1504001 c908 eo /crapers Service Training Linde Electric Reach Truck R14S R14HDS R16S R16HDS R16NS R20S R20NS Series 115-02 AC This dacument is ony orovided fo LANSING LINDE LTD. kingecere3 a Gite. Introduction Service Training ep 1 INTRODUCTION This is a guide to those responsible for the repair and maintenance of the 115-02 reach truck. A full inspection and maintenance procedure for up to 10000 hours, together with all necessary checks and adjustments can be found in the Operating Instructions publication 115 804 3301 E. ‘The TABLE OF CONTENTS gives the various sections into which this manual is divided. Dueto the ever increasing higher standard of production methods, materials used and the company policy of continuous improvement, various servicing procedures will have changed. some cases they might appear to fit. This is particularly important in the case of eyebolt M DANGER: On no account should metric and imperial threads be intermixed although in fixings which can be seriously weakened. CAUTION: It is imperative, that before working on the control system, that the battery is A disconnected, and the steering capacitor voltage is discharged. The steering capacitor voltage can be safely discharged by operating the horn with the battery plug DISCONNECTED. Check that the voltage between 3F1 and the main negative is less than 5V before working on the truck. Failure to carry out this procedure can lead to damage of the CAN interface drivers. Components MUST NOT be removed or replaced with the truck live. CAUTION: If the battery has been disconnected, before reconnecting, ensure that the emergency isolator is depressed and the keyswitch is turned off. DO NOT FIT PARTS OTHER THAN THOSE AVAILABLE FROM LANSING LINDE LIMITED, OR ALTER EXISTING EQUIPMENT. INCORPORATION OF PARTS OTHER THAN THOSE SUPPLIED BY LANSING LINDE LIMITED OR ALTERATION OF EXISTING EQUIPMENT WITHOUT THE MANUFACTURER'S PERMISSION MAY MAKE THE TRUCK UNSAFE AND WILL RENDER INVALID THE LANSING LINDE VEHICLE GUARANTEE. When overhauling any unit, all seals, tab washers or split pins must be renewed. The unit must then be greased or filed with correct grade lubricant. See Recommended Lubricants. Reference is made throughout the text to the front, rear, left hand side and right hand side of the truck. To avoid any confusion when ordering spare parts, it should be noted that the elevating forks are always considered to be on the rear of the truck. The left hand or right hand side is determined from the driving position facing towards the mast. TRUCK IDENTIFICATION The truck has a detailed Truck Identification Plate serial number which can be seen on the serial number plate. The plate is mounted on the top of the overhead guard facing the driver. Itis most important that the full serial number is quoted when ordering replacement parts, or when any reference is made to your vehicle, in any correspondence or by telephone conversation.Gitte. Introduction Page 2 Service Training ELECTRICAL SAFETY CHECKS ‘Should major electrical work or disassembly be carried outon the truck, then the following electrical safety checks MUST be carried out prior to returning the truck into service ) - Depress the emergency isolator, and disconnect the battery. = Connect a FUSED shorting link between traction LTM studs 1A1:1 and 1A1:2, - Connect the battery, release the emergency isolator, turn the keyswitch ON, close interlocks and select a direction of travel = Depress the accelerator. - Check that no function takes place and that an alarm is displayed on the driver's display - Tum the keyswitch OFF, depress the emergency isolator, disconnect the battery and remove the fused shorting link. 2) - Disconnect the steering sensor connector 3X8 from sensor 3B2. - Reconnect the battery, release the emergency isolator and turn the keyswitch ON. - Operate the steering from lock to lock. - Confirm that the line contactor releases and that an alarm is displayed on the driver's display. - Tum the keyswitch OFF, depress the emergency isolator and disconnect the battery. = Reconnect connector 3X8, - Reconnect the battery and return the truck to service. POI Chapter sissesap0tco03Po chap 5 Z A A A A A A A Gite. Introduction Service Training Page 3 SAFETY The waming precautions DANGER, WARNING, CAUTION and NOTE in this manual are provided to indicate special dangers or unusual information requiring special identification DANGER: Indicates hazards that may result in bodily injury or death and/or severe product damage. WARNING: Indicates hazards that may result in bodily injury and/or severe product A damage. A CAUTION: Indicates hazards that may result in damage to or destruction of the product. 03° NOTE: Identifies technical information requiring special attention because the connet may not even be obvious to skilled personnel. SAFETY GUIDELINES DANGER: Before attempting any repair work, apply the parking brake, turn the keyswitch off, disconnect the battery, and, unless the particular routine being performed requires otherwise, chock the load wheels securely front and rear. DANGER: Before carrying out any electrical maintenance or checks, raise the drive wh clear of the ground and securely chock the truck in position. DANGER: Take the necessary fire precautions when working on batteries. DANGER: Before attempting repairs or adjustments on the reach frame, the raised fork carriage or mast, always ensure that they are secured against accidental movement. DANGER: Always ensure any lifting equipment is of sufficient capacity, and has the relevant certification, All blocks, jacks and chains etc. are subject to regular examination and must only be used for the purpose intended. WARNING: Do not allow hydraulic oil under pressure, for example at a leak, to penetrate the skin. Medical aid is required if such an injury occurs. WARNING: Protective equipment using compressed air. . goagles and mask must be worn at all times whenGitte. Introduction Page 4 Service Training HANDLING LUBRICANTS Always handle lubricants safely and as specified by the manufacturer. Only store lubricants in approved containers at specified storage locations. As they could be inflammable, do not let them come in contact with hot objects or naked flames. Clean the area surrounding the part in question before lubrication, filter renewal or repairs in the hydraulic system, Only use clean containers when replenishing fuels and lubricants. Follow the manufacturer's safety and disposal instructions when using lubricants and cleaning com- pounds. Avoid spiling lubricants. Remove any spillage immediately with a suitable binding agent and dispose of as specified. Always dispose of used or contaminated lubricants as specified. Follow laws and regulations Dispose of used parts, filters etc., in an environmentally friendly manner. POI Chapter sissesap0tco03RPC /Chaper 3 vis woe apotoe Gite. Table of Content Service Training 07.00 Page 1 ELECTRIC REACH TRUCK R14S, R14HDS, R16S, R16HDS, R16NS, R20S, R20NS SERIES 115-02 AC 1 Traction motor and brake 1 44 Traction motor 1 4.4.2 Traction motor removal 1 4.1.21 Traction motor refitting 4 12 Parking brake agjustment 6 18 Parking brake drum removal 8 14 Parking brake friction plate seal renewal 9 16 Parking brake drum replacement 10 1.6 Cooling system 13 2 Transmission 1 24 Drive wheel removal 1 244 Drive wheel refitting 0806 4 22 Gearbox removal 2 221 Gearbox refiting 8 23 Gearbox 4 23.1 Steer bearing removal 5 23.1.1 Steer beating refiting 5 282 Gearbox dismanting 5 23.8 Gearbox reassembly 6 23.4 Gearbox tooth bearing check 7 24 Setting the steering stop bolts 9 8 Chassis and bodywork 1 a4 Chassis 1 82 Soat 2 321 Seatadjustment 2 822 — Seatremoval 2 83 Floorplate removal 4 83.1 — Floorplaterofitting 4 84 Battery carrier 5 34.1 Battery carrier removal 6 942 Battery cartier lubrication 6 888 Battery carrier replacement 6Gitte Table of Content Page 2 07.09 Service Training 3.5 Battery changing (hoist method) ? 86 Battery changing (fll on, ol of 8 a7 Covers and panelling 10 88 Top cover, opening 2 39 Binnacte removal 2 3.10 Consol removal 13 at | RNR 14 8.104 Serial number example 14 4 ‘Steering and load wheels 1 44 ‘Steering 1 42 ‘Steer motor removal 2 424 Searmebeetiing 2 43 ‘Steering encoder removal 3 aan 4 4.41 Load wheel removal 5 442 Load wheel reftting 5 5 Controls, 1 54 Accelerator and brake pedals 1 BAA Accelerator unit removal 2 S12 Asbeleatorunitretting 2 52 Hydraulic braking system: 3 S21 Hekate Brake reverent ieintonarte 4 5.2.2 Master cylinder removal 4 52.3 Master cylinder refitting 5 53 Brake bleeding 6 5.4 Load wheel brakes 7 544 Load wheel brake cylinders 8 5.4.2 Load wheel brake cylinder maintenance 8 543 Load wheel brake cylinder repair instructions 8 55 Load wheel brake shoes: 8 5K Lanois arom neneKaemameneaEN 8 552 Load wheel brake shoo removal 8 55.3 Load wheel brake shoe - fitting 10 BR (rare crue 10 57 Footbrake assembly 1 POL Chapter vi sae c700RPC /Chaper 3 vis woe apotoe Gite. os we Table of Content Service Training 07.00 Page 3 57.1 Foolbrake shoe removal 2 57.2 Foolbrake shoe adjustment 8 58 Hydraulic controls 14 58.1 Hythauliccontol lever emoval io 5.8.2 Hydraulic control lever refitting 15 8 Eloctial control 1 61 AC control - operating principle ¥ 61.1 Speed & drocton cont 3 61.2 Electro Magnetic Compatability (EMC) 4 62 Electrical components (under the top cover) 6 621 Electrical connections (drive unit) # 622 —_Electical components (pump motor & hydraulis tank area) 8 63 Fuses - control curent ° 631 Fuses ancilay ckouis 0 63.2 Fuse duties and positions - ancillary circuits 10 64 Emergency isolator - S2 1 61 24Vpowersupply-Ut 2 642 —_Electonic contol module -A2 1 64.24 Connector X13 pin duties: 14 643 Reservoir circuit capacitors, switching on and charging 16 64.81 Reservoir ckcuiteapactors,clacharging 7 64.4 Main contactor - K1 18 65 Traction convo! (L00) 19 65.1 Traction power module (LAC traction) - 1A1 19 65.1.1. Connector 1X17 pin duties 20 652 Traction enable signee a 65.8 Ditetion of travel switch - 1819 2 65.4 Parking brake switch - 184 23 65.5 Accelerator - 1A4 24 6551 Accolorator oloctomochanical chevectristios 25 65.5.2 Accelerator calibration and setting up 07.09 25 65.6 Traction moter speed sensor - 161 28 65.7 Brake pedal switch - 155. 7 65.7.1 Regenerative electrical braking a Bee “Tae poner rnsaa arpa MRE 28 65.8.1 Traction motor temperature monitoring - 1B4 28Gitte Table of Content Page 4 07.09 Service Training 6.5.8.2 Traction system cooling fans - 9M1, 9M2_ 29 659 Switch controled speed reduction & height sensor 8 5m -2813 30 6.5.10 Hom operation - 4H1 31 6511 Battery lock sensor - Bt 2 66 Load control (LLC) 33, 6.6.1 Hydraulic power module (LAC lift) - 21 33, 661.1 Gonnector 2X37 pin duties 34 6.6.2 Hydraulic enable signal 85 4 ioadtcenringe i shacbresblooomnacie pledlon-B02H 36 6.6.2.2 Hydraulic valve connector pin duties - 2X20 86 663 Joystick and valve voltage supply 37 6.6.4 Joysticks 38 85 Velo block elechical connections 39 6.6.6 Hydraulic pump motor speed sensor - 2B8. 40 ey iran ier means goers many a 6.6.7.1 Hydraulic pump motor temperature monitoring - 2B4 4a 6.6.7.2 Hydraulic system cooling fan - 9M4 42 668 Lock valve -2¥81 4s 6.6.9 Lift and lower joystick operation - 2B1 44 6.6.9.1 Lift 44 66.9.2 Lower 44 6610 Reach joystick operation -281 a 6.6.11 Tilt and sideshift joystick operation - 232 46 6612 Aunilay 4 and 2 (Bh & Gt) joystick operation - 288 a 6.6.18 _Liftstop sensor - 2820 48 6.6.14 Reach slowdowns 49 BACT! Fnanh posinoncvaue: ” 6.6.14.2 Reach limits: 50 6.6.14.3 Reach sensor mechanical adjustments 50. 6.6.14.4 Reach sensor operation - 2B18 and 2B21 50 67 ‘Steering system (LES) 51 674 LES circuit diagram 52 672 Steering safety sensors - 382, $89 and 684 88 6.7.3 ‘Steering wheel unit 54 674 ‘Steering wheel torque control 55 68 Operator's doplay (LID) 56 6.8.1 Display indicators S7 POL Chapter vi sae c700RPC /Chaper 3 vis woe apotoe Gite. os we Table of Content Service Training 07.00 Page 5 68.2 Mode indicators & height commands 58 688 Display notions 58 68.3.1 Hour meters 58 68.4 Help prompts +9 69 Circuit diagram 63 6.10 Connector locations 65 ¥ Hydraulic system ¥ 71 Hydtaulc overviow 1 72 Hydraulic control valve connections 2 73 Hydraulic control block removal 4 734 Hydraulic control valve re-fitting 4 7 Hydaulcunit and tank 5 74d Hydraulic tank filter renewal: 6 75 Hythaulic uid changing 7 76 Hydraulic pump and motor removal 8 7.61 Hydraulic pump and motor re-fitting 12 77 Hyckaule pump 1 TIA Hydraulic pump - introduction 14 72 Hydraulic pump routine maintenance 14 773 Hydraulic pump direction of rotation 14 78 Reach eyinder removal 6 79 Reach cylinder re-fitting 16 79.1 Reach eylnde ‘6 710 Tilt and lift cylinder hoses: 7 TAL Hydraulic circuit 07.09 19 8 Mast unit and attachments 1 81 Introduction 1 82 Forks removal 2 821 Forks rofiting 3 822 Forks inspection 3 823 Fok laiches 3 BS Mast unit removal 4 84 Mast unit refitting # 85 Mastuntdomanting ° a5. Mast unit reassembly 10Gitte Table of Content Page 6 07.09 Service Training 86 Mestrollersizng 10 BBA Mestronershimrig " 87 Mast rubbing pads 12 88 Primary lit jack removal 18 8.8.1 Primary lift jack replacement 15 Bg ‘Secondary lift jack removal 16 88.1 Secondary lit jack rfting 18 8.10 Primary and secondary lift jack dismantling 20 840i Frimenyoncicocentay tjaik rensenity i 8.11 Lift jack bleeding 22 BAZ Chains: 23 6124 Chain inspection 24 B:i22 Chain service fis 24 8.12.3 Chain replacement and shortening 24 818 Chain adjustment 2 8.13.1 Chain associated equipment check 25 8.13.2 Mast chain adjustment 25 mia Galaga adams 26 B14 Tilting sideshitt assembly (187 mast) 27 8144 Tilting sideshift unit removal (187 mast) 28 8142 Tilting sideshitt unit refitting (187 mast) 28 8.143 Tiling sideshit unit comanting 187 mast 29 8.14.4 Tilting sideshift reassembly 187 mast 29 8:15 Tiling sdeahit sembly (184 mast 30 8.15.1 Tilting sideshift unit removal (184 mast) 31 815.2 Tilting sideshift unit-replacement (184 mast) 3t 8.163 Ting sideshit unit cemanting 184 max) 32 8.15.4 Tilting sideshift reassembly (184 mast) 82 B16 Tilt jack dismantling 33 8.16.1 Tilt jack reassembly: 83 B17 Sideshift jack dismantling 34 BATA ‘Sideshift jack reassembly 34 818 Load backrest 36 8:19 Mastserial number 86 8.19.1 Mast serial number format 36 Sion Naame nintner explo 36 8.20 Mast hydraulic hoses 7 POL Chapter vi sae c700RPC /Chaper 3 vis woe apotoe Gite. os we Table of Content Service Training 07.00 Page 7 8.20.1 Hosereplacement 38 820.2 Mast hoses removal 8 8.20.3 Mast hoses refitting 39 821 Reach ame “ 8.22 Reach frame adjustment 41 8.23 Reach side rollers adjustment 42 824 Reach tram rl ubriction 3 8.25 Mast unit optional versions types 183 and 186 46 825.1 Reach carriage roles (18 and 186) “ 8.25.2 Mast removal (183 and 186) 46 825.3 Mast refitting (183 and 186) 46 10 Miscetaneous 1 10.1 AMP-SAAB connoctors 1 102 Standard torques 2 103 Nonstandard orquos wos 3 10.4 ‘Special tools, sealants and compounds: 4 105 Recommend lubricants 5Table of Content Page 8 07.09 Service TrainingGite. Section 1 Service Training age 1 1 TRACTION MOTORAND BRAKE is live. The battery must be disconnected, failure to do so can result in failure of the p CAUTION: Electrical components must not be connected or disconnected whilst the truck ‘modules. 4 TRACTION MOTOR The traction motor is an AC unit, rigidly fixed to the steer bearing plate by four screws. The motor incorporates a transmission brake mounted directly to the stator shaft, which is operated by either the foot brake or a solenoid brake within the same unit. Motor temperature is monitored by an internal sensor, with a warning indicator on the operator's display should motor temperatue become excessive Motor speed is monitored by an external sensor. A cooling fan is fitted which is only activated should the motor temperature exceed 40°C. 4.4.2 TRACTION MOTOR REMOVAL 33 a Q WARNING: The motors can become very hot. Risk of scalding. WARNING: Manual handling risk. The traction motor is heavy. Do not attempt to remove the motor without suitable lifting equipment. - Tum the keyswitch off, disconnect the battery, and chock the load wheels securely. Remove the driver's seat and floarplate, see SECTION 3. Loosen the screw that secures the cooling duct to the cooling fan, but do remove completely. Remove the two remaining cooling duct securing screws, Using a suitable screwdriver, push down, and release the plastic clip that secures steering sensor 382, Remove steering sensor 3B2, and mark to assist reassembly. Remove the plastic cooling duct.a 3 Service Training = Unclip and remove steering sensor 383, and if fitted, steering sensor 3B4. Mark sensors toassistreassembly, ~ Remove the traction motor speed sensor. ~ At the connector bracket, disconnect the brake sole- noid/temperature sensor connector, and remove the male half of the connector from the bracket. PON /Chapr sissesao0h 0203sesoesbor e503 RPO /chaper Section 1 Service Training age a ~ Remove the three power terminals from the motor, and mark their position to assist reassembly. = Disconnect the footbrake pipe connection and seal to prevent contamination, [35 NOTE: If the motoris to be disassembled, then to aid disassembly, the footbrake shoes, support as- sembly andthe brake drum should be removedat this point, see PARKING BRAKE DRUM REMOVAL. - Remove the four motor securing screws.te = : Service Training Page 4 - Using suitable lifting equipment, remove the motor. 1.1.2.1 TRACTION MOTOR REFITTING - Toreplace the traction motor, reverse the removal procedure, ensuring all fasteners are tightened to the correct torque. 0S NOTE: Before refitting the steering sensors, ensure that the plastic retaining clips are in place. - Bleed the brakes, see SECTION 5. PON /Chapr sissesao0h 0203Section Page Service Training THE TRACTION MOTOR 1. Cap 2 Pin 3. Magnet 4, Brake drum 5. Springte Section 1 Page 6 Service Training 12 PARKING BRAKE ADJUSTMENT hp WARNING: The traction motor can become very hot. Risk of scalding. By using Pathfinder diagnostic software, the calculated gap between the friction plates and brake drum when the brake is released, can be ascertained. This gap should be between 0.3 mm and 0.6 mm (0.45 optimum). In order to adjust the parking brake, special too! No. 002.941.80.15, and a PC with the relevant diagnostic software installed are required. ON Chap sissesao0h 0203 ~ Securely chock the drive wheel front and rearto prevent the traction motor armature from rotating, + Connect PC to the diagnostic port. ~ Screw the inner part of the tool fully into the armature shatt. A CAUTION: Do not overtighten.Section 1 Service Training rage 7 - Place the washer over the inner part of the tool ~ Screw the outer part of the tool onto the inner part, so that the hexagon section is in contact with the washer. = Turn the keyswitch on, and run Pathfinder diagnostic software, 33 a © NOTE: The 'GAP" will display 0.00 until the first release of the brake after power on. + Release the parking brake. The reading should be 0.45 mmwith an accepted range between 0.30 mm and 0.6 mm = To reduce the gap, using a 32 mm spanner, tum the outer part of the tool clockwise. US" NOTE: Only small adjustments should be made. 1/8 turn = approx. 0.12 mm reduction. ~ Apply, and release the parking brake. - Re-check the gap using the diagnostic software, and repeat the procedure until the correct adjustment is achieved. ESF NOTE: Should the gap need increasing, then the tool will need to be reversed in order to pull the drum away from the friction plates. See PARKING BRAKE DRUM REMOVAL. - Remove chocks, and test for correct operation.te Section 1 Page 8 Service Training 13 PARKING BRAKE DRUM REMOVAL WARNING: The traction motor can become very hot. Risk of scalding. Should the friction plate need replacing, then the brake drum will need to be removed. - Turn the keyswitch off. = Securely chock the drive wheel front and rearto prevent the traction motor armature from rotating, 62° NOTE: Although not necessary, removing the footbrake shoes will facilitate brake drum removal, see SECTION 5. + InsertanM8 x 15mm screw into the end of the armature shat. ON Chap sissesao0h 0203 ~ Screw the outer part of the removal tool into the brake drum. = To withdraw the drum from the armature shaft, screw the inner part of tool (hexagon section leading) into the outer part, using a 15 mm spanner,Section 1 Service Training age ° 14 PARKING BRAKE FRICTION PLATE SEAL RENEWAL When replacing the friction plate, new seals should be fitted. + Replace the inner seal. - Replace the outer seal.te Service Training Section 1 Page 10 18 PARKING BRAKE DRUM REPLACEMENT - Tum the keyswitch off ~ Securely chock the drive wheel frontand rearto prevent the traction motor armature from rotating, - Slacken the footbrake shoes 0 NOTE: Although not necessary, removing the footbrake shoes will facilitate brake drum replace- ment. ©3 NOTE:To facilitate replacement, the seat should be removed, and the seat and left foot switches by- passed. sembly is heavy. Assistance should be sought @ CAUTION: Manual handling risk. The seat as- when removing the seat assembly. « Insertthe six brass wear pads into the pressure springs. + Insert the wear pads/spring assemblies into the motor bearing cover. - Locate the friction plate on the three dowels. Using 3off MS x 20 mm cap head screws, clamp the disc down fully, then back off each screw half a tum. This will give approximately 0.5 mm movement. - Turn the keyswitch on, and operate the parking brake switch. Check for brake disc movement. ES NOTE: Take care not to dislodge the two seals. + Turn the keyswitch off. - Replace the brake drum, allowing it to rest on the armature shatt. PON /Chapr sissesao0h 0203Section 1 Service Training Bes " ~ Screw the inner part of the tool fully into the armature shatt A CAUTION: Do not overtighten. 5 Place the washer over the inner part ofthe tool. ~ Screw the outer part of the tool onto the inner part, so that the hexagon section is in contact with the washer. - Using a 32 mm spanner, draw the drum onto the armature shaft unt itisalmostin contact withthe friction, pads.te Section 1 Page 2 Service Training [& NOTE: The friction plate can be seen through the slotted holes in the drum. - Continue to draw the drum slowly onto the shaft, continually checking that the drum is free to rotate. - As soon as resistance is felt, remove the 3 off M5 screws. - Turn the keyswitch on, and run Pathfinder diagnostic software. [& NOTE: The ‘GAP’ will display 0.00 until the first release of the brake after power on. = Release the parking brake. The reading should be 0.45 mm with an accepted range between 0.30 mm and 0.6 mm = Continue to draw the drum slowly onto the shaft unti the correct adjustment is achieved. ISP NOTE: Only small adjustments should be made. 1/8 turn = approx. 0.12 mm reduction. ~ Apply, and release the parking brake ~ Re-check the gap using the diagnostic software, and repeat the procedure until the correct adjustment is achieved. £3" NOTE: Should the gap need increasing, then the too! will need to be reversed in order to pull the drum away from the friction plates. See PARKING BRAKE DRUM REMOVAL. = Replace the seat, - Remove chocks, and test for correct operation. ON Chap sissesao0h 0203sesoesbor e503 RPO /chaper Gite. Section 1 Service Training age 8 16 COOLING SYSTEM The traction motor is equipped with a cooling fan assembly, which forces air through a cooling duct into the motor when cooling is required, this is activated when the motor reaches 40°C Socket head screw Washer Cooling duct Spacer Washer Hex head screw Self tapping screw Screw Clip Bracket Fan Washer Screw ConnectorSection 1 Page 4 Service Trainingpor Chape Service Training Atte. Seation 2 09.08 Page 1 2 TRANSMISSION 24 DRIVE WHEEL REMOVAL ~ Apply the parking brake. Raise the truck at the drive end approximately 200 mm using a suitable jack (1) and chock in position, - Turn the steering whee! tull lock. + Remove accessible wheel nuts. Remount the truck, release the parking brake and rotate the wheel until further wheel nuts become accessible. Repeat the procedure untilall the wheel nuts have been removed - Manoeuvre the wheel off of the gearbox and from under the chassis. WARNING: Menual handling risk. The wheel is heavy. 244 DRIVE WHEEL REFITTING = To refit the drive wheel, reverse the removal procedure, 3° NOTE: The wheel nuts shouldbetightened dally after a whee! change until they are seated firmly, i.e. until the correct torque figure is consistently obtained. For effective wheel fixing, tighten wheel nuts to 195 Nm in accordance with the sequence shown,Gite. Section 2 Page 2 0900 Service Training 22 GEARBOX REMOVAL 5" NOTE: If the gearbox is to be stripped down, it is advisable to remove the drive wheel first, see DRIVE WHEEL REMOVAL. + Remove the traction motor, see SECTION 1 - Remove the steer motor, see SECTION 4, - Place asuitable tray beneath the gearbox, remove the gearbox drain plug and drain the gearbox oi WARNING: Follow the precautions for han- dling lubricants. + Support the drive wheel and/or the gearbox, ifthe drive wheel has been removed. P01 /Chapers|eC chapter sieseeapor eso Service Training - Remove the four screws securing the gearbox. + Using suitable lifting equipment, raise the front of the truck sutficiently to clear the gearbox and chock in position, = The gearbox can now be manoeuvred clear of the chassis, WARNING: Manual handling risk. The gear- @ box is heavy. Take care when manoeuvring the gearbox from under the chassis. = Remove chocks and lower the chassis onto suitable blocks. 2.24 QEARBOX REFITTING Reverse the removal procedure to replace the gearbox, but lower the chassis onto wooden blocks thick enough to allow final repositioning of the gearbox. Draw up the gearbox to the chassis using two of the securing bolts. Refitthe restof thebolts and tighten to correct torque, See SECTION 10. 1S? NOTE: When the gearbox s refitted in the truck, beforerefitting the traction motor, the gearboxshould be filled with recommended oil (see SECTION 10) to the level shown.AAA Section 2 Page 4 Service Training 23 GEARBOX Cc) i QoQ 1. Housing 17. Shim 33, Socket head screw 2 Cover 18 Bearing 84. Socket head screw 3. Cover 19. Tapered roller beating ae, ‘Somket head eco. 4. Wheel shaft 20. Tapered roller bearing 38. Socket head scraw 5. Pinion gear assembly 21. Taperedroller bearing 87. Hexagon screw 6. Pinion gear 22. Bearing 98, Spring washer 7. Gear 23. Sealring 89. Spring washer 8 Nut 24. Oring 40. Cylindrical pin 9. Wheelbott 25. Snap ring 10. Bush 26. Plug 41. Ring 27. Seal 12. Bush 28. Vent valve 13. Pinion gear 29. Socket head screw 14. Washer 80. Spring washer 15. Shim 81. Sooket head scrow 16. Shim 82. Sooket head screw POL Chapter siesoeabor conseC chapter sieseeapor eso Service Training Page 5 231 STEER BEARING REMOVAL + Support the gearbox securely in an upright position. - Remove the 12 off screws (2) securing the bearing to the gearbox. + Remove the bearing (2) from the cover (8), 2.3.1.1 STEER BEARING REFITTING + To reassemble, reverse the removal procedure, apply ing Loctite 243 to the securing screws (2), 2.3.2 GEARBOX DISMANTLING Before dismantling the gearbox, ensure that the oil has been completely drained and that all loose dirt has been removed from the assembly. - Remove the drive wheel, see DRIVE WHEEL REMOVAL. - Remove the steer bearing, see STEER BEARING REMOVAL. + Remove the cover (2) from the housing (1) after first removing securing screws (31,32, 88, 94,35,36) and spring washers (89). + Remove the cover plate (8) together with 'O' ring (24) after first removing the securing screws and spring washers (29 & 38). ~ Prevent pinion shaft (5) from turning and remove retaining nut 8). = Undo the retaining sorews (87) and remove together with washer (14). Carefully drive out the shaft (4) from the housing (1). Note the number of shims (16) when removed with the bush (10) and gear (5) to assist re-assembly. ~ Caretully drive out the pinion shaft (5) complete with bearing (19). distance sleeve (12) and shims (15) noting their number to assist in re-assembly. - Unless new bearings are to be fitted do not remove bearing outer shells from the housing (1). + The gearbox components are nowready for cleaning andinspection. During re-assemblynewseals and ‘0’ rings should be fittedAAA Section 2 Page 8 Service Training 233 GEARBOX REASSEMBLY - Before assembling the gearbox ensure the housing (1) is thoroughly clean. ~ Assemble to the housing (1) the outer shell of taper roller bearings (20), (19), (21) and (22), + Assemble ring (11) to the housing (1). - Assemble the inner race of taper roller bearing (20) to gear (7) + Assemble the taper roller bearing inner race (19) to the pinion (5), applying Loctite 603. + Assemble the bush (12), and shims (15) to the pinion (5). + The assembled pinion assembly can now be mounted into housing (1). + Assemble gear (7) to the pinion and secure with nut (8). ~ Assemble taper roller bearing inner race (21) to the shaft (4) after wheel bolts (9) are securely fitted + Assemble the inner race of taper roller bearing (22) onto the gear (6) - Fitsnap ring (11) and oil seal (28) (apply Loctite 574 to circumference) to housing (1) + Mount the assembled shaft (4) to the housing (1). ~ Assemble bush (10) and shims (16) into the housing (1). + Goar (5) can now be assombled to shaft (4) and secured by washer (14) and screws (37) ~ Adjust the gears to obtain the correct aurtace tooth contact and bearing play to the main drive shaft and vertical input shat. POL Chapter siesoeabor conseC chapter sieseeapor eso Gite. Seotion 2 Service Training Page 7 2.3.4 GEARBOX TOOTH BEARING CHECK To check the tooth bearing, coat 2 of 3 surfaces of the crown gear with marking ink. Move marked tooth surfaces.several imes into mesh with the bevel pinion. The bearing pattern willbe better visibleif the bevel pinion is slightly braked. Compare tooth bearing with the attached Tooth Bearing Char’. If correction is required proceeds shown on the chart. The gear shat (vertical inputshatt) is adjusted by shimming (18). The horizontal shaft (main drive shaft) is adjusted by the thickness of the shimming (16). Correct surface appearance Thrust drive \, surface Tooth contacts at crown wheel ‘To obtain correct surface appearnace, ‘Wrong surface appearance adjust the gears in the direction Concave flank Convex flank of the arrows. Fo | fe eS Contact at tooth head v 4 I » g > cont eS nee base + 2 ? \ Santen SS tooth ¥ — toe y Contact at tooth heel 4AAA Section 2 Page 8 Service Training The optimum backlash setting is marked on the crown gear. Measure backlash 0.26-0.80mm on bevel gear by locking spur gear shaft. Adjust backlash by positioning hub bevel gear assembly on splined end of wheel shaft by means of the shims (16). Proceed with final assembly, check backlash, bearing clearances and gear tooth engagement. + Apply Loctite 243, and tighten nut (8) . Torque to 176 Nm ~ Apply Loctite 243, and tighten screws (37). Torque to 180 Nin, + Assemble the plate (3) and O-ring (24) to the housing (1) and secure with screws (29) and spring washers (38). Ensure drain plug (26) and seal (27) is positioned at bottom of the gearbox. + Test gearbox for smooth, free running operation, - Clean face surfaces of housing (1) and cover (2) and seal with Loctite 874. + Tighten the securing screws (81,82, 33, 84,35,88) diametrically to the correct torque. + Replace the steer bearing, see STEER BEARING REFITTING. + The gearbox is now ready for assembly to the tuck and test, see GEARBOX REFITTING. POL Chapter siesoeabor conseC chapter sieseeapor eso Gite. Seotion 2 Service Training Page 9 24 SETTING THE STEERING STOP BOLTS ‘Should the steering stop bolts need to be adjusted, then the correct setting is shown below.Section Page 10 Service TrainingGite. Section 3 Service Training age 1 3 CHASSIS AND BODYWORK is live. The battery must be disconnected, failure to do so can result in failure of the n CAUTION: Electrical components must not be connected or disconnected whilst the truck modules. a4 CHASSIS The chassis has been designed to achieve maximum strength and rigidity. The rear lower chassis, consists of a steel casting giving a low centre of gravity for stability and excellent residual capacities at high lit. The operator's compartment, motors, and electronics, are protected within the rugged structure, with easy accessibility for maintenance 33 a 1. Cable assembly 7. Plate 13. Stop 2. Chassis 8. Shim 14, Socket head sorew 3. Panel 9. Countersunk screw 4. Adhesive 40. Hexagon screw 5. Right hand cover 11. Washer 6. Left hand cover 12. Spring washerAte Service Training Section 3 Page 2 32 SEAT 3.24 SEAT ADJUSTMENT - Tomove the seat forward or back, if ever (5) and while sat on the seat slide to the required position and release the lever (5) to lock into the nearest notch. - The handwheel (4) is for height adjustment. Rotate the handwheel clockwise to raise the seat. Rotate the handwheel anticlockwise to lower the seat + Lever (3) is used to set the height of the seat when itis, unoccupied. To adjust the height, sit on the seat and slide lever (3) to the right. Use handwheel (4) to adjust seat to the desired height. When the seat height adjust- ment is correct, slide lever (2) to the left to limit seat ‘movement when it is unoccupied 0° NOTE: This adjustment must be made whilst sat on the seat. ~ Button (2) is used to adjust lumber support. = Lever (1) mustbe lifted to alter the rake of the seat back. The rake can be adjusted to three positions, 3.22 SEAT REMOVAL ~ Turn the Keyswitch off and disconnect the battery. - Remove the securing screw. - Swing the seat assembly out from the chassis, until it locates in the open position. Chapters sissesao0h 0203RPO /chaper sesoesbor e503 Section 3 Service Training age a - Disconnect the seat switch. oot > 5 + Lift the seat from it's pivot, and store in a safe place. WARNING: Manual handling risk. The seat Soe: § is to be completely removed. | sought ifAte Section 3 5 at Page a Service Training 33 FLOORPLATE REMOVAL - Tum the keyswitch off and disconnect the battery. Open or remove the seat assembly. = Remove the rubber floorplate mat. ~ Remove the two securing screws (1),andiiftthefloorplate clear. 3.34 FLOORPLATE REFITTING - To refit the floorplate, reverse the removal procedure, IS NOTE: On single pedal trucks, ensure that the left foot microswitch actuator engages correctly. screws, ensure that none of the footpedals / DANGER: Before tightening the mounting foul on the floorplatGite. Section 3 Service Training age 5 34 BATTERY CARRIER Two types of battery carrier are available. Each type of battery carrier is mounted across the top of the chassis legs and located on two guides each side, The battery carrier in each case is released by lifting lever (14), which disengages the locking mechanism lever (22). This allows the battery carrier to be drawn out by the reach out operation, and allow the battery to be lifted or rolled clear. 0S NOTE: There are combinations of the above detailed plates and angles, which are fitted to the reach carriage to suit various chassis widths and amp hour capacities. See the Spare Parts List publication for details. 33 a 1. Buffer 16. Hexagon nut 81. Plate 2. Hexagon screw 17. Handle 32. Handle 3, Wavy washer 18. Hexagon screw 33. Stud 4 Shim 19. Spring washer 34, Hexagon nut 5. Plate 20. Washer 35. Clovis 6 Tension spring 21. Plate 36. Pin 7. Thrust washer 22. Lever assembly a7. Plate 8. Hexagon nut 23. Spring cotter 38. Support collar 9. Shim 24. Support 39. Support roller 40. Shim 25. Screw 40. Supportrolier 41, Thrust washer 26. Spring washer 41. Supportrolier 12. Spring 27. Locking disc 42, Support assembly 13. Pin 28. Rod 43. Support assembly 14. Rod 29. Rod 44, Hamess assembly 15. Bracket 30. Bushte Section 3 Page 8 Service Training 3.41 BATTERY CARRIER REMOVAL Should the battery carrier require removal, follow the battery changing procedure, see BATTERY CHANGING. Once the battery has been removed then the carrier can be lifted clear of the truck. If no suitable iting equipment is avaitable, then itis recommended that two persons are used to lft the battery carrier from the truck's reach legs 3.42 BATTERY CARRIER LUBRICATION To ensure correct operation of the battery carrier locking mechanism, and smooth reaching in and out of the carrier assembly, its is essential that the sliding surfaces are lubricated regularly. The following procedure be carried out at least every 1000 hours. Under certain conditions it may be necessary to lubricate the carrier more frequently - Remove the battery and battery carrier = Clean, inspect and lubricate the locking mechanism on the underside of the carrier assembly paying particular attention to the lever. Check that the release lever on the truck operates correctly and apply grease to the latching pin at the bottom of handle. = Apply grease to the four guides and to their mating surfaces on the reach legs. Refit the battery carrier. + Lubricate the battery carrier rollers if fitted. 3.33 BATTERY CARRIER REPLACEMENT Battery carrier replacement is a reversal of the battery carrier removal procedure. Ensure the carrier sits square and firm on the reach legs before replacing the battery. PON /Chapr sissesao0h 0203Section 3 Service Training rage 7 35 BATTERY CHANGING (HOIST METHOD) DANGER: When lifting the battery with a crane, ensure that no persons are within the vicinity. Never step under a elevated load. Use lifting equipment of sufficient capacity for the weight of the battery. (See Battery Plate) + Reach battery fully forward. = Tum the Keyswitch off, and depress the emergency isolator - Release the battery connector locking plate and unplug the battery from the truck. = Connect the lifting equipment to the battery and lift the battery up and outwards from the truck. Ensure the battery does not hit the mast or power unit chassis. WARNING: Manual handling risk. The bat- tery is heavy. Take care when manoeuvring the battery from the chassis. - Reverse the procedure to fit the battery. 33 a CAUTION: Before reconnecting the battery, ensure the keyswitch is turned off and the A emergency isolator is depressed. - Reconnect the battery, ensuring the battery connector locking plate is engaged. + Release the emergency isolator, tum the keyswitch on and operate the reach lever to reach the battery in unti the battery unlocked warning indicator on the driver's display extinguishes. A CAUTION: Ensure that the battery cables are not twisted when reaching the battery back. €3° NOTE: The battery cable is designed to face. In order to maintain this condition it is necessary to replace the battery so that the face adjacent to the cable route and negative terminal Is nearest to the truck bulkhead. imise the free cable projecting beyond the battery With some batteries the positive terminal is also on the same face as the cable route. CAUTION: It is essential that the battery is correctly seated on the battery trolley before A reaching back and locking into position. DANGER: The replacement battery MUST be identical in size and weight to the standard An battery.te Section 3 5 at Page 8 Service Training 3.8 BATTERY CHANGING (ROLL ON, ROLL OFF} tery Is heavy. Take care when manoeuvring @ WARNING: Manual handling risk. The bat- battery on and off the roller stand. ensure the keyswitch Is turned off and the / CAUTION: Before reconnecting the battery, emergency isolator is depressed. ensure that the roller stand is adjusted so that it's rollers are level wi those on the truck battery troll could cause damage to the battery trolley locking mechanism. h CAUTION: Before changing the battery, + Drive the truck up to the battery roller stand (1). ~ Reach the battery forward, manoeuvre the truck until the battery is aligned with the vacant track on the roller stand. - Snitch off, depress the emergency isolator, release the battery connector locking plate and disconnect the battery load = Open the latch (2) on the roller stand. © NOTE: The latch hinges over to secure one battery alternately. Undo the securing latch clamp (4) and release the battery securing latch (3) on the truck battery trolley. Push the battery from the truck onto the raller stand, Hinge the securing latch (2) over to retain the battery, Connect a slave lead between the charged battery and truck battery plug. Release the emergency isolator, switch on and ma- oeuvre the truck to align the truck battery trolley with the charged battery Push the charged battery onto the truck trolley and secure with the securing latch (3), ensuring clamp (4) is tightened Tum keyswitch off, and depress the emergency isola- tor. Disconnect the slave lead, ON Chap sissesao0h 0203Gite. Section 3 Service Training Page ° - Connect the truck battery plug, ensuring that the battery locking plate is engaged. - Release the emergency isolator, tum the keyswitch on and operate the reach lever to reach the battery in until the battery unlocked warning indicator on the driver's display extinguishes. /\ CAUTION: Ensure that the battery cables are not twisted when reaching the battery back. DANGER: The replacement battery MUST be identical in size and weight to the standard A battery. 33 aService Training33 a Service Training Section 3 Page ” Screw Spring washer Washer Pillar Shaft Support Pin Plate Seat support 10. Seal 11. Bottom cover 12. Top cover 13. Headrest 14. Cover 15. Locking disc 16. Floorplate 17. Floor mat 18. Battery cover 19. Fastening 20. Gas spring 21. Bolt 22, Hexagon nut 23. Wavy washer 24. Edge protection 25. Countersunk screw 26. Raised head screw 27. Washer 28. Wavy washer 29. Tension spring 30. Hinge 81. Plate 32. Hexagon screw 33. Hexagon nut 34. Cover 35. Socket head screw 36. Screw 37. Washer 38. Seal 39. Bracket 40. Gas spring 41. Screw 42. Socket head screw 43, Washer 44, Nut 45. Locking dies 46. Washer 47. Screw 48. Screw 49. Socket head screw 50. Countersunk screw eengasena 51 52, 53, 54, 56, 56. 57. 58. 59, 60. 61 62, 63, 64, 65. 66. er. 68. 60, 70. nm 72. 73, 74. 75. 76. 7. 78. 79. 80, 81 82, 83. 84, 85, 86, 87. 88, 89, 90. 1 92, 93, 94, 96, 96. 97. 98, 99, Button head screw Nut Washer Washer Cover Cable clip Safety screen Hinge Plate Armrest insert Screw Screw Screw Screw Washer Rubber washer Bracket Gasket Plate Screw Washer Button head screw Bush Screw Washer Washer Washer Button head screw Nut Washer Spring washer Housing Cover Socket head screw Button head screw Nut Nut Washer Washer Washer Hexagon screw Wavy washer Screw Button head screw Cover Nut Cable tie Button head screw Button head screwte Section 3 Page 2 Service Training 38 TOP COVER, OPENING - Tum the keyswitch off and disconnect the battery. - Unscrew the emergency stop button knob (2). = Undo the two socket head screws in the cover (1). Open the cover fully. + Reverse the procedure to close the cover. ~ Replace the emergency stop button (2) 3.9 BINNACLE REMOVAL - Turn the keyswitch off and disconnect the battery. ON Chap sissesao0h 0203 - Unscrew and remove the binnacle adjusting knob. ~ Extract the locking mechanism components, noting their order on the shatt for reassembly. - Disconnect the hamess and remove the binnacle. CAUTION: Ensurethe binnacleis supported. Do not allow the binnacle to hang from the harness.Service Training = Page 3.10 CONSOL REMOVAL - Turn the keyswitch off and disconnect the battery. - Remove the steering binnacle, see BINNACLE RE- MOVAL, - Remove the consol securing screw on the steering bracket 33 a - Remove the two screws from under the control unit shelf. ~ Disconnect the drivers display and remove the consolAte = Service Training a1 jgeRun MOMBERonamAT ‘The composition of the truck serial number is as follows:- XX XXXX X XXXXX_— senuanarunver Year (See table) ——_——————_ Familly type number Currently not used Production site 3.11.4 SERIAL NUMBER EXAMPLE G1 X115 M_ 50001 secwerianunver Year (2003) Family type (115) Currently not used Production site (Lansing Linde Basingstoke) U3 NOTE: When ordering spare parts, the truck serial number is normally required to ensure the correct replacement part is supplied. 4. Capacity plate and Truck serial number HEMT rrsesoesbor e503 RPO /chaper Gite. Section 4 Service Training age 1 4 STEERING ANDLOADWHEELS CAUTION: Always disconnect the battery connector and ensure the steering controller A capacitors are discharged by pressing the horn button prior to working on the system. CAUTION: Components must not be connected or disconnected whilst the truck is live. The battery must be disconnected, failure to do so can result in failure of the modules 44 STEERING ‘See SECTION 6 for electrical operation details. 4. Plate 44. Spring washer 24. Circlip 2 Pin 42. Hexagon nut 22. Clamping piece 3. Washer 13. Washer 23. Plate 4. Gas spring 14. Steering wheel 24. Cabletie 5. Washer 45. Handle 25. Countersunk screw 6. Bolt 16. Woodruff key 26. Nut 7. Bolt 17. Hexagon nut 27. Housing 8 Bolt 18. Cover 28. Washer 9. Bearing 49. Hexagon nut 10. Steering module 20. WasherAte Section 4 Page 2 Service Training 42 STEER MOTOR REMOVAL - Turn the keyswitch off and disconnect the battery. - Remove all electrical connections to the motor, noting their position for reassembly. - Remove the seat assembly support bracket. - Remove the four steer motor securing screws and withdraw the motor. + Iffitting anew or exchange unit, the pinion gear willneed tobe removed, Support the unit ina vice and remove the locking nut from the shaft. - Using a suitable puller, extract the pinion gear from the shatt 0S NOTE: The shafthas a keyway to locate the gear. 4.24 STEER MOTOR REFITTING To refit the steer motor, reverse the removal procedure. No setting up is required.Section 4 Service Training age a 43 STEERING ENCODER REMOVAL - Turn the keyswitch off and disconnect the battery. = Remove the plastic cover, and realease the central securing nut. + Remove the steering wheel and woodruft key. ~ Remove the four seouring screws (two on top, two underneath), and remove the binnacle top cover. 33 a = Remove the binnacle lower cover securing screw. - Remove the three encoder securing nuts, disconnect harness and remove the encoder.te a a Service Training ‘4 soap wae, Seal Bearing Hexagon screw Spring washer Hubcap Tab washer Wheel Tyre Nut 1 2. 3. 4 5. 6 7. 8 9.. is Section 4 Service Training age 5 441 LOAD WHEEL REMOVAL - Apply handbrake, turn keyswitch OFF, disconnect bat- i toy Securely chock the opposite load wheel and drive wheel Raise the load whee! tobe remaved clear of the ground, Rotate the wheel to position access hole as shown, and lower the load wheel. Usinga suitable lever through access hole and applying force to spring (5), lever the brake shoe away from the drum, Raise and rotate the load wheel to position access hole for remaining brake shoe. Lower the load wheel and repeat procedure for the second brake shoe. Raise the load wheel 33 a Remove the dust cap (2) with a screwdriver. Release tab on lock washer (4), Remove slotted ring nut (3). Tool number 000 941 8001 can be used for this operation on the 1.4 and 1.6 tonne ‘model, tool number 002 941 80 08 on the 2.0 tonne, Withdraw the load wheel lock washer andbearing inner races from the load wheel axle shat. 44.2 LOAD WHEEL REFTTING To replace the load wheel to the load wheel axle shatt, re-grease the bearings and reverse the removal procedure. See SECTION 10 for siotted nut tightening procedure.Section 4 Page 6 Service TrainingGite. Section 5 Service Training ramp 1 5 CONTROLS live. The battery must be disconnected, failure to do so can result in failure of the modules. p CAUTION: Electrical components must not be connected or disconnected whilstthe truck 5A ACCELERATOR AND BRAKE PEDALS 3 a b 1. Potentiometer 2. Needle bearing 3 Limit switch # Bearing blocks 23. Wavy washer 42, Pedal rubber 5. Rod 24. Wavy washer S Genopais 6. Gasket 25. Spring washer aa sain 7. Pinion gear 26. Spring washer a 7 5. Retainer ring 8 Gea 27. Washer ae Od Retainer ring 9. Bracket 28. Washer it Gackt 10. Bracket 29. Socket head screw te Lt eaiten 44. Spring 30, Hexagon nut 4S, Howagon cerew 12. Guide 31. Hexagon nut SHES ye Ole 2 50. Hexagon screw 14. Tension spring 33. Washer os foe 15. Retaining clip 34, Washer * 53. Wavy washer 16. Pin 35. Socket head screw ey Wanenachen 17. Pedal rubber 36. Master cylinder Oe Wanrwechen 18 Cable clip 37. Brake pedal ta Bota nadir 49. Hexagon screw 38. Right accelerator pedal 2" eye an 20. Socket head screw 29. Left accelerator pedal Soe 21. Hexagon head screw 40. Pedal rubber 2 22. Hexagon screw 4, Bede 59. Pedal box assemblyAte Section es i Service Training BAA ACCELERATOR UNIT REMOVAL + Remove the floorplate - Remove the securing clip, and disconnect the 4 way accelerator connector 1X10 - Remove the two cap head screws securing the accel ‘erator unit, 5.41.2 ACCELERATOR UNIT REFITTING To refit the accelerator, reverse the removal procedure. Ensure that the microswitch actuating cam locates correctly. After refitting, ensure the accelerator is adjusted correctly, refer to SECTION 6.Gite. Section 5 Service Training ramp a 52 HYDRAULIC BRAKING SYSTEM The hydraulic braking system is operated by the footbrake pedal and is used to supplement the regenerative braking and provide an emergency brake. The footbrake is directly coupled to the brake master cylinder, which is self replenished from an external supply reservoir. ‘The footbrake operates a single self adjusting leading brake shoe assembly on each of the load wheels and also a brake connected to top of the traction motor armature shaft. a 1. Hollow screw 15. Seal 2. Banjounion 16. Seal 3. Brake assembly 17. Hollow screw 4. Reservoir 18. Hexagon head screw 5. Pipe 19. Socket head screw 6 Adaptor 20. Wavy washer 7. Seal 21. Bracket 22. Washer 8. Seal wi 9. Pipe assembly 23, Washer 10. Pipe assembly 11. Pipe assembly 12. Pipe assembly 13. Pipe assembly 14. Banjo unionGitte. section 5 : at Page 4 Service Training 521 HYDRAULIC BRAKES - PREVENTATIVE MAINTENANCE To ensure the brakes operate with maximum efficiency, the following notes should be observed:- ~ Check the hydraulic fluid level in the master cylinder every 2000 hours. Under normal circumstances, topping up should only be required after considerable use. A rapid fallin the fluid level indicates either leak in the systom or overtiling of the cylinder. THE FLUID LEVEL SHOULD BE KEPT TOPPED UP TO THE MAX MARK ON THE RESERVOIR, DO NOT OVERFILL. + Check that the filer cap orifice is not blocked. Check the brake shoes periodically for wear. - If any part of the system is uncoupled, the system must be “bled. Theresa brake fluid low level warning indicator on the driver's display. If his indicator should illuminate, the truck brake reservoir must be topped up immediately and the system checked for leaks. 5.22 MASTER CYLINDER REMOVAL Chock load wheels securely, tum keyswitch OFF and disconnect the battery. - Remove the floorplate, sissesap0tco03 POL Chap Disconnect the feed pipe from the master cylinder and drain the brake fluid reservoir. Disconnect brake pressure pipe - Remove the retaining clip, and extract the clevis pin.Gite. Section 5 Service Training Page 5 - Remove the two screws, nuts and spring washers securing the master cylinder. = Remove the master cylinder. 5.2.3 MASTER CYLINDER REFITTING Po chap 5 Z - To replace the master cylinder, reverse the removal procedure, ~ Torque pressure pipe connector to 10 Nm. ~ Replenish the reservoir with fresh brake fluid and bleed the brake system. 13° NOTE: When replacing the clevis pin, ensure that the microswitch actuating lever is located cor- rectly.Gitte. Section 5 Page 8 Service Training 53 BRAKE BLEEDING [@" NOTE: While bleeding the brakes, keep reservoir topped up as necessary with correct grade of brake fluid. DO NOT use old brake fluid which has been bled from the system. LOAD WHEEL BRAKES - Apply handbrake, turn keyswitch OFF, disconnect bat- tery and chock wheels. Ensure all brake pipe connec- tions are secure. - Remove dust cover from bleed nipple on the right hand, load wheel backplate andconnecta lenath of 5mm bore rubber tube. Immerse other end in a small quantity of clean brake fluid in a glass container. - Gently depress the brake pedal and slacken the nipple, 4 of a tum, - Slowly depress brake pedal fully and lock the nipple. - Release the brake pedal - Repeat procedute until fuid in the containers free of air bubbles. - Replace dust cover. ~ Repeat procedure on the left hand load wheel TRACTION MOTOR BRAKE = Open the motor cover and bleed the drive unit brake cylinder at nipple. Carry out the bleeding procedure as for load wheel brakes. - Check brake operation and top up reservoir if neces sary. sissesap0tco03 POL ChapGite. Section 5 Service Training ramp 7 54 LOAD WHEEL BRAKES Each load wheel brake has a wheel cylinder mounted to the top of the brake backplate secure by two M6 x 16 screws and M6 spring washers. Hydraulicbrake tluid pressure applied to each wheel cylinder expands the brake shoes onto the load wheel brake drum. Each brake shoe pivots from the fixed anchor, thus the leading brake shoe is applied to the brake drum in the direction of rotation and the trailing brake shoe against the direction of rotation. ‘As a result the braking action is approximately the same in both directions of travel. Back plate Plug Slave cylinder Wavy washer Hexagon screw Brake shoe Spring Tension spring Spring BleednnippleGitte. Section 5 Page 8 Service Training 5.41 LOAD WHEEL BRAKE CYLINDERS ‘The wheel cylinder is operated by the hydraulic brake fluid pressure transmitted by the application of the driver's foot to the brake pedal, thus expanding the brake shoes by the wheel cylinder pistons, 5.42 LOAD WHEEL BRAKE CYLINDER MAINTENANCE The wheel cylinders and pipe connections should be checked for leaks in accordance with the periodical service in the operating instructions routine maintenance. 5.43 LOAD WHEEL BRAKE CYLINDER REPAIR INSTRUCTIONS Ropair of individual wheel cylinder items is not recommended. In the event of leaks or damage, replace the wheel cylinders complete and bleed the braking system, 55 LOAD WHEEL BRAKE SHOES 5.5.1 LOAD WHEEL BRAKE SHOES MAINTENANCE AND INSPECTION The brake shoes need lttle maintenance. They require only periodical inspection for damage and wear. Check the thickness of the brake linings. These should be examined every 2000 hours. Brake shoes should be replaced if the linings are worn to the following:- Bonded Brake Linings: Minimum thickness at the most wom part 1.0 mm. 5.5.2 LOAD WHEEL BRAKE SHOE REMOVAL Always replace a set of brake shoes. Use only Lansing Linde Ltd. genuine spare parts in all servicing and repair operations, otherwise the vehicle guarantee will be void. Apply the handbrake, turn keyswitch OFF, disconnect the battery, chock the drive wheels securely. With suitable jack or lifting equipment raise load wheel clear of the ground and securely chock under the chassis. Remove the load wheel. See SECTION 4 Take careful note of the positions of the shoes and their springs. Remove the retaining spring from each shoeby pushing iin and turing through 180°. Carefully store for reuse. sissesap0tco03 POL ChapGite. Section 5 Service Training Page ° ~ Using suitable lever, prise one side of the return spring from the brake shoe and remove. - Pull brake shoe outwards and release from self adjust- ing mechanism and slave cylinder slots. Unhook the tension spring and remove shoe. Repeat procedure for other shoe - Provent inadvertent ejection of the pistons by restrain- ing them with soft wire, or an elastic band, around the slave cylinder body. Take care not to damage the rubber boots - Remove all dust and ditt from the backplate, P01 / Chaps 04 $00 6598 The brake shoes should be renewed if the linings are contaminated with lubricants or hydraulic fluid irrespective of the state of wear. Check for signs of leakage from the wheel cylinders. Inspect the boots, also examine metal brake pipes for wear, damage or corrosion and pull-off springs for damage or overstretching and replace as necessary. Do not attempt to remove the adjusters from the backplate, if faulty a new backplate will be required Other than hydraulic parts, metal to metal contact points should be lightly coated with a high melting point grease that is shoe tips, the areas where the shoe platform seats against backplate, the wheel cylinder abutment slots. DO NOT allow grease to contaminate the shoe linings, rubber parts and the friction surface of the brake drum.Gitte. Section 5 Page 10 Service Training 55.3 LOAD WHEEL BRAKE SHOE - FITTING - To reassemble the brake shoes reverse the removal procedure. Ensure all springs are fitted correctly, and that the restraining wire or band is removed from the oylinder body. - Refit load wheel. See SECTION 4. To ensure balanced brake performance, it is necessary to replace the shoes on both load wheel brake assemblies. Repeat above procedure on the other load wheel brake assembly. Bed in the brakes. 58 LOAD WHEEL BRAKE DRUMS If the brake drum is found to be scored during periodical maintenance, new drums must be fitted. POI Chapter sissesap0tco03Gite. Section 5 Service Training ramp " 57 FOOTBRAKE ASSEMBLY 3 a 4. Traction motor 43. Return spring 2 Lever 14. Support 3. Brake cylinder 15. Hexagon screw 4. Air vent scree 16. Cotter pin 5. Support assembly 17. Thrust washer 6. Bush 18. Circlip 7. Hexagon screw 19. Washer 8. Wave washer 20. Sensor 9. Socket head screw 21. Buffer 40. Spring washer 22. Socket head screw 11, Washer 23. Wavy washer 12. Brake shoeGitte. =o Service Training 57 POOTURAKE:SHOE REMOVAL ~ Turn the keyswitch off. ~ Remove the two screws, nuts and washers, - Remove the two brake shoes from the levers, - Toreplace the brake shoes, reverse the removal proce- dure and adjust the brake shoes. POI Chapter sissesap0tco03Gite. Section 5 Service Training ramp a 57.2 FOOTBRAKE SHOE ADJUSTMENT = Set both brake pads so they are touching the drum and tighten the Durlok nuts to 37Nm. = Pump the brake pedal hard five times. ©" NOTE: The previous two steps are only neces- sary if fitting new shoes. ~ Slacken the Durlok nuts and insert a 0.37mm shim Pt. No. 002,914.65.28 between each of the shoes and drum. 23 - press the shoes against the drum and clamp in position 22 using blocks, Pt. No.115.527.18,00 and tighten the £2 Durlok nuts to 37Nm, [3 NOTE: It is important that when tightening the screws that the appropriate side of the nut/bolt is rotated to ensure the shoe does not loosen on the shim.Gitte. =o Service Training Bs HvoRAWUC CONTROLS Hexagon head screw Spring washer Bracket (3 position) Control lever (dual axis) Control lever (single axis) Control lever with button (clamp) Hames assembly Screw Wavy washer Label Housing SS eeneganena POI Chapter sissesap0tco03Gite. Section 5 Service Training Page 15 584 HYDRAULIC CONTROL LEVER REMOVAL ~ Chock load wheels securely. Reach battery out. Disconnect battery and apply the handbrake. + Open the top covers, - Remove the four screws securing the lever mounting bracket to the chassis. + Disconnect the relevant lever connector. = Push in the two tabs (2) on the connector body and remove from the bracket. - Pull rubber boot back and remove the two lever securing screws (1) = Squeeze the rubber boot and carefully push the lever assembly back through the hole in the mounting bracket, taking care not to damage the rubber boot. 5.8.2 HYDRAULIC CONTROL LEVER REFITTING To refit the lever assembly, reverse the removal procedure, taking care not to damage the rubber boot when refitting the lever. Ensure rubber boot s located correctly before securing the lever to the mounting bracket 3 aSection Page 16 Service Trainingsesoesbor e503 RPO /chaper Gite. Section 6 Service Training age 1 6 ELECTRICALCONTROL, CAUTION: It is imperative, that before working on the control system, that the battery is A disconnected, and the steering capacitor voltage is discharged. The steering capacitor voltage can be safely discharged by operating the horn with the battery plug DISCONNECTED. Check that the voltage between 3F1 and the main negative is less than 5V before working on the truck. Failure to carry out this procedure can lead to damage of the CAN interface drivers. Components MUST NOT be removed or replaced with the truck live, 61 AC CONTROL - OPERATING PRINCIPLE (On a typical 3 phase AC induction motor the current in the three windings is controlled by a "bridge" of six MOSFETS. By controlling when each of the six MOSFETS is on or off, itis possible to cause the current in each of the three motor windings (phases) to flow in either direction. MOTOR WINDING (PHASE) ONE tat active 2nd active pair of pair of MOSFETS MOSFETS. MOTOR WINDING (PHASE) TWO ‘st active 2nd active pair of pair of MOSFETS MOSFETS MOTOR WINDING (PHASE) THREE 4st active 2nd active pair of pair of MOSFETS MOSFETS.te Section 6 Page 2 Service Training Also, by varying the amount of time each MOSFET spends in conduction, itis possible to control the average voltage applied to each motor winding at any moment in time. inthis way a near sinusoidal voltage is applied to each winding as the motor rotor rotates, The frequency that the six MOSFETS switch on and off, is much faster than that of the AC supply seen by the motor. Typically, the traction and lit motors will see an AC frequency of 75 Hz at maximum speed, although the MOSFETS will be switched ON and OFF at 8 Khz to enable this 75 Hz to be accurately synthesised. MOTOR AT HALF SPEED (SINGLE PHASE SHOWN FOR CLARITY) 37 Hz seen by motor ‘Ast active pair 2nd active pair of MOSFETS of MOSFETS 20 14.V RMS ov 14 V RMS ~ 0% 50% 20V Percentage of time MOSFETS are in conduction MOTOR AT FULL SPEED (SINGLE PHASE SHOWN FOR CLARITY) 75 Hz seen by motor “« 4stactive pair 2nd active pair of MOSFETS of MOSFETS 40V 28 V RMS ov tt i 0% = 100% = one Percentage of time MOSFETS are 28 V RMS in conduction 40v PON /Chapr sissesao0h 0203Gite. Section 6 Service Training age a High speed microprocessors are used to carry out the complex mathematical calculations required to sequence this operation in order to generate a 3 phase variable rotating magnetic field. The synthesised ‘AC supply applied to the motor windings is therefore of variable AC frequency and voltage. The motor speed and available torque is controlled very accurately when driving and also when acting as an electric brake returning energy to the battery 614 SPEED & DIRECTION CONTROL ‘The speed of the truck is proportional to the frequency of the supply applied to the motor. The direction of travel is dependent on the direction of current flow through the three motor windings relative to each other. When the applied AC frequency is low, the average AC voltage applied to the motor windings is also low. On initial application of the accelerator the AC motor voltage and frequency will be low. As the speed of the truck increases the AC frequency and voltage increase simultaneously. With AC induction motors as used on 115-02, maximum torque is achieved when the rotational speed of the motor is very slightly less than that determined by the AC voltage generated by the controller - the "synchronous speed’. Thissmall difference is called ‘slip*. The controller regulates both motor voltage and, frequency to ensure that the slip is maintained at optimum for efficient performance. The controller monitors the motor current and in order to ensure that this does not become excessive will automatically override the accelerator demand and reduce the AC frequency and voltage when neces- sary.te Section 6 Page 4 Service Training 61.2 ELECTRO MAGNETIC COMPATABILITY (EMC) Electro magnetic compatibility is the ability of different pieces of electrical equipment to work alongside each other without causing each other undue interference. International standards have been established which set the limits for acceptable EMC compliance. EMC is broken down into two parts, Immunity & Emissions. Immurity is the amount of electrical Radio Frequency (RF) energy which the item should be able to be subjected to without its safe operation being impaired. Emissions is the amount of electrical AF energy which is allowed to be radiated by the item under normal operation and is considered acceptable. EMISSIONS When an electric currents changed in value there is always a small amount of RF energy radiated. Large changes in value take place when a current is switched ON or OFF. For example, its not unusual to hear a click on domestic radio / TV when a light switch is turned OFF, (On the 115-02, the current flowing in the motors is switched ON and OFF at eight thousand times per second (8Khz). There will be RF energy generated every time this switching takes place. To limitthe amount of RF energy produced the switching speed is limited. Also, Ferrite toroidal cores are fitted around the motor phase conductors as close as possible to the controllers. These ferrite cores act as a high impedance to the RF energy but have almost zero effect at the controller operating frequency. These ferrites are incorporated into a spacial cable termination arrangement around the motor cable conneetion studs of the controller such that all current flows though the ferrites. Ferrite cores are also fitted around the main truck hamess immediately behind the power module control connectors to ensure that any RF energy emanating from within the controller is attenuated. The same ferrite arrangement is used for both traction and lift controllers. PON /Chapr sissesao0h 0203Section 6 Service Training age 5 Special steel nut M10 Washer Link or cable Brass spacer Ferrites 33 a IMMUNITY The Ferrite cores fitted above serve two purposes ‘As well as stopping RF energy escaping from within the controller they also stop any RF energy in the environment from other sources getting back into the controller Furthermore the internal circuits of the controller include filter components to remove any RF energy picked up by the truck wiring, The earth bonding straps that connect the pump motor to the chassis are part of the provision necessary to achieve EMC compliance. US NOTE: When disconnecting, or replacing either the traction or lift power modules, ensure that all ferrites are in place on reconnection, © NOTE: The ferrites are extremely brittle, and should be handled with care.te Section 6 Page 6 Service Training 62 ELECTRICAL COMPONENTS (UNDER THE TOP COVER) phe B3eene 13, 14, 15, 16. 17. 18, 19, DCIDC converter 48/24 volt Connector 6 way DC/DC converter Ut UPA and hydraulic control lever connectors Hydraulic control levers Emergency isolator Power steering fuse Traction & hydraulic fuse Main contactor Contro} unit cooling fan Battery connector Traction power module connector Traction power module Direction switch connector (single pedal) Control unit cooling fan connector Copper link between power modules ‘Copper link to traction motor 1Mt Control current fuses, Control module connector Controt module connector Control module Charge resistor assembly connector Charge resistor assembly (under bracket) ut x8 6X63, 2X27, 2X26X, 2X26Y 2X26, X15X, 2X15Y, 2X15 82 3F1 1Fi Ki nit x10 1x17, 4A1 1x9 9x1 X13 (b) X13 (a) A2 xi2 PON /Chapr sissesao0h 0203Gite. Section 6 Service Training age 7 624 ELECTRICAL CONNECTIONS (DRIVE UNIT) The drive unit assembly is fited to the truck as a sub assembly and includes a bracket that supports 6 connectors. A separate wiring harness is used for he electric steering system which connects to the main truck wiring at the steering interface connector 3X15. Connector | Component 7. [Traction motor speed sensor 181 2. [ Hydraulic pump motor speed sensor 2X83 288 3. | Hydraulic pump motor temperature sensor 2x7 284 4, [Traction motor temperature sensor and parking brake solenoid aX7 iBt Yi 5. | Storing system interface 3x15 6. | 360° Steering sensor X10 364 7. | Traction motor speed sensor 1X16 181 8. | Motor terminal W 9. | Motor terminal V 10. [ Motor terminal U 33 ate Section 6 Page 8 Service Training 622 Mounted above the hydraulic tank are the connectors for the operator's seat and the optional lighting ELECTRICAL COMPONENTS (PUMP MOTOR & HYDRAULIC TANK AREA) distribution connector. Connector_| Component 1. |Ughting connector X27 2, [Seat connector 1x82 3, [Traction motor Mt 4. [Steering motor Mi 5. | Hydrautlc-pump mator-specd sensor 288) 6. [ Hydraulic pump motor 2M 7. [Hydraulic power module 2at '8, [ Hydraulic power module/hydraulic pump motor cooling fan ‘ona ‘9, [Traction power module Tat PON /Chapr sissesao0h 0203Gite. Service Training — ° Page 9 63 FUSES - CONTROL CURRENT Power circuit fuses are situated within the control unit enclosure and are to DIN 43560 form B. 4. Steering fuse 3F1 is rated at 50 A 2. Main battery fuse 1F1 is rated at 425 A 33 aAte Section 6 Page 10 Service Training 634 FUSES - ANCILLARY CIRCUITS ‘Small fuses are to DIN 72581 outline. These battery voltage fuses which are located within the control unit enclosure, are of a special sand filled type and rated at a nominal 80 volts, 0g NOTE: Although these fuses are interchangeable with automotive fuses, automotive fuses MUST NOT be used. Only genuine Linde fuses have sufficient voltage capability to ensure cor- rect operation at truck voltages. 6.3.2 FUSE DUTIES AND POSITIONS - ANCILLARY CIRCUITS 1F2 5A Key switch, traction and steering control circuits F8_ 5A Parking brake release & pre-charge resistor 1F6 5A Heated seat & horn supplies 5F1 5A Lighting supplies 6F1 5A BDI monitoring voltage 1F4 5A 24 volt output from DC-DC converter ES NOTE: All control fuses are rated at 80 voltsGite. Section 6 Service Training Bes 4 64 EMERGENCY ISOLATOR - S2 The emergency isolator 2, when operated, breaks the main battery positive feeds to the hydraulic, traction and steering circuits CAUTION: Always ensure that the emergency isolator is depressed before disconnecting ‘or reconnecting the battery. EMERGENCY ISOLATOR $2 33 a xo xo ‘COLOUR ABBREVIATIONS AK | N= EEN fai-anom | BU-BLUE Og =oRANGE LOW o=reo | He ¥eTE Negativete Section 6 Page 2 Service Training 644 24 V POWER SUPPLY - U1 With the keyswitch 1 tured on, a DC-DC converter U1 provides a stabilised 24 volt supply via fuse 1F4. This 24 volts is used to power the control electronics for traction, hydraulic and steering, as well as the truck's cooling fans. The converter has a 75 watt output capability. Battery voltage + 24V + Output t ‘COLOUR ASAE VATIONS ‘= GREEN a=BuE Wievout or=oRey ne WaE Connector x8 Pin Colour Duty 1 Not used 2 BU Battery negative 3 RDYE +24 volt output 4 BU Battery negative 5 BK +48 volt input 6 — Notused Battery negative ON Chap sissesao0h 0203Gite. Section 6 Service Training Page 13 64.2 ELECTRONIC CONTROL MODULE - A2 The digital control module A2 employs two microprocessors. One microprocessor controls hydraulics, and also acts as the safety processor for traction. The second microprocessor controls traction, and also acts as a safety processor for hydraulics. Should an error occur, it willbe instantly detected and the control system will ake appropriate action. This action may be a reduction in performance, ora system shut down depending on the severity of the fault The control module is fitted with two close coupled connectors which are numbered as one. In total, these two connectors have 121 pins. The connectoris designated X13. Part (a) has 81 pins, part (b) has 40 pins. The pins are grouped according to their usage. 0? NOTE: Thetraction power module 141, hydraulic power module 2A1 and electronic control module A2 are interconnected by second local CANbus (CAN 2). 33 a X13 Part b X13 Parta CONNECTOR X13 Parta Part b 0000ee00e@0: | (=e0000000"G OO B0GO0G006=| |»eeeo0000 O00 9 20000000" 260600006 BOO @ traction @ Hycraulies @® Traction and hydraulics O Notusedte Section Page Service Training 6.4.2.1 CONNECTOR X13 PIN DUTIES PIN COLOUR 1 WHBK 2 BU. 3 NYT 4 GND 5 _BKAD 6 7 8 BUEN 9 GN 10 11 vIWH 12 VTRD 13 BNGY 14 15 16 17 WH 18 WHoY 19 Wey 20 OS 21 22 23 BKBU 24 ROBK 25 26 27 28 29 30 PKWH 31 PKRD 22 3a YEBU 34 BNOG 35 «GYYE. 36 BKGN 37 YEGY 38 39 40 41 42 BKEU 43° YERD 44 45 46 47 VTWH 48 PKWH 49 50 51 OGvT. 52 BKYE 53 RDGY 84 WHYE 55 YEBN 586 WHEN 57 58 ‘TRACIMYD. Traction Traction/Hya, “Traction Traction Traction/Hyd Traction Traction Hydraulics Hycrauiies Hyaraulics Traction Traction Traction Traction Traction Traction Traction Hydraulies Hydraulics “Teaction/Hya, Traction Traction Traction Traction Hyarauties Traction Traction Traction Hydraulics Traction Traction Traction Traction Hy “Traction Traction Traction Traction Traction Traction Traction purty 1 coll negative Battery negative supply for module 1 call posite Battery positive 24.V supply for module Not connected Not connected Parking brake coll Enable LAC 1Mt Not connected CANT CANT Hi (Lit) Loin) Enable LAC 2M Not connected Not connected Not connected Digital: Digi: Direction switch reverse ‘Speed sensor (A) ‘Analogue: Accelerator 1 ‘Analogue: Accolerator 2 ‘Analogue: Spare Not connected Capacitor voltage (Traction) Phase monitor L1 (Traction) Not connected Not connected [Not connected Not connected Not connected CAN 2 Hi (Lit) CAN 2 Lo (Lin) Not connected Digi: Digita: Digital: Digital: Digita: ‘Seat swatch ‘Status LAC 1M1 Parking brake switch Direction switch forwards, Speed sensor (B) Not connected Not connected Not connected Not connected Capacitor votage (Lin) Phase monitor L2 (Traction) Relay drvo #1 Relay drive #2 1SO_K (Lif) CANT Hi (Traction) (CAN 2 Hi (Traction) 1S0_K (Traction) 15.V supply Digital: Digital Digital Digit: Digta': Digtat ‘Status LAC 241 Dive enable from steering UPA input Footbrake switch uPA DSS2 (check) ‘Analogue: Spare Not connected Not connected ASSOCIATED WITH Line contactor Supply 0V Lina contactor Battery vi isolator and fuse Connected 19 DCIDC output Connected to parking brake coll Connected to LAC (Traction) enable input (Connected to truck CAN bus Hi ‘Connected to tuck CAN bus Lo Connected 0 LAC (Lit) enable input Direction switch Connected to traevon motor speed sensor Accelerator potentiometer Accelerator potentiometer Not use Connected to LAC (Traction) battory supply Gonnected to traction motor phase Connected to LAC (Lit) CAN bus Hi Connected t0 LAC (Lit) CAN bus Lo ‘Seat switen Connected to status pin on LAC (Traction) Toggle action Direction switch Connected fo action motor speed sensor Connected 10 LAC (Lit) battery supply Connected to motor phase Not use Not used Not used Connected to tuck CAN bus Hi Connected to LAC (Traction) CAN bus Hi Not used Not used (Connected to status pin on LAC (Litt) Connected to staaring contraler pin 12 Connected to UPA connector 6X63:9 Footbrake (normally closed) Left foot swten Connected to DSS2 sensor signal Not use PON /Chapr sissesao0h 0203RPO /chaper sHeeoeso0h e508 Service Training Lite Section 6 Page 16 107 408 109 110 414 112 113 4 15 116 7 148 119 120 121 BNE Bucy Nek BKVT vTRD PKRO 5UBK cy WHGN nau RDBN BNWH ROGN KGY ueN waeu DYE. ROWH YEWH BN auye BUOG DOG YEVT DVT ‘ocwH WHAD ocau VTEN ADBU YEGN YEBU BNRD BKOG BUWH GNEN eNBU BU BK viBu cyos Gyan ‘OGGN Gwr Traction Traction Traction Traction Hydraulics Traction Traction Traction Traction/Hyd Traction/Hyd “Traction Traction Traction ‘Traction Traction Hydraulics Hydraulics Hydraulics Hydraulics Hydraulios Hydraulics Hydraulies Hydraulics, Hydrauiios Hydraulics Hydraulics Hydraulios, Hydraulics Hydraulics Hydraulics Hydraulics Hydraulics Hydraulics Hydraulics Hydraulics Hydrauiios Hydraulics, Hyaraulios Hydraulics Hydraulics Hydraulics Hydraulics Hydraulios Hydraulics Hydrauiios Traction/Hya Hydraulics Hydraulics Hydraulios Hydraulics Hydraulics, Hydrauiios +15 V supply Not connectod Phase monitor L3 (Tractor) Relay dive #3 Raley dive #4 180_L (Lit) GAN 1 Lo (Traction) GAN 2 Lo (Tracton) 180 _L (Traction) OV supply OV cupply Digtat Spare Digiak Speed override Not connected Digital: Desoton switch neutral Distal: DSS! (check) Not connectod Not connected Not connected OV supply Not connected Not connected Analogue’ Joystick 1 ¥1 ‘Analogue: Joystick 1X1 Analogue: Joystick 2 1 OV supply Not connected Digtat: Spare ave: Auxiiary 2 ave: Tit forwards Analogue: Joystick 2 X2 ‘Analogue: Joystick 3 ¥1 Analogue: Joystick 3 Xt 15 V supply Digtat: UPA input Not connected ave: Auniary 4 Vaive: Tit back Analogue: Joystek 1 Y2 Analogue: Joystick 1 X2 ‘Analogue: Joystek 2 V2 Dgiat Spare Digi Lit enable Digta: Spood sensor (A) vave: ah Valve: Sideshit right Analogue’ Joystek 2 x2 Analogue: Joystick 9 ¥2 ‘Analogue: Joystek 3 X2 Digital Reach_B Digitat ReachA Vave: 5h Vaive: Litt ave: Sidesht et Battery -ve supply for module Not connectod Battery ve Vaive: Lower lock valve ave: Common supoly Vave: Lower Vaive: Reach out Vave: Reach back ‘Accelerator supply Connected to motor phase Travel alarm relay Connected to K2 relay (charge circuit) Not used ‘Connected to truck CAN bus Lo Connected to LAC (Traction) GAN bus Lo Not used Not used Not used Not used Connected to 0 V via 8.5 metre switch Direction siten Connected to DSS1 sensor signal Accelocator supply Joystick input - Lif/Lower Joystick input - Reach ‘Joystick input - Sidestit ‘oystek supely Not used Sthveth hydraulic valve Standard valve Joystick input = Tit “oyatek input - sth Joystick input - 6th ‘Joystick supaly Connected to 6X63:7 Sthveth hydraulic valve Standard valve Joystek input - LitvLower ‘Joystick input - Reach ‘Joystek input - Sidosnit Not used Connected to 0 V via link on 2x19 Connected ta lit motar speed sensor stein nydraulc valve Standard valve yatek input it ‘Joystick input - 5th ‘Joystick input - 6th each position sensor each position sensor Bthéth hydraulic valve Standard valve Stanaara vaive Supply OV Battery voits via isolator, fuse and keyswitch Standard valve Supply to all valves Standard valve Standard valve Stangacd vaivete Section 6 Page 16 Service Training 64.3 RESERVOIR CIRCUIT CAPACITORS, SWITCHING ON AND CHARGING The reservoir circuit capacitors are located inside each of the main power units 11 and 12. In order to prevent very high current flowing across the contact tips of K1, these capacitors are pre-charged before Kt energises. This pre-charging is carried out via a charging circuit using two relays K2 and K3. When the keyswitch is tumed on, relay KG is activated directly by voltage transformer U1. Relay K2 is activated by the electronics within A2. As soon as the two relays are activated, the capacitors in the two power units can charge up via the charging resistor At. Only when the reservoir citcult capacitors are charged, can the activation of the main contactor K1 take: place (monitored by an electronic circuit inside A2). Approximately five seconds after that, the relay K2 is switched off again, since the capacitors are now receiving their charging voltage via the contacts of the main contactor K1 COTA RETAINS B=BAGK ] = EEN =a Views v=6Rey WH WATE PON /Chapr sissesao0h 0203Gite. Section 6 Service Training Page "7 6.4.31 RESERVOIR CIRCUIT CAPACITORS, DISCHARGING ‘As soon as the Keyswitch is turned off, relays K2 and K3 are released, allowing the reservoir capacitors to discharge to battery negative through the closed contacts of K3, K2, R1 and R2 in series. reservoir circuit capacitors are discharged. Measure between terminal 1 and 2 of power block 141. The voltage must be under five volts. Ifthe capacitors remain charged at battery voltage for more than 30 seconds after the truck is switched off, then the charging circuit is probably defective. Wait about fifteen minutes until the capacitors have discharged via the power supply. The voltage should be rechecked before working on the system. A CAUTION: When servicing the power supply or the power circuit, ensure that the ‘COLOUR ASBREVIATIONS yore i TE 33 aService Training 6.4.4 MAIN CONTACTOR - Kt Contactor coil characteristics: Resistance (20°C) 54 ohms Coil pullin voltage 28-92 volts Coil hold in voltage 18 volts Coil drop out voltage 4-10 volts Coil suppression Free wheel diode only. No series resistor. AA single pole normally open contactor with a magnetic arc extinguishing system is employed. After the reservoir capacitors within the power block are charged by the charge resistor circuit, this contactor is, initially energised at battery voltage but is then held closed at a reduced coil voltage. The reduced coil voltage is achieved by pulsing the switching FET within the electronic control module. Kt must be closed for traction and lift functions to operate. Power steering is not routed via Kt EOI Chap sissesao0h 0203Section 6 Service Training age 9 6s TRACTION CONTROL (LDC) 65.1 TRACTION POWER MODULE (LAC TRACTION) - 1A1 The traction power module 1A1 which is located on the shelf, incorporates all the power components for traction. It is connected to the electronic control module A2, and other inputs by the main truck harness. ES NOTE: The traction power module 141, hydraulic power module 2A1 and electronic control module A2 are interconnected by second local CAN bus (CAN 2). 0S NOTE: The traction power module 1A1 and lift power module 2A1 are interchangeable. 1X17 33 a MAIN CIRCUIT CONNECTIONS 1 11:1, Negative connection for the power unit (source for the power transistors) and negative supply to hydraulic power module 2A1:1 2 1A1:2, Positive connection forthe power unitvialine contactor, fuse andisolator, and positive supply to hydraulic power module 2A1:2 To motor phase L1 (U) To motor phase L2 (V) To motor phase L3 (W)te Section Page 6 20 Service Training 65.1.1 CONNECTOR 1X17 PIN DUTIES PIN COLOUR DUTY 1 BKRD 2 BNOG 3 YEGY 4 WHGY 5 VIYE 6 RDBK 7 YERD 8 BUGY 9 10 VTGN 11, BU 12 13 GYBK 14 BU 16 16 7 18 VTBU 19 PKRD 20 VTGN 21 22 GN 23. 24 OGGY 25 26 27 28 29 PKWH 24 V positive ERROR Traction motor speed sensor (B) Traction motor speed sensor (A) Traction motor speed sensor +15 V supply Phase L1 (U) to control module X13:24 Phase L2 (V) to control module X13:43 Phase L3 (W) to control module X13:62 Not connected ISO L (Power module diagnostics, developement trucks only) Negative Not connected Motor temperature 1 Traction coding pin Not connected Hydraulic coding pin (Not connected when module is used for traction) Not connected ISO H (Power module diagnostics, developement trucks only) CAN2 Lo Traction motor speed sensor negative Not connected Enable signal Not connected Motor temperature 2 Not connected Not connected Not connected Not connected CAN 2 Hi PON /Chapr sissesao0h 0203Gite. Section 6 Service Training age a 65.2 TRACTION ENABLE SIGNALS Traction is only available when:- the seat switch 1S1 is closed, the left foot switch 1811 (fitted) is operated and the steering enable circuit is activated, ‘The operator MUST press the left foot switch (ifitted) continually ifraction is required. The switch is fitted to stop the driver from operating the truck with his leg outside the protective cage of the truck. 1S NOTE: On trucks with twin pedal systems or cabs, left foot switches are not fitted and the switch connections are linked with a link plug fitted in place of the switch. The steering system provides a separately wired enable signal to the controller. COLOR SREVATONS 33 a Negative OPERATION For traction enable, a signal from the steering unit 3A1 is required. If the internal steering check confirms the system is fully operational, a negative traction enable signal is present at X13:52 Now, once the seat switch 1$1(X13:33) is closed, and, if fitted the left foot switch 1811 (X13:55) is operated, negative traction enable signals are present at X13:9te Section 6 Page 2 Service Training 65.3 DIRECTION OF TRAVEL SWITCH - 1813 The 115-02 is available with eitheran automotive configuration, with one accelerator pedal anda manually operated direction selection switch, or DUAL accelerator pedals situated either side ofa centrally mounted brake pedal. On trucks with DUAL accelerator pedals a link plug is fitted to the left foot switch connector 1X38 beneath the floor plate, and the wiring for the horn push links together pins 3, 4, § and 6 of connector 1X9, Connector 1X9 Pin Colour Duty 1 YEOG +48 Volt horn push supply 2 OGYE Horn push negative supply 3 BKGN Forward 4 BU Negative 5 GY Neutral 6 WH Reverse ‘COLOUR ABBREVIATIONS Negative oo ee 400 PON /Chapr sissesao0h 0203Section 6 Service Training age Bs 65.4 PARKING BRAKE SWITCH - 184 The parking brake is electrically controlled by the control module A2. The parking brake can be released by a single press of the momentary parking brake release switch 184. The brake may then be applied by the driver by a further single press of the momentary switch. 1 is the brake solenoid, which is fed a positive supply via fuse F8 and line contactor K1. The negative switching circuit is supplied via the controller connection X13:8. The parking brake switch 184 controls the braking function via a switched negative signal at X13:35. Connector 1X7 Pin Colour Duty + GYBK —_ Temperature sensor + 2 OGGY Temperature sensor - 3 BKBU Brake + 4 BUBN Brake - 48 V Positive 4x7 Sv J 1x7 COLO AESREATONS Negativete Section 6 Page 2 Service Training 65.5 ACCELERATOR - 104 The accelerator demand sensor is a special potentiometer of nominally 2Kohm resistance which has two sliders OP1 and OP2. Each slider has a series connected 1Kohm resistor. With the accelerator pedal(s) at rest, both sliders rest at the mid point on the potentiometer track, and the output of each slider will be anominal 7.5 volts. The potentiometerincludes a retum spring, which ensures that the shaftis biased anti- clockwise looking at the actuating lever end, SINGLE PEDAL TRUCKS When the accelerator pedalis depressed, OP2 moves towards the negative endof the track, andit’s output voltage will fall by approximately 4 volts at maximum pedal depression. OP 1 moves towards the positive end of the track, and it's output voltage will ise by approximately 4 volts at maximum pedal depression. This has the effect that the combined output from the two sliders (OP1 + OP2) will always be 15 volts, DUAL PEDAL TRUCKS (On dual pedal trucks, the shaft rotates each side of its mid position. When an accelerator pedal is depressed, depending on direction, OP2 moves towards either the negative or positive end of the track, andit’s output voltage will fall or rise by approximately 4 volts at maximum pedal depression. OP1 moves towards the opposite end of the track, and it's output voltage will rise or fall by approximately 4 volts at maximum pedal depression. This has the effectthat the combined output from the two sliders (OP1 +OP2) will always be 15 volts There is no adjustment of the accelerator neutral position. Connector 1X10 Pin Colour Duty + GNBU Negative 2 vTGY Potentiometer OP2 3 0G Potentiometer OP1 4 BNYE +15 volt supply ‘COLOUR ASBREVATIONS BR=BLACK | = GREEN ravesrow | a BLUE ooeonince | t= voter yesveuow | 6Y=cREY z o=eo | W4-WATE a 6 we ter us 450 PON /Chapr sissesao0h 0203PCI /chaper 3 i woe aoa Gite. . at Seaton 6 Service Training 07.09 rae 8 6551 _ ACCELERATORELECTROMECHANICAL CHARACTERISTICS SINGLE PEDAL DUAL PEDAL DUAL PEDAL FORWARD REVERSE Pedals in neutral position TV 75V 7.5V Maximum demand 11,.25V 11,.25V, 3.75V Maxim potmissablo overtavol isev 1ssv 1 Voltages exceeding the overtravel limit will result in an error being detected by the control module A2. 65.5.2 ACCELERATOR CALIBRATION AND SETTINGUP Ifthe accelerator potentiometer or control moduleis changed, then the accelerator willrequiredcalibrating, Calibration is cartied out using diagnostic software - Raise and securely block the drive wheel + With the accelerator in neutral position, select Guided Diagnostics -> Work Order -> Calibration + Select Start, and follow the on screen instructions. [3° NOTE: If the calibrated value is outside the 7.5 V + 0.9 tolerance, then this will be indicated. Adjusting the accelerator stops + Using diagnostic software Inputs + Outputs -> Traction -> Accelerator + Onsinglepedal trucks, press the accelerator pedal lly, the Accelerator % shouldread 100%, necessary, adjust the accelerator pedal stop to achieve the correct value. + Ondualpedal trucks, press the forks trailing accelerator pedal fully, the Accelerator %shouldread-1 00%. Itnecessary, adjust the forks trailing accelerator pedal stop to achieve the correct value. Press the forks leading accolerator pedal lly, the Accelerator %shouldread 100%. IInecessary, adjust the forks leading accelerator pedal stop to achieve the correct value.te Section 6 Page 28 Service Training 65.6 TRACTION MOTOR SPEED SENSOR - 1B1 A sensor 18:1 is fitted to the drive motor. This sensor monitors segments on the traction motor brake drum. The sensor provides two pulse outputs displaced 90° out of phase. Sixty four sets of these pulses are generated per revolution of the motor. These signals are fed into the traction drive power module 1A1 and also the control module A2 where they are processed to determine traction motor speed and direction. Connector 1X16 Pin Colour Duty 1 VTYE +15 volt supply 2 WHGY Output channel A 3 VTGN Negative 4 YEGY Output channel 8 Tee] Q [COLOUR ABBREVIATIONS] WH VTE PON /Chapr sissesao0h 0203Gite. Section 6 Service Training age a 65.7 BRAKE PEDAL SWITCH - 185 This microswitch 185 is located at the brake pedel, and is closed when the pedal is released. When the brake pedal is depressed the microswitch opens. The brake pedal signal is routed to the control module ‘A2. It is used to select an increased fixed level of electric braking. It is also used in conjunction with the diagnostic equipment to program some aspects of the controller. The operation of this switch can be checked using Pathfinder diagnostic software, COLOUR ABEREVATONS fe a Be c mai ge connector 1X14 sg} +t = Pin Colour Duty bade 1 Not used if [a 2 WHYE — Output ula 3 BU Negative ax Negative 65.7.1 REGENERATIVE ELECTRICAL BRAKING RELEASE OF ACCELERATOR When the accelerator is released the controller automatically configures into a braking mode to slow the truck and return energy to the battery. During electric braking the “slip” is reversed such that the motor frequency is slightly greater than that of the controller. Energy recovered is retumed to the battery. ELECTRICAL BRAKING - SELECTING OPPOSITE DIRECTION OF TRAVEL This process is similar to releasing the accelerator pedal with one differences:- The level of electric braking when the reverse pedal is selected can be controlled by accelerator pedal depression. Its maximum level is set using Pathfinder diagnostic software.te Section 6 Page 28 Service Training 65.8 TRACTION POWER MODULE TEMPERATURE MONITORING silicon sensor embedded within the traction power module 11, changes it's resistance according to temperature. The resistance of this sensor is monitored by the controller A2 via a local CANbus. The controller transmits this information via the main CANbus to the display 6P1 which will, if necessary operate cooling blowers or reduce output performance at high temperatures to allow the components to cool. 6.5.8.1 TRACTION MOTOR TEMPERATURE MONITORING - 1B4 A resistive sensor 184 embedded within the traction motor windings, changes its resistance according to temperature. The resistance of this sensor is monitored by controller A2 via the traction power module 11 anda local CANbus. The controller transmits this information via the main CANbus to the display 6P1 which wil, if necessary operate cooling blowers or reduce output performance at high temperatures to allow the components to cool Connector 1X7 Pin Colour Duty 1 GYBK Temperature sensor + 2 OGGY Temperature sensor - 3 BKBU Brake + 4 BUBN Brake - ‘COLOUR ABBREVIATIONS N= GREEN PON /Chapr sissesao0h 0203P01 / Cages Gite. Section 6 Service Training Page 29 65.8.2 TRACTION SYSTEM COOLING FANS - 9N1, 9M2 24 volt DC brushless fans, with long life bearings are used for cooling the traction motor and electrical controller Traction motor and controller temperature information is received via CANbus by the display 6P1. Fans 9M1 (control unit cooling fan) and 9M2 (traction motor cooling fan) operate individually when the temperature of the item to be cooled reaches 40°C, The traction power module will start to reduce power at 90°C and stop at 105°C The traction motor will start to slow at 120°C and stop at 140°C M1 Controller cooling fan 9M2 Traction motor cooling fan eS poe gg i 8g 8 i i 1 yong 3 el P g 3 5 3 eran och oe A A d g al al 9x1 9x2 | | Negative ss er se 8 TON oste Section 6 Page 30 Service Training 65.9 SWITCH CONTROLLED SPEED REDUCTION & HEIGHT SENSOR 8.5M - 2513 Control module pin X13:72 is associated with speed reduction. When this pin is connected to negative, normal maximum speed canbe achieved. When this pinis open circuit, traction performance willbe limited to a much reduced speed. Pin X13:72 is routed through the reach carriage via 2X20:22 and the reach carriage cable to the base of mast connector 1X36 and via the back of mast cable to a switch 2813 at the top of the fixed mast. On trucks with lit heights above 8.5 metres, this switch opens when the forks are raised above 8.5 metres which causes traction performance to be reduced. ES NOTE: If the mast is lowered whilst driving and the switch closes, normal traction speed will not be restored until the accelerator pedal is released and reapplied. This reduced speed can be adjusted using Pathfinder diagnostic software. On trucks with lft heights not exceeding 8.5 metres the mast height switch and cables replaced by a wire link at the base of the fixed mast connector 1X36. Connector 1X36 Pin Colour Duty 1 Notused 2 BK Output : 3 BK Negative at 4 Notused is x6 Negative [eoiouRABBREMATONS Cov 3 2x00 PON /Chapr sissesao0h 0203Gite. Section 6 Service Training age a 65.10 HORN OPERATION - 4H1 The horn circuit is powered direct from the emergency isolator 1S2. The horn push 4S1 is located next to the joysticks. Pressing 451 provides +48v to the hom 4H1 via fuse 1F6. 48 V Positive Connector 1x9 . Pin Colour Duty aie 1 YEOG + 48 Volt hom push supply * 2 OGYE ——_ Hon push negative supply 3 BKGN Forward 4 BU Negative 5 GY Neutral 6 WH Reverse 8 Be z5 SOLS ABBREVIATIONS g ‘R= GREEN Negativete Section 6 Page 2 Service Training 65.11 BATTERY LOCK SENSOR - B1 A battery lock sensor Bt is fitted to ensure the battery box is securely locked in position. Ifthe battery is, ‘not locked in position, the battery unlocked warning light is illuminated on the operator's display. The battery lock sensor B1 is powered by a 24V supply from the DC/DC converter. A negative switch output signal is sent to the display via 6X1:8. Battery lock sensor clearance is 3.5 mm 0.5mm. 24V Positive Connector X1 Pin Colour Duty 1 OGBN — Output 2 WH +24 volt supply 3 Notused 4 BK Negative zl: S| z| a | o| ‘COLOUR ABSREWATONS BK Bt Negative 70 71 73 78 PON /Chapr sissesao0h 0203