NEW MR ALL.pdf

0 (01/2014)Revision:Part no.:

Technical information for Yale service centres

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

550066261

D849.....

MR14 MR16N MR16 MR16HD MR20 MR20HDMR25

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INTRODUCTION

IMPORTANT

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

We therefore recommend that you read this manual carefully and keep it in a good condition so it is always decipherable and complete.This manual does not replace the use and maintenance manual, it is a supplement to it.

Product support group

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SECTIONS

This handbook is composed of the following sections:

Section 1: Presentation Section 2: Installation and settingsSection 3: Diagnostics and measurementsSection 4: Electrical systemSection 5: Hydraulic systemSection 6: Truck base mechanicsSection 7: Mast assembly mechanicsSection 8: Small fork mast mechanicsSection 9: Reduction gearSection 10: Braking systemSection 11: Standard maintenance

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

SYMBOLS

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

Signals danger due to high temperatures.

Signals important notes or information to take into particular consideration.

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

INSTALLATION PROCEDURES

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

GUIDE TO USING THE MANUAL

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GENERAL SAFETY RULES

PERSONAL SAFETYAlways wear the personal protective equipment in situations requiring it.

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

Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbut- toned jackets or tops with open zippers that can get caught up in moving parts.Never do any cleaning, lubrication or maintenance work with the battery connected.

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

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

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

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

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

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

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

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

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

When towing use solely the prescribed coupling points and check that the pins and/or bolts are firmly secured before pulling. Lift and handle all the heavy parts with lifting equipment of adequate capacity. Use the lifting eyebolts intended for this purpose. Make sure no one is near the load to be lifted.

Avoid twisting chains or metal ropes.

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

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

Used oil must be specially collected. It must not be disposed of into normal drainage system pipes. Special companies can be employed to dispose of or recycle industrial oils according to the laws in force in individual countries.

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

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

Do not short-circuit the terminals.

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

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

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

Always disconnect the battery before working on the electrical system.

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

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

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

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICEKeep a record of all the suspension elements used, stating the characteristics of the suspension elements and the data given on the identification plate .

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

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

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

Always rest the load in the race of the hook.

Never load the tip of the hook.

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

Never do any lifting with the ropes and belts twisted.

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

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

Using suspension elements under conditions of unbalanced loadIf lifting unbalanced loads it is advised as a precaution to downrate the load capacities of the lifting ele-ments:

Slings with 2 booms, consider them as corresponding to 1 boom. Slings with 3 and 4 booms, consider them as corresponding to 2 booms.

Tips for maintenancePeriodically examine the belts, ropes and suspension elements according to current legislation to define their state of service.Change them in the following cases:

When the components show: deformation, cracks, hollows, cuts or abrasions. When the wear of the components exceeds 10% of the original dimensions. When the sling shows signs of overloading.

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Belt capacity table

Rope capacity table

Colour Track (mm)

Working load capacity (kg)

black 35 500 1000 700 400purple 50 1000 2000 1400 800black 50 1500 3000 2100 1200green 60 2000 4000 2800 1600yellow 75 3000 6000 4200 2400grey 120 4000 8000 5600 3200red 150 5000 10000 7000 4000

brown 180 6000 12000 8400 4800blue 240 8000 16000 11200 6400

orange 300 10000 20000 14000 8000Coefficient 1 2 1.4 0.8

Colour


purple 1000 2000 1400 800green 2000 4000 2800 1600yellow 3000 6000 4200 2400grey 4000 8000 5600 3200red 5000 10000 7000 4000

brown 6000 12000 8400 4800blue 8000 16000 11200 6400

orange 10000 20000 14000 8000orange 12000 24000 16800 9600orange 15000 30000 21000 12000orange 20000 40000 28000 16000orange 25000 50000 35000 20000orange 30000 60000 42000 24000

Coefficient 1 2 1.4 0.8

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Suspension element capacity table

Colour


purple 1000 1400 2100 2100green 2000 2800 4200 4200yellow 3000 3800 6300 6300grey 4000 5600 8400 8400red 5000 6600 9800 10500

Coefficient 1 1.4 2.1 2.1

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

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TORQUE SETTINGS FOR SCREWS, NUTS AND FITTINGS

Before disassembling the various parts and nuts and bolts, read the following carefully.

To make the threaded matings secure, LOCTITE 270 is used for tightening the screws.If it is not possible to unscrew the bolts because this product has been used, avoid applying extensions to the tools, instead slightly heat the area (at most 50C) so as to eliminate the LOCTITE 270 effect.In the cases described, reapply LOCTITE 270 during installation in a moderate quantity (30% of the mating surface).The torque setting used for tightening the threaded couplings is extremely important to make the coupling secure and the machine safe.

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

Nominal diameter

TORQUE SETTING Nm

Class 8 Class 10M3 4 5.2

M4 7 9.15

M5 12.14 14.8

M6 17.2 20.9

M8 31.8 38.1

M10 50.5 60.3

M12 74.2 88.5

M14 101.2 120.8

M16 138.2 164.9

M18 176.6 203.5

M20 225.4 259.7

M22 278.8 321.2

M24 324.8 374.2

M27 422.3 486.5

M30 516.1 594.7

Pre-load N

TORQUE SETTING Nm

Class 5.8 Class 8.8 Class 10.9

M4 0.7 7 3 2400 1.92 1.44 3.07 2.3 4.17 3.13

M5 0.8 8 4 3880 3.88 2.91 6.2 4.65 8.43 6.33

M6 1 10 5 5490 6.58 4.94 10.5 7.9 14.3 10.8

M8 1.25 13 6 9990 16 12 25.6 19.2 34.8 26.1

M8 1 13 6 10700 17.1 12.8 27.4 20.5 37.3 27.9

M10 1.5 16 8 15825 31.7 23.8 51 38 69 52

M10 1.25 16 8 16700 33.4 25.1 53 40.1 73 55

M12 1.75 18 10 23025 55 41.4 88 66 120 90

M12 1.25 18 10 25150 60 45.3 96 72 130 98

M14 2 21 12 31400 88 66 140 105 190 145

M14 1.5 21 12 34125 96 72 155 115 210 155

M16 2 24 14 42850 135 105 220 165 300 225

M16 1.5 24 14 45600 145 110 235 175 320 240

M20 2.5 30 17 66875 270 200 430 320 580 435

M20 1.5 30 17 74250 295 225 475 355 650 485

= with lubricant

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

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

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

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

TORQUE SETTINGS

REVOLVING FEMALE jic 37

UNF thread Size

Torque setting Nm

Nominal torque min / max

7/16-20 -4 15 9 - 21

1/2-20 -5 20 13 - 27

9/16-18 -6 30 18 - 42

3/4-16 -8 50 30 - 70

7/8-14 -10 69 44 - 94

1.1/16-12 -12 98 63 - 133

1.3/16-12 -14 118 73 - 163

1.5/16-12 -16 140 90 - 190

1.5/8-12 -20 210 135 - 285

1.7/8-12 -24 290 200 - 380

2.1/2-12 -32 450 300 - 600

REMOVING FEMALE BSP

UNF thread

Torque setting Nm

Nominal torque max

G1/4 20 15 - 25

G3/8 34 27 - 41

G1/2 60 42 - 76

G5/8 69 44 - 94

G3/4 115 95 - 135

G1 140 115 - 165

G1.1/4 210 140 - 280

G1.1/2 290 215 - 365

G2 400 300 - 500

METRIC REVOLVING FEMALE

UNF thread

Outside diameter

of the pipe

Torque setting Nm

Nominal torque min / max

M 12x1.5 6 20 15 -25

M 14x1.5 8 38 30 - 45

M 16x1.58

45 38 - 5210

M 18x1.510

51 43 - 8512

M 20x1.5 12 58 50 - 65

M 22x1.514

74 60 - 8815

M 24x1.5 16 74 60 - 88

M 26x1.5 18 105 85 - 125

M 30x220

135 115 - 15522

M 36x225

166 140 - 19228

M 42x2 30 240 210 - 270

M 45x2 35 290 255 - 325

M 52x238

330 280 - 38042

REVOLVING FEMALE ORFS

UNF thread Size

Torque setting Nm

Nominal torque max.

9/16-18 -4 14 16

11/16-16 -6 24 27

13/16-16 -8 43 47

1-14 -10 60 68

1.3/16-12 -12 90 95

1.3/16-12 -14 90 95

1.7/16-12 -16 125 135

1.11/16-12 -20 170 190

2-12 -24 200 225

2-1/2-20 -32 460 490

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

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

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

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

InstallationAvoid twisting the pipe, which could cause it to burst under pressure.There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assem-bled pipe decreases considerably when below the minimum radius of curvature.The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly greater length than the requirement in order to compensate for these changes.

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INTRODUCTION

SECTION CONTENTS

Installation and settings

Diagnostics and measurements

Electrical system

Truck base mechanics

Mast assembly mechanics

Small fork mast mechanics

Braking system

Reduction gear

Standard maintenance

Hydraulic system

Presentation

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INTRODUCTION

1

PRESENTATION

PresentationtrUCK Presentation 2

VIEWS OF THE TRUCK 3

trUCK anD LoaD iDentiFiCation Data 4

TRUCK IDENTIFICATION DATA PLATE 4

RESIDUAL LOAD PLATE 4

MAST SERIAL NUMBER PUNCHING AND LOCATION OF DOCUMENTATION 5

GeneraL sPeCiFiCations 6

BATTERIES TABLE 10

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PRESENTATION

trUCK PresentationThe new range of retractable trucks consists of 7 models with nominal load capacities from 1400 kg to 2500 kg

electrical systemAll the motors benefit from the use of three phase AC alternate current technology: traction motor, steering motor and pump motor The high battery efficiency is ensured by the regenerative inversion and release braking. The electronic controls VCM, ACE2 Traction, ACE2 Pump and EPS ACW communicate via a CAN-Bus system (Controller Area Network Bus). There are two separate CAN-Bus lines to improve the efficiency, reliability and independence of the modules.

Hydraulic systemThe 14 kW pump motor provides excellent performance thanks to the technology with proportional sole-noid valves for the carriage out/return, lifting/lowering, fork tilting and side shifting operations with smooth movements of the actuators.

MastThe masts comprise three stages: external, middle and internal.The rigidity and stability characteristics of the masts allow the forks to reach maximum heights of between 5 and 12 metres depending on the modelThe lifting cylinders are single-acting plungers.

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PRESENTATION

VieWs oF tHe trUCK

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PRESENTATION

trUCK anD LoaD iDentiFiCation DatatrUCK iDentiFiCation Data PLate

The truck identification data plate is located inside the driver's cab

Manufacturer's name Model Serial number Weight without battery Year of manufacture

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

resiDUaL LoaD PLate

The load plate is located on the roof assembly

The load plate bears the following data:

Model Liftable load values up to varying heights up to the maximum load with different distances from the

load centre of gravity of the forks.

always refer to the load plate to be sure to lift an admissible load to an appropriate height

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PRESENTATION

Mast seriaL nUMBer PUnCHinG anD LoCation oF DoCUMentation

The mast serial number is stamped on the mast itself

The truck documentation is stored in the docu-ment holder behind the backrest of the seat

xxxxxxxx

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PRESENTATION

GeneraL sPeCiFiCations

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PRESENTATION

GeneraL sPeCiFiCationsCH

araC

teri

stiC

s 12 manufacturers type designation13 motor unit: battery, diesel, LPG, petrol, electric electric (battery)14 driving: manual, on ground, standing, seated seated15 load capacity/rated load Q (t) 14 16 1616 load centre of gravity c (mm) 600 600 60018 load distance from load wheel axle - forks x (mm) 258 308 20219 wheelbase (WB) y (mm) 1400 1450 1450

Wei

GH

ts 21 weight with no load (including battery) kg 3495 3546 349823 load on axle with no load (front/rear) (5) kg 2055/1440 2103/1443 1955/154324 load on axle with forks out with load (front/rear) kg 885/4010 810/4336 757/434125 load on axle with forks retracted with load (front/rear) kg 1711/3184 1779/3367 1514/3584

WH

eeLs

&

tYr

es

31 tyres: full rubber, polyurethane, vulkollan (front/rear) vulkollan/vulkollan32 front wheel size (mm x mm) 343 x 140 343 x 140 343 x 14033 rear wheel size (mm x mm) 285 x 100 285 x 100 285 x 10035 wheel quantity (x = traction) (front/rear) 1x/2 1x/2 1x/237 rear track width b 11 (mm) 1155 1155 1025

DiM

ensi

on

s

41 mast tilt / forks forward/backward / () 2 / 4 2 / 4 2 / 442 height of closed mast h1 (mm) 2195 2195 219543 free lift h2 (mm) 1648 1648 164844 lifting height h3 (mm) 5000 5000 500045 height, mast extended (1) h4 (mm) 5563 5563 556347 height of protective roof assembly (cab) (2) h6 (mm) 2175 2175 217548 seat height h7 (mm) 1082 1082 1082

410 armrest height h8 (mm) 308 308 308419 total length l1 (mm) 2523 2523 2629420 length to face of forks l2 (mm) 1373 1373 1479421 overall width (3) b1/b2 (mm) 1265 1265 1125422 fork dimensions DIN ISO 2331 s/e/l (mm) 40/80/1150 40/120/1150 40/120/1150423 fork carriage ISO 2328, class/type A,B 2A 2A 2A424 fork carriage width b3 (mm) 700 700 700425 outer fork width (min/max) (8) b5 (mm) 220/640 260/680 260/680426 distance between the clamps of the load wheels b4 (mm) 900 900 795428 retractable travel I4 (mm) 441 491 385431 ground clearance under mast with load m1 (mm) 75 75 75432 ground clearance at wheelbase centre m2 (mm) 75 75 75

4341 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2825 2834 28984342 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2895 2896 2976435 turning radius Wa (mm) 1671 1718 1700437 length between the wheel arms I7 (mm) 1795 1845 1845442 wheelbase height (from ground to footboard) mm 550 550 550

443 wheelbase height (between the steps between the footboard and the ground) mm 371 371 371

Per

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51 traction speed with/without load (7) km/h 11/11(14/14) 11/11(14/14) 11/11(14/14) 511 traction speed with/without load reverse drive (7) km/h 11/11(14/14) 11/11(14/14) 11/11(14/14)

52 lift speed with/without load (7) m/s 0,37 / 0,63 (0,47 / 0,73)0,32 / 0,63

(0,42 / 0,73)0,32 / 0,63

(0,42 / 0,73)53 lowering speed with/without load m/s 055 055 05554 Retractable carriage speed m/s 0,15 / 0,15 0,15 / 0,15 0.15 / 0.1557 grade ability with/without load % 12 / 15 11 / 15 11 / 1558 maximum gradeability with/without load % 12 / 15 12 / 15 12 / 1559 acceleration time, laden/unladen s - / - - / - - / -510 service brake Electrical

Mo

tor

Un

its 61 traction motor, power S2 60 minutes kW 6,4 6,4 6,4

62 lifting motor, power S3 15% kW 14 14 1463 battery in compliance with DIN 43531/35/36 A,B,C, no C C B64 battery rated voltage/capacity at 5 hours V/Ah 48/700 (6) 48/700 (6) 48/700 (6)

65 battery weight (4) kg 1119 1119 111966 consumption per VDI cycle kWh/h - / - - / - - / -

otH

er

Dat

a

81 type of drive control AC101 working pressure for additional attachments bar 180 180 180102 volume of oil for additional attachments l/min 20 20 20107 noise level at the operating station dB(A)

8

PRESENTATION

GeneraL sPeCiFiCations

CHar

aCte

rist

iCs 12 manufacturers type designation

13 motor unit: battery, diesel, LPG, petrol, electric electric (battery)14 driving: manual, on ground, standing, seated seated15 load capacity/rated load Q (t) 20 2516 load centre of gravity c (mm) 600 60018 load distance from load wheel axle - forks x (mm) 358 43119 wheelbase (WB) y (mm) 1500 1650

Wei

GH

ts 21 weight with no load (including battery) kg 3801 423023 load on axle with no load (front/rear) (5) kg 2296/1504 2565/166524 load on axle with forks out with load (front/rear) kg 770/5030 876/585525 load on axle with forks retracted with load (front/rear) kg 1971/3829 2306/4424

WH

eeLs

&

tYr

es

31 tyres: full rubber, polyurethane, vulkollan (front/rear) vulkollan/vulkollan32 front wheel size (mm x mm) 343 x 140 343 x 14033 rear wheel size (mm x mm) 285 x 100 285 x 14035 wheel quantity (x = traction) (front/rear) 1x/2 1x/237 rear track width b 11 (mm) 1155 1195

DiM

ensi

on

s

41 mast tilt / forks forward/backward / () 2 / 4 2 / 442 height of closed mast h1 (mm) 2195 219543 free lift h2 (mm) 1582 158244 lifting height h3 (mm) 4650 465045 height, mast extended (1) h4 (mm) 5263 526347 height of protective roof assembly (cab) (2) h6 (mm) 2175 217548 seat height h7 (mm) 1082 1082

410 armrest height h8 (mm) 308 308419 total length l1 (mm) 2523 2600420 length to face of forks l2 (mm) 1373 1450421 overall width (3) b1/b2 (mm) 1265 1345422 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150 45/120/1150423 fork carriage ISO 2328, class/type A,B 2A 2A424 fork carriage width b3 (mm) 700 700425 outer fork width (min/max) (8) b5 (mm) 260/680 260/680426 distance between the clamps of the load wheels b4 (mm) 900 900428 retractable travel I4 (mm) 541 614431 ground clearance under mast with load m1 (mm) 65 65432 ground clearance at wheelbase centre m2 (mm) 65 65

4341 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2846 29384342 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2900 2978435 turning radius Wa (mm) 1767 1911437 length between the wheel arms I7 (mm) 1895 2045442 wheelbase height (from ground to footboard) mm 550 550

443 wheelbase height (between the steps between the footboard and the ground) mm 371 371

Per

For

Ma

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e

51 traction speed with/without load (7) km/h 14 / 14 14 / 14511 traction speed with/without load reverse drive (7) km/h 14 / 14 14 / 1452 lift speed with/without load (7) m/s 0.37 / 0.64 0.30 / 0.6453 lowering speed with/without load m/s 0.55 / 0.50 0.55 / 0.5054 Retractable carriage speed m/s 0,15 / 0,15 0.15 / 0.1557 grade ability with/without load % 10 / 15 8 / 1458 maximum gradeability with/without load % 12 / 15 12 / 1559 acceleration time, laden/unladen s - / - - / -

510 service brake Electrical

Mo

tor

Un

its 61 traction motor, power S2 60 minutes kW 6,4 6,4

62 lifting motor, power S3 15% kW 14 1463 battery in compliance with DIN 43531/35/36 A,B,C, no C C64 battery rated voltage/capacity at 5 hours V/Ah 48/700 (6) 48/840 (6)

65 battery weight (4) kg 1119 130666 consumption per VDI cycle kWh/h - / - - / -

otH

er

Dat

a

81 type of drive control AC101 working pressure for additional attachments bar 180 180102 volume of oil for additional attachments l/min 20 20107 noise level at the operating station dB(A)

9

PRESENTATION

GeneraL sPeCiFiCationsCH

araC

teri

stiC

s 12 manufacturers type designation13 motor unit: battery, diesel, LPG, petrol, electric electric (battery)14 driving: manual, on ground, standing, seated seated15 load capacity/rated load Q (t) 16 2016 load centre of gravity c (mm) 600 60018 load distance from load wheel axle - forks x (mm) 308 28119 wheelbase (WB) y (mm) 1450 1500

Wei

GH

ts 21 weight with no load (including battery) kg 4224 461723 load on axle with no load (front/rear) (5) kg 2428/1796 2577/204024 load on axle with forks out with load (front/rear) kg 979/4845 985/563225 load on axle with forks retracted with load (front/rear) kg 2104/3720 2149/4468

WH

eeLs

&

tYr

es

31 tyres: full rubber, polyurethane, vulkollan (front/rear) vulkollan/vulkollan32 front wheel size (mm x mm) 343 x 140 343 x 14033 rear wheel size (mm x mm) 285 x 100 285 x 14035 wheel quantity (x = traction) (front/rear) 1x/2 1x/237 rear track width b 11 (mm) 1155 1195

DiM

ensi

on

s

41 mast tilt / forks forward/backward / () 2 / 4 2 / 442 height of closed mast h1 (mm) 3227 322743 free lift h2 (mm) 2680 261444 lifting height h3 (mm) 7900 775045 height, mast extended (1) h4 (mm) 8463 836347 height of protective roof assembly (cab) (2) h6 (mm) 2175 217548 seat height h7 (mm) 1082 1082

410 armrest height h8 (mm) 308 308419 total length l1 (mm) 2523 2600420 length to face of forks l2 (mm) 1373 1450421 overall width (3) b1/b2 (mm) 1265 1345422 fork dimensions DIN ISO 2331 s/e/l (mm) 40/120/1150 45/120/1150423 fork carriage ISO 2328, class/type A,B 2A 2A424 fork carriage width b3 (mm) 700 700425 outer fork width (min/max) (8) b5 (mm) 260/680 260/680426 distance between the clamps of the load wheels b4 (mm) 900 900428 retractable travel I4 (mm) 491 464431 ground clearance under mast with load m1 (mm) 65 65432 ground clearance at wheelbase centre m2 (mm) 65 65

4341 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2834 29034342 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2896 2970435 turning radius Wa (mm) 1718 1767437 length between the wheel arms I7 (mm) 1845 1895442 wheelbase height (from ground to footboard) mm 550 550

443 wheelbase height (between the steps between the footboard and the ground) mm 371 371

Per

For

Ma

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e

51 traction speed with/without load (7) km/h 14 / 14 14 / 14511 traction speed with/without load reverse drive (7) km/h 14 / 14 14 / 1452 lift speed with/without load (7) m/s 0,42 / 0,73 0,37 / 0,6853 lowering speed with/without load m/s 055 05554 Retractable carriage speed m/s 0,15 / 0,15 0.15 / 0.1557 grade ability with/without load % 10 / 14 8 / 1358 maximum gradeability with/without load % 12 / 15 12 / 1559 acceleration time, laden/unladen s - / - - / -

510 service brake Electrical

Mo

tor

Un

its 61 traction motor, power S2 60 minutes kW 6,4 6,4

62 lifting motor, power S3 15% kW 14 1463 battery in compliance with DIN 43531/35/36 A,B,C, no C C64 battery rated voltage/capacity at 5 hours V/Ah 48/700 (6) 48/840 (6)

65 battery weight (4) kg 1119 130666 consumption per VDI cycle kWh/h - / - - / -

otH

er

Dat

a

81 type of drive control AC101 working pressure for additional attachments bar 180 180102 volume of oil for additional attachments l/min 20 20107 noise level at the operating station dB(A)

10

PRESENTATION

notes

(1) with load grille h4 + 508 mm (all models except for 2 ton and 2.5 ton), h4 + 443 mm (2 ton and 2.5 ton models only)(2) with flashing light h6 + 120 mm; with protective grille h6 + 20 mm; with protective screen h6 + 30 mm

(3) with load wheel side cover: 1289 mm (all models except for Narrow, 2.5 ton, HD 2.0 ton versions), 1153 mm (Narrow model only), 1373 mm (2.5 ton, HD 2.0 ton models only)

(4) This value can vary by 5%(5) Forks retracted(6) see batteries table(7) the values in parentheses are optional(8) the side shift travel is 75 mm on all models. It is reduced to 25 mm for the Narrow model

Batteries taBLe

12 manufacturers type designation18 load distance from load wheel axle - forks x (mm) 402 330 402 330 25819 wheelbase (WB) y (mm) 1400 1400 1400 1400 140021 weight with no load (including battery) kg 3112 3309 3112 3320 354123 load on axle with no load (front/rear) (5) kg 1977/1135 2025/1285 1977/1135 2032/1289 2084/145724 load on axle with forks out with load (front/rear) kg 682/3830 792/3917 682/3830 800/3921 914/4027

25 load on axle with forks retracted with load (front/rear) kg 1778/2735 1753/2956 1778/2735 1760/2960 1741/3201

419 total length l1 (mm) 2379 2451 2379 2451 2523420 length to face of forks l2 (mm) 1229 1301 1229 1301 1373428 retractable travel I4 (mm) 585 513 585 513 441

4341 working aisle for pallet length 1000 x 1200 cross-wise Ast (mm) 2718 2771 2718 2771 2826

4342 working aisle for pallet length 800 x 1200 length-wise Ast (mm) 2764 2829 2764 2829 2895

435 turning radius Wa (mm) 1671 1671 1671 1671 1671

63 battery in compliance with DIN 43531/35/36 A,B,C, no C C C "Super" C "Super" C "Super"

64 battery rated voltage/capacity at 5 hours V/Ah 48/420 48/560 48/465 48/620 48/77565 battery weight (4) kg 750 939 750 950 1165







63 battery in compliance with DIN 43531/35/36 A,B,C, no C C C "Super" C "Super" C "Super"


SERVICE

Mr14

Mr16

11

PRESENTATION







63 battery in compliance with DIN 43531/35/36 A,B,C, no B B B "Super" B "Super" B "Super"


12 manufacturers type designation18 load distance from load wheel axle - forks x (mm) 430 430 35819 wheelbase (WB) y (mm) 1500 1500 150021 weight with no load (including battery) kg 3615 3626 384723 load on axle with no load (front/rear) (5) kg 2261/1354 2268/1358 2326/152024 load on axle with forks out with load (front/rear) kg 671/4943 679/4947 801/504625 load on axle with forks retracted with load (front/rear) kg 2032/3583 2039/3586 2002/3845

419 total length l1 (mm) 2451 2451 2523420 length to face of forks l2 (mm) 1301 1301 1373428 retractable travel I4 (mm) 613 613 541

4341 working aisle for pallet length 1000 x 1200 crosswise Ast (mm) 2795 2795 28464342 working aisle for pallet length 800 x 1200 lengthwise Ast (mm) 2835 2835 2900435 turning radius Wa (mm) 1767 1767 176763 battery in compliance with DIN 43531/35/36 A,B,C, no C C "Super" C "Super"64 battery rated voltage/capacity at 5 hours V/Ah 48/560 48/620 48/77565 battery weight (4) kg 939 950 1165




SERVICE

Mr16n

Mr20

Mr25

12

PRESENTATION







notes

(4) This value can vary by 5%(5) Forks retracted

The weights from point 21 to 25 are calculated with the mast lowered and standard forks

all values are nominal and may be subject to tolerances the values may vary with alterna-tive configurations.

SERVICE

Mr16HD

Mr20HD

1

InstallatIon and settIngs

BeFoRe InstallatIon 2

WEIGHT TABLES 2

tRUCK asseMBlY 6

LIST OF MATERIALS RECEIVED FROM THE DEALER 6

UNLOADING OFF THE TRUCK AND FITTING THE MAST TO THE TRUCK BASE 8

TOPPING UP THE OIL RESERVOIR 10

INSTALLATION OF THE BATTERY 11

ASSEMBLY OF MOVING FORKS 14

CONTRASTING ROLLER ASSEMBLY 15

lIst oF the settIngs and adJUstMents to Be CaRRIed oUt 16

SETTING THE ACE2 TRACTION AND THE ACE2 PUMP MODULE BATTERY VOLTAGES 16

CHECK THE CONDITIONS OF USE OF THE TRUCK 18

CHECK THE MOVEMENT OF THE CONTRASTING AISLE ROLLERS 18

ENABLING AND PROGRAMMING OF THE LEVEL PRE-SELECTOR 19

ENABLING AND PROGRAMMING MIDDLE FORK LIFTING BLOCKS 19

ENABLING AND PROGRAMMING OF THE PASSWORD 19

INSTALLATION AND SETTINGSSERVICE

2

BeFoRe InstallatIonDepending on the size of the mast and the kind of transportation (container, truck, etc), the carriage may be shipped: complete in vertical position (option A) with the mast assembly separate from the truck base (option B) In the second instance one must check in advance that one is equipped with all the tools necessary to bring ittotheverticalpositionandfitthecolumn(hireforklifttruck,bridgecrane,belts,etc.).Thesemachinesare tested for all their functions and the mast assemblies are then dismantled, tying the fork carrier plate to the base of the column so that it does not run along the inner mast; caps are also put on all the hydraulic connectors to prevent oil leaking out during transport When the unit arrives, the column must have been fittedandtestingperformedforallthefunctions.

Before delivering to the client it is very important to check the suitability of the place where the carriage is to be installed

WeIght taBles

COMPLETE FORKLIFT TRUCK

Model

height of mast assembly when

closed (h1)

height of mast assembly when

open (h3)

Weight of truck base

Weight of retractable

carriage

total weight (excluding

battery)

mm mm kg kg kg

(1) 2195 5000 1125 222 2435

(2) 2195 5000 1136 222 2485

(3) 2195 5000 1095 210 2432

(4) 2195 4650 1324 242 2740

(5) 2195 4650 1547 242 2978

(6) 3227 8050 1327 245 3134

(7) 3227 7900 1487 245 3335

(1) battery 420DinC, forks 80x40x1150(2) battery 420DinC, forks 120x40x1150(3) battery 420DinB, forks 120x40x1150(4) battery 560DinC, forks 120x40x1150(5) battery 700DinC, forks 120x45x1150(6) battery 560DinC, forks 120x40x1150(7) battery 700DinC, forks 120x45x1150

INSTALLATION AND SETTINGS SERVICE

MR14

MR16H

MR16N

MR20

MR25

MR16HD

MR20HD

3

BATTERIES

typeWeight (kg)

min max

48/420DIN C 735 810DIN B 736 811

48/560DIN C 922 1016DIN B 925 1018

48/700DIN C 1099 1211DIN B 1104 1216

48/840 DIN C 1282 1413

FORK CARRIAGE

ModelsWeight

(kg)

1156

1216

FORKS

dimensions Weight

mm kg80x40x1150 823

80x40x1200 848

120x35x800 843

120x35x1000 974

120x35x1150 1073

120x35x1200 1105

120x40x800 954

120x40x1000 1103

120x40x1150 1216

120x40x1200 1253

120x40x1500 1478

120x40x1800 1702

120x45x800 1064

120x45x1000 1233

120x45x1150 1359

120x45x1200 1401

120x45x1500 1654

120x45x1800 1907


MR14 MR16H MR16N MR20 MR16HD

MR25 MR20HD

4

MAST ASSEMBLIES

Modeltotal auxiliary lift

(mm) Free lift

(mm)

height, mast lowered

(mm)

extended dimensions

(mm)Weight

(kg)h 3 h 2 h 1 h 4

5000 1648 2195 5563 9115250 1734 2281 5813 9365500 1820 2367 6063 9615750 1906 2453 6313 9866000 1992 2539 6563 10106250 2078 2625 6813 10356500 2164 2711 7063 10606750 2250 2797 7313 10907000 2336 2883 7563 11157250 2422 2969 7813 11407500 2508 3055 8063 11647750 2594 3141 8313 12208000 2680 3227 8563 12448250 2766 3313 8813 12698500 2852 3399 9063 12998750 2938 3485 9313 13249000 3024 3571 9563 13499250 3110 3657 9813 13769500 3196 3743 10063 14009750 3282 3829 10313 142510000 3368 3915 10563 145410250 3454 4001 10813 147810500 3540 4087 11063 15034650 1582 2195 5263 9584900 1668 2281 5513 9855150 1754 2367 5763 10125400 1840 2453 6013 10385650 1926 2539 6263 10655900 2012 2625 6513 10926150 2098 2711 6763 11186400 2184 2797 7013 11506650 2270 2883 7263 11776900 2356 2969 7513 12047150 2442 3055 7763 12307400 2528 3141 8013 12887650 2614 3227 8263 13147900 2700 3313 8513 13418150 2786 3399 8763 1373


MR14MR16

MR16n

MR20MR25

5

Modeltotal auxiliary lift

(mm) Free lift

(mm)

height, mast lowered

(mm)

extended dimensions

(mm)Weight

(kg)h 3 h 2 h 1 h 4

7900 2614 3227 8513 13728150 2700 3313 8763 14018400 2786 3399 9013 14358650 2872 3485 9263 14648900 2958 3571 9513 15239150 3044 3657 9763 15529400 3130 3743 10013 15819650 3216 3829 10263 16099900 3302 3915 10513 163810150 3388 4001 10763 167110400 3474 4087 11013 169910650 3560 4173 11263 172810900 3646 4259 11513 175711150 3732 4345 11763 178611400 3818 4431 12013 181411650 3904 4517 12263 184311900 3990 4603 12513 187212150 4076 4689 12763 190112400 4162 4775 13013 192912650 4248 4861 13263 19588050 2680 3227 8613 13468300 2766 3313 8863 13748550 2852 3399 9113 14088800 2938 3485 9363 14369050 3024 3571 9613 14959300 3110 3657 9863 15249550 3196 3743 10113 15529800 3282 3829 10363 158010050 3368 3915 10613 161210300 3454 4001 10863 164110550 3540 4087 11113 166910800 3626 4173 11363 169811050 3712 4259 11613 172611300 3798 4345 11863 175511550 3884 4431 12113 1783


MR20hd

MR16hd

6

tRUCK asseMBlYlIst oF MateRIals ReCeIVed FRoM the dealeR

CARRIAGE SOLD WITHOUT BATTERY

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

Ref description

1 Truck base and mast assembled (option A)Truck base and mast separate (option B)2 Contrast rollers (optional)3 Battery runner rollers4 Forks5 Hydraulicfluidcanister6 Batter catch plate

1

6 54

3

2


7

CARRIAGE SOLD WITH BATTERY

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

Ref description

1 Truck base and mast assembled (option A)Truck base and mast separate (option B)2 Contrast rollers (optional)3 Battery runner rollers4 Forks5 Hydraulicfluidcanister6 Batter catch plate7 Battery

1

3

2

45

7

6


8

UnloadIng oFF the tRUCK and FIttIng the Mast to the tRUCK Base

equipment and tools

crane truck or bridge craneload capacity

2500 kg

fork lift truckload capacity

2500 kg

open ended span-ner

19 mmtorque wrench

lifting slingload capacity

2500 kg

Procedure

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

Phase 1TRUCK BATTERY - FORK LIFT TRUCK LOAD CAPACITY 2500kgConnect the battery to the truck base, switch on the forklift and transfer it to a place equipped with a crane truck or bridge crane Using the lift truck, fork the pallet on which the mast assembly is secured, raise it and carry it to the same place as the truck base

Phase 2BRIDGE CRANE - LIFT BELTRemove the packing of the mast assemblySlip the lifting belt beneath the upper crossbars of the mast assembly by making a noose and hook the other end to the bridge crane hook (fig.1)Start lifting slowly with the bridge crane and raise the mast assembly, separating it from the pallet Take the mast assembly into the vertical position

ladder

Fig 1


9

Phase 3OPEN ENDED SPANNER 19 mmUsing the open ended spanner, unscrew and remove the screws securing both side blocks of the mast assembly (ref.A fig.2) Remove the blocks (ref.B fig.2)Using the bridge crane, slowly lift the mast assembly and rest it vertically on the truck base in the special housings (ref.C fig.2) Keeping the belt taut, position both side blocks and, using a torque wrench, tighten the fixingscrews(ref.A fig.2) to a torque of 88 to 97 Nm

Phase 4BRIDGE CRANE - LADDER - LIFT BELTSet the ladder next to the mast assembly and climb upInsert the lift belt beneath the upper crossbar of the middle section of the mast assembly by making a noose and hook the ends to the bridge crane hook (fig.3) Climb down the ladder, raise the bridge crane to reveal the seats of the screws securing the mast assembly to the truck base (fig.4)

Phase 5TORQUE WRENCH - BRIDGE CRANE - LIFT BELTUsing the torque wrench, tighten the bolts securing the mast assembly to the truck base (ref.D fig.4) to a torque of 300 to 330 NmUsing the bridge crane, lower the mast assembly to the groundClimb up the ladder and remove the belt from the mast assembly

Phase 6Remove the cover to access the hydraulic control valve (fig.5)Connect the hydraulic pipes from the control valve on the truck base to the one on the mast assembly (fig.6)

Fig 2a

B

C

Fig 3

Fig 4 d

Fig 5

Fig 6


10

toPPIng UP the oIl ReseRVoIR

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

equipment and tools

oil resistant glovesfunnel T handle hex key5 mm

Procedure

Before starting work, ensure that you are wearing suitable protective clothingMove the carriage to a safe place, away from areas of transit of other vehicles and all pedestrians turn the keyswitch to oFF and disconnect the battery

Phase 1T-HANDLE HEX KEY 5 mmUse the T-handle hex key to unscrew and remove the motor cover screw (ref.A fig.1)Completely open the cover (fig.2)

Phase 3Tofacilitatethefillingofthetankunscrewthebreathervalve(ref.B fig.3), so that the air can come out when topping up

Phase 3FUNNELUnscrew the reservoir cap (ref.C fig.3),placethefunnelinthefillerholeand top up the oil levelBesurenottofillthereservoirtoomuchbycheckingthelevelviathemarks on the reservoir (fig.4).

Screw the breather valve and the reservoir cap back on

Fig 1

a

CB

Fig 2

Fig 3

Fig 4


11

Fig 1

a

Fig 2

Fig 3

Fig 4

InstallatIon oF the BatteRY

WITH VERTICAL REMOVAL

equipment and tools

bridge craneload capacity

2000 kgspreader bar

open ended spanner10 mm

Procedure

Before starting work, ensure that you are wearing suitable protective clothingMove the truck to a safe place, away from the transit areas of other vehicles and pedestrians

BRIDGE CRANE - SPREADER BARPull up the lever in front of the throttle pedal board next to the seat (fig.1) so as to free the battery housing Make the battery housing come fully out (fig.2)Using the open ended spanner, unscrew and remove the screws fastening the battery cover (where applicable) (ref.A fig.3) Remove the coverAttach the spreader bar to the bridge craneAttach the spreader bar to the battery, lift it using the bridge crane and position it over the battery housingLower the battery very carefully into the carriage compartment (fig.4)Unhook the spreader bar from the batteryConnect the cables to the batterySwitch on the truck and, using the controls in the cab, retract the re-tractable carriage completely so that the battery hooks onto the locking system


12

WITH LATERAL REMOVAL

equipment and tools

bridge craneload capacity

2000 kgspreader bar rollerway

Procedure


BRIDGE CRANE - SPREADER BAR - ROLLERWAYPull up the lever in front of the throttle pedal board next to the seat (fig.1) so as to free the battery housing Make the battery housing come fully out (fig.2) Remove the battery catch (ref.A fig.2) Position the rollerway alongside the battery housing and adjust the height so that the top of the rollerway is aligned with the bottom of the battery compartmentAttach the spreader bar to the bridge craneAttach the spreader bar to the battery; lift it using the bridge crane and place it on the rollerwayUnhook the spreader bar from the battery Push the battery into its hous-ing (fig.3) Position the battery catchConnect the cables to the batterySwitch on the truck and, using the controls in the cab, retract the re-tractable carriage completely so that the battery hooks onto the locking system

Fig 1

Fig 2

Fig 3

a


13

+

_

_

+

Positive terminal coloured Red

Negative terminal coloured BlUe

Tag coloured BlUeConnection of the cable to the negative terminal

CONNECTION OF CABLES TO BATTERY

Thepositivebatteryterminalisidentifiedwiththeredmarking or the symbol + , while the negative pole is identifiedwithbluemarking or the symbol The battery connector cables are in turn marked with a red tag for the connection to the positive pole and a blue tag for the connection to the negative pole

after connecting the clamps to the battery poles, apply some Vaseline grease to prevent the risk of oxidation

Tag coloured RedConnect lead to positive terminal


14

asseMBlY oF MoVIng FoRKs

Procedure


Phase 1Using the controls in the cab, lift the fork carriage to facilitate fork as-sembly operations

turn the keyswitch to oFF and disconnect the battery

Phase 2Insert the fork in and let it slide along the fork carrier plate (fig.1) until the fastening pin slots into the notch (fig.2)

Fig 1

Fig 2


15

ContRastIng RolleR asseMBlY

equipment and tools

Procedure

Before starting work, ensure that you are wearing suitable protective clothingMove the carriage to a safe place, away from areas of transit of other vehicles and all pedestriansturn the keyswitch to oFF and disconnect the battery

Phase 1Retrieve the contrast roller and its parts, apply the spacers (refa,B fig.2)

Phase 2FIXED GAUGE 19 mm SPANNERPositiontherollercompletewithspacersinitssectionandfixitwiththetwo screws to the truck base (ref.C fig.2)

Fig 1

open ended span-ner

19 mm

Fig 2B C

a


16

settIng the aCe2 tRaCtIon and the aCe2 PUMP ModUle BatteRY Voltages

If a battery that is not provided by the factory is installed on the truck, the battery voltage on the VCM module must be setTo carry out this regulation, it is good practice to proceed with an additional charging period for the battery used on the carriage in order that it may provide the maximum voltage

Procedure

programmer

equipment and tools

tester large Philips screw driver

Remove the rubber mat at the operator's feet inside the cab Using the T-handle hex key, unscrew and remove the screws securing the cover of the electronic controls Unscrew and remove the screw locking the bonnet (ref.A fig.1), remove the electronic controls cover and open the bonnet (fig.2)Usingacrossheadscrewdriver,unscrewthepanelfixingscrewtoaccesstheVCMcontrol(ref.B fig.3)With the engine turned off connect the programmerTurn on the machine (ON switch) and select the following parameter:VCMmodule/configmenuadjustment/ adjust battery

Using the tester, measure the exact voltage of the battery on the VCM control between the negative power connection (-Batt) on one of the two traction or pump inverters and the positive measured on pin 28 of connector a of the VCM module (fig.4) The parameter "adjust battery" must be set with the value of this tension

Turn the machine off (switch key OFF) and disconnect the programmerTurn the machine back on (ON switch)

lIst oF the settIngs and adJUstMents to Be CaRRIed oUtAfter assembling all the machine's components as described in the previous pages, the following operations must be carried out in the sequence given:

setting the battery voltage Checking the conditions of use of the truck Checking the contrast roller movement along the aisle Enabling and programming level pre-selection Enabling and programming middle fork lifting blocks Enabling and programming operator passwords

T handle hex key5 mm


17

+

Fig 4

Fig 1

a

B

Fig 2 Fig 3

A

1 1213 23

24 35


18

b6b6

CheCK the MoVeMent oF the ContRastIng aIsle RolleRs

Make sure that the truck can enter the aisle easily and that the contrasting rollers are correctly adjusted (maximum tolerance 5 mmon one side fig.1)If necessary remove or add shims Check the roller movement along the entire length of the aisle

CheCK the CondItIons oF Use oF the tRUCK

In order to ensure the safety personnel and materials, before proceeding with the opera-tions described below, it is important to assess the following: the type of load to be moved The general conditions of the warehouse, aisles and flooring

Having carried out these assessments verify whether the conditions given are compatible with the perform-ance levels set:

maximumtractionspeed tractionacceleration reductionoftractionspeed maximumforklifting/loweringspeed braking

Ifnecessary,reducetruckperformancebyusingtheprogrammertocustomisethetruckconfigurationpa-rameter (see "TRUCK FUNCTIONS"section "ELECTRICAL SYSTEM")

Fig 1

max 5 mm

In order not to jeopardize the safety of the truck, the only way in which the truck configu-ration parameters may be modified is by reducing the factory-set values. Parameter values that exceed the factory-set values are not permitted


19

enaBlIng and PRogRaMMIng oF the leVel PRe-seleCtoR

To enable and program the height pre-selector see "LEVEL PRE-SELECTOR" section "ELECTRICAL SYSTEM"

enaBlIng and PRogRaMMIng MIddle FoRK lIFtIng BloCKs

To enable and program the middle cab lifting blocks see "FORK LIFTING/LOWERING BLOCKS" section "ELECTRICAL SYSTEM"

enaBlIng and PRogRaMMIng oF the PassWoRd

To enable and program the operator passwords see "MAIN MENU 2 / PROGRAMMING ACCESS CODE WITH COMBINED OPERATOR CODE READING" section "ELECTRICAL SYSTEM"


20


1

DIAGNOSTICS AND MEASUREMENTS

Diagnostics anD measurements

DescriPtion moDuLe connectors 2

ace2 traction moDuLe 2

ACE2 PUMP MODULE 3

EPs ACw MODULE 4

MAsTER CONTROL CARD PREMIUM MODULE 5

tester menu 7

ACE2 TRACTION MODULE 7

ACE2 PUMP MODULE 7

EPs ACw MODULE 7

VCM MODULE 8

BreaKDoWn searcH 12

wARNING MEMORIZATION 12

ace2 PumP anD traction moDuLe Diagnosis sYstem 13

ACE2 PUMP AND TRACTION MODULE ALARMs 13

PUMP AND TRACTION ACE2 MODULE ALARM ANALYsIs AND TROUBLEsHOOTING 22

Diagnosis sYstem For Vcm moDuLe 33

Vcm - master moDuLe aLarm anaLYsis anD trouBLesHooting 33

Vcm - sLaVe moDuLe aLarm anaLYsis anD trouBLesHooting 38

ePs acW moDuLe Diagnosis sYstem 42

ePs acW moDuLe aLarm anaLYsis anD trouBLesHooting 42

SERVICE

2


DescriPtion moDuLe connectorsace2 traction moDuLe

A1 + 48V logic power supply A2 + 5V auxiliary power supply for Hall effect sensorsA3 Input of accelerator sensor output 1A4 Drive selector (analogue forward/reverse) (digital forward)A5 Reverse drive selectorA6 Input of service brake sensor output 2A7 Input CH A motor encoder A8 + 12V power supply for motor encoderA9 Horn negativeA10 Input of service brake sensor output 1A11 CAN communication line 2A12 CAN communication line 2A13 Input of accelerator sensor output 1A14 Input CH B motor encoder A15 - Batt auxiliary power supply for Hall effect sensors and encoderA16 Traction main contactor negativeA17 + 48V power supply for main contactor, electromagnetic brake, hornA18 Electromagnetic brake negativeA19 Man on board sensor output 1A20 CAN communication line 1A21 CAN communication line 1A22 Engine temperature sensor inputA23 - Batt engine temperature sensor

a

SERVICE

3


ace2 PumP moDuLe

A1 + 48V logic power supply A2 + 5V auxiliary power supply for Hall effect sensorsA3 Not used A4 Not usedA5 Not usedA6 Not used A7 Input CH A motor encoder A8 + 12V power supply for motor encoderA9 Flasher negativeA10 Not usedA11 CAN communication line 2A12 CAN communication line 2A13 Not usedA14 Input CH B motor encoder A15 - Batt auxiliary power supply for Hall effect sensors and encoderA16 Pump main contactor negativeA17 +48Vpowersupplyformaincontactor,flasher,fanA18 Fan negativeA19 Not usedA20 CAN communication line 1A21 CAN communication line 1A22 Engine temperature sensor inputA23 - Batt engine temperature sensor

a

SERVICE

4


ePs acW moDuLe

A1 CAN communication line 2A2 CAN communication line 2A3 Power supply positiveA4 Power supply positiveA5 Power supply positiveA6 Power supply negativeA7 Power supply negativeA8 Power supply negativeA9 Fan positive (+48V)A10 Fan negative A11 sensor with driving wheel at 90A12 sensor with driving wheel at 0 straight A13 Auxiliary power supply negativeA14 Not usedA15 + 48V logic power supply A16 stepper motor DL line power supply negativeA17 stepper motor QL line inputA18 Auxiliary power supply positive A19 stepper motor QL line power supply negativeA20 stepper motor DL line inputA21 Auxiliary power supply positive A22 CAN communication line 1A23 CAN communication line 1

a

SERVICE

5


master controL carD Premium moDuLe

A1 + 48V output power supply A2 Negative of proportional valve for carriage forward (PwM) Current controlledA3 Negative of proportional valve for carriage backward (PwM) Current controlledA4 Negative of diverter valve for Tilt or side shift (PwM) Current controlledA5 Negative of diverter valve for 5th way (PwM) Current controlledA6 Negative of electromagnet for battery block release (PwM) Current controlledA7 Negative of reverse drive buzzer (PwM) Current controlledA8 seat microswitchA9 Man on board sensor output 2A10 Traction speed reduction buttonA11 CAN communication line 1A12 CAN communication line 1A13 + 48V auxiliary power supplyA14 + 48V auxiliary power supplyA15 + 48V auxiliary power supplyA16 + 48V auxiliary power supplyA17 + 48V auxiliary power supplyA18 sensor 1 battery out Normally openA19 sensor 2 battery out Normally closedA20 seat belt microswitch A21 steering mode selection button 180- 360A22 - Batt auxiliary power supply A23 Carriage position potentiometer inputA24 Negative of lowering proportional valve (PwM) Current controlledA25 Negative of lifting proportional valve (PwM) Current controlledA26 Negative of proportional valve right hydraulic function (PwM) Current controlledA27 Negative of proportional valve left hydraulic function (PwM) Current controlled

aB

SERVICE

6


A28 + 48V logic power supply A29 - Batt logic power supplyA30 CAN communication line 2A31 CAN communication line 2A32 Not usedA33 + 12V auxiliary power supply A34 + 5V auxiliary power supply A35 Not used

B1 side shift position sensorB2 Not usedB3 Tilt position inclinometer inputB4 Encoder reset sensor input B5 Not usedB6 Pressure transducer sensor inputB7 + 48V output power supply B8 + 48V auxiliary power supplyB9 Main lifting cylinder position potentiometer transducer inputB10 Main lifting cylinder position potentiometer transducer inputB11 Load cell inputB12 Not usedB13 weighing buttonB14 Lifting by-pass button B15 Negative of pallet recognition laser (PwM) Current controlledB16 + 5V auxiliary power supply B17 Free lifting cylinder position potentiometer transducer inputB18 Free lifting cylinder position potentiometer transducer inputB19 - Batt auxiliary power supply B20 - Batt auxiliary power supply B21 Pallet presence sensorB22 Not usedB23 Negative of load wheel brakes (PwM 4A) Current controlled

SERVICE

7


ace2 traction moDuLe

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

MAIN TEsTER MENU

Parameter measurement unit

BatterY VoLtage Volt

Battery voltage measured on the key input

ace2 PumP moDuLe

MAIN TEsTER MENU




ePs acW moDuLe

MAIN TEsTER MENU




SERVICE

8


Vcm moDuLe

MAIN TEsTER MENU


WorKing Hours Hours

Indicates the truck's working hours according to the setting of the HOUR COUNTER option

ForK HeigHt mm

Indicates the fork height off the ground in real time if the HEIGHT INDICATOR option is activated

BatterY VoLtage V

Value of the voltage to 1 decimal place Level of battery voltage measured at key-switch on

BatterY cHarge %

Percentage value Provides the battery's residual charge as a percentage of the level of the complete charge

steer angLe degrees

Value in degrees Indicates the current steering angle

rtc Hour hours

Hour of the Real Time Clock

rtc minutes minutes

Minutes of the Real Time Clock

LiFt/LoW Pot %

Percentage value Level of the LIFT/LOwER control

reacH Pot %

Percentage value Level of the REACH control

tiLt Pot %

Percentage value Level of the TILT control

siDe sHiFt Pot %

Percentage value Level of the sHIFT control

autocssHiFt sW %

ON/OFF Level of the self-centring side shift button

autoctiLt sW %

ON/OFF Level of the self-centring side shift button

5 WaY sWitcH

ON/OFF Level of the hydraulic 5th way button

JoY Horn sW

ON/OFF Level of the horn button

SERVICE

9



PaLLet sWitcH

ON/OFF Level of the Pallet button

seatBeLt sWitcH

ON/OFF Level of the seat belt button

seat sWitcH

ON/OFF Level of the seat button

BatterY out sW1

ON/OFF Level of the Battery 1 disconnected sensor

BatterY out sW2

ON/OFF Level of the Battery 2 disconnected sensor

ssHiFt Pos sW %

ON/OFF Level of the side shift position sensor

tiLt Pos sW %

ON/OFF Level of the tilt position sensor

reacH an i sensor mV

Value in volts Level of the analog input A23 (truck potentiometer position)

outPut grouP #1 %

Value % Percentage of the maximum current applied on output unit #1 (EVP1 and EVP2 lifting/lowering)

outPut grouP #2 %

Value % Percentage of the maximum current applied on output unit #2 (EVP3 and EVP4 retractable carriage backward / forward)

outPut grouP #3 %

Value % Percentage of the maximum current applied on output unit #3 (EVP5 and EVP6 tilt down/left side shift - tilt up/right side shift)

outPut grouP #4 %

Value % Percentage of the maximum current applied on output unit #4 (EVP7 and EVP8 tilt / side shift valve sen-sor - 5th way valve sensor)

neVP9 outPut %

Value % Percentage of the maximum current applied on EVP9 (wheel brakes charge)

neV3 outPut %

Value % Percentage of battery voltage applied on EV3 (Laser)

neV2 outPut %

Value % Percentage of battery voltage applied on EV2 (Back-up alarm)

SERVICE

10



neV1 outPut %

Value % Percentage of battery voltage applied on EV1 (not used)

reset encoDer #1

ON/OFF Encoder reset sensor level

encoDer #1 pulses

Number of pulses ready by encoder 1

encoDer #2 pulses

Number of pulses ready by encoder 2

rPm PumP Hz

Value in Hz Pump motor speed

DigitaL inPut #1

ON/OFF A8 digital input level

DigitaL inPut #2


DigitaL inPut #3


DigitaL inPut #4


DigitaL inPut #5


DigitaL inPut #6


DigitaL inPut #7


DigitaL inPut #8

ON/OFF B13 digital input level

DigitaL inPut #9


Dig inPut #10


Dig inPut #11


SERVICE

11



anaLog inPut #1 mV

Value in volts Level of the analog input A23 (truck potentiometer position)

anaLog inPut #2 mV

Value in volts Level of the analog input A35 (not used)

anaLog inPut #3 mV

Value in volts Level of the analog input B1 (side shift position)

anaLog inPut #4 mV

Value in volts Level of the analog input B2 (not used)

anaLog inPut #5 mV

Value in volts Level of the analog input B3 (tilt position)

anaLog inPut #6 mV

Value in volts Level of the analog input B4 (encoder reset)

anaLog inPut #7 mV


anaLog inPut #8 mV

Value in volts Level of the analog input B6 (transducer pressure)

anaLog inPut #9 mV

Value in volts Level of the analog input B11 (load cell)

anaLog inPut #10 mV


SERVICE

12


BreaKDoWn searcHWarning memoriZation

Enter the main menu 1 /alarms on the display to visualize the last 20 warnings memorized and the infor-mation relative to the total number of hours worked by the module, the number of times the warning has beenactivatedandthenumberthatidentifiesthemodule.

MODULE 2: ACE2 Traction MODULE 6: EPs ACwMODULE 5: ACE2 Pump MODULE 1: VCM

SERVICE

13


ace2 PumP anD traction moDuLe Diagnosis sYstemace2 PumP anD traction moDuLe aLarms

programmer message

messagesicos description effect state of the truck

WatcHDog

CALL sERVICE

The watchdog signal is not in the correct state

MC open, EB activated, traction/pump station-ary

start upstand-byDuring traction

Re-start procedure:Re-start up of the key

eeProm Ko

CALL sERVICE

Error detected in EEPROM or in EEPROM management

The control device works using the default parameters

Continuous

Re-start procedure:None

Logic FaiLure #3

CALL sERVICE

Hardware protection cir-cuit failure due to high current

MC not closed, EB ac-tivated, traction/pump stationary

start up

Re-start procedure:Make a traction or hydraulic request

Logic FaiLure #2

CALL sERVICE

Motor phase voltage feed-back circuit failure


switch-on (im-mediately after the MC closes)


Logic FaiLure #1

CALL sERVICE

A condition of undervolt-age/overvoltage has been detected




Vmn LoW

CALL sERVICE

Motor output voltage low-er than expected


start upDuring traction


Vmn HigH

CALL sERVICE

Motor output voltage high-er than expected


start upstand-by


contactor cLoseD

CALL sERVICE The LC contact is locked

MC not closed (the control has not been activated), EB activat-ed, traction/pump sta-tionary

start up


SERVICE

14


programmer message


contactor oPen

CALL sERVICE

The MC coil has been ac-tivated, but the MC fails to close


switch-on (im-mediately after the MC closes)stand-byDuring traction


stBY i HigH

CALL sERVICE

In stand-by conditions (no current applied to the mo-tor), current feedback is outside the permissible stand-by limits


start up


caPacitor cHarge

CALL sERVICE

The voltage of the power capacitors fails to in-crease


start up


tH Protection

CALL sERVICE

The control device has reached the thermal re-duction temperature of 85C when the current is IMAX

The traction control de-vice reduces the maxi-mum current linearly from IMAX (85C) to 0A (105C)

Continuous


motor temPerat

CALL sERVICE

The motor temperature sensor is open (if dig-ital) or has exceeded the 150C threshold (if ana-logue)

The maximum current is halved and the speed is reduced

Continuous


BatterY LoW

CALL sERVICE

The battery is 0

The maximum current is halved and the speed is reduced (if CHECK OPTION=1)


Re-start procedure:Recharge the batteryRe-start up of the key

DriVer sHorteD

CALL sERVICE

The MC driver has short-ed and therefore is not capable of opening the contactor

MC open (the control has been released), EB activated, traction/pump stationary



SERVICE

15


programmer message


contactor DriVer

CALL sERVICE

The MC coil driver is dam-aged (it can't close)

MC open (the control has been released), EB activated, traction/pump stationary

stand-byDuring traction


Vacc not oK

CALL sERVICE

The value of the a c c e l e r a t o r / l i f t i n g potentiometer is greater than the minimum recorded value and the direction/activation switches are off

The traction/pump mo-tor is stationary



incorrect start

CALL sERVICE

Incorrect starting se-quences


start upstand-by


ForW + BacK

CALL sERVICE

Drive requests active in both directions at the same time

Traction is stationarystart upstand-byDuring traction

Re-start procedure:Make a traction request

encoDer error

CALL sERVICE

Problem in reading the encoder


During traction


VDc oFF sHorteD

CALL sERVICE

when switching on, the VDC-off logic signal is low


start up


Wrong sLaVe Ver

CALL sERVICE

The software versions for the slave and Master are not the same


start up


VDc LinK oVerV

CALL sERVICE

A condition of overvoltage has been detected



Re-start procedure:Make a valve or traction or hydraulic request

SERVICE

16


programmer message


tiLLer mismatcH

CALL sERVICE

TheMasterCandSlaveCdonothavethesamevalue for the tiller input from the VCM

Traction is stationarystart upstand-byDuring traction


BraKe run out

CALL sERVICE

The brakes potentiometer input is at the maximum value with no HB request

No effect The warning is shown on the con-sole only

Continuous


stoP rQ From ePs

CALL sERVICE

EPs sends a request to stop the motor Traction is stationary



init Vmn HigH

CALL sERVICE

The motor phase voltage is higher than expected, before activating the bridge


start up


init Vmn LoW

CALL sERVICE

The motor phase voltage is lower than expected, before activating the bridge


start up


eeProm Ko

CALL sERVICE

IT is impossible to recover the data from the memory

No effect start up


Param restore

CALL sERVICE

P a r t i a l / c o m p l e t e parameter reset has been performed since the last shutdown

No effect start up


Wrong ram mem

CALL sERVICE

The program checks the content of the main RAM registersandfindsadirtyvalue


Continuous


SERVICE

17


programmer message


staLL rotor

CALL sERVICE

The traction rotor is blocked

The traction/pump is stationary



Waiting sLaVe

CALL sERVICE

No activation message from the slave


start up


HarDWare FauLt

CALL sERVICE

The drivers fail to switch off with the watchdog sig-nal in an alarm state


start up


Pot acceL mism

CALL sERVICE

There is a discrepancy between Master and slave on the accelerator signal




Pot BraKe mism

CALL sERVICE

There is a discrepancy be-tween Master and slave on the brake signal




sens mot temP Ko

CALL sERVICE

The motor heat sensor output is outside the lim-its


Continuous


PeV not oK

CALL sERVICE

The PEV connector (A17) is not connected to the battery or the voltage is different

MC closed, EB acti-vated, traction/pump, valves stationary


Re-start procedure:Make a traction or hydraulic or valve request

VKeY oFF sHorteD

CALL sERVICE

when switching on, the Key-off logic signal is low


start up


SERVICE

18


programmer message


FLasH cHecKsum

CALL sERVICE

The program check is not OK


start up


mc coiL sHor

CALL sERVICE

short-circuit on the MC coil




Waiting For noDe

CALL sERVICE

No activation signals ar-rive from the other system units




Vacc out range

CALL sERVICE

The accelerator input is outside the Vacc_min to Vacc_max range that has been acquired with thePROGRAMMVACCfunction




tiLLer oPen

CALL sERVICE

The truck is on stand-by with the tiller switch off for longer than 30 seconds

LC opens stand-by


outPut mismatcH

CALL sERVICE

There is a discrepancy be-tween Master and slave on the motor control




WD sYncro

CALL sERVICE

TheSlaveChasnotre-ceived the watchdog sig-nalfromtheMasterC.




no sLaVe enaBLe

CALL sERVICE

No activation message from the slave


During traction


SERVICE

19


programmer message


Dir seL out rang

CALL sERVICE

The selected direction sig-nal is outside the limits

Traction/pump station-ary



PoWer mos sHort

CALL sERVICE

short-circuit on the power MOsFETs


start up


coiL sHor eB

CALL sERVICE

short-circuit on the EB coil




current gain

CALL sERVICE

The maximum current gain parameters are the default values This means that the maximum current adjustment proce-dure has not yet been car-ried out

The control device works, but with a low maximum current

start upstand-by


anaLog inPut

CALL sERVICE

The analogue channel reading is not up-to-date


start upDuring traction


tiLLer error

CALL sERVICE Tiller failure

The main remote-con-trol switch, open power bridge, electromagnetic brake activated


Re-start procedure:Re-synchronisation of the system:

release all requests (traction and hydraulic)make a traction or hydraulic request or both

SERVICE

20


programmer message


eVP DriVer oPen

CALL sERVICE

The EVP coil driver is open and is not able to close

MC closed, EB activat-ed, EVP stationary EVP on

Re-start procedure:Make an EVP request

m/s Par cHK mism

CALL sERVICE

The checksum test be-tween Master and slave has not been passed


start up


inPut mismatcH

CALL sERVICE

TheSlave C has differ-ent values to the inputs fromtheMasterC.




Param transFer

CALL sERVICE

The Master cannot trans-fer the parameters to the slave


start up


sP mismatcH

CALL sERVICE

TheSlaveChasdetect-ed an incorrect set point oftheMasterC.




tHrottLe Prog

CALL sERVICE

One of the potentiometers has not been programmed correctly

Traction/pump station-ary



iQ mismatcHeD

CALL sERVICE

The error between the lq set point and the estimat-ed lq is outside the limits

Traction stationary During traction


aux DriV oPen

CALL sERVICE

The AUX coil driver has failed (it cannot operate the brake)




SERVICE

21


programmer message


Data acQuisition

CALL sERVICE

The maximum current adjustment procedure is in progress (NOTE: This procedure must be per-formed by the Zapi testing department only)

Traction stationary stand-by


no can msg

CALL sERVICE

Communication error with the supervisor




cHecK uP neeDeD

CALL sERVICE

IT is time to carry out maintenance work

Traction is reduced or stationary


Re-start procedure:switch the key back on, after performing maintenance

tHermic sens Ko

CALL sERVICE

The control device heat sensor output is outside the limits


Continuous


Wrong set Bat

CALL sERVICE

The absolute difference between the voltage of the key and the nomi-nal voltage of the battery is greater than 20% of Vbatt nom


start up


Wrong Zero

CALL sERVICE

The motor phase voltage feedback is outside the permissible limits


start up


FieLD orient Ko

CALL sERVICE

The error between the ld set point and the estimat-ed ld is outside the limits


During traction


aux DriVsHrt

CALL sERVICE

The EB/AUX driver has shorted and therefore is not capable of opening the contactor




SERVICE

22


aLarm breakdown search

WatchdogThis alarm could be caused by a malfunctioning of the canbus shutting off Master-slave communication

Cause:This is a safety test IT is a self-diagnosis test within the logic between the Master and slave micro-controllers

eeprom ko Try to carry out a CLEAR EEPROM operation (see the console manual) Turn off then on again with the key to verify the result If the alarm persists, the

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