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Maintenance

Preliminary operations before commissioning

Below are listed the operations
that must be performed on the
forklift before delivering it to the
customer:
• General test of the forklift.
• Check and top-up, if

necessary, the oil in the
hydraulic system tank.

• Visually check the seal of the

lift cylinder gaskets, tilt
cylinders, steering control
cylinder and side shift,
distributor, oil pump, hydraulic
system piping and fittings;
eliminate any leaks. Check the
oil level and top-up, if
necessary, for the motor,
hydraulic and differential
transmission, reducers;
eliminate any leaks.

• Check the brake fluid level and

top-up, if necessary; visually
check the seal of the brake
system, service brakes and
parking brake; eliminate any
leaks.

• Check the motor cooling water

level and top-up, if necessary;
visually check the seal of the
motor cooling circuit; eliminate
any leaks.

• Check the inching pedal

linkage, fan belt tension,
handbrake tension and adjust
if necessary.

• Check and restore, if

necessary, the wheel nut
tightening, retaining screws
fastening the lift to the truck,
counterweight, protective roof,
lifting chains and their
anchorage, clearance between
movable parts, pneumatic
pressure.

• Check the operation of the

electrical recharging system,
ignition, control instruments,
and battery liquid level.

• Forklift lubrication and

greasing.

• Lift greasing (mast, rolling

tracks).

• Check of the safety devices

NOTE

For the description of the

operations, refer to the relative
paragraphs.

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Содержание KBET15

Страница 1: ......

Страница 2: ...https www truck manuals net Maintenance Manual ...

Страница 3: ...KION Baoli Jiangsu Forklift Co Ltd KB 2017 08 V1 0 ...

Страница 4: ...ad arms NOTE For use of a piece of field equipment after the sale it is necessary to apply to the authorized dealer which will verify its feasibility and if applicable perform the equipment installation the updating of the residual capacity plates and the testing The equipment will also have to be provided with identification plate and Assembly and Instructions Manual NOTE The crane arm attachment...

Страница 5: ...Definition of travel direction https www truck manuals net A Forwards I Backwards S Left D Right ...

Страница 6: ...Overall dimensions for four wheel truck ...

Страница 7: ...three wheel truck technical data ...

Страница 8: ...ight 505AH 595Ah 810KG 920KG The values shown refer to standard outfits they are indicative only and not binding Three wheel truck tyre characteristics WHEELS Type solid tyre Environmental protection solid tyre front rear front 1 5T 1 8T 16 6 8 18 7 8 16 6 8 2 0T 16 6 8 200 50 10 16 6 8 Fork lift truck capacities Model 1300 kg 3 wheels with vertical masts and ...

Страница 9: ...00 993 3300 2145 4342 1650 1143 3500 2245 4542 1690 1243 4000 1300 1600 2545 5042 1890 1543 VFHM Full free triple x 4000 1300 1500 1940 5042 1400 938 4350 1280 1400 2065 5392 1525 1063 4500 1250 1400 2115 5542 1575 1183 4700 1250 1300 2185 5742 1645 1183 4800 1200 1300 2215 5842 1745 1213 5000 1100 1200 2315 6042 1775 1313 5400 900 1000 2440 6442 1900 1483 5500 750 850 2465 6542 1925 1463 6000 500...

Страница 10: ... 3000 2007 4040 1417 1007 3300 2157 4340 1567 1157 3500 2257 4540 1667 1257 4000 1800 2557 5040 1967 1557 VFHM Full free triple x 4000 1700 2000 5035 1370 1000 4350 1550 2125 5385 1495 1125 4500 1450 2175 5535 1545 1175 4700 1350 2240 5735 1610 1240 5000 1200 2418 6035 1788 1418 5400 1000 2618 6435 1988 1618 5500 950 2652 6535 2022 1652 6000 750 2885 7035 2255 1885 Remark This data would be change...

Страница 11: ...LI without side shift SES Single superelastic tyres PN Pneumatic tyres TWIN Twin tyres Lift inclination Forward Forw Backward Back Alternative lift characteristics Abbreviations key Lift Lift DX Duplex lift SX Simplex lift TX Triplex lift Sing Single tyre Twin Twin tyres Opt Optional All lifts All the lifts S E Superelastic S Single PN Pneumatic RVE Reverse while empty ...

Страница 12: ...irection indicators lights 12V 21W Breadth indicators lights 12V 5W Tail and stop lights 12V 21W Reversing lights 12V 10W Flashing beacon 12V 2W Battery dimensions and weights Truck type Voltage V Capacity Ah Weight kg 5 1 5T 1 8 48 505 525 595 810 920 2 0T 48 625 700 900 990 The minimum and maximum weights of the batteries must be guaranteed ...

Страница 13: ... follows 1 upward open the battery cover 2 remove bolts open the electrical cover 3 remove bolts remove the floor 4 remove bolts removal of multi way valve cover NOTE The battery cover is held open by a gas spring 1 To close the cover follow the instructions above in the reverse order ...

Страница 14: ...ollevatore 1 Load carrying grate 2 Fork stop latches 3 Fork retaining device 4 Fork carriage retaining device 5 Chain retaining device 6 Chain tension rod retaining device 7 Emergency stop button 8 Shear protection net ...

Страница 15: ...ing beacon 10 Seat switch microswitch that blocks operation of the truck when the operator is not seated on the driver s seat 11 Restraining belt 12 Overhead guard 13 Alarm horn 14 Reverse gear warning buzzer ...

Страница 16: ... with hoist If the forklift s dimensions exceed the max clearance size allowed it is transported disassembled The sales network is in charge of the disassembly and reassembly operations The forklift must be secured to the transport means during transport using appropriate restraint systems Block the wheels with wedges to prevent even the slightest movement ...

Страница 17: ...oard the truck in order to perform the steering and braking operations NOTE Use non metallic cables for towing Version with reversing on the steering wheel Before towing models with reversing lever on the steering wheel check that this lever 1 is in the central position ...

Страница 18: ...Loading and unloading the truck Use an inclined plane or movable loading ramp to load and unload the truck If the truck is not operational or does not have the battery lift it as described below ...

Страница 19: ...s follows Insert a non metallic sling 1 into the rear tow coupling 2 of the truck Check that the sling adheres to the upper part of the slot in the counterweight Pass two slings 3 one on each side through the upper crossmember 4 of the lift s fixed mast Connect the free ends of the cables to the hook of the crane and lift without tearing The cables should have a suitable length so as to not graze ...

Страница 20: ...anger and its consequences and the description of how it can be avoided The types of warnings used are described below This warning indicates serious risks for the safety of the operator and maintenance staff It may be accompanied by additional comments This warning indicates serious risk of damaging the truck It may be accompanied by additional comments General safety Regulations ...

Страница 21: ...pt disconnected unless expressly prescribed by the maintenance or repair instructions All service actions must be carried out with maximum care and attention Do not wear rings wrist watches jewellery unfastened or hanging garments such as ties torn clothing scarves unbuttoned jackets or blouses or open zips which could be caught in the moving parts Operate in separate work areas specifically inten...

Страница 22: ...ions label all controls to mark that repairs are in progress Do not leave the machine unattended with parts in movement Immobilise the machine and all equipment or parts that are subject to maintenance while raised or which could accidentally move ...

Страница 23: ...eseen are firmly fixed before starting to tow the truck Do not remain in the vicinity of the tow bar ropes or chains working under tension To move a machine that has broken down use a trailer or a truck with a lowered loading platform if available When transporting the truck follow the indications in this manual To load and unload the machine on and off the transport means choose a level area with...

Страница 24: ...e vicinity even if not carrying out work Never look at the welding arc without adequate eye protection With use metal cables become frayed when handling them always use adequate protection gloves goggles etc Do not use chains r ropes that are worn or bent for lifting or pulling Electrical system batteries Before performing any operation on the electrical system disconnect the battery outlet from t...

Страница 25: ...e battery Before any operation check that no elements are short circuited eliminate such short circuits before proceeding with the work For electric heaters battery chargers and similar appliances use only effectively earthed auxiliary power sources in order to avoid the possibility of electric shocks ...

Страница 26: ... the pressure of the hydraulic system Disconnections and reconnections Before removal and installation of any component disconnect the relative plug from the battery outlet Lift and handle all particularly heavy parts by means of lifting gear of an adequate capacity Ensure that pieces are supported by appropriate harnesses and hooks Use the lifting rings specifically provided for the purposes Pay ...

Страница 27: ...inding material such as an oil binder and then disposed of in accordance with current regulations Always abide by the regulations of the anti pollution laws Before carrying out work that involves lubrication filter replacement or hydraulic equipment interventions the area in question must be thoroughly cleaned The replaced parts must always be disposed of in accordance with the anti pollution laws...

Страница 28: ...under pressure from the forklift s hydraulic system is dangerous If this type of lesion should occur contact a doctor immediately ...

Страница 29: ...is charged must be in compliance with the specific regulations on the subject e g CEI EN 50272 3 DO NOT smoke or use open flames and lights within a 2 m radius from the charged battery and in the battery charging area NOTE For greater information consult the specific battery manual that comes with the battery ENVIRONMENT NOTE The batteries contain substances that are hazardous to the environment T...

Страница 30: ...y visually check the seal of the brake system service brakes and parking brake eliminate any leaks Check the motor cooling water level and top up if necessary visually check the seal of the motor cooling circuit eliminate any leaks Check the inching pedal linkage fan belt tension handbrake tension and adjust if necessary Check and restore if necessary the wheel nut tightening retaining screws fast...

Страница 31: ... oil filter cartridge Protective roof tightening screws check Check fork wear 1 Check brake oil level Change hydraulic system oil Axial maintenance Change brake oil 1 To be carried out absolutely every 3 months or according to current legislation 2 Every 1000 hours or at least every 12 months 3 First change after 1000 hours then every 3000 hours ENVIRONMENT NOTE Proceed as follows at each lubricat...

Страница 32: ...uld spill Keep the product in a suitable and compliant place as per the instructions supplied with the product Dispose of the lubricating product in compliance with the current laws Supply Table Element to be supplied Quantity Lubricants I n t e r n a t i o n a l s p e c i ﬁ c a t i o n s Hydraulic circuit 1 5T 1 8T 24L L HM46 L HM32 I S O V G 3 0 2 0T 38L L HM46 L HM32 I S O V G 3 0 Bearings and ...

Страница 33: ...gearbox 1 5T 1 8T ATF220 2 0T SAE 80W S A E 8 0 W A P I G L 4 U T T O Chains Lubricant STRUCTOV FHD I S O V G 1 5 0 Oil immersed brakes 0 2 L d o t 3 ...

Страница 34: ...hrough the SME interface cable The connection can be performed on all modules The connection between PC and forklift must be performed with the forklift turned off The diagnostics unit must be used by trained personnel only The variation of some parameters or configurations may cause hazardous situations for the operator ...

Страница 35: ...ccessful starting the application from Windows Programs Menu or using short cut on desktop Fig 1 you can access main menu On left side there are some notes about software release operating mode and serial communication settings Below lift truck picture picture normally present in main menu doesn t appear in fig 2 There are actual active alarms code level and description in case of more alarms with...

Страница 36: ...ics Moreover if user programs flash memory EYEPLUS software loads source files from a directory named as lift truck model itself this way proper source files are automatically associated to selected truck model see FLASH PROGRAMMING section for further information In operator mode from main menu you can access following menus Exit Setup Test Data logging Password About Setup Password refer to chap...

Страница 37: ...menu front panel is reinitialized PASSWORD INSERTION Selecting Password mode from menu bar you can access Supervisor mode Fig 7 inserting the right password Fig 5 In case of wrong password insertion message in Fig 6 becomes visible Contact EYEPLUS software developer to know correct password ...

Страница 38: ... Supervisor mode you can access these further menus Calibration Flash Password menu disappears from menu bar In case of faulty serial communication main menu front panel is reinitialized as follows Fig 8 ...

Страница 39: ...not programmed flash memory so Flash menu is obviously active You can select active menus directly from main panel menu bar any greyed menu is not accessible in that moment you can also access present sub panels with a further selection by a pop up menu Fig 9 ...

Страница 40: ...he visualized button you can load in EEPROM default values if you don t execute this procedure calibration functions are inhibited You have now to execute calibration procedure see inverter manual A message signals also the presence of not actual software loaded on inverter panel In such a case you can access only basic EYEPLUS functions some menus for compatibility reasons will be inhibited ...

Страница 41: ... you select a non active window you can t communicate interact with inverter panel In such a case mouse cursor assumes the shape of an hour glass if a non active window is selected CONFIGURATION MENU SETUP From setup menu Fig 10 you can select communication serial port and image file format used by Print function TEST MENU SECTION This pop up menu includes following diagnostic items Drive menu bot...

Страница 42: ... a flashing display Steering angle in percent using following criteria 0 steering completely on left 50 straight wheels 100 steering completely on right Steering sensor voltage and steering switch status Request RPM and motor speed for both motors with an arrow signalling direction Drive motors encoder diagnostic leds both for A and B channel Both motors temperature you can select measure unit bet...

Страница 43: ...display Steering angle in percent using following criteria 0 steering completely on left 50 straight wheels 100 steering completely on right Steering sensor voltage and steering switch status Request RPM and motor speed for drive motor with an arrow signalling direction Drive motor encoder diagnostic leds both for A and B channel Motors temperature you can select measure unit between C and F Notic...

Страница 44: ...0 C is signalled by a red colour temperature above 90 C is signalled by a flashing display Request RPM and motor speed with an arrow signalling direction Motor temperature you can select measure unit between C and F Notice in case of an overheating alarm the corresponding green led becomes red Weight present on the forks Buzzer and electro valves output status Customizable input switches status Ti...

Страница 45: ...f there is more than one alarm of same level the latest is visualized There is a chronological list of latest 10 alarms with code description time and temperature First listed alarm is the first occurred Temperature value is obviously referred to faulty module or faulty motor Notice if there are no faulty modules or motors this is a no meaning data field With Reset alarms menu you can reset alarm ...

Страница 46: ...TIMERS TEST MENU Following items appear in Timers menu front panel total inverter working hours drive motor and pump motor hour meter and odometer readings ...

Страница 47: ...ical height Fig 28 Weight sensor Weight sensor calibration Fig 29 Brake sensor Brake sensor calibration Fig 30 Hydro threshold Hydro threshold calibration Fig 31 Cab lift Cab lift speed calibration Fig 32 Truck setup Some lift truck parameters setup Fig 33 Pliers calibration Some lift truck parameters setup Fig 34 Backing mode Slow mode calibration Fig 35 Timers reset Timers meters reset Fig 36 Lo...

Страница 48: ...menu without saving changes Notice you can t set a value out of fixed limits Such a case is signalled by the message OUT OF LIMIT Notice see Appendix A to find further explanation about programmable parameters meaning They are listed in functional groups ...

Страница 49: ...tton NEW data field will be automatically updated with default value 2 Press SAVE button and confirm OLD data field too will be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial value is restored Discard changes 1 Press CANCEL button initial ...

Страница 50: ...meter to be calibrated discharged battery voltage if battery voltage is less than this value the corresponding alarm appears on display This parameter is visualized on front panel as battery reset value and also calibration procedure is the same ...

Страница 51: ...ll be automatically updated with default value 2 Press SAVE button and confirm OLD data fields too will be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signalled and NEW data field initial value is restored Discard changes 1 Press CANCEL button initial values will be resto...

Страница 52: ...ed with steering sensor actual voltage if this value is out of permitted range you cannot calibrate it In such a case check for any lift truck fault You can execute following operations Load default value Press DEFAULT button VALUE data fields will be automatically updated with default values Change parameters value Discard changes Press CANCEL button initial value will be restored in VALUE data f...

Страница 53: ...a case check for any lift truck fault You can execute following operations Load default value Press DEFAULT button VALUE data field will be automatically updated with default Value Change parameters value Discard changes Press CANCEL button initial value will be restored in VALUE data fields If selected parameter value is out of permitted voltage range you cannot calibrate it in such a case check ...

Страница 54: ...l sensor Calibration procedure is like standard one except that START led present Fig 18 turns ON only after software verifies that the voltages on both pedal sensors are equal to Vmin 0 5 V voltage obtained slowly pressing accelerator pedal ...

Страница 55: ...is updated with lift sensor actual voltage if this value is out of permitted range you cannot calibrate it In such a case check for any lift truck fault You can execute following operations Load default value Press DEFAULT button VALUE data fields will be automatically updated with default values Change parameters value Discard changes Press CANCEL button VALUE data fields will be restored with in...

Страница 56: ... 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial value is restored Discard changes 1 Press CANCEL button NEW data fields will be restored with initial values 2 Press SAVE button and confirm OLD data fields too are restored with initial values With E_S_H pop up menu present in this window you can select one o...

Страница 57: ...ata about L1 L2 and L3 parameters description measure unit modifiable values expressed in per cent minimum and maximum settable values You can execute following operation Change actual value 1 insert new value 2 confirm If actually selected operating mode percent values are now modified exiting to ESH calibration menu user can load new default values Every parameter per cent value is referred to H...

Страница 58: ...fields will be automatically updated with default value 2 Press SAVE button and confirm OLD data fields too will be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial value is restored Discard changes 1 Press CANCEL button NEW data fields will...

Страница 59: ...enable apposite function You can execute following operations Change actual value 1 Set button INCREASE properly to select if increase or decrease service interval 2 Change assistance interval value using HOURS INCREASE pop up menu 3 Press SAVE AND EXIT button and confirm ...

Страница 60: ...ta fields and first 3 parameters will be updated Change actual value Insert changed value in NEW data field or modify one of first 3 parameters 1 Press SAVE button and confirm in case of good result OLD data field is updated 2 Otherwise an error is signaled and NEW data field or one of first 3 par initial value is restored Discard changes 1 Press CANCEL button NEW data fields will be restored with...

Страница 61: ...l versions You can find further parameters to be calibrated they obviously depend on application diameter of tires starting temperature motors fan braking ramp speed after stop on slope acceleration ramp limitation inversion ramp limitation release ramp limitation These parameters are visualized on front panel after partial release ramp and also calibration procedure is the same ...

Страница 62: ...T button NEW data fields will be automatically updated with default value 2 Press SAVE button and confirm OLD data fields will be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial value is restored Discard changes 1 Press CANCEL button NEW da...

Страница 63: ... value in percent You can execute following operations Select default value 1 Press DEFAULT button NEW data fields will be automatically updated with default value 2 Press SAVE button and confirm OLD data fields will be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled...

Страница 64: ...values Pressing SAVE button visualized pressure value is saved on actually selected parameter You can execute following operations Select default value Press DEFAULT button VALUE data fields will be automatically updated with default value Calibrate weight sensor Discard changes Press CANCEL button VALUE data fields will be restored with initial values BRAKE SENSOR CALIBRATION OPTIONAL MENU ...

Страница 65: ...ated with brake sensor actual voltage if this value is out of permitted range you cannot calibrate it In such a case check for any lift truck fault You can execute following operations Load default value Press DEFAULT button VALUE data fields will be automatically updated with default values Change parameters value Discard changes Press CANCEL button VALUE data fields will be restored with initial...

Страница 66: ...llowing operations Select default value 1 Press DEFAULT button NEW data fields will be automatically updated with default value 2 Press SAVE button and confirm OLD data fields too will be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial valu...

Страница 67: ...EW data field will be automatically updated with default value 2 Press SAVE button and confirm OLD data field will be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial value is restored Discard changes 1 Press CANCEL button NEW data field wil...

Страница 68: ...nge actual value 1 Insert changed status in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial status is restored Discard changes 1 Press CANCEL button NEW data fields will be restored with initial status 2 Press SAVE button and confirm OLD data fields are restored with initial status Optional ve...

Страница 69: ...ange defines the active level of pressure If no valid code is received it s not possible to change active pressure level The selected level value is not memorized so you lose it switching lift truck off In front panel appear 1st 2nd and 3rd setup pressures new and old value measure unit and default minimum and maximum settable values the same data are visualized for 4 tuneable parameters Kp Kd_1 K...

Страница 70: ...be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial value is restored Discard changes 1 Press CANCEL button NEW data field will be restored with initial values 2 Press SAVE button and confirm OLD data field are restored with initial values ...

Страница 71: ... button NEW data field will be automatically updated with default value 2 Press SAVE button and confirm OLD data field will be updated Change actual value 1 Insert changed value in NEW data field 2 Press SAVE button and confirm in case of good result OLD data field is updated Otherwise an error is signaled and NEW data field initial value is restored Discard changes 1 Press CANCEL button NEW data ...

Страница 72: ...u want to load default Eeprom configuration you have to use complete Eeprom reset to maintain already calibrated values you can use partial EEPROM reset procedure Pay attention using complete reset procedure you loose already calibrated values Both procedures in any case don t modify timers value and alarm history Partial EEPROM reset 1 Press PARTIAL LOAD EEPROM button 2 Give a confirmation to loa...

Страница 73: ... and configuration file name in the dialog box then press OK button Load saved configuration 1 Select IMPORT menu from menu bar 2 Select location path and file name in the dialog box then press OK button 3 You find now three new items see fig 40 NEW values the ones present in configuration file MATCH list to show unvaried values a light green led SELECTION list to choose parameter to be loaded all...

Страница 74: ... to adjust hour meter value You can execute following operations 1 You have to enable hour meter management pressing ENABLE DISABLE button Fig 41a 2 You can now access hour meter value field and adjust its value Fig 41b 3 Then you can save new value pressing SAVE ...

Страница 75: ...tion procedure is following 1 Select Nmax the number of variables you want to save 2 Select the variables whose value you want to record with apposite pop up menu 3 You can modify sampling period expressed in seconds 4 Pressing START button saving procedure begins in that phase you can t modify acquisition parameters During acquisition procedure Fig 43 following data are visualized A led signals s...

Страница 76: ...ource_DRV_FILE model3 model3 lift truck 9 C Source_SME Source_SNG_FILE model4 model4 lift truck Number identifies lift truck model the number corresponds to numeric code present in source filename xx xx xx xxXX xxx0 this value is read also from panel memory and used to customize automatically EYEPLUS menus Directory each model has its own linked directory which contains source files Motor system t...

Страница 77: ... files will be copied in it Old source files will be moved to C Source_SME_old Source_TRZ_FILE model1 directory automatically created and so in case of need they are anyway available PROCEDURE FOR LIFT TRUCK MODEL SELECTION With new source files operator can upgrade main controller software selecting FLASH item from EYEPLUS menu bar first of all disable active commands We distinguish case of flash...

Страница 78: ...tly installed in main board flash memory Automatically selection list box points model136V lift truck model and user can see source file filename is 12 02 07 0001 present now in C Source_SME Source_TRZ_FILE model1 Now user can confirm selection with Confirm button or select another lift truck model as in the following window Fig 45 ...

Страница 79: ...V lift truck model C Source_SME Source_TRZ_FILE model0 Fig 46 User can now confirm selection with confirm button or in any case of error he can exit without changing model pressing abort button Notice To prevent mistakes when operator is connecting to a single drive motor system in selection list box are accessible only single drive models and obviously in case of twin motor systems only twin driv...

Страница 80: ...CASE OF PANEL BLANK Starting EYEPLUS application in case of flash memory not programmed in main menu front panel PANEL BLANK message is visualized and following window Fig 47 automatically appears ...

Страница 81: ...can now choose lift truck model from selection list box as in the picture below Fig 48 Once operator has selected a lift truck model for example model1 see Fig 49 confirm button appears and you can read filename present in source directory corresponding to selected model ...

Страница 82: ...take care you are doing the correct selection In fact after selecting truck model and entering main menu you could load wrong file into control board i e if you ve selected a twin motor system while your lift truck is a single drive motor system PROGRAMMING PHASE Once selected truck model model0 for example EYEPLUS software points proper files in C Source_SME Source_TRZ_FILE model0 directory and f...

Страница 83: ...s with serial communication there will be an error message and flash programming phase will be stopped 4 After traction micro successful programming begins micro2 pump programming phase 5 A message will signal the end of programming phase and its result Notice In case of single drive motor systems step 3 and step 4 will not be executed Notice Both in case of single and twin motor systems if progra...

Страница 84: ...step by step In case of successful installation if application has a runtime error Verify if your PC complies minimal requirements Turn off PC and try again after turning it on Uninstall and install again EYEPLUS software SERIAL COMMUNICATION If application doesn t work and message not connected appears Verify system ground connections Verify if inverter panel works correctly Control serial connec...

Страница 85: ... M E In case of transmission error Verify system ground connections Control serial connection cable you must use a shielded one Verify if serial port works correctly Verify if there are any active commands OTHER PROBLEMS Application works slowly or doesn t work properly Verify if your PC complies minimal requirements Text and objects on main panel are not centred Verify if your PC complies minimal...

Страница 86: ...eed Maximum reverse lift truck speed with no speed limitation no alarms present and turtle not active Creep speed If the truck speed is greater then this threshold the speed reference becomes a parabolic function of the accelerator potentiometer voltage Steer limitation maximum speed Maximum speed reference in the angle in which the internal wheel is mechanically still Drive maximum current Drive ...

Страница 87: ...fan temperature If the motor temperature exceeds this threshold the motors fans are activated Maintenance time inserting enable If parameter is set to 1 program service function is enabled Maintenance time If the truck working hours exceed this value the display signals the maintenance request Timers PARAMETER NAME PARAMETER NAME Seat switch delay Time interval between seat switch opening and driv...

Страница 88: ...t function active Auxiliary maximum current Pump motor maximum current with lift lever released High lift switch 1 lift maximum speed Max lift speed when the forks are above the1st critical height High lift switch 2 lift maximum speed Max lift speed when the forks are above the 2nd critical height High lift switch 1 tilt maximum speed Max tilt speed when the forks are above the1st critical height ...

Страница 89: ...ometer voltage to which the lifting becomes proportional to the shift of the lever Lift sensor maximum value Lift sensor voltage with lift lever completely pressed Steering sensor minimum value Steering sensor voltage with wheels turned on left Steering sensor middle value Steering voltage with wheels straight ahead Steering sensor maximum value Steering sensor voltage with wheels turned on right ...

Страница 90: ... condition should be verified if the battery is new it is necessary to do some charge discharge cycles before reaching the rating declared by the constructor or has a high internal resistance If the case is the second and it is not possible to change the battery the solution may be to reduce the release and reverse braking ramp 2 incorrect wiring to battery positive or negative terminals 3 verify ...

Страница 91: ...tor circuit exceeds the value calculated averaging calibration and reachable voltages moreover start switch seems to be open In case of such an alarm follow these troubleshooting steps 1 verify if the potentiometer initial set up is correct if not repeat calibration procedure You can use both PC with serial communication software and COMPACT display 2 verify if the following 68 ways connector term...

Страница 92: ...edure 1 verify if main breaker coil and power terminals are in good conditions 2 verify if supply lines power fuse is damaged 3 verify if main breaker coils are correctly wired to their correspondent inputs K1 18 positive terminal K1 19 negative terminal 4 replace main breaker 5 replace control board Inverter desaturation or overcurrent alarm Eye alarm code 8 for right drive motor power module 24 ...

Страница 93: ...trol board with the corresponding inverter 3 replace the inverter connected with the CN1output of control board 4 replace control board Pump motor inverter overtemperature Eye alarm code 10 Alarm level 6 Alarm cause the inverter temperature measured with a temperature probe exceeds 100 º C or is inside 95 ºC 100 ºC range at least 30 s In case of alarm follow this procedure 1 alarm could be caused ...

Страница 94: ...in board In case of alarm follow this procedure 1 verify the correctness of wiring from pump motor and relative inverter 2 replace cable connecting the output CN4 of the control board with the corresponding inverter 3 replace the inverter connected to CN4 output of the control board 4 verify if main breaker has stuck closed terminals in such a case replace it 5 replace the cable connecting the out...

Страница 95: ...robe execute the measure at ambient temperature of 25 C If the measure is not correct it is necessary to replace the temperature probe 2 disconnect the temperature probe and check the wiring insulation between signal wire and ground wire towards control board 3 replace control board Presence of alarm with hot motors 1 If temperature value you can read it from display or via PC seems correct verify...

Страница 96: ... current offset alarm Eye alarm code 15 for right drive motor 16 for left drive motor 36 for pump motor Alarm level 1 Alarm cause non zero phase currents when you turn lift truck on In case of motor current offset alarm follow this procedure 1 replace the cable connecting the malfunctioning inverter to control board 2 replace inverter 3 replace main board Main breaker fault Eye alarm code 17 Alarm...

Страница 97: ...erter block and aluminium plate and between aluminium plate and truck ballast The presence of the correct amount of thermal grease in the coupling are essential to ensure a correct heat exchange 2 replace cable connecting the output CN1 for right drive motor or CN2 for left drive motor of the control board to the corresponding inverter 3 if temperature readings seem too high in function of total t...

Страница 98: ... is grounded cause an incorrect encoder wiring 2 verify if 5 V output is grounded cause any encoder malfunction In that case replace the defective one 3 replace control board Alarm on 12 V output voltage Eye alarm code 38 Alarm level 1 Alarm cause Main board K1 12 terminal 12 V output voltage is lower than 10 5 V In case of an alarm on 12 V output voltage follow this procedure 1 verify if 12 V out...

Страница 99: ... are stopped Alarm cause when you start working you find seat switch open or after the main breaker is closed the seat switch remains opened for at least seat switch delay s In case of alarm follow this procedure 1 verify if seat switch is defective 2 replace control board Wrong start Eye alarm code 64 Alarm level warning main breaker is opened and pump and drive motors are stopped Alarm cause whe...

Страница 100: ...7 terminal for left drive motor encoder B channel K1 36 terminal for right drive motor encoder K1 16 terminal for left drive motor encoder 2 if correctly wired replace the encoder 3 replace control board Alarm of motor thermal probe Eye alarm code 77 for right drive motor thermal probe 78 for left drive motor thermal probe 79 for pump motor thermal probe Alarm level 7 Alarm cause Temperature diffe...

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