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ECOVOLVE ED800 Owner's Manual

Battery hi-tip dumper
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Battery Hi-Tip Dumpers
ED800
ED1000
ED1500
OWNER'S MANUAL

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Summary of Contents for ECOVOLVE ED800

  • Page 1 Battery Hi-Tip Dumpers ED800 ED1000 ED1500 OWNER’S MANUAL...

  • Page 2: Table Of Contents

    CONTENTS 1 Introduction Introduction overview ............2 Safety Safety guidelines .
  • Page 3 CONTENTS Transportation ............Transporting the electric dumper .
  • Page 4 Technical data sheet US ........... . ED800 Parts list Exploded front view parts list .
  • Page 5 Electrical system ............Rear drive unit .

  • Page 6: Introduction

    INTRODUCTION...
  • Page 7 Servicing should only be carried out by qualified personnel approved by the manufacturer (specialists). This material is proprietary to Ecovolve, and is not to be reproduced, used, or disclosed except in accordance with written authorisation from Ecovolve. Each new user must read the Operator’s Hand Book before operating any Ecovolve truck for the first time.
  • Page 8 Information about this service manual including the specifications, illustrations, weight information and technical data are not binding and correspond to the design at the time of creation. Ecovolve reserve the right to make changes without prior notice in the area of design, configuration, appearance and technology on account of the ongoing further development of the products.
  • Page 9 (Overseas edition). User shall be responsible for any loss caused by improper use. Ecovolve Ltd will not be responsible for such loss. If you want to use an Ecovolve product for purposes that are not mentioned in the user manual, please contact dealers accredited by Ecovolve Ltd.
  • Page 10 It is therefore far more maneuverable than a conventional dump truck. The Ecovolve Range are intended to transport and empty materials within the specified load capacity in normal operating conditions. It is the operators responsibility to use sound judgment to assess whether a ground material is compatible with use of the Truck.

  • Page 11: Safety

    SAFETY...

  • Page 12: Safety Guidelines

    Safety Features Ecovolve has introduced many safety features to make the Ecovolve range safe and user friendly. An overview of these are as follows: Three operating speeds: Creeper for when the skip is raised (under 1 km), Walking (under �...
  • Page 13 2. SAFETY Safety guidelines Operating Instructions All operators must read and understand the operating instructions before operating the truck. A copy of the Operators Manual should be kept in the manual holder on the Truck at all times. A copy of this manual can be found in this document –...
  • Page 14 2. SAFETY Safety guidelines Driving Routes and Tip Over Stability is guaranteed if the electric dumper is used correctly according to specified targets. Driving routes shall be free of objects. � Gradients used by the truck cannot exceed a max of 10°. �...
  • Page 15 2. SAFETY Safety guidelines OPERATORS PERSONAL PROTECTIVE EQUIPMENT (PPE) HARD HAT REQUIRED When the instruction for a hard hat is stated, a hard hat must always be worn when operating the machine to avoid personal injury. PROTECTIVE EYEWEAR REQUIRED When the instruction for protective eyewear is stated, protective eyewear must always be worn when operating the machine to avoid personal injury.
  • Page 16 2. SAFETY Safety guidelines SAFETY SYMBOL EXPLANATION CAUTION! Indicates a hazardous situation which, if not avoided, could result in moderate injury. ELECTRICAL WARNING! Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CRUSH PARTS WARNING! Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
  • Page 17 2. SAFETY Safety guidelines SAFETY SYMBOL EXPLANATION DANGER! The operator must read and fully understand the owners manual including all warning signs and labels before use. DANGER! Operator must wear the correct Personal Protective Equipment (PPE) to ensure safe use. DANGER! Crush hazard.

  • Page 18: Overview

    OVERVIEW...

  • Page 19: Vehicle Identification Plate

    Identification plate NOTE The CE mark confirms compliance with the EC machinery directives and with all regulations applicable to the Ecovolve hi tip electric dumper. Identification pate 1 Nameplate 2 Manufacturer 3 Model number 4 Serial no/year of manufacture 5 Unladen weight...

  • Page 20: Operation

    OPERATION...
  • Page 21 Information Electric hi tip dumper important information All electric products from Ecovolve are very user friendly machines to drive and operate. They are carefully manufactured with high quality components which ensure a long trouble free life. Whilst being designed, many safety features were considered and built in as standard to protect the operator and fellow work colleagues.

  • Page 22: Dashboard Controls Overview

    3. OVERVIEW Controls CAUTION The following section is a brief overview of the dashboard controls. All operators must read and understand the operating instructions in section 4 of this manual before operating the truck. Dashboard controls overview FIG 4 Light switch Up = On | Down = Off Remote control (Specific models only) For applicable models, a switch to engage the the remote...

  • Page 23: Tiller Head Controls Overview

    3. OVERVIEW Controls CAUTION The following section is a brief overview of the tiller head controls. All operators must read and understand the operating instructions in section 4 of this manual before operating the truck. Tiller head controls overview FIG 1 FIG 2 FIG 3 Flashing Beacon &...

  • Page 24: Driving

    Driving and operation Driving and operation Switching the dumper on and off WARNING Risk of accident and injury as a result of the driver being distracted. The use of mobile phones or other electrical equipment is prohibited while the truck is in motion. It is not permitted to drive on long inclines greater than 15°.

  • Page 25: Operators Platform And Safety Rails

    Driving and operation Operators platform The truck has a two position platform for the operator to stand on when operating the truck. � In the raised position the operator can walk behind the dumper (fig 1). � In the down position the truck can be operated while standing on the platform (fig 2). The truck will default to walk mode speed when the platform is placed in the raised position.

  • Page 26: Forward Travel

    Driving and operation Forwards travel Pull out the emergency stop button, insert the key and start the truck. � For forward motion the traction paddles are pressed upwards and for reverse motion the traction � paddles are pressed downwards (Fig 1). The speed of the truck depends on the set position of the speed control switch (fig 2) and also if �...

  • Page 27: Operating Speed

    Driving and operation Operating speeds The dumper has three operating speeds. Creeper mode under 1 kph: The truck automatically selects creeper mode when the high tip � function is activated. Walking mode under 4 kph: The truck will automatically select walking mode when the �...

  • Page 28: Platform And Safety Rails

    3. OVERVIEW operators platform and safety rails Operators platform and safety rails CAUTION The following section is a brief overview of the operators platform and safety rails. All operators must read and fully understand the operating instructions in section 4 of this manual before operating the truck.

  • Page 29: Bdashboard Controls

    3. OVERVIEW Controls Controls CAUTION The following section is a brief overview of the dashboard controls. All operators must read and understand the operating instructions in section 4 of this manual before operating the truck. Dashboard controls overview FIG 1 Key switch To start the Truck, make sure the Emergency stop is raised up, turn the key clockwise to position II and hold for 3...

  • Page 30: Lights

    Driving and operation Lights The truck is equipped with both front and rear facing lights (fig 1 and fig 2). � The lights can be turned on and off using the switch on the dash (fig 3). FIG 3 FIG 1 FIG 2 The rear facing lights The location of the light switch...

  • Page 31: Operating The High Tip Function

    Driving and operation Hi tip skip operation DANGER CRUSH PARTS There is a risk of becoming trapped between moving parts due to the skip lifting arm. Therefore, never reach into area around the skip lifting arm and the dumper. Take note of the maximum lift height. Operating the hi tip skip functions The skip is equipped with a function that is capable of tipping the load at a height.

  • Page 32: Emergency Stop Button

    Driving and operation Parking the truck In the interest of safety, parking the truck is the operators responsibility. � The operator must ensure to park the truck in a safe and secure manner and not be in � obstruction of other traffic and people. For safety reasons the Emergency stop button must be engaged.

  • Page 33: Battery Discharge

    Battery Battery Battery discharge indicator The battery’s discharge indicator (BDI) is the rate at which the battery discharges during the � operation of the truck. The operator can check the status of the battery by viewing the multi function display. The display is located on the dashboard (fig 3). The battery’s discharge status is shown on the display and also indicated by the row of 5 LED’s �...

  • Page 34: Charging

    When charging the battery it is absolutely prohibited to smoke or use a naked flame. All electric trucks from Ecovolve are fitted with an internal automatic charging system. This charger has an automatic maintenance charging feature for a certain period after the mains charging period is complete. It will also eliminate the risk of overcharging the battery and the need to monitor the charging procedure.

  • Page 35: Charging The Dumper

    Charging Charging the battery The charging compartment is located at the side of truck (fig 1). The supplied 3m charging � cable is stored inside the compartment. The charging Compartment contains the location of the mounted battery charging plug and �...

  • Page 36: Charging The Quiq1000

    Charging Charging QuiQ 1000 operating instructions The QuiQ 1000 is replaced by the Delta Q IC1200 in the ED1000 models from june 2018 The charger may become hot during the charge process. Use hand protection to safely handle the charger during charging. Extension cors must be 3 - wire cord no longer than 30m (100’) at 10 AWG or 7.5M (25’) at 16 AGW per UL guidelines.

  • Page 37: Charging The Ic1200

    Charging Delta Q IC1200 Battery charger Replaces QuiQ1000 in ED1000 model from June 2018 Display icons 1. Fault / Error / Usb indicator Erreur / Erreur / Indicateur 2. Battery charging / Indicator 5. Charging output indicator Indicateur de charge de la ba�erie 6.

  • Page 38: Transportation

    Transportation Transportation The Ecovolve range are all easily transportable. It is comparatively lightweight for its capacity and can be loaded on to a vehicle with a load rating of 1300kg minimum. The operator’s platform and safety rails can be folded down for ease of transportation.
  • Page 39 Transportation Lifting and anchor points The truck has two lifting points and five anchor points which are used to lift and secure the machine � when transporting. Use certified slings and chains to secure the truck when being transported. � The assigned lifting and anchor points must be used in conjunction with approved straps or chains.
  • Page 40 Cleaning Cleaning the electric dumper Cleaning guidelines CAUTION Do not power wash the machine. Possibility of causing damage or destruction of electrical components. The frequency of required cleaning depends on the application of the truck. If highly abrasive materials such as cement, fertiliser, salt water etc are used, then the truck must be thoroughly cleaned after each task.

  • Page 41: Daily Checklist

    Daily checklist DAILY CHECKLIST DANGER Failure to follow the daily checklist could result in a hazardous situation which could result in serious injury and damage to the truck. Always carry out the daily checklist before operating the truck. �� If any item on the daily checklist fails, contact your site supervisor and DO NOT OPERATE THE �...

  • Page 42: Servicing

    SERVICING...

  • Page 43: Transporting The Electric Dumper

    5. SERVICING 100 Hour inspection checklist 100 WORKING HOUR INSPECTION The following items must be serviced at the specified working hours. The work must be completed by a competent technician. Failure to do this will reduce or void your warranty! The Truck has two Vehicle Identification Information items that are required and can be found on the rear drive unit and chassis as shown below (fig 1 and fig 2).

  • Page 44: Cleaning And Washing

    5. SERVICING 100 Hour inspection checklist 100 WORKING HOUR INSPECTION SERVICE ITEMS DATE COMPLETED BY Steering & -Light display Dashboard -Check all sensors -Test drive machine Lubrication Check all 15 grease point fittings for proper lubrication, add grease as required. Hydraulic Check hydraulic system for leaks System...

  • Page 45: Chassis And Frame

    5. SERVICING 100 Hour chassis and frame inspection Chassis and frame Chassis 1. Check all safety symbols and décor is clearly visible. 2. Check operator safety rails and platform. Frame DANGER CRUSH POINT Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 46: Wheels

    5. SERVICING 100 hour wheels inspection Wheels Wheels 1. Check all wheel nuts are tight. Inspect tyres for wear and damage. 2. Check wheel bearings. DANGER WHEEL CRUSH Indicates a hazardous situation which, if not avoided, could result in serious injury. Obey all safety messages that follow this symbol to avoid injury.

  • Page 47: Steering And Dashboard

    5. SERVICING 100 hour steering and dashboard inspection Steering and dashboard Steering & Check all steering functions and dashboard switches. Dashboard CAUTION Ensure when testing the steering system that the test area is free from obstructions and pedestrians. Check all steering functions and dashboard switches Ensure that all the tiller head controls are fully functional and working correctly.
  • Page 48 5. SERVICING 100 hour steering and dashboard inspection Check all steering functions and dashboard switches FIG 9 FIG 8 FIG 7 Multi Function Display. Ensure the flashing beacon Skip lever. Ensure all 4 is working correctly. Ensure all functions are functions work correctly.

  • Page 49: Lubrication

    If required, apply grease to each point with suitable grease using a grease gun (fig 1 to fig 8). �� The Ecovolve range requires just one pump of a standard grease gun. Clean surplus grease from point with a damp cloth and reapply dust cap.
  • Page 50 5. SERVICING 100 hour lubrication inspection Check all 15 grease point fittings for proper lubrication, add grease as required FIG 1 FIG 2 FIG 3 Grease point 1 Grease point 2-3 Grease point 4-5 FIG 4 FIG 5 FIG 6 Grease point 10-13 Grease point 14-15 Grease point 6-9...

  • Page 51: Hydraulic System

    Always use the same original type of oil when topping up or changing. � The Ecovolve range uses HYD 46 Hydraulic oil. Tank capacity is 2.8 litres � CRUSH POINT DANGER Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
  • Page 52 5. SERVICING 100 hour hydraulic system inspection 3. Check oil level When checking the hydraulic oil level protective gloves and glasses must be worn. � The skip MUST be in the lowered position with all hydraulic cylinders closed. Engage � the emergency stop button and remove key from ignition.

  • Page 53: Rear Drive Unit

    5. SERVICING 100 hour rear drive unit inspection Rear drive unit Rear Drive Check oil level of rear drive unit. Unit CAUTION Indicates a hazardous situation which, if not avoided, could result in moderate or serious injury. Check oil level of rear drive unit Securely park the Truck and take all safety precautions.

  • Page 54: Braking System

    5. SERVICING 100 hour breaking system inspection Braking system Braking Inspect brake performance and adjust as needed. system CAUTION Indicates a hazardous situation which, if not avoided, could result in moderate or serious injury. 1. Inspect brake performance and adjust as needed Ensure the area is free from objects and dangers.

  • Page 55: Battery Charging

    5. SERVICING 100 hour charging system inspection Battery and charging system Electric Check charging system and cable. Charging CAUTION Indicates a hazardous situation which, if not avoided, could result in moderate or serious injury. Check charging system and cable Test charging system and inspect cable for damage. �...

  • Page 56: Working Hour Service

    The following items must be serviced at the specified working hours. Proof must be submitted to Ecovolve that this service has been completed by a competent technician. To do this complete this form and submit it to Ecovolve including all relevant vehicle identification information at www.

  • Page 57: Rear Drive Unit

    Before starting any service, record the transmission identification number of the rear drive unit for � submission to Ecovolve. This is required to maximise your warranty. Record the necessary information as shown and submit to Ecovolve at www.ecovolve.eu. � A copy of this form is included at the end of this manual.
  • Page 58 5. SERVICING 150 hour rear drive unit service Changing the oil CAUTION Indicates When this operation is executed immediately after a long operating time, oil in the unit may be hot; please wear special gloves. Turn off the truck, remove the key and engage the emergency stop button. �...

  • Page 59: Working Hour Service

    The following items must be serviced at the specified working hours. Proof must be submitted to Ecovolve that this service has been completed by a competent technician. To do this complete this form and submit it to Ecovolve including all relevant vehicle identification information at www.

  • Page 60: Chassis And Frame

    5. SERVICING 500 hour chassis and frame service Chassis and frame Chassis Inspect for any damage to the chassis and bodywork. Inspect any load bearing parts and joints. And Frame DANGER CRUSH POINT Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 61: Wheels

    5. SERVICING 500 hour wheels service Wheels Wheels 1. Check all wheel nuts are tight. Inspect tyres for wear and damage. 2. Check wheel bearings. DANGER WHEEL CRUSH Indicates a hazardous situation which, if not avoided, could result in serious injury. Obey all safety messages that follow this symbol to avoid injury.

  • Page 62: Steering And Dashboard

    5. SERVICING 500 hour steering and dashboard service Steering and dashboard Steering & Check all steering functions & switches. Dashboard CAUTION Ensure when testing the steering system that the test area is free from obstructions and pedestrians. Steering and dashboard inspection As the steering and dashboard service requires the truck to be operational, ensure the test �...
  • Page 63 5. SERVICING 500 hour steering and dashboard service Steering and dashboard inspection FIG 9 FIG 7 FIG 8 Ensure the flashing beacon Multi Function Display. Skip lever. Ensure all 4 is working correctly. Ensure all functions are functions work correctly. working correctly.

  • Page 64: Lubrication

    If required, apply grease to each point with suitable grease using a grease gun (fig 1 to fig 8). � The Ecovolve range requires just one pump of a standard grease gun. Clean surplus grease from point with a damp cloth and reapply dust cap.
  • Page 65 5. SERVICING 500 Hour Lubrication service Check all 15 grease point fittings for proper lubrication, add grease as required FIG 1 FIG 2 FIG 3 Grease point 1 Grease point 2-3 Grease point 4-5 FIG 4 FIG 5 FIG 6 Grease point 6-9 Grease point 10-13 Grease point 14-15...

  • Page 66: Hydraulic System

    Always use the same original type of oil when topping up or changing. � The Ecovolve range uses HYD 46 Hydraulic oil. Tank capacity is 2.8 litres � CRUSH POINT DANGER Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
  • Page 67 5. SERVICING 500 Hour hydraulic system service 2. Replace hydraulic oil When replacing the hydraulic oil, protective gloves and glasses must be worn. � Lower skip fully to access the dipstick (fig 1). Remove the key from ignition and engage �...

  • Page 68: Rear Drive Unit

    5. SERVICING 500 Hour rear drive unit service Rear drive unit service Rear Drive 1. Inspect for leaks, defects or unusual noise in the rear drive unit. 2. Grease gears and check for wear. Unit 3. Check oil level. After the first 150 working hours of use, the rear drive unit requires its first oil change.

  • Page 69: Braking System

    5. SERVICING 500 Hour breaking system service Braking system Braking 1. Inspect brake performance and adjust as needed. system 2. Check for brake wear. CAUTION Indicates a hazardous situation which, if not avoided, could result in moderate or serious injury. 1.

  • Page 70: Battery Care

    The following items must be serviced at the specified working hours. Proof Battery Care must be submitted to Ecovolve that this service has been completed by a competent technician. To do this complete the relevant form and submit it to Ecovolve including all relevant vehicle identification information on www.

  • Page 71: 2000 Working Hour Service

    The following items must be serviced at the specified working hours. Proof must be submitted to Ecovolve that this service has been completed by a competent technician. To do this complete this form and submit it to Ecovolve including all relevant vehicle identification information at www.

  • Page 72: Rear Drive Unit Oil Change

    Rear drive unit oil change at 2000 working hours Before starting any service record the transmission identification number of the rear ��� drive unit for submission to Ecovolve. This is required to maximise your warranty. Record the necessary information as shown and submit to Ecovolve at www.ecovolve.eu. �...
  • Page 73 5. SERVICING 2000 Hour rear drive unit - oil change Rear drive unit oil change CAUTION Indicates When this operation is executed immediately after a long operating time, oil in the unit may be hot; please wear special gloves. Turn off the truck, remove the key and engage the emergency stop button. �...

  • Page 74: Service Forms

    5. SERVICING Service and inspection forms SERVICE AND INSPECTION FORMS...
  • Page 75 5. SERVICING Service and inspection forms DAILY CHECKLIST WARNING Failure to follow the daily checklist could result in a hazardous situation which could result in serious injury and damage to the truck. Always carry out the daily checklist before operating the electric dumper. If any item on the daily checklist fails, contact your site supervisor and DO NOT operate the truck before doing so..
  • Page 76 5. SERVICING Service and inspection forms 100 WORKING HOUR INSPECTION The following items must be serviced at the specified working hours. The work must be completed by a competent technician. Failure to do this will reduce or void your warranty! The Truck has two Vehicle Identification Information items that are required and can be found on the rear drive unit and chassis as shown below (fig 1 and fig 2).
  • Page 77 5. SERVICING Service and inspection forms 100 WORKING HOUR INSPECTION SERVICE ITEMS DATE COMPLETED BY Steering & -Light display Dashboard -Check all sensors -Test drive machine Lubrication Check all 15 grease nipple fittings for proper lubrication, add grease as required. Hydraulic Check hydraulic system for leaks System...

  • Page 78: Technical Data

    TECHNICAL DATA...

  • Page 79: Technical Data Sheet Eu

    6. TECHNICAL DATA EU Technical data sheet...

  • Page 80: Technical Data Sheet Us

    6. TECHNICAL DATA US Technical data sheet...
  • Page 81 PARTS LISTS...

  • Page 82: Exploded Front View Parts List

    6. TECHNICAL DATA ED800 Parts list ED800 ELECTRIC DUMPER ED800 Electric Dumper exploded front view parts list...
  • Page 83 6. TECHNICAL DATA ED800 Parts list ED800 Electric Dumper exploded front view parts list ITEM QTY. PART NUMBER DESCRIPTION E816-5001 E816-CHASSIS WELDMENT CP-816-2517 FRONT TYRE (TRELLEBORG SK800 27X8.5-15) E816-3001 CENTRAL LED LAMP CP-816-1653 EXISTING STUB SHAFT CP-816-1071 SAFETY BAR (RHS)

  • Page 84: Exploded Rear View Parts List

    6. TECHNICAL DATA ED800 Parts list ED800 Electric Dumper exploded rear view parts list.
  • Page 85 6. TECHNICAL DATA ED800 Parts list ED800 Electric Dumper exploded rear view parts list ITEM QTY. PART NUMBER DESCRIPTION CP-816-1523 REAR CHAMFER PANEL (RHS) CP-1119 CLEAR GLASS FOR REAR LIGHTS CP-816-1536 CONTROLLER COMPARTMENT (RHS) CP-816-1535 CONTROLLER COMPARTMENT (LHS) CP-816-1524 REAR CHAMFER PANEL (LHS)

  • Page 86: Steering

    6. TECHNICAL DATA ED800 Parts list ED800 Steering assembly tiller head parts list ITEM QTY. PART NUMBER DESCRIPTION CP-816-2502 TEMO 200 STEERING TILLER HEAD CP-816-2505 LORD STEERING DAMPER CP-816-1601 STEERING FLANGE PLATE-ASSY CP-816-1610 TEMO 200 MOUNTING PLATE CP-816-BUSH 44X40X2 FLANGE BUSH 44X40X2MM...

  • Page 87: Platform And Safety Rail

    6. TECHNICAL DATA ED800 Parts list ED800 Operators platform and safety arm parts list ITEM QTY. PART NUMBER DESCRIPTION CP-816-1071 SAFETY BAR (RHS) CP-816-1072 SAFETY BAR (LHS) CP-816-1073 SAFETY ARM BUFFER CP-816-2506 CAM INDEX PLUNGER 12mm CP-BUTTON H-S M6 X 16mm BUTTON HEAD SCREW...

  • Page 88: Tiller Head

    6. TECHNICAL DATA ED800 Parts list ED800 Tiller head parts list 18424081 18424082 SWITCH - GREEN SWITCH HARE/TORTOISE GREEN - ON-OFF 18424043 18424050 COVER/HOUSING LOWER HOUSING GREY GREY 18434035 18434040 (INTERNAL) EMERGENCY REVERSE BLUE BUTTON - RED 12-48V 0-5V(NO GRIP) ITEM QTY.

  • Page 89: Hydraulic System

    6. TECHNICAL DATA ED800 Parts list ED800 Hydraulic system parts list ITEM QTY. PART NUMBER DESCRIPTION CP-816-2511 TILT HYD. CYLINDER ASSY. CP-816-2516 TURNBUCKLE 900mm CP-816-2513 HYD. LIFT CYLINDER ASSY CP-816-2510 Vibo Hydraulic Power pack CP-816-5008 TAPERTD LOCKING COLLAR/SHAFT SET CP-816-BUSH 25X35X1.5 BUSH C/W SHOLDER 25X35X1.5...

  • Page 90: Electrical System

    6. TECHNICAL DATA ED800 Parts list ED800 Electrical system parts list...
  • Page 91 6. TECHNICAL DATA ED800 Parts list ED800 Electrical system parts list ITEM QTY. PART NUMBER DESCRIPTION CP-220V PEW163CS 220V SOCKET-ANGLE_BOX CP-816-3006 EXM MODULE CP-816-3007 1222 ELECTRIC STEERING CP-816-3003 LED LIGHT UNIT CP-4568 DATA PLUG CP-816-3008 SW80 - 1674 DC CONTACTOR...

  • Page 92: Rear Drive Unit

    6. TECHNICAL DATA ED800 Parts list ED800 Drive unit parts list...
  • Page 93 6. TECHNICAL DATA ED800 Parts list ED800 Drive unit parts list EBV570.000Q ITEM QTY. PART NUMBER DESCRIPTION 570.0057.00 EBv570 SUPPORT 0313197 BEARING 30211 J2/Q CL. A 475.0126.00 SPACER 0313055 BEARING 30213 J2/Q CL. A 350.0003.00 SHIM 86x65x0,3mm 0801198 SEALING RING AS-75x100x10 VITON 475.0127.00...

  • Page 94: Exploded Front View Parts List

    6. TECHNICAL DATA ED1000 Parts list ED1000 ELECTRIC DUMPER ED1000 Electric Dumper exploded front view parts list ITEM QTY. PART NUM CP-1016- CP-1016- CP-1016- CP-1016- CP-1016- E1016-5 E1016-1 CP-1016- CP-1016- CP-1016- CP-1016- CP-1016- CP-1016- CP-1016- CP-1016- CP-01-4 CP-SM-SL CP-CHOC CP-1016- CP-1016- CP-1016- CP-1016-...
  • Page 95 6. TECHNICAL DATA ED1000 Parts list ED1000 Electric Dumper exploded front view parts list ITEM NO. QTY. PART NUMBER DESCRIPTION E816-5001 E816-CHASSIS WELDMENT CP-816-2517 FRONT TYRE (TRELLEBORG SK800 27X8.5-15) E816-3001 CENTRAL LED LAMP CP-816-1653 EXISTING STUB SHAFT CP-816-1071 SAFETY BAR (RHS) E816-1053 FRONT WHEEL RIM CP-816-1537...

  • Page 96: Exploded Rear View Parts List

    6. TECHNICAL DATA ED1000 Parts list ED1000 Electric Dumper exploded rear view parts list...
  • Page 97 6. TECHNICAL DATA ED1000 Parts list ED1000 Electric Dumper exploded rear view parts list ITEM QTY. PART NUMBER DESCRIPTION CP-816-1523 REAR CHAMFER PANEL (RHS) CP-1119 CLEAR GLASS FOR REAR LIGHTS CP- 816 -1536 CONTROLLER COMPARTMENT (RHS) CP-816-1535 CONTROLLER COMPARTMENT (LHS) CP-816-1524 REAR CHAMFER PANEL (LHS) CP-220V PEW163CS...

  • Page 98: Steering

    6. TECHNICAL DATA ED1000 Parts list ED1000 Steering assembly Tiller head parts list. ITEM QTY. PART NUMBER DESCRIPTION CP-1016-2502 TEMO 200 STEERING TILLER HEAD CP-1016-2505 LORD STEERING DAMPER CP-1016-1601 STEERING FLANGE PLATE-ASSY CP-1016-1610 TEMO 200 MOUNTING PLATE CP-1016-BUSH 44X40X2 FLANGE BUSH 44X40X2MM CP-1016-2504 STEERING PULLEY LORD CP-1016-1607...

  • Page 99: Platform And Safety Rail

    6. TECHNICAL DATA ED1000 Parts list ED1000 Operators platform and safety arm parts list. ITEM QTY. PART NUMBER DESCRIPTION CP-1016-1071 SAFETY BAR (RHS) CP-1016-1072 SAFETY BAR (LHS) CP-1016-1073 SAFETY ARM BUFFER CP-1016-2506 CAM INDEX PLUNGER 12mm CP-BUTTON H-S M6 X 16mm BUTTON HEAD SCREW CP-1016-1036 PIVOT BOLT, STEP AND SAFETY BAR CP-1016-1037...

  • Page 100: Tiller Head

    6. TECHNICAL DATA ED1000 Parts list ED1000 Operators platform and safety arm parts list 18424081 18424082 SWITCH - GREEN SWITCH HARE/TORTOISE GREEN - ON-OFF 18424043 18424050 COVER/HOUSING LOWER HOUSING GREY GREY 18434035 18434040 (INTERNAL) EMERGENCY REVERSE BLUE BUTTON - RED 12-48V 0-5V(NO GRIP) ITEM QTY.

  • Page 101: Hydraulic System

    6. TECHNICAL DATA ED1000 Parts list ED1000 Hydraulic system parts list. ITEM QTY. PART NUMBER DESCRIPTION CP-1016-2511 TILT HYD. CYLINDER ASSY. CP-1016-2516 TURNBUCKLE 900mm CP-1016-2513 HYD. LIFT CYLINDER ASSY CP-1016-2510 Vibo Hydraulic Power pack CP-1016-5008 TAPERTD LOCKING COLLAR/SHAFT SET CP-1016-BUSH 25X35X1.5 BUSH C/W SHOLDER 25X35X1.5 E1015-2515 SET OF HYDRAULIC HOSED FOR ED 816...

  • Page 102: Electrical System

    6. TECHNICAL DATA ED1000 Parts list ED1000 Electrical system parts list...
  • Page 103 6. TECHNICAL DATA ED1000 Parts list ED1000 Electrical system parts list ITEM QTY. PART NUMBER DESCRIPTION CP-220V PEW163CS 220V SOCKET-ANGLE_BOX CP-1016-3006 EXM MODULE CP-1016-3007 1222 ELECTRIC STEERING-CONTROL CP-1016-3003 REAR LED LAMP CP-4568 DATA PLUG CP-1016-3008 SW80 - 1674 DC CONTACTOR CP-22232_01 TOGGLE SWITCH CP-1016-3009...

  • Page 104: Rear Drive Unit

    6. TECHNICAL DATA ED1000 Parts list ED1000 Drive unit parts list...
  • Page 105 NUT M36x2 CH55 0313056 BEARING 30305 J2 CL. A 570.0053.00 BEVEK COUPLE 9/51 400.0008.00-A CYLINDRICAL CROWN z66 i=25 230.0007.00-B NUT M20x1,5 570.0055.00 REAR COVER LOGO ECOVOLVE 0744037 CORK 0744030 CORK M14x1,5 0313057 BEARING 61906 CL. A 400.0009.00-B CYLINDRICAL PINION z15 i=25 400.0011.00-B...

  • Page 106: Exploded Front View Parts List

    6. TECHNICAL DATA ED1500 Parts list ED1500 ELECTRIC DUMPER ED 1500 Electric Dumper exploded front view parts list...
  • Page 107 6. TECHNICAL DATA ED1500 Parts list ED 1500 Electric Dumper exploded front view parts list ITEM NO. QTY. PART NUMBER DESCRIPTION 1516-5001 CHASSIS WELDMENT CP-1516-2517 EVO-0151 FRONT TYRE (TRELLEBORG SK80027X8.5-15) CP-1516-1053 FRONT WHEEL RIM CP-1516-5009 SAFETY ARM (RHS) E1516-1033 UNDER BELLY PLATE E1516-5006 TURN BUCKLE E1516-5301...

  • Page 108: Exploded Rear View Parts List

    6. TECHNICAL DATA ED1500 Parts list ED1500 Electric Dumper exploded rear view parts list...
  • Page 109 6. TECHNICAL DATA ED1500 Parts list ED1500 Electric Dumper exploded rear view parts list ITEM NO. QTY. PART NUMBER DESCRIPTION E1516-1522 TOP COVER PLATE CP-1516-2508 M5X25X16 RUBBER BUFFER E1516-1540 TRAPEZOIDAL CONSOLE PANEL E1516-1401 BATTERY BOX FRONT PLATE CP-1516-5009 SAFETY ARM (RHS) CP-1516-2501 WASHERS STEEL CP-1516-5601...

  • Page 110: Steering

    6. TECHNICAL DATA ED1500 Parts list ED1500 Steering assembly Tiller head parts list. ITEM QTY. PART NUMBER DESCRIPTION CP-1516-2502 TEMO 200 STEERING TILLER HEAD CP-1516-2505 LORD STEERING DAMPER CP-1516-1601 STEERING FLANGE PLATE-ASSY CP-1516-1610 TEMO 200 MOUNTING PLATE CP-1516-BUSH 44X40X2 FLANGE BUSH 44X40X2MM CP-1516-2504 STEERING PULLEY LORD CP-1516-1607...

  • Page 111: Platform And Safety Rail

    6. TECHNICAL DATA ED1500 Parts list ED1500 Operators platform and safety arm parts list. ITEM QTY. PART NUMBER DESCRIPTION CP-1516-1071 SAFETY BAR (RHS) CP-1516-1072 SAFETY BAR (LHS) CP-1516-1073 SAFETY ARM BUFFER CP-1516-2506 CAM INDEX PLUNGER 12mm CP-BUTTON H-S M6 X 16mm BUTTON HEAD SCREW CP-1516-1036 PIVOT BOLT, STEP AND SAFETY BAR CP-1516-1037...

  • Page 112: Tiller Head

    6. TECHNICAL DATA E1500 Parts list ED1500 Tiller head 18424081 18424082 SWITCH - GREEN SWITCH HARE/TORTOISE GREEN - ON-OFF 18424043 18424050 COVER/HOUSING LOWER HOUSING GREY GREY 18434035 18434040 (INTERNAL) EMERGENCY REVERSE BLUE BUTTON - RED 12-48V 0-5V(NO GRIP) ITEM QTY. PART NUMBER DESCRIPTION 18424082 SWITCH - GREEN - ON-OFF...

  • Page 113: Hydraulic System

    6. TECHNICAL DATA ED1500 Parts list ED1500 Hydraulic system ITEM QTY. PART NUMBER DESCRIPTION E1516-5008 30DIA TAPERED LOCKING COLLAR/SHAFT SET E1516-5006 TURN BUCKLE E1516-2512_ASM HYD CYLINDER - ARM LIFT E1516-2511_ASM HYD CYLINDER - TILT LIFT E1516-5201 CRANK ASSEMBLY E1516-30X40X2X17.5 BUSH C/W SHOLDER 30X40X2X17.5 E1516-2515 SET OF HYDRAULIC HOSES CP-1516-2510...
  • Page 114 6. TECHNICAL DATA ED1500 Parts list ED1500 Electrical system...
  • Page 115 6. TECHNICAL DATA ED1500 Parts list ED1500 Electrical system ITEM QTY. PART NUMBER DESCRIPTION CP-1516-3004 CURTIS JOYSTICK CP-VAF11150 BATTERY CHARGE LEVEL GUAGE CP-42464 60mm DIA E STOP CP-22232_01 TOGGLE SWITCH CP-SM-SL012-REV2 BEACON LIGHT FLASH - AMBER SM-SL012 CP-1516-3003 LED LIGHT UNIT CP-1516-3012 MEGA FUSE / CONTACTOR CP-1516-5601...
  • Page 116 6. TECHNICAL DATA ED1500 Parts list ED1500 Drive unit parts list...
  • Page 117 NUT M36x2 CH55 0313056 BEARING 30305 J2 CL. A 570.0053.00 BEVEK COUPLE 9/51 400.0008.00-A CYLINDRICAL CROWN z66 i=25 230.0007.00-B NUT M20x1,5 570.0055.00 REAR COVER LOGO ECOVOLVE 0744037 CORK 0744030 CORK M14x1,5 0313057 BEARING 61906 CL. A 400.0009.00-B CYLINDRICAL PINION z15 i=25 400.0011.00-B...
  • Page 118 ED1500 TX2 Axle Drive unit parts list ED1500 TX2 Axle Drive unit parts list...
  • Page 119 ED1500 TX2 Axle Drive unit parts list ED1500 TX2 Axle Drive unit parts list ITEM PART No. DESCRIPTION 49.01.3500 Gearbox 49.01.35011 Gearbox cover 49.03.3504 Brake housing 49.03.3509 Bell housing 49.05.3519 II Reduction driven gear 49.05.3520 I Reduction driving gear 49.05.3521 II Reduction driven gear 49.05.3524 Inout gear with brake...
  • Page 120 TROUBLESHOOTING...
  • Page 121 7. TROUBLESHOOTING Delta Q 1200 battery charger Delta-Q IC Series User Manual Delta Q IC1200 battery charger fault and error list Charger Error & Fault Codes Table Code Description Solution E-0-0-1 Battery high voltage Possible causes:wrong battery voltage for charger,other charger also attached, E-0-2-1 resistive battery.Possible solutions:check the battery voltage and cable connections.Check battery size and condition.This error willautomatically clear...
  • Page 122 7. TROUBLESHOOTING Delta Q 1200 battery charger Delta Q IC1200 charging profiles Charging Profiles The IC Series charger contains up to 25 selectable charging profiles stored in its internal memory to charge batteries. These profiles are specific to each manufacturer and model of battery. Your equipment supplier or charger Distributor is responsible for ensuring the active charge profile matches the battery pack charging requirements.
  • Page 123 Green Ifsolid:Charging complete and maintenance mode is active. Ifflashing: Short:<80% Charge. 7. TROUBLESHOOTING Long: >80% Charge. When battery is notconnected:Charge Profile (Algorithm Number)display Delta Q QuiQ1000 battery charger Ifflashing:Reduced powermode.Low AC voltage orhigh internalcharger Amber temperature. Delta Q QuiQ1000 battery charger fault and error list Ifflashing:Charging error.Reset chargerpowerand referto Troubleshooting Instructions below.
  • Page 124 7. TROUBLESHOOTING Curtis 1232/34 AC controller Curtis 1232/34 AC controller troubleshooting Troubleshooting a fault In the unlikely event a afault occurs on the dumper. Use the following codes to troubleshoot the fault. For further assistance contact your local dealer. DIAGNOSTICS AND TROUBLESHOOTING These controllers detect a wide variety of faults or error conditions.
  • Page 125 7. TROUBLESHOOTING Curtis 1232/34 AC controller Summary of LED Display Formats The two LEDs have four different display modes, indicating the type of information they are providing. Table 5 Types of LED Display Display Status Neither LED illuminated Controller is not powered on; or vehicle has dead battery; or severe damage. Yellow LED flashing Controller is operating normally.
  • Page 126 7. TROUBLESHOOTING Curtis 1232/34 AC controller PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS Controller Overcurrent 1. External short of phase U,V, or W motor Set: Phase current exceeded the current ShutdownMotor; connections. measurement limit. ShutdownMainContactor; 2. Motor parameters are mis-tuned. Clear: Cycle KSI.
  • Page 127 7. TROUBLESHOOTING Curtis 1232/34 AC controller PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS 1. Incorrect (to high) battery-voltage Set: KSI voltage exceeded Severe Overvoltage limiit applied to KSI (pin 1) Severe KSI Overvoltage Clear: Bring KSI voltage below the Severe 2.
  • Page 128 7. TROUBLESHOOTING Curtis 1232/34 AC controller PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS Motor Temp Hot Cutback 1. Motor temperature is at or above the Set: Motor temperature is at or above the programmed Temperature Hot setting, Reduced drive torque.
  • Page 129 7. TROUBLESHOOTING Curtis 1232/34 AC controller PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS Motor Open 1. Motor phase is open. Set: Motor phase U, V, or W detected open. ShutdownMotor; 2. Bad crimps or faulty wiring. Clear: Cycle KSI. ShutdownMainContactor;...
  • Page 130 7. TROUBLESHOOTING Curtis 1232/34 AC controller PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS 1. KSI, interlock, direction, and throttle Set: HPD (High Pedal Disable) or sequencing fault HPD/Sequencing Fault inputs applied in incorrect sequence. caused by incorrect sequence of KSI, interlock, direction, and throttle inputs.
  • Page 131 7. TROUBLESHOOTING Curtis 1232/34 AC controller PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS Stall Detected 1. Stalled motor. Set: No motor encoder movement detected. 2. Motor encoder failure. ShutdownEMBrake; Clear: Either cycle KSI, or if parameter LOS Upon 3.
  • Page 132 7. TROUBLESHOOTING Curtis 1232/34 AC controller PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS Motor Characterization Fault 1. Motor characterization failed during Set: Motor characterization failed during the motor characterization process. See ShutdownMotor; characterization process. Monitor menu » Controller: Motor ShutdownMainContactor;...
  • Page 133 7. TROUBLESHOOTING Curtis 1232/34 AC controller PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS VCL/OS Mismatch 1. The VCL software in the controller Set: VCL and OS software do not match; when KSI ShutdownMotor; does not match the OS software in the cycles, a check is made to verify that they match ShutdownMainContactor;...
  • Page 134 7. TROUBLESHOOTING Curtis 1222 Steering controller Curtis 1222 Steering controller Troubleshooting a fault In the unlikely event a afault occurs on the dumper. Use the following codes to troubleshoot the fault. For further assistance contact your local dealer. DIAGNOSTICS & TROUBLESHOOTING The 1222 controller detects a wide variety of fault conditions.
  • Page 135 7. TROUBLESHOOTING Curtis 1222 Steering controller Summary of LED Display Formats The two LEDs have four different display modes, indicating the type of information they are providing. Table 5: Types of LED Display Display Status Neither LED illuminated Controller is not powered on; or vehicle has dead battery; or severe damage. Yellow LED flashing Controller is operating normally.
  • Page 136 7. TROUBLESHOOTING Curtis 1222 Steering controller FAULT NAME STEER TRACTION CLEAR CODE CAN OBJECT POSSIBLE CAUSE SET CONDITIONS FAULT FAULT CONDITION ACTION ACTION Hardware Fault 1. An internal hardware error Hardware error detected. Cycle KSI. Shutdown. 1 = Stop. has been detected; controller 0x3800 0x02 defective.
  • Page 137 7. TROUBLESHOOTING Curtis 1222 Steering controller FLASH FAULT NAME STEER TRACTION CLEAR CODE CODE CAN OBJECT POSSIBLE CAUSE SET CONDITIONS FAULT FAULT CONDITION ACTION ACTION Motor Temp Hot 1. Motor is operating in an Sensor Enable = On and Steer motor Warning Only.
  • Page 138 7. TROUBLESHOOTING Curtis 1222 Steering controller FLASH FAULT NAME STEER TRACTION CLEAR CODE CODE CAN OBJECT POSSIBLE CAUSE SET CONDITIONS FAULT FAULT CONDITION ACTION ACTION Contactor Welded 1. Steer contactor tips are welded The steer contactor tips are Cycle KSI. Shutdown.
  • Page 139 7. TROUBLESHOOTING Curtis 1222 Steering controller FLASH FAULT NAME STEER TRACTION CLEAR CODE CODE CAN OBJECT POSSIBLE CAUSE SET CONDITIONS FAULT FAULT CONDITION ACTION ACTION CAN Not 1. 1222 CAN NMT State did not This check is made only when Cycle KSI.
  • Page 140 7. TROUBLESHOOTING Curtis 1222 Steering controller FLASH FAULT NAME STEER TRACTION CLEAR CODE CODE CAN OBJECT POSSIBLE CAUSE SET CONDITIONS FAULT FAULT CONDITION ACTION ACTION Parameter 1. A parameter value or the 1. A parameter was changed Cycle KSI. Shutdown. 1 = Stop.
  • Page 141 7. TROUBLESHOOTING Curtis 1222 Steering controller FLASH FAULT NAME STEER TRACTION CLEAR CODE CODE CAN OBJECT POSSIBLE CAUSE SET CONDITIONS FAULT FAULT CONDITION ACTION ACTION Wheel Position 1. Position feedback device 1. Wheel Position differs from Cycle KSI. Hold then 1 = Stop.
  • Page 142 7. TROUBLESHOOTING Curtis 1222 Steering controller FLASH FAULT NAME STEER TRACTION CLEAR CODE CODE CAN OBJECT POSSIBLE CAUSE SET CONDITIONS FAULT FAULT CONDITION ACTION ACTION Following Error 1. Position feedback device This fault is checked by the Cycle KSI. Warning then 1 = Stop.
  • Page 143 7. TROUBLESHOOTING Rear drive unit Rear drive unit troubleshooting ROTARY BEARING Rotary bearing Under normal circumstances this bearing must be greased once at year. At every unit cleaning with vapour or other mean, the bearing has to be greased again. In case of operation of the unit in dusty or in damp environment, the greasing of the bearing must be executed more times a month.
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