SERVICE MANUAL

Machine: X-Ergo

Manual No: 005997

Edition 2011A
4 Chassis

Design and function ....................................................................................................... 4.3

Scope .................................................................................................................. 4.3
Machine housing ................................................................................................. 4.3
Overhead guard ................................................................................................... 4.3
Elbow rest, driver seat and foot plate .................................................................. 4.4
Panels ................................................................................................................. 4.4
Castor wheel ........................................................................................................ 4.4
Repair and maintenance instructions .......................................................................... 4.5
Overhead guard ................................................................................................... 4.5
Removing the overhead guard ....................................................................................... 4.5
Fitting the overhead guard ............................................................................................. 4.5
Elbow rest ............................................................................................................ 4.6
Removing the elbow rest ................................................................................................ 4.6
Fitting the elbow rest ...................................................................................................... 4.7
Panels ................................................................................................................. 4.8
Removing the panels in the machine housing ............................................................... 4.8
Driver seat ........................................................................................................... 4.9
Raising the driver seat .................................................................................................... 4.9
Seat switch (2010w48 - ) .............................................................................................. 4.10
Fault tracing instructions for the seat switch ................................................................ 4.10
Floor plate .......................................................................................................... 4.10
Adjusting the floor plate ................................................................................................ 4.10
Removing the floor plate .............................................................................................. 4.10
Adjusting the control wire ............................................................................................. 4.11
Castor wheel ...................................................................................................... 4.12
Removing the castor wheel .......................................................................................... 4.12
Fitting the castor wheel ................................................................................................ 4.12
Dismantling the castor wheel ....................................................................................... 4.12
Assembling the castor wheel ........................................................................................ 4.12
Adjusting the angle of the truck ......................................................................... 4.13
Replacing the drive wheel ................................................................................. 4.13

SERVICE MANUAL
4.2

Battery ................................................................................................................4.14
Changing the battery .................................................................................................... 4.14
Replacing the battery rollers ......................................................................................... 4.14

SERVICE MANUAL
 Chassis / Design and function / Scope 4.3

Edition 2011A

4 Chassis
Design and function

Scope

A chassis normally includes the bearing parts of a structure. In the case of a truck the
chassis consists of the machine housing, panels, elbow rest, overhead guard and castor
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 instead in chapter 6,
Mast.

Machine housing

The chassis on the X-Ergo trucks consists of a machine housing, which is available in dif-
ferent versions depending on the battery size.
All the truck components such as the mast, drive unit and hydraulic system are mounted
on the machine housing, and it is therefore the most fundamental part of the truck.
The machine housing is prepared for different sizes of batteries. Spacers are fitted be-
tween the machine housing and mast in the event larger batteries are used, see figure 4.1.

Figure 4.1 Machine housing prepared for large battery

Overhead guard

The overhead guard consists of a grille roof mounted on two columns. The grille is de-
signed to ensure good upward visibility.
The design is dimensioned to comply with the applicable standards.

04_SM_X-Ergo_En_005997_2011A.fm
SERVICE MANUAL
4.4 Chassis / Design and function / Elbow rest, driver seat and foot plate

Elbow rest, driver seat and foot plate

The elbow rest, driver seat and foot plate interact to create an ergonomically correct
working position for the driver. They can all be adjusted upwards and downwards to suit
different drivers in the best possible way.

Panels

The function of the panels is to protect the driver from moving parts, electrical compo-
nents, oils and fluids, and to protect the components inside from external damage and
fouling.

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 foot
plate. 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 mounted between the castor wheel attachment plate and the machine housing
to compensate for differences in the diameter of the drive wheel and castor wheel.

Note!
Shims should be removed between the castor wheel and machine housing as the
drive wheel becomes worn. This is done to counteract the truck inclining to the side,
or to prevent the drive wheel from spinning. Check the number of shims when re-
placing the drive wheel.

SERVICE MANUAL
 Chassis / Repair and maintenance instructions / Overhead guard 4.5

Repair and maintenance instructions

Overhead guard

Removing the overhead guard

1. Remove the wall panel on the side of the pedals in the driver cab. See “Removing
the panels in the machine housing” , page 4.8.
2. Tilt forward the driver seat. See “Raising the driver seat” , page 4.9
3. Attach a lifting strap to the grille on the roof to relieve the weight of the roof from
the truck.
4. Loosen the screws between the machine housing and the columns for the overhead
guard.
5. Lift off the overhead guard.

Fitting the overhead guard

1. Screw the overhead guard roof back together with the columns. 109 Nm.
Tightening 2. Attach a lifting strap to the grille roof and lift up the overhead guard into position.
torque:
109 Nm 3. Screw tight the screw between the machine housing and the columns for the over-
head guard. 109 Nm.

SERVICE MANUAL
4.6 Chassis / Repair and maintenance instructions / Elbow rest

Elbow rest

Removing the elbow rest

1. Loosen the wing nut for the height adjustment.
2. Use a long Allen key (through the hole by the arrow in figure 4.2) to release the
locking screw at the seat side attachment.

Figure 4.2 Seat side locking screw, elbow rest

3. Lift up the elbow rest and disconnect all the cabling at the connectors.
4. Continue lifting the elbow rest so that it can be released from the pedal side attach-
ment.

Figure 4.3 Elbow rest raised

SERVICE MANUAL
 Chassis / Repair and maintenance instructions / Elbow rest 4.7

Figure 4.4 Pedal side attachment, elbow rest

5. Lift off the elbow rest.

Fitting the elbow rest

1. Fit the elbow rest to the pedal side attachment.
2. Screw tight the elbow rest to the pedal side attachment.
3. Connect the connectors.
4. Fit the seat side guide rail and gas spring in their slots.
5. Press down the elbow rest so that the seat side locking screw can be inserted.
6. Press down the elbow rest and lock in the required position.

SERVICE MANUAL
4.8 Chassis / Repair and maintenance instructions / Panels

Panels

Removing the panels in the machine housing

1. Remove the panel under the driver seat by releasing the three knobs that hold it in
place.

Figure 4.5

2. Remove the panel that encloses the traction motor and tank by loosening the three
screws that hold it in place.

Figure 4.6

SERVICE MANUAL
 Chassis / Repair and maintenance instructions / Driver seat 4.9

3. Remove the panel that covers the pedal side of the machine housing by loosening
the four screws. If the truck has midi-steering the steering column must be
removed in order to remove the panel.

Figure 4.7

Driver seat

Raising the driver seat

1. Release the three knobs that secure the plastic panel placed under the driver seat,
and lift off the panel.

Figure 4.8

2. Release the knob that locks the driver seat (placed behind the driver seat) and tip
the seat upwards and forwards. The seat tipping mechanism has two positions for
raising the seat. Make sure that the locking clamp has actually locked in raised
position before starting work under the seat.

SERVICE MANUAL
4.10 Chassis / Repair and maintenance instructions / Floor plate

Seat switch (2010w48 - )

The seat switch prevents the lever operations being used when the driver is not sitting in
the driving seat; when the driver leaves the seat the seat suspension rises to its uppermost
position, the switch goes on and the electrical circuit is broken.

Fault tracing instructions for the seat switch

1. Go into the Monitor menu.
2. Go to the Input/Output menu.
3. Go to TMC inputs.
4. Check that digital input no. 6 goes to 1 when the driver is sitting in the seat, and 0
when the seat is empty.
Measure the voltage at pin no. 2 in contact X62 relative to B-, if this is not 24 V, check
the cabling between TMC and the seat switch. Otherwise check the operation of the
switch in the driving seat.

Floor plate

Adjusting the floor plate

Warning!
Switch off the power before adjusting the floor plate.

The power must be switched off when adjusting the height of the floor plate. This is to
prevent the truck from moving during the adjustment. Stand on the middle of the floor
plate and push down the lever for the floor plate and seat adjustment. The floor plate can
now be adjusted to the required height.

Removing the floor plate

1. First remove the two covers under the driver seat to improve access. See “Remov-
ing the panels in the machine housing” on page 8.

SERVICE MANUAL
 Chassis / Repair and maintenance instructions / Floor plate 4.11

2. Grip the accelerator pedal and the back edge of the floor plate, and lift the floor
plate straight up.

Figure 4.9

3. Angle the floor plate so that it can be lifted out from the machine housing. The
cables are sufficiently long to allow the floor plate to be set to one side without
having to release the connectors.

Adjusting the control wire

1

Figure 4.10

1. Raise the seat to it upper position.

2. Remove the panel under the driver seat.
3. Adjust the wire with the adjusting screws and check that an adequate tension is
achieved. Adjusting screw 1 is for the seat, and adjusting screw 2 is for the floor
plate. The seat should move when the handle is in its upper position, and the floor
should move when the handle is in its lowest position. When the handle is released
neither the floor nor the seat should move.
4. Refit the panel.

SERVICE MANUAL
4.12 Chassis / Repair and maintenance instructions / Castor wheel

Castor wheel

Removing the castor wheel

1. Check that the battery is pushed in and locked.
2. Remove the floor plate, see “Removing the floor plate” , page 4.10
3. Block up the truck (check the balance).
4. Loosen the bolts to the castor wheel, and remove them.

Warning!
Pinch risk!
5. Pull out the castor wheel.

Fitting the castor wheel

1. Place the castor wheel under the truck (the truck is assumed to be raised on
blocks).
2. Lift up the wheel and place the shims in position.
Tightening
torque: 3. Insert the bolts and tighten them. 81Nm.
81 Nm
4. Lower down the truck.
5. Check the angle of the truck, see “Adjusting the angle of the truck” , page 4.13.

Dismantling the castor wheel

1. Remove the castor wheel from the truck, see “Removing the castor wheel” , page
4.12.
2. Support the complete castor wheel in a vice by gripping the opposite side of the
wheel fork where the retaining pin is fitted.
3. Tap out the retaining pin, and then tap out the axle.
4. Lift out the castor wheel from the wheel fork, taking care of the spacers.
5. Remove the bearings from the wheel by means of a bearing extractor.

Assembling the castor wheel

1. Press the bearings in the wheel with a drift.
2. The axle is lubricated with oil before fitting.
3. Insert the wheel with the shims in the wheel fork.
4. Check that the hole for the retaining pin in the axle comes opposite the hole on the
wheel fork.

SERVICE MANUAL
 Chassis / Repair and maintenance instructions / Adjusting the angle of the truck 4.13

5. Carefully press in the axle by using a hammer and a suitable drift.

6. Fit the retaining pin.
7. Turn the wheel and check that it rotates freely.
8. Fit the castor wheel in the machine, see “Fitting the castor wheel” , page 4.12.

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. Checking if the truck is level:

• Alt. 1: Place a spirit level against the sides of the mast, and check if
the mast is at an angle.
• Alt. 2: Measure with a rule on both sides of the truck between the
floor and the machine housing.

3. If alignment is necessary, remove the caster wheel as per “Removing the castor
wheel (page 4.12)”.
4. Add or remove shims. Shims are available in two sizes, 2.5 and 5 mm.
5. Fit the castor wheel, see “Fitting the castor wheel (page 4.12)”, and check measure.

Replacing the drive wheel

See chapter 5.

SERVICE MANUAL
4.14 Chassis / Repair and maintenance instructions / Battery

Battery
Changing the battery

1. Disconnect the battery plug.

2. Lift up the battery lock.

Figure 4.11 Battery lock

3. Roll out the battery on the charging/storage platform. Note that a safety stop is
actuated when the battery is half way out.
4. Roll in the new battery.
5. Lock the battery by means of the battery stop, and connect the battery plug.

Replacing the battery rollers

1. Remove the battery.

0

Warning!
Observe care to avoid “splashing” spilled acid or oxide from the battery.
2. The battery rollers sit loosely in their seats. Lift up the rollers in their back end, and

pull backwards/upwards.

SERVICE MANUAL