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(2) 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.. Page: 2. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(3) SERVICE. 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. NOTES:. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 3. CONTENTS. Section: CONTENTS.
(4) 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. Page: 4. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(5) SERVICE. 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 5. CONTENTS. Section:. Section: CONTENTS.
(6) SERVICE. CONTENTS. Section: CONTENTS. 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. Page: 6. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(7) SERVICE. 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 7. CONTENTS. 5.00 5.01 5.02 6.00 6.01 6.02 6.03 6.04 6.05. Section: CONTENTS.
(8) SERVICE. Section: ELECTRICAL SYSTEM. ELECTRICAL SYSTEM. NOTES:. Page: 8. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(9) SERVICE. ELECTRICAL SYSTEM. Section: ELECTRICAL SYSTEM. INTRODUCTION INSTALLING THE TRUCK D INTRODUCTION TO THE TRUCK ......................................................... 8 D INSTALLING THE TRUCK .................................................................... 9. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 9.
(10) SERVICE. Section: ELECTRICAL SYSTEM. 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.. I. TRUCK RESIDUAL CAPACITY RATING PLATE Fig.. 3. MAST SERIAL NUMBER PUNCH MARKING. Fig. 4. TRUCK SERIAL NUMBER DATAPLATE. Page: 10. Fig. 2. Part No.: 524159096. Fig. 1. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(11) SERVICE. 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 11. ELECTRICAL SYSTEM. Section: ELECTRICAL SYSTEM.
(12) SERVICE. Section: ELECTRICAL SYSTEM. ELECTRICAL SYSTEM. NOTES:. Page: 12. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(13) SERVICE. ELECTRICAL SYSTEM. Section: 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 13.
(14) SERVICE. ELECTRICAL SYSTEM. Section: ELECTRICAL SYSTEM. 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. Page: 14. 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. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(15) SERVICE. Sezione: ELECTRICAL SYSTEM. FUNCTIONAL ELECTRICAL DIAGRAM 1/7 MOTORS AND CONTROLLERS CONNECTION CONTROL CIRCUITS POWER SUPPLY. AGGIORNAMENTO. 0. 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14a.
(16) SERVICE. Sezione: ELECTRICAL SYSTEM. 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. AGGIORNAMENTO. 0. 1. 1501469-2. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14b.
(17) SERVICE. Sezione: ELECTRICAL SYSTEM. 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. AGGIORNAMENTO. 0. 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14c.
(18) SERVICE. 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. AGGIORNAMENTO. 0 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14d.
(19) SERVICE. 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. 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. J3 POT. J4. 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 FOUR 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. AGGIORNAMENTO. 0 1. 2. R1. 3. 4. RESITOR FOR COLD STORE VERSION. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14e.
(20) SERVICE. 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. NOTE: THE JUMPER ACROSS PINS 8-20 OF THE CN A IS NOT PRESENT WHEN THE TRAVEL DIRECTION CONTROL ON THE PEDALS IS UTILIZED. AGGIORNAMENTO. 0 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag.. 14f.
(21) SERVICE. 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. 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. SW26. FORWARD BACKWARD WITH SWITCH AND TWO JOYSTICKS FOR IDRAULIC CONTROL. Function Tilt Up Tilt Down Side Shift rh. Side Shift sh. 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. AGGIORNAMENTO. 0 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14g.
(22) SERVICE. 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. 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. 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. AGGIORNAMENTO. Function Tilt Up Tilt Down Side Shift rh. Side Shift sh. 4. R1 RESITOR FOR COLD STORE VERSION. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14h.
(23) SERVICE. 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. AGGIORNAMENTO. 0 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag.. 14i.
(24) SERVICE. Sezione: ELECTRICAL SYSTEM. FUNCTIONAL ELECTRICAL DIAGRAM 5/7 SICOS MODULE CONNECTIONS. 1501469 - 10. AGGIORNAMENTO. 0. 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag.. 14l.
(25) SERVICE. Sezione: ELECTRICAL SYSTEM. FUNCTIONAL ELECTRICAL DIAGRAM 6/7 CAN BUS MODULES CONNECTION. 1501469 - 11. AGGIORNAMENTO. 0. 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14m.
(26) SERVICE. Sezione: ELECTRICAL SYSTEM. FUNCTIONAL ELECTRICAL DIAGRAM 7/7 CONNECTION DIAGRAM POWER CABLES. 1501486. AGGIORNAMENTO. 0. 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag.. 14n.
(27) SERVICE. Sezione: ELECTRICAL SYSTEM. INPUT / OUTPUT CONNECTORS MODULES AC2 T, AC2 P. Input / output connectors module AC2 POMPA. Input / output connectors module AC2 TRAZIONE. AGGIORNAMENTO. 0. 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14o.
(28) SERVICE. Sezione: ELECTRICAL SYSTEM. INPUT / OUTPUT CONNECTORS MODULES EPS AC, MHYRIO. Input / output connectors module EPS AC. Input / output connectors module MHYRIO. AGGIORNAMENTO. 0. 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14p.
(29) SERVICE. Sezione: ELECTRICAL SYSTEM. INPUT / OUTPUT CONNECTORS MODULES CAN I/O, SICOS (display). Input / output connectors module CAN I/O. Input / output connectors module SICOS. AGGIORNAMENTO. 0. 1. 2. 3. 4. 5 6 Data: Mar. 2002. Part No: 524159096. Pag. 14q.
(30) SERVICE. Section: ELECTRICAL SYSTEM. ELECTRICAL SYSTEM. NOTES:. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 15.
(31) SERVICE. ELECTRICAL SYSTEM. Section: 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. Page: 16. 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. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(32) SERVICE. Section: ELECTRICAL SYSTEM. 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page 16a.
(33) SERVICE. 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page 16b.
(34) SERVICE. Section: ELECTRICAL SYSTEM. 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page 16c.
(35) SERVICE. Section: ELECTRICAL SYSTEM. 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). UPDATE. 0. 1. 2. 39 39. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page 16d.
(36) SERVICE. Section: ELECTRICAL SYSTEM. ELECTRICAL SYSTEM. NOTES:. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 17.
(37) SERVICE. ELECTRICAL SYSTEM. Section: 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:. Page: 18. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(38) SERVICE. 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. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. 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. 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. DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION MAX SPEED. 9/F. ON. l. l. 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. l. l l. l. l l. l. l l. l. 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 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. l. l l. l. l l. l. ON. l l. l. ON. l. ON ON. l. 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 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. l. WITH CARRIAGE ALL OUT FORWARD/BACKWARD WITH SWITCH. 9/F. AGGIORNAMENTO. 0 1. 2. 3. 4. 5 6 Data: Marzo 2002 Part No: 524159096. Pag. 18a.
(39) SERVICE. Sezione: IMPIANTO ELETTRICO INPUT TABLE OF THE FUNCTIONS (Sheet 2/3) Inputs. TRACTION REDUCTION SPEED. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. BACKWARD SPEED. AC2-TR. ELECTROMAGNETIC BRAKE. AC2-TR. FORWARD SPEED. AC2-TR. l. J1/J1. J1/J2. J3. J4. SW21. PEDAL MODE. ENABLE. BACKWARD. FORWARD. SW1. AUTOMATIC WEIGHT BUTTON. 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. SEAT SWITC (OPTIONAL). 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. 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 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. 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. WITH BATTERY OUT DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW TRACTION REDUCTION SPEED. 9/F. ON. l. l. 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. l. l. l. DUAL FUNCTION PEDAL WITH DIRECTIONAL CONTROL FW/ BACKW OR SWITCH PARKING BRAKE ACTIVITY. ELECTROMAGNETIC BRAKE. 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. ELECTROMAGNETIC BRAKE. 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. 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. 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. 0 1. 2. 3. 4. 5 6 Data: Marzo 2002 Part No: 524159096. l. Pag. 18b.
(40) 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. 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. AUTOMATIC WEIGHT BUTTON. l. 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. REDUCTION SPEED LIFT. 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. SEAT SWITC (OPTIONAL). 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. REDUCTION SPEED AND RESET ENCODER. 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. 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. 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. l. l. l. l. l. l. l. 1/G-8/G. ON. l. l. l. l. l. l. l. l. 8/G. OFF. 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. OFF. 6/G. OFF. l. l. l. l. l. 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. l. 0 1. 2. l. 3. 4. l. l. l OR. OR. OR. OR. l. l. l. l. 5 6 Data: Marzo 2002 Part No: 524159096. Pag. 18c.
(41) SERVICE. Section: ELECTRICAL SYSTEM. ELECTRICAL SYSTEM. NOTES:. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 19.
(42) 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. Section: 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.
(43) SERVICE. Section: ELECTRICAL SYSTEM. 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.
(44) 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. Section: 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.
(45) 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.
(46) SERVICE. ELECTRIC. Section: ELECTRIC SYSTEM. Page: 22b Comp. No.:524159096 Date: March 2004 0. 1. 2. 3 4. 5 6. UPDATE.
(47) SERVICE. Section: ELECTRICAL SYSTEM. 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.
(48) SERVICE. Section: ELECTRIC SYSTEM. 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.
(49) SERVICE. ELECTRIC. Section: ELECTRIC SYSTEM. UPDATE. 0 1. 2 3. 4. 5 6 Date: March 2004 Comp. No.:524159096 Page: 23b.
(50) SERVICE. ELECTRICAL SYSTEM. Section: 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. Page: 24. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. Fig. 9 5. 6. UPDATE.
(51) SERVICE. Section: ELECTRICAL SYSTEM. ELECTRICAL SYSTEM. 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Part No.: 524159096. Page: 25.
(52) SERVICE. ELECTRICAL SYSTEM. Section: ELECTRICAL SYSTEM. 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. Page: 26. Part No.: 524159096. Date: Mar. 2002. 0. 1. 2. 3. 4. 5. 6. UPDATE.
(53) SERVICE. 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. UPDATE. 0. 1. 2. 3. 4. 5. 6. Date: Mar. 2002. Fig. 16. Part No.: 524159096. Page: 27. ELECTRICAL SYSTEM. Section: ELECTRICAL SYSTEM.
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