CESAB B 200 Repair Manual
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CESAB B 200 Repair Manual

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Table of Contents

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REPAIR MANUAL
B 200
210- 213- 215
Code 036-0436-00
03/2012
https://www.forkliftpdfmanuals.com/

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Table of Contents
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Summary of Contents for CESAB B 200

  • Page 1 REPAIR MANUAL B 200 210- 213- 215 Code 036-0436-00 03/2012 https://www.forkliftpdfmanuals.com/...
  • Page 2 Document changes history: Edition Changes 036-0436-00 New version This manual covers the following truck models: Model Starting serial number Ending serial number B 210 CE365070 B 213 CE365283 B 215 CE364785 https://www.forkliftpdfmanuals.com/...
  • Page 3 INDEX GENERAL BATTERY CONTROLLERS DISPLAY TROUBLESHOOTING MOTOR DRIVE UNIT & REAR AXLE STEERING SYSTEM BRAKE BODY & FRAME MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE MAIN OPTIONS PROGRAMMER APPENDIX https://www.forkliftpdfmanuals.com/...
  • Page 4 https://www.forkliftpdfmanuals.com/...

  • Page 5: Table Of Contents

    GENERAL Page VEHICLE EXTERIOR VIEW.........0-2 VEHICLE MODELS............0-3 CHASSIS NUMBER .............0-3 TRUCK CAPACITY AND IDENTIFICATION PLATES ..............0-4 HOW TO USE THIS MANUAL........0-8 EXPLANATION METHOD ............0-8 TERMINOLOGY..............0-9 ABBREVIATIONS ..............0-9 ILLUSTRATIONS ..............0-9 SI UNITS ................0-10 OPERATING TIPS............0-11 GENERAL INSTRUCTIONS ..........

  • Page 6: Vehicle Exterior View

    VEHICLE EXTERIOR VIEW https://www.forkliftpdfmanuals.com/...

  • Page 7: Vehicle Models

    VEHICLE MODELS Load capacity Control method Supply voltage (V) 1.0 ton AC microcomputer controller ↑ ↑ 1.3 ton ↑ ↑ 1.5 ton CHASSIS NUMBER Serial number Vehicle type Serial number position format CE000000 CE000000 CE000000 https://www.forkliftpdfmanuals.com/...

  • Page 8: Truck Capacity And Identification Plates

    BATTERY V 6. Battery weight (min/max) 7. Truck weight (without battery) 8. Year of manufacture 9. Battery voltage CESAB Carrelli Elevatori S. p. A. 10. Notes Via Persicetana Vecchia 10 40132 - Bologna - Italia B: Load capacity plate ATTACHMENT OR SPECIAL CONDITION OF USE...
  • Page 9 TECHNICAL DATA https://www.forkliftpdfmanuals.com/...
  • Page 10 https://www.forkliftpdfmanuals.com/...
  • Page 11 a [mm] = 200 CAPACITY DIAGRAMS (with SE tyres) 1.0 t Barycentre [mm] Capacity [Kg] 1000 1000 BARYCENTRE [mm] 1.25 t Barycentre [mm] Capacity [Kg] 1250 1120 1010 1000 BARYCENTRE [mm] 1.5 t Barycentre [mm] Capacity [Kg] 1500 1340 1210 1100 1010 1000...

  • Page 12: How To Use This Manual

    HOW TO USE THIS MANUAL EXPLANATION METHOD Operating procedure (1) Operating procedures are described using either pattern A or pattern B Pattern A: Each step of the operation is explained with its own illustration Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and point operations Example of pattern B DISASSEMBLY ·...

  • Page 13: Illustrations

    Matters omitted from this manual This manual omits descriptions of the following jobs, but perform them in actual operation: Cleaning and washing of removed parts as required Visual inspection (partially described) TERMINOLOGY Caution: Important matters, whose negligence may cause accidents. Be sure to observe them. Note: Important items, whose negligence may cause accidents or matters during operating so it is required special attention.

  • Page 14: Si Units

    0-10 SI UNITS Meaning of SI This manual uses SI units. SI represents the International System of Units, which was established to unify the various systems of units used in the past for smoother international technical communication. New Units Adopted in SI Conventional Conversion rate Item...

  • Page 15: Operating Tips

    (6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each time they are disassembled (7) Use genuine Cesab parts for replacement (8) Use specified bolts and nuts and observe the specified tightening torque when reassembling (tighten to the medium value of the specified tightening torque range).

  • Page 16: Battery Recycling/Discarding

    0-12 BATTERY RECYCLING/DISCARDING This forklift truck uses a lead accumulator and, in case of some battery-powered trucks, a lithium battery. Materials contained in batteries (also accumulators) are hazardous to the environment and humans and therefore discarded batteries should be returned to the manufacturer for recycling.

  • Page 17: Jack-Up Point

    0-13 JACK-UP POINT Always observe the following instructions when jacking up the vehicle: • When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface. • Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous.

  • Page 18: Member Weights

    0-14 MEMBER WEIGHTS Member Vehicle model Weight (Kg) 372 ÷ 420 Battery 600 ÷ 690 676 ÷ 780 Drive motor 100 - 150 ~ 34 Pump motor (Hydraulic pump + electric motor) 100 - 150 ~ 40 Rear axle (without wheels and dry) 100 - 150 ~ 53 Counterweight...

  • Page 19: Towing The Truck

    0-15 TOWING THE TRUCK The standard fork lift trucks are not suited for towing. In special case, the rear draw bar can be used to tow a faulty lift truck. In this case it is obligatory to use a stiff towing bar, fastened between the rear draw bar of the truck and the towing vehicle.

  • Page 20: Electrical Parts Inspection

    0-16 ELECTRICAL PARTS INSPECTION 1. Always disconnect the battery plug before inspecting or servicing electrical parts. 2. Pay sufficient attention when handling electronic parts. (1) Never subject electronic parts, such as computers and relays, to impact (2) Never expose electronic parts to high temperature or moisture (3) Do not touch connector terminals, as they may be deformed or damaged due to static electricity...

  • Page 21: Tightening Torque Table

    0-17 TIGHTENING TORQUE TABLE The tables here below are valid for screws and bolts without superficial covering, preventively lubricated with oil. SCREWS WITH “ISO” METRIC COARSE THREAD PRELOADING V (N) TORQUE Max (Nm) Nominal diameter 10 K 12 K 10 K 12 K 10,9 12,9...

  • Page 22: Lubricants Capacity And Type Table

    0-18 LUBRICANTS CAPACITY AND TYPE TABLE Applicable place Capacity Type API GL-5 MT-1 6,20 l Drive unit Standard vehicle: Mobilube HD or equivalent Cold storage vehicle: Mobilube 1 SHC or equivalent Standard vehicle: Agip Arnica 46 or equivalent 18,0 l Hydraulic oil Cold storage vehicle: Agip Arnica VG32 or equivalent Standard vehicle: Mobilgrease Special or equivalent...

  • Page 23: Periodic Maintenance

    0-19 PERIODIC MAINTENANCE Periodic inspection and maintenance are necessary to keep your forklift truck running smoothly, and must be performed by specialized technicians: ask your Dealer Service Centre. Maintenance intervals are based on total operating hours, or months of truck life cycle, whichever comes first (i.e.

  • Page 24: Periodic Maintenance Table

    0-20 PERIODIC MAINTENANCE TABLE every 1 week months MAINTENANCE CYCLE (Based on total operating hours or months of truck life cycle, every 1000 2000 hours whichever comes first) DRIVE SYSTEM Wheels ← Tyre cuts, damage or uneven treads ← Metal chips, pebbles or other foreign matter trapped in tire tread I*, C* I, C ←...
  • Page 25 0-21 every 1 week months MAINTENANCE CYCLE (Based on total operating hours or months of truck life cycle, every 1000 2000 hours whichever comes first) ELECTRICAL SYSTEM General ← Truck insulation ← Static strap integrity (if present) Motor ← Cleaning I, C ←...
  • Page 26 0-22 every 1 week months MAINTENANCE CYCLE (Based on total operating hours or months of truck life cycle, every 1000 2000 hours whichever comes first) Controller ← Integrity, cleaning and operating condition I, C ← Presence of alarms in the logbook ←...
  • Page 27 0-23 every 1 week months MAINTENANCE CYCLE (Based on total operating hours or months of truck life cycle, every 1000 2000 hours whichever comes first) Brake pedal ← Pedal stroke and play ← Return stroke ← Linkages Parking brake ← Braking performance ←...
  • Page 28 0-24 every 1 week months MAINTENANCE CYCLE (Based on total operating hours or months of truck life cycle, every 1000 2000 hours whichever comes first) HYDRAULIC SYSTEM Cylinders ← Oil leakage ← Rod and rod end integrity, deformation, fastening ← Tilt cylinders mounting integrity, fastening, operating condition ←...
  • Page 29 0-25 every 1 week months MAINTENANCE CYCLE (Based on total operating hours or months of truck life cycle, every 1000 2000 hours whichever comes first) Seat ← Mounting integrity and fastening ← Seat switch operating condition ← Seat belt integrity and operating condition ←...

  • Page 30: Lubrication Chart

    0-26 LUBRICATION CHART 1. Fork positioning pins 2. Chain securing tie rods 3. Mast guides 4. Mast fasteners 5. Lifting chains 6. Brake fluid reservoir 7. Hydraulic oil tank 8. Transmission reduction gear 9. Steering unit 10. Side Shifter (OPT) Every 1000 hours (6 months) Every 2000 hours (12 months) Inspection and supply...
  • Page 31 BATTERY Page BATTERY CASING AND REQUIRED WEIGHT..1-2 BATTERY SERVICE STANDARDS ......1-3 DISPLAY..................1-3 MANAGING THE BATTERY........1-4 BDI ADJ MIN ................1-6 BDI ADJ MAX .................1-8 ADJUSTMENT 3 ..............1-9 ADJUSTING THE BATTERY VOLTAGE READING.. 1-12 ADJUST BATTERY ...............1-12 ADJUST CAPACITOR ............1-13 TROUBLESHOOTING ON THE BATTERY....

  • Page 32: Battery Casing And Required Weight

    BATTERY CASING AND REQUIRED WEIGHT if you purchase the battery locally, it must be of at least the following weight, as shown in the table: Size Capacity Minimum required of battery casing [mm] Vehicle model Battery (with casing) [Kg] (Ah) 400-500 700-875 800-1000...

  • Page 33: Battery Service Standards

    BATTERY SERVICE STANDARDS 1.280 [20 °C] Specific gravity (battery charged) 1.150 [20 °C] Specific gravity (80% battery discharged) Discharge end voltage 24 V 23.6 V Electrolyte Refined dilute sulfuric acid Fluid to be added Distilled water Insulation resistance 10MW or more * Battery value on standby (only with key ON and no power consumption) DISPLAY Battery Charge Indicator...

  • Page 34: Managing The Battery

    MANAGING THE BATTERY Battery discharge voltage and status indicator on the dashboard are managed by the Master traction logic unit. The indicator can be customised with the following parameters. Remarks: The battery indicator must be adjusted according to the characteristics and type of the battery installed in the truck.
  • Page 35 BDI RESET The BDI RESET parameter manages the indicator reset when the battery undergoes partial charges (trickle charge). It is expressed as a percentage of the reset curve and indicates the minimum recharge the battery has to receive for the partial or total reset of the indicator. Parameter Min value Max value...

  • Page 36: Bdi Adj Min

    BDI ADJ MIN The parameter BDI ADJ MIN determines the voltage below which the battery indicator signals 0% residual charge. Remarks: • When the battery indicator shows a residual charge of 0%, the specific weight of the electrolyte must not be less than 1.13 kg/ •...
  • Page 37 Setting BDI ADJ MIN The indicator may be set to modify the minimum battery voltage at which the last square switches off (indicator at 0%). At the end of discharging, the density value of the battery elements must not fall below 1.13 kg/l [POINT1] Access the SERVICE menu (see chapter 3, paragraph SERVICE MENU...

  • Page 38: Bdi Adj Max

    BDI ADJ MAX The parameter BDI ADJ MIN determines the voltage above which the battery indicator signals 100% charge. Parameter Min value Max value Step Standard Notes 0,00% = 25,320 V BDI ADJ MAX - 12,80% + 12,70% 0,10% - 3,00% ±...

  • Page 39: Adjustment 3

    ADJUSTMENT 3 The ADJUSTMENT 3 parameter determines the reset curve. Discharge curve + ADJUSTMENT 3 = Reset curve Parameter Min value Max value Step Standard Notes 0,00% = 0,000 V ADJUSTMENT 3 0,00% + 12,70% 0,10% + 3,00% ± 0,10% = ± 0,024 V ±...
  • Page 40 1-10 Battery indicator reset setting If after a battery charge cycle the indicator on the display has not reset, proceed as follows. [POINT1] At the end of complete charging. Disconnect the battery from the battery charger and connect it to the truck. Remarks: Ensure that the battery completes the whole charge cycle;...
  • Page 41 1-11 [POINT3] Access the SERVICE menu (see chapter 3, paragraph SERVICE MENU SERVICE MENU DESCRIPTION). Set the voltage PASSWORD measured at [POINT 2] in the SERVICE -> TRUCK CONF - > BATTERY -> menu, parameter BDI ADJ MAX Press twice TRUCK CONF Press OK and then 3 times BATTERY...

  • Page 42: Adjusting The Battery Voltage Reading

    1-12 ADJUSTING THE BATTERY VOLTAGE READING A correct adjustment allows a precise indication of the battery discharge. Use the ADJUST BATTERY and ADJUST CAPACITOR parameters to set the voltmeter inside the traction logic unit. Remarks: These parameter can be acquired with any battery discharge percentage. ADJUST BATTERY [POINT1] Connect the battery and turn on the truck.

  • Page 43: Adjust Capacitor

    1-13 ADJUST CAPACITOR [POINT1] Connect the battery and turn on the truck. Use a multimeter to measure the voltage present between the positive (+) and negative poles on the traction logic unit (-) 25,7 V [POINT2] Access the SERVICE menu (see chapter 3, paragraph SERVICE MENU SERVICE MENU DESCRIPTION).

  • Page 44: Troubleshooting On The Battery

    1-14 TROUBLESHOOTING ON THE BATTERY Plate corrosion Sulfation Plate warpage and active substance freeing Improper charging Repeated procedures Long time at over-discharge overdischarge End of life and overcharge without operation Short circuit of battery between cells of the battery Charging current Defect of electrolyte excessive Electrolyte...

  • Page 45: Inspection

    1-15 INSPECTION 1. Electrolyte level inspection: Before starting the inspection, ensure that the battery has been at rest for at least 30 minutes. Open the caps of each single battery element and check that the electrolyte level is high enough to cover the element plates.
  • Page 46 1-16 * How to use the hydrometer: (1) Fit the tube into the hole in the element containing the fluid, press teh pump, release it and let the fluid Hydrometer flow. (2) Allow the hydrometer to float without touching the Rubber external tube, or top or bottom, and when the bulb...

  • Page 47: State Of Battery Charge

    1-17 STATE OF BATTERY CHARGE The state of charge of a battery is measured by means of the electrolyte density. Before measuring the electrolyte, ensure that the battery has been at rest for at least 30 minutes (see previous paragraph). Remarks: The tables below represent ideal discharge values of lead-acid batteries Electrolyte density vs Discharged capacity RECOMMENDED...

  • Page 48: Battery Capacity

    1-18 BATTERY CAPACITY The capacity of a battery is the amount of electricity that it can supply to an external circuit before the voltage falls below the final limit value; it is expressed in Ah (Ampere-hour) The main factors that influence the capacity of lead-acid batteries are: (1)Discharge rate The capacity supplied at high discharge rates (high current intensity) is lower than that supplied at low discharge rates (low current intensity).

  • Page 49: Gel Batteries

    1-19 GEL BATTERIES The following paragraph provides general information on gel batteries. For more detailed information, refer to the supplier of the installed battery. It is possible to install and use GEL batteries on the forklift truck; always adapt their weight so as to respect the minimum weight required, as indicated in the table in the paragraph "BATTERY CASE AND REQUIRED WEIGHTS".

  • Page 50: Adjusting The Gel Battery Indicator

    1-20 ADJUSTING THE GEL BATTERY INDICATOR If the truck is fitted with a GEL battery, set the parameter BDI GEL = ON If this is not adjusted, it will not be possible to have a correct reading of the battery charge, risking serious damage to the battery itself.

  • Page 51: Battery

    1-21 BATTERY REMOVAL • INSTALLATION Removal procedure 1. Park the truck on a level surface and activate the parking brake 2. Turn off the truck 3. Open the compartment and disconnect the battery 4. Remove the battery safety locks [Point 1] 5.
  • Page 52 1-22 Point Operations [Point 1] Disassembly: Remove the battery safety hook (A) [Point 2] Disassembly: Remove the battery from the truck https://www.forkliftpdfmanuals.com/...
  • Page 53 CONTROLLERS Page GENERAL ..............2-2 SPECIFICATIONS............2-3 BEFORE REPAIR ............2-4 MAIN CONTROLLERS ..........2-6 TRACTION LOGIC UNIT............2-6 LIFTING LOGIC UNIT .............2-7 I/O BOARD ................2-8 ARMREST CARD..............2-11 MHYRIO.................2-13 CONTACTOR GROUP ............2-15 DASHBOARD................2-16 CONTROL UNIT ............2-17 I/O CONTROL BOARD..........2-21 MHYRIO LOGIC UNIT ..........

  • Page 54: General

    GENERAL The truck is equipped with traction & lifting logic units that control traveling and material handling system. They are multi-functional controllers equipped with micro computers. The traction & lifting logic units provide high performance in a wide range by means of inverter control of the AC motor drive system.

  • Page 55: Specifications

    SPECIFICATIONS 1.0 - 1.5 t FT (traction logic unit) 350 A POWER FUSES FP (lifting logic unit) 350 A F1 (I/O board) BLADE FUSE 10 A F2 (optional fuse holder) BLADE FUSE 40 A FUSES (+Vb) F3 (heater) BLADE FUSE 40 A F4 (key) BLADE FUSE 5 A CT1 (line)

  • Page 56: Before Repair

    BEFORE REPAIR INSPECTION Insulation resistance measurement Note: Carry out the measurement before inspecting the traction/lifting units. (1)Disconnect the battery plug and measure the resistance between the plug and the battery body Measurement terminals Logic units side of battery plug-body The resistance value depends greatly on the vehicle operating state, place Standard: and weather.
  • Page 57 CONNECTOR INSPECTION When inspect each board and find the cause of the trouble, do not replace the board immediately but check the following items. • Abnormalies in related harnesses • Looseness of the related connectors • Bending or damage of connector pin and defective contact of any related connector pin If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will be damaged.

  • Page 58: Main Controllers

    MAIN CONTROLLERS TRACTION LOGIC UNIT Basic conditions (battery plug connected, key switch ON). See the reference names of the connectors in the electrical diagram. CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ To JT (1-R04) J50 (2-R04) Input +V key JT (2-AG) J14 (3-AG) Output +V steering potentiometer...

  • Page 59: Lifting Logic Unit

    LIFTING LOGIC UNIT Basic conditions (battery plug connected, key switch ON). See the reference names of the connectors in the electrical diagram. CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ JP (1-R04) J50 (2-R04) Input +V key JP (2) Unused JP (3) Unused...

  • Page 60: I/O Board

    I/O BOARD (black connector) (white connector) Basic conditions (battery plug connected, key switch ON). See the reference names of the connectors in the electrical diagram. CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ J34 (1-MN) J93 (2-MN) Output +V rear lights J29 (2-HG) J34 (2-HN) Accelerator potentiometer negative ouptut...
  • Page 61 CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ GND with J34 (16-BM) J35 (4-BM) Horn button signal input micro closed J34 (17) Unused double pedal system reverse micro input GND with J34 (18-BN) J33 (9-BN) double micro closed J35 (3-RN) GND with J34 (19-RN)
  • Page 62 2-10 CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ J40 (11-V) J48 (11-V) Potentiometer cursor input lifting 0 - 5V J40 (12) Unused J40 (13) Unused J40 (14) Unused J40 (15-AN) CAN-BUS HIGH J40 (16-GR) J23 (3-GR) Output +V Tilt lock solenoid valve J40 (17-N) negative input J40 (18)

  • Page 63: Armrest Card

    2-11 ARMREST CARD JTRA JCAN JBRA JAUX JSOLL Basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle]. See the reference names of the connectors in the electrical diagram. CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ JCAN (1-HG) CAN-BUS LOW JCAN (2-AN)
  • Page 64 2-12 CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ JSOLL (7) Unused JSOLL (8) Negative micro JBRA (1) +V Pot JBRA (2) Pot slide 0-5V JBRA (3) Unused JBRA (4) Negative potentiometer JBRA (5) Microswitch JBRA (6) Microswitch JBRA (7) Unused JBRA (8)

  • Page 65: Mhyrio

    2-13 MHYRIO Basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle]. See the reference names of the connectors in the electrical diagram. CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ J50 (6-R07) J140 (1-R07) Output + V Board power J50 (5-R07) J50 (6-R07) J140 (2-R07)
  • Page 66 2-14 CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ JCM (1-GN) J107 (2-GN) solenoid valve negative output EVP1 J107 (1-G) JCM (2-G) Output +V solenoid valve EVP1 and EV2 +24V J108 (1-G) JCM (3-BG) J108 (2-BG) Solenoid valve negative output EV2 JCM (4-BM) J109 (2-BM) Solenoid valve negative output EV3...

  • Page 67: Contactor Group

    2-15 CONTACTOR GROUP Basic conditions (battery plug connected, key switch ON). See the reference names of the connectors in the electrical diagram. CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ J50 (1-Z) JT (16-Z) Contactor CT2 negative input J50 (2-R04) J50 (4-R02) Relay US3 power input...

  • Page 68: Dashboard

    2-16 DASHBOARD Basic conditions (battery plug connected, key switch ON). See the reference names of the connectors in the electrical diagram. CN (pin-colour) ⇔ CN (pin-colour) Description Standard Notes From ⇔ J137 (1-AN) CN1 (20-AN) CAN-BUS HIGH J137 (2-HG) CN1 (22-HG) CAN-BUS LOW J137 (3-N) J1 (-)

  • Page 69: Control Unit

    2-17 CONTROL UNIT MAIN CONTROL UNIT Traction Logic Unit Lifting Logic Unit ACE-2 ACE-2 Inverter for AC asynchronous 3-phase motors Regenerative braking functions Can-bus interface Flash Memory Digital control based upon a microcontroller Power 24 V 24 V Maximum current 350 A (RMS) 350 A (RMS) Operating frequency...
  • Page 70 2-18 CHECK TRACTION MOTOR PHASES BALANCING When traveling or material handling operation seems abnormal, it is possible to accurately judge if the controller is functioning correctly or not by measuring the motor phase balancing. Measuring method Procedure using a clamp amperometer (1)Remove the rear plastic (2)Jack up the front wheels (3)Connect a clamp amperometer...
  • Page 71 2-19 CHECK LIFTING MOTOR PHASES BALANCING Measuring method Procedure using a clamp amperometer (1)Remove the rear plastic (2)Jack up the front wheels (3)Connect a clamp amperometer (4)Operate the lifting lever (5)Check the value of the current of each phase (6)If the value of one phase is higher or lower respect the others it means that the system is not balanced and the motor is jerking.
  • Page 72 2-20 REMOVAL • INSTALLATION Before starting, disconnect the battery plug and measure the voltage across (+) and GND; if voltage is present, fit a 100Ω resistance between (+) and GND to discharge the condensers. Removal procedure 1. Remove the boot 2.

  • Page 73: I/O Control Board

    2-21 I/O CONTROL BOARD The card is located on the left side of the truck under the footboard. It controls and converts analogue signals to digital signals and vice versa. REMOVAL • INSTALLATION Removal procedure 1. Remove the footboard 2. Disconnect the connectors on the I/O control board 3.

  • Page 74: Mhyrio Logic Unit

    2-22 MHYRIO LOGIC UNIT OPERATIONAL FEATURES It works to 24 V and it is located on the left side of the truck below the left tilting cylinder. The Mhyrio card receives the digital inputs from the CAN and it converts them into analogue signals to control the solenoid valves.

  • Page 75: Contactor Group

    2-23 CONTACTOR GROUP REMOVAL • INSTALLATION Removal procedure 1. Remove the boot 2. Move the seat forward 3. Move the lever of the mechanic control valve forward (only with mechanic control valve version) 4. Open the battery cover 5. Disconnect the battery 6.

  • Page 76: Inspection

    2-24 INSPECTION MB (power supply contactor) Inspection method. Disconnect the connector from the wiring harness and measure the resistance of the coil. Part to be Measurement Tester Standard inspected measurament range: Both Approx. Ω × 1 Coil CT1 104 Ω coil terminals Both Approx.

  • Page 77: Dashboard

    2-25 DASHBOARD If the cause of trouble is in the display, measure the voltage at connector to whom voltage is applied. J137 connector basic condition (Battery plug connected) CN (pin-colour) Û CN (pin-colour) Description Standard Notes From ⇔ J137 (9-N) J1 (-) GND from battery P137 (8-R3)

  • Page 78: Armrest Card

    2-26 ARMREST CARD COMPONENTS Joysticks Fingertip Armrest Armrest card Wiring Direction switch Internal cabling Guard Guard Finger-tip Cushion Wiring Knob Guard Joystick REMOVAL • INSTALLATION Removal procedure 1. Park the vehicle on a level surface and apply the parking brake 2.
  • Page 79 2-27 Point Operations [Point 1] Disassembly: Disconnect wiring (A), placed in the armrest back part [Point 2] Disassembly: Remove the 4 fixing screws (B) placed in the armrest lower side [Point 3] Disassembly: Disconnect armrest board wirings and remove the armrest board 4 fixing screws https://www.forkliftpdfmanuals.com/...

  • Page 80: Fuse 24 Volt

    2-28 FUSE 24 VOLT This fuse box is situated under the dashboard and feeds only the optional equipments. 1. J90 connector for auxiliary wiring feeding 2. Feeding fuses positive connection bars 3. Connector for direction indicator intermittence Fuses Capacity (A) Wire colour Destination unused...

  • Page 81: Accelerator Potentiometer Adjustment

    2-29 ACCELERATOR POTENTIOMETER ADJUSTMENT Check the ON/OFF condition of the switch 1.1. SW8 (single pedal) 1.2. SW4 - SW5 (double pedal) Measurement terminals Status Pedal not ∞ Ω operated: Standard: Pedal operated Continuity Adjustment of Accelerator Potentiometer (P2) Installation (1) Before installing a new traction potentiometer it is suggest to check it with an analogue multimeter.

  • Page 82: Adjusting The Foot Brake Switch

    2-30 ADJUSTING THE FOOT BRAKE SWITCH Adjust the brake pedal play (approx. 1mm). Adjust brake rod length. Check the continuity of the speed reduction switch Standard: Not operated: OFF (∞ Ω ) operated: ON (0 Ω ) Check that the microswitch for the regenerative brake Approximately 1mm turns ON (OFF) when the brake pedal is depressed Brake pedal play in neutral position...

  • Page 83: Lifting Potentiometer Adjustment

    2-31 LIFTING POTENTIOMETER ADJUSTMENT Check the ON/OFF condition of the switch Measurement terminals Status Neutral position of ∞ Ω the lever CONTROL ROD Standard: Lever pulled Continuity Microswitch adjustment: MICROSWITC After the installation perform the following adjustments: Keep the microswitch in rest position as shown in the drawing according to the following points: •...

  • Page 84: Necessary Adjustments After Ahardware Component Replaced

    2-32 NECESSARY ADJUSTMENTS AFTER A HARDWARE COMPONENT REPLACED I/O BOARD Acquisition Serial number (LEARN SERIAL NUMBER) Accelerator potentiometer (LEARN TRAC POT) Lifting potentiometer (only in the mechanic distributor version) (LEARN LIFT POT) Balanced pedal configuration (SWAYING PEDAL) TRACTION LOGIC UNIT Acquisition Serial number (LEARN SERIAL NUMBER) Steering potentiometer (SET STEER ZERO/SET STEER LEFT/SET STEER RIGHT)
  • Page 85 DISPLAY Page MULTIFUNCTION DISPLAY ........3-2 GENERAL ................ 3-2 MAPS FOR USING THE DASHBOARD ....3-4 USER MENU ............3-4 USER MENU MAP ............3-5 USER MENU DESCRIPTION......... 3-6 USER MENU ..............3-7 HOUR METER ..............3-8 TRIP ................. 3-8 CLOCK................

  • Page 86: Multifunction Display

    MULTIFUNCTION DISPLAY The multi-function instrument panel helps operators to identify various information easily by changing screens depending on the vehicle conditions. GENERAL J137 PIN 14 PIN 1 Icon Description Flat battery indicator It flashes when battery drops below 20% charge Parking brake indicator enabled Dead man device indicator: The indicator comes ON when the driver leaves the driving seat without switching OFF the truck;...
  • Page 87 Icon Description Selected gear indicator Hour indicator Timer indicator Selected program indicator Steering direction indicator Hour meter mode indicators lifting motor, traction motor or key switch Password: The option activation button permits to digit the access password Board: it permits to navigate between the menus Brakes liquid level warning light: Braking system fault.

  • Page 88: Maps For Using The Dashboard

    MAPS FOR USING THE DASHBOARD USER MENU https://www.forkliftpdfmanuals.com/...

  • Page 89: User Menu Map

    USER MENU MAP hh:mm gg/mm/aa TRIP H:M 00000:00 https://www.forkliftpdfmanuals.com/...

  • Page 90: User Menu Description

    USER MENU DESCRIPTION The "user" menu is accessible to any operator, and allows to modify the parameters series contained in the chart USER MENU. USER MENU PASSWORD Notes on password insertion 1. Make sure to operate on the display membrane buttons using fingers only. Sharped or pointed tools can damage the buttons 2.

  • Page 91: User Menu

    USER MENU Menu Description Notes Unless otherwise The display shows the hours of work done: specified, the hour WORKING: lifting motor working counter counts the lifting TRACTION: traction motor working HOUR METER motor operation and can KEY: truck on (inserted key) be reset by the service RENT: rental time counter staff...

  • Page 92: Hour Meter

    HOUR METER Enter the user menu [see USER MENU PASSWORD INSERTION PROCEDURE paragraph] Press to view the information referred to the hour meter To exit the menu use lateral flowing arrows TRIP Press to view the information referred to the trip Press OK to reset the hours count TRIP H:M 00000:00...

  • Page 93: Clock

    CLOCK Enter the user menu [see USER MENU PASSWORD INSERTION PROCEDURE paragraph] Press OK to enter into the clock menu Remarks: The clock icon flashes Press to modify the setting. Press OK to confirm. Remarks: The selected modality has a flag beside Use the flowing arrows to set the hours Press OK to confirm hh:mm...

  • Page 94: Alarms

    3-10 3-10 ALARMS SETTING Enter the user menu [see USER MENU PASSWORD INSERTION PROCEDURE paragraph] to reach the clock alarm menu Press OK to confirm Remarks: The clock icon flashes Press OK to confirm Use the flowing arrows to set the hours hh:mm Press OK to confirm Use the scroll arrows to set the date...

  • Page 95: Display Setting

    3-11 3-11 DISPLAY SETTING TRUCK HOUR METER Enter the user menu [see USER MENU PASSWORD INSERTION PROCEDURE paragraph] to reach the display setting menu Press OK to confirm Press OK to confirm Press OK to confirm Use the scroll arrows to set the hour meter modality viewed on the display.
  • Page 96 3-12 LANGUAGE Enter the user menu [see USER MENU PASSWORD INSERTION PROCEDURE paragraph] to reach the display setting menu Press OK to confirm to reach the language setting menu Press OK to confirm to select the desired language Press OK to confirm Press OUT to exit the menu https://www.forkliftpdfmanuals.com/...
  • Page 97 3-13 3-13 STEERING DIRECTION Enter the user menu [see USER MENU PASSWORD INSERTION PROCEDURE paragraph] to reach the display setting menu Press OK to confirm to reach the steering direction setting menu Press OK to confirm to select the desired visualization. Press OK to confirm Press OUT to exit the menu https://www.forkliftpdfmanuals.com/...

  • Page 98: Maps For Using The Dashboard

    3-14 MAPS FOR USING THE DASHBOARD SERVICE MENU https://www.forkliftpdfmanuals.com/...

  • Page 99: Service Menu Description

    3-15 3-15 SERVICE MENU DESCRIPTION The "service" menu allows to enable all necessary functions for assistance, maintenance and rental activities. The access to this menu is for authorized personnel only. SERVICE MENU PASSWORD Notes on password insertion 1. Make sure to operate on the display membrane buttons using fingers only. The use of sharp or pointed tools could damage the buttons.

  • Page 100: Service Menu Map

    3-16 3-16 SERVICE MENU MAP PLEASE INSERT SERV. PASSWORD SOFT VERS PARAM CHANGE TRUCK CONF SERVICE RENT PSW MODIFY TESTER ALARMS LEARNING DEFAULT RST https://www.forkliftpdfmanuals.com/...

  • Page 101: Service Menu Functions

    3-17 SERVICE MENU FUNCTIONS Menu Description SOFTWARE VERSION Visualizes the software version of boards and logic units PARAMETER CHANGE Modify the selected program parameters TRUCK CONFIGURATION Modify the configuration parameters SERVICE RENT It allows to set up the programmed maintenance menu and rent menu MODIFY PASSWORD It allows to modify the passwords or to restore default ones TESTER...

  • Page 102: Soft Vers

    3-18 SOFT VERS Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press OK to confirm Use right and left arrows board buttons to navigate the menu Press OUT to exit the menu identifies the version of the installed software Remarks: X.XX https://www.forkliftpdfmanuals.com/...

  • Page 103: Software Version Menu Map

    3-19 3-19 SOFTWARE VERSION MENU MAP PLEASE INSERT SERV. PASSWORD SOFT VERS 1 - MCB 2 - ARMREST 3 -TRACTION 4 - MHYRIO 5 - PUMP 6 -DISPLAY SOFT VERS FUNCTION The SOFT VERS function is used to display the versions of the board and logic unit software installed in the truck.

  • Page 104: Param Change

    3-20 PARAM CHANGE Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press till reach the PARAM CHANGE menu Press OK to enter the menu to select TRACTION (traction parameters) MAT. HANDLING (hydraulic function parameters) Press OK to confirm Use buttons to navigate the menu Use the button...

  • Page 105: Param Change Advanced

    3-21 3-21 PARAM CHANGE ADVANCED Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press till reach the PARAM CHANGE menu Hold down the OK key for approx. 5 sec to enable the PARAMETER CHANGE ADVANCE menu to select TRACTION (traction parameters) MAT.
  • Page 106 3-22 PARAMETER CHANGE MENU MAP PLEASE INSERT SERV. PASSWORD SOFT VERS PARAM CHANGE PARAM CHANGE BASIC PARAM CHANGE ADVANCED TRACTION MAT. HANDLING TRACTION MAT. HANDLING 2 - T CURVE CUTBACK 1 - T TURTLE CUTBACK 1 - MIN SPEED UP 1 - MIN SPEED UP 7 - MAX SPEED FW 2 - MAX SPEED UP...
  • Page 107 3-23 3-23 TRACTION FUNCTION The Traction function is used to view/modify the traction system parameters. 1 - T TURTLE CUTBACK DESCRIPTION MIN. STEP UNIT Determines the speed reduction of the turtle function Minimum setting = maximum reduction Maximum setting = no reduction 2 - T CURVE CUTBACK DESCRIPTION MIN.
  • Page 108 3-24 4 - T SPEED CUTBACK DESCRIPTION MIN. STEP UNIT This parameter determines the traction speed reduction in relation to the state of the microswitch (normally closed N.C.) between pin 13 connector JT and pin 9 connector JT: Microswitch open = reduction on Microswitch closed = reduction off Minimum setting = maximum reduction Maximum setting = no reduction...
  • Page 109 3-25 3-25 6 - ANGLE THRESHOLD DESCRIPTION MIN. STEP UNIT Determines the steering angle from where the speed reduction starts °a on a bend, set by the parameter T CURVE CUTBACK SPEED REDUCTION RAMP IN CURVE Speed (%) T CURVE CUTBACK Steering angle (°a) °a ANGLE THRESHOLD...
  • Page 110 3-26 10 - SPEED LIMIT BRK DESCRIPTION MIN. STEP UNIT Determines the deceleration ramp when the accelerator pedal is 17.5 partially released Minimum setting = minimum deceleration Maximum setting = maximum deceleration 11 - INVERSION BRK DESCRIPTION MIN. STEP UNIT Determines the deceleration ramp when the direction is inverted 13.5 Minimum setting = minimum deceleration...
  • Page 111 3-27 3-27 14 - ACC SMOOTH DESCRIPTION MIN. STEP UNIT Determines the acceleration delay in the range between 0Hz and the frequency established by the STOP SMOOTH parameter: Minimum setting = maximum acceleration Maximum setting = minimum acceleration 15 - INV SMOOTH DESCRIPTION MIN.
  • Page 112 3-28 19 - THROTTLE X DESCRIPTION MIN. STEP UNIT Determines an X value zone in the acceleration curve Image reference 2 20 - THROTTLE Y DESCRIPTION MIN. STEP UNIT Determines an Y value zone in the acceleration curve Image reference 2 TRACTION POTENTIOMETER CURVE MAX SPEED THROTTLE Y...
  • Page 113 3-29 3-29 MAT. HANDLING The Mat. The Handling function is used to view/modify the hydraulic system parameters. 1 - MIN SPEED UP DESCRIPTION MIN. STEP UNIT Determines the minimum lifting speed Minimum setting = minimum speed Maximum value = maximum speed 2 - MAX SPEED UP DESCRIPTION MIN.
  • Page 114 3-30 6 - V WAY SPEED FINE DESCRIPTION MIN. STEP UNIT Determines the maximum 5th way speed Minimum setting = minimum speed Maximum value = maximum speed 7 - HYDRO SPEED FINE DESCRIPTION MIN. STEP UNIT Determines the frequency supplied to the pump motor to the hydraulic steering system Minimum setting = slow steer Maximum value = Fast steer...
  • Page 115 3-31 3-31 9 - P CUTBACK SPEED1 DESCRIPTION MIN. STEP UNIT This parameter determines the pump motor speed reduction in relation to the state of the microswitch (normally closed N.C.) between pin 13 connector JP and pin 9 connector JP: Microswitch open = reduction on Microswitch closed = reduction off Minimum setting = maximum reduction...
  • Page 116 3-32 12 - P THROTTLE 0 DESCRIPTION MIN. STEP UNIT This parameter determines a 0 value zone in the acceleration bend Only for version with mechanical distributor (Image reference 4) 13 - P THROTTLE X DESCRIPTION MIN. STEP UNIT Determines an X value zone in the acceleration curve Only for version with mechanical distributor (Image reference 4) 14 - P THROTTLE Y...
  • Page 117 3-33 3-33 15 - CURVE MODE DESCRIPTION MIN. STEP UNIT Determines the sensitivity of the joystick according to the potentiometer stroke Minimum setting = very sensitive Maximum setting = insensitive Only for version with electro-proportional distributor (Image reference 5) LIFTING POTENTIOMETER CURVE FINGERTIPS/JOYSTICK CURVE MODE 0 % EVP % RPM...
  • Page 118 3-34 TRUCK CONF Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press till reach the TRUCK CONF menu Press OK to confirm to select the required menu Press OK to confirm to navigate inside the menu and select the required parameter Press OK to confirm Press...
  • Page 119 3-35 TRUCK CONFIGURATION MENU MAP 1 - LOCK SET 4 - DY PIN ENABLE OPTION 2 - START ICON 5 - SWAYING PEDAL PLEASE INSERT 3 - PIN CODE 6 - GEAR RATIO SERV. PASSWORD SOFT VERS 1 - T MAX CURRENT 2 - P MAX CURRENT MOTORS PARAM CHANGE...
  • Page 120 ON = LPH function disabled ON-OFF OFF = LPH function enabled This parameter determines which logo must be visualized at the start- START ICON Cesab-BT Enables/Disables the PIN CODE entry request when switching on: PIN CODE NONE = disabled DISPLAY = enabled...
  • Page 121 3-37 RESET FUNCTION Reset of the hours counter and Fingertips-Joystick configuration Parameter Description Notes MCB board configuration reset RESET JOY FLAG (Mechanical/electro-proportional distributor) RESET PUMP HM Pump hours counter reset RESET TRAC HM Traction hours counter reset RESET KEY HM Key hours counter reset BATTERY FUNCTION Used to modify the battery indicator parameters.
  • Page 122 3-38 VALVE CURRENT FUNCTION Displays and modifies the currents of the solenoid valves of the electro-proportional distributor. Parameter Description Notes Determines the min. current of the DRAIN coil MIN CURRENT DRAIN min. = 100 mA max. = 500 mA Determines the max. current of the DRAIN coil MAX CURRENT DRAIN min.
  • Page 123 3-39 SERVICE RENT The SERVICE RENT function is used to set a time interval (days or hours of pump operation) after which the display cuts in speed reductions. NO REDUCTIONS NO REDUCTIONS NO REDUCTIONS WARNING WARNING SWITCH ON SWITCH ON WARNINGS ON THE DISPLAY WARNING...
  • Page 124 3-40 SERVICE RENT MENU MAP PLEASE INSERT SERV. PASSWORD SOFT VERS PARAM CHANGE TRUCK CONF SERVICE RENT WITH “RENT TIME/DAY” = DAY 1 - SERV TIMER EN 2 - RESET SERV HM 12 - RESET RENT HM 13 - RENT REQ TIME 3 - SERV REQ TIME 4 - SERV TIME BLIK 14 - RENT TIME BLINK...
  • Page 125 3-41 Function Description Notes SERV TIMER EN Enables/disables the programmed maintenance timer (service timer enable) RESET SERV HM (reset service This function resets the SERV TIMER EN timer hour meter) When the set This function determines the maintenance interval: SERV REQ TIME time expires the A reference (PROGRAMMED MAINTENANCE (service request time)
  • Page 126 3-42 Function Description Notes RENT icon and RENT REQ TIME expired notice: RENT TIME BLINK red led flash C reference (PROGRAMMED RENT DIAGRAM) (rental time blink) when the truck is RENT DIAGRAM) switched on This function determines, RENT REQ TIME expired, RENT CUT TIME after how much time the truck enters in limited working (rental cutback time)
  • Page 127 3-43 PSW MODIFY The PSW MODIFY function is used to associate profiles and modify the truck switch on code passwords. Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press till reach the PSW MODIFY menu Press OK to confirm to select CHANGE or DEFAULT Press OK to confirm...
  • Page 128 3-44 PSW MODIFY MENU MAP PLEASE INSERT SERV. PASSWORD SOFT VERS PARAM CHANGE TRUCK CONF SERVICE RENT PSW MODIFY 1 - CHANGE 2 - DEFAULT https://www.forkliftpdfmanuals.com/...
  • Page 129 3-45 Function Description Notes Code = switch on code This function allows to modify pin code and related profile PR = profile associated to the switch on code PSW CHANGE CHANGE CODE 00323 Reference to the Reset all the default passwords DEFAULT PIN CODE table SWITCHING THE TRUCK ON USING THE PIN CODE...
  • Page 130 3-46 TESTER The tester function is used to view the electronic components present on the truck (current, voltage, temperature, status, etc.) Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press to reach the TESTER menu Press OK to enter the menu to select TRACTION (traction) MAT.
  • Page 131 3-47 TESTER MENU MAP SPEED SET MOT SPEED MOT SLEEP MOT SPEED TRACTION POT SERVICE BRK SEAT FORWARD NOT FW BACKWARD NOT BW TRACTION ENABLE PLEASE INSERT NOT EN 10 - PARKING BRAKE SERV. PASSWORD MOTOR TEMP 11 - CONTR TEMP 12 - MOTOR VOLTAGE 13 -...
  • Page 132 3-48 TRACTION FUNCTION Views the traction system values Parameter Description Notes SPEED SET Theoretical speed requested to the drive motor MOT SPEED Drive motor encoder frequency MOT SLEEP Speed difference between the rotating field and the driving shaft MOT SPEED Drive motor encoder frequency TRACTION POT Accelerator potentiometer signal voltage...
  • Page 133 3-49 MAT. HANDLING Mechanical lever control valve Displays the hydraulic system settings for the mechanical version Ref. Parameter Description Notes LIFE PUMP Pump working hour counter from the first start Hours LIFE KEY Key working hour counter from the first start Hours SPEED SET Theoretical speed requested to the pump motor...
  • Page 134 3-50 ALARMS The alarms function is used to view the error codes present on the truck in real time and the last 20 errors memorized in the display Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press till reach the ALARMS menu Press OK to confirm Use right and left arrows board buttons to navigate the menu...
  • Page 135 3-51 ALARMS MENU MAP PLEASE INSERT SERV. PASSWORD SOFT VERS PARAM CHANGE TRUCK CONF SERVICE RENT PSW MODIFY TESTER ALARMS REALTIME LOGBOOK 1 - READ 2 - CLEAR https://www.forkliftpdfmanuals.com/...
  • Page 136 3-52 LEARNING The learning function is used to memorize in the various cards and logic units the minimum and maximum traction, lifting, steering potentiometer settings and to indicate the battery voltage and truck serial number Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press till reach the LEARNING menu...
  • Page 137 3-53 ALARMS MENU MAP PLEASE INSERT SERV. PASSWORD SOFT VERS PARAM CHANGE TRUCK CONF SERVICE RENT PSW MODIFY TESTER ALARMS LEARNING 1 - SERIAL NUMBER 5 - ADJUST CAPACITOR 2 - LEARN TRAC POT 6 - SET STEER ZERO 3 - LEARN LIFT POT 7 - SET STEER RIGHT 4 - ADJUST BATTERY 8 - SET STEER LEFT...
  • Page 138 3-54 Function Description Notes The serial number This function identifies the truck serial number acquisition must be LEARNING repeated each time a card or logic unit is SERIAL NUMBER replaced on the truck. To enter in the menu SERIAL NUMBER 000XXXXXX CHANGE ? To confirm and start...
  • Page 139 3-55 Function Description Notes The traction potentiom- Accelerator potentiometer acquisition eter acquisition must LEARNING be repeated whenever the MCB card or poten- LEARN TRAC POT tiometer is replaced. If the display does not memorize the acquisi- To enter the menu and tion data, repeat the start acquisition SERIAL NUMBER...
  • Page 140 3-56 Function Description Notes The lifting potentiome- Lifting potentiometer acquisition ter can be acquired LEARNING only on versions with electro-proportional LEARN LIFT POT distributor The lifting potentiome- ter acquisition must be To enter the menu and repeated whenever the start acquisition MCB card or potenti- ometer is replaced.
  • Page 141 3-57 Function Description Notes See chapter 1 para- Parameter used to set the voltmeter inside the traction graph ADJUSTING logic unit for reading the battery voltage THE BATTERY VOLT- LEARNING ADJUST BATTERY If the display does not memorize the acquisi- tion data, repeat the SERIAL NUMBER To enter the menu and...
  • Page 142 3-58 Function Description Notes See chapter 1 para- Parameter used to set the voltmeter inside the traction graph ADJUSTING logic unit for reading the battery voltage THE BATTERY VOLT- LEARNING ADJUST CAPACITOR If the display does not memorize the acquisi- tion data, repeat the SERIAL NUMBER To enter the menu and...
  • Page 143 3-59 Function Description Notes The steering potenti- Steering potentiometer acquisition in central position ometer acquisition (direction wheels straight) must be repeated LEARNING whenever the traction logic unit or potentiom- SET STEER ZERO eter is replaced. If the display does not memorize the acquisi- To enter the menu and tion data, repeat the...
  • Page 144 3-60 Function Description Notes The steering potenti- Steering potentiometer acquisition in right limit switch ometer acquisition position (steering wheels turned fully to the right) must be repeated LEARNING whenever the traction logic unit or potentiom- SET STEER RIGHT eter is replaced. If the display does not memorize the acquisi- To enter the menu and...
  • Page 145 3-61 Function Description Notes The steering potenti- Steering potentiometer acquisition in left limit switch ometer acquisition position (steering wheels turned fully to the left) must be repeated LEARNING whenever the traction logic unit or potentiom- SET STEER LEFT eter is replaced. If the display does not memorize the acquisi- To enter the menu and...
  • Page 146 3-62 DEFAULT RST Enter the service menu [see SERVICE MENU PASSWORD INSERTION PROCEDURE paragraph] Press till reach the DEFAULT RST menu Press OK to enter the menu Use buttons to navigate the menu Press OK to select the required parameter Press OK to save Press OK to exit without saving Turn the truck off and on again...
  • Page 147 3-63 DEFAULT RST MENU MAP PLEASE INSERT SERV. PASSWORD SOFT VERS PARAM CHANGE TRUCK CONF SERVICE RENT PSW MODIFY TESTER ALARMS LEARNING DEFAULT RST 1 - MCB 4 - MHYRIO 2 - ARMET 5 - PUMP 3 - TRACTION 6 - DISPLAY https://www.forkliftpdfmanuals.com/...

  • Page 148: Incorrect Start" Management

    3-64 “INCORRECT START“ MANAGEMENT The “INCORRECT START“ are recoverable errors, generated by: • an incorrect starting procedure • an incorrect sequence of use of the controls These alarms block truck functioning temporarily, generating an alarm icon on the display. Summary table of the “INCORRECT START“ Icon Description Configuration.
  • Page 149 TROUBLESHOOTING Page CONNECTOR CHECK..........4-2 BEFORE TROUBLESHOOTING..........4-2 WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE ............4-3 INSULATION CONTROL PROCEDURE .....4-5 MOTOR WINDING CONTROL PROCEDURE.....4-5 MECHANIC DISTRIBUTOR SYSTEM CONFIGURATION.............4-6 ELECTRIC DISTRIBUTOR SYSTEM CONFIGURATION.............4-7 DIAGNOSIS CODE LIST ..........4-8 WHEN AN ERROR CODE IS DISPLAYED....4-14 TRACTION LOGIC UNIT ............

  • Page 150: Connector Check

    CONNECTOR CHECK BEFORE TROUBLESHOOTING Disconnect the battery plug before connecting or disconnecting each connector or terminal When disconnecting a connector, do not pull it at the harness but hold the connector itself and pull it after unlocking it. To connect, push the connector fully until it is locked in position Bring a tester probe into contact with a connector terminal from the rear side of the coupler (harness side)

  • Page 151: Wire Harness And Connector Inspection Procedure

    WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to the following procedure: Continuity check Disconnect the connectors at both ends of the corresponding harnesses Measure the resistance between corresponding terminals of the connectors at both ends.
  • Page 152 Visual and contact pressure checks • Disconnect the connectors at both ends of the corresponding harnesses • Visually inspect that there is neither rust nor foreign matter trapped at connector terminals • Inspect that there is no loosening or damage at the locked portion.

  • Page 153: Insulation Control Procedure

    INSULATION CONTROL PROCEDURE When any trouble occurs, first inspect the truck insulation and its components, according to the following procedure: Truck insulation check Disconnect the battery from the truck Measure the resistance between the truck plug positive and the chassis (in an unpainted point) Standard: 10 MΩ...

  • Page 154: Mechanic Distributor System Configuration

    MECHANIC DISTRIBUTOR SYSTEM CONFIGURATION WIRING HARNESS CONTROL VALVE DASHBOARD MECHANICAL J148 (8) J137 (1) J137 (2) J137 (8) J148 (13) J137 (9) I/O CARD J132 (3) J40 (8) J40 (15) J132 (4) J34 (21) J34 (22) CAN-BUS SOCKET J34 (23) PROGRAMMER J34 (33) J34 (34)

  • Page 155: Electric Distributor System Configuration

    ELECTRIC DISTRIBUTOR SYSTEM CONFIGURATION MHYRIO UNIT DASHBOARD J140 (4) J137 (1) J137 (2) J137 (8) J140 (13) J137 (9) I/O CARD J132 (3) J40 (8) J40 (15) J132 (4) J34 (21) J34 (22) CAN-BUS SOCKET J34 (23) PROGRAMMER J34 (33) J34 (34) J34 (35) ARMREST...

  • Page 156: Diagnosis Code List

    DIAGNOSIS CODE LIST When an Error Code is Displayed Code Alarm specification Error mode Page WATCHDOG TRACTION LOGIC UNIT: Self-diagnostic test 4-14 EEPROM KO TRACTION LOGIC UNIT: Fault in the memory area 4-14 LOGIC FAILURE #3 TRACTION LOGIC UNIT: Logic defect 4-14 LOGIC FAILURE #2 TRACTION LOGIC UNIT: Fault in the hardware section...
  • Page 157 When an Error Code is Displayed Code Alarm specification Error mode Page WATCHDOG LIFTING LOGIC UNIT: Self-diagnostic test 4-30 EEPROM KO LIFTING LOGIC UNIT: Fault in the memory area 4-30 LOGIC FAILURE #3 LIFTING LOGIC UNIT: Logic defect. 4-30 LOGIC FAILURE #2 LIFTING LOGIC UNIT: Fault in the hardware section 4-31 LOGIC FAILURE #1...
  • Page 158 4-10 When an Error Code is Displayed Code Alarm specification Error mode Page I/O CARD: Failure in the signal of the accelerator potentiometer BAD VACC 4-64 at rest ERR SEAT I/O CARD: Does not see the seat microswitch closed. 4-64 UNUSED UNUSED 4-64...
  • Page 159 4-11 When an Error Code is Displayed Code Alarm specification Error mode Page UNUSED UNUSED 4-43 CONTACTOR CLOSED LIFTING LOGIC UNIT: Failure on the contactor driver 4-44 CHOPPER NOT CONF UNUSED 4-44 STEER WIRE KO LIFTING LOGIC UNIT: Failure on the contactor driver 4-44 DATA ACQUISITION LIFTING LOGIC UNIT: Logic in data acquisition phase...
  • Page 160 4-12 When an Error Code is Displayed Code Alarm specification Error mode Page WATCHDOG MHYRIO LOGIC UNIT: Self-diagnostic test 4-52 EVP DRIVER MHYRIO LOGIC UNIT: The valve driver is in short circuit 4-52 SHORTED STOP OPEN I/O CARD: Failure on the stop lights 4-66 ANT_OPEN or I/O CARD: Failure on front or rear light circuit...
  • Page 161 4-13 When an Error Code is Displayed Code Alarm specification Error mode Page INVALID RESTORE ARMREST CARD: Failure of the restore default parameter 4-56 STATE operation EEPROM ARMREST CARD: Alarm 4-56 INCONSISTENCY MHYRIO OR PUMP ARMREST CARD: Alarm in present in both Mhyrio logic unit and 4-57 ALARM lifting logic unit...

  • Page 162: When An Error Code Is Displayed

    4-14 WHEN AN ERROR CODE IS DISPLAYED TRACTION LOGIC UNIT WATCHDOG Condition for error detection The test is made in both running and standby. It is a self-diagnosing test within the logic. This alarm could also be caused by the can-bus malfunctioning. Verify: •...
  • Page 163 4-15 LOGIC FAILURE #2 Condition for error detection Fault in the hardware section of the logic board which manages the phase voltage feedback. The alarm appears also if the CT2 contactor is open during operation. Check: • the pins 1 and 14 of connector J50 and connections P6 and P5 •...
  • Page 164 4-16 VMN LOW Condition for error detection Failure in the VMN test. The test begins at the switching on; check the connections of the 3 supplying cables from the logic unit to the traction motor, the status of the cables and the status of the coil of the CT2 contactor (45 Ohm). If the coil is interrupted the truck will signal the alarm at the switching on.
  • Page 165 4-17 VMN HIGH Condition for error detection Failure in the VMN test. This test starts when the ignition key is turned ON and there is no current consumption (machine stationary) The alarm appears if the power circuit connections are open; check the connection of the 3 power cables from the logic unit to the traction motor and the cables condition.
  • Page 166 4-18 CONTACTOR OPEN Condition for error detection Failure on the CT2 contactor. The contactor is powered, but the contacts do not close. • Check the main contactor coil CT2 (45 Ω) and relevant cables • Check the state of the two-directional diode (D2) •...
  • Page 167 4-19 CAPACITOR CHARGE Condition for error detection At the ignition, the logic unit tries to charge the condensers by an internal power resistance and an inter- nal diode, and checks that the condensers are charged in the arranged time. If this does not occur, an alarm is send;...
  • Page 168 4-20 ENCODER ERROR Condition for error detection This alarm shows that the encoder information are incorrect or absents. The encoder transmits signals only when the motor is running. The alarm is noticed by the logics when 40Hz are passed. If on the dashboard appers the alarm and the operator makes the reset with the key with the machine stopped, the alarm disappears.
  • Page 169 4-21 THERMIC SENSOR KO Condition for error detection Logic unit thermal detector out of range, check: - The state of the wiring harness and the temperature sensor connector - Connect a 600 ohm resistance to the sensor connector: • If the alarm disappears, replace the temperature sensor •...
  • Page 170 4-22 WAITING FOR NODE Condition for error detection Communication failure in the can-bus.The alarm appears if the traction logic unit has identified a delay in the data transmission from the I/O board, the traction logic unit or armrest board. - Check if the alarm appears in combination with others alalms. In this case, this alarm is consequent. - Check the dashboard’s alarms, before replacing any cards If the alarm appears alone: - check the can bus connector: all wires must be well connected in both the side of the wiring loom.
  • Page 171 4-23 AUX COIL SHORTED Condition for error detection Failure on the CT2 contactor. - Check the state of the coil (45 ohm) - Check that there is no short circuit on the wiring harness - Check the connections: • on the contactor CT2 •...
  • Page 172 4-24 SEAT MISMATCH Condition for error detection Seat switch open during traction. the alarm appears If the information of the seat micro does not reach both traction logic units. Verify: - The state of the SW2 microswitch and relay US1 - The state of the connections and wiring harnesses: •...
  • Page 173 4-25 UNUSED SAFETY OUTPUT Condition for error detection SAFETY IN control output connector JT pin 19. Logic unit SAFETY driver defect. Check the truck insulation (see paragraph INSULATION CONTROL PROCEDURE) Replace the logic unit. SLIP PROFILE Condition for error detection Error in the memory data where the flowing parameters are loaded.
  • Page 174 4-26 POWER MOS SHORTED Condition for error detection The alarm signals a power circuit failure. Verify the correct connection of the motor to the logic: • One or more motor phases could be disconnected • Power cables connection • Truck insulation and motor state see paragraph INSULATION CONTROL PROCEDURE and MOTOR WINDING CONTROL PROCEDURE) •...
  • Page 175 4-27 THERMIC MOT KO Condition for error detection Interrupted or disconnected motor temperature sensor. Verify: - The state of the wiring harness and the temperature sensor connector - Connect a 600 ohm resistance to the sensor connector: • If the alarm disappears, replace the temperature sensor •...
  • Page 176 4-28 CONTACTOR CLOSED Condition for error detection CT2 contactor driver failure. The logic unit cuts the curret to the coil, but the controls remain closed. Disconnect the battery and check: - The CT2 contactor windings and the relevant wiring harnesses - Clean the contactor connections - Check the control of the contactor directly on connector JT pins 16 and 17 of the logic unit Replace the logic unit.
  • Page 177 4-29 WRONG 0 VOLT Condition for error detection Control internal error. • check the tuck and motor insulation (INSULATION CONTROL PROCEDURE and MOTOR WINDING CONTROL PROCEDURE) • check the power circuit and the battery • check the connections and wiring harnesses •...

  • Page 178: Lifting Logic Unit

    4-30 LIFTING LOGIC UNIT WATCHDOG Condition for error detection The test is made in both running and standby. It is a self-diagnosing test within the logic. This alarm could also be caused by the can-bus malfunctioning. Verify: • truck insulation (see paragraph INSULATION CONTROL PROCEDURE) •...
  • Page 179 4-31 LOGIC FAILURE #2 Condition for error detection Fault in the hardware section of the logic board which manages the phase voltage feedback. The alarm appears also if the CT2 contactor is open during operation. Check: • the pins 1 and 14 of connector J50 and connections P6 and P5. It could be present a false connection •...
  • Page 180 4-32 VMN LOW Condition for error detection Failure in the VMN test. The test begins at the switching on; check the connections of the 3 supplying cables from the logic unit to the lifting motor, the status of the cables and the status of the coil of the CT2 contactor (45 Ohm). If the coil is interrupted the truck will signal the alarm at the switching on.
  • Page 181 4-33 VMN HIGH Condition for error detection Failure in the VMN test. This test starts when the ignition key is turned ON and there is no current consumption (machine stationary) The alarm appears if the power circuit connections are open; check the connection of the 3 power cables from the logic unit to the pump motor and the cables condition.
  • Page 182 4-34 CONTACTOR OPEN Condition for error detection Failure on the CT2 contactor. The contactor is powered, but the contacts do not close. • Check the main contactor coil CT2 (45 Ω) and relevant cables • Check the state of the two-directional diode (D2) •...
  • Page 183 4-35 CAPACITOR CHARGE Condition for error detection At the ignition, the logic unit tries to charge the condensers by an internal power resistance and an inter- nal diode, and checks that the condensers are charged in the arranged time. If this does not occur, an alarm is send;...
  • Page 184 4-36 ENCODER ERROR Condition for error detection This alarm shows that the encoder information are incorrect or absents. The encoder transmits signals only when the motor is running. The alarm is noticed by the logics when 40Hz are passed. If on the dashboard appers the alarm and the operator makes the reset with the key with the machine stopped, the alarm disappears.
  • Page 185 4-37 THERMIC SENSOR KO Condition for error detection Logic unit thermal detector out of range, check: - The state of the wiring harness and the temperature sensor connector - Connect a 600 ohm resistance to the sensor connector: • If the alarm disappears, replace the temperature sensor If the alarm persists replace the logic unit.
  • Page 186 4-38 WAITING FOR NODE Condition for error detection Failure of the can bus comunication. The alarm appears if the lifting logic unit receives the information of I/O card ether traction logic unit or armrest board with a delay. • Check if the alarm appears in combination with other alarms. In this case, this alarm is consequent. •...
  • Page 187 4-39 DRIVER SHORTED Condition for error detection Alarm not used in pump configuration. Verify: • the presence of +Vb on pin 1 and 4 connector JP • Short circuit between pins 16 and 17 connector JP (replace the logic unit) •...
  • Page 188 4-40 SEAT MISMATCH Condition for error detection Seat switch open during traction. The alarm appears If the information of the seat micro does not reach both traction logic units. Verify: - The state of the SW2 microswitch and relay US1 - The state of the connections and wiring harnesses: •...
  • Page 189 4-41 SAFETY OUTPUT Condition for error detection Logic stop. Verify: - Traction logic unit alarms. • If YES, the alarm it is only a consequence. Check the diagnostics of the lifting logic unit • If NO, Check the LV wiring harness and the connection between pin 11 connector JT and pin19 connector JP •...
  • Page 190 4-42 POWER MOS SHORTED Condition for error detection The alarm signals a power circuit failure. Verify the correct connection of the motor to the logic: • One or more motor phases could be disconnected • Power cables connection • Truck insulation and motor state see paragraph INSULATION CONTROL PROCEDURE and MOTOR WINDING CONTROL PROCEDURE) •...
  • Page 191 4-43 THERMIC MOT KO Condition for error detection Interrupted or disconnected motor temperature sensor. Verify: - The state of the wiring harness and the temperature sensor connector - Connect a 600 ohm resistance to the sensor connector: • If the alarm disappears, replace the temperature sensor If the alarm persists replace the logic unit.
  • Page 192 4-44 CONTACTOR CLOSED Condition for error detection Alarm not used in pump configuration. Verify: - the presence of +Vb on pin 1 and 4 connector JP CHOPPER NOT CONF - UNUSED STEER WIRE KO Condition for error detection Alarm not used in pump configuration. Verify: - the presence of +Vb on pin 1 and 4 connector JP DATA ACQUISITION...
  • Page 193 4-45 WRONG 0 VOLT Condition for error detection Control internal error. • check the tuck and motor insulation (INSULATION CONTROL PROCEDURE and MOTOR WINDING CONTROL PROCEDURE) • check the power circuit and the battery • check the connections and wiring harnesses •...

  • Page 194: Mhyrio Logic Unit

    4-46 MHYRIO LOGIC UNIT Concerning this session, in the “Condition for error detection” description, if not expressly specified, the wording "logic unit" refers to the MHYRIO LOGIC UNIT. EEPROM KO Condition for error detection Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibists the truck operation;...
  • Page 195 4-47 FF VALVES Condition for error detection Problem in the 5th way hardware circuit. Check: • Wiring harness continuity • Presence of false contacts on connectors on the MHYRIO and solenoid valve sides • State of coils EV9 and EV10 •...
  • Page 196 4-48 EVPG2 DRIV SHORT Condition for error detection It is referred to the tilting forward or backward valves EVP3 or EVP4. Check: • Wiring harness continuity • Presence of false contacts on connectors on the MHYRIO and solenoid valve sides •...
  • Page 197 4-49 WRONG SET BATTERY Condition for error detection When the key is turned ON, the logic unit checks the battery voltage and compares it with the “SET BAT- TERY” parameter setting. If the actual value is 20% higher or lower than the nominal value, there is a fault.
  • Page 198 4-50 EVPG2 DRIVER KO Condition for error detection It is referred to the tilting forward or backward valves EVP3 or EVP4. Check: • Wiring harness continuity • Presence of false contacts on connectors on the MHYRIO and solenoid valve sides •...
  • Page 199 4-51 COIL SHORTED Condition for error detection Problem in the way hardware circuit. Check: • Wiring harness continuity • Presence of false contacts on connectors on the MHYRIO and solenoid valve sides • State of coils EV9 and EV10 • Replace the logic unit. Reference wiring diagram page 4/7 (chapter 17, section WIRING DIAGRAMS) UNDER VOLTAGE Condition for error detection...
  • Page 200 4-52 EV DRIVER KO Condition for error detection It is referred to the way. Check: • Wiring harness continuity • Presence of false contacts on connectors on the MHYRIO and solenoid valve sides • State of coils EV9 and EV10 •...

  • Page 201: Armrest Card

    4-53 ARMREST CARD Concerning this session, in the “Condition for error detection” description, if not expressly specified, the wording "logic unit" refers to the ARMREST BOARD PUMP INCORRECT START Condition for error detection Logic unit incorrect starting procedure. - check if one of the potentiometers is activated before switching the key ON. - verify using the console Enter the TESTER function in the menu MAT.
  • Page 202 4-54 BAD LIFT POT Condition for error detection Failure on the P4 lifting potentiometer in the fingertips / joysticks group. Check the voltages on the potentiometer at rest Enter the TESTER function in the menu MAT. HANDLING and check the LIFTING POT and LIFTING SWITCH parameters.
  • Page 203 4-55 BAD SIDESHIFT POT Condition for error detection Failure on the P6 sideshift potentiometer in the fingertips / joysticks group. Check the voltages on the potentiometer at rest Enter the TESTER function in the menu MAT. HANDLING and check the SIDESHIFT POT and SIDE- SHIFT SWITCH parameters.
  • Page 204 4-56 BAD V POT Condition for error detection Failure on the P8 5th way potentiometer in the fingertips / joysticks group. Check the voltages on the potentiometer at rest Enter the TESTER function in the menu MAT. HANDLING and check the V WAY POT and V WAY SWITCH parameters.
  • Page 205 4-57 MHYRIO OR PUMP ALARM Condition for error detection This alarm shows that an alarm is present in both logic units:Mhyrio and lifting Check the alarms which appear on the display in order to identify where the problem is located. UNUSED CHKSUM ERROR Condition for error detection...

  • Page 206: Dashboard

    4-58 DASHBOARD Concerning this session, in the “Condition for error detection” description, if not expressly specified, the wording "logic unit" refers to the INSTRUMENT PANEL. TRAC KO Condition for error detection Can-bus comunication failure. The alarm appears if the display does not receive information from the traction logic unit.
  • Page 207 4-59 PUMP KO Condition for error detection Can-bus comunication failure. The alarm appears if the display does not receive information from the lifting logic unit. Before replacing any board: - Check if the board is powered - Enter the SOFT VERS menu to see which card is not present on the can-bus line - Can-bus pull-up resistance presence •...
  • Page 208 4-60 BRAKE LEVEL Condition for error detection Brakes oil level low. Check the wiring harness and the microswitch on the brake oil tank ERROR READ PIN Condition for error detection Configuration error between the I/O card and the instrument panel If the key reset does not eliminate the alarm: •...
  • Page 209 4-61 UNUSED UNUSED SAS KO - UNUSED Condition for error detection Update the truck to the last software version UNUSED EEPROM ERROR Condition for error detection Instrument panel memory failure. Before replacing the instrument panel carry out the following operations: •...

  • Page 210: I/O Board

    4-62 I/O BOARD Concerning this session, in the “Condition for error detection” description, if not expressly specified, the wording "logic unit" refers to the I/O CONTROL BOARD. PUMP INCORRECT START Condition for error detection Incorrect starting procedure. One of the switches of the oil control valve has been activated before turning on truck. •...
  • Page 211 4-63 PUMP STUFFING ERROR Condition for error detection The I/O Board receives the information from the lifting logic unit in delay Check: - Check the power supply to the cards - Enter the SOFT VERS menu to see which card is not present on the can-bus line - Can-bus pull-up resistance presence •...
  • Page 212 4-64 BAD VACC Condition for error detection Execute the acquisition of the accelerator potentiometer value again. The alarm appears if the potentiometer is out of range. See chapter 2 “ADJUSTING THE ACCELERATOR POTENTIOMETERS” ERR SEAT Condition for error detection One of the functions is activated while the seat micro is open. UNUSED PARKING SELECTED Condition for error detection...
  • Page 213 4-65 TRUCK IN ALARM Condition for error detection General alarm. The logic unit detects an alarm from the traction logic unit. Check on the dashboard others alarms. TRUCK STUFFING ERROR Condition for error detection Comunication problem with the traction logic unit. Check on the dashboard others alarms. UNUSED UNUSED FW + BW...
  • Page 214 4-66 BOOT ERROR Condition for error detection The alarm is signalled after switching the machine on. The truck remains in the pre-operational status. All function are deactivated. The logic unit does not received information from lifting or traction logic unit or both. NOT REP ERROR Condition for error detection Not replay error.
  • Page 215 4-67 UNUSED RETRO OPEN Condition for error detection Failure on the reverse lights. Check the reverse light bulbs and the relative cables TILT_LOCK _FAULT Condition for error detection The alarm signals a failure in the forward/backward tilting solenoid valve EV13 coil. The coil could be opened or disconnected.
  • Page 216 4-68 https://www.forkliftpdfmanuals.com/...
  • Page 217 MOTOR Page DRIVE MOTOR ............5-2 GENERAL ................5-2 REMOVING THE GEARMOTOR UNIT ........5-4 ENCODER ..............5-7 GENERAL ................5-7 TRACTION TEMPERATURE SENSOR REPLACING ............5-13 LIFTING MOTOR ............5-14 GENERAL ................5-14 SPECIFICATIONS ..............5-14 ENCODER REPLACING ........... 5-19 LIFTING TEMPERATURE SENSOR REPLACING ............5-23 https://www.forkliftpdfmanuals.com/...

  • Page 218: Drive Motor

    DRIVE MOTOR GENERAL SPECIFICATIONS DRIVE MOTOR MOTOR TYPE ASYNCHRONOUS TSA200-140-085 POWER 4.9 kW NOMINAL VOLTAGE 16 V CURRENT 255 A FREQUENCY 52 Hz φ FACTOR POWER (cos 0.81 INSULATION CLASS DEGREE OF PROTECTION (IP CODE) IP 54 SERVICE S2-60 min NUMBER OF POLES R.P.M.
  • Page 219 COMPONENTS Cover Encoder ball bearing Elastic ring Temperature sensor Ring Engine body Spacer Cover Elastic ring Terminal board Driving shaft https://www.forkliftpdfmanuals.com/...

  • Page 220: Removing The Gearmotor Unit

    REMOVING THE GEARMOTOR UNIT 23 Nm ± 15% 79 Nm ± 15% + LOCTITE 243 Removal procedure 1. Lift the battery cover 2. Disconnect the battery plug 3. Remove the seat by screwing off the 4 bolts under the battery cover 4.
  • Page 221 Point Operation [Point 1] Disassembly: Remove the components in order to create the working space [Point 2] Disassembly: Remove the power cables and the wiring of the encoder sensor. Screw out the 6 screws of the motor. Assembly: After the installation, tightening torque of the 6 fixing screws of drive motor: Tightening torque = 79 Nm + Loctite 243 [Point 3]...
  • Page 222 Assembly: After the installation, tightening torque of the 6 fixing screws of drive motor: Tightening torque = 79 Nm + Loctite 243 https://www.forkliftpdfmanuals.com/...

  • Page 223: Encoder

    ENCODER GENERAL The encoder generates a feedback signal from the motor and sends it to the command logic monitoring:motor status, rpm and direction of rotation. ENCODER Irreversible damage: • + V > 13 Volts • Short circuit between the signal and the power supply •...
  • Page 224 TRACTION ENCODER REPLACING REMOVAL • INSTALLATION Dismantling procedure 1. Fulfil all the traction encoder removal procedure 2. Cut the clamps that fix togheter the temperature sensor cables and the encoder [Point 1] 3. Press untill extract from their site the rubber seals that protect the motor power cables [Point 2] 4.
  • Page 225 Point Operation [Point 1] Disassembly: Cut the clamps A that fix togheter the temperature sensor cables and the encoder [Point 2] Disassembly: Press untill extract from their site the rubber seals that protect the power cables B [Point 3] Disassembly: Unscrew and remove the 4 screws C then remove the metallic plate D [Point 4]...
  • Page 226 5-10 [Point 5] Disassembly: Remove the metallis plug on the upper shield and remove the seeger under it [Point 6] Disassembly: Remove the 4 M8x250 screws of the upper shield [Point 7] Disassembly: Place the extracting bar and fix it as shown in picture [Point 8] Disassembly: Screw the tension rod in order to lift the stator.
  • Page 227 5-11 [Point 9] Disassembly: Remove the seeger C from the shield and extract the encoder B Assembly: Replace the gasket A. Place the encoder B in the inner site of the motor shield. Fix the encoder using the special seeger C [Point 10] Assembly: Place the upper shield on the motor...
  • Page 228 5-12 [Point 12] Assembly: Reassemble the seeger and the metallic plug on the upper shield. Reassemble the 4 M8x250 screws E of the upper shield [Point 13] Assembly: Insert the rubber seals B that protect the power cables in their site [Point 14] Assembly: Fix the metallic plate D screwing the 4 screws C...

  • Page 229: Traction Temperature Sensor Replacing

    5-13 TRACTION TEMPERATURE SENSOR REPLACING REMOVAL • INSTALLATION Removal procedure 1. Fulfil all the encoder removal procedure 2. Cut the sensor wiring harness where is the fixing point of the same sensor with the stator winding [Point 1] 3. Insert the new sensor at contact of the stator winding, and fix it using the adhesive silicone paste for high temperature [Point 2] Installation procedure Fulfil all the traction encoder installation procedure...

  • Page 230: Lifting Motor

    5-14 LIFTING MOTOR GENERAL SPECIFICATIONS LIFTING MOTOR MOTOR TYPE ASYNCHRONOUS TSA170-210-033 DIMENSIONS Ø 177 x 338,5 mm POWER 7.5 kW NOMINAL VOLTAGE 16 V MAX. NOMINAL CURRENT 375 A FREQUENCY 70 Hz POWER FACTOR (cos phi) 0.82 EFFICIENCY (h) INSULATION CLASS SERVICE S3 - 40% NUMBER OF POLES...
  • Page 231 5-15 COMPONENTS Cover Encoder ball bearing Elastic ring Temperature sensor Seal Engine body Cover Ring Terminal board Driving shaft https://www.forkliftpdfmanuals.com/...
  • Page 232 5-16 REMOVAL • INSTALLATION 15 Nm Removal procedure 1. Lift the battery cover 2. Disconnect the battery plug 3. Remove the footboard 4. Remove the 2 pedals [Point 1] 5. Drain out the hydraulic oil 6. Disconnect the hoses from the priority valve 7.
  • Page 233 5-17 Point Operation [Point 1] Disassembly: Disconnect the wirings of the two pedals. Disconnect the brake hose of the brake pedal by closing it to avoid the loosing of the brake oil. Remove the 3 screws per pedal from the front of the frame. Assembly: After installation, tightening torque of the pedal bolts = 24 Nm...
  • Page 234 5-18 [Point 5] Disassembly: Chain or belt is needed to extract the pump motor from the truck https://www.forkliftpdfmanuals.com/...

  • Page 235: Encoder Replacing

    5-19 ENCODER REPLACING REMOVAL • INSTALLATION Dismantling procedure 1. Fulfill all the lifting motor removal procedure 2. Cut the clamps that fix togheter the temperature sensor cables and the encoder [Point 1] 3. Press untill extract from their site the rubber seals that protect the motor power cables [Point 2] 4.
  • Page 236 5-20 Point Operation [Point 1] Disassembly: Cut the clamps A that fix togheter the temperature sensor cables and the encoder [Point 2] Disassembly: Press untill extract from their site the rubber seals that protect the power cables B [Point 3] Disassembly: Unscrew and remove the 4 screws C then remove the metallic plate D...
  • Page 237 5-21 [Point 6] Disassembly: Remove the cover [Point 7] Disassembly: Extract the encoder using the special extractor [Point 8] Assembly: Insert the encoder on the motor axle with the part relevant to the sensor F towards the rotor. Pay attention not to damage the encoder then press exclusively on the internal ring of the sphere ball bearing that support the encoder [Point 9]...
  • Page 238 5-22 [Point 10] Assembly: Insert the rubber seals B that protect the power cables in their site [Point 11] Assembly: Fix the cover onto the motor screwing the 4 screws E [Point 12] Assembly: Fix the metallic plate D screwing the 4 screws C [Point 13] Assembly: Fix together with clamps the cables of the temperature...

  • Page 239: Lifting Temperature Sensor Replacing

    5-23 LIFTING TEMPERATURE SENSOR REPLACING REMOVAL • INSTALLATION Removal procedure 1. Execute the removal procedure of the lifting motor encoder from section 1 to section 8 2. Cut the sensor wiring harness where is the fixing point of the same sensor with the stator winding [Point 1] 3.
  • Page 240 5-24 https://www.forkliftpdfmanuals.com/...
  • Page 241 DRIVE UNIT & REAR AXLE Page TRANSMISSION ............6-2 GENERAL ................6-2 SPECIFICATIONS ..............6-3 COMPONENTS ...............6-3 REAR AXLE & DRIVE UNIT........6-4 https://www.forkliftpdfmanuals.com/...

  • Page 242: Transmission

    TRANSMISSION GENERAL 23 Nm ± 15% 79 Nm ± 15% + LOCTITE 243 Steer end stroke 14 Nm + LOCTITE 243 https://www.forkliftpdfmanuals.com/...

  • Page 243: Specifications

    SPECIFICATIONS Load capacity 1.0t 1.25t 1.5t Item ← ← Total reduction ratio 1:27 457 × 152 / 18 x 7- Rear / Front tyre size C/SE/PN ← ← (Cushion / Super Elastic / Pneumatic) 8 / 18 x 7-8 COMPONENTS https://www.forkliftpdfmanuals.com/...

  • Page 244: Rear Axle & Drive Unit

    REAR AXLE & DRIVE UNIT DISASSEMBLY • REASSEMBLY 140 Nm (± 10%) 283 Nm (± 5%) 340 Nm (+7% -3%) 140 Nm (± 5%) Disassembly Procedure 1. Disconnect the battery plug 2. Connect the chains on the mast [Point 1] 3.
  • Page 245 Reassembly Procedure The installation procedure is the reverse of the removal procedure. Notes: Pay attention to the teethes of the hydraulic motor and potentiometer during the reassembly of the drive unit Nots: • Type and quantity of gear oil Mobilube HD 80 W-90 Type Cold storage type Mobilube 1SHC 75 W-90...
  • Page 246 [Point 4] Disassembly: Remove the battery cover by removing the gas spring and the 2 bolts on the OHG [Point 5] Disassembly: Remove the power cables and the wiring of the encoder sensor. Screw out the 6 screws of the motor Reassembly: After installation, tightening torque of the 6 screws of the motor = 40 Nm...
  • Page 247 [Point 7] Disassembly: Remove the 4 screws of the plastic bottom cover of the drive unit [Point 8] Disassembly: Jack up the back of the vehicle from the counterweight by using a chain (required lifting measure about 400 [Point 9] Disassembly: Remove the 6 screws of the drive unit Reassembly:...
  • Page 248 https://www.forkliftpdfmanuals.com/...
  • Page 249 STEERING SYSTEM Page STEERING SYSTEM ........... 7-2 COMPONENTS ...............7-2 HYDRAULIC DIAGRAM (mechanical distributor version)........7-3 HYDRAULIC DIAGRAM (electro-proportional distributor version) ......7-4 POWER STEERING (ORBITROL) ......7-5 SPECIFICATIONS ..............7-5 PRIORITY VALVE ............7-7 HYDRAULIC MOTOR ..........7-9 STEERING POTENTIOMETER ......... 7-11 https://www.forkliftpdfmanuals.com/...

  • Page 250: Steering System

    STEERING SYSTEM COMPONENTS 16 17 11 12 Vibration damping Pressure socket Bracket R channel Motor L channel O-rings Steering motor Joint Pinion Pump LS channel Suction Nipple T channel Orbitrol CF channel Priority valve https://www.forkliftpdfmanuals.com/...

  • Page 251: Hydraulic Diagram (Mechanical Distributor Version)

    HYDRAULIC DIAGRAM (mechanical distributor version) https://www.forkliftpdfmanuals.com/...

  • Page 252: Hydraulic Diagram (Electro-Proportional Distributor Version)

    HYDRAULIC DIAGRAM (electro-proportional distributor version) https://www.forkliftpdfmanuals.com/...

  • Page 253: Power Steering (Orbitrol)

    POWER STEERING (ORBITROL) 40 Nm (± 15%) 70 Nm (± 10%) 55 Nm (± 10%) 35 Nm (± 10%) SPECIFICATIONS Capacity 1.0 - 1.25 - 1.5 t Parts Steering wheel diameter Steering wheel clearence 20 ~ 50 Power steering type Dynamic Discharge cc (cm...
  • Page 254 REMOVAL • INSTALLATION Removal procedure 1. Lower the forks to the ground 2. Disconnect the battery plug 3. Remove the cover from the front dashboard 4. Remove the steering column cover 5. Remove the hydraulic steering (orbitrol) Installation procedure The reassembly procedure is the reverse of the disassembly procedure. Remarks: •...

  • Page 255: Priority Valve

    PRIORITY VALVE GENERAL https://www.forkliftpdfmanuals.com/...
  • Page 256 REMOVAL • INSTALLATION Pressure socket 50 Nm (± 10%) 105 Nm (± 10%) 80 Nm (± 10%) 45 Nm (± 10%) 12 Nm (± 15%) Removal procedure 1. Lower the forks to the ground 2. Disconnect the battery plug 3. Remove the footboard 4.

  • Page 257: Hydraulic Motor

    HYDRAULIC MOTOR GENERAL R channel 55 Nm (± 10%) L channel 55 Nm (± 10%) Pinion 24 Nm (± 5%) + Loctite 243 https://www.forkliftpdfmanuals.com/...
  • Page 258 7-10 REMOVAL • INSTALLATION 140 Nm (±10%) Crown Removal procedure 1. Remove the battery cover 2. Disconnect the battery plug 3. Remove the rear cover 4. Remove the right side plate of the frame 5. Remove the battery 6. Disconnect the two hoses from the hydraulic motor 7.

  • Page 259: Steering Potentiometer

    7-11 STEERING POTENTIOMETER GENERAL Connector J14 Steer potentiometer unit https://www.forkliftpdfmanuals.com/...
  • Page 260 7-12 REMOVAL • INSTALLATION 5 Nm Shaft Gear Potentiometer Centering bushing Plate BEFORE REMOVING GREASE WITH MOLYKOTE G-4500 Gear 5 Nm Bracket 5 Nm Removal procedure 1. Lift the battery cover 2. Disconnect the battery connector 3. Remove the rear cover 4.
  • Page 261 7-13 TROUBLESHOOTING Only hydraulic related items are listed. Symptom Possible cause Action • damaged lines replace the steering wheel cannot • The shaft from the steering wheel to the inspect and adjust or be rotated power steering is incorrectly installed or replace damaged •...
  • Page 262 7-14 Symptom Possible cause Action • the shaft is not installed correctly inspect and adjust • The hydraulic motor is not working the steering wheel inspect and adjust correctly shimmies • The theets of the hydraulic motor or of inspect and adjust the crown are damaged the wheels steer contrary to •...
  • Page 263 BRAKE Page BRAKE SYSTEM ............8-2 GENERAL ..............8-2 SPECIFICATIONS ..............8-2 PARKING BRAKE............8-3 BRAKE GROUP............8-4 BRAKE SHOES AND BRAKE CYLINDER ....8-6 BRAKE PEDAL............8-8 BRAKE FLUID TANK..........8-10 WHEELS / TYRES .............8-10 https://www.forkliftpdfmanuals.com/...

  • Page 264: Brake System

    BRAKE SYSTEM GENERAL SPECIFICATIONS Model All models Item Service brake Mechanical drum brake Parking brake Mechanical drum brake Diameter Brake wheel Thickness Area 6073 (for shoe) Brake shoe Thickness https://www.forkliftpdfmanuals.com/...

  • Page 265: Parking Brake

    PARKING BRAKE DISASSEMBLY • REASSEMBLY Disassembly Procedure 1. Disconnect the battery plug 2. Remove the plastic cover 3. Disconnect the cables of the parking brake 4. Remove the 3 fixing screws 5. Remove the lever of the parking brake Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.

  • Page 266: Brake Group

    BRAKE GROUP DISASSEMBLY • REASSEMBLY T = 83 Nm (± 5%) T = 140 Nm (± 5%) Disassembly Procedure 1. Disconnect the battery plug 2. Jack up the vehicle and remove the front wheels (item 14,3) 3. Remove the hub wheel cover (item 10) [Point 1] 4.
  • Page 267 Point Operations [Point 1] Disassembly: Remove the hub wheel, pay attention not to damage it Reassembly: After installation, put 1/3 of appropriate grease inside the cover (around 30gr.) well distributed [Point 2] Disassembly: Before removing the bearing nut (item 16B) it is necessary to bend the teeth of the safety washer (item 17).

  • Page 268: Brake Shoes And Brake Cylinder

    BRAKE SHOES AND BRAKE CYLINDER DISASSEMBLY • REASSEMBLY 140 Nm (± 5%) 83 Nm (± 5%) Disassembly Procedure 1. Disconnect the battery plug 2. Jack up the vehicle and remove the front wheels (item 14,3) 3. Remove the hub wheel cover (item 10) 4.
  • Page 269 Point Operations [Point 1] Inspection: Measure the internal diameter of the brake drum. Standard inside diameter: 170 mm [Point 2] Inspection: Measure the brake material thickness of the brake shoes. Standard thickness: 5 mm Limit free thickness: 1 mm Reassembly: After installation, it is necessary to put the self adjusting cylinder in the standard position by turning the two bushings.

  • Page 270: Brake Pedal

    BRAKE PEDAL DISASSEMBLY • REASSEMBLY 24 Nm (± 10%) Disassembly Procedure 1. Disconnect the battery plug 2. Disconnect the wiring of the pedal 3. Drain out the brake oil 4. Disconnect the brake hose from the brake master cylinder [Point 1] 5.
  • Page 271 INSPECTION • ADJUSTMENT Brake pump play adjustment • Move the nut A to have a play of 0,2 - 0,5 mm Brake fluid system bleeding • Loosen the cap and press the brake pedal and let go out the air •...

  • Page 272: Brake Fluid Tank

    8-10 BRAKE FLUID TANK When the fluid in the brake tank (I) reaches a too low level, the warning light indicating the low level liquid brakes on the dashboard shall light up. Use the button (L) to verify the correct warning light functioning.
  • Page 273 BODY & FRAME Page BODY AND FRAME............. 9-2 GENERAL................9-2 BATTERY COVER ............9-3 OVERHEAD GUARD ........... 9-4 COUNTERWEIGHT ............. 9-5 OPERATOR’S SEAT............ 9-6 https://www.forkliftpdfmanuals.com/...
  • Page 274 BODY AND FRAME GENERAL https://www.forkliftpdfmanuals.com/...
  • Page 275 BATTERY COVER DISASSEMBLY • REASSEMBLY 40 Nm (± 5%) Disassembly Procedure 1. Open the battery cover 2. Disconnect the battery plug 3. Fix the battery cover with a rope between the operator’s seat and a mast of the overhead guard 4.
  • Page 276 OVERHEAD GUARD DISASSEMBLY • REASSEMBLY 49 Nm (±15%) 49 Nm (± 15%) Disassembly Procedure 1. Open the battery cover 2. Disconnect the battery plug 3. Remove the battery cover 4. Disconnect light wires on the overhead guard, if present 5. Secure the overhead guard using belts and a bridge crane 6.
  • Page 277 COUNTERWEIGHT DISASSEMBLY • REASSEMBLY 283 Nm (± 5%) 340 Nm (+7% / -3%) 140 Nm (± 5%) Disassembly Procedure 1. Place two wooden blocks under the frame of the fixed part of the mast 2. Disconnect the battery plug 3. Remove the rear cover and the battery cover 4.
  • Page 278 OPERATOR’S SEAT DISASSEMBLY • REASSEMBLY Disassembly Procedure 1. Open the battery cover 2. Disconnect the wiring of the seat switch 3. Remove the operator’s seat set nuts (be careful not to drop the operator’s seat) 4. Remove the operator’s seat Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.
  • Page 279 10-1 MATERIAL HANDLING SYSTEM Page HYDRAULIC CIRCUIT (LEVER CONTROL VALVE) ........10-2 HYDRAULIC CIRCUIT (ELECTRIC CONTROL VALVE) ......10-3 COMPONENTS..............10-4 STEERING SYSTEM ............10-4 HYDRAULIC SYSTEM (WITH LEVER CONTROL VALVE) ........10-4 HYDRAULIC SYSTEM (WITH ELECTRIC CONTROL VALVE)......10-5 MAST 2M T.V................. 10-6 MAST 3M T.V.................
  • Page 280 10-2 HYDRAULIC CIRCUIT (LEVER CONTROL VALVE) https://www.forkliftpdfmanuals.com/...
  • Page 281 10-3 HYDRAULIC CIRCUIT (ELECTRIC CONTROL VALVE) https://www.forkliftpdfmanuals.com/...
  • Page 282 10-4 COMPONENTS STEERING SYSTEM HYDRAULIC SYSTEM (WITH LEVER CONTROL VALVE) https://www.forkliftpdfmanuals.com/...
  • Page 283 10-5 HYDRAULIC SYSTEM (WITH ELECTRIC CONTROL VALVE) https://www.forkliftpdfmanuals.com/...
  • Page 284 10-6 MAST 2M T.V. MAST 3M T.V. https://www.forkliftpdfmanuals.com/...
  • Page 285 10-7 MAST 2M F.F.L. MAST 3M F.F.L. https://www.forkliftpdfmanuals.com/...
  • Page 286 10-8 HYDRAULIC OIL AND FILTER DISASSEMBLY • REASSEMBLY Tightening torque M =Nm 35 Nm (± 5%) A, B 11 Nm (± 10%) Disassembly Procedure 1. Place and stop the truck on a flat surface, with the mast in vertical position and the forks lowered 2.
  • Page 287 10-9 With the balanced pedal the hydraulic oil filter is on the left side of the tank (see drawing) Point Operations [Point 1] Two different procedures can be followed to remove the hydraulic oil from the tank: Remove the drain plug under the tank DRAIN PLUG Remove the oil filter cartridge and then use a pump in order to drain out the hydraulic oil...
  • Page 288 10-10 OIL LEAK TEST LIFTING CYLINDERS Set mast in vertical position with the standard load on forks Lift forks at 3 m and take the measure between the forks and ground with a meter and leave the key switch ON Make the measurement between forks and ground or between the datum lines on the inner and outer masts again after 10 minutes...
  • Page 289 11-1 MAST Page Page MAST ........11-2 SECONDARY CYLINDER SUPPLY PIPES - COMPONENTS.......11-2 MAST 2M FFL ..... 11-23 MAST ........11-6 THIRD WAY SYSTEM MAST CONNECTION (SUPPLY PIPES) - BUSHING....... 11-8 MAST 2M FFL ..... 11-24 PRIMARY CYLINDER SUPPLY THIRD WAY SYSTEM PIPES - MAST 2M TV..
  • Page 290 11-2 MAST COMPONENTS MAST 2M TV (V) MAST 3M TV (/) https://www.forkliftpdfmanuals.com/...
  • Page 291 11-3 MAST 2M TV (FW) MAST 3M FFL (FSW) https://www.forkliftpdfmanuals.com/...
  • Page 292 11-4 FORK CARRIAGE 2M TV - 3M TV - 2M FFL - 3M FFL CHAINS AND ROLLERS 2M TV - 3M TV - 3M F.F.L (side) https://www.forkliftpdfmanuals.com/...
  • Page 293 11-5 CHAINS AND ROLLERS 2M FFL - 3M FFL (central) https://www.forkliftpdfmanuals.com/...
  • Page 294 11-6 MAST REMOVAL • INSTALLATION T=N·m M = 24 Nm (± 10%) M = 83 Nm (± 15%) Removal procedure 1. Put the mast in vertical position 2. Disconnect the battery connector 3. Connect the chains on the mast [Point 1] 4.
  • Page 295 11-7 Point Operation [Point 1] Disassembly: Fully lower the mast; Connect the chain on the points shown before removing the mast [Point 2] Disassembly: Remove the 4 bolts that fix the mast to the frame from the bottom Installation: After installation, tightening torque of the 4 screw of the mast = 83 Nm [Point 3] Disassembly:...
  • Page 296 11-8 MAST CONNECTION BUSHING REMOVAL • INSTALLATION Removal procedure 1. Follow the procedure indicated in the previous page 2. Remove the bushings [Point 1] Installation procedure The reassembly procedure is the reverse of the disassembly procedure. Remarks: Apply suitable lubricating grease to the mast connection bushings https://www.forkliftpdfmanuals.com/...
  • Page 297 11-9 Point Operation [Point 1] Disassembly: Use a bronze extractor Installation: Prepare the bushing Use a bronze inserter Inspection: Check that the bushing is perfectly in position (i.e. it does not come out of its support) https://www.forkliftpdfmanuals.com/...
  • Page 298 11-10 PRIMARY CYLINDER SUPPLY PIPES - MAST 2M TV REMOVAL • INSTALLATION T=N·m A = 55 ± 5 Nm B = 75 ± 5 Nm C = 100 Nm Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eyebolts and belts 2.
  • Page 299 11-11 THIRD WAY SYSTEM (SUPPLY PIPES) - MAST 2M TV REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 300 11-12 Point Operation [Point 1] Installation: Comply with the sizing indicated in the figure to the side [Point 2] Installation: Prevent the pipes from rotating on their axis when raising/lowering Important: Prevent any pipes kept under pressure from causing a hazard during raising/lowering https://www.forkliftpdfmanuals.com/...
  • Page 301 11-13 THIRD WAY SYSTEM (PULLEYS) - MAST 2M TV REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 302 11-14 THIRD WAY SYSTEM (CHAINS) - MAST 2M TV REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 303 11-15 Point Operation [Point 1] Disassembly: Straighten the fins Disassembly: Slide out the split pin [Point 2] Installation: Comply with the sizing indicated in the figure to the side (image refers to fixed mast) Inspection: Remove the forks and check that the X height complies with the ISO tables shown in the MAST CHAINS section;...
  • Page 304 11-16 PRIMARY CYLINDER SUPPLY PIPES - MAST 3M TV REMOVAL • INSTALLATION T=N·m A = 55 ± 5 Nm B = 75 ± 5 Nm C = 100 Nm Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2.
  • Page 305 11-17 THIRD WAY SYSTEM (SUPPLY PIPES) - MAST 3M TV REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 306 11-18 Point Operation [Point 1] Installation: Comply with the sizing indicated in the figure to the side X = 240 mm (mast height 4310); X = 240 mm (mast height 4505); X = 320 mm (mast height 5000); X = 440 mm (mast height 5510); X = 500 mm (mast height 6005);...
  • Page 307 11-19 THIRD WAY SYSTEM (PULLEYS) - MAST 3M TV REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 308 11-20 THIRD WAY SYSTEM (CHAINS) - MAST 3M TV REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 309 11-21 Point Operation [Point 1] Disassembly: Straighten the fins Disassembly: Slide out the split pin [Point 2] Installation: Comply with the sizing indicated in the figure to the side (image refers to fixed mast) Inspection: Remove the forks and check that the X height complies with the ISO tables shown in the MAST CHAINS section;...
  • Page 310 11-22 PRIMARY CYLINDER SUPPLY PIPES - MAST 2M FFL REMOVAL • INSTALLATION T=N·m A = 55 ± 5 Nm B = 75 ± 5 Nm C = 100 Nm Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2.
  • Page 311 11-23 SECONDARY CYLINDER SUPPLY PIPES - MAST 2M FFL REMOVAL • INSTALLATION T=N·m A = 55 ± 5 Nm B = 75 ± 5 Nm C = 100 Nm Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2.
  • Page 312 11-24 THIRD WAY SYSTEM (SUPPLY PIPES) - MAST 2M FFL REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 313 11-25 Point Operation [Point 1] Installation: X = 245 mm (mast height = 2905); X = 270 mm (mast height = 3005); X = 315 mm (mast height = 3205); X = 345 mm (mast height = 3305); X = 395 mm (mast height = 3505); X = 440 mm (mast height = 3705);...
  • Page 314 11-26 THIRD WAY SYSTEM (CHAINS) - MAST 2M FFL REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 315 11-27 Point Operation [Point 1] Disassembly: Straighten the fins Disassembly: Slide out the split pin [Point 2] Installation: Comply with the minimum sizing indicated in the figure to the side (image refers to primary cylinder) Inspection: Remove the forks and check that the X height complies with the ISO tables shown in the MAST CHAINS section;...
  • Page 316 11-28 PRIMARY CYLINDER SUPPLY PIPES - MAST 3M FFL REMOVAL • INSTALLATION T=N·m A = 55 ± 5 Nm B = 75 ± 5 Nm C = 100 Nm Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2.
  • Page 317 11-29 Point Operation [Point 1] Disassembly: Comply with the sizing indicated in the figure to the side Disassembly: Prevent the pipes from rotating on their axis when raising/lowering Important: Prevent any pipes kept under pressure from causing a hazard during raising/lowering https://www.forkliftpdfmanuals.com/...
  • Page 318 11-30 SECONDARY CYLINDER SUPPLY PIPES - MAST 3M FFL REMOVAL • INSTALLATION T=N·m A = 55 ± 5 Nm B = 75 ± 5 Nm C = 100 Nm Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2.
  • Page 319 11-31 THIRD WAY SYSTEM (SUPPLY PIPES) - MAST 3M FFL REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 320 11-32 Point Operation [Point 1] Installation: Comply with the sizing indicated in the figure to the side [Point 2] Installation: Prevent the pipes from rotating on their axis when raising/lowering Important: Prevent any pipes kept under pressure from causing a hazard during raising/lowering https://www.forkliftpdfmanuals.com/...
  • Page 321 11-33 THIRD WAY SYSTEM (PULLEYS) - MAST 3M FFL REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 322 11-34 Inspection: Check that the step side is the same as the seeger hollow [Point 2] Installation: Replace the component [Point 3] Installation: Fix the pulley to the pin Installation: Use a brass inserter of a suitable diameter Installation: Install a seeger https://www.forkliftpdfmanuals.com/...
  • Page 323 11-35 THIRD WAY SYSTEM (CHAINS) - MAST 3M FFL REMOVAL • INSTALLATION Removal procedure 1. Tilt the mast forwards and lock the mobile mast and carriage using appropriately sized and protected eye bolts and belts 2. Lower the mast to prevent the supply pipes from remaining in tension 3.
  • Page 324 11-36 Point Operation [Point 1] Disassembly: Straighten the fins Disassembly: Slide out the split pin [Point 2] Installation: Comply with the sizing indicated in the figure to the side (image refers to fixed mast) Chain must be tensioned with the mobile mast open from the fixed mast by 5 mm (check that there is no interference on the limit switch when the mast is at maximum height)
  • Page 325 11-37 Inspection: Check that the step side is the same as the seeger hollow [Point 4] Installation: Replace the component [Point 5] Disassembly: Straighten the fins Disassembly: Slide out the split pin https://www.forkliftpdfmanuals.com/...
  • Page 326 11-38 [Point 6] Installation: Comply with the minimum sizing indicated in the figure to the side (image refers to primary cylinder) Chain must be tensioned with the mobile mast open from the fixed mast by 5 mm (check that there is no interference on the limit switch when the mast is at maximum height) Inspection:...
  • Page 327 11-39 ROLLER PAD INSPECTIONS • ADJUSTMENTS Long life roller bearing: Check: The clearance between roller pad and inner mast profile Standard clearance: 0.2 - 0.4 mm https://www.forkliftpdfmanuals.com/...
  • Page 328 11-40 Adjustment: Adjust by turning the regulating screw (A) shown in the image and lock in place with the nut (B) Check: The clearance (X) between roller pad and inner mast profile. Standard clearance: X = 0.2 - 0.4 mm Adjustment: It is not possible to adjust this clearance (X = 0.2 - 0.4mm).
  • Page 329 11-41 MOBILE MAST PAD 2M TV (4705 ÷ 5005 mm) INSPECTIONS • ADJUSTMENTS Check: Maximum clearance (0.5 mm); if the clearance is greater, replace the pad (cannot be shimmed) Inspection: When the total thickness is less than 3.8 mm, replace the pad;...
  • Page 330 11-42 MAST CHAINS INSPECTION • ADJUSTMENT Inspection: To check if the chain links are worn out, follow the appropriate rules: SST 09631 - 22000 - 71 The chains must be replaced when, in a portion correspondig to 34 pitches, only 33 pitches are found Note: Perform measurement without removing the chain from the vehicle.
  • Page 331 11-43 TABLE ISO 2328 - 1993 Class Lifting load (kg) "X" (± 5) 0 ÷ 999 76 mm II A 1000 ÷ 2500 76 mm III A 2500 ÷ 4999 76 mm IV A 5000 ÷ 8000 127 mm 8001 ÷ 10999 127 mm Class Lifting load (kg)
  • Page 332 11-44 FORK REMOVAL • INSPECTION Disassembly: Lift the fork to approx. 20 cm from the ground Place a wood block under the notched section of the fork rail Unlock the fork by lifting the fork stopper pin and shift one fork per time to the fork carriage bottom notch Slowly lower the fork for removal Installation: The reassembly procedure is the reverse of the...
  • Page 333 11-45 Remarks: Tampering with any component or the system can endanger vehicle safety All repairs and replacements must be done by appropriately trained and authorized staff. https://www.forkliftpdfmanuals.com/...
  • Page 334 11-46 https://www.forkliftpdfmanuals.com/...
  • Page 335 12-1 CYLINDER Page LIFTING CYLINDERS..........12-2 GENERAL................12-2 CYLINDER SPECIFICATIONS ..........12-3 COMPONENTS..............12-4 SIDE / REAR CYLINDER........... 12-7 SIDE CYLINDER GASKETS (2M TV) ..... 12-10 SIDE CYLINDER GASKETS (3M TV) ..... 12-15 SIDE CYLINDER GASKETS (2M FFL) ....12-20 SIDE CYLINDER GASKETS (3M FFL) ....
  • Page 336 12-2 LIFTING CYLINDERS GENERAL 1.0-1.5t CENTRAL CYLINDERS SIDE / REAR CYLINDER STANDARD 2 displacement cylinders without braking effect 2M TV OPTIONAL 2 displacement cylinders with braking effect on lowering STANDARD 2 displacement cylinders without braking effect 3M TV STANDARD 2 displacement cylinders with braking effect on lifting STANDARD 2 displacement cylinders with braking effect on lowering 2M FFL...
  • Page 337 12-3 CYLINDER SPECIFICATIONS SIDE / REAR LIFTING CYLINDERS (2M TV & 3M TV) Model 1.0 t 1.25 t 1.5 t Item Cylinder model Simple effect ← ← Cylinder bore ← ← Piston outside diameter ← ← Parachute valve s = 1 ←...
  • Page 338 12-4 COMPONENTS LIFTING CYLINDER (2M TV) STANDARD OPTIONAL SIDE LIFTING CYLINDERS (3M TV) https://www.forkliftpdfmanuals.com/...
  • Page 339 12-5 SIDE / REAR LIFTING CYLINDER (2M FFL) SIDE / REAR LIFTING CYLINDER (3M FFL) https://www.forkliftpdfmanuals.com/...
  • Page 340 12-6 CENTRAL CYLINDERS (2M FFL & 3M FFL) STANDARD OPTIONAL https://www.forkliftpdfmanuals.com/...
  • Page 341 12-7 SIDE / REAR CYLINDER REMOVAL • INSTALLATION Removal procedure 1. Set the mast in the vertical position and fully lower the forks 2. Hook on an appropriately sized and protected belt and eye bolt 3. Disconnect the battery connector 4.
  • Page 342 12-8 Point Operation [Point 1] Disassembly: Remove the pipe-hose clips C [Point 2] Disassembly: Remove the upper fixing bolt A Disassembly: Remove the bottom fixing bolts B Installation 2M TV: Respect the orientation between holes G3/8 and M6 RH = right cylinder LH = left cylinder https://www.forkliftpdfmanuals.com/...
  • Page 343 12-9 Installation 2M TV: After installation, perform adjustment if necessary in order to have following clearance of the upper fixing bolts of the cylinders. clearance = 4 (0 / -0.3) mm Installation 3M TV: After installation, perform adjustment if necessary in order to have following clearance of the upper fixing bolts of the cylinders.
  • Page 344 12-10 SIDE CYLINDER GASKETS (2M TV) DISASSEMBLY • INSPECTION • REASSEMBLY Tightening torque T=Nm 3 - 6 4 - 8 Removal procedure 1. Lock the cylinder in a vice [Point 1] 2. Position a container to collect the oil 3. Remove the piston rod [Point 2] 4.
  • Page 345 12-11 [Point 2] Disassembly: Use compressed air in point (A) to remove the rod Remarks: Prevent the rod from coming into contact with other parts [Point 3] Disassembly: Lock the bottom as shown in figure [Point 4] Disassembly: Unscrew the bushing as shown in figure Installation: Touch up the cover (if damaged during removal) with paint, without contaminating the rod...
  • Page 346 12-12 Installation: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning Remarks: Check that the gasket is correctly in its seat and is not damaged or twisted. Gaskets may be more elastic if heated to a max.
  • Page 347 12-13 Installation: Clean the housing seats with compressed air. Manual tightening Installation: Lubricate the bushing with grease before inserting the [Point 5] Installation: Clean the housing seat with compressed air; insert the seeger Inspection: Measure the external diameter of the piston rod; measure the bend of the piston rod Limit: 2.0 mm (0.079 in) Remarks:...
  • Page 348 12-14 [Point 6] Disassembly: SST09610-T1000-71 Tightening torque = 3 Nm Installation: Clean the housing seat with compressed air; insert the valve Remarks: See paragraph "Cylinder Specifications" for the valve opening diameter and setting Installation: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning Remarks:...
  • Page 349 12-15 SIDE CYLINDER GASKETS (3M TV) DISASSEMBLY • INSPECTION • REASSEMBLY Tightening torque T=Nm 3 - 6 4 - 8 Removal procedure 1. Lock the cylinder in a vice [Point 1] 2. Position a container to collect the oil 3. Remove the piston rod [Point 2] 4.
  • Page 350 12-16 [Point 2] Disassembly: Use compressed air in point (A) to remove the rod Remarks: Prevent the rod from coming into contact with other parts [Point 3] Disassembly: Lock the bottom as shown in figure [Point 4] Disassembly: Unscrew the bushing as shown in figure Installation: Touch up the cover (if damaged during removal) with paint, without contaminating the rod...
  • Page 351 12-17 Installation: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning Remarks: Check that the gasket is correctly in its seat and is not damaged or twisted. Gaskets may be more elastic if heated to a max.
  • Page 352 12-18 Installation: Clean the housing seats with compressed air. Manual tightening Installation: Lubricate the bushing with grease before inserting the [Point 5] Installation: Clean the housing seat with compressed air; insert the seeger Inspection: Measure the external diameter of the piston rod; measure the bend of the piston rod Limit: 2.0 mm (0.079 in) Remarks:...
  • Page 353 12-19 [Point 6] Disassembly: SST09610-T1000-71 Tightening torque = 3 Nm Installation: Clean the housing seat with compressed air; insert the valve Remarks: See paragraph "Cylinder Specifications" for the valve opening diameter and setting Installation: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning Remarks:...
  • Page 354 12-20 SIDE CYLINDER GASKETS (2M FFL) DISASSEMBLY • INSPECTION • REASSEMBLY Tightening torque T=Nm 3 - 6 4 - 8 Removal procedure 1. Lock the cylinder in a vice [Point 1] 2. Position a container to collect the oil 3. Remove the piston rod [Point 2] 4.
  • Page 355 12-21 [Point 2] Disassembly: Use compressed air in point (A) to remove the rod Remarks: Prevent the rod from coming into contact with other parts [Point 3] Disassembly: Lock the bottom as shown in figure [Point 4] Disassembly: Unscrew the bushing as shown in figure Installation: Touch up the cover (if damaged during removal) with paint, without contaminating the rod...
  • Page 356 12-22 Installation: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning Remarks: Check that the gasket is correctly in its seat and is not damaged or twisted. Gaskets may be more elastic if heated to a max.
  • Page 357 12-23 Installation: Clean the housing seats with compressed air; lubricate the scraper with hydraulic oil before installation to facilitate positioning Remarks: Check that the gasket is correctly in its seat and is not damaged or twisted. Gaskets may be more elastic if heated to a max.
  • Page 358 12-24 [Point 5] Installation: Clean the housing seat with compressed air; insert the seeger Installation: Lubricate the o-ring with hydraulic oil before mounting in order to facilitate its positioning Remarks: Check that the o-ring is correctly in its seat and is not damaged or twisted Installation: Clean the housing seats with compressed air;...
  • Page 359 12-25 Installation: Use pliers and twist slightly to insert Installation: Clean the housing seats with compressed air. Manual tightening Installation: Make a diagonal cut to facilitate insertion Installation: Use the inserter and lubricate to facilitate insertion Remarks: • Check that the o-ring is correctly in its seat and is not damaged or twisted •...
  • Page 360 12-26 Installation: Place the upper end near the pipe and tighten with a pneumatic screwdriver with percussion (or electrical equivalent) Inspection: Measure the external diameter of the piston rod; measure the bend of the piston rod Limit: 2.0 mm (0.079 in) Remarks: See paragraph "Cylinder Specifications"...
  • Page 361 12-27 Installation: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning Remarks: Check that the gasket is correctly in its seat and is not damaged or twisted. Gaskets may be more elastic if heated to a max.
  • Page 362 12-28 SIDE CYLINDER GASKETS (3M FFL) DISASSEMBLY • INSPECTION • REASSEMBLY Tightening torque T=Nm 3 - 6 4 - 8 Removal procedure 1. Lock the cylinder in a vice [Point 1] 2. Position a container to collect the oil 3. Remove the piston rod [Point 2] 4.
  • Page 363 12-29 [Point 2] Disassembly: Use compressed air in point (A) to remove the rod Remarks: Prevent the rod from coming into contact with other parts [Point 3] Disassembly: Lock the bottom as shown in figure [Point 4] Disassembly: Unscrew the bushing as shown in figure Installation: Touch up the cover (if damaged during removal) with paint, without contaminating the rod...
  • Page 364 12-30 Installation: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning Remarks: Check that the gasket is correctly in its seat and is not damaged or twisted. Gaskets may be more elastic if heated to a max.
  • Page 365 12-31 Installation: Clean the housing seats with compressed air. Manual tightening Installation: Lubricate the bushing with grease before inserting the [Point 5] Installation: Clean the housing seat with compressed air; insert the seeger Installation: Insert the bushing as shown in the figure, otherwise it will not be possible to apply the seeger https://www.forkliftpdfmanuals.com/...
  • Page 366 12-32 Installation: Use pliers and twist slightly to insert Inspection: Measure the external diameter of the piston rod; measure the bend of the piston rod Limit: 2.0 mm (0.079 in) Remarks: See paragraph "Cylinder Specifications" for the internal diameter [Point 6] Disassembly: SST09610-T1000-71 Tightening torque = 3 Nm...
  • Page 367 12-33 Installation: Lubricate the o-ring with hydraulic oil before mounting in order to facilitate its positioning Remarks: Check that the o-ring is correctly in its seat and is not damaged or twisted Installation: Use Loxeal 82-33 on the brake body before screwing it onto the bottom;...
  • Page 368 12-34 CENTRAL CYLINDERS REMOVAL • INSTALLATION Removal procedure 1. Set the mast in the vertical position and fully lower the forks 2. Disconnect the battery connector 3. Remove the lifting chain and roller from the cylinder [Point 1] 4. Disconnect the cylinder hose 5.
  • Page 369 12-35 Point Operation [Point 1] Disassembly: Remove the chain and then the allen screw in order to take away the roller on his support [Point 2] Disassembly: Remove the bottom fixing bolt B [Point 3] Disassembly: Remove the two screws of the upper fixing cylinder bracket A [Point 4] Installation 2M FFL:...
  • Page 370 12-36 CENTRAL CYLINDER GASKETS (2M FFL & 3M FFL) DISASSEMBLY • INSPECTION • REASSEMBLY Tightening torque T=Nm 3 - 6 4 - 8 Removal procedure 1. Lock the cylinder in a vice [Point 1] 2. Position a container to collect the oil 3.
  • Page 371 12-37 [Point 2] Disassembly: Use compressed air in point (A) to remove the rod Remarks: Prevent the rod from coming into contact with other parts [Point 3] Disassembly: Lock the bottom as shown in figure [Point 4] Disassembly: Unscrew the bushing as shown in figure Installation: Touch up the cover (if damaged during removal) with paint, without contaminating the rod...
  • Page 372 12-38 Installation: Clean the housing seats with compressed air; lubricate the gasket with hydraulic oil before installation to facilitate positioning Remarks: Check that the gasket is correctly in its seat and is not damaged or twisted. Gaskets may be more elastic if heated to a max.
  • Page 373 12-39 Installation: Clean the housing seats with compressed air. Manual tightening Installation: Lubricate the bushing with grease before inserting the [Point 5] Installation: Clean the housing seat with compressed air; lubricate the o-ring with hydraulic oil before installation to facilitate positioning Remarks: Check that the o-ring is correctly in its seat and is not...
  • Page 374 12-40 Remarks: • Place the gasket over the o-ring • Check that the gasket is correctly in its seat and is not damaged or twisted. Gaskets may be more elastic if heated to a max. temperature of 50°C Installation: Clean the housing seat with compressed air; insert the seeger Inspection: Measure the external diameter of the piston rod;...
  • Page 375 12-41 Installation: Lubricate the o-ring with hydraulic oil before mounting in order to facilitate its positioning Remarks: Check that the o-ring is correctly in its seat and is not damaged or twisted Installation: Use Loxeal 82-33 on the brake body before screwing it onto the bottom;...
  • Page 376 12-42 LOWERING VALVE (HAWE, for all masts) SPECIFICATIONS Hawe valve setting Mast type Hawe valve type s (mm) 2M TV sb 25 c 17.5 3M TV sb 25 c 16.0 2M FFL sb 25 c 17.5 3M FFL sb 25 c 17.5 https://www.forkliftpdfmanuals.com/...
  • Page 377 12-43 MAST PERFORMANCE TABLE LIFTING LOGIC UNIT Q1 max. load Q2 max. load at max. height Carry out the test with electrolyte density 1.18 ÷ 1.26 Kg/l, electrolyte temperature 20° ÷ 50°, oil temperature 30° ÷ 50° and room temperature > 18°C 1.0t Load m/sec...
  • Page 378 12-44 REMOVAL • INSTALLATION Note: The explanation here is for the flow regulator valve for all the mast. Tightening torque T=Nm A = 100 Nm 2M TV 3M TV 2M FFL 3M FFL Removal procedure 1. Set the mast in vertical position and lift it up to reach the valve. 2.
  • Page 379 12-45 TILTING CYLINDERS GENERAL Tightening torque T=Nm M = 300 Nm T = 300 Nm ROD HEAD ADJUSTMENT Tilt angle A (*) B (**) 3° forwards - 4° backwards 437.0 395.0 101.5 31.5 3° forwards - 6° backwards 436.5 384.5 77.0 38.0 4°...
  • Page 380 12-46 REMOVAL • INSTALLATION Tightening torque T=Nm T = 24 Nm T = 300 Nm Removal procedure 1. Remove the foot board 2. Set the mast to the vertical position 3. Disconnect the hoses (after lowering the remaining pressure in the tilting cylinders by operating the tilting lever a number of times) 4.
  • Page 381 12-47 Point Operation [Point 1] Disassembly: Remove the safety screw and then the tilting cylinder front pin T = 24 Nm [Point 2] Disassembly: Remove the safety screw and then the tilting cylinder rear pin T = 24 Nm SETTING Note: •...
  • Page 382 12-48 TILT CYLINDER GASKETS DISASSEMBLY • INSPECTION • REASSEMBLY Tightening torque T=Nm T = 200 Nm T = 300 Nm T = 300 Nm Removal procedure 1. Remove the rod connection 2. Loosen the rod guide [Point 1] 3. Extract the piston rod W/piston 4.
  • Page 383 12-49 [Point 2] Disassembly: Fix the front cylinder connection in a vice and loosen the piston fixing nut Installation: Tightening torque = 300 Nm Remarks: During installation insert the cylinder head and the pad on the piston side to prevent damage to the gaskets [Point 3] Disassembly: Remove the internal and external piston gaskets using a...
  • Page 384 12-50 Installation: Insert the internal/external gaskets or o-rings as shown to the side Remarks: Before installing the new gaskets, clean the seat carefully (A) Installation: Before re-installing, lubricate the gaskets and o-rings with vaseline https://www.forkliftpdfmanuals.com/...
  • Page 385 13-1 OIL PUMP Page GENERAL ..............13-2 SPECIFICATIONS..............13-2 COMPONENTS..............13-3 SERVICE PUMP............13-4 TEST METHOD..............13-5 MAST PERFORMANCE TABLE .......... 13-6 https://www.forkliftpdfmanuals.com/...
  • Page 386 13-2 GENERAL SPECIFICATIONS Vehicle model 1,0 - 1,25 - 1,5 ton Oil pump type Gear pump Oil pump name WSP 20-8 Transmission Direct motor drive Capacity (pompa a 1500 rpm) 12,45 Theoretical displacement 8,74 https://www.forkliftpdfmanuals.com/...
  • Page 387 13-3 COMPONENTS https://www.forkliftpdfmanuals.com/...
  • Page 388 13-4 SERVICE PUMP DISASSEMBLY • REASSEMBLY Pressure intake 50 Nm (± 10%) 105 Nm (± 10%) 80 Nm (± 10%) 45 Nm (± 10%) 12 Nm (± 15%) Disassembly Procedure 1. Disconnect the battery plug 2. Remove the foot board 3.
  • Page 389 13-5 TEST METHOD A bench test should be conducted for strict testing, but as it is generally impossible in practical service operation, install the oil pump on the vehicle and judge the oil pump discharge performance by means of cylinder operation. •...
  • Page 390 13-6 MAST PERFORMANCE TABLE LIFTING Q1 max. load Q2 max. load at max. height Perform the test with the electrolyte density 1.18 ÷ 1.26 Kg/l, electrolyte temperature 20° ÷ 50°, oil temperature 30° ÷ 50° and environment temperature > di 18°C 1.0t Load m/sec...
  • Page 391 14-1 OIL CONTROL VALVE Page MECHANICAL CONTROL VALVE ......14-2 GENERAL................14-2 CONTROL VALVE 3 WAYS..........14-2 CONTROL VALVE 4 WAYS..........14-3 HYDRAULIC CIRCUIT MECHANICAL CONTROL VALVE ................14-4 SPECIFICATIONS ..............14-4 MECHANICAL CONTROL VALVE........14-5 RELIEF VALVE ADJUSTMENT ........... 14-7 MAST PERFORMANCE TABLE .......
  • Page 392 14-2 MECHANICAL CONTROL VALVE GENERAL CONTROL VALVE 3 WAYS https://www.forkliftpdfmanuals.com/...
  • Page 393 14-3 CONTROL VALVE 4 WAYS https://www.forkliftpdfmanuals.com/...
  • Page 394 14-4 HYDRAULIC CIRCUIT MECHANICAL CONTROL VALVE SPECIFICATIONS Model All models Article Type Mechanic Lifting 175 ÷ 235 bar Maximum pressure Tilting 160 bar Ther functions Valvole di blocco sollevamento e brandeggio integrate https://www.forkliftpdfmanuals.com/...
  • Page 395 14-5 MECHANICAL CONTROL VALVE DISASSEMBLY • REASSEMBLY Notes: Operate the control lever to bring the mast and fork to the vertical and lowermost positions, respectively, to release the residual pressure in the material handling system before starting removal. Disassembly Procedure 1.
  • Page 396 14-6 Points Operation [Point 1] Disassembly: Remove the pin A of each lever Microswitch adjustment: After the installation perform the following adjustments: Keep the microswitch in rest position as shown in the CONTROL ROD drawing according to the following points: •...
  • Page 397 14-7 RELIEF VALVE ADJUSTMENT • Always follow the procedure below for adjustment. Careless adjustment may cause high- pressure generation, resulting in damage to hydraulic units such as the service pump • No adjustment is needed when the relief valve is not disassembled or the mast is replaced •...
  • Page 398 14-8 MAST PERFORMANCE TABLE LIFTING Q1 max. load Q2 max. load at max. height Perform the test with the electrolyte density 1.18 ÷ 1.26 Kg/l, electrolyte temperature 20° ÷ 50°, oil temperature 30° ÷ 50° and environment temperature > di 18°C 1.0t Load m/sec...
  • Page 399 14-9 LIFTING LOCKING AND UNLOCKING SCREW To be activated when forks can’t be lowered due to solenoid valve failure. EV13 EV12 Solenoid valve 24 Volt / 28 ohm Lifting locking/unlocking screw Lifting locking/unlocking screw https://www.forkliftpdfmanuals.com/...
  • Page 400 14-10 ELECTRIC CONTROL VALVE (MINILEVER AND JOYSTICKS) GENERAL Drain Left sideshift Right sideshift EVP3 EVP4 Forward tilting Backward tilting Lowering EVP1 Lifting 18 Ω 19 Ω 19 Ω 19 Ω 19 Ω 18 Ω 18 Ω 18 Ω 27 Ω https://www.forkliftpdfmanuals.com/...
  • Page 401 14-11 COMPONENTS https://www.forkliftpdfmanuals.com/...
  • Page 402 14-12 HYDRAULIC CIRCUIT ELECTRIC CONTROL VALVE SPECIFICATIONS Model All models Article Type Elettrico Maximum pressure 175 ÷ 235 Other functions With proportional solenoid valve type ON / OFF https://www.forkliftpdfmanuals.com/...
  • Page 403 14-13 ELECTRIC CONTROL VALVE DISASSEMBLY • REASSEMBLY Nota: Before starting removal, operate levers in order to bring mast in vertical position and forks to lowest position, releasing the residual pressure in the hydraulic system. Tightening torque M=Nm Disassembly Procedure 1. Park the truck on a level surface and activate the parking brake 2.
  • Page 404 14-14 PRESSURE RELIEF VALVE ADJUSTMENT Notes: • Always follow the procedure below for adjustment. Careless adjustment may cause high- pressure generation, resulting in damage to equipment such as the oil pump. • There is no adjustment if: the pressure relief valve is not disassembled the pressure relief valve is replaced in conformity with the mast supplied with the vehicle;...
  • Page 405 14-15 LIFTING LOCKING AND UNLOCKING SCREW T=Nm Lifting locking-unlocking screw • Loosen the lift lock unlocking bolt and operate the lift lever to manually lower the forks. Notes: Always retighten the locking bolt after an operation. If lift locking and unlocking bolt is left loose, much hydraulic oil is released from the pump and the lifting speed is significantly decreased, resulting in difficulty in smooth operation.
  • Page 406 14-16 https://www.forkliftpdfmanuals.com/...
  • Page 407 15-1 MAIN OPTIONS Page WIRING DIAGRAM OPTIONAL SYSTEMS ....15-2 FLASH BEACON..............15-4 REVERSE ACOUSTIC WARNING ........15-5 WORKING LIGHTS .............. 15-6 COMPLETE LIGHTING SYSTEM ........15-7 https://www.forkliftpdfmanuals.com/...
  • Page 408 15-2 WIRING DIAGRAM OPTIONAL SYSTEMS https://www.forkliftpdfmanuals.com/...
  • Page 409 15-3 https://www.forkliftpdfmanuals.com/...
  • Page 410 15-4 FLASH BEACON Flash beacon 10 ÷ 100V Fuse 2A Wiring Fuse board 24V Push-button DISASSEMBLY • REASSEMBLY Reassembly Procedure 1. Pass the beacon wiring inside the overhead guard bringing it out through the left front leg 2. Connect the beacon wiring to the fuse board 24V 3.
  • Page 411 15-5 REVERSE ACOUSTIC WARNING Reverse acoustic warning Clamp DISASSEMBLY • REASSEMBLY Reassembly Procedure 1. Remove the rear metallic cover 2. Fix the clamp to the chassis (rear compartment, left side) 3. Fix the reverse acoustic warning to the clamp 4. Connect the reverse acoustic warning to the wiring (J71 connector) Disassembly Procedure The disassembly procedure is the reverse of the reassembly procedure.
  • Page 412 15-6 WORKING LIGHTS Working lights 24V 70W Fuse 7,5A Wiring Fuse board 24V Push-button DISASSEMBLY • REASSEMBLY Reassembly Procedure 1. Pass the working lights inside the overhead guard bringing it out through the front legs 2. Connect the wiring to the fuse board 24V 3.
  • Page 413 15-7 COMPLETE LIGHTING SYSTEM Selector Flashing Push button Indicator Fuse board 24V Light Fuse Bulb DISASSEMBLY • REASSEMBLY Reassembly Procedure 1. Add two bulbs to the rear lights (indicators) 2. Pass the lights and the indicators inside the overhead guard bringing it out through the front legs 3.
  • Page 414 15-8 https://www.forkliftpdfmanuals.com/...
  • Page 415 16-1 PROGRAMMER Page PROGRAMMER............16-2 GENERAL ................16-2 PROGRAMMER CONNECTION BY CAN-BUS ....16-4 COLLEGAMENTO PROGRAMMATORE VIA SERIALE..16-5 PROGRAMMER FUNCTION..........16-6 AUTO MODE .................16-6 MANUAL MODE..............16-8 SAVE FUNCTION............... 16-11 RESTORE FUNCTION ............16-14 DELETE FUNCTION ............16-17 INFORMATION MESSAGES ..........16-19 SERIAL CONNECTION............16-20 SD CARD SOFTWARE UPDATE........16-23 https://www.forkliftpdfmanuals.com/...
  • Page 416 16-2 PROGRAMMER GENERAL The programmer allows programming of the logic units and cards on the truck. WIRING CONNECTOR SD CARD FUNCTIONS PROGRAMMER for updating software SAVE/RESTORE for saving/copying operator profiles https://www.forkliftpdfmanuals.com/...
  • Page 417 16-3 LEGEND Function buttons Possible choices Confirm choice Change screen Confirm Return to previous screen Software version out of date UPDATE Software version updated NOT CONNECTED Card not connected or not powered https://www.forkliftpdfmanuals.com/...
  • Page 418 16-4 PROGRAMMER CONNECTION BY CAN-BUS Procedure Put the truck in a safe position, parking it on a flat surface and raising the drive wheels Insert the SD card in the programmer and connect the interface wiring Connect the CAN-BUS connector of the programmer to the CAN-BUS connector (J132) of the truck, located under the display Turn on the truck...
  • Page 419 16-5 PROGRAMMER SERIAL CONNECTION Procedure Put the truck in a safe position, parking it on a flat surface and raising the drive wheels Insert the SD card in the programmer and connect the interface wiring Connect the CAN-BUS connector of the programmer to the CAN-BUS connector (J132) of the truck, located under the display Connect the serial connector of the programmer to the...
  • Page 420 16-6 PROGRAMMER FUNCTION The programmer function allows the updating of the software present in the logic units and cards on the truck. It is possible to update the cards in two different ways: • AUTO the programmer automatically recognizes the truck and the latest software version to be installed.
  • Page 421 16-7 Press F1 to select programming by CAN-BUS Please select Program type Press F3 to select programming by SERIAL VIA CAN SERIAL CONNECTION Press F1 to confirm your choice and start Do you want to program programming EVCB with vers X.XX? Press F3 to return to the previous screen Wait until the end of programming Please wait...
  • Page 422 Press F1 to confirm your choice Manual download mode selected proceed? Press F3 to return to the previous screen Use F1 if the truck to be updated is CESAB Please select truck type Use F3 if the truck to be updated is BT CESAB https://www.forkliftpdfmanuals.com/...
  • Page 423 16-9 Use the buttons to change screen and view 1 BLITZ312-420 AC FN the truck models 2 ECOP CESAB 3 B315-420 Use the buttons to select the truck model connected to the programmer selects line 1 selects line 2 selects line 3...
  • Page 424 16-10 11. Press F1 to confirm your choice and start Do you want to program programming EVCB with vers X.XX? Press F3 to return to the previous screen 12. Wait until the end of programming Please wait Program Running Note: Do not turn off the truck, disconnect the programmer or the battery during programming 13.
  • Page 425 16-11 SAVE FUNCTION With the SAVE function it is possible to create a file in the programmer SD card for saving the operator profile parameters. Procedure Connect the programmer and turn on the truck (see specific paragraph) Wait a few seconds for the data to load Press F3 to select the function SAVE/RESTORE Please select funct Programmer...
  • Page 426 16-12 If the CHOOSE option was chosen on the previous Profile to save screen, use the buttons to select the profile to be saved Press OK to confirm Press F1 to confirm Do you want to save XXX Press F3 to return to the previous screen Press OK to continue Personalisation will be saved in...
  • Page 427 16-13 10. Press F1 to start saving Do you want to save parameters? Press F3 to return to the previous screen 11. Wait until the end of saving Please wait save running Note: Do not turn off the truck, disconnect the programmer or the battery during saving 12.
  • Page 428 16-14 RESTORE FUNCTION The RESTORE function allows you to load on the truck the files for saving the operator profile parameters present on the SD card, created with the SAVE function Note: Before proceeding with the RESTORE function, it is necessary to ensure that the truck that is to receive the update has the same software versions as the truck from which the file was created.
  • Page 429 16-15 Press F1 if you intend to load all the profiles present in Please select the file Profile to restore CHOOSE Press F3 if you intend to load only one of the profiles present in the file Press F1 to confirm Do you want to restore all profiles? Press F3 to return to the previous screen...
  • Page 430 16-16 10. Restore ended Press OK to return to the first screen Restore successful https://www.forkliftpdfmanuals.com/...
  • Page 431 16-17 DELETE FUNCTION The DELETE function allows you to delete from the SD card the files that were created with the SAVE function. Procedure Connect the programmer and turn on the truck (see specific paragraph) Wait a few seconds for the data to load Press F3 to select the function SAVE/RESTORE Please select funct Programmer...
  • Page 432 16-18 Press F1 to delete the file Do you want to erase XXX Press F3 to return to the previous screen File deleted Press OK to return to the first screen Erase successful https://www.forkliftpdfmanuals.com/...
  • Page 433 16-19 INFORMATION MESSAGES N° Programmer message Description Card not found please check card insertion The programmer is connected without SD card Card error please check card The SD card is damaged File not found The file selected is not stored on the SD card Please key OFF and ON before program The machine needs to be reset with the key this board...
  • Page 434 16-20 SERIAL CONNECTION All the truck cards except the logic units have a serial connector inside. Note: The programmer must always be connected to the CAN-BUS connector in order to receive power MCB main control board Remove the rear cover by releasing the four clips Remove the front cover by unscrewing the 8 fixing screws The two serial connectors are near the black...
  • Page 435 16-21 ARMREST CARD Unscrew the 4 screws located under the head of the armrest Remove the cover from the head of the armrest The serial connector is situated on the right side of the card https://www.forkliftpdfmanuals.com/...
  • Page 436 16-22 DISPLAY Remove the 4 screws at the rear of the display Remove the front cover, disconnecting the wiring Unscrew the 3 screws that hold the screen The serial connector is situated under the screen https://www.forkliftpdfmanuals.com/...
  • Page 437 16-23 SD CARD SOFTWARE UPDATE Procedure for installing the new software on the programmer SD card. 1. Download the latest programmer software package and copy it onto the desktop of the computer 2. Unzip the programmer software package file if it is in .ZIP or .RAR format 3.
  • Page 438 16-24 https://www.forkliftpdfmanuals.com/...
  • Page 439 17-1 APPENDIX Page TECHNICAL DATA ............ 17-2 AUXILIARY WIRING HARNESS ....... 17-6 CONNECTORS..............17-7 ELECTRIC DIAGRAMS........... 17-12 https://www.forkliftpdfmanuals.com/...
  • Page 440 17-2 TECHNICAL DATA Model 1,0 ton 1,3 ton 1,5 ton Traction motor Type TSA200-140-085 Asynchronous Power 4,9 kW Nominal voltage 16 V Current 255 A Frequency 52 Hz Power factor 0,81 Insulation class Degree of protection IP 54 Service S2-60 min Poles R.p.m.
  • Page 441 17-3 Model 1,0 ton 1,3 ton 1,5 ton Rear axle Model ZF GK26LD Reduction ratio 1:27 Quantity of oil 6,2 litri Type of oil (standard version) MOBILUBE OIL 1 HD 80W-90 Type of oil (cold storage version) MOBILUBE OIL 1 SHC 75W-90 Tightening torque of fixing motor gear/chassis 283 Nm (±...
  • Page 442 17-4 Model 1,0 ton 1,3 ton 1,5 ton Contactor Key contactor - CT1 SW60B-230 24V Traction contactor - CT2 SU280B-1004 24V CO CT1 coil 104 ohm CT2 coil 45 ohm Tightening torque of fixing cables CT1 3,6 ÷ 3,9 Nm Tightening torque of fixing cables CT2 15,3 ÷...
  • Page 443 17-5 Model 1,0 ton 1,3 ton 1,5 ton Mechanical control valve Lifting maximum pressure 175 bar 215 bar 240 bar Tilting maximum pressure 130 bar Sideshift maximum pressure 130 bar IV way maximum pressure 130 bar Lifting oil capacity 30 l/min Tilting oil capacity 13 l/min Sideshift oil capacity...
  • Page 444 17-6 AUXILIARY WIRING HARNESS Connector Description Traction motor Pump motor Oil brake tank Horn Pump motor Steering pot Traction motor Seat Emergency button Valves Swaying pedal J29/A Parking brake Brake pedal Accelerator pedal Direction pedal I/O board Steering column I/O board Distributor/MHYRIO Contactor / Fuses Contactor / Fuses...
  • Page 445 17-7 CONNECTORS https://www.forkliftpdfmanuals.com/...
  • Page 446 17-8 https://www.forkliftpdfmanuals.com/...
  • Page 447 17-9 https://www.forkliftpdfmanuals.com/...
  • Page 448 17-10 https://www.forkliftpdfmanuals.com/...
  • Page 449 17-11 https://www.forkliftpdfmanuals.com/...
  • Page 450 17-12 ELECTRIC DIAGRAMS https://www.forkliftpdfmanuals.com/...
  • Page 451 17-13 https://www.forkliftpdfmanuals.com/...
  • Page 452 17-14 https://www.forkliftpdfmanuals.com/...
  • Page 453 17-15 https://www.forkliftpdfmanuals.com/...
  • Page 454 17-16 https://www.forkliftpdfmanuals.com/...
  • Page 455 17-17 https://www.forkliftpdfmanuals.com/...
  • Page 456 17-18 https://www.forkliftpdfmanuals.com/...
  • Page 457 17-19 https://www.forkliftpdfmanuals.com/...
  • Page 458 17-20 https://www.forkliftpdfmanuals.com/...
  • Page 459 https://www.forkliftpdfmanuals.com/...
  • Page 460 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 https://www.forkliftpdfmanuals.com/...

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