Service Manual A-Ergo — D003936, B, GBR, Translated
04 Chassis
04 CHASSIS
4.1 Design and function 39
4.1.1 Scope .............................................................................................................................. 39
4.1.2 Machine housing ............................................................................................................. 39
4.1.3 Overhead guard............................................................................................................... 39
4.1.4 Armrest and steering wheel panel ................................................................................... 39
4.1.5 Covers and panels........................................................................................................... 39
4.1.6 Foot plate......................................................................................................................... 39
4.1.7 Castor wheel.................................................................................................................... 40
4.2 Repair and maintenance instructions 40
4.2.1 Overhead guard............................................................................................................... 40
4.2.2 Armrest ............................................................................................................................ 41
4.2.3 Steering wheel panel ....................................................................................................... 42
4.2.4 Covers and panels........................................................................................................... 43
4.2.5 Foot plate......................................................................................................................... 43
4.2.6 castor wheel .................................................................................................................... 43
4.2.7 Adjusting the angle of the truck ....................................................................................... 44
4.2.8 Battery ............................................................................................................................. 45
4.2.9 Fitting the antistatic chain ................................................................................................ 45
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Service Manual A-Ergo — D003936, B, GBR, Translated
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Service Manual A-Ergo — D003936, B, GBR, Translated
04 Chassis
04 CHASSIS
4.1 Design and function
4.1.1 Scope
A chassis normally includes the supporting parts of a construction and in the case of a truck
the chassis consists of the machine housing, panels and caster wheel.
The straddle lift and load wheel could be considered to be part of the chassis, but since they
are part of the mast the instructions for these are to be found in Section 06, page 61.
4.1.2 Machine housing
The chassis on A-Ergo trucks consists of a machine housing, which is available in different
versions depending on the battery size.
The machine housing is where all the truck components, such as the mast, drive unit and
hydraulic system are mounted, and therefore this is the most basic component in the truck.
The construction of the machine housing is prepared to take different sizes of battery. In
cases where larger batteries are used, spacers are fitted between the machine housing and
the mast (see Figure 12, page 39).
Figure 12. Machine housing prepared for a large battery
4.1.3 Overhead guard
Driver protection consists of an overhead grille mounted on two stanchions. The grille is
designed to provide good upwards visibility.
The structure is dimensioned to cope with loads in accordance with the applicable standards.
4.1.4 Armrest and steering wheel panel
The function of the armrest is to provide an ergonomic posture for the driver. The armrest,
together with the steering wheel panel, can be adjusted upwards and downwards in order to
suit different drivers.
4.1.5 Covers and panels
The function of the panels is to protect the driver from moving parts, electrical components,
oils and fluids, and to protect the components inside from external damage and dirtying.
4.1.6 Foot plate
The foot plate supports a soft mat and a brake pedal (see Section 11, page 191). The foot
plate covers the castor wheel attachment.
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4.1.7 Castor wheel
The castor wheel functions as a support wheel for the drive wheel, since the drive wheel is
mounted asymmetrically on one side of the truck.
The castor wheel is a completely separate and free-turning wheel placed under the driver. It
consists of a double-wheel mounted in a wheel fork. Between and at the sides of the wheel
there are spacer washers, which have the purpose of guiding the wheel to the correct
position in the wheel fork.
Shims are fitted between the castor wheel attachment plate and the machine housing to
compensate for any difference in the diameters of the drive wheel and castor wheel.
CAUTION!
When the drive wheel becomes worn, the shims between the castor wheel and the
machine housing must be removed. This is done to counteract the entire truck
leaning sideways, or the drive wheel spinning. Check the number of shims when
replacing the drive wheel.
4.2 Repair and maintenance instructions
4.2.1 Overhead guard
4.2.1.1 Removing the overhead guard
1) Remove the panel from the cab (5 screws).
Figure 13. Securing of the panel in the cab
2) Secure a lifting strop to the overhead grille and take its weight from the truck.
3) Remove the screws securing the machine housing to the overhead guard stanchions.
4) Lift off the overhead guard.
4.2.1.2 Installing the overhead guard
1) Torque
Bolt the overhead guard to the stanchions. The tightening torque is 109 Nm.
2) Secure a lifting strop to the overhead grille and lift it into place.
3) Torque
Fit the screws securing the machine housing to the overhead guard
stanchions. The tightening torque is 109 Nm.
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Service Manual A-Ergo — D003936, B, GBR, Translated
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Production week Screw quality Screw Tightening torque Important
identification comments
-2009w35 8.8 Bright zinc-coated 81 Nm
2009w36- 12.9 Black, “12.9” 109 Nm 12.9 quality screws
stamped into the must be lubricated
screw head with special
graphite grease.
See Section 2.1,
page 19.
4.2.2 Armrest
4.2.2.1 Removing the armrest
1) Slacken the height adjustment wing nut.
2) Remove the height adjustment knob from beneath the writing surface.
3) Pull up the armrest so that the locking screw for the right hand bracket can be removed.
Figure 14. Armrest front securing screw
4) Lift up the armrest and detach all the wiring at the connectors.
5) Continue lifting the armrest so that the locking screw on the left bracket can be
removed.
Figure 15. Armrest lifted up
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Figure 16. Armrest rear securing screw
6) Lift off the panel.
4.2.2.2 Installing the armrest
1) Align the left side guide rail into its track.
2) Tighten the locking screw.
3) Connect the connectors.
4) Align the right side guide rail and gas spring into their tracks.
5) Push the panel down so that the right side locking screw can be fitted.
6) Push the panel down and lock it in the desired position.
4.2.3 Steering wheel panel
4.2.3.1 Removing the steering wheel panel
1) Slacken the height adjustment wing nut.
2) Lift the steering wheel panel up as far as possible, and lock it in place using the wing
nut.
3) Open the machine cover.
4) Disconnect all the wiring to the components on the steering wheel panel.
5) Slacken the inner guide rail locking knob.
Figure 17. Steering wheel panel locking knob
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6) Slacken the height adjustment wing nut and lift off the steering wheel panel.
4.2.3.2 Installing the steering wheel panel
1) Hold the machine cover open during the whole installation procedure.
2) Align the guide rails with their tracks.
3) Tighten the locking screws when the panel is in its uppermost position.
4) Connect the connectors.
5) Close the machine cover.
6) Push the panel down and lock it in the desired position.
4.2.4 Covers and panels
4.2.4.1 Removing the machine housing cover.
1) Remove the panel from the cab.
2) Slacken the height adjustment wing nut on the steering wheel panel.
3) Lift the steering wheel panel up as far as possible, and lock it in place using the wing
nut.
4) Open the machine cover.
5) Use an Allen key to hold the socket head cap screw in the hinge still, and unscrew the
lock nut.
6) Remove the screw from the hinge and lift the cover down.
4.2.5 Foot plate
4.2.5.1 Removing the foot plate
1) Bend back the 4 pieces of the mat that cover the securing screws, to gain access to
them.
Figure 18. Removing the foot plate
2) Remove the screws and lift up the foot plate.
3) Disconnect the brake pedal electrical connector.
4.2.6 castor wheel
4.2.6.1 Removing the castor wheel
1) Check that the battery is pushed in and locked.
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2) Remove the foot plate, see Section 4.2.5.1, page 43.
3) Position the truck on a pallet (check that it is balanced properly).
4) Loosen the bolts to the swivel wheel, and remove them.
WARNING!
Pinch risk!
5) Pull out the castor wheel.
4.2.6.2 Fitting the castor wheel
1) Put the castor wheel under the truck (which is resting on a pallet).
2) Lift up the wheel and place the shims in position.
3) Torque
Insert the bolts and tighten to 81 Nm.
4) Lower the truck down to the floor.
5) Check if the truck is leaning over, see Section 4.2.7, page 44.
4.2.6.3 Dismantling the castor wheel
1) Remove the castor wheel from the truck, see Section 4.2.6.1, page 43.
2) Brace the complete castor wheel in a vice by gripping the opposite side of the wheel fork
where the clamping pin is fitted.
3) Tap out the retaining pin and drive out the shaft.
4) Lift out the castor wheel from the wheel fork; keep the spacers in a safe place.
5) Remove the bearings from the castor wheel by using a bearing puller.
4.2.6.4 Assembling the castor wheel
1) Use a mandrel to press the bearings into the castor wheel.
2) The shaft is lubricated with oil before fitting.
3) Insert the castor wheel with the spacers into the wheel fork.
4) Check that the hole for the retaining pin in the shaft is aligned with the hole on the wheel
fork.
5) Carefully tap the shaft into place by using a hammer and a suitable mandrel.
6) Insert the retaining pin.
7) Turn the castor wheel and check that it rotates freely.
8) Fit the castor wheel into the truck, see Section 4.2.6.2, page 44.
4.2.7 Adjusting the angle of the truck
The angle of the truck can be adjusted by shimming the castor wheel.
1) Place the truck on a level surface.
2) Check if the truck is leaning over.
• or 1: hold a spirit level to the side of the mast and check whether the mast and truck
is leaning to one side.
• or 2: measure with a ruler, on both sides of the truck, the distances from the floor to
the truck machine housing.
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3) If realignment is necessary, remove the castor wheel in accordance with Section 4.2.6.1,
page 43.
4) Add or remove shims. Shims are available in several different dimensions.
5) Fit the castor wheel, see Section 4.2.6.2, page 44, and check the measurements.
4.2.8 Battery
4.2.8.1 Battery replacement
WARNING!
Observe care to avoid splashing waste acid or oxide from the battery.
1) Separate the battery plug.
2) Lift up the battery lock.
Figure 19. Battery lock
3) Roll the battery out on to the charging/storage structure.
4) Roll in the new battery.
5) Lock the battery in place with the battery lock and put back the battery plug.
4.2.8.2 Replacing the battery rollers
1) Remove the battery.
2) The battery rollers are loose in their attachments. Lift up the rollers in the back edge,
and pull backwards and upwards.
4.2.9 Fitting the antistatic chain
In some applications customers can experience disturbances in the truck operation due to
large static electricity build up in the machine. One way to limit the negative effects of this
can be to fit a metal chain dragging on the floor to improve potential equalisation of the truck.
See the illustration for the recommended installation points for a chain on the truck.
NOTE!
This information may not be interpreted as a basis for warranty claims.
1) In accordance with the illustration, drill an M6 diameter hole.
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2) Cut the chain to the calculated length, so that no more than two links are in contact with
the floor.
3) Secure the anti-static chain with an M6 x 18 bolt and washer on the top.
Ensure that the chain will not affect any moving parts after installation.
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