A

6A

2A

1A

CONNECT.

open circuit

open circuit

16 NO CAN MSG,

01 INCORRECT START, also "TON" display

02 HANDBRAKE

ALARM

2

3

Check battery negative and SICOS module (renew module if necessary). Check the keysw itch, connections w ith the SICOS module, and the SICOS module itself (renew the sw itch or SICOS if necessary) Check connections w ith CAN I/O: Check SICOS and CAN I/O and renew if necessary.

Check sw itch and connections; renew sw itch if necessary.


Check sw itch and connections w ith SICOS and renew sw itch if


Check sw itch and connections; renew

ACTIONS REQUIRED

TROUBLESHOOTING GUIDE (SICOS MODULE 1)

Display and f unctions unavailable if open at pow er-on; all f unctions available if circuit opens w hen truck is already operating. All f unctions available w ith truck in 16 CAN KO EPS, then 16 NO CAN operation, f or other possibilities no MSG, f unctions available.

no f unctions permitted.

alarm at keysw itch pow er-on, no hydraulic f unctions permitted.

closed circuit

open circuit

f unction request not f ulf illed, no alarm.

same as w hen open, but translation not executed.

closed circuit

open circuit

f unction request not f ulf illed, no alarm


closed circuit

open circuit


Parking brake active, alarm present at traction request.

closed circuit

open circuit

f unction request not f ulf illed; no alarm

no movement even though sw itch is activated

closed circuit

open circuit

no movement even though sw itch is

TRUCK REACTION

open circuit

FAULT TYPE

SICOS - Display (MODULO 16)

ELECTRICAL SYSTEM


SERVICE

4

5

6

UPDATE

SERVICE


ELECTRICAL SYSTEM

NOTES:

UPDATE

0

1

2

3

4

5

6

Date: Mar. 2002

Part No.: 524159096

Page: 65

SERVICE


ELECTRICAL SYSTEM

14

WIRING HARNESS CONNECTION DIAGRAM

The following diagrams are to be used in the event of replacement of wiring harnesses or auxiliary cables between connectors and modules. Each diagram carries indications of connectors and the relative cable insulation colours. NOTES:

Page: 66

Part No.: 524159096

Date: Mar. 2002

0

1

2

3

4

5

6

UPDATE

SERVICE

Sezione: ELECTRICAL SYSTEM VEDI Pag. 66e

VEDI Pag. 66f

VEDI Pag. 66i

VEDI Pag. 66g

WIRING DIAGRAM AUXILIARI CABLES VEDI Pag. 66C

VEDI Pag. 66b

VEDI Pag. 66f

VEDI Pag. 66c

VEDI Pag. 66g VEDI Pag. 66g

VEDI Pag. 66i

VEDI Pag. 66h

VEDI Pag. 66e VEDI Pag. 66i VEDI Pag. 66d AGGIORNAMENTO

0 1

2

3

4


Pag. 66a

SERVICE

Sezione: ELECTRICAL SYSTEM WIRING CONNECTIONS MODULE AC2 TRAZIONE MODULE AC2 POMPA

WIRING CONNECTIONS MODULE AC2 TRAZIONE

WIRING CONNECTIONS MODULE AC2 POMPA

AGGIORNAMENTO

0 1

2

3

4


Pag. 66b

SERVICE


WIRING CONNECTIONS MODULE EPS - AC, MODULO CA I/O

WIRING CONNECTIONS MODULE CAN I/O

WIRING CONNECTIONS MODULE EPS - AC

AGGIORNAMENTO

0 1

2

3

4


Pag. 66c

SERVICE

Sezione: ELECTRICAL SYSTEM WIRING CONNECTIONS MODULE MHYRIO, ELETTROVALVES, SENSORS COLLEGAMENTO FILI MODULO MHYRIO

AGGIORNAMENTO

0 1

2

3

4


Pag. 66d

SERVICE

Sezione: ELECTRICAL SYSTEM WIRING CONNECTIONS MODULE SICOS, JOYSTICK ITT

WIRING CONNECTIONS MODULE SICOS

AGGIORNAMENTO

0 1

2

3

4

WIRING CONNECTIONS JOYSTICK ITT


Pag. 66e

SERVICE

Sezione: ELECTRICAL SYSTEM WIRING CONNECTIONS GROUP 2 JOYSTICKS GROUP 4 JOYSTICKS

WIRING CONNECTIONS 2 JOYSTICKS

WIRING CONNECTIONS 4 JOYSTICKS

AGGIORNAMENTO

0 1

2

3

4


Pag. 66f

SERVICE

Sezione: ELECTRICAL SYSTEM WIRING CONNECTIONS INVERSORE MARCIA, HORN BUTTON, EMERGENCY SWITCH, KEYSWITCH, PANEL FAN

TRACTION INVERTER

HORN BUTTON

EMERGENCY SWITCH

KEY SWITCH

AGGIORNAMENTO

0 1

2

3

4

PANEL FAN


Pag. 66g

SERVICE


WIRING CONNECTIONS SENSORS, POTENTIOMETER

COLLEGAMENTO FILI SENSORI

AGGIORNAMENTO

0 1

2

3

4


Pag. 66h

SERVICE

Sezione: ELECTRICAL SYSTEM WIRING CONNECTIONS ENCODER, THERMAL SENSORS, SENSORS, WORK LIGHTS, FLASHING BEACON

ENCODER AND MOTOR THERNMAL SENSOR WIRING CONNECTIONS

WORK LIGHTS AND FLASHING BEACON WIRING CONNECTIONS AGGIORNAMENTO

0 1

2

3

4


Pag. 66i

SERVICE

Section: ADDITIONAL FUNCTIONS

ADDITIONAL FUNCTIONS ! OPTION SHEET No. 1 Setting of the steering for a turn of “360° and 90°”............................4

! OPTION SHEET No. 2 DC_DC converter installation.............................................................6

! OPTION SHEET No. 3 -

Flashing rotating light installation........................................................8

! OPTION SHEET No. 4 Working light installation....................................................................10

! OPTION SHEET No. 5 Reverse motion audible alarm installation.......................................12

! OPTION SHEET No. 6 -

Height preselector installation .........................................................14

! OPTION SHEET No. 7 ! ! ! ! ! !

! !

REVISION

Installation and enabling of the 5. function ......................................16 OPTION SHEET No. 8 Deceleration of the “HE” mast lifting limit switches..........................19 OPTION SHEET No. 9 Electric block of the lowering forks with 1200mm pallet...................21 OPTION SHEET No. 10 Warmed seat installation .................................................................23 OPTION SHEET No. 11 Cab for -30° refrigerating room ........................................................27 OPTION SHEET No. 12 Seat belt installation.........................................................................35 UPDATE OPTION SHEET No. 1 Intermediate lifting lock sensor Function release by means of the push button on the display.........37 UPDATE OPTION SHEET No. 2 Enabling of the weighing function.....................................................42 UPDATE OPTION SHEET No. 3 removal of the speed reduction function with the carriage completely extended.........................................................................43

0 1

2 3

4

5 6 Date: Mar. 2002 Comp. No.: 524159096

Page: 1

SERVICE


NOTES:

Page: 2 Comp. No.: 524159096 Date: Mar. 2002 0 1

2 3

4

5 6

REVISION

SERVICE


ADDITIONAL FUNCTIONS

According to the different functions, which can be applied on this model, it might be necessary to install further components and above all change some settings on various modules in order to obtain the desired function. This section aims at guiding the technician through the installation and through the settings, which are necessary for the new function. Every function sheet consists of 3 parts: NECESSARY ADDITIONAL COMPONENTS INSTALLATION NOTES MODULE CONFIGURATION The section “CONFIG MENU” indicates the adjustments, which must be carried out on each model in order to obtain the desired function. The table containing such data is described below.

Progressive No.

Accessories

Module

MAIN MENU CONFIG MENU

Parameters

Setting

Parameter to be modified Setting to be modified Module configuration submenu access menu Machine parameter access menu Module on which you must act Devices to be used Progressive number

REVISION

0 1

2 3

4

5 6 Date: Mar. 2002 Comp. No.: 524159096

Page: 3

SERVICE


OPTION SHEET No. 1

a)

STEERING SETTING FOR “360°” MOVEMENTS

PROCEDURE TO CONNECT THE “EPS - AC” MODULE TO SET THE STEERING FOR THE “ 360°” MOVEMENT ON PAGE 4a

Pict. 1

b)

STEERING SETTING FOR “90°” MOVEMENTS

PROCEDURE TO CONNECT THE “EPS - AC” MODULE TO SET THE STEERING FOR THE “ 90° “ MOVEMENT ON PAGE 4b

Pict. 2


2 3

4

5 6

REVISION

SERVICE


OPTION SHEET No. 1/A EPS-AC CONTROL

360° STEERING GUIDE X

NECESSARY ADDITIONAL COMPONENTS -NONE

X

CONSOLE CONNECTOR

5mm Allen wrench

INSTALLATION NOTES

To carry out this operation open the engine compartment bonnet by means of a 5mm Allen wrench in order to see the steering movement during the tests. Remove the cap from the EPS module connector and once the machine is off, connect the console and adjust the steering referring to the “EPS - AC” manual on page 19. procede as shown in the table enclosed.

CONSOLE COUPLING EPS AC CONNECTOR

NOTE: This table does not substitute the procedure described on the “EPS_AC” Service manual. It is only an indication to connect quickly to the module.

EPS CONNECTOR CAP

CONSOLE

MODULE CONFIGURATION TABLE

Pict. 3

STEERING ADJUSTMENT TO ACT AT 360° Sequence No.

Accessories

Module

MAIN MENU CONFIG MENU

Parameters

Description of the operations to be performed

Setting

W hen the machine is off, connect the console to the EPS Module. Place the key switch in position ON and check that the automatic wheel reaches the central position

1

3

SET OPTIONS

RANGE 360°

ON

SET OPTIONS

LIMIT DEVICE

OFF

EPS - AC 4

ADJUSTMENT

Key switch on OFF and then on ON. Check that the wheel reaches automatically the central position. If the wheel is not centered consider the following point Remove the stop of the steering wheel at 90° and perform the steering at 360°

Increase the value displayed in order to adjust the centering of the wheel clockwise (+5mV). Decrease the value displayed in order to adjust the SET STEER 0-POS Va lue displa ye d 5V centering of the wheel antickwise (-5mv). Key switch OFF then ON. Check that at the starting the automatic wheel reaches the central position Rotate the steering clockwise till 180° position is reached

5

6

ADJUSTMENT

SET 180° ENC

REVISION

If the SET 180° ENC parameter does not correspond to 10V, position on the parameter, press ENTER. From the centered position of the wheel, steer the wheel clockwise until 10V appears, press OUT then ENTER

Va lue displa ye d 10V

0 1

2

3

4

5 6

Date: March 2002

Comp.No.: 524159096

Page 4a

SERVICE


OPTION SHEET No. 1/B EPS-AC CONTROL

90° STEERING GUIDE X

NECESSARY ADDITIONAL COMPONENTS -NONE

X

CONSOLE CONNECTOR

5mm Allen wrench

INSTALLATION NOTES

To carry out this operation open the engine compartment bonnet by means of a 5mm Allen wrench in order to see the steering movement during the tests. Remove the cap from the EPS module and once the machine is off connect the console and adjust the steering referring to the “EPS - AC” manual on page 19. Procede as shown in the table enclosed CONSOLE COUPLING EPS AC CONNECTOR

NOTE: This table does not substitute the procedure described in the “EPS_AC” Service manual.It is an indication to connect quickly to the module.

EPS CONNECTOR CAP

CONSOLE

MODULE CONFIGURATION TABLE

Pict. 4

STEERING ADJUSTMENT TO ACT AT 90° S eq u en ce No.

Access o ries

Mo d u le

M AIN ME N U C ON F IG ME N U

P ara m eters

W hen the m ac hine is off, c onnec t the c ons ole to the E P S M odule. P lac e the k ey s witc h in pos ition ON and c hec k that the autom atic wheel reac hes the c entral pos ition

1

2

S ET O P TIONS

3

ADJUS T M ENT EP S - AC

4

D e scrip tio n o f th e o p e ratio n s to b e p erfo rm ed

S ettin g

S ET O P TIONS

RANGE 360

K ey s witc h on OF F then on O N. Chec k that the wheel reac hes autom atic ally the c entral pos ition. If the wheel is not c entered, c ons ider the following point

O FF

Inc reas e the value dis play ed to adjus t the c entering of the wheel c loc k wis e (+ 5m V ). Dec reas e the value dis play ed to adjus t the c entering of the wheel S ET S T EER 0-P O S V a lu e d isp la ye d 5V antic loc k wis e (-5m v). K ey s witc h OF F then O N. A nd c hec k that at the s tarting the autom atic wheel reac hes the c entral pos ition L IM IT DEV ICE

ON

K ey s witc h on OF F then on O N. Chec k that the wheel reac hes autom atic ally the c entral pos ition

5

ADJUS T M ENT

S ET M AX ENC

V a lu e disp la ye d 7,2V

6

ADJUS T M ENT

S ET M IN ENC

V a lu e disp la ye d 2,6V

7

S ET O P TIONS

L IM IT DEV ICE

ON

REVISION

0 1

Rotate the s teering c loc k wis e in order to reac h the 90° pos ition 90° (value dis play ed 7,2V ). S ave the s et value by pres s ing E NTE R then O UT and s till E NTE R, then plac ee the k ey s witc h in pos ition O FF then on ON and c hec k that at the s tarting the autom atic wheel reac hes the c entral pos ition Rotate the s teering antic loc k wis e untill the 90° pos ition is reac hed (value dis play ed 2,6V ). S ave the s et value by pres s ing E NTE R then O UT and s till E NTE R, then plac e the k ey s witc h in pos ition O FF then on O N and c hec k that at the s tarting the autom atic wheel reac hes the c entral pos ition S et on O N. K ey s witc h on OF F to s ave the param eters

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Date: March 2002

Comp.No.: 524159096

Page 4b

SERVICE


NOTES:

REVISION

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5 6 Date: Mar. 2002 Comp. No.: 524159096

Page: 5

SERVICE


OPTION SHEET NO. 2 DC-DC CONVERTER INSTALLATION AND CONNECTION NECESSARY ADDITIONAL COMPONENTS - DC_DC CONVERTER KIT MODULE CONFIGURATION -NONE INSTALLATION NOTES NECESSARY STANDARD TOOLS

Slotted screwdriver

Medium Phillips screwdriver

13mm Spanner

5mm Allen wrench

The DC-DC converter is supplied with a kit including connection sheaths and fastening screws and is assembled behind the seat next to “EPS_AC” 6 module. For the assembly it is necessary to open the engine compartment bonnet by means of a 5mm Allen wrench and fix, by means the Allen wrench itself, the converter to the holes already provided. Open the system compartment bonnet by means of the Phillips screwdriver, connect a cable terminal to the B-Batt of the Pump AC2 module by means of the 13 mm spanner, connect the other cable terminal to the B+ 48V of the FU7 fuse by means of the slotted screwdriver as shown in the drawing below. The sheath with the connector is linked to the converter output; the converter is used for the auxiliary system connections. NOTE: Before starting the assembly and the connection put the key switch in position OFF and disconnect the battery. Pict. 5 Connector to join the auxiliary systems

B+ 48V Connection to the Aux FU7 fuse

B- Batt Connection to the Pump AC2 module


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REVISION

SERVICE

DC-DC CONVERTER WIRING DIAGRAM


DC-DC CONVERTER CONNECTION

REVISION

0 1

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4

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Page: 7

SERVICE


OPTION SHEET No. 3 FLASHING ROTATING LIGHT CONNECTION AND INSTALLATION NECESSARY ADDITIONAL COMPONENTS - FLASHING ROTATING LIGHT KIT

MODULE CONFIGURATION -NONE INSTALLATION NOTES NECESSARY STANDARD TOOLS


5mm Allen wrench

The flashing rotating light is provided with a kit complete with connection sheath and fastening screws and is assembled on the roof in the outer corner over the support column (as shown in the picture). For the assembly it is necessary to open the bonnet under the steering wheel and the system compartment bonnet by means of the Phillips screwdriver. The assembly point is provided with two M6 holes to fasten the flashing rotating light and with a Ø 30 hole for the cable. Insert the wire in the hole and make it pass through the roof interspace by following the direction indicated by the arrow, then join the connector end cable and drag it completely up to the Inverter Pump AC2 5 Module and insert the connector in the connector No. 26. Connect the other end of the cable to the flashing rotating light and fix it to the roof by means of the 5mm Allen wrench. NOTE: Before starting the assembly and the connection put the key switch in position OFF and disconnect the battery. Connector already provided and connected to Pin 2/F 8/F of the PUMP AC2 module

Ø 30 hole for the cable passage

FLASHING ROTATING LIGHT

Cable passage interspace

Pict. 6


Pict. 7

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REVISION

SERVICE

WIRING DIAGRAM FOR THE FLASHING ROTATING LIGHT CONNECTION


FLASHING ROTATING LIGHT CONNECTION

REVISION

0 1

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SERVICE


OPTION SHEET No.4 WORKING LIGHT INSTALLATION AND CONNECTION NECESSARY ADDITIONAL COMPONENTS - WORKING LIGHT KIT

MODULE CONFIGURACONFIGURAZIONE MODULI -NONE INSTALLATION NOTES NECESSARY STANDARD TOOLS Medium Phillips screwdriver

5mm Allen wrench

The working lights are provided with a kit complete with connection sheath, selector for the starting and fastening screws.They are assembled on the outer part of the roof facing the mast (as shown in the picture). For the assembly open the bonnet under the steering wheel and the system compartment bonnet by means of the Phillips screwdriver. The assembly point is provided with four M6 holes, two for each light, and two Ø 30 holes for the cable passage (as shown in picture 8). Insert the wire in the holes and make it pass through the roof interspace by following the direction indicated by the arrow. Then join the cables and drag them completely up to the connector No. 24 (already provided), insert the starting selector sheath, fix the selector on the dashboard and join the two connectors. Connect the other ends of the cables to the lights and fix them to the roof by means of the 5mm Allen wrench. NOTE: Before starting the assembly and the connection put the key switch in position OFF and disconnect the battery

cable passage interspace Ø 30 holes provided for the sheath passage

Connector already provided and connected: Pin 1/24 to B- Batt, 2/24 to FU4 B+ Batt 48V fuse

Pict. 8

Pict. 9


Pict. 10

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REVISION

SERVICE

WORKING LIGHT CONNECTION

REVISION

0 1

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WIRING DIAGRAM FOR THE WORKING LIGHT CONNECTION


5 6 Date: Mar. 2002 Comp. No.: 524159096

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SERVICE


OPTION SHEET No. 5 INSTALLATION AND CONNECTION OF THE REVERSE MOTION AUDIBLE ALARM NECESSARY ADDITIONAL COMPONENTS - AUDIBLE ALARM KIT

INSTALLATION NOTES NECESSARY STANDARD TOOLS


5mm Allen wrench

The buzzer is provided with a kit complete with a connection sheath and is assembled under the board on a slotted bracket near the klaxon (as shown in picture 11). For the assembly it is necessary to open the engine compartment bonnet and the board by means of the 5mm Allen wrench, remove the system compartment bonnet by means of the Phillips screwdriver. Loosen the buzzer ring nut, insert the buzzer itself in the proper slot and tighten the ring nut to fasten the buzzer to the bracket. Bring the sheath connector into the system compartment by making it follow the way of the sensors and join it to the connector No.28. NOTE: Before starting the assembly and the connection, place the key switch in position OFF and disconnect the battery.

Pict. 12

Buzzer application

Connector joint to Pin 16/G - 7/G of the CAN I/O module

Pict. 11


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REVISION

REVISION

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5 6 Date: Mar. 2002 Comp. No.: 524159096

1

CAN I/O

Se que nce Acce ssorie sModule No.

SET OPTIONS

AUX FUNCTION 3

MENU CONFIG. CONSOLE CONSOLE PARAMETER

Audible alarm enabled with reverse movement Audible alarm enabled with forward movement

OFF

W hen the machine is off, connect the console to the CAN I/O module, key switch ON.

De scription of the ope ra tions to be pe rform e d

ON

SETTING

ADJUSTMENT TO ENABLE THE AUDIBLE ALARM W HEN THE TRUCK IS RUNNING

CAN I/O MODULE CONFIGURATION TABLE

SERVICE Section: ADDITIONAL FUNCTIONS WIRING DIAGRAM FOR THE REVERSE MOTION AUDIBLE ALARM CONNECTION

REVERSE MOTION AUDIBLE ALARM CONNECTION

Page: 13

SERVICE


OPTION SHEET No. 6 ENABLING OF THE HEIGHT PRESELECTOR FUNCTION THERE ARE TWO TYPES OF CONFIGURATION a) RETRACTABLE CARRIAGE INCLUDED IN THE AUTOMATIC DRAWING/STORING SEQUENCE b) RETRACTABLE CARRIAGE EXCLUDED IN THE AUTOMATIC DRAWING/STORING SEQUENCE NECESSARY ADDITIONAL COMPONENTS - HEIGHT PRESELECTOR KIT SW5 = LIFTING SPEED REDUCTION SENSOR

NYLON THREAD FOR THE ENCODER OPERATION

ENCODER RESET.

INDUCTIVE ENCODER

SHEATH CONNECTORS JOINT TO THE MHYRIO MODULE Pict. 13

CONNECTION OF THE INDUCTIVE ENCODER AND SPEED REDUCTION SENSOR ON “ MHYRIO” 6 MODULE

“MHYRIO” 6 MODULE

Pict. 14 CONNECTOR “A” FOR THE ENCODER RESET SENSOR CONNECTION

CONNECTOR “D” FOR THE ENCODER CONNECTION


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REVISION

SERVICE

Section: ADDITIONAL FUNCTIONS PROCEDURE TO INSTALL THE HEIGHT PRESELECTOR COMPONENTS

OPTION SHEET No. 6/A

HEIGHT PRESELECTOR COMPONENT TABLE Ref. 1 2 3 4 5 6 7 8 9

6

7

5

NECESSARY STANDARD TOOLS

Component description Height measurement encoder Fork lifting deceleration sensor Sensor support bracket Encoder locking bolts Nylon thread for the encoder rotation Spring coupling upper ring Tightening spring Insertion for the thread connection Threads coupling lower ring

Tapeline Drill

Pict. 16

Pliers for faston

ø 8,5

10mm spanner

drill

INSTALLATION PROCEDURE Before starting the working, make sure to wear suitable safety clothing. Drive the truck in a safety area far from the passage of pedestrians or other vehicles, move forward the retractable carriage, lower the forks till they touch the ground, put the switch in position OFF, disconnect the battery.

ROTATION DIRECTION OF THE THREAD ON THE PULLEY

8

Screw tap

Ladder

1) 10mm SPANNER, LADDER WITH PLATFORM - Position the ladder on the right side of the column and assemble the ENCODER on the proper bracket (Pict. 17).

5

2) DRILL COMPLETE WITH 5mm DRILL , TAP WRENCH COMPLETE WITH M6 SCREW TAP, LADDER WITH PLATFORM , 10mm SPANNER - Draw the holes (as shown in the picture enclosed) of the sensor support bracket of the fixed mast (Ref. 3 Pict. 17), carry out the holes and thread. Draw the holes (as shown in the picture enclosed) of the bracket with ring on the lower part of the intermediate mast upper crosspiece (Ref. 6 Pict. 16), carry out the holes and thread. Fasten the bracket complete sensor and the bracket with ring by means of the spanner.

3

2 + 50mm estention

3) PLIERS FOR FASTON - Take the nylon rope and form a ring (Ref. 8 Pict. 16) and by means of the pliers tighten the crimp in order to fix it; hook the spring to the ring fixed on the mast crosspiece, hook the ring of the nylon rope to the spting lower hook (Pict. 19). By means of the nylon rope make a complete revolution on the encoder pulley observing the direction of revolution (as shown in pict. 19) by letting the other end of the rope fall down.

2 1

4) Move the ladder far from the truck, connect the battery and put the key switch in position ON. Lift the forks till the lower crosspiece of the intermediate mast reaches 1m height from the floo; position the beam under the mast (Pict. 20), lower the forks and lean the mast on the beam, put the key switch in position OFF and disconnect the battery.

4

WARNING: The beam has a safety function and so it must be positioned well. Pict. 19

Pict. 17

6) PLIERS FOR FASTON - Make the nylon rope end go through the ring and tighten it by pulling it until the spring is stretched of about 50mm (Pict. 19); using the nylon rope form a ring and tighten the crimp in order to fix (Ref. 8 Pict. 4), cut the exceeded rope.

5

7) Fasten the onnection cable to the right mast cylinder by moving the connector upwards; connect the cable lower ends to the MHYRIO module (see diagram on page 10), join the encoder and sensor connectors. Connect the battery, put the key switch in position ON, lift the forks and remove the beam, lower the forks till they touch the ground and program the preselector referring to the table enclosed and the Service manual on page 51 of the electric section.

8

Pict. 15

5) DRILL COMPLETE WITH 5mm DRILL, TAP WRENCH COMPLETE WITH M6 SCREW TAP, 10mm SPANNER- Draw the holes (as shown in the picture enclosed) of the bracket with ring on the upper part of the intermediate mast lower crosspiece (Pict. 18-20), draw the holes and thread. Fix the bracket by means of the bracket.

9 Pict. 18

Bracket locked by ring

Support beam

REVISION

Pict. 20

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Date: March 2002

Comp. No.: 524159096

Page 14a

SERVICE


WIRING DIAGRAM TO CONNECT - INDUCTIVE ENCODER - DECELERATION SENSOR (UPWARD MOVEMENT) AND ENCODER RESET

OPTION SHEET No. 6/B

INDUCTIVE ENCODER

MHYRIO 6 MODULE

Sw5 INDUCTIVE ENCODER INDUTTIVO ENCODER

REVISION

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Comp. No.: 524159096

Page 14b

SERVICE


OPTION SHEET No. 6/C

EPS-AC

ENABLING OF THE HEIGHT PRESELECTOR FUNCTION WITHOUT RETRACTABLE CARRIAGE -CONSOLE CONNECTION NOTES

To carry out this operation the console must be linked to the “SICOS” 16 module in order to enable the preselector function. All the height setting operations are carried out by means of the “SICOS” (Display) module keyboard. To enable the “SICOS” 16 module to the preselector function, the console can be connected (when the machine is off) to the “EPS-AC” 6 module by means of the access hole located behind the seat; by means of the CAN BUS connection the “SICOS” 16 module can be entered. To search the module, refer to the “SERVICE MANUAL” (electric section)on page 24-25

CONSOLE CONNECTION CONNECTOR Pict. 21

NOTE: This table does not substitute the procedure described on the Manual Service; it is an indication of a function quick configuration

MODULE CONFIGURATION TABLE HEIGHT PRESELECTOR ENABLING WITHOUT RETRACTABLE CARRIAGE IN SEQUENCE Sequence No.

Accessories

Module

CONSOLE MAIN MENU

CONFIG MENU SELECTION MAIN MENU 1 MAIN MENU 2 SELECTION CONSOLE KEY DISPLAY DISPLAY DISPLAY KEY DISPLAY

CONSOLE PARAMETER

DISPLAY PARAMETER

SELECTION KEY DISPLAY

Setting

When the machine is off connect the console to the SICOS (Display) 16 module. Put the key switch in position ON

1 2

16 - SICOS (Diaplay)

3

SET OPTIONS

ENCODER TYPE

SET OPTIONS

PRE-HEIGHT SELECTOR

4

Enter

5

Enter

6



MAIN MENU 1

Set 1 to enable the SICIS to read the encoder ON

DOWN arrow UP arrow

PROGRAM OFFSET

Enter

MEMO

LEVEL SETTING - SEQUENCE TO BE REPEATED FOR EVERY LEVEL

7 8

Enter Enter

9

OUT

OUT

Set ON to link Sicos to the HEIGHT PRESELECTOR function, press OUT, then ENTER to store. Put the key switch in position OFF to save. Remove the console. Put the key switch in position ON Lift the forks up to the level after whch the withdrawing of the mast begins. Measure the fork height from the ground. Set the value using the numeric keyboard on the display. Put the key switch in position OFF then in position ON to save the value. Lift the forks till the desired height is reached (the programmed level must be higher than the "PROGRAM OFFSET" value). Type the No. Of the desired level (i.e. 03) To enter the "AUTOTEACHING" selector program To save the value acquired To restore the preselector working screen and to restore the main DISLAY

DELTA ADJUSTMENT TO DRAW AND STORE THE PALLET ON THE SHELF 10 CAN I/O 11

PRAMETER CHANGE PRAMETER CHANGE

To modify the store stroke delta (default value 5). Increasing the value, the store stroke is increased. To modify the drawing stroke delta (default value 5) Increasing the value the drawing stroke is increased.

OPTION 5 OPTION 6

REVISION

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Date: March 2002

Comp. No.: 524159096

Page 14c

SERVICE


OPTION SHEET No. 6/D

EPS-AC

ENABLING OF THE HEIGHT PRESELECTOR FUNCTION WITH RETRACTABLE CARRIAGE IN SEQUENCE

-CONSOLE CONNECTION NOTES

To carry out this operation the console must be linked to the “SICOS” 16 module in order to enable the preselector function. All the height setting operations are carried out by means of the “SICOS” (Display) module key board. To enable the “SICOS” 16 module to the preselector function, the console can be connected (when the machine is off) to the “EPS-AC” module by means of the access hole located behind the seat; By means of the CAN BUS connection the “SICOS” 16 module can be entered. to search the module, refer to the “SERVICE MANUAL” (electric section) on page 24-25

CONSOLE CONNECTION CONNECTOR

NOTE: This table does not substitute the procedure described on the Service Manual; it is an indication of a function quick configuration

Pict. 22

TABLE CONFIGURATION MODULE ENABLING OF THE HEIGHT PRESELECTOR WITH RETRACTABLE CARRIAGE IN SEQUENCE Sequence No.

Accessories

Module

CONSOLE MAIN MENU

CONSOLE CONFIG MENU


DISPLAY DISPLAY SELECTION MAIN MENU 1 MAIN MENU 2 KEY DISPLAY

CONSOLE PARAMETER

DISPLAY PARAMETER


Setting

When the machine is off connect the console to the SICOS (Display) 16 module. Put the key switch in position ON

1 2 3


4

SET OPTIONS

ENCODER TYPE

SET OPTIONS

PRE-HEIGHT SELECTOR

ON

SET OPTIONS

AUX FUNCTION 2

ON

5

Enter

6

Enter

7



MAIN MENU 1

Set 1 to enable the SICOS to read the encoder

DOWN arrow UP arrow

PROGRAM OFFSET

Enter

MEMO

LEVEL SETTING - SEQUENCE TO BE REPEATED FOR EVERY MODEL

8 9

Enter Enter

10

OUT

OUT

Set ON to link Sicos to the HEIGHT PRESELECTOR function, press OUT, then ENTER to store Set ON to link Sicos to operate with retractable carriage, press OUT, then ENTER to store. Put the key switch in position OFF to save. Remove the console. Put the key switch in position ON Lift the forks up to the level after which the withdrawing of the mast begins. Measure the fork height from the ground. Set the value using the numeric keyboard on the display. Put the key switch in position OFF then ON to save the value. Lift the forks till the desired height is reached (the program level must be higher than "PROGRAM OFFSET" value). Type the No. Of the desired level (i.e. 03) To enter the "AUTOTEACHING" selector program To save the value acquired To restore the preselector working screen and to restore the main DISPLAY

DELTA ADJUSTING TO DRAW AND STORE THE PALLET ON THE SHELF 11 CAN I/O 12

PARAMETER CHANGE PARAMETER CHANGE

To modify the store stroke delta (delta value 5) Increasing the value, the store stroke is increased. To modify the drawing stroke delta (default value 5). Increasing the value, the drawing stroke value is increased.

OPTION 5 OPTION 6

REVISION

0 1

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3

4

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Date: March 2002

Comp. No.: 524159096

Page 14d

SERVICE


NOTES:

REVISION

0 1

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Page: 15

SERVICE


OPTION SHEET No. 7 ENABLING OF THE 5. HYDRAULIC FUNCTION NECESSARY ADDITIONAL COMPONENTS - 5. HYDRAULIC FUNCTION KIT

PUSHBUTTON TO BE PRESSED TO ENABLE THE 5. FUNCTION

S Y M B O L APPEARING IN THE DISPLAY WINDOW +

100

50

20

-

S T N D

Pict. 23

5. FUNCTION

CONNECTOR “F” PIPE FITTING TO CONNECT THE FOR THE SOLENOID HOSE REEL SUPPLY PIPE V A L V E CONNECTION

SOLENOID VALVE IN ADDITION TO THE HYDRAULIC UNIT

Pict. 24


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REVISION

SERVICE


INSTALLATION NOTES Before ordering the assembly kit, refer to the hose reel/ “H3” mast height and assembled battery pairing table (Page 12a). NECESSARY STANDARD TOOLS

13-17-18-19mm SPANNER

SMALL SLOTTED SCREWDRIVER

M10 SCREW TAP

6mm ALLEN WRENCH

ELECTRIC DRILL

SCRIBE

ø 4 and 8,5 STEEL DRILL

SQUARE

TAPELINE

LADDER

WITH TAP WRENCH

PROCEDURE Before starting any work always wear suitable safety clothings. Drive the truck to a safety area, far from the passage of pedestrians and other vehicles, move forward the retractable carriage. lower the forks until they touch the ground, put the key switch in position OFF, disconnect the battery. 1) LADDER WITH PLATFORM, SCRIBE SQUARE, TAPELINE - Place the ladder on the left side of the truck connected with the mast, climb the ladder with the tools and the drawing in order to mark the position of the holes to fix the hose reel support bracket. NOTE: In case of “HE” mast the holes must be carried out on the crosspiece as shown in picture 26 on page 18a In case of “BETA mast the holes must be carried out aside the mast as shown in picture 27 on page 18a 2) ELECTRIC DRILL, Ø 4 e 8,5 STEEL DRILL, M10 SCREW TAP COMPLETE WITH TAP WRENCH, 17mm SPANNER - carry out the holes marked earlier by means of the Ø 4 small drill and then by means of the Ø 8,5 large drill and the thread using the M10 screw tap. Fasten the bracket to the column by means of the spanner and then fix the hose reel complete with hoses on the bracket. 3) No. 2 13mm SPANNER - Loosen the valve (Ref. A Pict. 30) to discharge the pressure inside the valve unit, tighten the valve. By means of the same spanner, unscrew the threaded bar stop nuts keeping the valve unit joint (Ref. B-B1 Pict. 30). Take out the threaded bars and replace them with the longer ones contained in the kit, add the new solenoid valve with the proper O-Rings (Ref. C Fig. 30) and tighten, paying attention that the O-Rings do not move from their seat. Carry out the solenoid valve electric connection referring to the wiring diagram enclosed on page 18b.

REVISION

0 1

2 3

4

A C B

B1 E

D Pict. 30

5 6 Date: Mar. 2002 Comp. No.: 524159096

Page: 17

SERVICE


4) 17-18-19mm SPANNER - Screw the pipe fittings of an end of the hoses twined to the hose reel pipe fittings and bring the other end of the hoses to the hydraulic unit and bind them to the hoses located on the mast by means of clamps and screw the the pipe fittings to the 5. function solenoid valve 5) SCRIBE, TAPELINE, SQUARE - Connect the battery, enable the emergency pushbutton and put the key switch in position ON. Enable the lifting and move the upper part of the fork holder plate to the height of 1m. Mark the position of the holes (see the drawing enclosed) on the fork holder plate shoulder (Ref. 9 Pict. 20 on page 18a) by means of the tools in order to apply the support bracket of the revolving joint. 6) ELECTRIC DRILL, Ø 4 e 8,5mm STEEL DRILL, M10 SCREW TAP - carry out the holes on the points marked earlier with the Ø 4mm small drill and then with the Ø 8,5mm large drill, thread the holes by means of the M10 screw tap. 7) 17mm SPANNER, 6mm ALLEN WRENCH - Fix the bracket to the fork holder plate shoulder by means of the spanner (Ref. 9 Pict. 20 on page 18a) and fasten the revolving joint to the bracket by means of the Allen wrench (Ref. 7 Pict. 20 on page 18a). 8) 18-19mm SPANNER - Act the lifting and align the revolving joint with the lower hose reel base. Keeping the hoses completely rolled load the spring by turning the hose reel clockwise three times and connect the hose pipe fittings to the revolving joint pipe fittings. Carry out a complete lifting and lowering movement and make sure that the hose reel twined hose is always tightened. 9) Connect the console to the “SICOS” 16 module and carry out the procedure to enable the 5. function referring to the table on page 18b and to the “Service Manual” on page 41 of the electric section.


2 3

4

5 6

REVISION

SERVICE



COMPONENTS TO ASSEMBLE THE 5. HYDRAULIC FUNCTION

6

4

3

2

1

5

HOSE REEL WITH SUPPORT FOR THE A 709 (HE) MAST Pict. 26

HOSE REEL WITH SUPPORT FOR THE A 708 (BETA) MAST Pict. 27

10 7

8

9

Pict. 25

1032 X 784 X 350 1032 X 784 X 440

420 Ah 560 Ah

FROM 4500 TO 6700 FROM 4500 TO 6700

COMPONENTS FOR THE 5. HYDRAULIC FUNCTION APPLICATION Re f Com pone nt de scription 1 Hose reel for "HE" Ø 340mm & Ø 400mm mast 2 Hose reel support bracket for the "HE" mast 3 Bolts to fasten the hose reel to the bracket 4 Hose reel for "BETA" Ø 340mm & Ø 400mm mast 5 Hose reel support bracket for "BETA" mast 6 Bolts to fasten the hose reel to the bracket 7 Rotating joint to connect the hoses 8 Rotating joint support bracket 9 Bolts to fasten the bracket to the fork holder plate 10 Solenoid valve to be added for the 5. Function 11 threaded bars to connect the solenoid valve 12 Hydraulic hose kit (supplied according to the column height)

Pict. 28

TABLE OF COUPLING HOSE REEL H3 MAST TYPE OF MAST A708 & A709 A709 HOSE REEL DIAMETER Ø 340m m Ø 400m m H3 H3 TYPE OF BATTERY DIN "C" 1220 X 784 X 280 420 Ah FROM 4500 TO 6700 FROM 6700 TO DIN "C" 1220 X 784 X 352 560 Ah FROM 4500 TO 6700 FROM 6700 TO DIN "C" 1220 X 784 X 424 700 Ah FROM 4500 TO 6700 FROM 6700 TO DIN "C" 1220 X 784 X 496 840 Ah FROM 4500 TO 6700 FROM 6700 TO DIN "B" DIN "B"

11 Pict. 29

NOTES 9800 9800 9800 9800

FROM 6700 TO 8700 FROM 6700 TO 8700

Only for the NARROW truck

REVISION

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Date: Marzo 2002

Comp. No.: 524159096

Page 18a

SERVICE



-SOLENOID VALVE CONNECTION DIAGRAM -MODULE CONFIGURATION TABLE

MODULO 6 MHYRIO

5. FUNCTION

5. FUNCTION

Se que nce No.

Acce ssorie s

Module

CONSOLE MAIN MENU

CONSOLE SELECTION CONFIG MENU KEY

CONSOLE PARAMETER

Se tting

De scription of the ope ra tion to be pe rform e d W hen the machine is off connect the console to the 16 SICOS (Display) module. Place the key switch in position ON

1 16 - SICOS (Diaplay)

SET OPTIONS

2

REVISION

OPTIONAL 1-2 HYDRAUL VALVE ON/OFF

0 1

2

3

4

5 6

OFF

Select OFF, key switch OFF then ON to save. By pressing the key the 5. Function is enabled and on the display the fork symbol is replaced by the hydraulic jaws symbol

Date: Marzo 2002

Comp. No.: 524159096

Page 18b

SERVICE


OPTION SHEET No. 8 DECELERATION OF THE SIDE CYLINDERS AND OF THE CENTRAL CYLINDER OF THE “HE” MASTS (LAST 50mm - UPWARD MOVEMENT)

DECELERATION SENSOR OF THE SIDE CYLINDERS

DECELERATION SENSOR OF THE CENTRAL CYLINDER

READING CAM OF THE SIDE CYLINDER SENSOR

REVISION

0 1

Pict. 31

2 3

4

READING CAM OF THE CENTRAL CYLINDER SENSOR

5 6 Date: Mar. 2002 Comp. No.: 524159096

Page: 19

SERVICE


OPERATING PROCEDURE OF THE DECELERATION KIT (UPWARD MOVEMENT) NECESSARY ADDITIONAL COMPONENTS -DECELERATION KIT (UPWARD MOVEMENT) MODULE CONFIGURATION -NONE OPERATING NOTES

The kit is applied on the great elevation “HE” masts where some hole rod plunger cylinders without any internal deceleration device are assembled. This equipment is applied to avoid any metallic flapping at the end of every end of stroke of the central cylinder and of the side cylinders. POSITIONING OF THE DEVICES 1) The deceleration sensor of the free lifting (central cylinder) is fastened on a plate (already provided with threaded holes) and welded on the outer side of the fixed mast (Ref. 1-2 Pict. 40 on page 20b). The reading cam is welded on the rear side between the fork holder plate and the mast shoulder (Ref. 3 Pict. 39 on page 20b). 2) The side cylinder deceleration sensor is fixed on a plate welded on a metallic collar, fastened on the upper end of the right cylinder (Ref. 1-2 Pict. 34 on page 20a). The reading cam is welded on the internal withdrawing device base (Ref. 3 Pict. 33 on page 20a) bent as shown in pict. 36-37 on page 20a). 3) The connection is obtained by means of sheath with two connector to join the two sensors which becomes a sole connector. It joins on connector “A” “Pin 1-16-19” of the “MHYRIO” 6 module. See the connection diagram enclosed on page 20c. OPERATION When the lifting is carried out and the free lifting cam is connected with the sensor , the pump motor reduces the number of revolutions decelerating the stroke in the last 50 mm. Once the stroke is over the pump motor increases the number of revolutions carrying out the lifting with the maximum speed until the second cam is connected with the second sensor causing the decreasing of the pump motor revolution number and decelerating the side cylinder stroke in the last 50mm.


2 3

4

5 6

REVISION

SERVICE

Section: ADDITIONAL FUNCTIONS POSITION OF THE READING SENSOR ON THE RIGHT LIFTING CYLINDER


2

COM P ONENTS FOR THE DECELERATION OF THE S IDE CYLINDER END OF S TROKE Re f. Com pone nt de scription S ens or s upport with fas tening c ollar on the c y linder 1 Induc tive s ens or 2 S ens or reading c am 3 Connec tion s heath 4

APPLICATION OF THE SENSOR AND CAM TO DECELERATE THE SIDE CYLINDERS OF THE “HE” MAST (LAST 50mm - UPWARD MOVEMENT)

CAM WELDING ON THE “A 708” “BETA” MAST

CAM WELDING ON “A 709” “HE” MAST

1

3 3

Pict. 34

POSITION OF THE READING CAM ON THE INTERMEDIATE MAST

3

Pict. 37

Pict. 36

Pict. 33

Pict. 35 Pict. 32

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APPLICATION OF THE SENSOR AND CAM TO DECELERATE THE CENTRAL CYLINDER OF THE “HE” MAST (LAST 50mm - UPWARD MOVEMENT)

1 POSITION OF THE READING SENSOR ON THE MAST UNDER THE CROSSPIECE

2

Pict. 40 COMPONENTS FOR THE DECELERATION OF THE CENTRAL CYLINDER END OF STROKE Ref. Com pone nt de scription Plate to be welded to support the sensor 1 Inductive sensor 2 Sensor reading cam 3 Connection sheath 4

POSITION OF THE READING CAM ON THE REAR SIDE OF THE FORK HOLDER PLATE

3 Pict. 39

Pict. 38

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WIRING DIAGRAM FOR THE DECELERATION SENSOR CONNECTION OF THE CENTRAL CYLINDER AND THE SIDE CYLINDERS (LAST 50mm - UPWARD MOVEMENT)

OPTION SHEATH No. 8/C DECELERATION SENSOR OF THE CENTRAL CYLINDER (LAST 50mmUPWARD MOVEMENT CON. 16/B

CON. 16/A

CON. 16

1/A

16/A

DECELERATION SENSOR OF THE SIDE CYLINDERS (LAST 50mm UPWARD MOVEMENT)

19/A

CON. 16/C

Page Page

MHYRIO 6 MODULE

5. Function

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APPLICATION OF THE PHOTOCELL FOR THE DECELERATION IN THE LAST 50 mm (UPWARD MOVEMENT) OF THE HE” AND “BETA” MAST SIDE CYLINDERS

OPERATING PROCEDURE OF THE DECELERATION KIT (UPWARD MOVEMENT) WITH PHOTOCELL The kit is applied on the great elevation “HE” masts where some hole rod plunger cylinders without any internal deceleration device are assembled. This equipment is applied to avoid any metallic flapping at the end of every forward movement of the central cylinder and of the side cylinders. POSITION OF THE PHOTOCELL 1) The deceleration photocell of the side cylinders is fixed on a plate. The Plate is fixed on the front part connecting to the fixed mast (Ref. A Pict. 2-3) 2) The rear reflector is welded on the internal withdrawing device base (Hin. B Pict. 4) 3) The electric connection is obtained by means of a sheath complete with connectors. A connector is joint to the photocell connector, the other one is joint to the sensor and the third one to the connector 16, which is connected to connector “A” on the “Pin 1-16-19” of “MHYRIO” modul 6. See the connection diagram (page 20c)

OPERATION When the lifting is carried out and the free lifting cam is connected with the first reading sensor. The pump motor reduces the number of revolutions decelerating the stroke in the last 50mm. Once the stroke is over the pump motor increases the number of revolutions carrying out the lifting with the maximum speed until the rear reflector is connected with the photocell causing the decreasing of the pump motor revolution number and decelerating the side cylinder stroke in the last 50mm. NOTE: In case the photocell is assembled on operating machines, it is advisable to carry out some tests in order to determine the right position, before fixing the photocell and sticking the rear reflector.

Ref. 1 2 3 4

Component Description Reading Photocell Photocell Support Photocell Fixing Plate (welded) Photocell Reading Reflective Strip

A A 1 2 3

4

Fig. 1

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Fig. 4

Fig. 3

Fig. 2

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OPTION SHEET No. 9 FORK LOCK WITH 1200mm PALLET (DOWNWARD MOVEMENT)

sensor

Reading cam

Pict. 41

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OPERATING PROCEDURE OF THE BLOCK WITH 1200mm PALLET (DOWNWARD MOVEMENT) NECESSARY ADDITIONAL COMPONENTS -FORK LOCK KIT (DOWNWARD MOVEMENT) OPERATION NOTES The kit is applied on the machines using the pallet from the 1200mm side. This equipment is applied to avoid that during the lowering phase with retractable carriage completely retracted, the pallet flaps against the truck wheelbase. NOTE: This option allows lowering the forks till they touch the ground only when the sideshift carriage is completely extended. In some narrow aisles it will be impossible to draw or store the pallet placed on the ground. POSITION OF THE DEVICES. 1) The block sensor is fastened on a plate welded on the left shoulder of the retractable carriage under the mast support (Ref. 1-2 Pict. 43 on page 22a for the Standard machine, Ref. 1-2 PICT. 45 on PAGE 22a for the Narrow machine), and it is connected electrically to connector 19 on “MHYRIO” “Pin 7-1720 CN A” 6 Module. See the wiring diagram on page 22b. 2) The reading cam is welded on the mast side fork holder plate shoulder (Ref. 3 Pict. 44 on page 22a for Standard machine, Ref. 3 Pict. 46 on page 22a for Narrow machine) OPERATION When the pallet resting on the forks is lowered and the retractable carriage is completely retracted the cam reaches the sensor and locks the lowering. This prevents the pallet from flapping against the wheelbase. To place the pallet on the ground it is necessary to extend the retractable carriage.

CAN I/O MODULE CONFIGURATION TABLE To enable the machine to work with the pallet forked on the 1200mm side it is necessary to perform the procedure described below by setting the AUX FUNCTION 1 in position ON. ADJUSTMENT TO ENABLE THE MACHINE TO THE 1200m m PALLET DRAW ING Se que nce Acce ssorie s Module No.

MENU CONFIG. CONSOL CONSOLE PARAMETER

De scription of the ope ra tion to be pe rform e d

SETTING

W hen the machine is off, connect the console to the CAN I/O module, key switch ON.

1

CAN I/O

SET OPTIONS

AUX FUNCTION 1


To enable the machine to draw pallet on the 1200mm side and to prevent the pallet from leaning on the wheelbase with retractable carriage retracted.

ON

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APPLICATION OF THE SENSOR AND CAM FOR THE FORK LOWERING LOCK WITH 1200mm PALLET


COM P ONENTS TO AP P LY THE FORK LOW ERING BLOCK W ITH 1200m m P ALLET Re f Com pone nt de scription P late to be welded for the s ens or s upport 1 Induc tive s ens or 2 S ens or reading c am 3 Connec tion s heath 4

1 2 1

2

Pict. 43

Pict. 45 SENSOR POSITION OF THE “STANDARD” RETRACTABLE CARRIAGE.

SENSOR POSITION ON THE “NARROW” RETRACTABLE CARRIAGE

READING CAM POSITION FOR THE “STANDARD” MACHINE

READING CAM POSITION FOR “NARROW” MACHINE

3

3

Pict. 42

Pict. 44

REVISION

Pict. 46

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OPTION SHEET No. 10 WARMED SEAT

CONNECTOR TO JOIN THE RESISTANCE

Fig. 47

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PROCEDURE TO INSTALL THE WARMED SEAT KIT NECESSARY ADDITIONAL COMPONENTS - WARMED SEAT KIT MODULE CONFIGURATION -NONE INSTALLATION NOTES NECESSARY STANDARD TOOLS


5mm Allen wrench

The warmed seat is equipped with a kit complete with connection sheaths. For the assembly it is necessary to open the motor compartment bonnet by means of an Allen wrench, take out the standard seat and assemble the warmed seat on the same guides. Open the system compartment bonnet by means of the Phillips screwdriver and disconnect the engine compartment cooling fan connection from connector “L”. Join the sheath male connector to the system connector “L”, the famale connector “L” to the cooling fan and the sheath connector “G” to the seat connector. See the picture below. NOTE: Before starting the assembly and the connection, put the key switch in position OFF and disconnect the battery

SHEATH MALE CONNECTOR “L” MUST BE CONNECTED TO THE SYSTEM CONNECTOR “L”

CONNECTOR “L” JOINT TO THE SYSTEM

SHEATH FEMALE CONNECTOR “G” MUST BE JOINT TO THE SEAT

WARMED SEAT

SHEATH

SHEATH FEMALE CONNECTOR “L” MUST BE CONNECTED TO THE FAN

Pict. 48


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WIRING DIAGRAM TO CONNECT THE WARMED SEAT


STARTING INTERNAL THERMOSTAT

WARMED SEAT RESISTANCE CONNECTION FOR THE REFRIGERATING ROOM

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SERVICE


NOTES:


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OPTION SHEET No. 11 - 30° REFRIGERATING ROOM

Pict. 49

INTERCOM FOR THE EXTERNAL COMMUNICATION FIXED INSIDE THE ROOF COLUMN

Pict. 50 ELECTRIC DEVICE AND PROGRAMMING CONSOLE CASE

Pict. 51

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ELECTRIC COMPONENTS OF THE REFRIGERATING ROOM 22

23

25

24

Pict. 52 7

1

4

10 11 12 13 14 15 16

8

5

6 3

17 18 19 20 21 2 9

Pict. 53


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ELECTRIC COMPONENT POSITION The electric components shown in the previous page are described in the table below.

Re f. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Com pone nt de scription Card Resistance container to heat the cab Fan to heat the cab Main remote control switch Resistance remote control switch to heat the secondary devices Resistance remote control switch to heat the primary devices Primary resistances Cab heating resistance thermal switch Connector connection Fuse 3A to protect the control card Fuse 3A to protect the starting key Fuse 3A to protect the fan Fuse 10A to protect the cab heating resistance ( 1 ) Fuse 10A to protect the cab heating resistance (1a) Fuse 10A to protect the cab heating resistance (2) Fuse 10A to protect the cab heating resistance (2a) Fuse 7,5A to protect the windscreen defroster resistance Fuse 3A to protect the upper roof glass defroster resistance Fuse 5A to protect the driver's side front glass defroster resistance Fuse 1A to protect the side door glass defroster resistance Fuse 5A to protect the central door glass defroster resistance Console to program the temperatures and the intercom audio Upper air recirculation louver Lower air recirculation louver Control panel closing door

NOTE: All the Yale codes of the components are contained in the spare part catalogue

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NECESSARY ADDITIONAL COMPONENTS -NONE MODULE CONFIGURATION -NONE OPERATION NOTES

ELECTRIC SYSTEM OPERATION DESCRIPTION

“CAB CONSOLE” CAB TEMPERATURE ADJUSTMENT LED

HEATER

TIME ADJUSTMENT OF THE GLASS RESISTANCE LED

20°

ON

15°

ON

10°

INTERCOM VOLUME ADJUSTMENT LED

GLASS HEATER

00

INTERCOM

ON TALK

MINUTES

+

-

RESISTANCE STARTING TIME By using the console you can adjust: 1)

The inner temperature of the cab by acting on the “HEATER” keys.

2)

The glass resistance operating time to allow the refrigeration room inlet and outlet defrosting by acting on the “GLASS HEATER” keys.

3)

Variation of the volume of the intercom for the external audio connection by acting on the “INTERCOM” keys.

The procedures of the adjustments are described in the following pages.


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“HEATER” CAB HEATING

LED

HEATER

LED

GLASS HEATER

20°

ON

00

ON

15°

MINUTES

10°

ON

LED

INTERCOM

ON

+

TALK

-

KEY “ON” - By pressing this key the resistance starting remote control switch to heat the cab is enabled and disabled.

GREEN LED - If it is on, it indicates that the resistance starting remote control switch is enabled.

20°

15°

10°

TEMPERATURE INDICATOR - It indicates the set or the real temperature (from 10°C to 20°C with level of 1°C). The indication of the set temperature occurs immediately when the key “ON” is enabled and not when the machine is started. The real temperature is displayed by pressing the arrows and at the same time. If the temperature is lower than the minimum scale temperature, the first LED of the indicator flashes. If the temperature is higher than the maximum scale temperature the whole indicator scale flashes. UP and DOWN ARROWS - To vary the set temperature press one of the two keys for a second at least, till the desired temperature is reached. To display the real temperature press both keys at the same time.

The two cab heating elements are inserted at the same time till the set temperature is reached (1 or 2 degrees earlier), afterwards, the resistances 2 and 2A are automatically disabled and the heating operates with a heating element only: resistances 1 e 1A. After the manual disabling of the function, the fan remains enabled for about 5 minutes. The last set temperature stored when the machine is turnd off.

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2)

ENABLING TIME ADJUSTMENT OF THE “GLASS HEATER” GLASS DEFROSTING RESISTANCES

LED

HEATER

LED

20°

ON

15°

10°

ON

ON

LED

GLASS HEATER

00

INTERCOM

ON TALK

MINUTES

+

-

KEY “ON” - By pressing this key the glass resistance automatic starting remote controlswitch is enabled and disabled. NOTE: a) The glass heater starting and the cab heating starting must not be performed at the same time. b) The glass resistences must be enabled 5 minutes before going in or out the refrigerating room.

GREEN LED - If it is on, it indicates that the glass heating resistance remote control switch is enabled.

00

MINUTE INDICATOR DISPLAY - It indicates the real time during which the heater is operating (the minute scan) and the initial set time displayed when the machine is started. the time MINUTI selection can occur between 1 and 15 minutes. When the machine is stopped, the last set datum is stored.

UP AND DOWN ARROW - To vary the heating time press one of the tow key for at least ½ second until the desired value is reached. To display the set time press both keys at the same time.


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SERVICE 3)


“INTERCOM” EXTERNAL COMMUNICATION AUDIO VOLUME ADJUSTMENT LED

HEATER

LED

GLASS HEATER

20°

ON

00

ON

15°

MINUTES

10°

ON

LED

INTERCOM

ON

+

TALK

-

KEY “ON” - By pressing the key, the audio reception from the inside to the outside of the cab is enabled. GREEN LED - If it is on, it indicates that the audio function is enabled.

TALK

KEY “TALK” - By keeping this key pressed the transmission of the audio from the inside to the outside of the cab is enabled, by releasing the key the audio transmission stops.

+ VOLUME INDICATION - It indicates the 10 different levels of volume intensity coming from the outside and displayed any time the intercom is started. Once the machine is off the last set set value is stored.

UP and DOWN ARROW’ - To vary the volume intensity from the outside to the inside, press one of the two keys for ½ till the desired volume is reached.

ADJUSTMENT OF THE VOLUME FROM THE INSIDE TO THE OUTSIDE - it can be adjusted by means of a trimmer located inside the cab on the intercommunication system/loudspeaker unit.

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POSITION OF THE COMPONENTS ON THE REFRIGERATING ROOM CAB PANEL

RES - 1 - 1A RES - 2 - 2A THERMAL DEVICE

FAN

J4

J2

J3

CONNECTOR TO JOIN THE HEATER

J1

F1 F2

F5

F3

F6

F4

F7

F11

F8

F12

F9

F13

F10

J5

J6

T1

T2

T3

-

CONNECTOR TO JOIN THE HEATER


2 3

+

BATT

BATT

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Section: ELECTRIC INSTALLATION WIRING DIAGRAM TO CONNECT THE CABLES OF THE REFRIGERATING ROOM CAB MOD. ALL THE MODELS

“CONTROL” ELECTRONIC CARD J1

J4 J2

TERMICA

T2 F11

F14

F13

RES-1

1 2

RED RED BLEU VIOLET VIOLET

8

BLEU BROWN

ORANGE

BLEU

RED

1

T1

J5

J3 1

6

1

GRUPPO ALTOPARLANTE SULLA PORTA

5

SCREENED CABLE 8 POLES

T3

OUT MC + -

+ BATT

DEFROSTER

RES-2 FAN

J6

BLACK BLACK

2

1

MIC.

SCREENED CABLE & POLES W IRING DIAGRAM

T1

T2

T3 F5

F3

F4

F1 RES-2 400 H

RES-1 400 H

RES-1A 400 H

Dia gra m re f. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 T1 T2 T3 RES-1-1A RES-2-2A V MIC +Ba tt -Ba tt

F6

F7

F8

F9

F10 RED RED RED

F2 RES-2A 400 H

- BATT HEATER CONNECTOR

DOOR DEFROSTER RESISTANCES

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De scription of the function Fuse to protect the RES-2 Fuse to protect the RES-2A Fuse to protect the RES-1 Fuse to protect the RES-1A Not used Fuse to protect the central door defroster resistance Fuse to protect the side door defroster resistance Fuse to protect the driver front glass defroster resistance Fuse to protect the roof upper glass defroster resistance Fuse to protect the windscreen glass defroster resistance Fuse to protect the fan of the air recirculation in the cab Fuse to protect the control card output cable Fuse to protect the control card input cable RES-1 e 1A remote control switch RES-2 e 2A remote control switch Door defroster remote control switch 400 H cab heating resistances 400 H cab heating resistances fan of warm air recirculation in the cab Microphone to communicate with the outside Battery positive connection cable Battery negative connection cable

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Fuse va lue 10A 10A 10A 10A 5A 1A 5A 3A 7,5A 3A 3A 3A

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SERVICE


OPTION SHEET No. 12 SEAT BELT NECESSARY ADDITIONAL COMPONENTS -SEAT BELT KIT MODULE CONFIGURATION -NONE INSTALLATION NOTES NECESSARY STANDARD TOOLS

ELECTRIC DRILL

8,5mm STEEL DRILL

TAPELINE

SCRIBE

5-6mm ALLEN WRENCH

13mm SPANNER

SQUARE

PROCEDURE Before starting working, make sure to wear suitable safety clothing.

Drive the carriage in a safety area far from pedestrian and other vehicle passage, move forward the retractable carriage, lower the forks, put the key switch in position OFF, disconnect the battery. 1) 5mm ALLEN WRENCH, TAPELINE, SCRIBE, SQUARE - By means of the Allen wrench open the engine compartment bonnet and remove the seat by taking it out from the guides (Pict. 54 on page 29a). By means of the tapeline, the scribe and the square mark the holes to fix the seat belt support bracket on the bonnet observing the measures shown in picture 56 for the NARROW truck and in picture 57 for the STANDARD truck ON PAGE 29A). 2) ELECTRIC DRILL, STEEL DRILL, 6mm ALLEN WRENCH, 13mm SPANNER - Assemble the drill and carry out the holes in the marked points; by using the two wrenches assemble the bracket complete with seat belt as shown in picture 58 on page 36a.

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Section: ADDITIONAL FUNCTIONSI

OPTION SHEET No. 12a

SCHEMA DI MONTAGGIO CINTURA DI SICUREZZA

COMPLESSIVO CINTURA MONTATO

Pict. 58 Pict. 55

N° 2 Fori Ø 8,5 No. 2 Ø 8,5 holes HOLE TO APPLY THE NARROW TRUCK SEAT

HOLE TO APPLY THE STANDARD

BELT

TRUCK SEAT BELT

Pict. 56

Pict. 57

Pict. 54

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OPTION SHEET: UPDATE No. 1 -INTERMEDIATE LIFTING LOCK SENSOR (“SW11”) -FUNCTION RELEASE BY MEANS OF THE PUSH BUTTON ON THE DISPLAY (“SW18”)

Picture 01 UPDATES TO BE INSERTED IN THE SERVICE MANUAL MR1.4/2.5 SECTION "ADDITIONAL FUNCTIONS" Page 36 Release 1 2 3

UPDATE

0 1

Update description Description of the lifting lock sensor assembly and SICOS module configuration Description of the weighing function programming Description of the speed reduction removal speed with carriage completely extended

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OPERATING PROCEDURE OF THE LIFTING LOCK KIT !

NECESSARY ADDITIONAL COMPONENTS - LIFTING BLOCK KIT

!

OPERATION NOTE

The kit is generally installed on machines, which are not provided with encoder or height preselector. The equipment is used for programming an intermediate lifting lock, in case some hindrances prevents the operator from working with the mast completely withdrawn. POSITION OF THE EQUIPMENT The sensor is fixed on a collar, which is generally fastened on the right lifting cylinder of the column (Picture 04-05). The sensor is turned to the internal mast (Picture 05-06) . It is connected to connector 20, which is already provided on module 9 “MHYRIO” “Pin 8-17-20 CN A”. The sensor reading cam correspond to the internal mast profile (Ref. B Picture 06) whereas the final end is the base of the mast itself (Ref. A Picture 06). HOW IT OPERATES When performing the lifting, the internal mast base reaches the sensor and stops the lifting to the established position. To disable the lock, press push button “BATTERY OUT” located on the display panel (Picture 02) and, in the same time, pull the lifting lever (Joystick) to take the forks to the maximum height.

PUSH BUTTONS LOCATED ON THE DISPLAY AND USED FOR ENABLING THE INTERMEDIATE LIFTING REALESE

Picture 02

CONFIGURATION TO MODULE 16 SICOS TABLE To enable the lifting lock function, follow the procedure below by setting “AUX INPUT 1” to 2 of the SET OPTION configuration menu.

ADJUSTMENT TO ENABLE THE LIFTING LOCK MENU CONSOLE Sequence SETTING Accessorie s Module CONFIGURATI PARAMETER No. ON CONSOLE

Description of the operations to be follow ed W hen the machine is off, connect the console to the module 6 "EPS" control and enter module 16 "SICOS", then start the machine, (key switch "ON")

1

SICOS

SET OPTIONS

AUX INPUT 1

Page: 38 Comp. No.:524159096 Date:March 2004 0 1

2

2

To enable an intermediate lifting block with realese by means of key "BATTERY OUT" on the display keyboard

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SERVICE


INSTALLATION OF THE LIFTING LOCK SENSOR (“SW11”)

Picture 04

LIFTING LOCK SENSOR KIT

SENSOR SUPPORTING UNIT

Picture 05 FIXED ON THE CYLINDER

Picture 03

UPDATE

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4

SENSOR READING PROFILE

(B)

Picture 06

(A)

SENSOR READING FINAL POINT

INTERMADIATE MAST


SERVICE


"

INSTALLATION NOTE

NECESSARY STANDARD TOOLS

5-6mm ALLEN WRENCH PROCEDURE

No. 2 13mm OPEN ENDED SPANNER

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,extend the retractable carriage

1) 5mm ALLEN WRENCH - Unscrew the bolts fastening the valve unit on the carriage, remove the bonnet to reach module 9 “MHYRIO”. To lock, lift the forks, until the desired height is reached. Disable the key switch, disconnect the battery.

2) No. 2 13mm OPEN ENDED SPANNER - Assemble the various components of the sensor kit. Fix the collar complete with sensor to the lifting cylinder (Picture 05) by means of the spanner and position it near the end of the intermediate mast (Picture 06 arrow “A”). Connect the sensor to Module 9 “MHYRIO” (see diagram on page 41), bind the cable to the cylinder by means of a clamp. Connect the battery, set the key to “ON”, lower the forks and enable the sensor by performing the configuration procedure of Module 16 “SICOS” (see table on page 2).


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SW11 LOCK SENSOR CONNECTING DIAGRAM


UPDATE

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OPTION SHEET: UPDATE No. 2 ENABLING OF THE WEIGHING FUNCTION !

OPERATION NOTE

This option allows enabling the automatic weighing function of the weight lifted by the forks. Carry out the weighing by keeping the forks in “FFL” (free fork lift) and by lifting them up to about 1000mm. To store the real weight to be lifted, it is necessary to store two weighings: a) Weight with empty forks b) Weight with different loads (1.000 Kg, 1.500 Kg,2.000 Kg) according to the nominal capacity weight written on the residual capacity plate.

a) WEIGHT WITH EMPTY FORKS 1) Connect the console (see table) and perform procedure 1 and 2. Press push button “SW23” provided with the balance symbol (Picture 07) located on the display. The system starts the weighing. 2) Pull the lifting lever (Joystick), the forks lift only few seconds by keeping constant speed. It is now possible to detect the weight value. This value is shown on the display about 4/5 seconds then it disappears and appears automatically the weighing function.

PUSH BUTTON (“SW23”)TO SELECT THE WEIGHING FUNCTION

Picture 07

b) WEIGHT WITH LOADS ON THE FORKS 3) Carry out table procedure 3. Put the nominal load on the forks. Take the forks with the load up to 1000mm, press push button “SW23” provided with the balance symbol (Picture 07). Carry out procedure “2” to detect the weight.

TABLE OF CONFIGURATION TO MODULE 16 SICOS To enable automatic weighing function, follow the procedure below WEIGHING FUNCTION ENABLING Sequence Accessories Module No.

Config Menu

Parameters

SICOS

1

SET OPTIONS

2

ADJUSTMENTS

3

ADJUSTMENTS

AUTOMATIC WIEGHT

Settings


When the machine is off, connect the console to the Module 6 "EPS-AC" and enter Module 16 "SICOS". Start the machine (set key switch to "ON") Press "ENTER" to save the data, press ON "OUT" to quit (See description 1 and 2 ).Press ADJ 0 KG "ENTER" and store the weight without POINT load (See description 3 and 2). Press ADJ 1000 KG "ENTER" to store the sample weight. POINT Press "OUT" to quit.


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SERVICE


OPTION SHEET: UPDATE No. 3 REMOVAL OF THE SPEED REDUCTION FUNCTION WITH THE CARRIAGE COMPLETELY EXTENDED !

OPERATION NOTE

This option allows removing the speed reduction function with the carriage completely extended. To disable the speed reduction, connect the console to Module 1 “CAN I/O, enter the parameter Speed Limit and set to OFF. (the parameter is generally set to “ON”). Perform the procedure described in the enclosed table.

TABLE OF CONFIGURATION TO MODULE 1 CAN I/O PROCEDURE TO REMOVE SPEED REDUCTION FUNCTION WITH WITHDRAWN CARRIAGE Sequence Accessories Module No.

Config Menu

Parameters

Settings

SICOS

1

UPDATE

SET OPTIONS

0 1

2 3

4

SPEED LIMIT

OFF

Description of the operations to be performed When the machine is off, connect the console to Module 6 "EPS-AC" and enter Module 1 "CAN-I/O". Start the machine (set the key switch to "ON") Press "ENTER" to save the data, press "OUT" to quit


SERVICE



2

3 4

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UPDATE

SERVICE

Section: HYDRAULIC SYSTEM

a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a

UPDATE

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM KEY TO HYDRAULIC SYSTEM SYMBOLS ............................................................ 2 ELECTRICAL DIAGRAMS ..................................................................................... 2a CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS ..................................... 3 HYDRAULIC UNIT COMPONENTS ......................................................................... 4 BASIC TRUCK HYDRAULIC SYSTEM .................................................................... 6 BETA TYPE MAST HYDRAULIC SYSTEM ............................................................. 7 SINGLE ACTING LATERAL LIFT CYLINDER ........................................................... 8 SELF-BRAKING DURING LOWERING .................................................................... 8 SINGLE ACTING CENTRAL LIFT CYLINDER .......................................................... 9 SELF BRAKING DURING LIFTING AND LOWERING .............................................. 9 SINGLE ACTING LIFT CYLINDERS WITH STROKE END HYDRAULIC CUSHIONING IN LIFTING AND LOWERING DIRECTIONS .................................... 10 LATERAL PLUNGER TYPE LIFT CYLINDER ........................................................ 11 CENTRAL PLUNGER TYPE LIFT CYLINDER ....................................................... 12 PLUNGER TYPE LIFT CYLINDERS ...................................................................... 13 REACH TRUCK REACH CYLINDER ..................................................................... 14 FORKS TILT CYLINDER........................................................................................ 15 FORKS SIDESHIFT CYLINDER ............................................................................ 16 DISASSEMBLING LATERAL LIFT CYLINDERS FROM MAST .............................. 17 REPLACING SINGLE ACTING LATERAL CYLINDER SEALS ............................... 19 DISASSEMBLING CENTRAL LIFT CYLINDERS FROM MAST ............................. 20 REPLACING SINGLE ACTING CENTRAL CYLINDER SEALS .............................. 22 REPLACING THE LATERAL PLUNGER CYLINDER SEALS ................................. 23 REPLACING THE CENTRAL PLUNGER CYLINDER SEALS ................................ 25 DISASSEMBLING THE FORKS TILT CYLINDER .................................................. 27 REPLACING THE SEALS ..................................................................................... 29 REPLACING THE FORKS SIDESHIFT CYLINDER SEALS ................................... 30 DISASSEMBLING THE REACH TRUCK CYLINDER ............................................. 31 REPLACING THE FORKS REACH CYLINDER SEALS ........................................ 32 REPLACING THE OIL SUPPLY HOSES TO THE TILT CYLINDER AND SIDESHIFT CYLINDER ................................................................................. 33 DISASSEMBLING THE CENTRAL CYLINDER OIL SUPPLY LINE ........................ 34

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Section: HYDRAULIC SYSTEM 1.01 KEY TO HYDRAULIC SYSTEM SYMBOLS MODEL ALL MODELS

HYDRAULIC SYSTEM

Here we give the symbols used in the diagrams in this section with their meanings.

TWO-POSITION SOLENOID VALVE

THREE-POSITION SOLENOID VALVE

FILTER

CHECK VALVE

DOUBLE-ACTING CYLINDER

PROPORTIONAL VALVE

SINGLE-ACTING CYLINDER

PUMP

HYDRAULIC MOTOR

TANK

Page: 2

LINE CONNECTION

ELECTRIC MOTOR

PRESSURE RELIEF VALVE

FLOW CONTROL VALVE

MANUAL VALVE

BY-PASS VALVE

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Section: HYDRAULIC SYSTEM HYDRAULIC FUNCTIONAL DIAGRAM MODEL ALL MODELS

Ev2

Ev4

Ev6

Ev8

Ev1

Ev4

Ev6

Ev8

Ev1

Ev5

Ev3

Ev2

Ev3

Ev5

Ev7

Ev7

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SERVICE


THE INPUT MODULE IS HMT TYPE FOR LIFT TRUCKS, DESIGNED TO RESTRICT INTERNAL LEAKAGE DURING DOWNWARD MOVEMENT TO 3 CM3 PER MINUTEAT FULL LOAD.

3 8 A

B

D

C

LIFTING AND LOWERING CONTROL VALVES BANK MODEL ALL MODELS

E

5

LIFTING VALVE A 9

B

2

C

P 1

H C

A

D

M

R

A

B

(1) PROPORTIONAL VALVE This is a cartridge type valve When it is activated it opens completely and the oil flow is proportional to the pump motor rpm. It provides proportional operation exclusively for simultaneous movements (fork lift/reach carriage extension) Min. opening 250mA Max. opening 650mA

(3)PRESSURE RELIEF VALVE Composed of adjuster screw (A), spring (C), spool (D) and poppet (E). The function of this valve is to regulate pressure in the hydraulic circuit. The relief valve is calibrated at between 200 and 220 bar depending on the rated capacity of the truck

D C

B

B

A

A

B

D

C

6

(6) CHECK VALVE Composed of plug (A), spring (C), plunger (D) The function of the check valve is to prevent oil from returning to tank through the valve and pump when the joystick is in the rest position

7 4

INPUT MODULE

Ev3

Ev 6 Ev 4

8

5

3

1

(4) REGULATOR SPOOL Composed of spool (A), precalibrated spring (B) and adjuster screw (D). The function of the regulator spool is to control oil flow during lowering movements. Screw: adjustment for maximum speed (16.8 mm opening)

(2) PILOT VALVE Composed of magnet (A) and pilot valve (B) screwed into the block. The pilot valve serves to drive the regulator spool

Ev2

Ev1

7

(7) EMERGENCY LOWERING VALVE Composed of screw (A), sector (B), and spool (C). This valve is used to lower the forks without electrical command signals

Ev5

Ev8

Ev7

LOWERING VALVES BANK

2 4

(5) PRESSURE COMPENSATOR Composed of spool (A) and spring (B). The pressure compensator serves to assure constant speed of hydraulic movements in loaded or unloaded conditions

16.8mm 6

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SERVICE

Section: HYDRAULIC SYSTEM REACH CARRIAGE AND FORKS "UP" TILT "BACK" / "FORWARD" CONTROL VALVES BANK MODEL ALL MODELS

OVERCENTRE VALVE INSTALLED ON THE TILT CYLINDERS

SOLENOID VALVE

100 bar

FORKS TILT MOVEMENT

200 bar

VALVE PILOT TRANSMISSION RATIO 1-8

3

P

12 bar

If a load on the forks generates pressure of 100 bar, the pilot pressure required in point “P” will be: 200 - 100 = 12 8

PRESSURE COMPENSATOR

(REACH CARRIAGE 10 BAR)

FORKS TILT VALVES BANK

B

Ev4

Ev6

Ev8

Ev1

1

After valve EV5 or EV6 opens oil flows through the overcentre valve located on the tilt cylinders, which operates on the tilt "forward" stroke

Closed centre solenoid valve on return line to prevent hydraulic accumulator effects resulting from the large amount of oil contained in the truck's hydraulic lines. EV5 fork tilt "back" control EV6 fork tilt "forward" control

In the event of tilt problems, with the load tending to descend when no command is present, renew the overcentre valve - do not attempt to clean

INPUT MODULE REACH CARRIAGEVALVES BANK

Proportional 4-way closed centre solenoid valve carriage retract control valve EV3 carriage extend control valve EV4

Ev2

235mm

2

Ev3

Ev5

Ev7

1) EV3 carriage retraction antishock valve EV3 calibrated at 60 bar. 2) EV4 carriage extension antishock valve calibrated at 80 bar. Removing the plug reveals a spring that exerts pressure on a check ball; in the event of malfunctions remove the parts and clean the seat

A and B proportional spools for maximum opening adjusted to a distance between stroke limits of 235 mm

Solenoid valves proportional opening min. 390 mA - max 900 mA

A

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3) Pressure compensator. The pressure compensator performs a dual function in forks lifting and reach carriage extension movement. This component provides pressure compensation that eliminates performance differences in loaded and unloaded conditions lifting 200 bar .

Example

carriage 50 bar

3) TRANSLATION MOVEMENT BLOCKED. The compensator closes and the oil is dumped to tank through the pressure relief valve. Remove the valve, unscrew the plug, clean the internal parts thoroughly and then refit

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SERVICE

Section: HYDRAULIC SYSTEM HYDRAULIC CIRCUIT STATUS IN FORKS LIFTING PHASE

SINGLE JOYSTICK HYDRAULIC CONTROL

Ev2

Ev4

Ev6

Ev8

Ev1

Ev7

Ev5

Ev3 2-JOYSTICK HYDRAULIC CONTROL

OIL DELIVERY OIL RETURN 4-JOYSTICK HYDRAULIC CONTROL

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Section: HYDRAULIC SYSTEM HYDRAULIC CIRCUIT STATUS IN FORKS LOWERING PHASE


Ev2

Ev4

Ev6

Ev8

Ev1

Ev5

Ev3

Ev7

2-JOYSTICK HYDRAULIC CONTROL

OIL DELIVERY OIL RETURN


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Section: HYDRAULIC SYSTEM HYDRAULIC CIRCUIT STATUS IN REACH CARRIAGE EXTENSION PHASE


Ev2

Ev4

Ev6

Ev8

Ev1

Ev5

Ev3

Ev7



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Section: HYDRAULIC SYSTEM HYDRAULIC CIRCUIT STATUS IN REACH CARRIAGE RETRACTION PHASE

ITT JOYSTICK HYDRAULIC CONTROL

Ev2

Ev4

Ev6

Ev8

Ev1

Ev5

Ev3

Ev7



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SERVICE

Section: HYDRAULIC SYSTEM HYDRAULIC CIRCUIT STATUS IN FORKS UPWARD TILT PHASE


Ev2

Ev4

Ev6

Ev8

Ev1

Ev5

Ev3

Ev7




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Section: HYDRAULIC SYSTEM HYDRAULIC CIRCUIT STATUS IN FORKS FORWARD TILT PHASE


Ev2

Ev4

Ev6

Ev8

Ev1

Ev5

Ev3

Ev7




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Section: HYDRAULIC SYSTEM HYDRAULIC CIRCUIT STATUS IN FORKS SIDESHIFT TO LEFT


Ev2

Ev4

Ev6

Ev8

Ev1

Ev5

Ev3

Ev7



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Section: HYDRAULIC SYSTEM HYDRAULIC CIRCUIT STATUS IN FORKS SIDESHIFT TO RIGHT


Ev2

Ev4

Ev6

Ev8

Ev1

Ev5

Ev3

Ev7




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1.02 CORRECT ASSEMBLY METHOD FOR FEMALE UNIONS To ensure an oil-tight connection between the female unions and adapters shown in this manual, observe the following procedure, which differs from that used for flexible hoses.

HYDRAULIC SYSTEM

FEMALE UNIONS WITHOUT SEALS (METAL TO METAL COUPLING) Snug the nut by hand and then tighten with a wrench by no more than 1/4 turn. FEMALE UNIONS WITH O-RING SEAL

12

Snug the nut by hand and then use a wrench to tighten by no more than a further 1/2 turn. In all cases, ensure that the line is correctly aligned before tightening the adapter nut. Note:

The values supplied in the tables are typical for the recommended assembly method in the case of galvanized unions. Unions made of different materials call for the use of alternative values.

TORQUE VALUES TORQUE VALUES

TORQUE VALUES

ORFS

METRIC FEMALE UNION METRIC THREAD M12x1,5 M14x1,5 M16x1,5 M18x1,5 M20x1,5 M22x1,5 M24x1,5 M26x1,5 M30x2 M36x2 M42x2 M45x2 M52x2

Nm

Nm OUTSIDE ø 6 8 8 10 10 12 12 14 15 16 18 20 22 25 28 30 35 38 42

NOMINAL

MIN./MAX

20 38

15-25 30-45

45

38-52

51

43-58

58

50-65

74

60-88

74 105

60-88 85-125

135

115-155

166

140-192

240 290

210-270 255-325

330

280-380

UNF THREAD

SIZE

9/16-18 11/16-16 13/16-16 1-14 1.3/16-12 1.3/16-12 1.7/16-12 1.11/16-12 2-12

-4 -6 -8 -10 -12 -14 -16 -20 -24

MIN

MAX

14 24 43 60 90 90 125 170 200

16 27 47 68 95 95 135 190 225

Table 2

Table 1 TORQUE VALUES

TORQUE VALUES

JIC 37° FEMALE UNION

FEMALE UNION BSP Nm

UNF THREAD

SIZE

7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1.1/16-12 1.3/16-12 1.5/16-12 1.5/8-12 1.7/8-12 2.1/2-12

-4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32

Nm

NOMINAL

MIN./MAX

BSPP THREAD

15 20 30 50 69 98 118 140 210 290 450

9-21 13-27 18-42 30-70 44-94 63-133 73-163 90-190 135-285 200-380 300-600

G1/4 G3/8 G1/2 G5/8 G3/4 G1 G1.1/4 G1.1/2 G2

NOMINAL

MIN./MAX

20 34 60 69 115 140 210 290 400

15-25 27-41 42-76 44-94 95-135 115-165 140-280 215-365 300-500

Table 3

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Table 4

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SERVICE

Section: HYDRAULIC SYSTEM 1.03 HYDRAULIC UNIT COMPONENTS 13

15

10

EV6

EV8

EV5

EV7

60 bar

200/220 bar

16

8 EV4

6

EV1

HYDRAULIC SYSTEM

11

2

3

17

1 14

80 bar

12

38

5 EV3

4

EV2

11

32

32

33

24

34

35

25

36

27

26

29

30

Fig. 1

9

7

28 23 Ev2

Ev4

Ev6

Ev8

Ev1

2 21

13

18

22

19

Ev7

Ev5

Ev3

31

20

Fig. 2

37 37

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1.04 TABLE OF HYDRAULIC UNIT COMPONENTS MODEL ALL MODELS The hydraulic unit components illustrated on the previous page are described in the following table. Ref. Ref. Diagram Component Description

Re f. 1 2 3 4 5 6 7 8 9 10 11

Re f. Dia gra m

EV1 EV2 EV3 EV4 EV5 EV6 EV7 EV8

Compone nt de scription Oil inlet module Hydraulic pressure regulator valve (set at between 200 and 220 bar) Mast lowering proportional solenoid valve Mast lifting proportional solenoid valve Reach carriage cylinder "retract" proportional solenoid valve Reach carriage "extend" proportional solenoid valve Tilt cylinder "back" solenoid valve Tilt cylinder "forward" solenoid valve Forks sideshifter cylinder "Lh" movement solenoid valve Forks sideshifter cylinder "Rh" movement solenoid valve Adjustment of proportional spools for maximum opening of the reach carriage valve Lowering movement oil flow regulator spool adjusted with maximum capacity at 51 l. and at 155 bar (screw adjusted for maximum speed 16.8 mm opening). Valve for emergency lowering when no electrical controls are available Connection union for oil delivery hose arriving from pump Connection union for lift cylinders delivery hose Connection union for oil return line to tank Pressure gauge connection union for system pressure testing Pump motor Lift pump Return oil filer Valve bank hydraulic supply line (lift pump to valves bank) Oil return line (valves bank to tank) Lift cylinders supply line (valves bank to cylinders) 3/8" Reach carriage cylinder supply lines (valves bank to cylinder) 1/4" Tilt cylinders supply lines (valves bank to cylinders) 1/4" Forks sideshifter cylinders hydraulic supply lines (valves bank, cylinders) Valve controlling oil flow to forks sideshifter cylinders Tilt cylinders pressure relief valve Reach cylinder anti-shock valve located internally to the valves bank Valve controlling oil flow of cylinders during lowering Pressure compensation valve for simultaneous activation of lift function and reach Mast lifting lateral cylinders Mast lifting central cylinder Extend/Retract reach carriage cylinder Forks "back/forward" tilt cylinders Forks right/left sideshift cylinder Oil tank Pressure compensator valve for mast descent

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Component reference in exploded view Reference to symbol in functional diagram Function of component

P H R M

LB DW

DW

NOTE: All Yale Part Numbers are given in the parts catalogue.

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HYDRAULIC SYSTEM

Key:

SERVICE

Section: HYDRAULIC SYSTEM 1.05 BASIC TRUCK HYDRAULIC SYSTEM MODEL ALL MODELS

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM COMPONENTS

6

8

7

3

10 9

2

5

11 13 14 12 1

4 Fig. 3

1.06 TABLE OF BASIC TRUCK HYDRAULIC SYSTEM COMPONENTS Ref. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Component description Lift pump l. 11 - MR20 - MR25 Lift pump l. 16 - MR14 - MR14H - MR16 - MR16H - MR20H - MR20W Solenoid valves bank Reach carriage cylinder Oil suction line (tank/pump) Oil pressure line (pump/valves bank) Oil return line (valves bank/tank) Cylinders delivery diverter block Connection line between valves bank and cylinders delivery diverter block Return oil filter Oil filter housing Oil tank Pump suction line union Pump pressure line union 11 KW pump unit


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1.07 MAST HYDRAULIC SYSTEM MODEL ALL MODELS HYDRAULIC SYSTEM COMPONENTS 5 HYDRAULIC SYSTEM

1 6

3

4

9 8

7

12 4 10 11 4 1

3

2 Fig. 4 1060175

1.08 TABLE OF MAST HYDRAULIC SYSTEM COMPONENTS Ref. 1 2 3 4 5 6 7 8 9 10 11 12

Component description Connection hose to central cylinder Connection hose to lateral cylinders Twin connection hoses to forks sideshifter cylinder Twin connection hoses to tilt cylinder Pulleys unit for hoses on mast Pulleys unit for hoses on central cylinder Single-acting central lift cylinder with upward stroke cushioning Single-acting Rh lateral lift cylinder with downward stroke cushioning Single-acting Lh lateral lift cylinder with downward stroke cushioning Bracket for twin hoses and central cylinder Bracket for twin hoses Hose connecting bracket


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Section: HYDRAULIC SYSTEM 1.09 SINGLE ACTING LATERAL LIFT CYLINDER WITH SELF-BRAKING DURING LOWERING MODEL BETA - HE140L - HE140

HYDRAULIC SYSTEM

CYLINDER COMPONENTS

4

5

3

2

1

7 9

8

Fig. 5

6

1.10 TABLE OF LATERAL SINGLE ACTING CYLINDER COMPONENTS Ref. 1 2 3 4 5 6 7 8 9

Component description Complete cylinder Cylinder barrel Cylinder rod Gasket bushing Set of seals for gasket bushing LB hose break safety valve (prevents oil flow in the event of a hose break) Seals holder piston and lowering cushioning valve Set of cylinder piston seals Cushioning valve


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1.11 CENTRAL SINGLE ACTING LIFT CYLINDER WITH SELF-BRAKING DURING LIFTING MODEL BETA - HE140L - HE140

HYDRAULIC SYSTEM

CYLINDER COMPONENTS

4

5

3

1 2

7 6 9

8

Fig. 6

1.12 TABLE OF SINGLE ACTING CENTRAL CYLINDER COMPONENTS Ref. 1 2 3 4 5 6 7 8 9

Component description Complete cylinder Cylinder barrel Cylinder rod Gasket bushing Set of seals for gasket bushing LB hose break safety valve (prevents oil flow in the event of a burst supply hose) Sealks holder piston and lift stroke cushioning valve Set of seals for cylinder piston Cushioning valve


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Section: HYDRAULIC SYSTEM 1.13 SINGLE ACTING LIFT CYLINDERS WITH HYDRAULIC STROKE-END CUSHIONING IN LOWERING AND LIFTING

lateral lift cylinder

HYDRAULIC SYSTEM

The cylinders with hydraulic cushioning are designed using special features that provide hydraulic cushioning at the end of each lift or lower cycle, thereby eliminating mechanical impact at the stroke end positions.

OPERATION OF LATERAL LIFT CYLINDER WITH CUSHIONING IN LOWERING During lowering movement, when the piston guide ring (Ref. A Fig. 7) reaches the position of the oil return port (Ref. B Fig. 7), it partially restricts the outward oil flow thus causing the descent movement to decelerate through the final 40 mm.

OPERATION OF CENTRAL CYLINDER WITH CUSHIONING ON LIFT STROKE

B

The cylinder rod features a hollow core (Ref. G Fig. 8) which is terminated with a seals holder piston (Ref. F) complete with valve (Ref. E Fig. 8); the rod also features two oilways for forced oil flow (Ref. C-D Fig. 8).

A

C

Fig. 7 central lift cylinder

Before starting the lifting movement pour 150 cc of oil inside the cylinder barrel through the plug (Ref. A Fig. 8). During the lift stroke, when the piston (Ref. F Fig. 8) reaches its stroke limit it causes the oil previously poured into the barrel to be compressed against the bush (Ref. B) thus causing a pressure rise that causes the oil to enter the hollow core in the piston rod by way of the hole (Ref. C) thus compressing the air in the hollow core (Ref. G) and resulting in the slowing of upward movement during the final 40 mm of the stroke.

B

A

During the lowering stroke the thrust exerted by the rod decreases as the air pressure in the core decreases, thus causing the 150 cc of oil to flow out of the rod core into the cylinder barrel. The function of the valve (Ref. E Fig. 8) is that of maintaining constant pressure in the rod cavity at the time of ingress of the oil compressed the bushing. The valve is calibrated in order to witstand the compression of 150cc of oil. Any excess oil unloaded to the conventional circuit through the valve. If no deceleration occur over the final 4-5 mm of stroke this indicates that the valve has ceased functioning and must therefore be replaced.

G OIL LEVEL

D C

Through prolonged use and with constant pressure changes inside the cylinder, the oil in the barrel tends to return to the normal hydraulic circuit due to infiltration past the piston seals. To counter this problem, 150 cc of oil must be poured into the cylinder barrel through the plug (Ref. A) every 500-600 duty hours.

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1.14 LATERAL PLUNGER TYPE LIFT CYLINDER MODEL HE140 - HE140R CYLINDER COMPONENTS 10 11

HYDRAULIC SYSTEM

10

4 5

5

4

3 3 1 2

8 7 6

8

9

9 7

1511146_1

Fig. 9

1.15 TABLE OF LATERAL PLUNGER TYPE LIFT CYLINDER COMPONENTS Ref. 1 2 3 4 5 6 7 8 9 10 11

Component description Complete cylinder Cylinder barrel Hollow rod Gasket bushing Set of seals for gasket bushing LB hose break safety valve (prevents oil flow in the event of a hose burst) Hollow rod lower plug Rod guide bush Valve for oil flow to rod cavity Rod air bleed plug Hollow rod upper plug

Table 10 NOTE: All Yale Part Numbers are given in the parts catalogue.

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Section: HYDRAULIC SYSTEM 1.16 CENTRAL PLUNGER TYPE LIFT CYLINDER MODEL HE140 - HE140R CYLINDER COMPONENTS

HYDRAULIC SYSTEM

4

5 8

5 3

1

3 6

2

2

6

7

1512290_1

Fig. 10

1.17 TABLE OF CENTRAL PLUNGER TYPE CYLINDER COMPONENTS Ref. 1 2 3 4 5 6 7 8

Component description Complete cylinder Cylinder barrel Cylinder rod Gasket bushing Set of seals for gasket bushing LB hose break safety valve (prevents oil flow in the event of a hose burst) Rod guide bush Cylinder air bleed plug


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1.18 PLUNGER TYPE LIFT CYLINDERS LATERAL CYLINDER

The lateral plunger cylinders with hollow rod are utilised on high lift masts. In these cylinders, unlike single acting cylinders, both the barrel and the rod are filled with oil before starting the lift stroke. This solution is adopted to increase the strength of the cylinders at maximum elevation, and to make it possible to use compactly sized barrels and rods.

HYDRAULIC SYSTEM

A

LATERAL PLUNGER TYPE CYLINDER WITH HOLLOW ROD

B

OPERATION When the cylinder is assembled in the test phase the air must be bled out by opening the bleed screws (A - B Fig. 11). Before supplying oil to the cylinder it is essential to loosen the two bleed screws on the rod (A Fig. 11) and the barrel (B Fig. 11). When oil is supplied to the cylinder the first cavity to be filled is the rod; continue to pump in oil until only oil and no air escapes through the bleed screw (A Fig.11); this indicates that the rod is full of oil and empty of air and so the bleed screw must be tightened. In the second stage the cylinder barrel is filled; continue to pump in oil until only oil and no air escapes through the bleed screw (B Fig. 11); this indicates that the barrel is full of oil and empty of air and so the bleed screw must be tightened.

1511146_1

Fig. 11

CENTRAL CYLINDER

The oil pressure formed inside the rod and in the barrel increases the strength of the cylinder assembly and reduces the flexibility of the parts at full extension. CENTRAL PLUNGER TYPE CYLINDER This type of cylinder differs from the lateral type because it does not have a hollow rod. The operating characteristics and the air bleed procedure through the bleed screw (A Fig. 12) are identical to those of the lateral cylinder.

A

1512290_1 Fig. 12

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Section: HYDRAULIC SYSTEM 1.19 REACH CARRIAGE CYLINDER MODEL ALL MODELS

HYDRAULIC SYSTEM

CYLINDER COMPONENTS

1

9 8

4

2

6

3

7

5 Fig. 13

1.20 TABLE OF REACH CARRIAGE CYLINDER COMPONENTS Ref. 1 2 3 4 5 6 7 8 9

Component description Complete cylinder Cylinder barrel Cylinder rod Gasket bushing Set of seals for gasket bushing Set of cylinder seals Set of bushing seals Rod eye Grease nipple


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1.21 FORKS TILT CYLINDER MODEL ALL MODELS

1

10 7 8

6 3

9

2

4 5 Fig. 14

1.22 TABLE OF FORKS TILT CYLINDER COMPONENTS Ref. 1 2 3 4 5 6 7 8 9 10

Component description Complete cylinders block Cylinder rod Rod piston Gasket bushing Bushing retaining circlip Piston seal Piston O-ring Set of bushing external seals Set of bushing internal seals Piston to rod fixing screw


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HYDRAULIC SYSTEM

CYLINDER COMPONENTS

SERVICE

Section: HYDRAULIC SYSTEM 1.23 SIDESHIFT CYLINDER MODEL ALL MODELS

HYDRAULIC SYSTEM

CYLINDER COMPONENTS

1 5 3 4 6 2

Fig. 15

1.24 TABLE OF FORKS SIDESHIFT CYLINDER COMPONENTS Ref. 1 2 3 4 5 6

Component description Piston cylinder incorporated in fork arm carriage Cylinder rod Rod guide bush Rod guide bush circlip Seal Wiper seal


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To replace the seals of the single acting lateral cylinders the complete cylinders must first be removed from the mast. The operations described below are also applicable to the removal of lateral plunger type cylinders for integral renewal. To perform these procedures it is important to work in a place with sufficient headroom for the truck with the mast at its full extension and equipped with an overhead crane; it is also necessary to have access to suitable equipment for the recovery of the cylinder. SPECIAL TOOLS REQUIRED ® ® ® ® ®

Long lifting sling with a capacity of 2000 kg Short lifting sling with a capacity of 3000 kg “Parcher” type male/female 1/2" plugs for hydraulic hoses Ladder with overhead platform Operator lift for recovery of the cylinder

STANDARD TOOLS REQUIRED 4 mm ALLEN WRENCH

OVERHEAD CRANE

A MEDIUM EXTERNAL CIRCLIP PLIERS

13-22-24 mm HEX WRENCH

PROCEDURE Fig. 17

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its fully forward position. 1) LADDER WITH PLATFORM - CIRCLIP PLIERS 13 mm HEX WRENCH - Place the ladder on the side of the mast in order to access one of the cylinders, and ascend with the necessary tools. Use the circlip pliers to remove the circlip from the end of the cylinder (Ref. A Fig. 17). Use the hex wrench to unscrew and remove the cylinder mounting bracket fixing screws (Ref. B Fig.18); this done, descend the ladder and remove it from the work area.

B

C

Fig. 18

Fig. 19 Fig. 16

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HYDRAULIC SYSTEM

2.00 REMOVING THE LATERAL LIFT CYLINDERS FROM THE MAST MODEL ALL MODELS

SERVICE


HYDRAULIC SYSTEM

2) 22-24 mm HEX WRENCH - HYDRAULIC PLUGS - The hydraulic hoses must be detached from inside the reach carriage. Use the 24 mm hex wrench to unscrew the hydraulic supply hose union on the cylinder to be removed (Ref. C Fig. 19). With the 22 mm wrench fit the male plug to the hose union (Ref. D Fig. 20) and the female plug to the cylinder union (Ref. E Fig. 20). 3) SHORT LIFTING SLING - OVERHEAD CRANE - Attach the short lifting string to the top of the inner mast section and attach the to ends of the sling to the overhead crane (Fig.16). Start lifting with the only cylinder still connected and simultaneously lift with the overhead crane; continue the lift stroke to maximum height and allow the sling to take the strain.

D

The same operation must be used to remove the second cylinder.

E

G

Fig. 20

4) LONG LIFTING SLING - 4 mm ALLEN WRENCH - LIFT TRUCK - Attach the sling to the mid point of the cylinder (Ref. F Fig. 16), attach the sling to the lift truck and take the strain. Use the wrench to unscrew the cylinder fixing grub screw (Ref. G Fig. 20), lift the cylinder and extract it from the lower seat; now lower the cylinder and angle it towards the outside so that it can be extracted from the upper cross member. Bring the cylinder to a horizontal position and place it on a workbench. Now either fit a new cylinder or strip the original unit and renew the seals. F

Fig. 21

NOTES:

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2.01 REPLACING LATERAL SINGLE-ACTING CYLINDER SEALS MODEL MR14 - MR16 SPECIAL TOOLS REQUIRED

®

Tube clamp Ø 60÷80 Oil collection container

HYDRAULIC SYSTEM

®

STANDARD TOOLS REQUIRED

C-SPANNER Ø 60 ÷ 80

MEDIUM SLOTTED SCREWDRIVER

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing.

H

1) TUBE CLAMP - OIL COLLECTION CONTAINER - C-SPANNER Position the cylinder in the clamp and tighten carefully to avoid distorting the barrel, position the container under the cylinder bush. Use the wrench to completely unscrew the seal holder bush (Ref. H Fig. 22), remove the bush from the rod and withdraw the rod from the barrel; place the bush on a clean workbench and fit new seals. 2) SMALL SCREWDRIVER - Use the screwdriver to remove the seals from the bush and from the rod piston; carefully clean and oil the seal seats to facilitate refitting. Now fit the new seals. To reassemble, perform the disassembly steps in reverse order.

Fig. 22

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Section: HYDRAULIC SYSTEM 2.02 REMOVING THE CENTRAL LIFT CYLINDER FROM THE MAST MODEL ALL MODELS

HYDRAULIC SYSTEM

To renew the single acting central cylinder seals the cylinders must be first removed from the mast. The operations described below also apply to the removal of central plunger type cylinders for complete replacement purposes. SPECIAL TOOLS REQUIRED Long sling with lifting capacity of 2000 kg ® Parcher type male-female 3/4 plugs for hydraulic hoses ® Wooden beam 100x100x800 ®



PROCEDURE

4 mm ALLEN WRENCH

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its fully forward position.

L Fig. 26

Fig. 25

I

N M Fig. 27

Fig. 24

Fig. 23

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1) WOODEN BEAM - Raise the forks until the fork arm carriage is high enough to clear the beam on the floor (Fig. 23). Position the beam and then lower the forks until the fork arm carriage is supported on the beam. Continue to lower the forks until the cylinder is completely closed.

2) 13 mm HEX WRENCH - Use the hex wrench to unscrew and remove the fixing screw from the fork shaped plate of the pulleys assembly (Ref. L Fig. 25), remove the plate and lift the pulleys assembly complete with hoses and chain, withdrawing it from the cylinder. Use the same wrench to unscrew and remove the cylinder mounting bracket fixing screws (Ref. I Fig. 24): now remove the bracket. 3) 22-24 mm HEX WRENCH - 4 mm ALLEN WRENCH - Use the 24 mm hex wrench to unscrew the cylinder oil supply hose union (Ref. N Fig. 24); now use the 22 mm wrench to fit the male plug to the hose union and the female plug to the cylinder union. Use the Allen wrench to unscrew the cylinder securing grub screw (Ref. M Fig. 27). 4) LIFTING SLING - OVERHEAD CRANE - Attach one end of the sling to the cylinder in the vicinity of the bush; attach the other end to the overhead crane hook. Take the strain with the sling and then continue to lift in order to extract the cylinder from the top of the fork arm carriage; this done, use the crane to transfer the cylinder to a workbench. Now either fit a new cylinder or strip the original unit and renew the seals. To reassemble, perform the disassembly steps in reverse order.

NOTES:

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HYDRAULIC SYSTEM

Warning: The beam is of fundamental importance to safety for the entire duration of the work and must therefore be in a stable and secure position before proceeding.

SERVICE

Section: HYDRAULIC SYSTEM 2.03 REPLACING THE SINGLE ACTING CENTRAL CYLINDER SEALS MODEL MR14 - MR14H - MR16 - MR16H - MR16N SPECIAL TOOLS REQUIRED

HYDRAULIC SYSTEM

® ®

Tube clamp Ø 60 ÷ 80 Container for collecting oil





O

1) TUBE CLAMP, OIL COLLECTION CONTAINER, C-SPANNER - Place the cylinder in the clamp and tighten with care to avoid distortion of the cylinder barrel, place the container beneath the cylinder bush. Use the wrench to completely unscrew the seals holder bush (Ref. O Fig. 28), withdraw the bush from the rod and the rod from the cylinder barrel; place the assembly on a clean workbench and renew the seals. 2) SMALL SCREWDRIVER - Use the screwdriver to remove the seals from the bush and the rod piston, clean the seal seats thoroughly and oil them to facilitate insertion of the new seals. Now fit the new seals. To reassemble, perform the disassembly steps in reverse order.

Fig. 28

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2.04 REPLACING THE LATERAL PLUNGER CYLINDER SEALS MODEL MR16H Optional - MR20 - MR20H - MR20W - MR25 SPECIAL TOOLS REQUIRED

®

Wooden chock 100x100x800 Ladder with platform

HYDRAULIC SYSTEM

®


MEDIUM EXTERNAL CIRCLIP PLIERS



CHAIN TYPE OIL FILTER WRENCH

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its fully forward position. Q

Fig. 31

P

Fig. 29

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SERVICE


HYDRAULIC SYSTEM

1) CIRCLIP PLIERS - LADDER WITH PLATFORM Place the ladder on the side of the mast in order to access one of the cylinders, and use the circlip pliers to remove the circlip from the cylinder rod (Ref. Q Fig. 31). 2) WOODEN BLOCK - Raise the forks until the block can be inserted under the central mast profile as shown (Fig. 32). Position the beam and then lower the forks until the mast rests on the beam and the cylinder whose circlip has been removed has closed with the rod completely inside the barrel.

Fig. 32

Warning: The beam is of fundamental importance to safety for the entire duration of the work and must therefore be in a stable and secure position before proceeding. 3) C-SPANNER - CHAIN TYPE OIL FILTER WRENCH - SMALL CROSSHEAD SCREWDRIVER - Two persons are required in order to unscrew the ringnut. Fit the filter wrench at the mid point of the cylinder barrel (Ref. P Fig. 29) in such a way that it tightens in the reverse direction with respect to the direction in which the bush must be unscrewed. Use the C-spanner to unscrew the ring completely and then withdraw it from the cylinder rod. Now renew the seals. 4) SMALL SLOTTED SCREWDRIVER - Remove the seals from the bush, clean and oil the seats. Renew the seals. To reassemble, perform the disassembly steps in reverse order. Repeat the same procedure for the cylinder on the other side of the mast. NOTES:

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2.05 REPLACING THE CENTRAL PLUNGER CYLINDER SEALS MODEL MR16H Optional - MR20 - MR20H - MR20W - MR25 SPECIAL TOOLS REQUIRED Wooden beam 100x100x800

HYDRAULIC SYSTEM

®


13 mm HEX WRENCH



PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its fully forward position.

R Fig. 35

Fig. 35b

Fig. 34

Fig. 33

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SERVICE


1) WOODEN BEAM - Raise the forks to the height necessary to clear the beam as shown (Fig. 33). Position the beam under the fork arm carriage, lower the forks until the carriage is resting on the beam. Continue to lower the forks until the cylinder has retracted completely, causing the hoses and chain to become slack.

HYDRAULIC SYSTEM

Warning: The wooden block is of fundamental importance to safety for the entire duration of the work and must therefore be in a stable and secure position before proceeding. 2) 13 mm HEX WRENCH - Unscrew and remove the fixing screw of the pulleys assy. mounting plate (Ref. R Fig. 35), withdraw the mounting plate from the cylinder and lift the complete pulleys assy away from the cylinder. 3) C-SPANNER - Completely unscrew the bush from the cylinder, withdraw it from the rod and place it on a workbench. 4) SMALL SLOTTED SCREWDRIVER - Remove the seals from the bush, clean and oil the seal seats to facilitate fitting of the new seals; renew the seals. To reassemble, perform the disassembly steps in reverse order. NOTES:

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2.06 REMOVING THE FORKS TILT CYLINDER MODEL ALL MODELS SPECIAL TOOLS REQUIRED Wooden block 100x100x200

HYDRAULIC SYSTEM

®


LARGE SLOTTED SCREWDRIVER

19 mm SOCKET WRENCH WITH RATCHET

17-19 mm HEX WRENCH

5-10 mm ALLEN WRENCH

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its fully forward position and lift the forks to a position one metre above the ground. 1) Disassemble the fork arm carriage (refer to “mechanics section” heading 2.01 page 9).

Fig. 37 T S

Fig. 38

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Fig. 36

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SERVICE

HYDRAULIC SYSTEM

Section: HYDRAULIC SYSTEM 2) 19 mm SOCKET WRENCH WITH RATCHET - WOODEN BLOCK - Activate the tilt control lever in the up direction until the tilt cylinders are at their fully extended position. Use the wrench to unscrew and remove the nuts responsible for securing the cylinder rods to the plate (Ref. T Fig. 38), and wedge the block between the oscillating plate and the mast (Ref. S Fig. 36). Activate the tilt control lever in the down direction and cause the rods to retract into the cylinders (Fig. 40). Set the keyswitch to “OFF” and disconnect the battery.

Fig. 39 U

Warning: The wooden block is of fundamental importance to safety for the entire duration of the work and must therefore be in a stable and secure position before proceeding.

U

3) 5 mm ALLEN WRENCH - 17 mm HEX WRENCH - Use the hex wrench to unscrew the unions on the cylinder supply hoses (Ref. Z Fig. 42) and detach the hoses. Use the Allen wrench to unscrew and remove the two fixing screws of the valve block (Ref. V Fig. 42) and remove the block, taking care not to lose the O-rings inserted between valve and cylinder.

Fig. 40

4) 10 mm ALLEN WRENCH - Unscrew and remove the fixing bolts of the cylinder restraints (Ref. U Fig. 40). Remove the restraints and remove the cylinder (Fig. 39) for complete replacement or so that it can be stripped down in order to replace the seals.

Fig. 41

To reassemble, perform the disassembly steps in reverse order.

V

Z

Fig. 42

NOTES:

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2.07 REPLACING THE TILT CYLINDER SEALS MODEL ALL MODELS

MEDIUM INTERNAL CIRCLIP PLIERS

HYDRAULIC SYSTEM




1) CIRCLIP PLIERS - After having disassembled the cylinder place it on a workbench and use the relative pliers to remove the circlip (Ref. A Fig. 43); now extract the rod complete with bush.

A

2) SMALL SCREWDRIVER - Remove the bush (Ref. D Fig. 44) from the rod and then use the screwdriver to remove the outer seals (Ref. C Fig. 44), the inner seals (Ref. E Fig. 44) and the piston seals (Ref. B Fig. 44). Before fitting the new seals clean the parts and oil the seats to facilitate installation; now fit the new seals and reassemble the cylinder.

Fig. 43


A

B

E

D

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C

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Fig. 44

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SERVICE

Section: HYDRAULIC SYSTEM 2.08 REPLACING THE SIDESHIFT CYLINDER SEALS MODEL ALL MODELS

HYDRAULIC SYSTEM


MEDIUM INTERNAL CIRCLIP PLIERS


PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its fully forward position and lift the forks to a position one metre above the ground. Set the keyswitch to “OFF” and disconnect the battery. 1) Remove the fork arm carriage (see “mechanics section” heading 2.01 page 9).

I H

2) CIRCLIP PLIERS - SMALL SCREWDRIVER Extract the piston from its seat; use the small screwdriver to remove the wiper seal (Ref. F Fig. 45-46) and use the circlip pliers to remove the circlip (Ref. G Fig. 47). Extract the rod guide bush (Ref. H Fig. 45) and then remove the seal (Ref. I Fig. 45). Before fitting the new seals clean the parts carefully and oil the seats to facilitate replacement. Now fit the new seals. To reassemble, perform the disassembly steps in reverse order.

G

F

Fig. 45 I

F G

H Fig. 46

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2.09 REMOVING THE REACH CYLINDER MODEL ALL MODELS

13-19 mm HEX WRENCH

PROCEDURE

5 mm ALLEN WRENCH

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its fully forward position and lift the forks to a position one metre above the ground. 1) 5 mm ALLEN WRENCH - Unscrew and remove the fixing screws of the valves assembly protective guard on the reach carriage; remove the guard. 2) 13-19 mm HEX WRENCH - Use the 13 mm hex wrench to unscrew and remove the screw responsible for securing the cylinder to the reach carriage (Ref. N Fig. 50). Lift the cylinder and withdraw from the rod. Operate the cylinder control lever and cause the rod to retract; then set the keyswitch to “OFF” and disconnect the battery. Use the 19 mm wrench to unscrew the unions of the cylinder hydraulic hoses (Ref. L Fig. 51) and detach the relative hoses. Use the 13 mm wrench to unscrew the second cylinder fixing screw (Ref. M Fig. 49) then raise and withdraw from the rod. Recover the cylinder by extracting it from the mast direction. To reassemble, perform the disassembly steps in reverse order. L L

Fig. 51

M

N

Fig. 50

Fig. 49

Fig. 48

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HYDRAULIC SYSTEM


SERVICE

Section: HYDRAULIC SYSTEM 2.10 REPLACING THE REACH CYLINDER SEALS MODEL ALL MODELS

HYDRAULIC SYSTEM


C-SPANNER Ø5


PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. 1) C-SPANNER - SMALL SCREWDRIVER - When the cylinder has been removed, place it on a workbench equipped with a vice. Lock the cylinder in the vice taking care not to deform the barrel. Use the c-spanner to unscrew and remove the ringnut (Ref. O Fig. 52), extract the rod complete with seals holder piston. Use the screwdriver to remove the seals from the bush and the rod piston. Before fitting the new seals clean the parts and oil the seats to facilitate installation; now fit the new seals. To reassemble, perform the disassembly steps in reverse order.

O

Fig. 52

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2.11 REPLACING THE TILT AND SIDESHIFT CYLINDERS OIL SUPPLY HOSES AND THE CENTRAL CYLINDER SUPPLY HOSE MODEL ALL MODELS The procedure for disassembling the tilt, sideshift, and central cylinders oil supply hoses are identical, because the hoses follow the same path and run on different pulleys.

® ®

HYDRAULIC SYSTEM

SPECIAL TOOLS REQUIRED Ladder with platform Wooden beam 100x100x800


13-16-18-22 mm HEX WRENCH

5-6 mm ALLEN WRENCH

22 mm HEX WRENCH

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its fully forward position.

P Fig. 55 Q

R

Fig. 56 S

S

Fig. 53

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Fig. 57

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Fig. 54

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SERVICE


1) WOODEN BEAM - Raise the forks until the fork arm carriage is high enough to clear the beam on the floor (Fig. 53). Position the beam and then lower the forks until the fork arm carriage is supported on the beam. Continue to lower the forks until the chain and hoses become slack. Set the keyswitch to “OFF” and disconnect the battery.

HYDRAULIC SYSTEM

Warning: The beam is of fundamental importance to safety for the entire duration of the work and must therefore be in a stable and secure position before proceeding. 2) 10-13 mm HEX WRENCH - 5 mm ALLEN WRENCH - Use the 13 mm wrench to unscrew and remove the hoses anti-shear bracket fixing bolts (Ref. U Fig. 60) and remove the bracket. Use the 10 mm hex wrench and 5 mm Allen wrench to unscrew and remove the bolts from the hose restraining block (Ref. S Fig. 57). Use the Allen wrench to unscrew and remove the hose restraint fixing bolts (Ref. X Fig. 61). After this sequence of operations all the hoses will be loose along their entire length. 3) 13 mm HEX WRENCH - 6 mm ALLEN WRENCH - LADDER WITH PLATFORM - Use the Allen wrench to unscrew and remove the fixing bolts of the upper hose carrier bracket (Ref. T Fig. 59). Remove the bracket with the hoses. To access the lower ones place the ladder alongside the mast next to the hydraulic lines and then climb the ladder and use the 13 mm wrench to unscrew and remove the bracket fixing bolts (Ref. P Fig. 55). Remove the bracket and shift the upper hydraulic lines support. 4) 18 mm HEX WRENCH - Unscrew the twin hose unions (Ref. R Fig. 56) and unions (Ref. Y-Z Fig. 61). Remove the pipelines and fit replacements. To reassemble, perform the disassembly steps in reverse order.

2.12 REMOVING THE CENTRAL CYLINDER OIL SUPPLY LINE

T

Fig. 59

1) 22 mm HEX WRENCH - Unscrew the hose union at the base of the cylinder (Ref. V Fig. 61) and the hose union on the mast (Ref. Q Fig. 56). Remove the hose and fit a replacement.

U


Fig. 60

V

Z

X Fig. 61

Fig. 58

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HYDRAULIC SYSTEM

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HYDRAULIC SYSTEM

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Section: MASTS

UPDATE

a

TYPE OF MASTS ....................................................................... 3

a

MAST REMOVAL PROCEDURE ................................................ 8

a

DRAWING WITH MAST ASSEMBLY NOTES ........................... 10

a

MAST TILT ANGLES TABLE ..................................................... 11

a

FORK ARM CARRIAGE REMOVAL PROCEDURE ................... 12

a

BEARINGS REPLACEMENT PROCEDURE ............................. 14

a

GREASING OF BEARING ........................................................ 15

a

MAST BEARINGS REPLACEMENT PROCEDURE .................. 16

a

LIFT CHAIN ............................................................................... 17

a

REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT) ............. 19

a

REPLACING THE LATERAL LIFT CHAINS ................................ 20

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MASTS

MASTS

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Section: MASTS

MASTS

NOTES:

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Section: MASTS TABLE OF MAST - TRUCK COMBINATIONS

COMPOSITION OF TRUCK AND MAST IN RELATION TO CAPACITY AND LIFT HEIGHT Mast Geared Geared Driver Driver Load Load Load Load Mast Mast Mast Truck Front Rear Wheelbase Maximun Motor Motor Wheel Wheel Wheel Wheel Wheel Wheel Model Channel Channel Channel Channel Type Forks tilt Y Height MDU 150 MDU 170 305x140 342x140 250x100 285x100 350x100 350x127 Beta HE140 HE140L HE140R MR14 4500/6700 x 1 2° / 4° 1435 x x x MR14H 7000/8700 x 2 2° / 4° 1450 x x x MR16 4500/6700 x 3 2° / 4° 1485 x x x MR16H 7000/9200 x 3 2° / 4° 1485 x x x MR20 4500/6300 x 4 2° / 4° 1550 x x x MR20H 6700/8000 x 4 2° / 4° 1550 x x x MR20H 8500/11400 x 4 2° / 4° 1550 x x x MR25 4500/8000 x 5 2° / 4° 1650 x x x MR25 8500/11400 x 5 2° / 4° 1650 x x x MR16N 4500/6700 x 6 2° / 4° 1435 x x x MR16N 7000/8700 x 6 2° / 4° 1435 x x x MR20W 4500/8000 x 7 2° / 4° 1580 x x x MR20W 8500/11400 x 7 2° / 4° 1580 x x x

BETA MAST

HE 140 - 140L MAST

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Load wheel Bracke No No Option Option Std Std Std Std Std No No Std Std

HE 140 R MAST

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SERVICE

Section: MASTS POSITION OF PUNCH MARKING SHOWNIG DIAMETER OF BEARINGS UTILIZED ON MAST MODELS HE 140L - HE 140 - HE 140R CENTRAL

EXTERNAL BEARING 2

BEARING 1

BEARING 3

TOURELLE COMPLETE

INTERNAL BEARING 4

DETAIL W DETAIL X

DETAIL Z

DETAIL Y BEARING 2 INFO MARKING

BEARING 1 INFO MARKING

BEARINGS 4 & 6 INFO MARKING MARQUAGE INFO GALET 3 ET 5

MARQUAGE INFO GALET 8

MARQUAGE INFO GALET 7

INTERNAL MAST SECTION

GALET 5 INFO MARKING (LETTER A, B OR C) ON OUTER SIDE OF BEARING 1 MAST CHANNEL

DETAIL X

FOR BEARING 2 APPLY SYMMETRICAL MARKING ON OTHER SIDE OF CHANNEL

GALET 6

EXTERNAL MAST SECTION

GALET 7

GALET 8 INFO MARKING (LETTER A, B OR C) ON OUTER SIDE OF BEARING 7 MAST CHANNEL

INFO MARKING (LETTER A, B OR C) TOP LETTER: BEARING 3 BOTTOM LETTER: BEARING 5

DETAIL Z

DETAIL Y FOR BEARINGS 4 & 6 APPLY SYMMETRICAL MARKING ON OTHER SIDE OF CHANNEL

CENTRAL MAST SECTION

FOR BEARINGS 4 & 6 APPLY SYMMETRICAL MARKING ON OTHER SIDE OF CHANNEL

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BEARING DIAMETER

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SERVICE

Section: MASTS

1.00 MAST TYPES The masts installed on the new reach trucks are available in 4 models (“Beta”, “HE 140”, “HE 140L”, “HE 140R”) and are all of the telescopic triplex F.F.L. (Full Free Lift) type with tilt cylinder and fork sideshift cylinder integrated in the fork arm carriage. Tables 1 and 2 show the characteristics of the masts in relation to: lift height, load capacity, and carriage type. More detailed technical information is given in the following pages.

1.01 FORK SIDESHIFTER COMPONENTS MODEL BETA - HE 140 - HE 140L - HE 140R

12 1

11

2 10

6 13

MASTS

18 12

14

99

4 15

13

17 5

7

3 8

8

16 Fig. 1

1.02 TABLE OF FORK SIDESHIFTER COMPONENTS Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Component description Sideshifter carriage Tilt plate incorporating sideshifter cylinder Forks sideshifter plate Tilt cylinders assy. Forks sideshifter cylinder rod Sideshifter movement upper shoe Sideshifter movement lower shoe Forks sideshifter plate mechanical stop Forks sideshifter rod guide bush Forks tilt cylinder rod Forks tilt cylinder assy. mechanical stop Valve controlling oil flow to tilt cylinder Kit of seals for tilt cylinder Tilt cylinder bush retaining circlip Tilt cylinder rod guide bush Forks sideshifter cylinder seals kit Forks sideshifter cylinder rod guide retaining circlip Mast channel bearings

Table 1 NOTE: All Yale Part Numbers are given in the parts catalogue.

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Section: MASTS

1.03 “BETA” MAST The “BETA” mast is installed on truck models MR 14 - MR 16 - with maximum elevation of 6700 mm. (see table 1 page 2a). SPECIFICATIONS: The external stage is built of “C” profiles and anchored to the reach carriage by means of two pins welded to each side of the mast, to be fastened to the reach carriage supports. The lower part of the mast is secured to the reach carriage by means of three screws

MASTS

The intermediate and internal stages are constructed of “J” section profiles. Reciprocal movement of the two sections is assured by interposed bearings. The fork arm carriage runs inside the internal mast section. The carriage incorporates the mast tilt cylinder and forks sideshift cylinder. The mast is equipped with a total of 8 “taper roller ” bearings Ø 91 mm (Fig. 2). The roller journals are welded in an inclined position to allow them to run on the internal corner of the profile. Specially designed shims of various dimensions are utilized to reduce play between the mast stages. The fork arm carriage is equipped with 4 Ø 81mm taper roller bearings. The journals of the upper rollers are welded in an inclined position with the angle in the opposite direction with respect to the lower roller journals in order to eliminate front and side play.

Fig. 2

The lateral lift cylinders are of the “Single acting self-braking” type, with cushioning activated on the downward stroke (for more information consult the hydraulic section of the manual). The central cylinder is of the “Single acting self-braking” type with cushioning activated at the top of the upward stroke (for more information consult the hydraulic section of the manual). The lift chains are prime quality “Fleyer series AL and BL” type, wherein Fleyer denotes a traction type chain.

MAST VIEWED FROM FORKS SIDE

MAST VIEWED FROM ABOVE

MAST VIEWED FROM CYLINDERS SIDE

VIEW OF BEARING POSITIONS IN MAST CHANNEL

Fig. 3

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Section: MASTS

1.04 MAST “HE 140L” Mast model “HE 140L” is installed on trucks with lift heights from 4500 mm to 8000 mm according to the rated load capacity of the truck (see table 1 page 2a).

SPECIFICATIONS: The external, intermediate, and internal stages are constructed of “HE” section channels. Anchorage to the reach carriage is identical to that of the “Beta” mast, thus ensuring that the masts are fully interchangeable on the same reach carriage.

1 The mast complete with fork arm carriage is equipped with a total of 12 “Combined roller” bearings Ø 101 mm (Fig. 4). 2 The bearings are composed of an outer roller that runs in a plane parallel to the mast channel and a lateral roller that runs on the internal profile; this combination, with the aid of suitable shims, has made it possible to minimize play between lateral and front mast sections. Fig. 4 The lateral lift cylinders are of the “Single acting self-braking” type with cushioning activated on the downward stroke (for more information consult the hydraulic section of this manual). The central cylinder is of the “Single acting self-braking” type with cushioning activated at the top of the upward stroke (for more information consult the hydraulic section of the manual). The lift chains are prime quality “Fleyer series AL and BL” type, wherein Fleyer denotes a traction type chain.

MAST VIEWED FROM FORKS SIDE

MAST VIEWED FROM ABOVE

MAST VIEWED FROM CYLINDERS SIDE

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MASTS

The fork arm carriage runs within the internal mast stage and it incorporates the mast tilt cylinder and forks sideshift cylinder.

SERVICE

Section: MASTS

1.05 MAST “HE 140” Mast model HE 140 is installed on trucks with lift heights from 6700 mm to 9200 mm according to the rated load capacity of the truck (see table 1 page 2a). SPECIFICATIONS: The specifications of this mast are analogous the data quoted for type HE 140L. The principal difference lies in the use of different types of lateral lift cylinders.

MASTS

The lateral lift cylinders are “Plunger type with hollow rod” (for more information consult the hydraulic section of this manual). The central cylinder is “Single acting self-braking” type with cushioning activated at the top of the upward stroke (for more information consult the hydraulic section of the manual). The lift chains are prime quality “Fleyer series AL and BL” type, wherein Fleyer denotes a traction type chain.

VIEW OF MAST FROM FORKS SIDE

VIEW OF MAST FROM ABOVE

VIEW OF MAST FROM CYLINDERS SIDE

VIEW OF BEARING POSITIONS IN THE MAST CHANNEL

Fig. 6

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Section: MASTS

1.06 MAST TYPE “HE 140R” Mast model “HE 140R” is installed on trucks with lift heights up to 11400 mm (see table 1 page 2a). SPECIFICATIONS: The specifications of the mast profile and bearings are identical to those quoted for mast model “HE 140L”.

The lateral lift cylinders are “Plunger with hollow rod” type (for more information consult the hydraulic section of this manual). The central lift cylinder is of the “Plunger” type (for more information consult the hydraulic section of this manual). The lift chains are prime quality “Fleyer series AL and BL” type, wherein Fleyer denotes a traction type chain.

VIEW OF MAST FROM FORKS SIDE

VIEW OF MAST FROM ABOVE

VIEW OF MAST FROM CYLINDERS SIDE


Fig. 7

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MASTS

To enable the mast to reach high elevations a series of reinforcements have been applied to the external stage and the intermediate stage. This mast also utilizes different lift cylinders.

SERVICE

Section: MASTS

2.00 MAST REMOVAL PROCEDURE MODEL BETA - HE 140 - HE 140L - HE 140R The mast must be disassembled from the carriage when they are to be completely renewed or in order to renew the bearings. The removal procedure is identical for all models. SPECIAL EQUIPMENT REQUIRED ® ® ®

Wooden beam 100x100x800 Sling with max. load capacity of 3000 kg Overhead crane with lifting capacity of 4000 kg max.

MASTS


6-8 mm ALLEN WRENCH



OVERHEAD CRANE

G

G

Fig. 12 F

E

D

A

H C

Fig. 8

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Fig. 10

Fig. 9

Fig. 11

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SERVICE

Section: MASTS

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position.

2) SLING - OVERHEAD CRANE - Attach one end of the sling to the top cross beam of the external mast stage (Fig. 8). Attach the other end of the sling to the crane hook and then allow the crane to take the strain. 3) WOODEN BEAM - Lift the forks beyond the free lift thus exposing the screws that fasten the mast to the reach carriage (Fig. 9) and then continue to lift until the beam can be inserted under the intermediate section; place the beam under the section (Ref. H Fig. 9) then lower the forks until they are supported on the beam. Now set the keyswitch to “OFF” and disconnect the battery. Warning: the beam fills an important safety function for the entire duration of the work and must therefore be positioned where it is perfectly stable and safe. 4) 24 mm SOCKET WRENCH - Unscrew and remove the three screws that secure the mast to the reach carriage (Ref. A Fig. 9). Connect the battery and set the keyswitch to “ON”. Lift the mast by 10 centimeters and remove the wooden beam. Now lower the mast until it is completely closed and then set the keyswitch to “OFF” and disconnect the battery. Use the same wrench to unscrew and remove the mast stop screws on the reach carriage (Ref. C Fig. 11). Remove the upper stops. 5) 17-19-24 mm HEX WRENCHES - Use the 17 mm wrench to unscrew the unions of the twin hydraulic lines supplying the tilt cylinder and sideshift cylinder (Ref. D Fig. 12). With the 24 mm hex wrench unscrew the central cylinder hydraulic hose union (Ref. E Fig. 12). With the same wrench unscrew the union of the lateral cylinders hydraulic supply line (Ref. B Fig. 13). 6) Lift the mast ensuring that the mast base, supported on the reach carriage, does not foul the solenoid valve pipelines and that the lateral profiles transit past the mast stabilizer mechanical stops (Fig.14-15). Now lower the mast to the ground and proceed with repair work or fit new bearings. To reassemble, perform the disassembly steps in reverse order.

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MASTS

1) SLING - CRANE - 6-8 mm ALLEN WRENCH - Lift the forks until they are positioned at one metre above the ground, then use the 7 mm. Allen wrench to unscrew and remove the fixing screws of the load restraint grille (Ref. G Fig. 10). Remove the grille from the fork arm carriage. Using the 8 mm Allen wrench unscrew and remove the forks mechanical locking screw (Ref. F Fig. 10). Move the forks one at a time towards the centre of the carriage and remove them with the aid of the overhead crane and the sling.

SERVICE

Section: MASTS 2.01 DIAGRAM WITH DESCRIPTION OF MAST ASSEMBLY STEPS

Notes on installing or removing the mast with indications of the shims to be inserted to provide the correct inclination in relation to height and screw torquing directions for mast installation.

MASTS

TORQUE TO 300 Nm / ASSEMBLE WITH LOCTITE 243 / 4 SCREWS

TORQUE TO 300 Nm / ASSEMBLE WITH LOCTITE 243 / 4 SCREWS SHIMS TO ADD OR REMOVE TO ADJUST THE MAST INCLINATION ANGLE

CHAIN/CARRIAGE VIEWED FROM BELOW

NOTA: FARE ATTENZIONE AD INSERIRE NOTE: LA COLONNA PIASTRA DI ENSURE NELLA THE MAST IS CORRECTLY FERMO DEL CARRO RETRATTILE

INSERTED IN THE REACH CARRIAGE RETAINER PLATE

Fig. 15a

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2.02 TABLE OF MAST INCLINATION ANGLES The following table gives the inclination measurements for the various mast types and the ground to stabilizer shoe distance in relation to the height and model. QUOTA

“A”

+

-

MASTS

QUOTA “B”

h1

STABILIZER SHOE - GROUND DISTANCE

Fig. 15b

MAST INCLINATION

MAST INCLINATION A708 BETA Reference H3 Reference H1 mm mm 4500 5000 5400 6000 6300 6500 6700 7000 7500 8000 8500 8700 9000 9300 9500 10000 10500 11400

2075 2275 2376 2575 2675 2775 2825 2925 3175 3325 3525 3725 3825 3925 3975 4275 4425 4725

A709 HE 140 A709 HE 140L A709 HE 140R Horizontal distance reference H1 mm 9 9 10 10 11 11 12 12 13 13 14 14 15 15

Horizontal distance reference H1 mm 11 11 12 12 13 13 14

Horizontal distance reference H1 mm 9 9 10 10 11 11 12 12 13 13 14 14 15 15

QUOTA "A"

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Horizontal distance reference H1 mm

13 14 14 15 15 16 16 17 17

Stabilizer shoe Adjustment Shoe to Ground Clearence mm 30 30 30 30 30 30 30 30 30 30 20 20 20 20 20 10 10 10 QUOTA "B"

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SERVICE

Section: MASTS

2.03 FORK ARM CARRIAGE REMOVAL PROCEDURE MODEL BETA - HE 140 - HE 140L - HE 140R The procedure for removal of the fork arm carriage is identical for all models of masts. The form arm carriage must be removed when new bearings are to be fitted. SPECIAL EQUIPMENT REQUIRED ® ®

Sling with load capacity of 2000 kg max. Overhead crane with lifting capacity of 2000 kg max.

G

G

MASTS


5-6-8 mm ALLEN WRENCH

F

17-19 mm HEX WRENCH

OVERHEAD CRANE

Fig. 20

REGULAR

Fig. 17 L M

N Fig. 16

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Section: MASTS

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position.

2) SLING - OVERHEAD CRANE - Attach one end of the sling to the fork arm carriage (Fig. 16) and attach the other end to the crane hook; now allow the crane to take the strain. Continue to lift until the lift chain and tilt/sideshift cylinder hydraulic hoses have become slack. 3) 5 mm ALLEN WRENCH - REGULAR PLIERS - 17 mm HEX WRENCH - Use the 5 mm Allen wrench to unscrew and remove the hose carrier block (Ref. I Fig. 18), use the hex wrench to unscrew the hydraulic hose unions (Ref. L Fig.19). Use the pliers to remove the circlip from the chain pin (Ref. N Fig. 18). Remove the chain fixing pin (Ref. M Fig. 18). Lower the fork arm carriage to the ground and then remove the lifting sling. 4) Attach one end of the sling to the mast internal section cross beam (Fig. 16) and attach the other end to the crane hook and then take the strain with the crane. Lift the mast section until the fork arm carriage is free of its location. Place the fork arm carriage on a workbench and proceed to repair the carriage or replace the bearings. To reassemble, perform the disassembly steps in reverse order

NOTES:

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MASTS

1) 6-8 mm ALLEN WRENCH - Lift the forks until they are one metre above the ground. Use the 6 mm wrench to unscrew and remove the load restraint grille fixing screws (Ref. G Fig. 20). Remove the load restraint grille from the fork arm carriage. With the 8 mm wrench unscrew and remove the forks mechanical fastening screw (Ref. F Fig. 20). Move the forks towards the centre of the carriage one at a time and then use the crane and sling to remove them.

SERVICE

Section: MASTS

MASTS

2.04 BEARING REPLACEMENT PROCEDURE MODELS HE 140 - HE 140L - HE 140R The combined bearings are available in three different sizes characterized by the following outside diameters “Ø 101.5 - Ø 101.9 - Ø 102.3” (Ref. N Fig. 21). When the mast is assembled the bearings are first tested by running them inside the channels so that the bearing that offers the smallest frontal play can be utilized (Fig. 22). Shims are also utilized to insert on the journal at the rear of the bearing in order to eliminate lateral play (Fig. 22). Once the mast has been assembled, the measurement of the rollers is punched onto each profile in the form of a letter that identifies the diameter utilized. For more information regarding the position of the punch marking (see Page 2b). The bearings must be renewed every 6000/7000 duty hours. The lifetime of the bearings depends basically on the conditions and work cycles, the working environment, and the grease lubrication frequency. Failure to observe correct maintenance practices can result in excessive play on the mast profiles both in the frontal and axial directions, or even seizure of the internal rollers due to inadequate lubrication. In this situation it becomes necessary to renew the rollers before the normal end of their working life. Alternatively, it is possible to measure both the axial and frontal clearance of the rollers in the mast channels caused by cold deformation and, if the tolerance values surpass the values shown in (Fig. 22) it is advisable to renew the bearings. If at the time of refitting it should be noted that the original size bearing presents clearances that are outside the requested tolerance, this bearing must be substituted for the bearing of the next diameter up and punch mark the letter indicating the size of the new bearing (see position on page 2b). The roller is supplier as a spare part complete with a contrast roller but without the weld-on journal. The procedures for removing and refitting bearings on the mast and on the fork arm carriage are identical.

N

Fig. 21

0,5

0,5

Fig. 22

Mast channel

STANDARD TOOLS REQUIRED 3 mm ALLEN WRENCH

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. 1) 3 mm ALLEN WRENCH - Unscrew the four fixing screws securing the welded journal bearing (Ref. O Fig. 24), remove the plate and bearing complete with contrast roller and fit a new replacement part.

Fig. 23


Fork arm carriage

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Section: MASTS

2.05 GREASING THE BEARING The bearing lubrication frequency depends on several factors such as the environment in which lifting is performed and the type of work that the truck is called to carry out. Dusty and corrosive environments, with high or excessively low temperatures and constant use of the truck over multiple shifts will make it necessary to increase the frequency of maintenance. For normal use of the truck in low dust environments with temperatures within average values the required greasing frequency is once every 300/400 duty hours. Recommended lubricants: Standard bearing grease = “Mobil Grease 532” Low temperature bearing grease = “Texaco Regal AFB2” Mast lubricant = “Molykotez Graphitized Grease”

®

MASTS

SPECIAL EQUIPMENT REQUIRED Grease gun

STANDARD TOOLS REQUIRED GREASE NIPPLE

3 mm ALLEN WRENCH

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. 1) 3 mm ALLEN WRENCH, GREASE GUN, GREASE NIPPLE - Using the Allen wrench unscrew and remove the grub screw currently plugging the bore (Ref. P Fig. 29) fit a 6 mm diameter grease nipple (Ref. Q Fig. 26) and proceed to inject grease. Repeat the same procedure for all four mast bearings. This procedure must be repeated every 300/400 duty hours. With the same frequency it is good practice to lubricate the bearing tracks by brushing them with grease as shown (Fig. 30). Fig. 29

Fig. 27

P

Fig. 30

Q Fig. 28

Fig. 26

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Section: MASTS

2.06 MAST BEARINGS REPLACEMENT PROCEDURE MODEL BETA The roller utilised in conjunction with the “BETA” mast is composed of a ball bearing inside a steel shell with radiused outer edge. The bearing is fitted over a welded journal inclined with respect to the mast channel in such a way that the rounded part of the bearing runs on the internal corner of the channel (Ref. S Fig. 31). To minimise lateral and frontal play shims, in the required number and thicknesses, are installed on the journal behind the bearing (Ref. T Fig. 31).

MASTS

The bearings must be renewed every 6000/7000 duty hours. The bearings, not equipped with grease nipples, are sealed and prelubricated with long life grease. The roller must be renewed when play is detected between shell and internal bearing, or when the dimensional tolerance of the convex section of the roller becomes too great and the roller ceases to run truly in the corner of the mast channel (Ref. S Fig. 31). In both cases it will be necessary to remove the mast from the truck.

S

T

Fig. 31

STANDARD TOOLS REQUIRED R Fig. 32

MEDIUM CIRCLIP PLIERS

PROCEDURE Fig. 33 Before starting work, make sure you are wearing suitable safety clothing. 1) CIRCLIP PLIERS - Remove the bearing retaining circlip from the journal (Ref. R Fig. 32) and remove the shims. Remove the bearing and fit a replacement part. To reassemble, perform the disassembly steps in reverse order. If you notice that the new bearing presents excessive play in the mast channel, insert one of the previously removed shim washers under the circlip. To ensure the maximum freedom of movement of the bearings, use a brush to apply a coating of grease to the mast channel as shown (Fig. 34). This operation should be performed every 400 ÷ 500 duty hours using “Molykotez Graphitized Grease”.

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Section: MASTS

2.07 LIFT CHAIN The chains are prime quality “Fleyer series AL and BL” type traction chains. The chains installed are subjected to levels of mechanical stress that are significantly lower than their effective breaking strength. GREASING THE CHAINS

MASTS

Long life of the chains is assured by performing proper lubrication. The chains should therefore be lubricated periodically using a brush as shown (Fig. 35) or spray canister. The frequency with which the chains are to be lubricated depends largely on the type of work performed and the environment conditions in the workplace. CHAIN STRETCHING Fig. 35

Over a period of time and with constant use the chains tend to stretch. The resulting length increase can be compensated for using the chain tensioner. The maximum possible compensation for chain stretching is 2% of total length. When the chains stretch beyond this point they must be renewed. Measure chain elongation over a number of sections of 10 links in length selected from the parts of the chain most subject to stress. This check should be performed every 1500/2000 duty hours. The 10 links measurement is shown in the following table in reference to the type of mast and relative chain. LIFT CHAIN STRETCH REFERENCE TABLE

Lateral Mast Mast Type Chains Pitch L== P 15,875 BETA HE 140 HE 140L HE 140R

Central Mast Chains Pitch L= P 25,40

P 15,875 P 25,40 P 15,875 P 25,40 P 15,875 P 25,40

Sample Length Equal to N° 10 Links

Maximum Stretch Referred to Sample Length

158,75 254 158,75 254 158,75 254 158,75 254

162 259 162 259 162 259 162 259

Table 3

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Section: MASTS

2.08 MEASURING THE CHAIN If chains are found to display an insignificant degree of stretching (less than 2%), this fact alone cannot be construed as indicating that the chains are in perfect condition. On the contrary, chains may display signs of stress-related distortion; for this reason it is good practice to carefully inspect the chain over its entire length.

B

A

D

G F

MASTS

CHECKING CHAIN LINKS C

Prepare for the inspection by cleaning the chain with paraffin or a paraffinbased solvent. The chains may be inspected without removing them from the mast. Inspect the chain and associated components (Fig. 36-37):

E Fig. 36

A) B) C) D) E) F) G) H) I)

Wear of the journal Condition of the journal (possible damage) Cracked links Wear of the link edges Wear of the link bores Excess play between the links Rust Out of round of the chain tensioner bore Wear of the chain pivot pin H

If the chains and/or associated parts display one or more of the foregoing defects, they must be replaced.

I Fig. 37 NOTES:

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2.09 REPLACING THE CENTRAL LIFT CHAIN (FREE LIFT) MODEL BETA - HE 140 - HE 140L - HE 140R SPECIAL TOOLS REQUIRED ®

Wooden beam 100x100x800

STANDARD TOOLS REQUIRED REGULAR PLIERS

13 mm HEX WRENCH

PROCEDURE

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position. 1) WOODEN BEAM - Raise the forks until the beam can be inserted under them; position the beam under the forks (Fig. 38); lower the forks until they are resting on the beam and then continue to lower until the chain and hydraulic hoses become slack. Set the keyswitch to “OFF” and disconnect the battery. Warning: the beam fills an important safety function for the entire duration of the work and must therefore be positioned where it is perfectly stable and safe. 2) 13 mm HEX WRENCH - Unscrew and remove the anti-derailment bracket fixing screws (Ref. L Fig. 41). Remove the bracket. 3) REGULAR PLIERS - Remove the split pins and chain pivot pins, (Ref. M-N Fig. 40-41), remove the chain, and fit a replacement. To reassemble, perform the disassembly steps in reverse order. L Fig. 41

M

N Fig. 38

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Fig. 39

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MASTS

Before starting work, make sure you are wearing suitable safety clothing.

SERVICE

Section: MASTS

2.10 REPLACING THE LATERAL LIFT CHAINS MODEL BETA - HE 140 - HE 140L - HE 140R SPECIAL TOOLS REQUIRED ®

Wooden beam 100x100x800

STANDARD TOOLS REQUIRED PROCEDURE

REGULAR PLIERS

MASTS

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position.

O

O

Fig. 35

Fig. 36 P

P

Fig. 34 Fig. 37

Fig. 38

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1) WOODEN BEAM - Lift the forks beyond the free lift until the beam can be inserted under the internal section (Fig. 34). Insert the beam and lower the forks until the internal section is resting on the beam; continue to lower the forks until the chains become slack. Set the keyswitch to “OFF” and disconnect the battery. Warning: the beam fills an important safety function for the entire duration of the work and must therefore be positioned where it is perfectly stable and safe. 2) REGULAR PLIERS - Remove the split pins and chain pivot pins at the base of the internal section (Ref. P Fig. 37-38) and then disengage the chain from the terminal connection. Remove the split pins and the chain pivot pins from the chain tensioners (Ref. O Fig. 35). Recover the chains and fit replacements. MASTS


NOTES:

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Section: MASTS

MASTS

NOTES:

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Section: MECHANICS

UPDATE

TABLE OF SCREW TIGHTENING TORQUES ................................ 2

a

DRIVE WHEEL REPLACEMENT PROCEDURE ............................ 3

a

LOAD WHEELS REPLACEMENT PROCEDURE .......................... 4

a

FORK SIDESHIFTER SHOES REPLACEMENT PROCEDURE ..... 7

a

FUNCTION OF THE BATTERY RESTRAINT ................................... 9

a

BATTERY RESTRAINT REMOVAL PROCEDURE ....................... 10

a

REPLACING THE LATCH AND SPRING ...................................... 11

a

REPLACING THE TRACTION MOTOR ......................................... 12

a

TRACTION MOTOR COMPONENTS ............................................ 13

a

ENCODER BEARING REPLACEMENT ....................................... 14

a

REMOVAL OF THE PUMP MOTOR ............................................. 16

a

PUMP MOTOR COMPONENTS .................................................. 18

a

REPLACING THE ENCODER BEARING ...................................... 19

a

STEERING GEARED MOTOR REMOVAL PROCEDURE ............ 20

a

STEERING MOTOR COMPONENTS ........................................... 21

a

ENCODER BEARING REPLACEMENT ....................................... 22

a

STEERING UNIT .......................................................................... 23

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MECHANICS

a

MECHANICS

MECHANICS

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SERVICE

Section: MECHANICS

1.00 TABLE OF SCREW TIGHTENING TORQUES NOTE: before disassembling and reassembling parts of the truck and fasteners, read the following information carefully. LOCTITE 270 is used to lock threaded fasteners and ensure that they will not work loose during operation. A certain amount of resistance may be encountered when undoing bolts, etc. Should they prove impossible to unfasten using normal tools, do not use extensions (the head of the bolt might shear off), but instead, heat the area slightly so as to eliminate the effects of the Loctite (max 50 °C). In the cases described above, apply a moderate amount of Loctite when refitting (generally speaking, 30% of the mating surface should be coated) The tightening torque applied to threaded fasteners is of maximum importance for the safety of the joint itself and therefore for the safety of the machine.

MECHANICS

The following table indicates the classes of nuts and bolts normally used on the machine with the relative tightening torques.

NOM SIZE

TENSILLE

X

STRESS

PITCH

PROPERTY CLASS 5.8 CLAMP

TORQUE (N.m

PROPERTY CLASS 8.8 CLAMP

PROPERTY CLASS 10.9

TORQUE (N.m)

CLAMP

TORQUE (N.m)

AREA

LOAD

DRY

LUBEET

LOAD

DRY

LUBED

LOAD

DRY

LUBED

As (mm)

W (N)

K=0.20

K=0.15

W (N)

K=0.20

K=0.15

W (N)

K=0.20

K=0.15

M4 x 0,5 M5 x 0,8 M6 x 1

8,78 14,20 20,10

2 400 3 880 5 490

1,92 3,88 6,58

1,44 2,91 4,94

3 830 6 200 8 770

3,07 6,20 10,50

M8 x 1,25 M8 x 1 M10 x 1,5 M10 x 1,25

36,60 9 990 39,20 10 700 58,00 15 825 61,20 16 700

16,00 17,10 31,70 33,40

12,00 12,80 23,80 25,10

15 975 17 100 25 325 25 725

25,60 27,40 51,00 53,00

19,20 20,50 38,00 40,10

21 750 23 275 34 450 36 350

36 800 88,00 66,00 40 200 96,00 72,00 50 200 140,00 105,00 54 550 155,00 115,00

50 075 54 700 68 300 74 250

M12 x 1,75 M12 x 1,25 M14 x 2 M14 x 1,5

84,30 92,10 115,00 125,00

23 025 25 150 31 400 34 125

55,00 60,00 88,00 96,00

41,40 45,30 66,00 72,00

M16 x 2 M16 x 1,5 M20 x 2,5 M20 x 1,5

157,00 167,00 245,00 272,00

42 850 45 600 66 875 74 250

135,00 145,00 270,00 295,00

105,00 110,00 200,00 225,00

68 525 72 900 106 950 118 750

2,30 5 220 4,65 8 430 7,90 11 950

220,00 235,00 430,00 475,00

165,00 175,00 320,00 355,00

93 250 99 200 145 550 161 550

4,17 8,43 14,30

3,13 6,33 10,80

34,80 37,30 69,00 73,00

26,10 27,90 52,00 55,00

120,00 90,00 130,00 98,00 190,00 145,00 210,00 155,00 300,00 320,00 580,00 650,00

225,00 240,00 435,00 485,00

Table 1

NOTE: The truck is assembled using screws and bolts of PROPERTY CLASS 8.8 - LUBED.

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Section: MECHANICS

1.01 DRIVE WHEEL REPLACEMENT PROCEDURE MODEL ALL MODELS SPECIAL EQUIPMENT REQUIRED ®

N° 2 wooden blocks 150x150x200



MECHANICS


HYDRAULIC JACK

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) HYDRAULIC JACK - WOODEN BLOCKS - Set the jack in the centre of the truck in correspondence with the drive wheel, and raise the truck until the blocks can be inserted. Position the blocks as shown (Fig. 2) and lower the jack until the truck is resting on the blocks. Remove the jack. 2) 5-10 mm ALLEN WRENCH - Use the 5 mm Allen wrench to open the motor compartment door, then use the 10 mm Allen wrench to remove the wheel protection plate (Ref. A Fig. 1). 3) 19 mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the wheel fixing screws (Ref. B Fig. 2). Remove the drive wheel and fit a replacement. To reassemble, perform the disassembly steps in reverse order.

Fig. 1

A

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MECHANICS

PROCEDURE

SERVICE

Section: MECHANICS

1.02 LOAD WHEELS REPLACEMENT PROCEDURE MODEL MR14 - MR16 - MR16N SPECIAL EQUIPMENT REQUIRED ®

2 wooden blocks 150x150x200


MECHANICS

3 mm ALLEN WRENCH

D

HYDRAULIC JACK

1 kg HAMMER

Fig. 3

Ø 20x200 DRIFT

PROCEDURE

Fig. 4

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. C

1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack alongside the load wheel and raise the truck until the block can be inserted. Position the block alongside the jack (Fig. 4) and lower the jack so that the truck is resting on the block. Repeat the same procedure for the opposite side wheel.

Fig. 5

2) 3 mm ALLEN WRENCH - HAMMER - DRIFT - Using the 3 mm Allen wrench unscrew and remove the wheel spindle fixing screws (Ref. C Fig. 5) Use the hammer and drift to drive out the wheel spindle (Ref. D Fig. 3) as shown (Fig. 6). Remove the wheel and proceed to change the entire wheel or the bearings only. Recover the shims interposed between the bearings and the load wheel channels because they must be refitted together with the new wheel.

Fig. 6


Fig. 7

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Section: MECHANICS

1.03 LOAD WHEELS REPLACEMENT PROCEDURE MODEL MR16 Optional - MR20 - MR20H - MR20W - MR25 SPECIAL EQUIPMENT REQUIRED ®


STANDARD TOOLS REQUIRED HYDRAULIC JACK

MECHANICS

5-8 mm ALLEN WRENCH

Fig. 8

Ø 25x200 DRIFT

1 kg HAMMER

E

MECHANICS

7-14 mm HEX WRENCH

Fig. 9

COMPASS WRENCH WITH Ø 5 mm PINS

C-SPANNER FOR RINGNUTS Ø 40


Fig. 10

G

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack at the side of the load wheel and raise the truck until the block can be inserted. Place the block alongside the jack and lower the jack so that the truck is resting on the block. Repeat the same procedure for the opposite side wheel.

F

2) 14 mm HEX WRENCH - Empty and remove the brake fluid line union nut with thru hole (Ref. E Fig. 9) and collect the brake fluid, ensuring that it does not come into contact with the brake unit.

H

Fig. 11

I

3) 5 mm ALLEN WRENCH - Unscrew and remove the five screws that secure the brake unit to the truck body (Ref. F Fig. 11) thereby freeing the wheel. 4) COMPASS WRENCH - 8 mm ALLEN WRENCH - Position the compass wrench pins in the holes in the spindle (Ref. G Fig. 10). Using the Allen wrench, unscrew and remove the spindle fixing screw (Ref. H Fig. 11).

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SERVICE

Section: MECHANICS 5) HAMMER - DRIFT - Use the hammer and drift to drive out the wheel spindle from the inside of the straddle channel towards the outside (Ref. I Fig. 12). Remove the wheel and place it on a workbench. 6) C-SPANNER - Unscrew and remove the ring responsible for fixing the brake unit to the wheel (Ref. L Fig. 13). Remove the brake unit and proceed to change the wheel and the bearings (Fig. 14). L

NOTE: it is advisable to order and replace the wheel complete with hub; this ensures that the new wheel will be perfectly centred.

Fig. 13

To reassemble, perform the disassembly steps in reverse order. 7) 7 mm HEX WRENCH - Bleed the brake circuit of air (see procedure in the “braking system” section, heading 6.02 Page 13).

MECHANICS

Fig. 14 NOTES:

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Section: MECHANICS

2.00 FORKS SIDESHIFT SHOES REPLACEMENT PROCEDURE MODEL ALL MODELS

MECHANICS

Due to constant use of the sideshift facility, the shideshift shoes tend to wear with the result of excess friction during sliding movements or, in extreme cases, jamming of the mechanism. The lifetime of the shoes depends basically on the working conditions and cycles, the working environment, and the frequency of use of the sideshift. For normal use in a low dust environment with average temperatures and greasing carried out every 300/ 400 duty hours, the shoes should be renewed on average every 4000/5000 duty hours. The replacement procedure is described below.

SPECIAL EQUIPMENT REQUIRED ®

Lifting sling with terminal rings and max load capacity of 2000 kg


MECHANICS


OVERHEAD CRANE MAX. LOAD CAPACITY 2000 kg


Fig. 15

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, raise the forks until they are one metre from the ground, set the keyswitch to “OFF” and disconnect the battery. 1) 8 mm ALLEN WRENCH - SLING - OVERHEAD CRANE Unscrew the forks fixing screw located at the centre of the fork arm carriage (Ref. M Fig. 16). Shift the forks towards the centre of the carriage one at a time to the position of the lower forks latch. Attach the two ends of the sling to the fork (one end next to the fork tip and the other near the fork heel (Fig. 15). Attach the mid-section of the sling to the crane hook and then lift the fork, detaching it from the fork arm carriage.

M

N

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Fig. 17

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SERVICE

Section: MECHANICS 2) 12 mm ALLEN WRENCH - SLING - OVERHEAD CRANE Attach the ends of the sling to the top bar of the fork arm carriage (Fig. 18). Attach the mid section of the sling to the crane hook and allow the crane to take the strain. Using the Allen wrench unscrew and remove the fixing screws of the sideshift blocks (Ref. N Fig. 17) and remove the blocks. Move the base of the carriage outwards and lift until it is possible to remove the sideshift and thus expose the sliding shoes (Ref. O - P Fig. 19); at this point, remove the shoes and fit replacement parts. After replacing the shoes apply a generous amount of grease to the sliding surface. It is good practice to grease the parts every 300 ÷ 400 duty hours

Fig. 18

MECHANICS


O

Fig. 19

P

NOTES:

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Section: MECHANICS

2.01 FUNCTION OF THE BATTERY RESTRAINT MODEL ALL MODELS

SITUATION OF BRACKET DURING BATTERY EXTRACTION

- Battery extraction Bring the reach carriage to the position in which it is completely located against the battery. Use your shoe heel to press pedal (Ref. A Fig. 22) located opposite the accelerator pedal alongside the motor hood, and then lift the pin (Ref. C Fig. 23). At this point spring (D) forces the bracket to the left, thus moving hook (B) out of the centre of pin (C) and simultaneously engaging hook (E) with reach carriage pin (F). Now move the reach carriage towards the load wheels, causing the battery to be drawn out of is compartment in the truck body (Fig. 20). - Reinserting the battery Once the battery has been charged, move the reach carriage back towards the battery compartment. When it reaches its stroke limit the bevel of hook (B) slides over pin (C) causing the bracket to move to the right and, thanks to the force exerted by spring (D) it engages with the pin, thus locking the battery in the truck body battery compartment (Fig. 21).

MECHANICS

DESCRIPTION OF HOW THE MECHANISM WORKS E F D B

C

Fig. 20 C Fig. 23

- Battery in working position As can be seen (Fig. 21) hook (B) of the bracket is engaged with pin (C) and, assisted by the force exerted by spring (D), it maintains the bracket locked to the hook thus enabling the truck to be operated with the battery completely restrained in its position. Due to the sliding friction of the bracket hooks when the locate with the pins, it is advisable to keep all the parts properly greased to facilitate engagement and disengagement movements. F

E

D B SITUATION OF BRACKET DURING BATTERY LOCKING

A

C

Fig. 22

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MECHANICS

The battery restraint performs the important job of keeping the battery secured when the truck is in operation, while also allowing the extraction of the battery compartment for charging purposes. The bracket complete with hooks is anchored below the battery enclosure, hook E engages with pin F during extraction, while hook B engages with pin C in the locked, work position.

SERVICE

Section: MECHANICS

2.02 BATTERY RESTRAINT REPLACEMENT PROCEDURE MODEL ALL MODELS STANDARD TOOLS REQUIRED

13-32 mm HEX WRENCH

REGULAR PLIERS

5 mm ALLEN WRENCH


PROCEDURE

MECHANICS

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks, set the keyswitch to “OFF” and disconnect the battery. 1) 5 mm ALLEN WRENCH - Open the motor compartment door and remove the platform. 2) 13 mm HEX WRENCH - Extract the battery towards the load wheels. Use the wrench to unscrew and remove the restraint assy. fixing screws (Ref. Q Fig. 26). Remove the assy. and fit a complete replacement or strip down the original assy to replace the worn parts. 3) 13 mm HEX WRENCH - REGULAR PLIERS - Use the wrench to loosen the locking nut (Ref. R Fig. 27) Use the pliers to disengage the pin restraining clips (Ref. S Fig. 27) and then remove the pin (Ref. T Fig. 28) taking care to recover the bush (Ref. V Fig. 28). Manually keep the pin pressed upwards (Fig. 28) and unscrew the latch and nut. Withdraw the pin complete with spring (Fig. 29) and fit replacement parts.

Fig. 24

To reassemble, perform the disassembly steps in order. T

S

reverse

V Fig. 25

R Q

Fig. 27

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Fig. 28

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Section: MECHANICS

4) CIRCLIP PLIERS - 5 mm ALLEN WRENCH Move the reach carriage towards the load wheels. To access the bracket you will need to lie on the ground and, using a worklight to illuminate the area, proceed with removal. Use the Allen wrench to unscrew and remove the spring fixing screws (Ref. W Fig. 30-31) and then remove the spring. Use the pliers to remove the circlip (Ref. Z Fig. 3031), remove the latch from the pivot pin and fit a replacement. To reassemble, perform the disassembly steps in reverse order.

W

Z

Fig. 30

MECHANICS

W

Z

NOTES:

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MECHANICS

LATCH AND SPRING REPLACEMENT

Part No.: 524159096

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SERVICE

Section: MECHANICS

3.00 TRACTION MOTOR REPLACEMENT PROCEDURE MODEL ALL MODELS SPECIAL EQUIPMENT REQUIRED ®

Lifting sling with hook


12 12 12 12 12

MECHANICS

5 mm ALLEN WRENCH

OVERHEAD CRANE

13-17 mm 8 mm HEX WRENCH

Ø 8 mm EYEBOLT CAPACITY 100 KG

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks, set the keyswitch to “OFF” and disconnect the battery. 1) 5 mm ALLEN WRENCH - Open the battery compartment door and remove the platform. 2) 13 - 17 mm HEX WRENCH - Use the 17 mm wrench to unscrew the power cable terminals on the motor and detach the cables. Use the 13 mm wrench to unscrew and remove the four screws that secure the motor to the gear unit (Ref. Y Fig. 32). 3) EYEBOLT - SLING - OVERHEAD CRANE - Screw the eyebolt into the rotor shaft through the electromagnetic brake unit (Fig. 32). Attach the sling hook to the eyebolt and attach the other end of the sling to the crane hook. Carefully lift the motor clear of the gear unit in order to fit a replacement or to strip down the original motor. To reassemble, perform the disassembly steps in reverse order.

Fig. 32

Y

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Section: MECHANICS

3.01 TRACTION MOTOR COMPONENTS MODEL ALL MODELS

7 2

5

10

9

3

13

MECHANICS

4 11 12

8

6

MECHANICS

1

Fig. 33

TABLE OF TRACTION MOTOR COMPONENTS

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13

Component description Rotor Stator Casing Upper motor flange Lower motor flange Tie rod ø 8 Terminal block Encoder bearing Encoder connector Motor thermal cutout connector Dust seal Circlip Wiring between terminal block and stator Table 2


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SERVICE

Section: MECHANICS

3.02 REPLACING THE ENCODER BEARING MODEL ALL MODELS Once the motor has been removed from the truck it can be stripped down to access the various parts. STANDARD TOOLS REQUIRED

13-17 mm HEX WRENCH


5 mm ALLEN WRENCH

BEARING PULLER

MECHANICS

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. 1) 5 mm ALLEN WRENCH - 17 mm HEX WRENCH - Place the motor in a vice and clamp the casing carefully. Use the hex wrench to unscrew and remove the motor power cable terminal nuts (Ref. A Fig. 35). Use the Allen wrench to unscrew and remove the screws securing the terminal block to the motor (Ref. B Fig. 35). Remove the terminal block. Fig. 34

2) 13 mm HEX WRENCH - Unscrew and remove the fixing nuts of the flange connecting tie bars (Ref. C Fig. 37) and remove the four bars (Ref. D Fig. 37) thereby freeing the flanges. Withdraw the rotor complete with upper flange (Fig. 38).

A

B

3) 5 mm ALLEN WRENCH - Remove the casing from the vice and, in its place, insert the rotor after fitting the vice jaws with aluminium cheeks to prevent marring of the rotor. Clamp the rotor carefully. Use the wrench to unscrew and remove the fixing screws of the bearing retaining flange (Ref. E Fig. 39). Remove the flange from the rotor (Fig. 40).

Fig. 35

D

E

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Fig. 39

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Fig. 38

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Fig. 36

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SERVICE

Section: MECHANICS

4) CIRCLIP PLIERS - PULLER - Use the pliers to remove the bearing circlip (Ref. F Fig. 41). Fit the puller to the bearing (Fig. 42) and withdraw the bearing from the rotor shaft (Fig. 43); fit a new bearing (Fig. 44). To reassemble, perform the disassembly steps in reverse order.

MECHANICS

Fig. 40

Fig. 41 MECHANICS

F

Fig. 43

Fig. 44

Fig. 42

NOTES:

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SERVICE

Section: MECHANICS

4.00 PUMP MOTOR REMOVAL PROCEDURE MODEL ALL MODELS SPECIAL EQUIPMENT REQUIRED ® ®

Sufficiently large container to hold 30 l of oil. Lifting sling with hook


12 12 12 12 12 12

5 mm ALLEN WRENCH

OVERHEAD CRANE



Ø 8 mm EYEBOLT LOAD CAPACITY 100 kg

MECHANICS

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) 5 mm ALLEN WRENCH - Open the hatch to access the motor compartment. 2) OIL COLLECTION CONTAINER - At the base of the tank next to the pump suction hose there is a Ø 8 mm vertically disposed oil tube that functions as an oil level gauge. This line also serves to empty the oil tank. Detach the line from the upper restraint and insert it into the 30 litre oil collection drum, allowing the oil tank to empty completely. 3) SLOTTED SCREWDRIVER - 17-22 mm HEX WRENCH - Once the tank is empty, use the screwdriver to loosen the steel clamp securing the suction hose (Ref. I Fig. 46) and detach the hose from the pump. Using the 22 mm hex wrench unscrew the pump pressure line union (Ref. H Fig. 46). Using the 17 mm hex wrench unscrew the motor cable terminal nuts and detach the cables from the terminals.

Fig. 45

4) 17 mm HEX WRENCH - EYEBOLT - SLING - OVERHEAD CRANE Screw the eyebolt into the pump rotor shaft (Fig. 45) and attach one end of the sling to the eyebolt and the other to the crane hook. Take the strain with the crane and then use the wrench to unscrew and remove the pump support fixing nuts (Ref. G Fig. 46); now lift the pump and transfer it to a workbench.

H

I G

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SERVICE

Section: MECHANICS

5) 17-19 mm HEX WRENCH - Use the 17 mm wrench to unscrew and remove the two screws responsible for fixing the pump casing to the motor (Ref. M Fig. 47), detach the pump casing. Use the 19 mm wrench to unscrew and remove the four screws responsible for fixing the support to the motor (Ref. L Fig. 47) and remove the support. Now fit a completely new unit or strip down the original motor.

4.01 REPLACING THE PUMP CONNECTION FLANGE OIL SEAL

L

M

Fig. 47

Remove the pump motor (see heading 4.00 Page 16).

MECHANICS

1) 17 mm HEX WRENCH - MEDIUM CROSSHEAD SCREWDRIVER - Use the wrench to unscrew the screws that fix the pump to the flange (Ref. M Fig. 47) and remove the pump body. Use the screwdriver to remove the flange oil seal (Ref. N Fig. 48) and fit a replacement seal. To reassemble, perform the disassembly steps in reverse order. N

Fig. 48

NOTES:

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MECHANICS


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SERVICE

Section: MECHANICS

4.02 PUMP MOTOR COMPONENTS MODEL ALL MODELS

10

7 2

9

3

14

4

8 11 12 13

5

MECHANICS

1 Fig. 49

6

PUMP MOTOR COMPONENTS TABLE

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Component description Rotor Stator Casing Lower pump body flange Upper flange Flange connecting tie rod Terminal block Encoder bearing Encoder connector Motor thermal cutout connector Lower flange oil seal Lower flange bearing Lower flange bearing circlip Wiring between terminal block and stator Table 3


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Section: MECHANICS

4.03 REPLACING THE ENCODER BEARING MODEL ALL MODELS Once the complete pump motor has been removed strip it down in order to access the various parts. NOTE: The encoder bearing can be removed also without first removing the motor from the truck.

MECHANICS


13-17 mm HEX WRENCH

Fig. 50

BEARING PULLER TOOL

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. 1) 17 mm HEX WRENCH - 5 mm ALLEN WRENCH - Place the motor in a vice and carefully clamp the casing. Use the hex wrench to unscrew and remove the power cable terminal nuts (Ref. S Fig. 51). Use the Allen wrench to unscrew and remove the screws fixing the terminal block to the motor (Ref. Q Fig. 51) and remove the terminal block.

S Q

R

Fig. 51

2) 13 mm HEX WRENCH - Unscrew and remove the flange connection tie bar nuts (Ref. R Fig. 51). Remove the flange to gain access to the encoder bearing (Fig. 52-53). 3) PULLER - Fit the puller to the bearing and withdraw the encoder/ bearing from the rotor (Fig. 54-55) and proceed to fit a replacement. To reassemble, perform the disassembly steps in reverse order. Fig. 52

Fig. 55

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Fig. 53

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MECHANICS

5 mm ALLEN WRENCH

SERVICE

Section: MECHANICS

5.00 STEERING GEARED MOTOR REMOVAL PROCEDURE MODEL ALL MODELS STANDARD TOOLS REQUIRED

5 mm ALLEN WRENCH

10-13 mm HEX WRENCH

PROCEDURE

MECHANICS

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) 5 mm ALLEN WRENCH - Open the motor compartment hatch. Use the same wrench to unscrew and remove the pinion fixing screw (Ref. O Fig. 57) and extract the pinion. 2) 10-13 mm HEX WRENCH - Use the 10 mm wrench to unscrew and remove the motor power cable terminal nuts. Use the 13 mm wrench to unscrew the four screws that secure the geared motor to the gear unit flange (Ref. P Fig. 57), extract the geared motor and either fit a replacement part or strip down the original part on a workbench. To reassemble, perform the disassembly steps in reverse order.

P

Fig. 56

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SERVICE 5.01

Section: MECHANICS

STEERING MOTOR COMPONENTS MODEL ALL MODELS

11

10

9

MECHANICS

3

4

5 6

8

1

2

MECHANICS

7

Fig. 58

TABLE FO STEERING MOTOR COMPONENTS

Ref. 1 2 3 4 5 6 7 8 9 10 11

Component description Rotor Stator Casing Lower flange Upper flange Lower flange oil seal Lower flange bearing Upper flange encoder bearing Terminal block Encoder connector Motor thermal cutout connector Table 4


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Section: MECHANICS

5.02 REPLACING THE ENCODER BEARING MODEL ALL MODELS Once the motor has been removed from the truck it can be stripped down to access the various parts. STANDARD TOOLS REQUIRED Fig. 59

4-5 mm ALLEN WRENCH

BEARING PULLER

MECHANICS

PROCEDURE

T

Fig. 60

Before starting work, make sure you are wearing suitable safety clothing. 1) 5 mm ALLEN WRENCH - Place the motor in a vice and carefully clamp the jaws. Using the wrench unscrew and remove the screws that fix the gear unit to the motor (Ref. T Fig. 60). Remove the gear unit paying attention to the shims and gears, which should not be moved from their locations. 2) 4 mm ALLEN WRENCH - PULLER - Unscrew and remove the upper and lower motor flange fixing screws (Ref. U-V Fig. 62-63). Remove the upper flange. Fit the puller to the lower flange for connection to the gear unit (Fig. 64), detach the flange from the motor bearing and extract the rotor from the stator (Fig. 65). Remove the motor casing from the vice and insert the rotor in its place, ensuring you first fit aluminium cheeks to the vice jaws to prevent marring. Clamp the vice carefully (Fig. 66). Fit the puller to the bearing/encoder and remove it from the rotor shaft. Now fit a new bearing. To reassemble, perform the disassembly steps in reverse order.

Z

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Fig. 66

Part No.: 524159096

Fig. 61

V

Fig. 63

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Fig. 64

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SERVICE

Section: MECHANICS

6.00 STEERING UNIT MODEL ALL MODELS The steering unit is designed so that it can be adjusted to suit the preferences of the operator by means of a gas spring and series of linkages.

Activating lever no. 2 (Fig. 69) provides two adjustment functions: extending or shortening the reach of the steering unit and up/down rotation of the panel. Lever no. 2 operates an eccentric pin that serves to unlock rotary movement of the steering handwheel unit and display, while simultaneously loosening the conical plug in the tube so that steering handwheel reach can be adjusted and the handwheel rotated until the operator finds the most comfortable position.

MECHANICS

Activating lever no. 1 (Fig. 68), which is located on the instrument panel next to the hydraulic joysticks, causes a valve to be operated in the gas spring by means of a wire cable and sheath system, thus allowing the steering unit to be positioned at the most comfortable height for the operator.

MECHANICS

The following pages present the components that make up the steering unit, with details of the disassembly steps required for repair or replacement.

Fig. 68

LEVER

1

ROTATION

G IN EN G H T IN NG TEN LE R O SH

LEVER

2

REACH ADJUSTMENT TUBE

Fig. 67

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Part No.: 524159096

GAS SPRING

Fig. 69

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SERVICE

Section: MECHANICS

6.01 STEERING UNIT LINKAGE COMPONENTS MODEL ALL MODELS 5

36

33

1

34

35

40

32 38

STEERING UNIT ASSEMBLY DRAWING

30

26 25

31

24 28

MECHANICS

41

39

29

2

23

44

43

2 22

STEERING UNIT SECTIONAL VIEW

HANDWHEEL BEARING ENCODER SECTIONAL VIEW

14 20

37

42

27 2

13

3

3

19

13

14

7

6

4

17

21

15

16

4

12 7

STEERING LINKAGES ASSEMBLY DRAWING

11

9 18

5

8

10

10

2 STEERING LINKAGES SECTIONAL VIEW

RETURN GAS SPRING

Fig. 70

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Section: MECHANICS

6.02 TABLE OF STEERING LINKAGE COMPONENTS MODEL ALL MODELS The components of the steering unit illustrated on the previous page are described in the following table Key:

Ref. Component Description

MECHANICS

Component description Steering unit assembly Display assy. and steering handwheel assy. support bracket Steering assy. fixed support tube Steering assy. reach adjustment tube Steering assy. gas spring Steering assy. reach adjustment locking conical tube Conical tube sliding and locking threaded bar Steering assy. angle adjustment eccentric pin Eccentric pin adjuster plate Eccentric pin precision bushings Rotary pin for screw torquing of the threaded bar inserted in the eccentric pin Locking lever angle adjuster pins Locking lever acting on the eccentric pin Locking lever knob Locking lever locknut Eccentric pin adjuster plate thrust spring Locking lever system circlip Spring retainer washer Conical tube retainer washer Conical tube self-locking nut Sliding tube locking nut Steering encoder Encoder drive shaft bearing support Steering encoder drive shaft Steering encoder shaft guide bearing Steering encoder drive shaft guide bearing circlip Screws or fixing encoder to bracket and to bearing support Encoder fixing bolt nuts Teflon pin for stiffening steering action Steering action stiffening Teflon pin thrust spring Steering action stiffening system shims Steering handwheel Handwheel knob Screws for fixing steering handwheel to the encoder drive shaft Shim Steering handwheel central bore cover Steering and display assy. lower cover Steering and display assy. upper cover Display Control buttons Button locking nuts and washers Upper and lower covers fastening screws Fastening screws Display fixing screws

MECHANICS

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Component reference in exploded view Function of component


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Section: MECHANICS

6.03 REPLACING THE STEERING UNIT GAS SPRING MODEL ALL MODELS The gas spring fills an important function in moving the steering unit to the position that the operator considers to be most comfortable. Therefore, when the spring no longer provides sufficient force, it must be renewed. STANDARD TOOLS REQUIRED

13 mm HEX WRENCH


REGULAR PLIERS

MEDIUM CROSSHEAD SCREWDRIVER

PROCEDURE

MECHANICS

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery.

B Fig. 72

C A

D D

Fig. 73 E

A

F F

Fig. 71

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Section: MECHANICS

1) MEDIUM CROSSHEAD SCREWDRIVER, REGULAR PLIERS - Using the screwdriver, unscrew and remove the fixing screws of the hood under the steering handwheel unit (Ref. A Fig. 71) and remove the hood. Use the pliers to remove the pin securing the steel cable of the lever that operates the gas spring valve (Ref. C fig. 73). 2) CIRCLIP PLIERS, 13 mm HEX WRENCH - Remove the circlips that couple the gas spring to the bracket (Ref. D Fig. 73) and extract the gas spring and place it on a workbench. Use the hex wrench to loosen the locking nut (Ref. E Fig. 74) and unscrew the lever (Ref. F Fig. 74-75); remove the lever and then screw it to the new gas spring. Now fit the new gas spring in place of the original part.

6.04 ADJUSTING STEERING HANDWHEEL TORQUE MODEL ALL MODELS If the handwheel turns too easily, the turning torque can be increased to suit the expectations of the operator. Beneath the handwheel there are two Teflon pins that exert frictional force on the handwheel; by increasing the pressure of the relative thrust spring by adding shims it is possible to increase the effort required to turn the handwheel. STANDARD TOOLS REQUIRED

5 mm ALLEN WRENCH

G

SMALL SLOTTED SCREWDRIVER

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Fig. 76

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) 5 mm ALLEN WRENCH, SLOTTED SCREWDRIVER - Use the screwdriver to remove the handwheel central cover cap (Ref. G Fig. 76). Using the Allen wrench, unscrew and remove the handwheel locking screw (Ref. H Fig. 77). Remove the handwheel from the shaft. Remove the Teflon pin (Ref. L Fig. 77), remove the spring (Ref. M Fig. 77) and add shimming washers until obtaining the required stiffness of handwheel rotation.

H L M N

I

L M


N

Fig. 77

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MECHANICS

MECHANICS


SERVICE

Section: MECHANICS

6.05 DISMANTLING THE HANDWHEEL - DISPLAY ASSEMBLY MODEL ALL MODELS The following pages illustrate the method for dismantling the entire linkage system. The same procedure is used for replacement of the complete display. STANDARD TOOLS REQUIRED UPPER COVER DISPLAY

13 mm HEX WRENCH

MEDIUM CROSSHEAD SCREWDRIVER

P

6 mm ALLEN WRENCH

MECHANICS

LOWER COVE R


REGULAR PLIERS

Fig. 78

O

PROCEDURE Q

Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery.

R

S

1) Remove the handwheel (see heading N° 5.04 page 27) T

2) CROSSHEAD SCREWDRIVER - Detach the steering tube protective bellows from the hood side and the display side (Ref. W Fig. 80). Using the screwdriver, unscrew and remove the fixing screws of the upper hood and lower truck body side hood (Fig. 71); remove the hoods to gain access to the spring and display electrical connectors. Using the same screwdriver, unscrew and remove the fixing screws of the display upper and lower covers (Ref. O Fig. 78) and remove the covers to expose the complete display. Unscrew and remove the display fixing screws (Ref. P Fig. 78); disconnect the electrical connector, and remove the display. Disconnect the power cable connector from the electrical system side under the hood.

Z

Fig. 79

W

Fig. 80

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Section: MECHANICS

3) 6 mm ALLEN WRENCH - Loosen the guide screw of the sliding tube (Ref. R Fig. 79), loosen the eccentric pin lever (Ref. Q Fig. 79) to unlock the linkage system, and then extract the assembly from the supporting tube (Ref. S Fig. 79) and place it on a workbench (Fig. 81).

5) REGULAR PLIERS - Unscrew the threaded bar from the pin (Ref. U Fig. 83), and extract the eccentric pin from its seat as shown in (Fig. 84). Fig. 81

MECHANICS

6) CIRCLIP PLIERS - Remove the circlip (Ref. V Fig. 85), extract the spring (Ref. J Fig. 85) and disassemble the eccentric pin as shown in (Fig. 85); carry out the necessary replacement or repair operations.

To reassemble, perform the disassembly steps in reverse order. Z Fig. 82 V

J U

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4) 13 mm HEX WRENCH - Unscrew and remove the locknut of the conical tube guide bar (Ref. Z Fig. 79-82), withdraw the short conical tube and the long conical tube as shown in (Fig. 82).

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SERVICE

Section: MECHANICS

MECHANICS

NOTES:

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Section: REACH CARRIAGE

REACH CARRIAGE REACH CARRIAGES UTILIZED ............................................... 2

a

REACH CARRIAGE REMOVAL PROCEDURE ........................ 5

REACH CARRIAGE

a

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1.00 REACH CARRIAGES UTILIZED MODEL ALL MODELS 1.01 REACH CARRIAGE COMPONENTS 12 4

“STANDARD” TRUCK 13

8

3

8

16

14

10

9

7 15

11 2 9

1

9

2

REACH CARRIAGE

5

6

Fig. 1

“NARROW” TRUCK 12

4 8

13 3 8

16 10

14

9

7 15

11 2 9

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“PLUS” WIDE TRUCK

12 4

13 8 3

8

16

10

14

9

7 15

11 2 1

2

9 5

6

Fig. 3

1.02 TABLE OF REACH CARRIAGE - TRUCK COMBINATIONS REACH CARRIAGE - TRUCK COMBINATIONS Reach Carriage Combination with Truck MR14 - MR14H MR16 - MR16H Standard MR20 - MR20H MR25 MR16N Narrow MR20W Plus

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REACH CARRIAGE

9

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1.03 TABLE OF REACH CARRIAGE COMPONENTS MODEL ALL MODELS The components shown are described in the following table Key:

REACH CARRIAGE

Ref. Component Description

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Component reference Function of component

LIST OF REACH CARRIAGE COMPONENTS Component description Reach carriage Sliding carriage guide blocks Upper Lh mast channel fixing support Upper Rh mast channel fixing support Carriage guide shoe Carriage guide shoe shim washer Carriage rollers Battery return buffers Carriage rollers grease nipples Carriage equipment cover plate Carriage guide fixing screws Upper mast supports fixing screws Spring washers for support screws Equipment cover plate fixing screws Rollers to carriage fixing screws Battery extraction attachment pin

NOTE: All Yale Part Numbers are given in the spare parts catalogue. NOTES:

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2.00 REACH CARRIAGE REMOVAL PROCEDURE MODEL ALL MODELS The reach carriage is equipped with four roller bearings and two “U” guides mounted to the left-hand side of the truck next to the cylinder. The bearings run on case hardened plates secured to the inside of the load wheel support straddles. The guides run in a case hardened plate secured to the left-hand straddle to avoid possible sideways play during forward and backward carriage movements. Movement must be uniform and frictionless. Therefore, when either the bearings or shoes must be replaced, it is essential to slide the reach carriage out of the truck. The procedure is described below. SPECIAL EQUIPMENT REQUIRED ®

Lifting sling with three hooks, max. capacity 1000 kg


HEX WRENCH 13-19-24 mm


OVERHEAD CRANE

D

C

C Fig. 8

Fig. 7

Fig. 9

B Fig. 6

A Fig. 5 Fig. 4

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REACH CARRIAGE

ALLEN WRENCH 3-5 mm

SERVICE

Section: REACH CARRIAGE PROCEDURE Before starting work, make sure you are wearing suitable safety clothing.

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) Remove the mast (see “masts section” heading 2.01 page 10) 2) 13 mm HEX WRENCH - 5 mm ALLEN WRENCH - With the Allen wrench unscrew and remove the two reach carriage travel limit stops (Ref. A Fig. 5); use the hex wrench to unscrew and remove the cylinder fixing screw (Ref. B Fig. 6), lift the cylinder and remove it from its pivot pin.

REACH CARRIAGE

3) HEX WRENCH 19-24 mm - Use the 19 mm wrench to loosen the guide shoe fixing screws (Ref. C Fig. 7-8). Using the 24 mm wrench unscrew the solenoid valve bank hydraulic line unions (Ref. D Fig. 9) and disconnect the Mhyrio board electrical connector. 4) SLING - OVERHEAD CRANE - Attach the sling to the reach carriage in such a way that it can be withdrawn horizontally (Fig.10). Attach the other end of the sling to the bridge crane and allow it to take the strain. Extract the reach carriage outwards and then renew the bearings and sliding shoes.

2.01 BEARING REPLACEMENT 5) 3 mm ALLEN WRENCH - Unscrew and remove the fixing screws of the bearing retainer cover (Ref. E Fig. 11). Remove the cover and renew the bearings.

Fig. 10

2.02 REPLACING THE CARRIAGE GUIDE SHOES 6) MEDIUM SLOTTED SCREWDRIVER - Using the screwdriver press the shoe pin through the assembly hole in the guide (Ref. F Fig.11). Remove the shoe and fit a replacement part. E


F Fig. 11

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REACH CARRIAGE

NOTES:

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REACH CARRIAGE

NOTES:

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Section: REDUCTION GEAR

REDUCTION GEAR a REDUCTION GEAR COMPONENTS ...................................... 2 a REDUCTION GEAR REMOVAL PROCEDURE ...................... 3 a REPLACING THE MOTOR SHAFT OIL SEAL ...................... 5

REDUCTION GEAR

a REPLACING THE DRIVE WHEEL AXLE SHAFT OIL SEAL ... 6

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1.00 REDUCTION GEAR COMPONENTS MODEL ALL MODELS

4

2

2

9

8 5

6

4

5 8

1

7 3

REDUCTION GEAR

Fig. 1

1.01 TABLE OF REDUCTION GEAR COMPONENTS Ref. 1 2 3 4 5 6 7 8 9 MDU 150 MDU 170

Component description Complete reduction gear Upper flange Drive wheel Drive motor shaft oil seal Drive wheel axle shaft oil seal Wheel stud Motor shaft Steering gear wheel Oil filler plug Oil Kg 2,00 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel Oil Kg 2,50 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel


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2.00 REDUCTION GEAR REMOVAL PROCEDURE MODEL ALL MODELS There are two different models of reduction gear utilized, identifiable by means of a code: - MDU 150 installed on models MR14 - MR14H - MR16 - MR16N - MDU 170 installed on models MR16H - MR20 - MR20H - MR20W - MR25 The technical specifications of the two units are similar and the units are interchangeable. The removal and installation procedure is therefore identical for both units. SPECIAL EQUIPMENT REQUIRED ® ® ®

500 mm lever with flat bladed end 2 Wooden blocks 150x150x200 Sling with two hooks


12 12 12 12 12

EYEBOLT

HEX WRENCH 10-13-17-24 mm

ALLEN WRENCH 5-6 mm

OVERHEAD CRANE

HYDRAULIC JACK


1) 5-6 mm ALLEN WRENCH - Use the 6 mm Allen wrench to open the motor compartment hood, and use the 5 mm Allen wrench to remove the floor panel. 2) HYDRAULIC JACK - Place the jack alongside the drive wheel and lift the truck until the blocks can be inserted under it. Place the blocks at the sides (Fig. 2) and lower the jack so that the truck is supported on the blocks. Remove the jack. 3) Remove the steering motor (see “mechanical section” heading 5.00, page 20). Fig. 2

4) Remove the drive motor (see “mechanical section” heading 3.00 page 12).

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REDUCTION GEAR

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery.

SERVICE

Section: REDUCTION GEAR 5) Remove the drive wheel (see “mechanical section” heading 1.01 page 3). 6) LIFTING SLING - EYEBOLTS - Screw the eyebolts into two opposite side drive motor fixing holes, (Fig. 4). Attach the lifting sling hooks to the two eyebolts (Fig. 4) and the other end of the sling to the overhead crane hook. Take the strain with the sling.

A

7) TWO 24 mm HEX WRENCHES - LEVER - Unscrew the nuts of the bolts responsible for fixing the reduction gear to the truck body (Ref. A Fig. 3) and withdraw the bolts. The reduction gear fixing holes are equipped with precision steel bushings that protrude 20 mm above the seat. When the reduction gear unit is installed the protruding part of the bushings is inserted in the holes in the truck body with the maximum precision. In order to extract the bushings in order to remove the reduction gear, insert the lever or screwdriver between the reduction gear unit and the truck body (Ref. B Fig. 4) and pry the reduction gear until the bushings are disengaged. Remove the reduction gear and replace it or strip it down in order to replace the necessary components.

Fig. 3

B

To reassemble, perform the disassembly steps in reverse order. Fig. 4

REDUCTION GEAR

NOTES:

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2.01 REPLACING THE MOTOR SHAFT OIL SEAL MODEL ALL MODELS The motor shaft oil seal is located in the reduction gear upper flange and cannot be removed without first removing the drive motor. STANDARD TOOLS REQUIRED

HEX WRENCH 13-17 mm

ALLEN WRENCH 5 mm


PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) Remove the drive motor (see heading “mechanical section” heading 3.00 page 12). 2) SLOTTED SCREWDRIVER - Use the screwdriver to prise the oil seal (Ref. C Fig. 5), remove the oil seal and fit a replacement.

REDUCTION GEAR


C

Fig. 6

Fig. 5

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2.02 REPLACING THE DRIVE WHEEL AXLE SHAFT OIL SEAL MODEL ALL MODELS The oil seal can be removed without having to remove the reduction gear from the truck. SPECIAL EQUIPMENT REQUIRED ® ® ® ®

Lever or tube Ø 30x300 Loctite sealing compound for gaskets 2 wooden blocks 150x150x200 Oil collection container


ALLEN WRENCH 5-10 mm

DRIFT Ø 30x200

SOCKET WRENCH 13-19 mm WITH RATCHET

HYDRAULIC JACK

MEDIUM-WEIGHT STEEL HAMMER


RUBBER MALLET

REDUCTION GEAR

C-SPANNER FOR Ø 60 RINGNUTS

HEX WRENCH 13 mm

SMALL CHISEL

F

Fig. 7

G E Fig. 10

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Fig. 8

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H

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack in the centre of the carriage alongside the drive wheel, and lift the truck until the wooden blocks can be inserted. Place the blocks alongside the jack and then lower the jack until the truck body is resting on the blocks. Now remove the jack. 2) ALLEN WRENCH 5-10 mm - Use the 5 mm wrench to open the motor compartment hood. With the 10 mm Allen wrench remove the guard in correspondence with the drive wheel.

Fig. 11

3) Remove the drive wheel (see “mechanical section” heading 1.01 page 2). 4) 10 mm ALLEN WRENCH - OIL COLLECTION CONTAINER - Position the container under the reduction gear drain plug (Ref. D Fig. 9), using the Allen wrench unscrew and remove the plug and allow the oil to drain out of the reduction gear.

Fig. 12

5) 13 mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the reduction gear cover fixing screws (Ref. E Fig. 9). Remove the cover to gain access to the gears.

7) C-SPANNER - LEVER OR TUBE - Fit two screws into the axle shaft flange and between them insert the tube or lever; use the C-spanner to unscrew the locking ring completely (Fig. 14). 8) RUBBER MALLET - DRIFT - Place the drift on the shaft (Ref. G Fig. 8) and using the hammer to drive out the shaft from the opposite side. Attention is required because inside the reduction gear there are a distance ring and several shims located beyond the bevel gear; these components must be recovered and then re-fitted when the unit is reassembled (Fig. 12).

Fig. 13

9) SLOTTED SCREWDRIVER - Use the screwdriver to prise between the oil seal and bearing (Ref. H Fig. 11). Extract the oil seal from its seat and fit a replacement part. To reassemble, perform the disassembly steps in reverse order. MDU 150 MDU 170

UPDATE

Fig. 14

Oil Kg 2,00 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel Oil Kg 2,50 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel

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REDUCTION GEAR

6) CHISEL - MEDIUM-WEIGHT STEEL HAMMER - Using the hammer and chisel raise the clenched lip of the locking ring in the axle shaft seat (Ref. F Fig. 7) so that the locking ring can be unscrewed.

SERVICE


REDUCTION GEAR

NOTES:

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Section: BRAKING SYSTEM

BRAKING SYSTEM ELECTROMAGNETIC BRAKE COMPONENTS ................................... 2

a

LOAD WHEEL BRAKING SYSTEM COMPONENTS ........................... 3

a

LOAD WHEEL BRAKE COMPONENTS .............................................. 4

a

BRAKING SYSTEM ............................................................................. 5

a

REMOVING AND ADJUSTING THE ELECTROMAGNETIC BRAKE ..... 6

a

ADJUSTING THE ELECTROMAGNETIC BRAKE AND PUTTING IT INTO SERVICE ................................................................................ 7

a

REMOVING THE BRAKE MASTER CYLINDER ................................... 8

a

REPLACING THE LOAD WHEEL BRAKES ......................................... 9

a

BLEEDING AIR THE BRAKES CIRCUIT ............................................ 11

BRAKING SYSTEM

a

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1.00 ELECTROMAGNETIC BRAKE COMPONENTS MODEL ALL MODELS

55

2 6

1

5

4

3

Fig. 1a

1.01 TABLE OF ELECTROMAGNETIC BRAKE COMPONENTS

BRAKING SYSTEM

Ref. 1 2 3 4 5 6

Component description Complete electromagnetic brake Electromagnet coil Brake disc Brake disc guide pinion Fixing screws Brake disc adjuster nut


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1.02 LOAD WHEEL BRAKING SYSTEM COMPONENTS MODEL MR16 OPTIONAL - MR20 - MR20H - MR20W - MR25

14

10

9

13 15

11

12 4 6 3

7 2

8

5 1 Fig. 1b

1.03 TABLE OF BRAKING SYSTEM COMPONENTS Component description Brake master cylinder Master cylinder plunger rod Brake cylinder pipelines distributor connection Master cylinder supply line union Brake pedal sensor Master cylinder fixing screws Brake fluid reservoir Rh brake line branch connection Rh wheel brake unit Lh wheel brake unit Line connecting master cylinder to Rh brake unit Line connecting master cylinder to Lh brake unit Line connecting brake fluid reservoir to master cylinder Brake unit pipeline union Brake pedal

BRAKING SYSTEM

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15


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1.04 LOAD WHEEL BRAKE COMPONENTS MODEL MR16 OPTIONAL - MR20 - MR20H - MR20W - MR25 8

3

14 4

5

1

2 7

9

10

13

6 19

11

11 9

12 G

17

15 16 18

Fig. 1c

1.05 TABLE OF LOAD WHEEL BRAKE COMPONENTS

BRAKING SYSTEM

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Component description Load wheel Brake unit complete Brake shoes Brake shoe support spring Brake shoe tension spring Brake/wheel pivot pin Brake unit pin assembly flange Brake cylinder Taper roller bearings Dust seal Bearing shield rings Serrated lock washer Locking ring Brake block holder plate Wheel pivot pin Pin restraining washer Wheel spindle fixing screw Screws securing brake unit to straddle arm Screws for securing spindle and brake unit


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1.06 BRAKING SYSTEM MODEL ALL MODELS The reach trucks are fitted with four braking systems: A) B) C) D)

Release braking. Service or reverse travel braking. Emergency braking. Parking braking.

A) RELEASE BRAKING Activates a deceleration ramp when the travel control is released. “Release braking” is activated by releasing the travel pedal when the truck is travelling in either direction. This action results in regenerative braking, the intensity of which is proportional to the current value entered using the programming console (“RELEASE BRAKING” parameter): level 9 corresponds to maximum intensity. Since release braking and service braking are separate functions, release braking intensity can be customized on the basis of the customer’s preferences.

B) SERVICE BRAKING Service braking involves application of a deceleration ramp when the travel direction signal is inverted. “Service braking”, which as also known as “reverse current braking”, consists of reversing the current delivered to the drive motor thereby changing the travel direction when the truck is moving. When the motor current is inverted the truck starts to decelerate at an intensity that is proportional to the current value entered with the programming console (“INVERSION BRAKING” parameter): level 9 corresponds to maximum intensity. Braking current must be regulated in such a way that the truck stops in a distance that is no less than its length.

C) EMERGENCY BRAKING

“Emergency braking” consists of a regenerative braking action that is activated when the brake pedal is pressed. This action is combined with regenerative braking associated with the release of the accelerator pedal, thereby causing the truck to stop in a shorter distance. Once the truck is stationary the electromagnetic brake is applied. Braking intensity is proportional to the current value entered with the programming console (“PEDAL BRAKING” parameter). Simply pressing the accelerator pedal will cause the electromagnetic brake to be released. All truck models are equipped with this type of brake function. Truck models MR16 OPTIONAL, MR20, MR20H, MR20W, MR25, which are heavier vehicles, are additionally equipped, on the load wheels, with brake units that are activated by means of a brake master cylinder connected to the brake pedal. The load wheel brakes are activated after regenerative braking has been applied, by increasing the pressure exerted on the brake pedal.

D) PARKING BRAKE The “parking brake function” is provided by the electromagnetic brake mounted on the drive motor. The electromagnetic brake is applied in two situations: A) If the operator releases the deadman button when the truck is stationary. In this case power is disconnected from the electromagnetic brake coil causing the brake to be applied. B) If a button marked with the brake symbol on the instrument panel is pressed when the truck is on a grade. In this case power is disconnected from the electromagnetic brake coil causing the brake to be applied and inhibiting drive; hydraulic functions, however, remain operational.

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BRAKING SYSTEM

Applies a deceleration ramp when the travel control is released and the brake pedal switch contacts are closed.

SERVICE


2.00 REMOVING AND ADJUSTING THE ELECTROMAGNETIC BRAKE MODEL ALL MODELS Having described the truck’s brake system, this section illustrates the procedures for removing the various units in the system so that they can be renewed or so that their subassemblies can be renewed. Due to rubbing friction during braking, the brake disk is subject to wear. Once the depth of wear exceeds 4 mm the disc must be renewed. The removal and adjustment procedure is described below. STANDARD TOOLS REQUIRED

6 mm ALLEN WRENCH

13 mm HEX WRENCH

FEELER GAUGE

CIRCLIP PLIERS

PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) 6 mm ALLEN WRENCH - 13 mm HEX WRENCH - Use the Allen wrench to open the motor compartment hood. Using the 13 mm hex wrench loosen the three locking nuts (Ref. A Fig. 2). Now use the Allen wrench to unscrew and remove the three electromagnetic brake fixing screws (Ref. B Fig. 2) and detach the brake from the motor. 2) CIRCLIP PLIERS - Withdraw the brake disk from the guide pinion; use the circlip pliers to remove the circlip from the motor shaft and extract the brake disk guide pinion.

BRAKING SYSTEM

NOTE: When you fit a new brake disk it is essential to renew also the pinion. To reassemble, perform the disassembly steps in reverse order. B

A

Fig. 2

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Part No.: 524159096

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SERVICE


2.01 ADJUSTING THE ELECTROMAGNETIC BRAKE AND PUTTING IT INTO SERVICE MODEL ALL MODELS - After refitting the brake assembly, before operating the truck you must adjust the brake disk. - To obtain good braking action, the distance between the brake disk and the electromagnet plate (Ref. S Fig. 3) should be no more than 0.4 mm. You will therefore need a feeler gauge of this size. - With the three nuts (Ref. R) loosened off, insert the feeler gauge next to one of the bolts and then tighten bolt (Ref. V) with the 6 mm Allen wrench. Adjust the plate so that the feeler gauge can be with drawn with slight friction. Repeat the same operation on all three bolts (Ref. V). Tighten nuts (Ref. R). - Adjusting braking distance: start the truck and travel at maximum speed. Remove your foot from the deadman button. The truck must brake in a distance that is no less than and no greater than its own length. To optimize the braking distance turn adjuster nut (Ref. G): turn clockwise to reduce braking distance and counter-clockwise to increase it.

G

V

R

S

P

Fig. 3

BRAKING SYSTEM

NOTES:

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Part No.: 524159096

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SERVICE


3.00 REMOVING THE BRAKE MASTER CYLINDER MODEL MR16 optional - MR20 - MR20H - MR20W - MR25 The brake unit master cylinder is a hydraulic system and it is subject to wear of the seals and internal parts. In the case of worn internal parts, a new master cylinder must be fitted in order to restore efficient braking action. STANDARD TOOLS REQUIRED

5-6 mm ALLEN WRENCH


PROCEDURE Before starting work, make sure you are wearing suitable safety clothing. Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. 1) 5-6 mm ALLEN WRENCH - Use the 6 mm Allen wrench to unscrew the motor compartment hood fixing screws to gain access to the brake system. With the 5 mm Allen wrench unscrew and remove the floor panel fixing screws (Ref. F Fig. 5); remove the floor panel. C

2) 17 mm HEX WRENCH - Unscrew the brake master cylinder supply line union (Ref. C Fig. 4); detach the brake cylinder pipeline and use self-locking pliers to clamp the line to prevent the brake fluid from draining out and emptying the reservoir.

BRAKING SYSTEM

3) 22 mm HEX WRENCH - Unscrew the union of the load wheel brake unit supply pipelines (Ref. D Fig. 4) and detach the union from the master cylinder.

D

E

Fig. 4

4) 13 mm HEX WRENCH - Unscrew the two screws responsible for fixing the master cylinder to the support (Ref. E Fig. 4), recovery the defective master cylinder and fit a replacement unit. To reassemble, perform the disassembly steps in reverse order. For information on how to bleed the brake circuit of air, refer to the procedure on page 11.

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Part No.: 524159096

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Fig. 5 3

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SERVICE


3.01 REPLACING THE LOAD WHEEL BRAKES MODEL MR16 OPTIONAL - MR20 -MR20H - MR20W - MR25 SPECIAL EQUIPMENT REQUIRED ®



5-8 mm ALLEN WRENCH


500 g HAMMER

REGULAR PLIERS

HYDRAULIC JACK

C-SPANNER FOR Ø 60 RINGNUTS

DRIFT Ø 25x200 mm

COMPASS SPANNER WITH Ø 5 PINS

PROCEDURE

Before starting work, make sure you are wearing suitable safety clothing Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach carriage to its forward position, lower the forks to the ground, set the keyswitch to “OFF” and disconnect the battery. Fig. 6

BRAKING SYSTEM

1) Remove the load wheel (see “mechanical section” heading 1.02 page 4). 2) C-SPANNER - Unscrew the ring that fastens the brake unit boss to the wheel (Ref. G Fig. 7) and withdraw the kit from the wheel hub as shown (Fig. 6). Now strip down the brake unit in order to renew individual parts or renew the entire unit.

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G

Fig. 7

Part No.: 524159096

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SERVICE

Section: BRAKING SYSTEM 3) 5 mm ALLEN WRENCH - To renew the complete brake unit you must first remove the bearings (Ref. H Fig. 8) and then use the wrench to unscrew the screws responsible for fastening the spindle to the brake unit (Ref. M Fig. 9). Extract the spindle and renew the brake unit.

L

H

To reassemble, perform the disassembly steps in reverse order. Using the same procedure described in point 3 it is also possible to replace exclusively the spindle.

Fig. 8

4) 10 mm HEX WRENCH - To renew the brake cylinder (Ref. L Fig. 8) unscrew the screws that secure the cylinder to the shoe carrier plate (Ref. M Fig. 9), remove the cylinder and fit a replacement.

M

To reassemble, perform the disassembly steps in reverse order. 5) REGULAR PLIERS - To replace the brake shoes, remove the retaining springs using the pliers, remove the shoes, and then fit replacement parts. To reassemble, perform the disassembly steps in reverse order. Fig. 9

I

BRAKING SYSTEM

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SERVICE


3.02 BLEEDING AIR FROM THE BRAKE CIRCUIT MODEL MR16 Optional - MR20 - MR20H - MR20W - MR25 After changing the brake units, the brake cylinder, the load wheel or the master cylinder it is essential to bleed air from the brake fluid circuit. To bleed the brakes efficiently it is advisable to prepare two stands of approximately 300 ÷ 400 mm in height, each equipped with a container for collecting drained oil. Fit one end of a Ø 6 mm tube to the brake unit bleed union and insert the other end in the collection container (Ref. N Fig. 10). SPECIAL EQUIPMENT REQUIRED ® ® ® ®

2 stands (Fig.12) Oil collection container Rubber tube, inside Ø 6 - length 200 mm 2 litres of brake fluid

SPECIAL TOOLS REQUIRED

N

7-8 mm HEX WRENCH

P

Fig. 10

O

1) Remove the dust cap from the bleed screw located behind the brake unit (Fig. 10). 2) 7-8 mm HEX WRENCH - STAND - CONTAINER - Place the stand complete with container and tube next to the wheel and fit the tube to the bleed union. Using the wrench loosen the bleed union by rotating it through 3/4 of a turn (Ref. N Fig. 10); repeat the same procedure on the opposite side wheel and then pour brake fluid into the two containers until the bleed screw connecting tube is completely submerged.

Fig. 11

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BRAKING SYSTEM

3) Fill the master cylinder reservoir with brake fluid (Ref. O Fig. 11) to start the flow of brake fluid to the collection containers. Slowly depress the brake pedal and release it ten times in succession (Ref. P Fig.11) after which do not press the pedal for approximately five minutes, allowing the brake fluid to flow into the container under the pressure accumulated in the circuit. The brake fluid reservoir is higher than the collection containers positioned next to the load wheels, therefore the fluid in the master cylinder will be transferred into the containers via the master cylinder, forcing all the air out of the circuit in the process. Ensure that the reservoir is kept permanently full of oil. Repeat the sequence of brake pedal cycles at five minute intervalsuntil all the air has been expelled from the circuit. Now use the wrench to tighten the bleed union screws.

Fig. 12

Part No.: 524159096

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SERVICE


4) Fit the cap to the brake fluid reservoir and remove the collection containers; depress the brake pedal 4 or 5 times to pressurize the circuit, until you meet solid resistance when attempting to depress the pedal, indicating that the master cylinder has no internal leakage. Now re-close the various panels and hoods on the truck. Test the brake circuit with the truck in motion. If you detect a spongy feel when pressing the brake pedal, this indicates that there is still air in the circuit so the air bleeding operation described above must be repeated.

BRAKING SYSTEM

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Part No.: 524159096

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BRAKING SYSTEM

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SERVICE


BRAKING SYSTEM

Part N° 524159096

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524159096.pdf

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