CESAB BT BLITZ 312 Скачать руководство пользователя страница 1 | Manualshive

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CESAB BT BLITZ 312 Скачать руководство пользователя страница 1

SERVICE MANUAL

C3E120

C4E120

C3E150

C4E150

C3E160

C4E160

C3E160L C4E160L
C3E180

C4E180

C3E180L C4E180L
C3E200

C4E200

036-0410-07

04/2005

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Содержание BT BLITZ 312

Страница 1: ...SERVICE MANUAL C3E120 C4E120 C3E150 C4E150 C3E160 C4E160 C3E160L C4E160L C3E180 C4E180 C3E180L C4E180L C3E200 C4E200 036 0410 07 04 2005...

Страница 2: ...PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALMENTE BLANCA...

Страница 3: ...ESAB S p a reserves all rights of reproduction of this handbook The text and the numbering system may not be used in other printed matter reprinted or translated whether entirely or in part without wr...

Страница 4: ...MOTORS ENGINES chapter 1000 TRANSMISSION DRIVE GEAR chapter 2000 BRAKE WHEEL chapter 3000 STEERING SYSTEM chapter 4000 ELECTRICAL SYSTEM chapter 5000 HYDRAULIC PNEUMATIC SYSTEM chapter 6000 MAST GROU...

Страница 5: ...chapter A page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER A GENERAL INFORMATION...

Страница 6: ...chapter A page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 GENERAL INFORMATION INDEX TECHNICAL DATA page3...

Страница 7: ...chapter A page 3 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 TECHNICAL DATA...

Страница 8: ...chapter A page 4 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 9: ...chapter A page 5 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 10: ...page 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALMENT...

Страница 11: ...chapter 0000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 0000 CHASSIS...

Страница 12: ...ric 036 0410 07 CHASSIS INDEX TRUCK S LAY OUT page3 PEDALS page4 DRIVE DIRECTION LEVER ON STEERING COLUMN page4 STEERINGCOLUMNPUSHBUTTONS page5 LOAD HANDLING COMMANDS page6 DASHBOARD page7 DASHBOARD C...

Страница 13: ...A Mastframe B Openingforliftingbattery C Seat D Electroniccontrolunitcompartment E Counterweight F Hydraulicvalvecommands G Controlvalvecover H Liftingjack I Liftingforkcarriage J Overhead guard K Pre...

Страница 14: ...R ON STEERING COLUMN Alternative version Direction selector lever F 1 Forward direction 0 Neutral 2 Backward direction Parking brake lever A Emergency push button H Single drive pedal G Horn push butt...

Страница 15: ...w Settingscanbeselectedpullingthepushbuttonseveraltimes Threeledswillshowtheselectedprogram as indicated at the dashboard description page item 11 P Maximum drive speed Acceleration and braking action...

Страница 16: ...OL VALVE VERSION A JOYSTICK VERSION B FINGERTIPS VERSION C Levers unit H Lifting control lever yellow cap K Tilting control lever green cap J Sideshift control lever red cap L Device control lever opt...

Страница 17: ...rakefluidlowlevelwarninglight 4 Lifting speed reduction due to flat battery 5 Presentmandevice warninglight 6 Driveleftmotortemperaturewarninglight 7 Driverightmotortemperaturewarninglight 8 Liftingmo...

Страница 18: ...ing light The pilot light comes ON when the driver leaves the driving seat without switching OFF the truck under these conditions the traction and the lifting movement are disabled 6 Drive left motor...

Страница 19: ...SERIAL N DRAW BAR PULL 1h SERVICE MASS BATTERY MASS MANUFACT YEAR TENSION kW kg N Without Battery kg kg min kg max V CESAB LDT Bevan Way Smethwick Warley West Midla 1ds B66 1BZ A CAPACITY PLATE ATTAC...

Страница 20: ...gequipmentsmustbeusedtolifttheforklifttruckwith overhead guard standard N 2 slings A in accordance with DIN B2N UNI 9531 minimumlength9mandcapacityof2800kg LIFTING OF THE FORKLIFT TRUCK WITH CABIN The...

Страница 21: ...chapter 1000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 1000 MOTORS ENGINES...

Страница 22: ...chapter 1000 page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MOTORS ENGINES INDEX ELECTRICAL MOTORS CHARACTERISTICS page3 ELECTRICAL MOTORS ARRANGEMENT page5...

Страница 23: ...tric 036 0410 07 MANUFACTURER SAUER DANFOSS SCHABM LLER POWER 4 5 KW f 80 Hz POLES NUMBER 4 FREQUENCY 80 Hz NOMINALVOLTAGE 27 V AC POWER FACTOR cos f 0 915 SERVICE S2 60 INSULATION CLASS F R P M 2295...

Страница 24: ...E MANUAL Electric 036 0410 07 MANUFACTURER SAUER DANFOSS SCHABM LLER POWER 10 KW POLES NUMBER 4 FREQUENCY 80 Hz NOMINALVOLTAGE 28 V AC POWER FACTOR cos f 0 83 SERVICE S3 26 INSULATION CLASS F R P M 23...

Страница 25: ...chapter 1000 page 5 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 ELECTRICAL MOTORS ARRANGEMENT TRACTION MOTORS LIFTING MOTOR...

Страница 26: ...00 page 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Страница 27: ...chapter 2000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 2000 TRANSMISSION DRIVE GEAR...

Страница 28: ...hapter 2000 page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 TRANSMISSION DRIVE GEAR INDEX REDUCTION GEAR VIEW page 3 REDUCTION GEAR MAINTENANCE page 4 REPLACEMENT OF THE REDUCTION GEAR page 5...

Страница 29: ...chapter 2000 page 3 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 REDUCTION GEAR VIEW Reduction ratio of the reduction gear 1 18 2...

Страница 30: ...afterrunningthetruckforafewminutes to warm them up For a correct operation of the reduction gears do not fill with more oil than necessary PLUG FOR OIL LEVEL CHECK AND TOPPING UP OIL DRAIN PLUG REDUCT...

Страница 31: ...GEAR Liftthetruck Removethewheelfromthereductiongear Removethecablefortheparkingbrakeand thetubefortheoilbrakesystem Putashimundertheelectricmotor Tubefortheoilbrakesystem Cablefortheparkingbrake Remo...

Страница 32: ...00 page 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Страница 33: ...chapter 3000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 3000 BRAKES WHEELS...

Страница 34: ...t A C SERVICE MANUAL Electric 036 0410 07 BRAKES WHEELS INDEX SERVICE BRAKES page3 PARKING BRAKE page4 BRAKE OPERATING SYSTEM DESCRIPTION page5 BRAKE DISKS page6 REPLACEMENT OF THE WHEEL BRAKE CYLIND...

Страница 35: ...RAKE OIL TANK SERVICE BRAKE Oil bath brakes are inside the reduction gear box and use the same oil SERVICE BRAKE SYSTEM DIAGRAM M Reduction gears and braking unit N Parking brake command O Bleedingscr...

Страница 36: ...ck the parking brake travel which should correspond to 3 notches If necessary adjust the appropriate screws X check the condition of the stay bolt cables and the anchors The hand parking brake operate...

Страница 37: ...surface ofthereductiongear movesthewheelbrakecylinder Thisturnsaroundthefulcrumandpressesagainstthe brakepinthatpushesthepad Thepadpushesthemainpistonthatclosesthebrakedisks obtainingthe brakingeffect...

Страница 38: ...thatotherwisewouldturnwiththebrakedisks Thepinionturnsongeargroup2wheregeargroup1 andthebrakedisksarefixed Thebrakediskshaveatootedshapeontheexternal diameterinordertoblockthemonthereductiongear body...

Страница 39: ...e cylinder D it is possible to proceed in two different ways 1st WAY 1 Liftthetruck 2 RemovecableEandhoseF 3 RemovewheelA 4 Replacethethreescrewsusedforfixingthe reductiongeartotheelectricmotorwiththr...

Страница 40: ...EandhoseF 3 RemovewheelA seepreviouspage 4 Removethescrewsthatfixedthegearboxtothe frame 5 FixbarG of 40cm intotheupmostholeinthe frameusingitasaguidetokeepthereductiongear 5 10cm offtheframe therefor...

Страница 41: ...30 mm TIGHTENINGTORQUES STANDARD TYRES 14 daNm 14 daNm 2 3 daNm 13 5 daNm 5 daNm 5 daNm 2 2 daNm 4 9 daNm 0 8 1 2 daNm 20 daNm WHEEL TORQUE steering wheels driving wheels DRIVE UNIT TORQUE electric m...

Страница 42: ...0 page 10 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Страница 43: ...chapter 4000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 4000 STEERING SYSTEM...

Страница 44: ...apter 4000 page 2 STEERING SYSTEM INDEX STEERING CONTROL page3 POWER STEERING HYDRAULIC DIAGRAM page4 POWER STEERING HYDRAULIC LAYOUT page5 POWER STEERING SETTING page6 STEERING AXLE 3 WHEELS page8 ST...

Страница 45: ...a volume of oil and sends it into the steering cylinder Every 1000 hours checktheentiresystemtoidentifyanyleak anyinterventionmustbecarriedoutwithout pressure in the system Every 5000 working hours r...

Страница 46: ...1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 chapter 4000 page 4 FILTER ORBITROL A POWER STEERING HYDRAULIC DIAGRAM STEERING CYLINDER A PUMP TO THE CONTROL VALVES P R I O R I T Y VALVE...

Страница 47: ...0 page 5 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 3 AND 4 WHEELS VERSION L R L R 3 WHEELS L 4 WHEELS L R Drain Oilinlet Load sensor and Valve for the maximum pressure ORBITROL LOAD SENSOR R L...

Страница 48: ...07 chapter 4000 page 6 The same pressure is used for both versions 3 and 4 wheels Adjusting Screwin highterpressure Screwout lowerpressure POWER STEERING SETTING Inordertosetthepressureremovethecapand...

Страница 49: ...lwaysreachestheloadsensoronthepriorityvalve OnthepriorityvalvethereisachannelthatconnectLStoPPinordertoguaranteealwaysaflowofoilforaprompt replayofthesteering Theincreasingofthepressureonthesystemcanc...

Страница 50: ...410 07 chapter 4000 page 8 3 WHEEL STEERING AXLE Control of steering unit The steering unit D does not require greasing or lubrication Every 1000 hours check and if necessary adjust the wheel hub bear...

Страница 51: ...check and if it is necessary adjust the wheel hub bearings Max steering angle internal wheel B 80 End stroke setting adjustment make the cylinder reach the internal end stroke then operate on the spe...

Страница 52: ...ove cap 1 fasten the nut with a torque setting of 6 dNm turn the hub of 2 3 turns in both senses unfasten nut 3 and retighten with a 2 1 daNm torque check that the wheels slide correctly max rolling f...

Страница 53: ...chapter 5000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 5000 ELECTRIC ELECTRONIC SYSTEM...

Страница 54: ...page13 TRACTIONELECTRICBLOCKDIAGRAM page15 STEERING SYSTEM page16 CONNECTION OF THEAUXILIARY CIRCUIT LIFTING page18 LIFTING ELECTRIC BLOCK DIAGRAM page20 ELECTRICALCIRCUITCONNECTIONTRACTION AND LIFTIN...

Страница 55: ...the battery while it is being charged Do not lean metal tools on the battery while under charge Never repair the battery while under charge Check that during the charging phase the electrolyte temper...

Страница 56: ...ES NUMBER 4 FREQUENCY 80 Hz NOMINALVOLTAGE 28 V AC POWER FACTOR cos f 0 83 SERVICE S3 26 INSULATION CLASS F R P M 2314 rpm PUMPCAPACITY 11l m LIFTING MOTOR MANIFACTURER SAUER DANFOSS SCHABM LLER POWER...

Страница 57: ...e view Encoder Motor signals connector The encoder function is to generate motors feed back signals to thelogicunitis motorrunning R P M rotationdirection Itis built in the bearing placed on the oppos...

Страница 58: ...evice with the two longer screws Press on the sensor bearing with the screw Pos 11 Be shure to press only the inner ring of the sensor bearing Put the connection of the temperature sensor in the 9 pin...

Страница 59: ...ERATOR PEDAL Set the potentiometer Position the tester set in OHM between the green and the red wire Set the potentiometer from 5 13 to 6 27 KOHM pedal released from 1 087 to 1 32 KOHM pedal pressed A...

Страница 60: ...10Amp 2 F2 horn fuse 5 Amp 3 F3 DC DC converter fuse 20Amp 4 Diode LIGHTCARD CONTACTORS 24 VOLT FUSES This box is located under the dashboard and it is used for all the 24 V fuses only 5 Connectorfor...

Страница 61: ...73042 360W 2773043 720W 2773044 960W EQUIPMENT CONSUPTION OF THE EQUIPMENT CONNECTED TO 24 V STD MACHINE 86 W REVERCEACUSTIC WARNING 05 W FLASH BEACON 03 W ROTARYBEACON 70 W WIPER 100W 2 WORKING LIGHT...

Страница 62: ...z Externaltemperaturerange 30 C 40 C Maximuminvertertemperature atfullpower 75 C ELECTRONIC PANELS TECHNICAL SPECIFICATIONS Inverter for pairs ofAC asynchronous 3 phase motors Regenerativebrakingfunct...

Страница 63: ...tfivealarmswithrelativehour meterandtemperaturedisplayedontheconsole Testfunctionwithinconsoleforcheckingmainparameters Hydraulicsteeringfunction 1 tractioninverter thetractioninvertersendsa hydraulic...

Страница 64: ...eforecarryingoutanyarc weldingonthetrucks disconnectthebatteryandshort circuittheunitbetween positive andnegative PROTECTIONS ConnectionErrors Allinputsareprotectedagainstconnectionerrors Thermalprote...

Страница 65: ...chapter 5000 page 13 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CONNECTION OF THE AUXILIARY CIRCUIT DUAL AC2 UNIT TRACTION CABLES ASSEMBLY INSTRUCTIONS...

Страница 66: ...der power supply C3 KEY Connected to Batt through the series costituited by the key switch the protection diode and a 10A fuse C4 CM Common of FW REV HB PB SEAT ENABLE microswitches C5 SEAT Seatpresen...

Страница 67: ...external side Type of PINS used AMP770854 3 ENABLING OF C10 SPEED REDUCTION By connecting a wire between the pin C10 and the positive Vb from the seat switch it is possible to disable the reduction of...

Страница 68: ...point B 3 WHEELS 4 WHEELS LEFT RIGHT STEERING POTENTIOMETER 4 WHEELS Whenthepotentiometerreachesthemaximum strokethetractionlogicunitcontrolsthemotor inordertostoponemotorcompletelyaccording to the d...

Страница 69: ...hthand 80 2 5Vwithstraightwheel 3 8Vwithmax steeringanglelefthand 58 Black 0 V 3WHEELS Steering potentiometer 3wheels Yellow 12 V Green 0 7Vwithmax steeringanglerighthand 90 2 5Vwithstraightwheel 4 3V...

Страница 70: ...chapter 5000 page 18 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CONNECTION OF THE ELECTRIC CIRCUIT AC2 UNIT LIFTING...

Страница 71: ...encoderpowersupply D3 LiftingmotorencoderphaseA D5 LiftingmotorencoderphaseB E4 CM Common of LIFT ENABLE 1st SPEED 2nd SPEED 3rd SPEED 4th SPEED HYDRO SR microswitches E12 HYDRO REQ Inputforhydraulics...

Страница 72: ...chapter 5000 page 20 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 LIFTING ELECTRIC BLOCK DIAGRAM CONTROL LOGIC KEY POTENTIOMETER MICROSWITCHES PROGRAMMING CONSOLE KEY...

Страница 73: ...chapter 5000 page 21 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 SEGNALI CAN BUS 355 A FUSE 300 A FUSE ELECTRICAL CIRCUIT CONNECTION DUAL AC2 TRACTION UNIT AND AC2 LIFTING UNIT...

Страница 74: ...2 ADJUSTBATTERY 3 STEERINGPOTENTIOMETER 4 Vacc PROGRAM 5 STEERTABLE for all references see MAPS FOR USING THE CONSOLE TRACTION in the following pages NECESSARY SETTING AFTER REPLACING THE LIFTING LOG...

Страница 75: ...CTION 4 WIRES ANALOGIC CONNECTION SEVERAL WIRES see legend at the next page CAN BUS AND ONBOARD COMMANDS DIAGRAM ARM COMMANDS ARM CARD LIGHT CARD I O CARD DASHBOARD TRACTION ON BOARD COMMAND LIFTING O...

Страница 76: ...ward switch horn switch liftingfingertip tiltfingertip fingertip sideshiftfingertip 4 way fingertip opt 5 way fingertip opt ARM CARD LIGHT CARD I O CARD AC2 liftinglogicunit DUAL AC2 tractionlogicunit...

Страница 77: ...hipslocatedindifferentpartsofthetruck Oneofthegreatestadvantagesisthatallmicrochipscancommunicatewitheachotherandcontrolfunctionswhich workcontemporaneouslyinashorttime TheCANtransfersalldatagivingpri...

Страница 78: ...o inform the card about the potentiometers type used the followingsettingisrequired JOYSTICKS all the dip switches layout pos 9 are setted on OFF position FINGERTIPS the dip switch n 2 layout pos 9 is...

Страница 79: ...chapter 5000 page 27 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 FINGERTIP PB1 Horn pushbutton PB2 Backward pushbutton PB3 Forward pushbutton JOYSTICK PB2 PB3 PB1...

Страница 80: ...lied to all the other cards FUNCTIONS Controllingofthebacklights The light card permits the automatic control of the back lights according to the operation of the traction motors Thecardiscontrolledby...

Страница 81: ...4Volt input for the converter 24 5Volt located on the card Connector 2 It is a connector to 6 Pins PIN 1 CAN L PIN 2 CAN H PIN 3 GND PIN 4 Not used PIN 5 Out put 24Volt PIN 6 Not used Connector 3 It i...

Страница 82: ...n motorstemperature sensors Connector J8 J98 BV feedingforMhyriologicunit Connector J10 J40 for the mechanic distributor in this case the voltage on the microis5volt Connector J13 J139 CAN BUS signals...

Страница 83: ...the electro control valve group The Mhyrio card receivesthedigitalinputsfromtheCANanditconvertsthem inanalogicsignalstocontrolthesolenoidvalveswith In the front it has three connectors connector 1 is...

Страница 84: ...pter 5000 page 32 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 POTENTIOMETER CONFIGURATION ARM COMMAND JOYSTICKS FINGERTIPS VERSION BACKWARD PUSHBUTTON PB2 FORWARD PUSHBUTTON PB3 HORN PUSHBUTTON...

Страница 85: ...e amarillo H grigio grey grau gris gris M marrone brown braun marron casta o N nero black schwarz noir negro S rosa pink pink rose rosa R rosso red rot rouge rojo V verde green gr n vert verde Z viola...

Страница 86: ...tentiometercanbecarriedoutintwodifferentways Values optained by the console Yellow 1 6 V Green 0 6 1 6 V with pedal pressed Black 0 6 V There is a difference between the values obtained in the two met...

Страница 87: ...nedbythemultimeter 137 4 6 V 135 1 1 4 6V withliftingleverpulled 136 1 1 V LIFTING POTENTIOMETER CONFIGURATION CONTROL VALVE VERSION There is a difference between the values obtained in the two method...

Страница 88: ...chapter 5000 page 36 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CONSOLE FUNCTION GENERAL DESCRIPTION...

Страница 89: ...tedfromthekeyboard RESTOREPARAMETER ItmakesitpossibletoprogramachopperwiththeparameterscontainedinaprogramgeneratedbyaSAVE ALARMS Theconsolefeaturesthepossibilitytoreadthelastfivealarmmessagesstoredin...

Страница 90: ...chapter 5000 page 38 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MHYRIO UNIT TRACTION UNIT LIFTING UNIT Theconnectionhastobemadewiththemachineatrest CONSOLE CONNECTION...

Страница 91: ...otorslowsdown MAX SPEED FORWARD determinesthemaximumspeedinforwarddirection MAXSPEEDBACKWARD determinesthemaximumspeedinbackwarddirection CUTBACKSPEED1 speedreductionwhenthecutbackswitchisactive Turtl...

Страница 92: ...chapter 5000 page 40 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PARAMETER CHANGE DUALAC2 SLAVE TRACTION UNIT NOTAVAILABLE...

Страница 93: ...e V E4 inputE13 ifE13isopentheCutbackspeedison istheE13isclosedtheCutbackspeedisoff CUTBACKSPEED2 speedreductionwhenthecutbackswitchisactive V E4 inputE14 ifE14isopentheCutbackspeedisoff ifE14isclosed...

Страница 94: ...sideshiftleftsolenoidvalve MIN EVP7 Minvoltageonthe4thwayforwardsolenoidvalve MAX EVP7 Max voltage on the 4th way backward solenoid valve MIN EVP8 Minvoltageonthe5thwayforwardsolenoidvalve MAX EVP8 Ma...

Страница 95: ...0 t A C SERVICE MANUAL Electric 036 0410 07 PARAMETER CHANGE DASHBOARD UNIT HOURS COUNTER RUNNING KEY key on lifting unit working hours counter switch DISPLAYON OFF displaiedspeedswitch SPEED RATIO 0...

Страница 96: ...the ratio of the two speeds SEATSWITCH stateoftheSeatMicroswitchdigitalinput ON VB active input closed switch OFF GND non active input open switch FORWARD SWITCH state of the Forward direction digital...

Страница 97: ...mperaturemeasuredonthealuminumheatsinkholdingtheMOSFET devices SEATSWITCH stateoftheSeatMicroswitchdigitalinput ON VB active input closed switch OFF GND non active input open switch FORWARD SWITCH sta...

Страница 98: ...ratorpotentiometer swiper CPOT Thevoltage levelisshownontheLeftHandSideoftheConsoleDisplayandthe valueinpercentageisshownontheRightHandSide LIFTINGSWITCH stateoftheliftingswitch 1STSPEEDSWITCH stateof...

Страница 99: ...eringvalve CAN POT GROUP 2 group 2 proportional valves current setpoint received by the canbus 0 100 of the current supplied to the tilt box CAN POT GROUP 3 group 3 proportional valves current setpoin...

Страница 100: ...chapter 5000 page 48 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 TESTER MHYRIO UNIT NOTAVAILABLE...

Страница 101: ...chapter 5000 page 49 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 TESTER DASHBOARD UNIT NOTAVAILABLE...

Страница 102: ...overvoltage protection Logic defect Replace the tractionunit c The alarm appears also when one or more phases of the right traction motor doesn t present a correct insulation Check the motor insulatio...

Страница 103: ...current of both inverters is reduced to zero If the alarm is signalled whenthecontrolleriscold Replacethetractionunit 12 MOTOR Thiswarningissignalledifthesensorofthe rightmotor isopened digital TEMPE...

Страница 104: ...an that the problemislinkedtotheencoder Anyofthefollowingcomponentsmay haveafault Thelogicinternalcircuit The encoder Thewiring Youmayuseadigitaloranaloguemultemetertodeterminewherethe problem is loca...

Страница 105: ...icunithasgeneratedtheproblem 4TheMasterlogicunitreceivestheinformationscamingfromtheSlave logicunitwithatimelagfault The fault can be caused by interference on the can bus Check the CAN BUS comunicati...

Страница 106: ...defined by the Set steer min and the Set steer max parameters In the first case repeat the steering potentiometer acquisition In the second case check the steering potentiometer and its wiring again I...

Страница 107: ...vervoltage protection Logic defect Replace the tractionunit c The alarm appears also when one or more phases of the left traction motor doesn t present a correct insulation Check the motor insulation...

Страница 108: ...current of both inverters is reduced to zero If the alarm is signalled whenthecontrolleriscold Replacethetractionunit 72 MOTOR Thiswarningissignalledifthesensorofthe rightmotor isopened digital TEMPE...

Страница 109: ...an that the problemislinkedtotheencoder Anyofthefollowingcomponentsmay haveafault Thelogicinternalcircuit The encoder Thewiring Youmayuseadigitaloranaloguemultemetertodeterminewherethe problem is loca...

Страница 110: ...eratedtheproblem 4TheSlavelogicunitreceivestheinformationscamingfromtheMaster logicunitwithatimelagfault The fault can be caused by interference on the can bus Check the CAN BUS comunication brokenlog...

Страница 111: ...isappears remember thatthe parameters previously stored have been deleted and replaced by the default values seeadjustintables 33 LOGIC FAILURE 3 Logicdefect Replacetheliftingunit 34 LOGIC FAILURE 2 F...

Страница 112: ...rrent sensor Replacetheliftingunit 40 CAPACITOR When the key is switch ON the inverter tries to charge the capacitor CHARGE through a power resistance and check if the capitor are charged within a tim...

Страница 113: ...er connector If the problem persists to replace the encoder sensor CODE ALARM DESCRIPTION 43 ENCODER ERROR Encoderfailure This alarm indicates that the encoder information is not correct or is not pre...

Страница 114: ...logicunithasgeneratedtheproblem 4TheLiftinglogicunitreceivestheinformationscamingfromtheSlave logicunitwithatimelagfault The fault can be caused by interference on the can bus Check the CAN BUS comuni...

Страница 115: ...cunitwithatimelagfault The fault can be caused by interference on the CAN BUS Check the CAN BUS comunication false contact Check the connections of CAN H and CAN L wires brokenlogic ReplacetheMhyriolo...

Страница 116: ...mMhyriounit b4 thedashboarddoesn treceiveinformationfromlightscard Combinations of the above alarms as follows d3 d1 d2 d5 d1 d4 d6 d2 d4 d7 d1 d2 d4 dA d2 d8 dB d1 d2 d8 dC d4 d8 dD d1 d4 d8 dE d2 d4...

Страница 117: ...t used C7 Not used C8 Not used I O CARD NOT SHOWN BY THE CONSOLE 81 TRACTION Incorrect start sequence control valve version Check INCORRECTSTART forward backward microswitches and relevant cables park...

Страница 118: ...0 90 100 CUTBACKSPEED MAXSPEED 10 20 30 40 50 60 70 80 90 100 FREQUENCYCREEP HZ 0 3 0 6 0 9 1 2 1 5 1 8 2 1 2 4 2 7 3 0 MAXIMUMCURRENT IMAX 47 53 58 64 70 76 82 88 94 100 ACC SMOOTH INV SMOOTH STOPSMO...

Страница 119: ...esoftware therealrampcouldchangeaccordingtothemotorparameterssettingand obviously accordingtotheload Adjustablewitha1Hzresolutioninthe0to200Hzrange PROGRAMMEDLEVEL PARAMETER UNIT 0 1 2 3 4 5 6 7 8 9 A...

Страница 120: ...0 page 68 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Страница 121: ...chapter 5000 page 69 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAPS FOR USING THE CONSOLE TRACTION...

Страница 122: ...ectric 036 0410 07 NECESSARYSETTINGAFTER REPLACINGTHETRACTION LOGIC UNIT 1 TRACTIONACQUISITION seefollowingpages 2 ADJUSTBATTERY seefollowingpages 3 STEERINGPOTENTIOMETER seefollowingpages 4 Vacc PROG...

Страница 123: ...n the map here below Press ENTER Press ROLLand PARAM together Incasetheconsoleisconnectedtotheliftinglogicunit Itistheconnectionnumberoftheliftinglogicunit Press SET and select the connection number o...

Страница 124: ...T BATTERY TYPE 48 72 80 96 ADJUST BATTERY V MAX STEER RIGHT V MAX STEER LEFT V SET STEER 0 POS 2 5V SET STEER RIGHT V SET STEER LEFT V THROTTLE 0 ZONE THROTTLE X ZONE THROTTLE Y ZONE ADJUSTMENT 02 1 9...

Страница 125: ...RENT RMS A TEMPERATURE C SEAT SWITCH ON OFF FORW SWITCH ON OFF BACK SWITCH ON OFF ENABLE SWITCH ON OFF VOLTAGE BOOSTER BATTERY VOLTAGE V SET BATTERY TYPE 48 72 80 96 ADJUST BATTERY V AUX OUTPUT VOLT V...

Страница 126: ...ompletely BRAKECUTBACK determinesthedecelerationrampwhenthespeedreductioninput becomes activeandthemotorslowsdown MAX SPEED FORWARD determinesthemaximumspeedinforwarddirection MAXSPEEDBACKWARD determi...

Страница 127: ...ing ROLL Press OUT to escape Press ENTER Press ROLL MOTOR VOLTAGE FREQUENCY ENCODER SLIPVALUE CURRENT RMS TEMPERATURE TEMPERATURE 1 TEMPERATURE 2 ACCELERATOR STEERANGLE BRAKE PEDAL POTI INTERNALWHEELC...

Страница 128: ...2M2B C Program version stored MAIN MENU PARAM CHANGE MAIN MENU TESTER MAIN MENU SAVEPARAM Press ROLL Press ROLL Press ENTER Press ENTER Press ENTER Press ENTER MAIN MENU SAVEPARAM Press OUT to escape...

Страница 129: ...2B C Program version stored Press ROLL to select the box 0 31 where you want to save the program Press ROLL Press ROLL MAIN MENU RESTOREPARAM Press OUT to escape Press ENTER toconfirm STORING RUN ALL...

Страница 130: ...ARM Press ENTER MAIN MENU ALARM NONE 00000h 00 0 C Press ENTER hourmeter no alarms temperature max 5 alarms stored no alarms stored Press OUT Press ENTER ALARM CODE 23h 2 25 C CLEARLOGBOOK YES ENTERNO...

Страница 131: ...reaching the programVACC These are the old parameters stored Press ENTER Reset of the parameters Select the forward direction Presstheacceleratorpedalslowlyuntilthemaximumstroke Press OUT keeping the...

Страница 132: ...corresponds to the min voltage 2 Select MAX STEER LEFT pressing ENTER to delete the old parameter with the wheels turned completelyleftandstoretheparameterpressing OUTandthenENTERtoconfirm Thisvalue...

Страница 133: ...IG MENU SETOPTIONS DA2M2B C CE1 13 48V 280A 00000 HOUR COUNTER RUNNING KEY ON BATTERYCHECK ON OFF HYDRO KEY ON ON OFF STOP ON RAMP ON OFF AUX INPUT 1 EXCLUSIVEHYDRO OPTION 1 CUT BACK SPEED PEDALBRAKIN...

Страница 134: ...PEDAL BRAKING ANALOG DIGITAL SETTEMPERATURE ANALOG DIGITAL NONE STEERTABLE OPTION 1 OPTION 2 Select STOPON RAMPand change the status using PARAM or SET ON ACTIV ATED OFF DEACTIV ATED and store the par...

Страница 135: ...k with this configuration SLIP CONTROL MASTER connection number 3 Select SLIP CONTROL ON or OFF and store the parameter pressing OUT and then ENTER to confirm After that switch the truck OFF and ON CO...

Страница 136: ...the truck on In order to have a pricise measure of the battery voltage you have to set the parameterADJUSTBATTERY with the same value read directly on the battery by a multimeter Note that the logic...

Страница 137: ...of the full charge With highter value there is not the rearm of the indicator It means that it does not come back to 100 The battery indicator is adjustable by the console in order to change the ther...

Страница 138: ...URE ANALOG DIGITAL NONE STEERTABLE OPTION 1 OPTION 2 Press ENTER Press OUT Press ENTER Press ROLL Press ENTER SET POT BRK MIN V SET POT BRK MAX V SETBATTERYTYPE 48 ADJUSTBATTERY V MAXSTEERRIGHT V MAXS...

Страница 139: ...ENT 02 adjustment of the lowest value of charge of the battery ADJUSTMENT 01 adjustment of the reset value of the battery indicator ADJUSTMENT 01 ADJUSTMENT 02 0 45 70 1 45 98 2 46 22 3 46 51 4 46 75...

Страница 140: ...re the following functions SUBMENU SET OPTIONS Not available SUBMENU ADJUSTMENT 1 SET BATTERY TYPE selects the battery nominal voltage 2 ADJUST BATTERY fine adjustment of the battery voltage measured...

Страница 141: ...Press ENTER Press ENTER Press ROLL Scroll the parameters using ROLL Press OUT to escape MAIN MENU PARAM CHANGE MAIN MENU TESTER MOTOR VOLTAGE FREQUENCY ENCODER SLIPVALUE CURRENT RMS TEMPERATURE SEAT...

Страница 142: ...where you want to save the program SELECT Mod 00 Program number FREE DA2S2B C Program version stored MAIN MENU SAVEPARAM Press ENTER SELECTMod00 FREE Press ENTER READING RUN ALL PARAMETERS MAIN MENU...

Страница 143: ...UN ALL PARAMETERS MAIN MENU RESTOREPARAM Press ENTER Press ROLL Press ENTER SELECT Mod 00 Program number FREE DA2S2B C Program version stored Press ROLL to select the box 0 31 where you want to save t...

Страница 144: ...RM Press ENTER MAIN MENU ALARM NONE 00000h 00 0 C Press ENTER hourmeter no alarms temperature max 5 alarms stored no alarms stored Press OUT Press ENTER ALARM CODE 23h 2 25 C AREYOUSURE YES ENTER NO O...

Страница 145: ...chapter 5000 page 93 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAIN MENU PROGRAM VACC SLAVE connection number 4 It must be carried out in the MASTER traction logic unit...

Страница 146: ...3 Connect the console to the TRACTIONlogic unit Press ROLLand PARAM together Press ENTER 0withdoublepedalversion 1withhandinversorversion 2withinversoronthearm Press OUT Press ENTER to confirm Press R...

Страница 147: ...chapter 5000 page 95 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAPS FOR USING THE CONSOLE LIFTING...

Страница 148: ...0 page 96 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 NECESSARYSETTINGAFTER REPLACINGTHE LIFTINGLOGIC UNIT 1 LIFTINGACQUSITION seefollowingpages 2 VaccPROGRAM withmechanicdistributoronly seefoll...

Страница 149: ...ase the console is connected to the traction logic unit Itistheconnectionnumberofthetractionlogicunit CONNECTION NUMBERS 3 TRACTION MASTER 4 TRACTION SLAVE 5 PUMP 9 MHYRIO 11 DASHBOARD Press ROLLand P...

Страница 150: ...HzCUTBACK SPEED CUTBACK SPEED 2 1ST SPEED FINE Hz 2ND SPEED FINE Hz 3RD SPEED FINE Hz 4TH SPEED FINE Hz AUX FUNCTION 1 HYD SPEED FINE Hz MAXIMUM CURRENT A AUXILIARY TIME sec MOTOR VOLTAGE FREQUENCY Hz...

Страница 151: ...losed CUTBACKSPEED speedreductionwhenthecutbackswitchisactive V E4 inputE13 ifE13isopentheCutbackspeedison istheE13isclosedtheCutbackspeedisoff CUTBACKSPEED2 speedreductionwhenthecutbackswitchisactive...

Страница 152: ...ENTER Press ROLL MAIN MENU PARAM CHANGE MAIN MENU TESTER AC2P2BD CE 1 06 48V 350A 00000 MOTORVOLTAGE FREQUENCY ENCODER SLIPVALUE CURRENT RMS TEMPERATURE MOTORTEMPERATURE SEATSWITCH ACCELERATOR LIFTIN...

Страница 153: ...P2B D Program version stored Press ROLL Press ROLL Press ENTER Press ENTER Press ENTER Press ENTER Press OUT to escape Press ENTER toconfirm MAIN MENU PARAM CHANGE MAIN MENU TESTER MAIN MENU SAVEPARAM...

Страница 154: ...B D Program version stored Press ROLL to select the box 0 31 where you want to save the program MAIN MENU RESTOREPARAM Press OUT to escape Press ENTER toconfirm STORING RUN ALL PARAMETERS MAIN MENU RE...

Страница 155: ...TER hourmeter no alarms temperature max 5 alarms stored no alarms stored Press OUT Press ENTER AREYOUSURE YES ENTER NO OUT LOGBOOKCLEARED PRESS OUT Press OUT to escape Press ENTER toconfirm Press OUT...

Страница 156: ...the programVACC These are the old parameters stored Press ENTER Reset of the parameters Pulltheliftingleverslowlyuntilthemaximunstroke Press OUT keeping the lever pulled Press ENTER to confirm and rel...

Страница 157: ...t work with this configuration SLIP CONTROL PUMP connection number 5 Select SLIP CONTROL ON or OFF and store the parameter pressing OUT and then ENTER to confirm After that switch the truck OFF and ON...

Страница 158: ...N 1 CUT BACK SPEED PEDAL BRAKING ANALOG DIGITAL SETTEMPERATURE ANALOG DIGITAL NONE STEERTABLE OPTION 1 OPTION 2 Press ENTER Press OUT Press ENTER Press ROLL Press ENTER SET BATTERYTYPE 48 ADJUST BATTE...

Страница 159: ...ENTER Press ROLL withelectricdistributor withmechanicdistributor Connect the console to theLIFTINGlogic unit Press OUT Press ENTER to confirm LIFTING ACQUISITION Lifting connection number 5 CONFIG MEN...

Страница 160: ...0 page 108 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALM...

Страница 161: ...chapter 5000 page 109 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAPS FOR USING THE CONSOLE MHIRIO...

Страница 162: ...0 page 110 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALM...

Страница 163: ...CRIPTION OF THE CONSOLE STANDARD MENU OF THE MHYRIO UNIT Press ROLLand PARAM together Press SET and select the connection number of the Mhyrio logic unit Press ENTER Press ROLL OUT and SET together Co...

Страница 164: ...al EVP2 TYPE Analogic digital EVP3 TYPE Analogic digital EVP4 TYPE Analogic digital EVP5 TYPE Analogic digital EVP6 TYPE Analogic digital EVP7 TYPE Analogic digital EVP8 TYPE Analogic digital PROGRAM...

Страница 165: ...ftsolenoidvalve MAX EVP6 Maxvoltageonthesideshiftleftsolenoidvalve MIN EVP7 Minvoltageonthe4thwayforwardsolenoidvalve MAX EVP7 Max voltage on the 4th way backward solenoid valve MIN EVP8 Minvoltageont...

Страница 166: ...ber 9 Press ENTER Press ROLL BATTERYVOLTAGE V VALVESSUPPLY V CAN POT EVP CAN POT GROUP 1 CAN POT GROUP 2 CAN POT GROUP 3 CAN POT GROUP 4 INPUT 0 ON OFF INPUT 1 ON OFF INPUT 2 ON OFF ANALOG INPUT 1 0 2...

Страница 167: ...EE MHYCB Program version stored Press ENTER SELECTMod00 FREE Press ENTER READING RUN ALL PARAMETERS MAIN MENU SAVEPARAM Press ENTER Press OUT to escape Press ENTER toconfirm READING RUN ALL PARAMETERS...

Страница 168: ...s ROLL to Select the box 0 31 where you want to save the program Press ROLL Press ENTER Press ENTER Press ROLL Press ROLL MAIN MENU RESTOREPARAM MAIN MENU RESTOREPARAM STORING RUN ALL PARAMETERS Press...

Страница 169: ...ALARM Press ENTER MAIN MENU ALARM NONE 00000h 00 0 C Press ENTER hourmeter no alarms temperature max 5 alarms stored no alarms stored Press OUT Press ENTER ALARM CODE 23h 2 25 C CLEARLOGBOOK YES ENTER...

Страница 170: ...chapter 5000 page 118 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAIN MENU PROGRAM VACC Mhyrio connection number 9 Not available...

Страница 171: ...chapter 5000 page 119 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAPS FOR USING THE CONSOLE DASHBOARD...

Страница 172: ...0 page 120 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALM...

Страница 173: ...ted to the traction logic unit Itistheconnectionnumberofthetractionlogicunit CONNECTION NUMBERS 3 TRACTION MASTER 4 TRACTION SLAVE 5 PUMP 9 MHYRIO 11 DASHBOARD Press ROLLand PARAM together Press ENTER...

Страница 174: ...e parameter HOURS COUNTER is switched in KEY ON option the hourglass will start to blink whenever the ignition key will be tourned on key workhours count If the parameter DISPLAYSPEED is switched ON o...

Страница 175: ...chapter 5000 page 123 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 WIRING DIAGRAMS...

Страница 176: ...chapter 5000 page 124 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 177: ...chapter 5000 page 125 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 178: ...chapter 5000 page 126 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 179: ...chapter 5000 page 127 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 180: ...chapter 5000 page 128 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 181: ...chapter 5000 page 129 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 182: ...chapter 5000 page 130 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 183: ...chapter 5000 page 131 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 184: ...chapter 5000 page 132 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Страница 185: ...chapter 6000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 6000 HYDRAULIC PNEUMATIC SYSTEM...

Страница 186: ...Electric 036 0410 07 HYDRAULIC PNEUMATIC SYSTEM INDEX CONTROL VALVE SYSTEM CONTROL VALVE VERSION page3 CONTROL VALVE SYSTEM JOYSTICKS FINGERTIPS VERSION page9 POWER STEERING HYDRAULIC DIAGRAM page13 O...

Страница 187: ...chapter 6000 page 3 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 HYDRAULIC DIAGRAM Control valve version ORBITROL LIFTING STEERIG AXLE TILTING SIDESHIFT...

Страница 188: ...5 Bar CONTROL VALVE HYDRAULIC SYSTEM Control valve version 3 AND 4 WHEELS Manometerconnection Loweringvalve Priorityvalve Drainhose Hydraulicoiltank AGIP ARNICA 46 20litres Thecorrectpositionofthevalv...

Страница 189: ...POINT FOR HYDRAULIC PRESSURE CONTROL screw in to increase pressure screw out to decrease pressure HYDRAULIC CONTROL VALVES Control valve version Sideshift max pressure valve Lifting max pressure valv...

Страница 190: ...age 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CONTROL VALVE 4th way Lifting Sideshift Tilting Sideshift max pressure valve Tilting max pressure valve 4th way max pressure valve Lifting max p...

Страница 191: ...It corresponds to the maximum load of the machine at maximum load FFL Full free loft mast TV Total visibility mast m sec Lifting speed min 0 30 m sec it means 3 3 sec to cover 1 meter max 0 50 m sec i...

Страница 192: ...ORMANCE Here below the table with the performance of a STD machine Q1 It corresponds to the maximum load of the machine at 3mt See capacity plate Exercise It means mast in movement End stroke It corre...

Страница 193: ...chapter 6000 page 9 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 HYDRAULIC DIAGRAM Joysticks fingertips version LIFTING STEERIG AXLE TILTING SIDESHIFT ORBITROL 4th WAY...

Страница 194: ...AL Electric 036 0410 07 ELECTRIC CONTROL VALVE HYDRAULIC SYSTEM Joysticks fingertips version 3 AND 4 WHEELS Manometerconnection Loweringvalve Priorityvalve Drainhose Hydraulicoiltank AGIP ARNICA 46 20...

Страница 195: ...caseoffailure oftheliftingsolenoidvalve 2 Maximumpressurevalve 3 Liftingbox 4 Tiltbox 5 Sideshiftbox 6 4 Way box 7 Proportionalvalve EVP 8 Drainpipeconnection 9 Mainliftingpipeconnection HYDRAULIC ELE...

Страница 196: ...on lifting sideshift Forsafetyreasonthelogicunitissettothelower speed 4thWAY has two valves already set to 150 Bar Shims are used in order to increase or decrease the pressure Each shim corresponds to...

Страница 197: ...chapter 6000 page 13 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 ORBITROL A POWER STEERING HYDRAULIC DIAGRAM STEERING CYLINDER FILTER PUMP TO THE CONTROL VALVES PRIORITY VALVE...

Страница 198: ...nge the oil place and stop the truck on a flat surface with the mast tilted backwards and the forks lowered After the first 50 hours filterchange Every 500 hours check the oil level in the tank using...

Страница 199: ...can be followedtoreplacethehydraulicoil 1 Todrainthetankitispossibletouseapumptosuch upthehydraulicoil 2 Itisalsopossibletoremovethedrainhoseofthe controlvalvefromthetankandplaceitonan externalcase By...

Страница 200: ...CASTROLOPTIMOLT WHITE paste orspray Ifnot restorethelayerwiththeproductbefore mentioned screwinandtightthetwobolts Afterthepumpreplacementitissuggestedtofill thesuctionhoseC seepreviouspage Itisalso p...

Страница 201: ...chapter 7000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 7000 MAST GROUP...

Страница 202: ...BRAKING EFFECT page 6 SIDE DISPLACEMENT CYLINDER WITH BRAKING EFFECT page 7 SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT page 8 TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT page 9 CYLINDER CHECKING MET...

Страница 203: ...temhasbeenhousedinsidetheprofiles The mast group is a roller type with a variable centre distance i e a fixed roller is fitted on the outer mast and a mobileoneontheinnermast insteadofanumberofmobiler...

Страница 204: ...chapter 7000 page 4 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 Intermediate section bar TRIPLE MAST SECTION Fork carriage Internal section bar External section bar...

Страница 205: ...chapter 7000 page 5 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 LIFTING CYLINDERS ON THE MAST...

Страница 206: ...nnels1and2arepluggedbythecap Therefore sincetheoilflowingbetween the two chambers passes only through channel 3 it has a lower capacity The outcomeisaslowing downor Braking effect Thedownwardslidingof...

Страница 207: ...vementisallowedbytheoilflow from chamber A to chamber B through holeFandtheguidering Thedownwardslidingoftherodis allowedbytheopeningofthe Oilinlet circuit sothattheoilcanberetrieved intothetankbymean...

Страница 208: ...utofchannel2whiletherod ismoving butfreeing allthesame the passageoftheoilbetweenchannel2and chamberA Thedownwardslidingoftherodisallowed bytheopeningofthe Oilinlet circuit so thattheoilcanberetrieved...

Страница 209: ...ictionrings 5 Thedustcontrolring 6 preventsanydirtandwater frompenetratingthecylinder Slight leakages that may occur are directed to the tank through the drain pipe connected to the pipe coupling 7 Th...

Страница 210: ...drain pipecoupling itmeansthattheloadloweringisonlyduetotheleakages onthedistributor In the presence of leakages it will be necessary to replace the seal Shouldthisbethecase inspectthecylinderliner 2...

Страница 211: ...lers E they have to rotate freely and not to be too worn out A Tilting jacks 2 2 greasenipples B Mast connections 1 1 greasenipples adjust the guide shoes grease the mast guide rollers E FORK CARRIAGE...

Страница 212: ...he collars C are present and tightly fixed Every 500 hours check that there is a clearance D of 0 5 to 3 mm between the collar and external lifting jack cylinder check that the self locking nuts E are...

Страница 213: ...Picture2 4 removethesafetyclipofthechainpinonthecarriage Picture3 5 removethenutstoppingthechainpinwithatoolasshownin Picture4 Afterthatmovethetwochainstotheoppositesidein order to have more space 6 r...

Страница 214: ...PLACING A B B C D E F G Inordertocarryoutthejobproceedasfollows 1 removeoneofthetwosidebarsBfrom theforkcarriage Picture8 2 takeoutthemobileplateC Picture8 3 replacetheupperandlowerguideshoesD E Pictu...

Страница 215: ...SPECTION CHECKING THE CHAINS Every 1000 hours Check the condition of the chains which in any case must not be faulty worn out or damaged To check the links for wear use the appropriate gauge Remove th...

Страница 216: ...ning lock Check that the fork positioning lock G is in good working order Legibility of marking If the fork arm marking is not clearly legible it must be renewed by the original fork supplier Fork wea...

Страница 217: ...chapter 8000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 8000 ATTACHEMENT...

Страница 218: ...00 page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Страница 219: ...chapter 9000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 9000 OPTIONS...

Страница 220: ...00 page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Страница 221: ...chapter B page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER B MAINTENANCE TABLES...

Страница 222: ...page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAINTENANCE TABLES INDEX OILAND GREASE SPECIFICATION page3 TYRE TIGHTENING TORQUES page3 RUNNING IN MAINTENANCE TIMES TABLE page4 MAINTENANCE T...

Страница 223: ...s DRIVE UNIT TORQUE electric motor securing unit securing to frame service brake delivery pipes screw parking brake cable fixing screw oil filling and draining cap VARIOUS TORQUES mast securing U bolt...

Страница 224: ...ess The servicing periods are divided into hours considering an average working day of 8 hours of effective operation If the truck is used on average for less than 8 hours per day refer to the schedul...

Страница 225: ...ast carriage and chain rollers tilting jacks supply pipes lifting oil filter lifting system oil mast guides mast and jack fixing lifting jack retaining collars fork carriage position forks mast inclin...

Страница 226: ...ation BATTERY specific gravity and charge level ELECTRIC MOTORS external cleaning electric fans motor bearings motor supports CHASSIS AND CONTROLS steering and pipe systems seal hoses from orbitrol to...

Страница 227: ...chapter C page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER C SAFETY INFORMATION...

Страница 228: ...pter C page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 SAFETY INFORMATION INDEX WORK CLOTHES page3 WORK PLACE page3 LIFTING THE TRUCK page3 ELECTRIC PART page4 WELDING page5 TRUCK WASHING pag...

Страница 229: ...fting the truck Beforedoinganyjob itisobligatorytoliftthefrontwheelswithblocks toavoidtheriskofaccident 1 Blockthesteeredwheelswithchocks A 2 Tiltthemastbackandplaceblocks B undertheirbase 3 Tiltthema...

Страница 230: ...ifiersorpowersupplies Withthekeyswitchedoff thefiltercapacitorscouldremainchargedforsomeminutes Toensuresafeworking conditions weadvise To wait some seconds with the machine stopped and the key insert...

Страница 231: ...eperformableinsidetheworkingareawhereyouare Whentheseoperationsarecarriedoutonatruck inordertoavoidthedangerofexplosion coverandprotect thebatteryandthepartsincontactwithfuelcarefully Makesurethatarou...

Страница 232: ...page 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALMENT...

Страница 233: ...PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALMENTE BLANCA...

Страница 234: ...CESAB S p A via Persicetana Vecchia 10 40132 Bologna Italy Tel 0039 051 20 54 11 Fax 0039 051 72 80 07 E mail cesab cesab it Cargo Range...

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