Related Manuals for CESAB BT BLITZ 312
Summary of Contents for CESAB BT BLITZ 312
- Page 1 SERVICE MANUAL C3E120 C4E120 C3E150 C4E150 C3E160 C4E160 C3E160L C4E160L C3E180 C4E180 C3E180L C4E180L C3E200 C4E200 036-0410-07 04/2005...
- Page 2 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 3 CESAB reserves the right to make any necessary modifications without obligation to promptly update this handbook. Copyright by CESAB S.p.A...
- Page 4 1,2 - 2,0 t A.C. Electric SERVICE MANUAL index 036-0410-07 page 2 INDEX GENERAL INFORMATION chapter CHASSIS chapter 0000 MOTORS / ENGINES chapter 1000 TRANSMISSION / DRIVE GEAR chapter 2000 BRAKE / WHEEL chapter 3000 STEERING SYSTEM chapter 4000 ELECTRICAL SYSTEM chapter 5000 HYDRAULIC / PNEUMATIC SYSTEM...
- Page 5 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter A 036-0410-07 page 1 CHAPTER A GENERAL INFORMATION...
- Page 6 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter A 036-0410-07 page 2 GENERAL INFORMATION INDEX TECHNICAL DATA page3...
- Page 7 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter A 036-0410-07 page 3 TECHNICAL DATA...
- Page 8 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter A 036-0410-07 page 4...
- Page 9 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter A 036-0410-07 page 5...
- Page 10 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter A 036-0410-07 page 6 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 11 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 0000 036-0410-07 page 1 CHAPTER 0000 CHASSIS...
- Page 12 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 0000 036-0410-07 page 2 CHASSIS INDEX TRUCK’S LAY OUT page 3 PEDALS page 4 DRIVE DIRECTION LEVER ON STEERING COLUMN page 4 STEERING COLUMN PUSH BUTTONS page 5 LOAD HANDLING COMMANDS page 6 DASHBOARD page7...
- Page 13 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 0000 036-0410-07 page 3 TRUCK’S LAY OUT DESCRIPTION OF MAIN PARTS A) Mast frame B) Opening for lifting battery C) Seat D) Electronic control unit compartment E) Counterweight F) Hydraulic valve commands G) Control valve cover H) Lifting jack I) Lifting fork carriage...
- Page 14 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 0000 036-0410-07 page 4 OPERATOR'S SEAT FOOT PEDALS VERSION FOOT DRIVE DIRECTION (Standard version) - Forward direction (D) - Backward direction (E) - Service brake pedal (B) DRIVE DIRECTION LEVER ON STEERING COLUMN (Alternative version) Direction selector lever (F) é...
- Page 15 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 0000 036-0410-07 page 5 STEERING COLUMN PUSH BUTTONS It is strongly recommended to avoid operating both push buttons when the truck is running. Selected setting push button (M): P (programmable), H (high), L (low) Speed reduction push button (N) (turtle function) M) Selected setting push button: at the start up, the truck is setted in the same condition as it was turned off.
- Page 16 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 0000 036-0410-07 page 6 LOAD HANDLING COMMANDS The truck can be equipped with three types of commands for load handling CONTROL 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)
- Page 17 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 0000 036-0410-07 page 7 DASHBOARD The dashboard consists of a series of instruments and warning lights to check the correct operation of the truck. Battery charge status indicator. Parking brake ON warning light. Brake fluid low level warning light.
- Page 18 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 0000 036-0410-07 page 8 DASHBOARD CONTROLS Battery charge status indicator: This bar consists of 3 green LEDS on the right side, 4 orange LEDS in the middle and 3 red LEDS on the left side; when the battery is charged the first green LED on the right is On;...
- Page 19 Without min. max. Battery kg MANUFACT. YEAR TENSION DERATED CAPACITY Kg CARRELLI ELEVATORI S.p.A. CESAB LDT via Persicetana vecchia, 10 Bevan Way CAPACITY PLATE 40132 - Bologna - Italia Smethwick - Warley West Midla 1ds B66 1BZ LOAD PLATE IDENTIFICATION PLATE...
- Page 20 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 0000 036-0410-07 page 10 LIFTING OF THE TRUCK If the truck is equipped with mudguard extensions, the chains can be hooked only after the extensions disassembling. HOOK ATTACHMENT POINTS FOR LIFTING THE TRUCK The hooking points are shown on the carriage with the symbol shown on the side (see picture).
- Page 21 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 1000 036-0410-07 page 1 CHAPTER 1000 MOTORS/ ENGINES...
- Page 22 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 1000 036-0410-07 page 2 MOTORS / ENGINES INDEX ELECTRICAL MOTORS CHARACTERISTICS page 3 ELECTRICAL MOTORS ARRANGEMENT page 5...
- Page 23 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 1000 036-0410-07 page 3 ELECTRICAL MOTORS CHARACTERISTICS TRACTION MOTORS MANUFACTURER SAUER DANFOSS (SCHABMÜLLER) POWER 4,5 KW f=80 Hz POLES NUMBER FREQUENCY 80 Hz NOMINAL VOLTAGE 27 V (AC) POWER FACTOR (cos f) 0,915 SERVICE S2 60’...
- Page 24 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 1000 036-0410-07 page 4 LIFTING MOTOR MANUFACTURER SAUER DANFOSS (SCHABMÜLLER) POWER 10 KW POLES NUMBER FREQUENCY 80 Hz NOMINAL VOLTAGE 28 V (AC) POWER FACTOR (cos f) 0,83 SERVICE S3 = 26% INSULATION CLASS R.P.M.
- Page 25 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 1000 036-0410-07 page 5 ELECTRICAL MOTORS ARRANGEMENT TRACTION MOTORS LIFTING MOTOR...
- Page 26 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 1000 036-0410-07 page 6 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 27 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 2000 036-0410-07 page 1 CHAPTER 2000 TRANSMISSION / DRIVE GEAR...
- Page 28 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 2000 036-0410-07 page 2 TRANSMISSION / DRIVE GEAR INDEX REDUCTION GEAR VIEW page 3 REDUCTION GEAR MAINTENANCE page 4 REPLACEMENT OF THE REDUCTION GEAR page 5...
- Page 29 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 2000 036-0410-07 page 3 REDUCTION GEAR VIEW Reduction ratio of the reduction gear: 1 : 18,2...
- Page 30 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 2000 036-0410-07 page 4 REDUCTION GEAR MAINTENANCE DRIVE UNIT The drive unit, one for each driven wheel, consists of an electric motor and a reduction gear, complete with oil-bathed brake discs inside. To top up or drain oil remove the magnetic plugs.
- Page 31 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 2000 036-0410-07 page 5 REPLACEMENT OF THE REDUCTION GEAR - Lift the truck - Remove the wheel from the reduction gear. - Remove the cable for the parking brake and the tube for the oil brake system. - Put a shim under the electric motor.
- Page 32 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 2000 036-0410-07 page 6 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 33 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 3000 036-0410-07 page 1 CHAPTER 3000 BRAKES / WHEELS...
- Page 34 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 3000 036-0410-07 page 2 BRAKES / WHEELS INDEX SERVICE BRAKES page 3 PARKING BRAKE page 4 BRAKE OPERATING SYSTEM DESCRIPTION page 5 BRAKE DISKS page 6 REPLACEMENT OF THE WHEEL BRAKE CYLINDER page 7 WHEELS / TYRES page 9...
- Page 35 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 3000 036-0410-07 page 3 BRAKE SYSTEM 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) Bleeding screw P) Electric drive motor Q) Distribution block...
- Page 36 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 3000 036-0410-07 page 4 PARKING BRAKE The hand parking brake operates by means of the same disks as the service brake. J) Release system K) Parking brake lever V) Microswitch W)Brake block anchor X) Parking brake lever adjusting screw PARKING BRAKE CONTROL AND ADJUSTMENT Every 1000 hours...
- Page 37 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 3000 036-0410-07 page 5 BRAKE OPERATING SYSTEM DESCRIPTION Main piston Brake pin Fulcrum Brake cylinder Oil brake tube Parking brake cable Wheel cylinder Oil area Spring Disks group The brake effect is activated when the brake cylinder of the reduction gear is moving. It moves when the parking brake pedal or the brake pedal is pressed.
- Page 38 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 3000 036-0410-07 page 6 BRAKE DISKS Reduction gear body Gear group 1 Plate disk Gear group 2 Pinion The brake effect starts when the wheel brake cylinder is moving. The brake cylinder presses the free cylinder and the pad.
- Page 39 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 3000 036-0410-07 page 7 REPLACEMENT OF THE WHEEL BRAKE CYLINDER A: Wheel B: Reduction gear C: Electric motor D: Wheel brake cylinder E: Metal parking brake cable F: Oil brake hose G: Threaded bar M8 H: Threaded bar M14 (see next page) In order to replace the wheel brake cylinder D it is possible to proceed in two different ways:...
- Page 40 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 3000 036-0410-07 page 8 2nd WAY Lift the truck Remove cable E and hose F Remove wheel A (see previous page) Remove the screws that fixed the gear box to the frame Fix bar G (of 40 cm) into the upmost hole in the frame using it as a guide to keep the reduction gear...
- Page 41 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 3000 036-0410-07 page 9 STANDARD TYRES SAFETY OF RIMS AND WHEELS FOR FORKLIFT TRUCKS “PNEUMATIC” tyres must be replaced when the tread is less than 1.6 mm. “SUPERELASTIC” tyres must be replaced when the tread reaches the “60J” indication printed on the side. The replacement of “CUSHION”...
- Page 42 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 3000 036-0410-07 page 10 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 43 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 4000 036-0410-07 page 1 CHAPTER 4000 STEERING SYSTEM...
- Page 44 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 4000 036-0410-07 page 2 STEERING SYSTEM INDEX STEERING CONTROL page 3 POWER STEERING HYDRAULIC DIAGRAM page4 POWER STEERING HYDRAULIC LAYOUT page5 POWER STEERING SETTING page 6 STEERING AXLE 3 WHEELS page 8 STEERING AXLE 3 WHEELS page 9 BEARING ADJUSTMENT...
- Page 45 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 4000 036-0410-07 page 3 STEERING CONTROL The steering uses the same oil as the lifting by means of a priority valve, which guarantees a sufficient oil flow to the power steering. The oil capacity is checked by the Ls signal (load - sensing), coming from the steering unit so that the oil quantity sent to the power steering is equal to its real request.
- Page 46 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 4000 036-0410-07 page 4 POWER STEERING HYDRAULIC DIAGRAM STEERING CYLINDER ORBITROL TO THE CONTROL VALVES P R I O R I T Y VALVE PUMP FILTER...
- Page 47 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 4000 036-0410-07 page 5 3 AND 4 WHEELS VERSION 3 WHEELS LOAD SENSOR 4 WHEELS LOAD SENSOR ORBITROL Oil inlet Drain Load sensor and Valve for the maximum pressure...
- Page 48 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 4000 036-0410-07 page 6 POWER STEERING SETTING In order to set the pressure remove the cap and adjust the Allen screw PRESSURE SETTING 90-100 BAR The same pressure is used for both versions (3 and 4 wheels) Adjusting: Screw in = highter pressure...
- Page 49 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 4000 036-0410-07 page 7 3 WHEELS VERSION The 3 wheels uses a static system. It means that the oil reaches the load sensor on the priority valve only when the steering is moving. PRIORITY VALVE OSPC 50 LS STATIC ORBITROL...
- Page 50 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 4000 036-0410-07 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 bearings. 24 daNm Steering potentiometer fixing...
- Page 51 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 4000 036-0410-07 page 9 4-WHEEL STEERING AXLE Steering axle check Every 1000 hours - lubricate the steering gear joints using the appropriate grease nipples (I); - check the steering angles. - 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 special screws fixing...
- Page 52 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 4000 036-0410-07 page 10 BEARING ADJUSTMENT Steering wheel bearings require an adjustment once a year. Steering wheels lift the steering wheels remove cap (1); fasten the nut with a torque setting of 6 dNm; turn the hub of 2-3 turns in both senses;...
- Page 53 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 1 CHAPTER 5000 ELECTRIC & ELECTRONIC SYSTEM...
- Page 54 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 2 ELECTRIC & ELECTRONIC SYSTEM INDEX BATTERY AND BATTERY CHARGER page3 ELECTRICAL MOTOR CHARACTERISTIC page 4 ENCODER page 5 MAIN ELECTRICAL COMPONENTS DESCRIPTION page7 ACCELERATOR PEDAL page7 FUSE BOX page8 24 VOLT FUSES page8...
- Page 55 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 3 BATTERY AND BATTERY CHARGER General indications for battery maintenance Every 50 working hours - measure electrolyte density. Approximate density data For a temperature of 15° C - a density of 1.12 to 1.13+ kg/dm indicates that the battery is flat;...
- Page 56 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 4 ELECTRICAL MOTORS CHARACTERISTICS TRACTION MOTORS MANIFACTURER SAUER DANFOSS (SCHABMÜLLER) POWER 4,5 KW f=80 Hz POLES NUMBER FREQUENCY 80 Hz NOMINAL VOLTAGE 27 V (AC) POWER FACTOR (cos f) 0,915 SERVICE S2 60’...
- Page 57 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 5 ENCODER The encoder function is to generate motors feed-back signals to the logic unitis (motor running; R.P.M.; rotation direction). It is Encoder built-in the bearing placed on the opposite side of the motor drive shaft Motor signals connector cable color...
- Page 58 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 6 Disassembly Disconnect the motor electrically and remove it. Open and remove the 4 cylinder head screws LIFTING MOTOR (M8x250 for the lifting motor, M8x130 for the traction motor) Pos. 1 between non drive end plate Pos.
- Page 59 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 7 MAIN ELECTRICAL COMPONENTS DESCRIPTION A) Traction module B) Lifting module C) Contactors D) Panel cooling fan E) Power fuses F) Fuses (covered by the light board) G) Light card ACCELERATOR PEDAL Set the potentiometer Position the tester set in OHM between the green and the red wire.
- Page 60 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 8 FUSE BOX The fuse box is located next to the battery connector, covered by the light card. FUSE DESCRIPTION 1. F1 key fuse 10 Amp 2. F2 horn fuse 5 Amp 3.
- Page 61 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 9 DC/DC CONVERTER 140 W DC/DC converter (STD) The DC/DC converter is located on the truck front side, under the I/O card fixed on the same plate. The STD machines use a converter to 140 Watt.
- Page 62 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 10 ELECTRONIC PANELS TECHNICAL SPECIFICATIONS “DUALAC2” TRACTION Inverter for pairs of AC asynchronous 3-phase motors Regenerative braking functions Can-bus interface Digital control based upon a microcontroller (one per each motor) Voltage: Maximum current 2 x 275A (RMS) for 3'...
- Page 63 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 11 OPERATIONAL FEATURES - Speed control. - Very good behaviour on a slope due to the speed feedback. - The motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set point.
- Page 64 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 12 GENERAL PRECAUTIONS - Do not connect the inverter to a battery with a nominal value different from the value indicated on the chopper plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit does not "power up".
- Page 65 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 13 CONNECTION OF THE AUXILIARY CIRCUIT - DUAL AC2 UNIT TRACTION CABLES ASSEMBLY INSTRUCTIONS...
- Page 66 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 14 CONNECTORS CAN_H High level CANBUS. CANL_OUT Low level CANBUS: to be used as repetition for CAN_L line. CAN_L Low level CANBUS. CAN_H_OUT High level CANBUS: to be used as repetition for CAN_H line or to be connected to CANT_L to insert termination resistance.
- Page 67 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 15 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 speed (CUTBACK SPEED 3) normally on. By connecting a microswitch on the wire between the pin C10 and the seat switch, it is possible to set ON or OFF the CUTBACK SPEED 3 (parameter located in the menu PARAMETER CHANGE).
- Page 68 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 16 STEERING SYSTEM 3 WHEELS When the potentiometer reaches approximately 70° the traction logic unit controls the motor in order to stop one motor completely according to the direction. In this case the truck turns around point A.
- Page 69 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 17 3 WHEELS +90° -90° Steering potentiometer (3 wheels) Yellow 12 V Green 0,7 V with max. steering angle right hand + 90° 2,5 V with straight wheel 4,3 V with max.
- Page 70 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 18 CONNECTION OF THE ELECTRIC CIRCUIT - AC2 UNIT LIFTING...
- Page 71 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 19 CONNECTORS PCLRXD NCLRXD PCLTXD NCLTXD Console connector FLASH FLASH CAN-L Low level CAN-BUS voltage I/O. CAN-H High level CAN-BUS voltage I/O. Positive of lifting motor encoder power supply (+12V). Negative of lifting motor encoder power supply.
- Page 72 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 20 LIFTING ELECTRIC BLOCK DIAGRAM POTENTIOMETER MICROSWITCHES PROGRAMMING CONSOLE...
- Page 73 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 21 ELECTRICAL CIRCUIT CONNECTION DUAL AC2 TRACTION UNIT AND AC2 LIFTING UNIT 355 A FUSE SEGNALI CAN-BUS 300 A FUSE...
- Page 74 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 22 NECESSARY SETTING AFTER REPLACING THE TRACTION LOGIC UNIT TRACTION ACQUISITION ADJUST BATTERY STEERING POTENTIOMETER Vacc PROGRAM STEER TABLE for all references see “MAPS FOR USING THE CONSOLE - TRACTION” in the following pages NECESSARY SETTING AFTER REPLACING THE LIFTING LOGIC UNIT LIFTING ACQUSITION Vacc PROGRAM (with mechanic distributor only)
- Page 75 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 23 CAN-BUS AND ONBOARD COMMANDS DIAGRAM COMMANDS ARM CARD DASHBOARD LIFTING ON BOARD COMMAND LIGHT CARD I / O CARD TRACTION ON BOARD COMMAND ELECTRO MHYRIO CONTROL VALVE DUAL AC2 LIFTING TRACTION...
- Page 76 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 24 LEGEND ARM COMMANDS - forward switch - backward switch - horn switch joystick - 5° way (opt) - lifting-tilt joystick - sideshift / 4° way (opt) joystick - forward switch - backward switch - horn switch...
- Page 77 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 25 CAN - BUS DESCRIPTION Controller Area Network The CAN BUS technology is a way to assemble the electronic parts of the machines. It has been designed to avoid the enormous quantity of cables that normally are used to connect two or more electric components.
- Page 78 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 26 ARM CARD The arm card, located inside the seat arm is present in fingertips / joysticks truck version. It is supplied by the dc / dc converter with 24 V.
- Page 79 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 27 FINGERTIP JOYSTICK PB1=Horn pushbutton PB2=Backward pushbutton PB3=Forward pushbutton...
- Page 80 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 28 LIGHT CARD The light card is located in the compartment on the left side of the truck. The 24 V supplied by the converter arrive at the card. It is used as a bridge so that the voltage is supplied to all the other cards.
- Page 81 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 29 CONNECTOR DESCRIPTION Connector 1 It is a connector to 8 Pins used for controlling the lights. PINS 1-5 are connected together = 24 Volt. PINS 2-6 are connected together = output of the stop lights 0-24 Volt. It is a proportional value given that the voltage depends on the temperature of the lamp bulbs PINS 3-7 are connected together = output of the reverse lights 0-24 Volt.
- Page 82 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 30 I/O CARD INPUT / OUTPUT CARD The card is located on the left side of the truck under the footboard. controls and converts analogic signals to digital signals and vice versa Connector J1 (J38*) for input of the brake oil tank LED, button for the programmed performance, button for the speed reduction.
- Page 83 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 31 MHYRIO CARD It works to 48 V and it is located on the upper side of the truck over the electro control valve group. The Mhyrio card receives the digital inputs from the CAN and it converts them in analogic signals to control the solenoid valves with.
- Page 84 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 32 POTENTIOMETER CONFIGURATION ARM COMMAND (JOYSTICKS / FINGERTIPS VERSION) HORN PUSHBUTTON (PB1) BACKWARD PUSHBUTTON (PB2) FORWARD PUSHBUTTON (PB3)
- Page 85 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 33 FINGERTIPS : 5 V GREEN : 0 ÷ 5(AT REST 2,5 V) BLACK : 0 V S1 - S3 - S5 - S7 S2 - S4 - S6 - S8 JOYSTICK (FORWARD-BACKWARD MOV.) ORANGE : 5 V...
- Page 86 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 34 ACCELERATOR POTENTIOMETER CONFIGURATION The test of the potentiometer can be carried out in two different ways: Values optained by the console Yellow 1,6 V Green 0,6 ÷1,6 V with pedal pressed Black 0,6 V Values optained by the multimeter...
- Page 87 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 35 LIFTING POTENTIOMETER CONFIGURATION (CONTROL VALVE VERSION) The test of the potentiometer can be carried out in two different ways: Values optained by the console 1,5 ÷ 5 V with lifting lever pulled 1,5 V Values optained by the multimeter 4,6 V...
- Page 88 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 36 CONSOLE FUNCTION GENERAL DESCRIPTION...
- Page 89 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 37 CONSOLE FUNCTION GENERAL DESCRIPTION HOUR METER The hour meter appears in the second line of the display when the chopper is connected. It shows the real working hours.
- Page 90 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 38 CONSOLE CONNECTION LIFTING UNIT TRACTION UNIT MHYRIO UNIT The connection has to be made with the machine at rest.
- Page 91 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 39 PARAMETER CHANGE DUAL AC2 MASTER TRACTION UNIT ACCELER/DELAY determines the acceleration ramp. RELEASE BRAKING controls the deceleration ramp when the travel pedal is released. INVERSION BRAKING controls the deceleration ramp when the direction switch is inverted during the travel.
- Page 92 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 40 PARAMETER CHANGE DUAL AC2 SLAVE TRACTION UNIT NOT AVAILABLE.
- Page 93 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 41 PARAMETER CHANGE AC2 LIFTING UNIT ACCELER/DELAY acceleration ramp. DECELER/DELAY deceleration ramp. MAX SPEED UP determines the maximum lifting speed controlled by a potentiometer. MIN SPEED UP determines the minimum lifting speed controlled by a potentiometer when the lift enabling switch is closed.
- Page 94 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 42 PARAMETER CHANGE MHYRIO UNIT MIN EVP Min voltage on the draining solenoid valve MAX EVP Max voltage on the draining solenoid valve MIN EVP1 Min. voltage on the lowering solenoid valve MAX EVP1 Max voltage on the lowering solenoid valve MIN EVP2...
- Page 95 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 43 PARAMETER CHANGE DASHBOARD UNIT HOURS COUNTER RUNNING/KEY: key on / lifting unit working hours counter switch DISPLAY ON/OFF: displaied speed switch SPEED RATIO 0-5 12: speed calculation ratio...
- Page 96 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 44 TESTER DUAL AC2 MASTER TRACTION UNIT MOTOR VOLTAGE: voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends on the battery voltage). FREQUENCY: frequency of the voltage and current supplied to the motor.
- Page 97 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 45 TESTER DUAL AC2 SLAVE TRACTION UNIT MOTOR VOLTAGE: voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends on the battery voltage). FREQUENCY: frequency of the voltage and current supplied to the motor.
- Page 98 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 46 TESTER AC2 LIFTING UNIT MOTOR VOLTAGE: voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends on the battery voltage). FREQUENCY: frequency of the voltage and current supplied to the motor.
- Page 99 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 47 TESTER MHYRIO UNIT BATTERY VOLTAGE: level of battery voltage measured with the key switch ON. VALVES SUPPLY: level of voltage at the positive valve supply (0-VB). CAN POT EVP: single proportional valve current setpoint, received by the canbus (% of the current supplied to the valve).
- Page 100 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 48 TESTER MHYRIO UNIT NOT AVAILABLE.
- Page 101 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 49 TESTER DASHBOARD UNIT NOT AVAILABLE.
- Page 102 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 50 ALARMS FUNCTIONS DUAL AC2 TRACTION MASTER UNIT CODE ALARM DESCRIPTION WATCH - DOG It is a self-diagnostic test within the logic between the Master and Slave µcontrollers. This alarm could also be caused by the canbus malfunctioning or data transmission interferences.Therefore, before replacing the Dual AC2 unit check the correct canbus functioning and the general turck insulation.
- Page 103 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 51 CODE ALARM DESCRIPTION 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 timout.
- Page 104 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 52 CODE ALARM DESCRIPTION ENCODER ERROR Encoder failure. This alarm indicates that the encoder information is not correct or is not present. The encoder transmits signals only when the motor is running. The alarm is detected by the logics when it exceeds 20Hz.
- Page 105 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 53 CODE ALARM DESCRIPTION THERMIC SENS KO The values indicated by the temperature sensor of the inverter are always checked and if they are out of range this warning appears. - Replace the logic unit.
- Page 106 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 54 CODE ALARM DESCRIPTION VACC NOT OK Failure on the acceleration potentiometer signal at rest. The alarm points out that the voltage value detected on the accelerator potentiometer is 1Volt higher than the least value programmed with the Vacc function.
- Page 107 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 55 DUAL AC2 TRACTION SLAVE UNIT CODE ALARM DESCRIPTION WATCH - DOG It is a self-diagnostic test within the logic between the Master and Slave µcontrollers. This alarm could also be caused by the canbus malfunctioning or data transmission interferences.Therefore, before replacing the Dual AC2 unit check the correct canbus functioning and the general turck insulation.
- Page 108 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 56 CODE ALARM DESCRIPTION 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 timout.
- Page 109 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 57 CODE ALARM DESCRIPTION ENCODER ERROR Encoder failure. This alarm indicates that the encoder information is not correct or is not present. The encoder transmits signals only when the motor is running. The alarm is detected by the logics when it exceeds 20Hz.
- Page 110 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 58 CODE ALARM DESCRIPTION THERMIC SENS KO The values indicated by the temperature sensor of the inverter are always checked and if they are out of range this warning appears. - Replace the logic unit.
- Page 111 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 59 CODE ALARM DESCRIPTION PEDAL WIRE KO Failure on the acceleration potentiometer signal at rest. This alarm appears when there is an interruption on the potentiometer positive (PPOT) or the negative (NPOT).
- Page 112 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 60 CODE ALARM DESCRIPTION VMN HIGH Failure in the VMN test. This test starts when the ignition key is turned on. The alarm appears if one or more pover cables are not connected; check the connections of the 3 power cables from the Lifting unit to the lifting motor and the cables condition also.
- Page 113 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 61 CODE ALARM DESCRIPTION ENCODER ERROR Encoder failure. This alarm indicates that the encoder information is not correct or is not present. The encoder transmits signals only when the motor is running. The alarm is detected by the logics when it exceeds 20Hz.
- Page 114 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 62 CODE ALARM DESCRIPTION THERMIC SENS KO The values indicated by the temperature sensor of theinverter are always checked and if they are out of range there is a warning. - Replace the logic unit.
- Page 115 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 63 CODE ALARM DESCRIPTION VACC NOT OK Failure on the lifting potentiometer signal at rest. The alarm points out that the voltage value detected on the lifting potentiometer is 1Volt higher than the least value programmed with the Vacc function.
- Page 116 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 64 CODE ALARM DESCRIPTION CAN BUS KO Failure wires connecting the logic units: traction (Master & Slave), lifting, Mhyrio and all the cards. FF VALVES Replace the logic unit. DRIVER OPEN The transistor that controls the lifting and lowering valvespositive supply is open when it should be closed.
- Page 117 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 65 CODE ALARM DESCRIPTION LIGHTS CARD (NOT SHOWN BY THE CONSOLE) STOP-OPEN Failure on the stop lights. Check the bulbs of the stopstreetlights and the relevant cables. Not used. Not used.
- Page 118 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 66 PARAMETER SETTING TABLE DUAL AC2 TRACTION UNIT PROGRAMMED LEVEL PARAMETER UNIT ACCELERATION DELAY (*) RELEASE BRAKING (**) INVERS BRAKING (**) PEDAL BRAKING (**) SPEED LIMIT BRAKING (**) BRAKE CUTBACK (**) MAX SPEED FW MAX SPEED BW...
- Page 119 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 67 PARAMETER SETTING TABLE AC2 LIFTING UNIT PROGRAMMED LEVEL PARAMETER UNIT ACCELERATION DELAY (*) DELERATION DELAY (**) MAX SPEED UP MIN SPEED UP 12.0 13.5 15.0 16.5 18.0 19.5 21.0 22.5...
- Page 120 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 68 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 121 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 69 MAPS FOR USING THE CONSOLE TRACTION...
- Page 122 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 70 NECESSARY SETTING AFTER REPLACING THE TRACTION LOGIC UNIT TRACTION ACQUISITION see following pages ADJUST BATTERY see following pages STEERING POTENTIOMETER see following pages Vacc PROGRAM see following pages STEER TABLE see following pages...
- Page 123 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 71 DESCRIPTION OF THE CONSOLE STANDARD MENU DUAL AC2 MASTER TRACTION UNIT The console can be connected to the traction logic unit in two different ways: Directly, by means of an interface cable in the concerned connector of the traction logic unit. By connecting the console in another logic unit (pump or Mhyrio) and selecting the relevant connection number as shown in the map here below.
- Page 124 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 72 DESCRIPTION OF THE CONSOLE STANDARD MENU DUAL AC2 TRACTION UNIT MASTER MENU HEADING MAIN MENU ACCELERATION DELAY RELEASE BRAKING INVERS. BRAKING PEDAL BRAKING PARAMETER SPEED LIMIT BRAK. CHANGE SET MODEL CONNECTED TO 3...
- Page 125 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 73 DESCRIPTION OF THE CONSOLE STANDARD MENU DUAL AC2 TRACTION UNIT SLAVE MENU HEADING MAIN MENU PARAMETER NOT AVAILABLE CONNECTED TO SET MODEL CHANGE NOT AVAILABLE SET OPTIONS MOTOR VOLTAGE FREQUENCY ENCODER...
- Page 126 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 74 MAIN MENU: PARAMETER CHANGE (MASTER connection number 3) Select the program P on the dashboard before working with the main menu PARAMETER CHANGE. DA2M2B C CE 1.13 280A 00000 Press ENTER...
- Page 127 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 75 MAIN MENU: TESTER (MASTER connection number 3) DA2M2B C CE 1.13 280A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ENTER MOTOR VOLTAGE FREQUENCY ENCODER SLIP VALUE...
- Page 128 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 76 MAIN MENU : SAVE PARAMETER (MASTER connection number 3) DA2M2B C CE 1.13 280A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ROLL MAIN MENU SAVE PARAM Press ENTER...
- Page 129 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 77 MAIN MENU : RESTORE PARAMETER (MASTER connection number 3) DA2M2B C CE 1.13 280A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ROLL MAIN MENU SAVE PARAM Press ROLL...
- Page 130 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 78 MAIN MENU : ALARM (MASTER connection number 3) DA2M2B C CE 1.13 280A 00000 Press ENTER MAIN. MENU PARAM. CHANGE Press ROLL until reaching MAIN MENU ALARM MAIN.
- Page 131 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 79 MAIN MENU: PROGRAM VACC. (MASTER connection number 3) This setting must be made with the parking brake released DA2M2B C CE 1.13 280A 00000 Press ENTER MAIN MENU PARAM.
- Page 132 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 80 STEERING POTENTIOMETER ADJUSTMENT (MASTER connection number 3) The setting of the steering potentiometer is made in the MASTER (connection number 3) of the traction logic unit, that is automatically selected when the console is fisically connected to the MASTER unit. DA2M2B C CE 1.13 280A...
- Page 133 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 81 STEER TABLE (MASTER connection number 3) Select the type of truck according to the 3 wheels or 4 wheels configuration. OPTION #1 3 WHEELS 1,2-2,0 t AC OPTION #2 4 WHEELS 1,2-2,0 t AC OPTION #3...
- Page 134 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 82 STOP ON RAMP (MASTER connection number 3) DA2M2B C CE 1.13 280A 00000 Press ROLL and PARAM together * CONFIG. MENU * SET MODEL Press ROLL * CONFIG. MENU * SET OPTIONS Press ENTER HOUR COUNTER...
- Page 135 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 83 SLIP CONTROL (MASTER connection number 3) This function is useful to understand if a traction problem is due to the encoder or not. In case the truck stops or works with low speed with high consumption of current (and relevant alarm code shown on the dashboard) it is possible to disable the encoder for some seconds, no longer, given that the logic unit cannot control the motor any longer.
- Page 136 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 84 BATTERY INDICATOR The control of the battery LED indication on the dashboard and the relevant reduction of the speed are managed by the traction logic unit. The dashboard reads only the information coming from the logic unit and shows, using the led battery indicator, the status of the battery.
- Page 137 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 85 REARM OF THE BATTERY INDICATOR 100 % The battery indicator rearms only below the 70% of the full charge. With highter value there is not the rearm of the indicator.
- Page 138 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 86 BATTERY (MASTER connection number 3) The control of the battery LED indication on the dashboard and the relevant reduction of speed are performed by the MASTER of the traction logic unit. DA2M2B C CE 1.13 Scroll the parameters using ROLL and...
- Page 139 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 87 SET BATTERY TYPE: selects the nominal battery voltage ADJUST BATTERY: adjusts the value displayed in the console to adapt it to the real value of the battery (measured with a multimeter) ADJUSTMENT #02 adjustment of the lowest value of charge of the battery ADJUSTMENT #01...
- Page 140 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 88 MAIN MENU: PARAMETER CHANGE (SLAVE connection number 4) DUAL AC2 - SLAVE By means of the config menu of the programming console, the user can configure the following functions.
- Page 141 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 89 MAIN MENU: TESTER (SLAVE connection number 4) DA2S2B C CE 1.13 280A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ENTER MOTOR VOLTAGE Scroll the parameters using ROLL.
- Page 142 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 90 MAIN MENU : SAVE PARAMETER (SLAVE connection number 4) DA2S2B C CE 1.13 280A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ROLL MAIN MENU SAVE PARAM Press ENTER...
- Page 143 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 91 MAIN MENU : RESTORE PARAMETER (SLAVE connection number 4) DA2S2B C CE 1.13 280A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ROLL MAIN MENU SAVE PARAM Press ROLL...
- Page 144 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 92 MAIN MENU : ALARM (SLAVE connection number 4) DA2S2B C CE 1.13 280A 00000 Press ENTER MAIN. MENU PARAM. CHANGE Press ROLL until reaching MAIN MENU ALARM MAIN.
- Page 145 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 93 MAIN MENU: PROGRAM VACC. (SLAVE connection number 4) It must be carried out in the MASTER traction logic unit.
- Page 146 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 94 TRACTION ACQUISITION (MASTER connection number 3) Connect the console to the TRACTION logic unit DA2M2B C CE 1.13 280A 00000 Press ROLL and PARAM together * CONFIG MENU * SET MODEL Press ENTER CONNECTED TO 3...
- Page 147 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 95 MAPS FOR USING THE CONSOLE LIFTING...
- Page 148 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 96 NECESSARY SETTING AFTER REPLACING THE LIFTING LOGIC UNIT LIFTING ACQUSITION see following pages Vacc PROGRAM (with mechanic distributor only) see following pages...
- Page 149 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 97 DESCRIPTION OF THE CONSOLE STANDARD MENU AC2 LIFTING UNIT The console can be connected to the lifting logic unit in two different ways: Directly by means of an interface cable on the logic unit. By connecting the console to another logic unit (traction or Mhyrio) and selecting the relevant connection number as shown in the map here below.
- Page 150 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 98 DESCRIPTION OF THE CONSOLE STANDARD MENU AC2 LIFTING UNIT MENU HEADING MAIN MENU ACCELER/DELAY PARAMETER DECELER/DELAY CONNECTED TO 5 SET MODEL CHANGE MAX SPEED UP MIN SPEED UP HzCUTBACK SPEED CUTBACK SPEED 2 1ST SPEED FINE...
- Page 151 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 99 MAIN MENU: PARAMETER CHANGE (PUMP connection number 5) AC2P2B D CE 1.06 350A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ENTER ACCELER/DELAY acceleration ramp. DECELER/DELAY deceleration ramp. MAX SPEED UP determines the maximum lifting speed controlled by a potentiometer.
- Page 152 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 100 MAIN MENU: TESTER (PUMP connection number 5) AC2P2B D CE 1.06 350A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ENTER MOTOR VOLTAGE FREQUENCY ENCODER SLIP VALUE...
- Page 153 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 101 MAIN MENU : SAVE PARAMETER (PUMP connection number 5) AC2P2B D CE 1.06 350A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ROLL MAIN MENU SAVE PARAM Press ENTER...
- Page 154 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 102 MAIN MENU : RESTORE PARAMETER (PUMP connection number 5) AC2P2B D CE 1.06 350A 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ROLL MAIN MENU SAVE PARAM Press ROLL...
- Page 155 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 103 MAIN MENU : ALARM (PUMP connection number 5) AC2P2B D CE 1.06 350A 00000 Press ENTER MAIN. MENU PARAM. CHANGE Press ROLL until reaching MAIN MENU ALARM MAIN.
- Page 156 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 104 MAIN MENU: PROGRAM VACC. (PUMP connection number 5) This setting must be made with the parking brake released AC2P2B D CE 1.06 350A 00000 Press ENTER MAIN MENU PARAM.
- Page 157 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 105 SLIP CONTROL (PUMP connection number 5) This functions is useful to understand if a lifting problem is due to the encoder or not. In case the truck stops or works with low speed with high consumption of current (and relevant alarm code displayed on the dashboard) it is possible to disable the encoder for some seconds, no longer, given that the logic unit cannot control the motor any longer.
- Page 158 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 106 BATTERY (PUMP connection number 5) The control of the battery LED indication on the dashboard and the relevant reduction of speed are performed by the MASTER of the traction logic unit. Scroll the parameters using ROLL and AC2P2B D CE 1.06...
- Page 159 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 107 LIFTING ACQUISITION (Lifting connection number 5) Connect the console to the LIFTING logic unit AC2P2B D CE 1.06 350A 00000 Press ROLL and PARAM together * CONFIG. MENU * SET MODEL Press ENTER CONNECTED TO 5...
- Page 160 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 108 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 161 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 109 MAPS FOR USING THE CONSOLE MHIRIO...
- Page 162 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 110 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 163 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 111 DESCRIPTION OF THE CONSOLE STANDARD MENU OF THE MHYRIO UNIT The console can be connected to the MHYRIO logic unit in two different ways: Directly by means of an interface cable on the logic unit. By connecting the console to another logic unit (pump or traction) and selecting the relevant connection number as shown in the map here below.
- Page 164 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 112 DESCRIPTION OF THE CONSOLE STANDARD MENU MHYRIO UNIT HEADING MAIN MENU MIN EVP EVP OPEN DELAY MAX EVP EVP CLOSE DELAY PARAMETER MIN EVP1 EVP1 OPEN DELAY CHANGE SET MODEL CONNECTED TO 9...
- Page 165 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 113 MAIN MENU: PARAMETER CHANGE (Mhyrio connection number 9) MHY CB ZP 0.11 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ENTER MIN EVP Min voltage on the draining solenoid valve MAX EVP Max voltage on the draining solenoid valve MIN EVP1...
- Page 166 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 114 MAIN MENU: TESTER (Mhyrio connection number 9) MHY CB ZP 0.11 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ENTER BATTERY VOLTAGE VALVES SUPPLY CAN POT EVP CAN POT GROUP 1...
- Page 167 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 115 MAIN MENU : SAVE PARAMETER (Mhyrio connection number 9) MHY CB ZP 0.11 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ROLL MAIN MENU SAVE PARAM Press ENTER...
- Page 168 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 116 MAIN MENU : RESTORE PARAMETER (Mhyrio connection number 9) MHY CB ZP 0.11 00000 Press ENTER MAIN MENU PARAM. CHANGE Press ROLL MAIN MENU TESTER Press ROLL MAIN MENU SAVE PARAM Press ROLL...
- Page 169 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 117 MAIN MENU : ALARM (Mhyrio connection number 9) MHY CB ZP 0.11 00000 Press ENTER MAIN. MENU PARAM. CHANGE Press ROLL until reaching MAIN MENU ALARM MAIN. MENU ALARM Press ENTER max 5 alarms stored...
- Page 170 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 118 MAIN MENU : PROGRAM VACC. (Mhyrio connection number 9) Not available...
- Page 171 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 119 MAPS FOR USING THE CONSOLE DASHBOARD...
- Page 172 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 120 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 173 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 121 DESCRIPTION OF THE CONSOLE STANDARD MENU DASHBOARD The console can be connected to the dashboard unit in the following way: By connecting the console to another logic unit (traction, lifting or mhyrio) and selecting the relevant connection number as shown in the map here below.
- Page 174 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 122 MAIN MENU : PARAMETER CHANGE (Dashboerd connection number 11) Parameters shown in the adjusting table wich can be modified in a fixed range. DASH CE V 1.00 00000 Press ENTER MAIN MENU...
- Page 175 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 123 WIRING DIAGRAMS...
- Page 176 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 124...
- Page 177 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 125...
- Page 178 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 126...
- Page 179 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 127...
- Page 180 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 128...
- Page 181 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 129...
- Page 182 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 130...
- Page 183 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 5000 036-0410-07 page 131...
- Page 184 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 5000 036-0410-07 page 132...
- Page 185 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 6000 036-0410-07 page 1 CHAPTER 6000 HYDRAULIC / PNEUMATIC SYSTEM...
- Page 186 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 6000 036-0410-07 page 2 HYDRAULIC / PNEUMATIC SYSTEM INDEX CONTROL VALVE SYSTEM (CONTROL VALVE VERSION) page 3 CONTROL VALVE SYSTEM (JOYSTICKS/FINGERTIPS VERSION) page 9 POWER STEERING HYDRAULIC DIAGRAM page 13 OIL AND OIL FILTER page 14 PUMP REPLACEMENT page 15...
- Page 187 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 6000 036-0410-07 page 3 HYDRAULIC DIAGRAM Control valve version...
- Page 188 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 6000 036-0410-07 page 4 CONTROL VALVE HYDRAULIC SYSTEM Control valve version 3 AND 4 WHEELS Control valve Manometer connection Priority valve Drain hose Hydraulic oil filter Hydraulic oil tank Lowering valve AGIP ARNICA 46 ~20 litres The correct position of the valve is shown...
- Page 189 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 6000 036-0410-07 page 5 HYDRAULIC CONTROL VALVES Control valve version Tilting Lifting Sideshift 4th way Lifting max pressure valve * Tilting max pressure valve * Sideshift max pressure valve * 4th way max pressure valve * *: screw in to increase pressure, screw out to decrease pressure MANOMETER CONNECTION POINT FOR HYDRAULIC PRESSURE CONTROL...
- Page 190 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 6000 036-0410-07 page 6 CONTROL VALVE Lifting Tilting 4th way Sideshift 4th way max pressure valve Lifting max pressure valve Tilting max pressure valve Sideshift max pressure valve...
- Page 191 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 6000 036-0410-07 page 7 LIFTING PERFORMANCE Here below the table with the performance of a STD machine. It corresponds to the maximum load of the machine at 3mt. (See capacity plate). It corresponds to the maximum load of the machine at maximum load.
- Page 192 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 6000 036-0410-07 page 8 TILTING AND SIDESHIFT PERFORMANCE Here below the table with the performance of a STD machine. It corresponds to the maximum load of the machine at 3mt. (See capacity plate). Exercise = It means mast in movement.
- Page 193 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 6000 036-0410-07 page 9 HYDRAULIC DIAGRAM Joysticks / fingertips version...
- Page 194 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 6000 036-0410-07 page 10 ELECTRIC CONTROL VALVE HYDRAULIC SYSTEM Joysticks / fingertips version 3 AND 4 WHEELS Electric Control valve Manometer connection Priority valve Drain hose Hydraulic oil filter Hydraulic oil tank Lowering valve AGIP ARNICA 46 ~20 litres...
- Page 195 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 6000 036-0410-07 page 11 HYDRAULIC ELECTRIC CONTROL VALVES Joysticks / fingertips version Proportional valve 4th way Sideshift Lifting Tilting Drain line Plug Safety valve for load lowering in case of failure of the lifting solenoid valve.
- Page 196 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 6000 036-0410-07 page 12 Version with fingertips control and joysticks It consists of: One 48 V lifting ON/OFF solenoid valve One 24 V proportional solenoid valve for the lowering Two 48 V ON/OFF tilt control solenoid valves Two 48 V ON/OFF sideshift control solenoid valves One 24 Vproportinonal valve for the drain.
- Page 197 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 6000 036-0410-07 page 13 POWER STEERING HYDRAULIC DIAGRAM STEERING CYLINDER ORBITROL TO THE CONTROL VALVES PRIORITY VALVE FILTER PUMP...
- Page 198 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 6000 036-0410-07 page 14 LIFTING EQUIPMENT OIL AND OIL FILTER The hydraulic oil tank is located under the platform. The filter cartridge (A) is beneath the screw cap (C). To check and change the oil, place and stop the truck on a flat surface, with the mast tilted backwards and the forks lowered.
- Page 199 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 6000 036-0410-07 page 15 To change oil and filter: The tank does not have the drain plug. Place and stop the truck on a flat surface, with the mast tilted backwards and the forks lowered.
- Page 200 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 6000 036-0410-07 page 16 clean carefully the motor coupling surface insert the shaft in the tootded seating Before insert the motor shaft be sure that in the toothed seating there is a thin layer of "CASTROL OPTIMOL T. WHITE" (paste or spray).
- Page 201 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 7000 036-0410-07 page 1 CHAPTER 7000 MAST GROUP...
- Page 202 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 7000 036-0410-07 page 2 MAST GROUP INDEX MAST GROUP page 3 TRIPLE MAST SECTION page 4 LIFTING CYLINDERS ON THE MAST page 5 CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT page 6 SIDE DISPLACEMENT CYLINDER WITH BRAKING EFFECT page 7 SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT...
- Page 203 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 7000 036-0410-07 page 3 MAST GROUPS The mast profile with double stiffening flange is characterised by a high flexural and torsional strength. It allows wide visibility thanks to the reduced dimensions of the profile itself. Cylinders are single-acting type.
- Page 204 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 7000 036-0410-07 page 4 TRIPLE MAST SECTION Fork carriage Internal section bar Intermediate section bar External section bar...
- Page 205 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 7000 036-0410-07 page 5 LIFTING CYLINDERS ON THE MAST...
- Page 206 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 7000 036-0410-07 page 6 CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON THE LIFTING The oil flows into the cylinder from the “Oil inlet” when the control valve is operated. Flowing through channels 1, 2 and 3, it fills chamber A until the inner oil pressure exerts an upward force against the surface Bleeder...
- Page 207 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 7000 036-0410-07 page 7 SIDE DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON THE LOWERING Channel A The oil flows into the cylinder from the (to the central “Oil inlet” when the control valve is Chamber B cylinder) operated.
- Page 208 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 7000 036-0410-07 page 8 SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT IN THE LOWERING (WITH SPHERE) The oil flows into the cylinder from the “Oil inlet” when the control valve is operated. Flowing through channels 1 and 2 and thanks to the upward movement of the sphere, the oil fills chamber A until the...
- Page 209 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 7000 036-0410-07 page 9 TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT DESCRIPTION OF THE CYLINDER COMPONENTS The cylinder pistons are single-acting types (fig. A). Dust control ring (6) In these cylinders a seal (1) has been fitted on the Anti-friction piston (2) that works on the inner surface of the ring (5)
- Page 210 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 7000 036-0410-07 page 10 CYLINDER CHECKING METHODS CHECK Remove the drain pipe from the cylinder (fig. C) Lift the cylinder some times to end stroke, so as to discharge any oil residual.
- Page 211 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 7000 036-0410-07 page 11 LUBRICATION OF LIFTING EQUIPMENT MASTS After the first 50 hours - adjust the guide shoes through socket head (Allen) screw (D) For this purpose use a 0.2-0.5 mm thickness gauge, inserting it from below upwards to the centre of the Allen screw (D) passing behind the roller (F) and sliding on the outer mast..
- Page 212 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 7000 036-0410-07 page 12 Sideshift unit upper par 3 grease nipples (P) lower part without grease nipples excessive wear. SECURITY INSTALLATIONS CONTROL Make sure that: - the lifting chain stay bolts are free of defects and the adjusting nuts are locked by the appropriate cotter pins (A);...
- Page 213 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 7000 036-0410-07 page 13 GUIDE ROLLERS AND GUIDE SHOES REPLACING Mast-Fork carriage guide rollers and guide shoes replacing In order to carry out the job proceed as follows: remove the two forks from the carriage Picture 1 Picture 1 disconnect the two sideshift hoses on the fork carriage...
- Page 214 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 7000 036-0410-07 page 14 FORK CARRIAGE GUIDE SHOES REPLACING In order to carry out the job proceed as follows: remove one of the two side bars B from the fork carriage (Picture 8) take out the mobile plate C (Picture 8) Picture 8...
- Page 215 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 7000 036-0410-07 page 15 MAST CHAINS INSPECTION CHECKING THE CHAINS: Every 1000 hours - Check the condition of the chains which in any case must not be faulty, worn out or damaged.
- Page 216 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 7000 036-0410-07 page 16 FORK INSPECTIONS General criteria Fork arms in use must be inspected at intervals of not more than 1000 hours, and whenever a defect or permanent deformation is detected. If the truck is subject to intensive use, more frequent inspections may be required.
- Page 217 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 8000 036-0410-07 page 1 CHAPTER 8000 ATTACHEMENT...
- Page 218 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 8000 036-0410-07 page 2 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 219 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter 9000 036-0410-07 page 1 CHAPTER 9000 OPTIONS...
- Page 220 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter 9000 036-0410-07 page 2 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 221 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter B 036-0410-07 page 1 CHAPTER B MAINTENANCE TABLES...
- Page 222 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter B 036-0410-07 page 2 MAINTENANCE TABLES INDEX OIL AND GREASE SPECIFICATION page 3 TYRE TIGHTENING TORQUES page 3 RUNNING-IN MAINTENANCE TIMES TABLE page 4 MAINTENANCE TIMES page 5...
- Page 223 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter B 036-0410-07 page 3 OIL AND GREASE SPECIFICATIONS FOR NORMAL ENVIRONMENTS type specifications q.ty PARTS INVOLVED AGIP ARNICA 46 ISO-L-HV FZG 20 L Hydraulic system, lifting and power tests to stage 11 steering AGIP ATF II D GM DEXRON II 6137-M...
- Page 224 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter B 036-0410-07 page 4 RUNNING-IN MAINTENANCE TIMES TABLE at # hours for MEDIUM/INTENSE USE at # days/months FOR OCCASIONAL USE LIFTING UNIT - MASTS guide pads - masts and sideshift unit slides &...
- Page 225 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter B 036-0410-07 page 5 MAINTENANCE TIMES TABLES 500 1000 2000 5000 10000 after # hours FOR MEDIUM/INTENSE USE -/12 -/24 -/60 after # days/months FOR OCCASIONAL USE LIFTING EQUIPMENT - MASTS carriage - sideshift unit '"...
- Page 226 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter B 036-0410-07 page 6 MAINTENANCE TIMES TABLES 500 1000 2000 5000 10000 after # hours FOR MEDIUM/INTENSE USE -/12 -/24 -/60 after # days/months FOR OCCASIONAL USE ELECTRICAL SYSTEM ' ' ' ' ' electronic control ' ' ' ' ' contactors, pushbuttons, pedals and control valves...
- Page 227 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter C 036-0410-07 page 1 CHAPTER C SAFETY INFORMATION...
- Page 228 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter C 036-0410-07 page 2 SAFETY INFORMATION INDEX WORK CLOTHES page 3 WORK PLACE page 3 LIFTING THE TRUCK page 3 ELECTRIC PART page 4 WELDING page 5 TRUCK WASHING page 5...
- Page 229 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter C 036-0410-07 page 3 SAFETY INFORMATION Work clothes protective gloves overalls safety boots protective goggles Work place The work place must be lighted and aired. The area around the truck must be obstacles free Oil signs or grease substances must not be presents on the pavement (danger of sliding).
- Page 230 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter C 036-0410-07 page 4 ELECTRIC PART It is obligatory to disconnect the battery before doing any job to avoid the risk of accident. - Do not connect the chopper to a battery with a nominal voltage different from the voltage stated on the unit plate. If the battery voltage is higher, it may cause the MOS failure.
- Page 231 Electric 1,2 - 2,0 t A.C. SERVICE MANUAL chapter C 036-0410-07 page 5 Welding Wear a leather overall, gloves and a welding mask. It is obligatory to wear gloves and protective goggles during the grinding operations because they could cause the projection of metallic particles.
- Page 232 1,2 - 2,0 t A.C. Electric SERVICE MANUAL chapter C 036-0410-07 page 6 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 233 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE PÁGINA INTENCIONALMENTE BLANCA...
- Page 234 Cargo Range CESAB S.p.A via Persicetana Vecchia, 10 40132 Bologna - Italy Tel. (0039) 051.20 54 11 (0039) 051.72 80 07 E-mail: cesab@cesab.it...