Service Manual - PS-PSH - EnG - 159221 - 2016w38 [PDF]

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Service Manual Pedestrian Stackers PS • PSH

PS PSH SERVICE MANUAL

  

The content of this manual is protected by copyright law and may not be copied, fully or in part, without written permission. The material has undergone careful examination with regard to correctness. We reserve the right to make changes.

© Copyright UniCarriers Europe AB, 2015

PS/PSH

Table of contents

2016w38

01

General information and technical data

1

2016w38

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

02

Introduction........................................................................................................................ 1 Safety ................................................................................................................................ 1 Environmental considerations ........................................................................................... 5 Preparations ...................................................................................................................... 5 Data ................................................................................................................................... 6 Component specification ................................................................................................. 10 Recommended consumable materials ............................................................................ 10 Standards and abbreviations............................................................................................11

Special tools

17

2016w38

2.1

03

List of tools ...................................................................................................................... 17

Service

18

2016w38

3.1 3.2

04

Routine periodic maintenance ......................................................................................... 18 Specific instructions......................................................................................................... 28

Chassis

31

2016w38

4.1 4.2

05

Design and function......................................................................................................... 31 Repair and maintenance instructions .............................................................................. 32

Drive unit

36

2016w38

5.1 5.2 5.3

06

Design and function......................................................................................................... 36 Maintenance and repair instructions................................................................................ 37 Diagnostics and trouble shooting .................................................................................... 42

Mast system

44

2016w38

6.1 6.2 6.3

07

Design and function......................................................................................................... 44 Repair and maintenance instructions .............................................................................. 46 Diagnostics and trouble shooting .................................................................................... 62

Steering

63

2016w38

7.1

Design and function......................................................................................................... 63

7.2

Maintenance and repair instructions................................................................................ 63

PS/PSH

Table of contents

08

Hydraulic system

70

2016w38

8.1 8.2 8.3

09

Design and function......................................................................................................... 70 Repair and maintenance instructions .............................................................................. 85 Diagnostics and trouble shooting .................................................................................... 92

Lift cylinders

94

2016w38

9.1 9.2

10

Design and function......................................................................................................... 94 Repair and maintenance instructions .............................................................................. 94

Electrical system

107

2016w38

10.1 10.2 10.3 10.4

11

Design and function....................................................................................................... 107 Repair and maintenance instructions ............................................................................ 108 Diagnostics and trouble shooting .................................................................................. 145 Appendix 1, Overview of the menu trees....................................................................... 182

Speed control and brake systems

230

2016w38

11.1 11.2

Design and function....................................................................................................... 230 Maintenance and repair instructions.............................................................................. 230

PS/PSH

01  General information and technical data

01

GENERAL INFORMATION AND TECHNICAL DATA

1.1

Introduction

1.1.1

General You may find contradictions in this Manual compared to the models supplied due to special design features, upgrades, and other detail differences. The content of this Manual is protected by copyright law and may not be copied, fully or in part, without written permission. The material has undergone careful examination with regard to correctness. Subject to alteration. In the event of inconsistent information in the Swedish and translated editions, it is the Swedish edition that applies. Modifications and updates will be distributed via Service Manual Change. For further information concerning Service Instructions, operation of the truck and the ATC truck computer, refer to the truck Instruction Handbook supplied.

1.1.2

The trucks The manual covers the PS and PSH stackers which are included in the P series of stackers and low lifters .

1.1.3

Structure of the Manual This Manual is arranged in accordance with a system consisting of 12 Chapters, where Chapters 4-12 contain information limited to specific parts of the truck. For example the Mast (Chapter 6) and Hydraulic System (Chapter 8). Chapters 1 - 3 in this Manual contain more general information regarding technical data, general service instructions and tools. The software is described in Chapter 10. The main principle for extra accessories is to place them in their respective Chapters. Otherwise they are located in Chapter 12 "Others". For this reason Chapter 12 is not always included in the Service Manual. For specific problems or information about procedures, look in the main index for the correct section in the manual.

1.1.4

Symbol key WARNING! Used for risk of personal injury. CAUTION! Used with the risk of damage to the machine. NOTE! Used for general observation.

1.2

Safety

1.2.1

General Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle. A general rule is to always implement preventive measures that are adapted to the type of vehicle to be worked on. The general rules below must always be observed:

PS/PSH

1

01  General information and technical data

• • • • •

• •

• •

Local fire directives should always be followed. Smoking or naked flames are strictly forbidden as there is a risk of explosion in the vicinity of batteries and while working on gas equipped vehicles. The battery should always be protected during grinding work. The drive wheel must always be lifted up free from the floor during service work to prevent the vehicle from moving. Before working on the electrical system, the battery plug must be pulled out The battery plug may only be connected while troubleshooting, while taking great care (with the truck raised). It is essential that all cables (especially the battery cables) are connected correctly as the electronics used in the truck are sensitive to incorrectly polarised supply voltage. When working on or close by the electrical system, all metal objects such as watches and rings should be taken off. A short-circuit from such objects can result in serious burn injuries. To ensure correct operation, all dust and magnetic particles should be regularly cleaned off solenoid switches and magnets. Always pull out the battery plug to prevent pinching injury when working on and around the truck. The battery plug may only be connected while trouble shooting, while taking great care (with the truck raised). WARNING! Having the power connected to the truck while working on and around the mast can lead to fatal injury!

• •

• •

2

When working on and around lifting devices and the hydraulic unit, they must be locked by using the mast lock, wooden blocks or some other appropriate means. No other persons should be in the vicinity of the truck when it is test run in conjunction with repair work, in view of the risk of accidents or near-accidents from the truck making an unexpected manoeuvre. Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck. When the truck is lifted, for example using a jack, make sure you secure it with blocks. The truck must not rest on the jack while work is carried out.

PS/PSH

01  General information and technical data

•

The system should not be pressurised, e.g. the pump motor shut off and the forks down, when dismantling parts of the hydraulic system.

Figure 1. Emergency release valve in the hydraulic unit.

• •

•

1.2.2

If the forks need to be released in an emergency, due to a short-circuit or similar occurrence. Press the emergency release valve in the hydraulic unit. Always use genuine spare parts. This ensures correct and safe operation of the truck and is a condition for any guarantee claim to succeed. Anyone using non-approved spare parts must accept, without exception, full responsibility for any resulting damage. Hydraulic hoses should be kept so that they do not age too quickly. Servicing and maintenance may only be carried out by authorised service personnel. We cannot accept responsibility for servicing or maintenance that is carried out by non-authorised service personnel.

Truck modification NOTE! Unauthorized truck modification is not permitted. No modifications or alterations to a powered industrial fork lift truck, which may affect, for example, the capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the truck manufacturer, its authorized representative, or a successor thereof. Contact an authorized dealer before making any modification or alteration to your industrial truck that may affect, for example braking, steering, visibility and the addition of removable attachments. After obtaining approval from the truck manufacturer, its authorized representative, or a successor thereof, the capacity plate, decals, labels and operation and maintenance handbooks shall also be changed appropriately. Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided, however, that the user shall: • •

PS/PSH

Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety; Maintain a permanent record of the design, test(s) and implementation of the modification or alteration;

3

01  General information and technical data

• •

1.2.3

Approve measures and in an equivalent manner make appropriate changes to the capacity plate(s), decals, labels and Instruction Handbooks. Affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name and address of the organization that accomplished the tasks.

Lifting the truck Inspection and preparation • When the truck is lifted using a jack, make sure you secure it with blocks. The truck must not rest on the jack while work is carried out. • Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck. • Ensure that the drive wheel runs free of the floor before trouble shooting. Lifting points

Figure 2. Permitted lifting points

•

Permitted fork lift truck lifting points. The lifting points are marked with a decal representing a lifting hook. WARNING! The machine must never be lifted in any other points than the ones shown.

1.2.4

Welding on the truck •

•

4

During welding work the battery plug must always be disconnected and all connections to the control units and controllers (applies to all electronic units) disconnected. On completion of welding work the connectors must first be connected to the electronic units, after which the battery plug is then connected to the battery. The welding ground connection must always be connected as close to the welding area as possible to eliminate damage to surrounding components.

PS/PSH

01  General information and technical data

1.2.5

Gas spring WARNING! During service and preventive maintenance it is important to check that the steering arm is raised up automatically when the driver releases it. If this does not happen it should be reported to the truck supervisor, with the recommendation that the truck be taken out of service until the requisite measures have been implemented. WARNING! Care must be taken when dismantling the gas springs. 1. 2. 3.

Make sure that no other persons are in the vicinity, or in the lengthwise direction of the gas springs. Stand to the side of the gas spring when removing. Never point the gas spring toward any person or part of the body.

1.3

Environmental considerations

1.3.1

We respect the environment The majority of our products consist of steel, and can be completely recycled. Environmental impact All products have an impact on the environment throughout their entire life cycle. The consumption of energy when in use is one of the most important factors that influences the environment. Through correct care, maintenance and use the consumption of energy can be reduced, thereby reducing the environmental impact. Waste Waste material in conjunction with repairs, maintenance, cleaning, or scrapping, must be collected and disposed of in an environment-friendly way and in accordance with the directives of respective countries. Such work should only be carried out in areas intended for this purpose. Recyclable material should be taken care of by specialised authorities. Environmentally hazardous waste, such as oil filters, hydraulic oil, batteries and electronic equipment, can, if handled incorrectly, have a negative effect on the environment and human health.

1.4

Preparations

1.4.1

Service • • • • • •

PS/PSH

Go through all the safety instructions. Make sure that you have all the essential tools close at hand before starting work. Before wiring or other electrical components are disconnected, check the colour codes and check for any damage to the wiring or connections. When complex components are repaired and dismantled, make sure that you keep track of the different component parts to avoid the risk of confusion. When repairing or maintaining sensitive components, make sure that you use clean tools and work on a clean work surface. Dismantle, inspect and adjust components according to the prescribed routines. Refer to the respective Chapters for detailed information.

5

01  General information and technical data

1.4.2

Trouble shooting When you suspect that a component is defective, do not replace it immediately. First check the surrounding equipment and carry out complete trouble shooting routines. Make sure you know the reason for the fault before replacing a component.

1.5

Data

1.5.1

Designations

1.5.1.1

Truck designation Truck

Type

Load capacity

PS 125

Pedestrian stacker

1250 kg

PSH 160

Pedestrian stacker

1600 kg

PSH 200

Pedestrian stacker

2000 kg

Explanation of Model designation Table 1. Truck designations Example: PS 125 TV 299

6

Truck Type

PS

Load capacity *10 [kg]

125

Mast type

TV

Mast lifting height [cm]

299 = lifting height [cm]

PS/PSH

01  General information and technical data

1.5.1.2

Type designation

Figure 3. Example of type plate (–2006w36) 1. 2.

Model designation.    Type Series no./Version (S=Special ver.).   

3.

4.

PS/PSH

Year of manufacture, week, and warranty period in months (on the assumption that the service instructions in the warranty regulations are followed).    Where appropriate, load limitations depending on the position of the load on the forks (D) and/or lifting height (Q).   

7

01  General information and technical data

Figure 4. Example of type plate (2006w37-) 1. 2.

Model designation.    Type Series no./Version (S=Special ver.).   

3.

4.

Year of manufacture, week, and warranty period in months (on the assumption that the service instructions in the warranty regulations are followed).    Where appropriate, load limitations depending on the position of the load on the forks (D) and/or lifting height (Q).   

NOTE! If the machine plate is lost or becomes illegible, it must be replaced as soon as possible. In order to identify the serial number of the machine there is a label placed on each principal component, such as the traction motor, gearbox, hydraulic unit, TMC, etc. On some machines there is also a label glued inside the battery space or the serial number is punched on the side of the mast.

8

PS/PSH

01  General information and technical data

Figure 5. Example of a serial number label.

1.5.2

Dimensions and weights

1.5.2.1

Dimension designations

Figure 6. Positions for dimension designations PS XXX PSH

PS/PSH

9

01  General information and technical data

1.6

Component specification Table 2. Component specifications, PS and PSH Component

Specification

Traction motor

Drive voltage

24 V

Output standard

1.1 kW 60 min.

Gearbox

Insulation resistance

25 MΩ

Gear ratio (standard)

28,0:1

Oil volume

1.5 litre

Max pressure

150-160 bar

PS 125

Oil volume

max 6.0 litre

PSH 160/200

Oil volume

max 12.0 litre

PS 125

Output

2.2 kW

PSH 160/200

Output

3.0 kW

Type FZ2009

AC0 CAN

Voltage

24 V

Max. current

150A (RMS) for 2 min

Control fuse

7.5 A (1 pcs)

PS 125

Pump motor fuse

125 A (1 pcs)

PSH 160/200

Pump motor fuse

160 A (1 pcs)

Drive motor fuse

100 A (1 pcs)

ZF

Hydraulic system

Hydraulic unit (motor and pump)

Control system for traction motor

Fuses

1.7

Recommended consumable materials

1.7.1

Oil and grease types The table below shows the lubricants which are used in production and are recommended for servicing. They have been carefully selected and are suitable for, among other things: • • •

extending the life of the products reducing electrical consumption having the greatest respect for the environment

If the recommended lubricants cannot be obtained, alternative lubricants must comply with the stated classifications. Bear in mind that it is important to use the stipulated environmentally friendly oils for the guarantee to be valid. Biodegradable-classified oils have a poor conductive ability and therefore require that both the oil and the filter are well grounded to the chassis. If secure grounding is not present, this can cause problems, such as static discharge through the oil. All truck models are earthed. It is important that different products and brands are not mixed – particularly synthetic and mineral oils. CAUTION! Never mix different lubricants, and definitely not synthetic oil with mineral oil! Product

Part no.

Class

008935

ISO VG 32, viscosity index 150 or greater.

Hydraulic oil Standard

10

PS/PSH

01  General information and technical data

Product

Part no.

Class

Cold store

008936

ISO VG 26, viscosity index 300 or greater, (Liquid temperature, -40°C or better).

Biodegradable oil

014160

SS 15 54 34. CAUTION! The guarantee only applies if the truck is delivered with this oil from the factory, as this oil cannot be mixed with other types of oil.

Oil for the food industry

014161

NSF H1. CAUTION! The guarantee only applies if the truck is delivered with this oil from the factory, as this oil cannot be mixed with other types of oil.

Gearbox oil Drive unit, all models Standard

116444

Class GL5, 85W-90.

Cold store

116447

Class GL5, 75W-90.

Standard/Cold stores

014163 180 kg

Fully synthetic, lithium complex, NLGI grade 1.5. viscosity 220. -40 °C to +180 °C.

Standard

001197 0.4 kg tube

-20 °C to +110 °C.

Cold store

014164 0.4 kg tube

-40 °C to 150 °C.

Grease, ball bearings

001207

Grease for bearings.

Biodegradable oil Grease

Protective grease for electrical 124525 contacts. For cold store 30 g tube version truck only.

Tool for tube, part no. 110782. Electrical grease specification. -50°C to +270°C.

Miscellaneous Rust protection

014162

No specification.

Chain spray

001196

No specification.

Electronics spray

001198

No specification.

Degreasing compound

112268

No specification.

1.8

Standards and abbreviations

1.8.1

Screws

1.8.1.1

Tightening torques for screws and nuts Table 3. Tensile grade

PS/PSH

DIM

4,6 Nm

8,8 Nm

10,9 Nm

12,9 Nm

M4

1,1

2,9

4,0

4,9

M5

2,2

5,7

8,1

9,7

M6

3,7

9,8

14

17

M8

8,9

24

33

40

11

01  General information and technical data

DIM

4,6 Nm

8,8 Nm

10,9 Nm

12,9 Nm

M10

17

47

65

79

M12

30

81

114

136

M14

48

128

181

217

M16

74

197

277

333

M18

103

275

386

463

M20

144

385

541

649

The tightening torques in the table are standard values. In some cases a specific tightening torque is specified in the respective Chapter. If no tightening torque is specified in the service instructions, the values shown in the table apply. CAUTION! The above-mentioned tightening torques do not apply to screws tightened in plastic. Only tighten hand-tight so as not to damage the truck.

1.8.1.2

Tightening torques for hydraulic couplings Table 4. Pipe thread/metric threads DIM

Whitworth pipe thread MA (Nm) with pipe olive

MA (Nm) with elastic

M10 x 1

G 1/8"

25

10

30

20

M12 x 1.5 M14 x 1.5

G 1/4"

50

30

M16 x 1.5

G 3/8"

80

35

90

40

130

50

M22 x 1.5

150

60

M26 x 1.5

250

70

250

80

250

90

350

140

400

140

M18 x 1.5 M20 x 1.5

M27 x 1.5

G 1/2"

G 3/4"

M27 x 2 G 1" M33 x 2 M42 x 2

G 11/4"

600

240

M48 x 2

G 11/2"

800

300

NOTE! Other bolts and screws are to be tightened to the torques stated in this Chapter.

1.8.1.3

12

Conversion table for tightening torques Newton metres (Nm)

Kilopond metre (kpm)

Pound force inch (lbg x in)

Pound force foot (lbf x ft)

1

0,10

8,85

0,74

9,81

1

86,80

7,23

0,11

0,01

1

0,08

1,36

0,14

12,00

1

PS/PSH

01  General information and technical data

1.8.1.4

1.8.1.5

1.8.2

1.8.3

Conversion table, pressure units Pa (N/m2)

Bar (1mb=1hPa)

at (kp/cm2)

torr (mm Hg, 0 C) atm

1

10-5

1,020*10-5

7,501*10-3

9,869*10-6

9,807*104

0,9807

1

735,6

0,9678

133,3

1,333*10-3

1,360*10-3

1

1,316*10-3

1,013*105

1,013

1,033

760

1

Conversion table, speed m/s

km/h

1

3,6

0,278

1

Standard abbreviations and units Magnitude

Unit

Designations

Current

Ampere

A

Voltage

Volt

V

Resistance

Ohm

Ω

Output

Watt

W

Torque

Newton metre

Nm

Pressure

Pascal

Pa

-

Kilo (=1000)

k

-

Mega (=1 000 000)

M

Screw types and tensile grades Screw type

Designation

Tensile grade

M6S

Hexagon screw

8,8 10,9

MC6S

Hexagon hole screw

8,8 10,9 12,9

PS/PSH

MLC6S

Hexagon socket screw, low head

8,8

MF6S

Hexagon hole screw, countersunk

10,9

MCS

Slotted screw

4,6

13

01  General information and technical data

Screw type

Designation

Tensile grade

MVBF

Oval head countersunk screw

4,6

K6SF

Oval head socket screw

10,9

Markings with the manufacturer’s trademark, including the tensile grade, is compulsory for screws with a thread diameter from 5 mm and in tensile grades according to the table above. Marking only takes place when the shape of the product permits this.

NOTE! Other screw heads and types exist, but they have no general tightening torques based on the tensile grade.

1.8.4

1.8.5

1.8.6

14

Machine colour codes Machine colour

Part Number

Yellow, spray

001816

Yellow, 1 litre

001815

Dark grey, spray

001550

Dark grey, 1 litre

001553

Silver, spray

001389

Light grey, spray

150788

Colour coding according to NCS Machine colour

Designations

Yellow

NCS 0070-Y20R

Medium grey

NCS 7000

Dark grey

NCS 8000

Light grey

NCS 5000

Colour codes for wiring diagrams Code

Cable colour

BL

Blue

BN

Brown

PS/PSH

01  General information and technical data

Code

Cable colour

GN

Green

GR

Grey

OR

Orange

P

Pink

R

Red

SB

Black

VO

Violet

W

White

Y

Yellow

NOTE! Two-colour cables are shown with both colour codes separated by a slash. Example: Blue/yellow cable is defined by colour code BL/Y.

1.8.7

Designations for electrical components Electrical components normally have a designation of two letters: Table 5. First letter Code

Designation

Designation (Eng)

A

Component or function without its own letter in the list

Component or function without its own letter below

C

Capacitor

Capacitor

D/V

Diode

Diode

E

Electrical component

Electrical component

F

Fuse

Fuse

I

Indicator

Indicator

K

Contactor/relay

Contactor/relay

L

Coil/inductive element

Coil/inductive element

M

Motor

Motor

P/X

Connection

Connection

R

Resistor

Resistor

S

Switch/Change-over switch

Switch/Change-over switch

T

Terminal

Terminal

Y

Valve/brake

Valve/brake

H

Audible warning unit/lamps/lights Audible warning unit/lamps/lights

G

Battery

Battery

Code

Designation

Designation (Eng)

B

Brake

Brake

C

Control system

Control system

E

Emergency function

Emergency function

F

Forward

Forward

H

Hour

Hour

Table 6. Second letter

PS/PSH

15

01  General information and technical data

16

Code

Designation

Designation (Eng)

K

Key

Key

L

Lower

Lower

M

Manoeuvre

Manoeuvre

P

Pump

Pump

R

Reverse

Reverse

S

Speed

Speed

PS/PSH

02  Special tools

02

SPECIAL TOOLS

2.1

List of tools Table 7. List of tools Tools

Part number P/N

Application

Communications cable, truck computer (ATC)

108005

Data transfer cable between truck and PC

ESD wristband

158066

Lifting eye

104737

Insulation test instrument

111111

Crimping tool (Molex)

006454

Cable connections

Pin extractor (Molex minifit)

006456

Cable connectors

Cleaning fluid

112268

Cleaning of electric motors from gearbox oil and other dirt

Chain spray

001196

Lubrication of chains

Lifting eye for drive unit

For detailed information on the above products, please contact the truck manufacturer's spare parts department. All special tools can be ordered from the truck manufacturer's spare parts department.

PS/PSH

17

03  Service

03

SERVICE

3.1

Routine periodic maintenance

3.1.1

Introduction Preventive maintenance should be carried out regularly when the truck is used in normal conditions. The planned service includes operations such as test driving, function tests, and the changing of filters and oils etc. Service is planned at different intervals depending on the running time of the truck. If the truck is working in extreme conditions or in demanding environments, servicing must be planned at tighter intervals.

3.1.2

Safety NOTE! Check under each separate section which safety instructions are applicable for work on the truck. Inspection of the external functions in the power steering system should be carried out after every service and after work carried out in the electrical system. All functional tests of the safety system must be carried out with the truck speed controller in its neutral position, see Section 10, page 107.

3.1.3

Recommendation Information on what the truck owner should take into consideration. Regular inspection should be carried out by specially appointed and trained personnel with a good working knowledge of the function and maintenance of the truck. To obtain the best results from your truck investment, we advise you to contact your local truck representative and to sign up for a service contract for regular inspection.

3.1.4

Daily inspection For instructions, refer to the Operator´s Manual

3.1.5

Weekly inspection (30 hours of operation) For instructions, refer to the Operator´s Manual

3.1.6

First service (200 hours) The first service must be carried out after 200 hours. This service has the purpose of ensuring the function of the truck and its component parts. • • •

3.1.7

Change the oil in the gearbox. Change the hydraulic oil filter. Test the function of the entire machine in accordance with Section 3.1.7, page 18

Main service EN-1726 and ISO 3691 specify that regular preventive maintenance should be carried out on the truck. To guarantee high quality, operational reliability and personal safety, this maintenance should be carried out by specially trained personnel. To comply with this requirement, we have prepared the following main service points (A service), which must be checked every 500 hours of operation, on condition that the truck is being used in normal conditions. • • •

18

Check for external damage on chassis. Check of weld joints at vital points. Check of lifting devices.

PS/PSH

03  Service

• • • • • • • • • • • • • •

3.1.8

Check of component attachments. Functional test, lever, lever bolts, 195 Nm. Check of the horn. Test drive backwards and forwards, and turning. Check of the drive unit. Check of all the wheels. Test of the brake function. Change the oils and filter in accordance with instructions. Check for oil leakage. Check of the hydraulic unit, pipes and hoses. Check of the cylinders. Function test, lifting and lowering Lubrication in accordance with lubrication chart. Measurement and check of the battery and charging function.

Extra service inspections What has been mentioned above is applicable on the assumption that the machine is working in normal conditions on single shifts. In dirty or dusty environments, poor floor conditions, or where there are large variations in temperatures, the service intervals must be arranged more frequently. None of the inspections mentioned above can be charged to the truck manufacturer.

3.1.9

Check list, service inspection For further information about procedures for inspections, repairs and replacements refer to respective sections. Planned service inspections are implemented in accordance with the following points: Table 8. Chassis Chassis Inspection points Symptom

Inspection

A Service

Service code

Signs/Decals

None, illegible

Visual

X

1024, 1101

Panels

Attachment, damage

Visual, tools

X

1102, 1032

Visual

X

1108, 1109

Listen, tool

X

Attachment

Visual, tools

X

Rubber mats, Rubber protectors

Damage

Visual

X

Attachment

Visual, tools

X

Chassis, general

Appearance

Visual

X

Damage

Visual

X

Loose screws

Tools

X

Load wheel, Castor Damage, wear wheel Noise

1105, 1058 1001, 1033, 1112

Table 9. Mast Mast

PS/PSH

Inspection points Symptom

Inspection

A Service

Service code

Push rods

Locking.

Tools

X

2105

Damage

Visual

X

19

03  Service

Mast Inspection points Symptom

Inspection

A Service

Service code

Forks

Cracks, damage

Visual

X

2026

Wear

Visual

X

Fork carriage*

Mast profiles*

Angle, deformation Visual, tools

X

Cracks, damage

Visual

X

Play, damage, wear on rollers

Visual, operating test

X

Angle, deformation Visual

X

Attachment rollers

Visual, tools

X

Cracks, damage

Visual

X

Wear, cracks

Visual

X

2007, 2004

2101

Table 10. Drive unit Drive unit Inspection points Symptom

Inspection

A Service

Service code

Gearbox

Oil level

Visual, filling

X

3006, 3101, 3107

Oil leakage

Visual, tools

X

Function, noise

Listen, tool

X

Traction motor

7028, 7113, 7039, 7027, 7112

Cable connections Visual, tools

X

Noise

Listen, tool

X

Damage, wear

Visual

X

Attachment, play

Visual, tools

X

Sliding bearing

Noise

Listen, lubricate

X

3103

Drive shaft

Noise

Listen, tool

X

3104

Gear

Noise

Listen, tool

X

3102, 3106

Drive wheel

3002, 3005

Table 11. Steering Steering Inspection points Symptom

Inspection

A Service

Service code

Steering Bearing

Noise

Listen, lubricate

X

4101

Tiller arm attachment

Play

Visual

X

4103

Attachments

Tools

X

Table 12. Brake Assembly Brake Assembly

20

Inspection points Symptom

Inspection

A Service

Service code

Braking force

Malfunction

Function test, tools X

5012

Parking brake

Malfunction

Function test, tools X

5014

Brake cable

Abrasion

Visual

X

5002

Brake disc

Wear

Visual, tools

X

5104

PS/PSH

03  Service

Table 13. Hydraulic system Hydraulic system Inspection points Symptom

Inspection

A Service

Service code

Hydraulic fluid tank Oil level

Visual, filling

X

6012, 6102

Damage, leakage, contamination

Visual, cleaning

X

Filter blocked

Visual, replace

X

Functionality

Function test, stop X watch

Damage

Visual, replace

X

Leakage

Visual, tools, replace

X

Weld damage

Visual, tools, replace

X

Damage, chain attachments

Visual, tools

X

Leakage, damage

Visual, tools

X

Attachment

Visual, tools

X

Nipples

Leakage

Visual, tools

X

6019

Pump motor

Function, noise

Visual, tools

X

7030, 7029

Cable connections Visual, tools

X

Leakage

Visual, tools

X

Damage

Visual, tools

X

Noise

Listen

X

Malfunction

Test

X

Leakage

Visual, tools

X

Malfunction

Test

X

Leakage

Visual, tools

X

Malfunction

Test

X

Leakage

Visual, tools

X

Cylinders

Hoses

Hydraulic pump

Overflow valve Solenoid valve Prop. valve

6001, 6017

6007, 6008

6109

6105 6018 6018

For more information regarding the hydraulic system, see also Section 08, page 70 and Section 09, page 94. Table 14. Electrical system Electrical system Inspection points Symptom

Inspection

A Service

Service code

Contactors

Malfunction

Visual, tools, replace

X

7107

Cable break

Visual, tools

X

Contactor tip

Visual, tools

X

Charging

Tools

X

Low acid level

Tools

X

Low acid weight

Tools

X

Damage

Visual

X

Battery

PS/PSH

7032

21

03  Service

Electrical system

3.1.10

Inspection points Symptom

Inspection

A Service

Service code

Transistor system AC.

Cable break

Visual, tools

X

7025

Cabling

Damage, break

Visual, tools

X

7007, 7009 7010, 7039 7104, 7112

Horn

Malfunction

Function test

X

7014

Speed Controller

Attachments

Visual, tools

X

7011, 7106

Malfunction

Function test

X

Calibration

X

Fuses

Blown

Visual, replace

X

7103

Battery plug

Malfunction

Function test, tools X

7008

Hour meter

Malfunction

X

7012

Battery indicator

Malfunction

X

7013

Safety circuit breaker.

Emergency stop

Malfunction

X

7020

Microswitch

Functionality

Function test

X

7017

ATC T4

Function, cable connections

Visual

X

7004

Code explanation Table 15. Chassis Chassis Code

22

Description

Check

Reference

1001

Machine housing

Cracks in weld joints, collision damage, tightening of screws/attachments.

Section 01, page 1

1024

Machine plate

Attachment: text must correspond with machine type, and symbols and warning decals must be present.

Section 01, page 1

1032

Panels

Attached with screws and clips, as well as bonded parts.

Section 04, page 31

1033

Colour

Paint scrapes and attachment/missing decals. Section 01, page 1

1042

Load Guard

Cracks in welded joints, collision damage, tightening of screws/attachments.

Section 01, page 1

1058

Rubber strips

Attached with glue or screws/weld bolts.

-

1101

Decals

Damage.

-

1102

Chassis, covers

Damage, battery cover

Section 04, page 31

1108

Section 04, page 31

1109

Load wheel bearing The operation is frictionless, remove any string, plastic bands etc. that have stuck. Castor wheel Vulkollan wheel wear. Dirt. bearing

1112

Accessories

-

User Manual, areometer and battery water bottle.

Section 06, page 44

PS/PSH

03  Service

Table 16. Mast Mast Code

Description

Check

Reference

2004

Frame section

Mast attachment to machine housing.

Section 01, page 1

2007

Rollers in fork carriage

Washers. Lubrication of roller surfaces.

Section 01, page 1

2026

Forks

Cracks, damage, parallelism , height above floor level.

Section 06, page 44

2101

Mast play

Check maximum play, Cams. Lubricate slide surfaces.

Section 06, page 44

2102

Lift chains

Check wear.

Section 04, page 31

2105

Push rods / Pull rods

Locking, damage.

Section 06, page 44

Section 06, page 44

Table 17. Drive unit Drive unit Code

Description

Check

Reference

3002

Drive wheel

Damage, wear. Clean.

Section 05, page 36

3005

Drive wheel bolt

Attachment.

Section 05, page 36

3006

Oil leakage

Leakage from shafts, joints, plugs or material.

Section 05, page 36

3101

Oil level

Oil level. Oil change.

Section 01, page 1 Section 05, page 36

3102

Noise

Gears.

Section 05, page 36

3103

Sliding bearing

Noise, lubrication needed.

Section 05, page 36

3104

Drive shaft

Tightening,play.

Section 05, page 36

3106

Gears

Gear ratio

Section 05, page 36

3107

Gear housing

Check wear.

Section 05, page 36

Table 18. Steering Steering Code

Description

Check

Reference

4103

Tiller arm attachment

Play, bushings, attachment

Section 07, page 63

4104

Steering Bearing

Play, lubrication

Section 01, page 1 Section 07, page 63

Table 19. Brake unit Brake unit Code

PS/PSH

Description

Check

Reference

5002

Brake cable

Attachment, damage.

Section 11, page 230

5012

Braking force

Braking distance

Section 11, page 230

5014

Parking brake

Function, cable connections.

Section 11, page 230

5104

Brake discs

Friction surface greater than minimum level all round.

Section 11, page 230

23

03  Service

Table 20. Hydraulic system Hydraulic system Code

Description

Check

Reference

6001

Lift cylinders

Leakage at attachments, welded joints, wiper seals, piston rod.

Section 09, page 94

6007

Couplings

Leakage.

-

6008

Hoses

Cracks, wear, damage.

Section 01, page 1

6012

Oil level in tank

Oil level between min. and max.

Section 01, page 1 Section 08, page 70

6017

Lowering

Check lowering speed.

Section 08, page 70

6018

Solenoid

Leakage at the slide. Connections. Tightening.

-

6019

Nipples

Leakage. Tightening.

-

6102

Filter

Replacement necessary.

Section 08, page 70

6105

Pressure relief valve

Function, setting to maximum lift capacity. Locking.

Section 08, page 70

6109

Hydraulic pump

Leakage between pump and motor.

-

Table 21. Electrical system Electrical system Code

24

Description

Check

Reference

7004

Truck computer

Error log.

Section 10, page 107

7007

Battery cables

Attachment, damage.

-

7008

Battery connections That cable connections are not overheating. Remove oxide.

7009

Main power cable

Attachment, damage.

-

7010

Control cable

Attachment, damage.

-

7011

Speed Controller

Function.

-

7014

Horn

Operation. Oxide deposits.

7017

Microswitch

Operation. Attachment.

7020

Emergency switch

Function.

7025

Transistor system

Dirt, moisture. Cable connections. Oxidation.

7029

Pump motor carbon Wear. brushes

Section 08, page 70

7030

Pump motor

Attachment. Cleaning.

Section 05, page 36

7032

Battery

Acid level, charging. Note: read-off from hydrometer, clean if necessary.

7035

Speed switch

Switches in gates and platform that control creep speed. Attachment.

Section 10, page 107

7103

Fuses

That they are not brittle, oxidised.

Section 01, page 1

7104

Cabling

Cable connections, attachment, run free from sharp edges. Insulation.

7106

Speed Controller

Attachment and function.

Section 11, page 230

7107

Contactors

Contact surfaces, cable connections, dust guard.

-

7112 7039

Traction motor cables

Attachment, damage. Insulation. Oxidation. Cleaning.

-

PS/PSH

03  Service

Electrical system Code

Description

Check

Reference

7113

Storage of traction motor

Noise, grease, play.

Section 05, page 36

7004

Truck computer

Error log.

Section 10, page 107

3.1.11

Lubrication chart

3.1.11.1

General NOTE! For recommended oil and grease types, see Section 1.7, page 10.

PS/PSH

25

03  Service

3.1.11.2

PS

Figure 7. Lubrication chart.

26

PS/PSH

03  Service

3.1.11.3

PSH

1.

500 hour service   

2.

Annual service   

Servicing consists partly of servicing that is required due to how heavily the truck is loaded an how often it is used (see Section 3.1.9, page 19), and partly of annual routine servicing.

3.1.11.4

PS/PSH

Components requiring lubrication Location

Explanation

Location

Explanation

A1

Mast profile roller surfaces and G slide surfaces

Castor wheel - sliding bearing, grease nipple

A2

Thrust rollers

H

Speed and brake controls - slide surfaces and springs

B

Lift chains

I

Steering arm - gas spring

C

Straddle legs

J

Steering arm housing

27

03  Service

3.1.11.5

Location

Explanation

Location

Explanation

D

Fork carriage

K

Hydralic tank

E

Bogie wheel

L

Guide ring

F

Battery rollers

M

Gearbox

Symbol key, lubrication chart Table 22. Symbols in the lubrication chart Symbol

Explanation

Symbol

Explanation

Hydraulic oil

Hydraulic oil, oil filter and air filter, change

Gearbox oil

Gearbox oil, change

Grease

Chain spray

Chain spray/oil

Only cold store version

Applicable in general for the symbols: • •

Unfilled symbol: Check/lubricate Filled symbol: Replacement

3.2

Specific instructions

3.2.1

Storage of machines and motors Machines in storage that will not to be used within one month, must be given special attention so that problems do not occur when they are to be used again. Dust, dirt, condensation and moisture caused by large changes in temperature and problems with rust and oxidisation must be prevented. Motors should therefore be protected with waxed paper or the like, and a moisture absorbing material.

3.2.2

Traction motor Preventive maintenance Preventive maintenance is implemented at the recommended intervals in accordance with the service chart. In some cases, however, exceptions must be made and the intervals shortened in relation to the conditions at the customer, e.g. a severe environment with dust, high humidity levels, or salt, etc. • •

•

3.2.3

Listen for abnormal noise from the bearings while the motor is running. Check that it does not vibrate abnormally. The motor is blown clean with dry compressed air, or cleaned with a vacuum cleaner. If oil has leaked from the gearbox into the motor, a special cleaning fluid must be used to drive out oil and dirt, see Section 02, page 17. Finally, blow dry with compressed air. Check the insulation resistance of the motor, see Section 1.6, page 10 for the correct value.

Gearbox First service After about 25 hours of operation:

28

PS/PSH

03  Service

• • •

Tighten the wheel nuts. Inspect for possible damage, leaks and the oil levels. Tighten the securing bolts between the motor and gearbox.

After about 200 hours of operation: • •

The first oil change must be made after 200 hours. Top up with the recommended type of oil, see Section 1.7, page 10.

After approx. 1500 hours of operation, or at least once a year (whichever comes first): • •

Oil change Inspect for possible damage, leaks and the oil levels.

Preventive maintenance • The oil level is checked during each service. • The guide bearing must be greased at least once a year. New greasing is essential if steam cleaning or high-pressure washing has been carried out. • In the case of operation in a dusty or damp environment, (such as a cold store), the steering bearings must be re-greased twice per month. NOTE! Remember to fill up the gearbox after changing the oil or changing the gearbox. Se Section 05, page 36 for the procedure. NOTE! Spent oil should be taken care of and recycled according to the applicable legislation in respective countries.

3.2.4

Lift chains and forks Check For safety reasons the forks and all lifting chains should be checked during each service. Section 3.1.9, page 19. If a lifting chain fails to be approved in any respect, the complete chain must be replaced and it is not permitted to replace single parts of a lifting chain. NOTE! If the lifting chain is not up to standard at any point, the complete chain must be replaced. See Section 6.2.3, page 54 for instructions concerning the checking of chains and forks. Regular maintenance The chain should be kept clean. Lubricant (see Section 3.1.9, page 19) must be regularly applied on the chain so that all the working surfaces are constantly lubricated. The chains must be kept in motion when lubricating to ensure that the lubricant penetrates the working surfaces between the link plates and pins. All excess lubricant must be wiped off, but solvent must not be used. If the chain runs dry it should be lubricated more often, and this also applies if the truck is working in special environments such as cold stores, etc.

PS/PSH

29

03  Service

3.2.5

Hydraulic oil NOTE! For recommended oil and grease types, see Section 1.7, page 10. Intervals After 500 hours of operation: The hydraulic oil tank air filter must be changed after no more than 500 hours of operation. Clean the suction filter. After every 1000 hours of operation: Change the hydraulic oil after 1,000 hours of operation, or once every year (whichever comes first). If the hydraulic oil has been heated over 60 degrees Celsius the oil and the filter should be immediately changed since its lubricating properties will have been altered. If the hydraulic oil has been contaminated with water (e.g. from cold store) this can be detected in that the oil becomes milky, or smells bad. Hydraulic oil must be filtered when filling.

3.2.6

Recommended replacement Hydraulic hoses should be replaced after 5 years, since the rubber in the hose is perishable.

30

PS/PSH

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 44.

4.1.2

Machine housing The chassis consists of a machine housing. This is where all the truck components, such as the mast, drive unit, and hydraulic system are mounted.

Figure 8. PS chassis

4.1.3

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.

4.1.4

Caster wheel The castor wheel functions as a support wheel, since the drive wheel is mounted asymmetrically on one side of the truck. The caster wheel is a completely separate and free-turning wheel placed under the machine housing. It consists of a wheel mounted in a wheel fork. The caster wheel is sprung to maintain good contact with the floor surface and to reduce noise. 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.

PS/PSH

31

04  Chassis

4.2

Repair and maintenance instructions

4.2.1

Covers and panels

4.2.1.1

General The recyclable panels are manufactured of sheet metal and durable plastic.

4.2.1.2

Dismantling of panels • • •

32

Remove the panels with an Allen key, size 5. Clean the panels using a soapy water solution. White impact marks may appear with minor damage. These can be removed by carefully heating with a hot air gun.

PS/PSH

04  Chassis

4.2.2

Caster wheel

4.2.2.1

Removing the caster wheel/bearing

Figure 9. Caster wheel

1)

Remove the plastic cover from the machine housing.

2)

Lift up the machine housing approx. 30 cm, and secure with blocks underneath.

3)

Remove the bolts, item 1, Figure 9, page 33.

4)

Take out the caster wheel assembly and support the fork in a vice.

5)

Remove the bolt, (item 2), and drive out the wheel axle, (item 3), so that the wheel can be removed from the fork. NOTE! Re-use the spacers and shims.

4.2.2.2

PS/PSH

6)

Support the wheel in the vice.

7)

Pull out the bearings with a bearing extractor.

Fitting the caster wheel/bearing 1)

Lubricate the wheel bearing seats with grease, and press in the bearings with a suitable drift.

2)

Lay the wheel fork with the side facing down.

3)

Hold the wheel and spacers together, and insert the wheel in the fork.

4)

Fit the wheel axle (item 3).

5)

Fit the bolts (item 2). 33

04  Chassis

6)

Lift up the complete castor wheel under the machine housing. Fit the screws (item 1). NOTE! Check the positioning to make sure the grease cup comes in the right direction.

7)

Tighten to the correct torque.

8)

Refit the covers and lower down the machine to the floor.

4.2.3

Battery

4.2.3.1

Battery replacement PS Work in an area where the old battery can be removed without risk to the environment from battery acid. Wear acidproof gloves and clothes, plus acidproof glasses, to provide protection from burn injuries. WARNING! Take care not to splash waste acid or oxide from the battery.

4.2.3.2

1)

Separate the battery plug.

2)

Open the battery cover.

3)

Attach the lifting device in the lifting eyes.

4)

Lift the battery and set it to one side.

Battery replacement PSH NOTE! A battery carriage must be used when changing battery. WARNING! Take care not to splash waste acid or oxide from the battery.

34

1)

Remove the battery plug

2)

Open the battery cover.

PS/PSH

04  Chassis

4.2.3.3

3)

Open the battery door using the battery key.

4)

Roll out the battery on the battery carriage.

Replacing the battery rollers 1)

Remove the battery. WARNING! Take care not to splash waste acid or oxide from the battery

2)

PS/PSH

The battery rollers are loose in their attachments.

35

05  Drive unit

05

DRIVE UNIT

5.1

Design and function

5.1.1

Introduction The drive unit is mounted in an assembly containing the brakes, drive motor, gearbox and drive wheel. The steering servo motor is mounted on the same motor bed. For technical data regarding the component parts, see Section 01, page 1.

1. 2. 3. 4. 5.

5.1.2

Wheel nuts    Wheel axle    Gearbox housing    Drive wheel    Centre bearing   

6. 7. 8. 9.

Traction motor    Upper oil plug    Lower oil plug    Grease nipple for centre bearing   

Traction motor The dive motor is a three phase asynchronous motor. A pulse transducer is enclosed in the bearing on the non-driving end of the motor and this provides speed feedback to the traction controller, see Section 10, page 107. The motor is mounted directly on the gearbox and the transmission of power takes place via individually adjusted gear wheels.

5.1.3

Gearbox The gearbox is designed to produce the best gear ratio over the speed range of the traction motor.

36

PS/PSH

05  Drive unit

5.2

Maintenance and repair instructions

5.2.1

Introduction NOTE! Only relevant for Sauer-Danfoss/ZF traction units. For field service it is important to know that the turning bearing (item C) and the gearbox (item D) will fall down when all motor screws (item X) are removed from the motor housing (item A). The cover (B) stays with the axle body, or rather with the machine housing since it is separately attached. When servicing the traction unit the gearbox must be secured to make sure that it cannot fall down and cause personal injury.

5.2.2

Preparatory work 1)

Switch off all electrical power.

2)

Remove the panels on the machine housing, see Section 4.2.1.2, page 32.

5.2.3

Traction motor

5.2.3.1

General The traction motor is mounted on the top of the inner ring in the guide bearing, with a total of eight screws. During all maintenance work on the bearing block it is important to observe care during assembly and dismantling to avoid damaging the bearing and shaft seal. Special attention should also be paid to the gear wheel, since damage to this can result in abnormal noise.

5.2.3.2

Motor screws Since the motor screws (item X) are secured with Loctite the recommended tool to loosen the screws is an Allen key with guide point in accordance with DIN 6911. Torque The motor bolts (item X) must be tightened to a torque of 10.9 Nm.

PS/PSH

37

05  Drive unit

Figure 10. Motor screws (M8x35mm/DIN 6912).

5.2.3.3

Assembly of the transducer bearing When fitting the transducer bearing (item 1) in the upper housing on the motor it is very important that it is pressed into place. The transducer bearing must not be exposed to any form of shock loads. It is also important that the pressure is applied directly on the outer bearing ring. No pressure must be applied on the inner bearing ring.

Figure 11. Transducer bearing in the traction motor.

CAUTION! The transducer bearing must not be exposed to any form of shock loads. Once the transducer bearing is in position in the upper housing it is secured with its lock ring and the extra protective ring, and with the screws and underlying lock rings. After fitting the transducer bearing the rotor shaft is pressed into the inner bearing ring. It is important not to expose the outer bearing ring to pressure, and this is achieved in that the inner bearing ring receives counter pressure during the pressing. 38

PS/PSH

05  Drive unit

The assembly of the rotor shaft is complete when the unit is fixed by the circlip in its groove.

5.2.3.4

Assembly of ball bearing and shaft seal in the guide bearing inner ring/gear box upper housing The ball bearing (item 2) is pressed into place in the inner ring on the guide bearing. The pressure must be applied on the outer bearing ring to avoid damaging the balls and ball races. The bearing is secured by fitting a circlip (item 3) in its groove. The shaft seal can now be fitted.

Figure 12. Ball bearing and circlip

When assembling the complete motor on the gearbox the inner ring on the guide bearing and the inner surface shaft seal should be protected with grease to avoid damage, especially on the sealing surface.

5.2.3.5

Storage of traction motor Machines in storage that will not to be used within one month must be given special attention so that problems do not occur when they are to be used again. Dust, dirt, condensation and moisture caused by large changes in temperature and problems with rust and oxidisation must be prevented. Motors should therefore be protected by waxed paper or the like, together with a moisture absorbing material.

5.2.3.6

External Speed Sensor Assembly The external sensor is mounted on the outside of the traction motor which makes it easy to maintain and repair.

PS/PSH

39

05  Drive unit

Figure 13. External speed sensor

The traction motor control unit uses the feedback information about the actual speed and direction of motor rotation. The sensor is a two-channel Hall effect tacho sensor with two phases 90 degrees apart. The sensor detects the movement of ferromagnetic structures, such as gears, by sensing changes in the magnetic flux. Wheel teeth and gaps which move past the sensor affect the magnetic field in different ways. The output signal from the sensor is a square wave which reflects the changes in magnetic flux.

5.2.4

Gearbox

5.2.4.1

General

Service work on the gearbox is limited to changing the wheel studs on the wheel and changing the lower shaft seal.

5.2.4.2

Changing the wheel studs Torque After removing the wheel stud that is to be changed the threads on the new wheel stud and the threads in the hole should be cleaned from oil and grease. The threads should be treated with Loctite 270 or the equivalent before the new wheel stud is screwed in. The stud must be tightened to a torque of 25 Nm.

40

PS/PSH

05  Drive unit

5.2.4.3

Service and fitting of the lower shaft seal on the gearbox The shaft seal can be removed after removing the protective disc. The seal seat in the casing and the surface to which the seal is to seal should be cleaned before fitting a new seal. The seal should also be greased before it is fitted. The protective disc is replaced after fitting the shaft seal.

5.2.4.4

5.2.4.5

Applying more grease to the centre bearing in the gearbox upper housing 1)

Locate the two grease nipples (item 9) on the side of the gearbox upper housing.

2)

Use a hand grease gun to apply grease while rotating the gear.

3)

Turn the gear several times to spread the grease evenly.

4)

Remove any surplus grease from the centre bearing.

Checking the oil level and filling up with oil Oil is poured in through the upper filler screw hole (item 7). The correct level is at the lower edge of the hole. The oil level should be regularly checked to avoid damaging the gearbox. Torque Tighten the oil plug to a tightening torque of 22 Nm.

5.2.4.6

Oil change The oil is drained out through the lower oil plug hole (item 8). The oil can be drained more easily if it is warm. Spent oil should be taken care of and recycled according to the applicable legislation in respective countries. Torque Before screwing in the oil plug again it should be cleaned. Tighten the plug to a tightening torque of 22 Nm.

5.2.5

Drive wheel

5.2.5.1

Replacing the drive wheel

PS/PSH

1)

Lift up the truck so that the drive wheel can rotate freely.

2)

Release the battery plug.

3)

Turn the drive wheel 45°.

41

05  Drive unit

4)

Loosen the wheel nuts.

5)

Replace the drive wheel.

6)

Tighten the wheel nuts. Torque Use a tightening torque of 80 Nm.

7)

Start the truck and test drive in both directions. The wheel must not catch or jam.

5.3

Diagnostics and trouble shooting

5.3.1

Troubleshooting chart Symptom

Cause

Procedure

The wheel has a flapping sound when driving.

The tyre has separated due to an 1. impact. 2.

Change the wheel. Examine the floor for any irregularities.

The wheel squeaks continuously Bearing is damaged. when driving.

1.

Replace bearing.

2.

Inform the driver that string and plastic etc. should be removed daily, and the floor kept clean.

The wheel is flat after long The wheel mass has become breaks, but becomes round after warm while driving and deforms driving for a while. when parked.

Try a different type of wheel.

The wheel has a deformity that A “blow out” has taken place due Change the wheel. does not disappear when driving. to overheating and changed the molecular structure of the wheel mass. The truck seems to jerk when driving.

Hard foreign object has fastened 1. in the drive wheel.

The truck jumps at regular intervals, proportional to the speed, when driving.

The wheel is oval.

The wheel has transverse The wheel has been heated. cracks, and small bits have fallen Small cracks appear with hard out of the tyre. acceleration and reversing.

The wheel has one or more small deformations.

Oil on the floor.

Remove the object or change the wheel.

2.

See also items above.

1.

Change the wheel.

2.

Check/adjust the brake.

3.

See also items above.

1.

Adjust to reduce the acceleration and reversing rate.

2.

Change the wheel if necessary.

Locking of the brakes so that the 1. wheel slides, or loose objects on the floor that prevent the wheel 2. from rotating.

Remove objects on the floor.

Leaking seal around the drive axle.

Replace seal

•

Tell the driver to brake more smoothly.

or: •

If there are cracks in the casting the gearbox must be replaced.

Grating noise when accelerating Defective gear wheel in the drive Check the teeth by removing the or using the reversing brake. unit. cover. Too little oil in the gearbox.

42

If there are cracks in the casting the gearbox must be replaced.

PS/PSH

05  Drive unit

Symptom

Cause

Procedure

Grating noise when the truck is Faulty bearing in the traction lifted up and the drive wheel can motor. rotate freely and the motor rotates.

Dismantle and renovate the traction motor.

The truck rolls "sluggishly".

•

The brakes are applied.

Replace brake disc.

If this does not help: •

replace the complete brake unit.

The drive unit has seized.

If there are cracks in the casting the gearbox must be replaced.

Clicking sound when driving.

Faulty wheel bearing.

Change the wheel.

Clicking sound when driving.

Loose wheel.

•

Tighten the wheel.

If this does not help: •

PS/PSH

Change the wheel.

43

06  Mast system

06

MAST SYSTEM

6.1

Design and function

6.1.1

Mast system

6.1.1.1

General There are four mast types as standard, depending on the application or roof height etc. Table 23. Mast types Designation

Description

PS

PSH

–

160

T

Telescopic mast

TV

Telescopic Free-view mast

125

160

TFV

Telescopic Free-lift Free-view mast

125

160, 200

DTFV

Double Telescopic Free-lift Free-view mast

–

160, 200

A telescopic mast consists of an outer and inner mast, fork carriage and lift cylinder. The fork carriage is lifted up and down in the inner mast, which in turn moves up and down in the outer mast. The lift cylinder first lifts the fork carriage approx. 15 cm, and then the mast system follows the lifting movement. A mast of the double telescopic type also has, in addition to an inner and outer mast, an intermediate mast. The lifting movement is the same as for a telescopic mast, and all the masts begin to move up (or down) simultaneously. A mast type with free-lift function works in a similar way, but with the difference that the fork carriage moves to its top position in the inner mast before the next mast section starts to lift. Free-lift frames can be used to advantage in rooms with low ceilings or low door openings. A mast of the free-view type implies that the distance between the mast profiles is longer, which gives better visibility. PSH 160 is available with adjustable straddle legs.

6.1.2

Fork carriage Different fork arrangements are mounted on the back of the fork carriage. Fixed forks Forks with a fixed width and length.

Figure 14. Fork carriage with fixed forks

Laterally adjustable forks The forks can be adjusted to different widths.

44

PS/PSH

06  Mast system

Figure 15. Fork carriage with laterally adjustable forks

6.1.3

Straddle lift Straddle lift means that the straddle legs can be raised sufficiently high to lift a pallet from the floor. On masts with straddle lifting, pallets can be transported by the fork carriage. And if the fork carriage is raised high enough, it is possible to transport a pallet directly on the straddle legs. This enables two pallets to be transported at the same time

Figure 16. Straddle lift

PS/PSH

45

06  Mast system

6.2

Repair and maintenance instructions

6.2.1

Replacing the mast/straddle legs

6.2.1.1

Dismantle the mast/straddle legs from the chassis 1)

Remove the battery.

2)

Block up the chassis.

Figure 17. Blocking up the chassis

3)

Support the mast to relieve the attachment

Figure 18. Supporting the mast

If the mast has straddle lift:

Figure 19. Straddle lift

46

PS/PSH

06  Mast system

4)

Screw a screw into one of the screw holes on the spacer between the guide and chassis in order to hold up the spacer when dismantling.

Figure 20. Screw, spacer/guides

5)

Remove the screws attaching the mast to the chassis.

Figure 21. Upper screw attachment, mast

6)

Detach the hydraulic connections. CAUTION! Contain surplus hydraulic oil in a suitable way

PS/PSH

47

06  Mast system

Figure 22. Hydraulic connection

6.2.1.2

Mount the mast/straddle legs on the chassis 1)

Make sure that the mast is suitably supported so that it cannot move

Figure 23. Example of supported mast

2)

If the mast has straddle lift: Make sure to screw tight the spacer between the mast and chassis in the guide in one of the screw holes that are not used.

Figure 24. Screw, spacer/guides

48

PS/PSH

06  Mast system

3)

Insert a suitable number of shims. Normally 3.

Figure 25. Shims

4)

Lower the mast so that the link arms slide in under the chassis when the mast and chassis are brought together.

5)

Connect the hydraulic couplings together.

6)

Bring the mast and chassis together and tighten the screws.

7)

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm. If the mast has straddle lift:

8)

Remove the screw holding the spacer to the guides.

Figure 26. Remove screw, spacer/guides

9)

Check that there is sufficient clearance between the floor and forks, see Section 6.2.6.1, page 60.

6.2.2

Replacing mast

6.2.2.1

Dismantling and assembling the masts The following is generally applicable for all types of masts when dismantling: •

Stand in an area with adequate ceiling height and with approved lifting devices.

The following is generally applicable for all types of masts when assembling: •

The mast is assembled in the reverse order to dismantling.

Inspecting or repairing the mast system:

PS/PSH

49

06  Mast system

• •

6.2.2.2

Check that the thrust rollers bear against the roller surfaces on the mast. Also check that they roll easily. A function test must be made after each measure/action on the mast system. The mast must not jam or run slowly (the mast sections move in the wrong order) when lifting and lowering.

Adjustment of the side lean in the top position 1)

Lower the mast and slacken the chains.

2)

Adjust the attachment of the outer cylinders with the top nut (item 1). Adjust both cylinders equally so that the mast does not pull skew.

3)

If there is sufficient movement in the cylinder attachment, the rollers will be in contact with the running surfaces of the mast at all lifting heights.

4)

Test the operation of the lifting movement. Lift up to top position and check that the mast does not swing to the side when the end position is reached.

5)

Lock the top nut with the locking screw (item 2).

6)

Tighten the chain and check that the rollers still make contact with the running surface.

7)

The cylinder attachment should be flexible.

8)

Adjusting the mast, see Section 6.2.2.3, page 50.

Figure 27. Attachment of outer cylinder

6.2.2.3

Adjusting the play in the mast The lateral play is adjusted with 0.5 or 1 millimetre shims behind the thrust rollers. If there is excessive play between thrust roller and roller surface on the mast profile, the thrust roller must be replaced with a new roller with a larger diameter. Thrust rollers are available in three different diameters (the diameter is specified on each roller): 160 mast: •

50

78.2 mm, 78.6 mm 79.0 and 79.4 mm. PS/PSH

06  Mast system

200 mast and TF-mast: •

6.2.2.4

107.0 mm, 107.5 mm 108.0 mm, and 108.5 mm. Mast type

Permitted play between thrust rollers and roller surfaces between mast sections and fork carriage and mast

160

0,5 mm

200

0,6 mm

Replacing T mast 1)

Lower the fork carriage onto a European pallet, or equivalent, so that the intermediate cylinder lift chain slackens.

2)

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and removing the pin between the bolt and chain.

3)

Lift until the fork carriage comes free from the inner mast.

4)

Lower the mast to its bottom position.

5)

Secure the lift cylinder so that it cannot move sideways.

6)

Remove and plug the oil pipes.

7)

Release the upper retaining bolts on the lift cylinder from the inner mast.

8)

Remove the lower retaining screw.

9)

Carefully lift up the inner mast until it can be lifted out from the cylinder.

10) Lift the inner mast straight up until the inner mast's lower support roller and the outer mast's upper support roller meet. Then pull the inner mast forward to release it from the outer mast. If the ceiling is too low dismantle the mast, see Section 6.2.1.1, page 46, and set it down.

Figure 28. Position for dismantling intermediate masts

11)

6.2.2.5

PS/PSH

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm.

Replacing TV mast 1)

Lower the fork carriage onto a European pool pallet, or equivalent, so that the lifting chains slacken.

2)

Release the lift chains from the outer mast by removing the upper pins.

51

06  Mast system

3)

Lift until the fork carriage comes free from the inner mast.

4)

Lower the mast to its bottom position.

5)

Remove the upper retaining screws for the side cylinders.

6)

Lift the inner mast straight up until the inner mast's lower support roller and the outer mast's upper support roller meet. Then pull the inner mast forward to release it from the outer mast.

Figure 29. Position for dismantling intermediate masts

7)

6.2.2.6

52

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm.

Replacing TFV mast 1)

Lower the fork carriage onto a European pallet, or equivalent, so that the intermediate cylinder lift chain slackens.

2)

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and removing the pin between the bolt and chain.

3)

Lift the mast until the fork carriage comes free from the inner mast.

4)

Lower the mast to its bottom position.

5)

Release the hose from the outer mast and plug it. Remember to remove the cable ties.

6)

Remove the upper securing screws for the side cylinders.

7)

Lift the inner mast straight up until the inner mast's lower support roller and the outer mast's upper support roller meet. Then pull the inner mast forward to release it from the outer mast.

PS/PSH

06  Mast system

Figure 30. Position for dismantling intermediate masts

8)

6.2.2.7

PS/PSH

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm.

Replacing DTFV mast 1)

Lower the fork carriage onto a European pallet, or equivalent, so that the intermediate cylinder lift chain slackens.

2)

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and removing the pin between the bolt and chain.

3)

Lift the mast until the fork carriage comes free from the inner mast.

4)

Place a wooden block on the straddle legs between the outer profiles so that it comes under the intermediate cylinder. Lower the inner and intermediate mast so that the inner mast rests on the wooden block and the outer chains slacken.

5)

Remove the two outer chains by removing the pins in the upper chain attachment.

6)

Release the hoses that run in the mast from the block in the outer mast, and plug them.

7)

Remove the pulley wheel for the hoses from the intermediate mast.

8)

Remove the pulley wheel for the chains from the intermediate mast.

9)

Unscrew the screw for the lifting stop.

53

06  Mast system

Figure 31. Screw, lifting stop

10) Lift the inner mast straight up until the inner mast's lower support roller and the intermediate mast's upper support roller meet. Then pull the inner mast forward to release it from the intermediate mast. If the ceiling is too low dismantle the mast, see Section 6.2.1.1, page 46, and set it down.

Figure 32. Position for dismantling intermediate masts

11) Remove the upper retaining screws for the side cylinders. 12) Lift out the intermediate mast in the same way as the inner mast. 13)

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm.

6.2.3

Lift chains

6.2.3.1

Replacement 1)

54

Remove any stop screw in the inner mast. PS/PSH

06  Mast system

6.2.3.2

2)

Lower the fork carriage onto a European pool pallet, or equivalent, so that the lifting chains slacken.

3)

Remove the lift chain.

Re-fitting the chains When chains are re-fitted it is important to align them correctly, and that there is no deterioration of the clearance.

6.2.3.3

Checking the lift chains For safety reasons, all the lift chains should be checked at maximum intervals of 1000 hours of operation. If the lifting chain is not up to standard at any point, the complete chain must be replaced. It is not permitted to change any part of a lift chain. • •

Check that the chain is clean. Measure when the forks are unloaded. Measure the chain elongation. Measure along the 25 links that go over the pulley wheel, since elongation is normally greatest here. Compare with the measurements below, If the chain has stretched by more than 2% it must be replaced.

Figure 33. Chain dimensions 1.

Nominal pitch dimension   

Chain dimensions (inches)

2.

Height of the chain's link plate   

Nominal pitch dimension (mm)

Actual pitch dimension (mm)

Measured over 25 links New chain (mm)

Maximum stretch over 25 links is 2% (mm)

Measurement 1 in figure above

Measurement 1 in figure above

1/2”-2*2

12.70

12.59

314.75

321.05

5/8”-4*4

15.88

15.875

396.88

404.81

3/4”-3*4

19.05

19.05

476.25

485.78

3/4”-4*4

19.05

18.91

472.75

482.21

1”-4*4

25.40

25.32

633.00

645.66

1 1/4”-4*4

31.75

31.54

788.50

804.27

1 1/2”-4*4

38.10

38.06

951.50

970.53

•

Measure the height of the chain's link plates, measurement 2 in Figure 33, page 55. Max. wear is 5%. Measure the original height where the chain is not worn as a comparison.

Example: A chain has an original plate height of 23.2 mm. Therefore the plate height must be at least 23.2 - 5% = 23.2 x 0.95 = 22 mm.

PS/PSH

55

06  Mast system

•

Make sure than none of the pins in the plates have twisted.

Figure 34. Chain pin A. Correct pin   

• • • •

B. Twisted pin   

Make sure that there are no cracks in the plates. Look for traces of mechanical damage or rust. Check that the chain runs easily over the pulley wheel and does not jam. Lubricate the chain after cleaning and inspection. For the recommended types of oil and grease, see Section 1.7, page 10.

6.2.4

Forks

6.2.4.1

Adjusting the lowest height on forged forks

6.2.4.2

1)

The inner and outer masts should be lowered.

2)

Adjust the two outer lifting chains so that the mast just hangs a little from them.

3)

Adjust the middle chain so that the fork head is 5 ± 2 mm from the ground.

Adjusting the lowest height on welded forks 1)

The inner and outer masts should be lowered.

2)

Adjust the two outer lifting chains so that the mast just hangs a little from them.

3)

Adjust the lifting chains so that the fork height is as shown in the table. Fork height in lowered position: Table 24. Height of forks over floor in rest position Mast type

Min

Max (mm)

85

95

PSH 160

controlled by ground clearance

89

PSH 200

controlled by ground clearance

91

PS

6.2.4.3

Inspection of forged forks

6.2.4.3.1

General CAUTION! Inspection of the forks must be carefully performed by trained personnel.

56

PS/PSH

06  Mast system

The purpose of the inspection is to detect damage, faults, deformation, etc. Forks showing this type of damage may not be used before they have been repaired and tested in accordance with ISO 2330. Several test points are included in the fork inspection. A fork inspection in accordance with ISO/ 5057 must be carried out on at least one (1) occasion per year on forks that are in use; if deformation, damage or other permanent changes are discovered at any other time, an inspection must be carried out immediately. If the forks are often used for heavy lifting, the fork inspection interval may be shorter. If the forks fail to meet any of the inspection points, the machine must be taken out of service. If the customer is not prepared to do this, it should be written in the report that: "The forks do not comply with the requirements in ISO/ 5057". When the customer subsequently signs the service order, they bear the responsibility for the defective forks. In case of doubt, comply with the requirements set by the applicable ISO standard or by the fork manufacturer. See table.

6.2.4.3.2

The fork blade is bent

ISO/5057

Crack formation

ISO/5057

Wear

ISO/5057

Fork tip

Fork manufacturer

Fork angle

Fork manufacturer

Difference in height between the tips of the forks

ISO/5057

Locking device

ISO/5057

Worn fork hook

ISO/5057

Fork labelling

ISO/5057

The fork blade is bent

A. Ruler   

B. Deformation location   

The fork blade must not be bent downwards by more than a certain proportion of the length of the fork. l= fork blade length in mm. k= measurement in mm between the fork blade tips and a ruler. Measurement when a blade must be changed: greater than k=l/33. Example: k=1150/33= 34 mm.

PS/PSH

57

06  Mast system

6.2.4.3.3

Crack formation

A. Attachment hooks   

B. Heel   

Use a non-destructive method to check if there are cracks in the forks. Take extra care when checking around the insides of the holes and the securing hooks. If cracks are detected, the forks must not be used.

6.2.4.3.4

Wear

Figure 35. Wear/markings A. Fork labelling.    C. Wear in the fork heel.    B. Location for measuring the shank thickness.   

Check the forks for wear, especially around the heel. If 10% of the original thickness of the fork has been worn away, the fork must not be used. Example: original thickness (n) = 40 mm -> limit after which the fork must not to used = 36 mm. (n)-10% = fork must be replaced. Worn forks must not be welded or repaired in any other way. The original thickness is found by: •

•

6.2.4.3.5

read the markings. The markings must show the lifting capacity in kg for one fork and the centre of gravity distance in mm. The markings often also show the original thickness. measure the blade thickness at the centre of the shank (position B).

Fork tip

As soon as a fork tip is worn, it must be shortened or the complete fork changed.

58

PS/PSH

06  Mast system

6.2.4.3.6

Fork angle

Measure 500 mm along the fork blade and 500 mm along the back of the fork and mark these positions. Measure the diagonal distance between these two points and use the table. The distance must be within the acceptable values in accordance with Table 25, page 59, otherwise the forks must not be used. Table 25. Fork angle

6.2.4.3.7

The results

Measurement result

Optimal

707 mm

Acceptable

695-713 mm

Difference in height between the tips of the forks

A. Difference in height between the forks   

The difference in height between the fork tips must not exceed 3% of the fork blade length. Example: fork length 1150 mm - max. height difference 34 mm. If the difference in height between the fork blades is greater than 3%, the forks must not be used.

6.2.4.3.8

Locking device

Figure 36. Locking device

The function of the locking device is to prevent the fork from moving sideways by itself. Check that the originally fitted locking device works as intended. If this is not the case, the forks must not be used until the fault in the locking device has been rectified.

PS/PSH

59

06  Mast system

6.2.4.3.9

Worn fork hook

Sideways forces and long periods of use can result in bent fork hooks. If this has occurred, the forks must not be used.

6.2.4.3.1 0

Fork labelling The fork markings must be clearly legible and include the lifting capacity in kg for one fork, and the centre of gravity distance in mm. If the markings are illegible, the forks must not be used. See Figure 35, page 58. Older forks do not have these markings, but may be used anyway. The prohibition applies to forks which have markings but are damaged.

6.2.5

Fork carriage

6.2.5.1

Adjusting the fork carriage 1)

The thrust rollers have a specific clearance to the roller surfaces.

2)

The lateral play is adjusted by adjusting the number of shims behind the load rollers, and by replacing the rollers. For the amount of permitted play, see Section 6.2.2.3, page 50.

6.2.5.2

Dismantling the fork carriage 1)

Lower down the fork carriage on to a Euro pallet, or equivalent.

2)

Remove the lift chain.

3)

Lift up the inner mast with truck’s standard hydraulic system until the fork carriage is released. CAUTION! Observe great caution!

4)

Reverse the truck away.

6.2.6

Straddle lift

6.2.6.1

Adjusting the straddle lift 1)

Place the truck on a level floor and lower the forks and the adjustable straddle lift.

2)

Check that the distance between the floor and top of the forks corresponds to Table 26, page 61. Measure at four points: • •

60

at each fork tip at the back of the fork on each side

3)

Check that the distance is the same between mast and guides. If necessary, adjust to the same distance with the adjusting screws, both at the top and bottom.

4)

The side play of the mast must not exceed 0-0.5 mm. Because of the tolerance in the linearity of the mast section a maximum amount of play of 1.5 mm is permitted at the

PS/PSH

06  Mast system

“worst point”, raised or lowered. This means that if for example the play is 0.5 mm with the straddle lift raised, the play with the straddle lift in its lower position should be max 1.5 mm, and the reverse. 5)

Check the play between the roller surfaces on the mast and guides. For permitted play see Section 6.2.2.3, page 50, 160 mast.

6)

Check that the forks are horizontal.

7)

If the fork tips point upwards, the shims over the pressure plate should be removed (on the assumption that the forks are straight).

8)

If the fork tips point downwards, shims should be added over the pressure plate (on the assumption that the forks are straight).

Figure 37. Positioning of shims

9)

When the forks are parallel, check the height. The cylinders can be extended if it is too small.

10) Test lift, and check that the straddle lift does not lift skew. If so, adjust the length of the cylinders until the best lifting movement is obtained. 11) Check measure, and if necessary make further adjustments. Table 26. Truck with straddle lift Truck with straddle lift Distance to top of fork

Max 95 mm

Distance to top of straddle leg

Max 90 mm Min 85 mm

6.2.6.2

PS/PSH

Dismantling and assembling of straddle lift 1)

Lift up the straddle lift with the truck. Place a block under the tips of the straddle lift and lower down the straddle lift. The load wheel thereby lifts up from the floor.

2)

Tap out the retaining pin through the shaft and drive out the shaft holding the wheel fork.

3)

Tap out the retaining pin at the pressure link arm and pull out the load wheel, pull rods and pressure link arm complete.

4)

Tap out the shafts from the ends of the pull rods.

5)

Check for wear and replace damaged parts if necessary.

6)

Install in the reverse order.

7)

Check the lifting movement. If the straddle lift pulls at an angle it must be adjusted. See Section 6.2.6.1, page 60.

61

06  Mast system

6.3

Diagnostics and trouble shooting

6.3.1

Troubleshooting chart Table 27. Symptom/Corrective action table Symptom

Possible cause

Corrective action

Play in mast.

Mast rollers are not shimmed enough.

Adjust shimming.

The mast lowers unevenly, and jerks.

Mast rollers are too severely shimmed.

Adjust shimming.

No lubrication on the mast roller surfaces.

Grease the roller surfaces.

No lubrication on the mast roller surfaces.

Grease the roller surfaces.

The mast squeaks.

62

PS/PSH

07  Steering

07

STEERING

7.1

Design and function

7.1.1

General The steering movement is transferred mechanically from the tiller arm directly to the traction unit.

7.1.2

Steering The truck is steered by turning the complete tiller arm, which directly affects the angle of the drive wheel. There is a switch in the arm, which by means of switching off the current and actuating the brake causes the truck to stop when the arm is in its upper and lower end positions. It is therefore only possible to drive the truck when the arm is between these end positions. There is also a belly switch, which stops the truck when pushed in. The purpose of the belly switch it to prevent the operator being crushed between the truck and other objects.

7.2

Maintenance and repair instructions

7.2.1

Cleaning The tiller arm and tiller arm head are cleaned with compressed air, or by vacuum cleaning. The covers can be cleaned with lukewarm water and a mild soap solution. CAUTION! High-pressure washing must not be used.

7.2.2

Tiller arm head (-2007w27)

7.2.2.1

Replacement

PS/PSH

1)

Remove the three screws (item 20), that secure the upper cover.

2)

Press in the belly safety switch (item 7), and release the cover by carefully pushing it upwards and outwards.

63

07  Steering

3)

Remove the two screws (item 15).

4)

Loosen the requisite connectors to replace the head.

5)

Refit in the reverse order. CAUTION! Lubricate all moving parts, except for axel through the circuit board. For the recommended types of oil and grease. refer to Section 1.7, page 10.

7.2.2.2

Gas spring

CAUTION! During service and preventive maintenance it is important to check that the steering arm is raised up automatically when the driver releases it. If this does not happen it should be reported to the truck supervisor, with the recommendation that the truck be taken out of service until the requisite measures have been implemented.

64

PS/PSH

07  Steering

WARNING! Care must be taken when dismantling the gas springs. 1. 2. 3.

Make sure that no other persons are in the vicinity, or in the lengthwise direction of the gas springs. Stand to the side of the gas spring when removing. Never point the gas spring toward any person or part of the body.

7.2.3

Tiller arm head (2007w28-)

7.2.3.1

Removal and installation of the tiller arm head 1)

Remove the three screws that hold the upper and lower covers together.

2)

Release the snap fastener (item A) furthest forward on the tiller head.

3)

Carefully lift up the front part of the upper cover (item B). Then move the upper cover backwards (item C).

4)

Lift the upper cover over to the right. The cover can now hang on the main cabling. CAUTION! Ensure that the programming cable is not strained.

5)

Refit in the reverse order. CAUTION! Ensure that no cables are trapped when the head is assembled.

PS/PSH

65

07  Steering

7.2.3.2

Removal and installation of the lift/lower buttons 1)

Open the tiller arm head in accordance with Section 7.2.3.1, page 65

2)

Remove the buttons by releasing the snap fasteners from inside in accordance with the illustration.

Figure 38. Dismantling of the lift/lower buttons

3)

Remove the inner part by pushing it in the direction of the shaft. Then lift the part out from above. NOTE! After dismantling a new button must be fitted, since the snap fastener may have been damaged.

7.2.3.3

Removal and installation of the speed controls

1. 2.

1. 2. 3. 4. 5.

Screw    Wing   

3. 4.

Mechanical spring    Bearing   

Remove the screws (item 1) from speed controller wing (item 2). Remove the wing. Remove the mechanical spring (item 3). Remove the bearing (item 4). Refit in the reverse order. NOTE! Grease the springs during assembly.

66

PS/PSH

07  Steering

NOTE! Apply thread locking fluid, such as Loctite 243, to the accelerator screws during assembly. NOTE! Ensure that accelerator springs are working properly after assembly. To achieve this, the wing must be installed at the correct angle relative to the bearing.

7.2.3.4

Fitting the main cabling Securing the tiller arm main cabling The cabling is secured by cable clips to the tiller arm head. The cabling is secured inside the truck by cable ties to the motor. CAUTION! The cabling must have enough slack so that the arm can be lowered to its lowest position without straining the cable. It must also be possible to open the upper part of the tiller head with being restricted by the cabling. CAUTION! The cabling must not be so long that the programming cable takes the load when the upper part is hanging on the cabling. Cable routing, standard version

Figure 39. Cable routing, standard version

PS/PSH

67

07  Steering

Cable routing, options

Figure 40. Cable routing, options

Table 28. Cable routing, options

68

Position

Descriptions

1

Smart card

2

Heat resistance

3

Tiller Up Drive

PS/PSH

07  Steering

7.2.4

Tiller arm (2007w28-)

7.2.4.1

Removing the gas spring

Figure 41. Tiller arm

WARNING! During service and preventive maintenance it is important to check that the steering arm is raised up automatically when the driver releases it. If this does not happen it should be reported to the truck supervisor, with the recommendation that the truck be taken out of service until the requisite measures have been implemented. WARNING! Care must be taken when dismantling the gas springs. 1)

Remove the rubber damper (item 10).

2)

Move the arm forwards.

3)

Release the gas spring by first opening the clip on the bearing holder with a screwdriver. Then pull the gas spring away from the ball roller screw.

4)

Refit in the reverse order. NOTE! Apply grease to the bearing holder.

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08  Hydraulic system

08

HYDRAULIC SYSTEM

8.1

Design and function

8.1.1

General

8.1.1.1

Lift In the hydraulic system there is a pressure limiting valve which limits the maximum hydraulic oil pressure. The pressure of the hydraulic oil is built up when the cylinder goes towards its end position. The relief valve opens if the maximum system pressure is reached and leads the oil from the pump back to the tank. The opening pressure of the relief valve is set at the factory, so that the machine will be able to handle the load it is designed for. WARNING! The relief valve must only be adjusted by authorised and trained personnel, since it is a safety part. All work with the hydraulic system must be carried out in a pressureless state, and in a clean environment.

8.1.1.2

Lower Between the hydraulic pump and the cylinder there is a restrictor, on certain trucks in the form of a lowering brake valve, which regulates the lowering speed by restricting the return flow of hydraulic oil.

8.1.2

Hose rupture valve Hose rupture valves, the purpose of which is to prevent the forks from dropping down out of control if, for example, a hydraulic hose ruptures, are fitted in most of the lift cylinders. They are placed in front of the nipples that are connected for the supply of hydraulic oil.

8.1.3

Electric solenoid valve

8.1.3.1

General The electric solenoid valve controls the lifting and lowering movements on the truck. The solenoid valve is actuated electrically by the driver by means of a switch.

8.1.3.2

Lifting function The pump produces a pressure and flow to the lift cylinder. If the lift cylinder is obstructed, or has an excessive load, the oil goes back to the tank through the relief valve.

8.1.3.3

Lowering function opens to release the oil from the lift cylinder. When the fork carriage presses down the lift cylinder the oil flow goes through the lowering valve, which regulates the lowering speed.

8.1.4

Hydraulic diagram Table 29. List of hydraulic schematic diagrams Descriptions

70

Reference

Hydraulic schematic diagram, hydraulic unit PS (–2007w23)

Figure 47, page 74

Hydraulic schematic diagram, hydraulic unit PS (2007w24-)

Figure 48, page 75

Hydraulic schematic diagram, hydraulic unit PSH (–2008w37)

Figure 49, page 76

Hydraulic schematic diagram, hydraulic unit PSH (2008w38–2009w51)

Figure 50, page 77

Hydraulic schematic diagram, hydraulic unit PSH (2009w52–)

Figure 51, page 78

Hydraulic schematic diagram, hydraulic unit PSH straddle lift (–2008w37)

Figure 53, page 80

PS/PSH

08  Hydraulic system

Descriptions

Reference

Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2008w38–2009w51)

Figure 54, page 81

Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2009w52–)

Figure 55, page 82

Table 30. Symbol explanations Symbol

Explanation

Symbol

Explanation

A1

Hydraulic lift cylinder, forks

e

Flow control valve

A2

Hydraulic lift cylinder, straddle lift

Y2

Lowering control valve

M

Hydraulic motor

Y3

Proportional valve

a

Pressure relief valve

Y4

Directional valves, A2

b

Check valve

Y5

Directional valves, A1

d

Auxiliary port

Hydraulic unit PS (–2007w23)

Figure 42. Hydraulic unit PS (–2007w23)

Hydraulic unit PS (2007w24–)

Figure 43. Hydraulic unit PS (2007w24–)

PS/PSH

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08  Hydraulic system

Hydraulic unit PSH (–2008w37)

Figure 44. Hydraulic unit PSH (–2008w37)

Hydraulic unit, PSH (2008w37-)

Figure 45. Hydraulic unit, PSH (2008w37-)

72

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08  Hydraulic system

Hydraulic unit, PSH straddle lift (2008w38–)

Figure 46. Hydraulic unit, PSH straddle lift (2008w38–)

PS/PSH

73

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PS (–2007w23)

Figure 47. Hydraulic schematic diagram, hydraulic unit PS (–2007w23)

74

PS/PSH

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PS (2007w24-)

Figure 48. Hydraulic schematic diagram, hydraulic unit PS (2007w24-)

PS/PSH

75

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH (–2008w37)

Figure 49. Hydraulic schematic diagram, hydraulic unit PSH (–2008w37)

76

PS/PSH

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH (2008w38–2009w51)

Figure 50. Hydraulic schematic diagram, hydraulic unit PSH (2008w38–2009w51)

PS/PSH

77

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH (2009w52–)

Figure 51. Hydraulic schematic diagram, hydraulic unit PSH (2009w52–2010w37)

78

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08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH (2010w38–2012w13)

Figure 52. Hydraulic schematic diagram, hydraulic unit PSH (2010w38–2012w13)

PS/PSH

79

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH straddle lift (–2008w37)

Figure 53. Hydraulic schematic diagram, hydraulic unit PSH straddle lift (–2008w37)

80

PS/PSH

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2008w38–2009w51)

Figure 54. Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2008w38–2009w51)

PS/PSH

81

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2009w52–)

Figure 55. Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2009w52–)

82

PS/PSH

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH-H straddle lift (2012w14–

Figure 56. Hydraulic schematic diagram, hydraulic unit PSH-H straddle lift (2012w14–

PS/PSH

83

08  Hydraulic system

Hydraulic schematic diagram, hydraulic unit PSH (2012w14–)

Figure 57. Hydraulic schematic diagram, hydraulic unit PSH (2012w14–)

84

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08  Hydraulic system

8.2

Repair and maintenance instructions

8.2.1

Hydraulic system General rules NOTE! Cleanliness during all work with hydraulic components is of the greatest importance for the operating safety and service-life of the system. The following should be taken into consideration: • • • • • • • • • • •

Dirt particles must not get into components. Do not use cloths that release fibres or particles. Only use clean tools. Carefully clean tanks, pipes and hoses before installation. Welded or hot-bent pipes must be pickled (cleaned in an acid bath) and washed before they are built in. The oil tank must be closed and provided with an efficient air filter to prevent dirt contaminating the hydraulic oil. Sealing compounds such as flax, cement or thread tape are not permitted. Take into consideration the specified operating data. Do not exceed the permitted pressures and volume flows. Do not exceed or go below the specified temperature range. Pay attention to specified electrical voltages and power consumption.

NOTE! All work with the hydraulic system should be carried in a pressureless state and in a clean environment. Installation To prevent dirt and corrosion in the hydraulic system all hydraulic components must be provided with plastic plugs blocking the connections before they are delivered. Only remove these plugs just before the component is to be installed in the machine. Retaining screws and connections must correspond with those on the drawing. Retaining screws should not be tightened with a higher torque than what is specified on the drawing. If such information is missing, the torque should not exceed that specified in Section 1.8.1.1, page 11. Connections Couplings must be fitted in accordance with the tightening torques specified in the table at Section 1.8.1.2, page 12. We recommend couplings with elastic seals. Connect pipes and hoses in accordance with the hydraulic diagram. Pay attention to the connection designations. Do not use force, and avoid building-in tensions in pipes, etc, Start up Check that everything is connected in accordance with the hydraulic diagram. Set the relief valves down to a very low pressure if they are not sealed. Start-up with low pressure and volume flows. Test the function and tightness of the system. Check the oil level. Slowly increase the pressures and volume flows to their appropriate values. If measuring equipment is fitted, check this continuously. Pay attention to the noise level since abnormal noise implies defects. Test during variable loads that components are correctly fitted, and that the system is tight.

PS/PSH

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08  Hydraulic system

In the event of returning equipment to the manufacturer, protect polished surfaces from damage and dirt by covering them with foil and protective paper. Fit plastic plugs in all connections. Send the complete components, not loose parts.

8.2.2

Hydraulic oil

8.2.2.1

Properties of the hydraulic oil The hydraulic oils that are recommended in this manual have properties that promote a long service life and good functionality, and these are the oils that must be used in the truck. These contribute to: • • • • • • • • • • •

Smooth action. Long service-life. High viscosity index with wide range of temperature applications. Good low-temperature properties. High filterability. Good air and water separating capacity. Good wear protection. Good oxidation stability. Minimum foaming. Provide protection from rust and corrosion. Good adhesive capacity. NOTE! Never mix oils of different types or brands! Environmentally adapted oils must not be used without the approval of the truck manufacturer if the warranty is to be valid. NOTE! For recommended oil and grease types, see Section 1.7, page 10.

8.2.2.2

Checking the hydraulic oil level 1)

Carefully raise the fork carriage to its topmost position.

2)

Check that the hydraulic pump is not drawing in air. This can be recognised by the function in operation moving jerkily, or by an abnormal screeching noise.

3)

If the hydraulic pump is drawing in air, move all the hydraulic functions to their lowest positions, open the machine housing cover, and check the oil level in the hydraulic tank.

4)

Fill with hydraulic oil of the grade recommended in Section 8.2.2.1, page 86 so that the level rises a few cm. Then perform the “test lift” and check as above.

5)

Repeat this procedure until a normal function is obtained.

8.2.3

Hydraulic unit motor

8.2.3.1

General If the performance of the electric motor changes it should be inspected internally. One of the most common sources of faults is wear on the carbon brushes in the motor. The brushes can wear out, or stick in the brush holders. In both cases inadequate contact between the brushes and the commutator can lead to serious damage on the commutator surface.

86

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08  Hydraulic system

8.2.3.2

When should the brushes be replaced? •

•

8.2.3.3

If a carbon brush cannot move freely in the brush holder. To check this the brush holder must be released from the brush rigging. The force from the brush spring should then press out the brush from the brush holder as far as is permitted by the cable. If a carbon brush is approaching the end of its usable length. The length of the brushes must never be less than 10 mm (a new brush has a length of 17 mm). Since this is difficult to measure there is an alternative method. Measure the difference between the cable and the groove in the brush holder. The difference must be at least 1 mm. Even if the difference is only slightly more, it is recommended that the brushes are changed anyway, since their remaining service life may be shorter than the interval to the next inspection.

Replacing the brushes The brushes themselves cannot be changed, as they are part of a set consisting of the brush, brush holder and spring. Installation is in accordance with the following instructions.

Figure 58. Replacing the brushes

PS/PSH

1)

Release the cables from the terminals on the motor (item 1, Figure 58, page 87).

2)

Remove the through bolts from the rear end of the motor (item 2, Figure 58, page 87).

3)

Lift out the electric motor from the truck.

4)

Place the electric motor on the drive end.

5)

Remove the nuts from the terminals, (item 3, Figure 58, page 87). If the motor has an earth return, the earth connection on the rear end of the motor should also be detached (pos 4, Figure 58, page 87).

6)

Remove the rear end (item 5, Figure 58, page 87). Make sure that the terminals remain in their positions.

87

08  Hydraulic system

Figure 59. Replacing the brushes

7)

Disconnect all four carbon brushes by releasing the screws (pos 6, Figure 59, page 88). • • •

A. Then press each brush set towards the commutator. B Remove the brush set from the brush rigging. C. The old brush set is replaced with a new set by the reverse procedure.

It is recommended to replace each brush separately to avoid confusion. Make sure that each brush set is replaced with the correct part, i.e. one that has the cable on the correct side. (The service kits consist of two matching pairs of brush sets!) 8)

Torque Tighten the screw (item 6, Figure 59, page 88), to approx. 1.3-1.8 Nm.

9)

Replace the terminals in the grooves in the rear end, and replace it back on the motor. Check that there is a washer between the rotor and the end (pos 12, Figure 59, page 88) and that the attachment is held in place by a lug and a slot on the casing and the end.

10)

Torque Insert the through bolts and replace the electric motor in the truck. Tighten the bolts to approx. 4.8-6.8 Nm.

11)

Torque Tighten the terminal nuts to 10-14 Nm (item 3, Figure 58, page 87).

12) Replace the cables to the motor terminals.

8.2.3.4

Tips for prolonging the service-life of the motor •

•

88

The rapid wearing of carbon brushes and the commutator is often caused by oil. Oil or grease is burned by the sparks produced at the brushes, and leaves a residue of abrasive ash. If oil or grease is detected in the motor the reason for this must be eliminated immediately. Never overload the motor. Brushes that have been severely overheated expand permanently and can fasten in the brush holders.

PS/PSH

08  Hydraulic system

•

• •

• • •

The service-life of the brushes does not only depend on the loading, but also on how worn the commutator is. The commutator should have smooth, level and greyish black surface. A worn commutator must be machine milled (never use abrasive paper, grindstone or a file!) to a surface finish of Ra = 0.8-1.8µm and a maximum runout of 0.03 mm (with the rotor resting in the bearing seats). The service-life of the commutator is prolonged if it is machined a little and often, rather than seldom and a lot. The minimum permitted diameter of the commutator is 40.8 mm. The motor must not be exposed to full load immediately after changing the brushes. Look for signs of overheating on the windings, dark patches, brittle or burned insulation, and damage to the soldering on the commutator. The electric motor should be replaced if such damage is found. If possible, remove dust and dirt from inside the motor with compressed air. A dirty commutator should always be cleaned with a cloth moistend with petrol (do not used cotton rags since these shred fibres), and carefully blown dry with compressed air. If the bearing cup looks as if it has run out of oil (i.e. if there is a lot of oil on the rotor washer or brush holder) lubricate it with a little bearing grease.

8.2.4

Hose rupture valve

8.2.4.1

Dismantling and assembling 1)

Lower the forks and relieve the pressure.

2)

Place protective paper under the cylinder to be repaired.

3)

Loosen the pipe or hose that goes to the cylinder, and plug it.

4)

Remove the nipple placed in the cylinder.

5)

Unscrew the hose rupture valve (item 1, see Figure 60, page 89) that is screwed into the cylinder.

Figure 60. Hose rupture valve

PS/PSH

6)

If a fault is suspected, check the length of the spring in relation to the table or data sheet. Adjust, or fit a new valve.

7)

Fit the nipple, connect the pipes, and wipe clean.

8)

Test run.

89

08  Hydraulic system

Figure 61. Hose rupture valve

8.2.5

Solenoid

8.2.5.1

General instructions when working with solenoid valve 1.

Cleanliness • Dirt particles must not be allowed to get into components. • Cloths must not shed fibres and particles. • Tools must be clean. • Tanks, pipes and hoses must be carefully cleaned before installation. • •

8.2.5.2

8.2.6

Welded or hot-bent pipes must be pickled and cleaned before they are built-in The oil tank must be closed and provided with an efficient breather filter that prevents the penetration of dirt.

2.

Sealing compound • Hemp, cement or sealing tape is not permitted.

3.

Operating data • Do not exceed the permitted pressures and volume flows. • Do not go beyond the specified temperature range. • Pay attention to specified electrical voltages and maximum power consumption.

Solenoid valve, dismantling and assembling 1)

Lower down the forks and relieve the pressure in the hydraulic system.

2)

Place protective paper under the valve and release the electric cables to the valve.

3)

Loosen all the oil pipes connected to the valve and plug them.

4)

Loosen the valve from the truck, and lift it out.

5)

When fitting, tighten the valve and then the oil pipes.

6)

Adjust the relief valve to the rated weight in accordance with the machine plate.

7)

Seal the setting.

Installation instruction for pipe couplings To achieve a safe and tight connection when installing pipe couplings in the hydraulic system, the following points should be taken into consideration: CAUTION! Do not cut the pipe, as this could mean that metal chips would get into and damage the hydraulic system. 1)

90

Small pipe dimensions can be fitted directly in the coupling connected to the machine part. Screw the nut by hand until it lies flush with pipe olive, press the pipe towards the shoulder in the coupling cone, and tighten the nut a ¾ turn.

PS/PSH

08  Hydraulic system

NOTE! The pipe must not follow round. 2)

The pipe olive will now have gripped the pipe, which no longer needs to be pressed against the shoulder. Complete the fitting with an additional ¾ turn of the nut. Marking the nut simplifies complying with the prescribed torque (see Figure 62, page 91).

Figure 62. A mark on the nut simplifies the specified torque

3)

Larger pipe dimensions and couplings in free pipes are preferably fitted by placing the coupling body in a vice. The U-ring spanner length should be 15 times the nut width (the spanner can be extended with a piece of pipe). Otherwise fit according to point 3. If several couplings of the same type are to be fitted, make sure that each pipe end goes in the same coupling cone it was previously fitted in. Final fitting is facilitated if the nut is loosened a little and oil is applied between the friction surfaces.

4)

After fitting, release the cap nut and check that the pipe olive has pressed up a visible swelling in the area in front of it (see Figure 63, page 91). If not, give it another short turn. It is of no importance whether the pipe olive can still be turned.

Figure 63. A visible swelling should have formed after tightening

After a visible swelling has formed the nut should be fitted without extension of the U-ring spanner, and without excessive force. NOTE! Refitting: After a visible swelling has formed the nut should be fitted without extension of the U-ring spanner, and without excessive force.

PS/PSH

91

08  Hydraulic system

5)

If the pipe is to be bent after a coupling, the straight pipe end should have a length of at least 2 nut heads, H. Long and heavily loaded pipes should be provided with pipe clips.

Figure 64. Straight pipe length between bend and coupling

6)

The final assembly must be done with at least 1 turn of the nut from the point where it can no longer be turned by hand.

8.3

Diagnostics and trouble shooting

8.3.1

Symptom and Action A number of fault symptoms have been listed in the table below, with a number of possible faults and repair procedures. It is therefore possible for other faults to have occurred in addition to the ones listed. Symptom

Possible fault

Procedure

The lift motor runs, but the fork carriage does not lift.

The lowering valve has jammed and is open.

1.

Close the valve.

2.

Adjust, or remove any dirt from the valve.

The lift motor runs, but the fork carriage lifts very slowly.

The machine is overloaded.

Lighten the load.

The overflow valve is defective.

Adjust the valve to the rated weight.

A foreign object has partially Take apart and clean. blocked a hose, hydraulic pipe or valve. Hydraulic hose has been clenched. The lift motor emits a screeching The oil level is too low in the noise just before the fork hydraulic tank. carriage reaches the top.

The fork carriage will not lower.

Valve does not open on return because of foreign object in the system.

Rearrange the hose and clamp secure. 1.

Fill with hydraulic oil. When the tank is almost full, try with 0.1 litre at a time to avoid overfilling.

2.

Find out the reason for the low level, and rectify the fault.

Dismantle the valve and clean it.

The hose rupture valve is closed Limit the lowering speed. because the lowering speed is too high. The hose rupture valve is closed Replace the hose rupture valve. because the spring in the valve is defective.

92

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08  Hydraulic system

Symptom

Possible fault

Procedure

The fork carriage lowers too slowly.

Lowering valve or lowering brake 1. valve is dirty or defective. 2.

The fork carriage lowers too quickly.

If not, dismantle the valve and clean, or replace defective parts.

The oil filter is blocked and dirty.

Change filter.

The lowering brake valve is defective.

Replace the lower brake valve.

The lowering brake valve is incorrectly adjusted.

Adjust the lowering brake valve.

Hydraulic oil flows out via the air Oil level too high. filter.

Reduce the oil level to correct level.

The oil foams.

Change the oil with oil that has the correct properties.

Condensation water in oil tank.

Empty the tank of oil and fill with new hydraulic oil to correct level.

The fork carriage rocks when lifting.

Air in the hydraulic system.

Bleed the system via the air cylinders.

The hydraulic oil has a bad smell, sulphur.

The oil separators in the hydraulic oil are ruined.

1.

Change the oil and filter.

2.

Flush the complete system with new hydraulic oil.

Motor oil has been used and caused the hydraulic oil to emulsify with water and become contaminated.

PS/PSH

Run the lift motor for a maximum of 1 minute to see if the dirt releases.

93

09  Lift cylinders

09

LIFT CYLINDERS

9.1

Design and function

9.1.1

General The lift cylinders consist of single-acting hydraulic cylinders, where hydraulic oil is pumped into the cylinder, pressing out the piston rod. When the driver activates the lowering function the cylinders are pressed together through a control valve releasing oil out from the cylinders. They are then pushed together by the weight of the forks, at the same time as the oil returns to the hydraulic tank.

9.2

Repair and maintenance instructions

9.2.1

General

9.2.1.1

Bleeding of the hydraulic cylinders with the air bleed screw WARNING! When bleeding, the air screw must be opened no more than approx. a half turn. If the air screw is opened completely the oil will spurt out and the forks crash uncontrollably to their bottom position. The hose rupture valves do not function in this phase.

Figure 65. Example, air screw.

9.2.1.2

1)

Open the air bleed screw about half a turn.

2)

Check that there is sufficient oil in the hydraulic tank and that the pump does not suck air.

3)

When oil without air bubbles comes out, the cylinders have been bled.

4)

Tighten the air bleed screw.

5)

Adjust the oil level in the hydraulic tank.

6)

Repeatedly lift from bottom to top position.

7)

Check that the forks do not bounce. If they do, bleed the air one or more times.

Bleeding of the hydraulic cylinders without a bleed air screw Cylinders without bleed air screws are bled by running the cylinder repeatedly between its end positions.

94

PS/PSH

09  Lift cylinders

NOTE! Check the oil level regularly.

9.2.2

Lift cylinder TV/ TFV (PS)

9.2.2.1

Dismantling and assembling

PS/PSH

1)

Lift the forks until the inner mast is raised approx. 20 cm. Place wooden blocks under the inner mast, and lower it down onto the blocks.

2)

Loosen the securing screw (item 1).

3)

Lower the cylinder to its compressed position.

4)

Disconnect, and plug the oil pipe.

5)

Lift out the cylinder.

6)

Install in the reverse order.

95

09  Lift cylinders

96

PS/PSH

09  Lift cylinders

9.2.2.2

Dismantling 1)

Make a nore of how far the adjusting screw (1) is screwed into the piston rod end (this will be needed when reassembling).

2)

Unscrew the adjusting screw (1).

3)

Support the lower end of the cylinder in a vice. CAUTION! Risk of deformation: use moderate force.

4)

Place a container for oil spillage under the cylinder.

5)

Unscrew and remove the top nut (item 2). Pull out the piston rod (item 3).

6)

Remove the sealing rings and guides rings (item 4) from the top nut.

7)

Remove the guide rings (item 5) from the piston rod.

8)

Clean all parts and check for damage. Replace if necessary. NOTE! Always use original spare parts for maximum safety and service life.

9)

PS/PSH

Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.

97

09  Lift cylinders

9.2.3

Lift cylinder T (PSH)

9.2.3.1

Dismantling and assembling

98

1)

Lower the forks, e.g. on a pallet, so that the chains slacken. Remove the split pin bolt (item 1) that sits in the top end of the cylinder.

2)

Remove the chain and place it over the back of the fork carriage.

3)

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

4)

Place a wooden block, 10-15 cm thick, under the inner mast, and carefully lower the inner mast until it rests on the block.

PS/PSH

09  Lift cylinders

9.2.3.2

5)

Secure the cylinder so that it cannot drop out of the mast! Remove the circlip (item 2) and remove the lower securing screw (3).

6)

Lower carefully so that the piston rod comes out of the yoke (item 4). When the piston rod is fully pushed in, remove the oil pipe and return pipe. Tilt the cylinder forward and lift it out.

7)

Install in the reverse order.

Dismantling and assembling 1)

Place the cylinder on a bench with the chain attachment facing down.

2)

Slacken and remove the top nut (1) with a hook spanner.

3)

Pull out the piston rod (item 2) and place it carefully on the bench to avoid damaging it.

4)

Remove the parts (items 3, 5, 6, 7 and 8).

5)

Clean all parts and check for damage. Replace if necessary. NOTE! Always use original spare parts for maximum safety and service life.

6)

PS/PSH

Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.

99

09  Lift cylinders

9.2.4

Lift cylinder TV/TFV/DTFV (PSH)

9.2.4.1

Dismantling and assembling

100

1)

Lift the forks until the inner mast is raised approx. 20 mm. Place wooden blocks under the inner mast, and lower it down onto the blocks.

2)

Remove the upper securing screws (item 1).

3)

Lower the cylinder to its compressed position.

4)

Loosen, disconnect, and plug the oil pipe.

5)

Remove the retaining screw (item 2).

6)

Lift out the cylinder.

7)

Install in the reverse order.

PS/PSH

09  Lift cylinders

9.2.4.2

Dismantling and assembling 1)

Make a nore of how far the adjusting screw (1) is screwed into the piston rod end (this will be needed when reassembling).

2)

Unscrew the adjusting screw (item 1).

3)

Support the lower end of the cylinder in a vice. CAUTION! Risk of deformation: use moderate force.

4)

Place a container for oil spillage under the cylinder.

5)

Unscrew and remove the top nut (item 2). Pull out the piston rod (item 3).

6)

Remove the sealing rings and guides (item 4) from the top nut.

7)

Remove the guide rings (item 5) from the piston rod.

8)

Clean all parts and check for damage. Replace if necessary. NOTE! Always use original spare parts for maximum safety and service life.

PS/PSH

101

09  Lift cylinders

9)

Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.

9.2.5

Free lift cylinder, TFV/DTFV (PSH)

9.2.5.1

Dismantling and assembling

102

1)

Remove the retaining screw that holds the lower end of the cylinder.

2)

Lower the forks, e.g. on a pallet, so that the chains slacken. Remove the chain pin that goes through the chain bolt on the cylinder, and place the chain over the back of the fork carriage.

3)

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

PS/PSH

09  Lift cylinders

9.2.5.2

4)

Lower so that all the cylinders are pushed together completely.

5)

Loosen the bolts that hold the clamp at the top end of the cylinder, without removing it.

6)

Disconnect the oil pipe.

7)

Remove the clamp, and lift out the cylinder.

8)

Plug the oil pipe.

9)

Install in the reverse order.

Dismantling 1)

Support the lower end of the cylinder in a vice. CAUTION! Risk of deformation: use moderate force.

PS/PSH

2)

Remove the circlip (1) and remove the yoke (2).

3)

Place a container for oil spillage under the cylinder. 103

09  Lift cylinders

4)

Remove the top nut (3) with a suitable tool and take it off the piston rod.

5)

Pull out the piston rod.

6)

Remove the seals (4) and guide rings (5) on the piston. Use a thin tool that will not scratch.

7)

Remove the seal (6) and scraper (7) from the top nut and O-ring (8).

8)

Clean all parts and check for damage. Replace if necessary. NOTE! Always use original spare parts for maximum safety and service life.

9)

Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.

9.2.6

Lift cylinder, vertically adjustable support arm (PSH 160)

9.2.6.1

Dismantling and assembling

104

1)

Lower the forks so that all the cylinders are pushed together completely.

2)

Remove the screws that hold the cylinder lower and upper holders, see Figure 66, page 105.

3)

Disconnect the oil pipe.

4)

Lift out the cylinder.

5)

Plug the oil pipe.

6)

Install in the reverse order.

PS/PSH

09  Lift cylinders

Figure 66. Lift cylinder, vertically adjustable support arm

9.2.6.2

Dismantling 1)

Support the lower end of the cylinder in a vice. CAUTION! Risk of deformation: use moderate force.

2)

Remove the swivel head (item 9) and nut (item 8), see Figure 67, page 106.

3)

Place a container for oil spillage under the cylinder.

4)

Remove the circlip (item 17), and press in the guide (item 16) so that the securing ring (item 15) is released. Take out the securing ring (item 15) and the guide (item 16).

5)

Pull out the piston rod (item 2).

6)

Remove the seal (item 11) and guide ring (item 12).

7)

Remove the seal (item 6), guide ring (item 3) and O-ring (item 4).

8)

Clean all parts and check for damage. Replace if necessary. NOTE! Always use original spare parts for maximum safety and service life.

PS/PSH

105

09  Lift cylinders

9)

Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.

Figure 67. Lift cylinder, vertically adjustable support arm

106

PS/PSH

10  Electrical system

10

ELECTRICAL SYSTEM

10.1

Design and function

10.1.1

General

10.1.1.1

Component descriptions, PS (–2011w15), PSH (–2012w22)

1. 2. 3.

PS/PSH

Traction motor, TM    Pump motor, PM    Traction motor controller, TMC.   

4. 5.

Hydraulic valve controller, HVC.    Truck computer, ATC.   

107

10  Electrical system

10.1.1.2

Component descriptions, PS (2011w16–), PSH (2012w23–)

1. 2.

10.1.1.3

Traction motor, TM    Pump motor, PM   

3. 4.

Combination controller, CMC.    Truck computer, ATC.   

Description of components and interface

The ATC system consists of a keyboard (pos. 1), display (pos. 2) and an ATC card (pos. 3).

10.2

Repair and maintenance instructions

10.2.1

General

10.2.1.1

Safety procedures Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle. • •

108

The drive wheel should always be lifted up free from the floor during service work to prevent the vehicle from moving. The battery plug should be pulled out before working on the electrical system. The battery plug may only be connected while trouble shooting, while taking great care (with the truck raised).

PS/PSH

10  Electrical system

•

•

•

No other persons should be in the vicinity of the truck when it is test run in conjunction with repair work, in view of the risk of accidents or near-accidents occurring due to the truck making an unexpected manoeuvre. All metal objects such as watches, chains, spectacles and rings should be removed when working on the electrical system, or in its immediate vicinity. A short circuit through such an object can result in very serious burn injuries. Working with electrical vehicles can result in personal injury. All testing, trouble shooting and adjusting must be carried out by authorised personnel. The drive wheel should run free of the floor and be able to rotate freely during work. WARNING! Working with electrical vehicles can result in personal injury.

Electronic controllers • •

All the electronic controllers in the truck have multiple safety systems. When replacing or repairing the electronic controllers, or removing wiring, the battery must always be disconnected. NOTE! Incorrectly connected battery cables can destroy the electronic controllers. WARNING! During all work on the truck the drive wheel must be lifted up from the floor to prevent accidents occurring.

After the power has been disconnected to the controller and work or trouble shooting is to be conducted, there can be residual voltage in the capacitors for a few minutes. For this reason observe care when working with current-carrying tools during this period.

10.2.1.2

PS/PSH

Acronyms and abbreviations Abbreviatio n

Full name

Explanation

AC

Alternating Current

Alternating current

B+

Battery positive

Battery positive terminal

B-

Battery negative

Battery negative terminal

CAN

Controller Area Network

The truck computer's communication interface with external units.

CMC

Combi Motor Controller

Combination controller

DC

Direct Current

Direct current

ELCB

Electronically Load Compensated Brake

Brake with electronic load compensation

EPS

Electric Power Steering

Control regulator for electrical servo steering

ESD

Electrostatic Discharge

Electrostatic discharge

GND

Ground

Ground

HVC

Hydraulic Valve Controller

Hydraulic valve controller

PMC

Pump Motor Controller

Regulator that controls the pump motor

S3

Support systems

Assistance system for stability and safety

TMC

Traction Motor Controller

Traction motor controller

TV

Telescopic View

Telescopic sight

WG

Wire Guidance

Wire guidance

109

10  Electrical system

10.2.2

Battery

10.2.2.1

Battery capacity

Figure 68. Battery capacity

The battery capacity is shown to the left on the bottom row on the display. Measurements are fully controlled by software, and no further electronics are required. The capacity is measured by measuring the battery voltage. When the battery capacity gets too low the battery capacity value starts flashing and a buzzer is actuated. A lift stop is connected to the battery capacity measurement and is activated when only 20% capacity remains. Table 31. Battery capacity Battery capacity %

Unloaded pole voltage

Acid density g/cm3

0

22,92

1.070

10

23,20

1.093

20

23,47

1.116

30

23,75

1.139

40

24,03

1.162

50

24,30

1.185

60

24,58

1.208

70

24,85

1.231

80

25,13

1.254

90

25,41

1.277

100

25,68

1.300

Calibration of the battery indicator CAUTION! Calibration is performed when the truck is manufactured, and must not be done afterwards. Incorrect calibration can damage the battery. Only use the factory values.

110

PS/PSH

10  Electrical system

1. 2.

Switch on the voltage to the truck. Go into “Lowering high“ (Service menu » Settings » Battery » Lowering high). This parameter ((0-9) determines how quickly BDI reduces the indicated level when the battery has just been charged. • If the indication does not show 100% after a complete charging cycle, or falls too quickly in the range 100%-60%, this parameter must be reduced. • If the indication falls too slowly in the range 100%-60%, this parameter must be increased.

3.

Go into “Lowering low“ (Service menu » Settings » Battery » Lowering low). This parameter ((0-9) determines how quickly BDI reduces the indicated level when the battery is almost discharged. • If the indication falls too quickly in the range 60%-20%, this parameter must be reduced. • If the indication falls too slowly in the range 60%-20%, shows too high a battery status, or if the truck stops due to a low voltage level alarm, this parameter must be increased.

10.2.3

General handling

10.2.3.1

Keyboard operation The keyboard is used for driver identification, settings, and for diagnostics. The keyboard consists of 12 keys, which have different functions depending on which position the system is in. Table 32. 10.2 Key:

Function in Operation mode:

Input mode: Enter a zero.

-

-

Enter an eight.

-

-

Enter a two.

Switch between creep speed and full speed.

Step one step down in the menu tree.

Enter a three.

-

-

Enter a four.

-

Step one step to the left in the menu tree.

Enter a five.

-

-

Enter a six.

-

Step one step to the right in the menu tree.

Enter a seven.

-

-

Enter an eight.

Set the truck to full speed.

Step one step up in the menu tree.

Enter a nine.

-

-

-

Set the truck to standby mode, or else log off.

Steps to the upper menu level loop if pressed during input in the upper level.

See Section 10.2.3.2, page 112. Used to accept the shown value.

PS/PSH

Service mode:

-

Used to select the shown menu alternative.

111

10  Electrical system

Function key combinations A “monitor menu” can be obtained if the keys are pressed down at the same time in the Operational mode. WARNING! As the monitor menu is active, the truck reacts physically by activating the controls.

10.2.3.2

Menu tree – start-up and top level

Figure 69. Menu tree

On the Operational mode: If the [i] key is pressed and held down for one second the truck will go to the “stand-by” mode. The changeover is confirmed by a beep sound. In Stand-by mode If the [i] key is pressed for less than one second the truck will go to the “Operational mode” without asking for a PIN code. If the [i] key is pressed and held down for one second, the truck will return to the upper level and ask for an operator ID. There is no reason for the operator to release the [i] key if the intention is to log out directly from the "Operational mode".

112

PS/PSH

10  Electrical system

10.2.4

Contactors in cold storage rooms

10.2.4.1

Greasing electrical connectors in cold storage rooms Kryotox grease must be applied to all electrical connectors in the truck that are not self-sealing.* A hand pump must be used for this. The grease should be applied to the contact surfaces when the connectors are disconnected, after which the connectors are reconnected and the grease is pressed from behind into the connector housings so that each are filled. All blocks that have more than one cable are considered to be contact blocks. Flat pins, ring terminals and other simple equipment does not need to be greased. * In spaces in the truck which are considered to be particularly exposed, sealed connectors have been chosen, to protect against damp and dirt. These connectors do not need to be greased in the cold store version. To identify whether a connector is of the sealed type, look at the back piece of the connector. If there is a seal around the wiring in the connector housing, the connector is sealed.

10.2.5

Positioning of ferrites NOTE! The ferrites present on the truck must be put back in the same locations after any part of the truck has been replaced.

PS/PSH

Ferrite ring

P/N

A

118212

B

118213

113

10  Electrical system

Figure 70. (-2005w42), 2006w22-

114

PS/PSH

10  Electrical system

Figure 71. 2005w43-2006w21

PS/PSH

Ferrite ring, PS (2011w16–)

P/N

A

014516

115

10  Electrical system

Figure 72. PS 2011w16-; PSH 2012w23-

10.2.6

Drive and valve controller, PS (–2011w15), PSH (–2012w22)

10.2.6.1

Connector traction motor controller, specification The traction motor controller has two connectors with inputs and outputs for valves, sensors, switches, programming tools, etc. Each connector pin is specified below with, where appropriate, the voltage level in the connected condition. Connector X6 (figure shows connector from the cabling side).

Table 33. 10.3 Connector X6 traction motor controller AC0

116

Pin

Description

Comment

X6.1

Controlling of Drive contactor.

Controlled to B-.

X6.2

Supply to Drive contactor.

+24 V

X6.3

Controlling of electric brake.

Controlled to B-.

X6.4

Controlling of pump contactor.

Controlled to B-.

X6.5

Supply to pump contactor/horn.

+24V

X6.6

Controlling of horn.

Controlled to B-.

PS/PSH

10  Electrical system

Pin

Description

Comment

X6.7

CAN communication.

CAN Low.

X6.8

Temp SW In.

-

X6.9

Pos. supply to drive motor encoder.

+12 V

X6.10 Neg. supply to drive motor encoder.

B-

X6.11 Controlling of lowering valve.

+24 V

X6.12 Neg. supply to lowering valve.

B-

X6.13 Signal input temp. sensor. X6.14 -

-

X6.15 -

-

X6.16 +12 V supply to the HVC.

+12 V

X6.17 CAN communication.

CAN High.

X6.18 -

-

X6.19 Input A from drive motor encoder.

Synchronises the motor movement with pulses from the encoder.

X6.20 Input B from drive motor encoder.

Synchronises the motor movement with pulses from the encoder.

Connector X5 (figure shows connector from the cabling side).

Table 34. 10.4 Connector X5 traction motor controller AC0 Pin

10.2.6.2

PS/PSH

Description

Comment

X5.1

Supply from F3 fuse.

+24 V

X5.2

Joint supply to all digital inputs.

+24 V

X5.3

Input from brake switch.

Closes in the upper and lower arm position.

X5.4

-

-

X5.5

-

-

X5.6

-

-

X5.7

Digital input.

Accessories: Input from lift stop switch, closed, breaks during lift stop.

X5.8

Digital input.

Brake open. The switch must be closed to be able to drive the truck.

X5.9

-

-

X5.10 -

-

X5.11 -

-

X5.12 -

-

Hydraulic valve controller HVC, connector

117

10  Electrical system

Pin

Description

Comment

X23.1

Proportional valve

Activated during fork lifting and lowering

X23.2

-

-

X23.3

Electrically operated valve, forks Closes during fork lifting and lowering

X23.4

Electrically operated valve, support arms

Closes when the "straddle" option is selected and the support arms are raised or lowered.

X23.5

Positive supply to proportional valve

+24 V

X23.6

Common positive supply to electrically operated valves

+24 V

X23.7

-

-

X23.8

-

-

Pin

Description

Comment

X22.1

Supply from TMC

+12V

X22.2

Supply to outputs

+24V

X22.3

CAN communication

CAN low

X22.4

Negative supply

B

X22.5

-

-

X22.6

CAN communication

CAN high

Connector X24 is not used on PS/PSH.

10.2.6.3

Wiring diagram, PS (-2011w15), PSH (–2012w22) All the electrical wiring diagrams can be found in a separate "Wiring diagram handbook". Contact the truck manufacturer for further information. Descriptions

Machine

Wiring diagram

PS/PSH

Reference

Document code 118281 116384 (2007w28–)

Circuit diagram

PS/PSH

118280

10.2.7

Combination controller, PS (2011w16–), PSH (2012w23–)

10.2.7.1

Description of combination controller To improve the handling ability when lifting and lowering, PS and PSH have been equipped with a speed regulated pump motor controlled by a single CMC (Combi Motor Controller). The CMC replaces the TMC (Traction Motor Controller), HVC (Hydraulic Valve Controller) and pump contactor used in earlier models. This solution gives a smoother and more precise control, has a low sound level and is in combination with an equally smooth and precise proportional valve for the lowering function. It also reduces the number of major components in the truck. The lift motor is protected against overheating by a temperature sensor inside which will open at 120 °C to turn off the lift function if the motor becomes overheated. The CMC consists of an AC Traction Motor Controller, a DC Pump Motor Controller and drivers for hydraulic valves in one unit.

118

PS/PSH

10  Electrical system

There are two sizes of CMC with different part numbers depending on the truck model. PS (TMC 220A/PMC 270A) PSH (TMC 220A/PMC 400A) The traction function of the CMC is the same as the earlier TMC using the same traction motor. Pump motor speed, and therefore lift speed, is regulated by the CMC pump motor controller. The lowering speed is controlled by the CMC opening proportional valve Y3, which corresponds to a command signal from the ATC.

10.2.7.2

Combination controller connector The combination controller has a connector with inputs and outputs for valves, sensors, switches, programming tools, etc. Each connector pin is specified below with, where appropriate, the voltage level in the connected condition.

Table 35. Connector X5 for Combination controller AC0

PS/PSH

Pin

Description

Comment

X5.1

Input from brake switch.

Closes in the upper and lower arm position.

X5.2

Controlling of electric brake.

Controlled to B+.

X5.3

Supply to valves and horn.

+24 V.

X5.4

Controlling of electric brake.

Controlled to B-.

X5.5

Negative supply to Traction motor encoder and temp SW In.

Controlled to B-.

X5.6

-

X5.7

-

X5.8

-

X5.9

Controlling of lowering valve.

Controlled to B-.

X5.10

Supply from F3 fuse.

+24 V.

X5.11

-

X5.12

Control of main contactor.

Controlled to B-.

X5.13

Input B from drive motor encoder.

Synchronises the motor movement with pulses from the encoder.

X5.14

Input A from drive motor encoder.

Synchronises the motor movement with pulses from the encoder.

X5.15

-

119

10  Electrical system

10.2.7.3

Pin

Description

Comment

X5.16

-

X5.17

-

X5.18

-

X5.19

Digital input.

X5.20

-

X5.21

-

X5.22

Temp SW Out.

X5.23

-

X5.24

Proportional valve.

X5.25

Positive supply to Traction motor +12 V. encoder and temp SW In.

X5.26

Controlling of horn.

Controlled to B-.

X5.27

CAN communication.

CAN Low.

X5.28

CAN communication.

CAN High.

X5.29

-

X5.30

-

X5.31

-

X5.32

-

X5.33

Electrically operated valve, forks. Closes during fork lifting and lowering

X5.34

Electrically operated valve, support arms.

X5.35

-

Brake open. The switch must be closed to be able to drive the truck.

Activated to lift the forks.

Closes when the "straddle" option is selected and the support arms are raised or lowered.

Wiring diagram, PS (2011w16-), PSH (2012w23-) All the electrical wiring diagrams can be found in a separate "Wiring diagram handbook". Contact the truck manufacturer for further information. The relevant wiring diagrams are specified in the table below. Descriptions

Machine

Wiring diagram

PS, PSH

118951

Circuit diagram

PS, PSH

118952

10.2.8

Insulation resistance

10.2.8.1

Insulation test

Reference

Document code

To protect the truck's three controllers, computer and display, the connectors (plugs) must be disconnected before the truck is insulation tested. This is because damage can occur, which will shorten the life of component parts. In the event of large insulation errors it is appropriate to use a universal instrument until the error has been found and then make a final insulation test. This applies to all electronic units on the truck.

120

PS/PSH

10  Electrical system

WARNING! The instrument has a dangerous voltage across the measuring terminals. Do not touch the terminals during testing. Routines for insulation testing of all truck models. 1)

Set the test voltage to 100 V on the insulation test instrument.

2)

Pull out the battery plug. Electrical components and electronic systems can be damaged by the test voltage. For this reason always disconnect connections and connectors to these before doing the test.

3)

Connect the instrument’s earth lead to the truck chassis at a point with good electrical contact. The other lead is connected to the minus pole on the electrical panel plug.

4)

Press the start button and wait until the display has stabilised. Then release the button and read off the value on the display. The approved value on 24 V machines must be at least 24000 Ω (24 kΩ).

5)

Let the earth lead remain attached to the chassis and connect the other lead to the plus pole on the electrical panel plug. After this repeat point 4.

10.2.9

Main controller unit ATC, operation

10.2.9.1

Menus When starting the ATC system there are four different basic menus the user can select. The user navigates between these different menus by means of the [i] key as shown in the illustration. Certain menus are password-protected. 1.

Operator ID: ?

2. 3.

Local code: ????

4. 5.

Authorised service code: ????

6. 7.

Settings

Navigation in the menus takes place by means of the keys on the keyboard. The keys four and six are used to step up and down, and keys two and eight to step from side to side. The arrows on the display show the possible directions. The enter key is used to go into the submenus. To leave a selected menu, use the Exit selection together with the Enter key. One refinement is that the horn key can be used as an escape key. It can also be used to step back in the menus to the Exit position. This function can also be used to cancel an initiated parameter change. The menus are divided into three levels, as follows: Operation mode This menu is used to log on to the Operational mode. Logon takes place by selecting driver ID, entering a password, and finally using the safety switch as an enter key. In the Operational mode it is possible to use the truck and all its functions.

PS/PSH

121

10  Electrical system

Local Service In the Local Service menu it is possible to change passwords for local service, add and remove drivers, and set the time/date, LCD contrast, and key sound. Certain statistical functions are also available here. A password is needed to access the Local Service menu. Authorised service The Auth. Service menu includes all the functions that may be used by authorised service personnel. A password is needed to access the Auth. Service menu. The Auth. Service menu is built up as shown in fig. 1.

Authorised service menu: < Exit >

2.

Authorised service menu: < Options >

3.

Authorised service menu: < Settings >

4.

Authorised service menu: < Tests >

5.

Authorised service menu: < Calibrate >

6.

Authorised service menu: < Logs/counters >

7.

Authorised service menu: < SET ACCESS >

8.

Authorised service menu: < Reset menu >

• • •

Exit – selected to exit the Auth. Service menu. Options – possibility to set those options that are available for the truck. Settings – possibility to set driver parameters, hydraulic parameters and battery parameters.

Table 36. Hydraulic lifting settings:

122

Settings

Range [%]

With HVC

With Combi controller

Raise min

0–100

The amount of voltage used to open The pump motor speed on receiving the proportional valve on receiving the command for minimal lifting the command for minimal lifting

Raise max

0–100

The amount of voltage used to open The pump motor speed on receiving the proportional valve on receiving the command for maximum lifting the command for maximum lifting

Lower min

0–100

The amount of voltage used to open The amount of voltage used to open the proportional valve on receiving the proportional valve on receiving the command for minimal lowering the command for minimal lowering

Lower max

0–100

The amount of voltage used to open the proportional valve on receiving the command for maximum lowering

The amount of voltage used to open the proportional valve on receiving the command for maximum lowering

PS/PSH

10  Electrical system

Settings

Range [%]

With HVC

With Combi controller

Break point

0–100

Adjusts the curve for both the lifting Adjusts the curve for both the lifting and lowering functions and lowering functions

Dead zone

8–100

Dead zone for both the lifting and lowering functions

Dead zone for both the lifting and lowering functions

Table 37. Pump settings Settings Speed ctrl

Can be set for the motor or valve. Depends on whether the truck is equipped with a Combi controller unit or if the throttle is controlled by a proportional valve.

Cont delay

Delay before the pump contactor is activated. This function is used to allow the valves to open before the pump motor starts. Not used on machines with a Combi controller.

Delay1

Delay1 is used to set the delay from pressing the button to initiate lifting until lowering is again possible. The proportional valve must remain completely open until the delay has elapsed. Delay1 is set in steps of 100 ms. The range is 0–255 seconds.

Delay2

Delay2 is used to delay the closing of valves Y2 and Y5 when the buttons change from lifting/lowering to the neutral position. Delay2 is set in steps of 100 ms. The range is 0–255 seconds.

Lower acc

Defines how quickly the lowering movement can accelerate.

Lower ret

Defines how quickly the lowering movement can be retarded.

During lowering, the signal from the button changes linearly. The value from the button for lowering is between 0 and -32 767. Lower acc and lower ret define how much the value can change for each program cycle. This filters the signal so that small changes are applied immediately, while large changes are divided into several smaller changes which take a longer time to reach the full value.

• • • • •

Test menu - tests the inputs and outputs. Calibrate – possibility to calibrate inputs. Logs – possibility to read and clear temperature log, error log and hour counter. Set access – possibility to add drivers and set passwords for Auth. Service and Local service. Reset menu - possibility to reset all parameters, accessories, users, calibrations and log on to the factory settings.

Table 38. Hydraulic lifting settings:

PS/PSH

Parameter

PS (sw -2.28)

PS (sw 2.29-)

PSH

PSH with T mast

Raise ctrl

Speed

Speed

Speed

Speed

Raise min

42%

10%

55%

55%

Raise max

12%

100%

12%

12%

Lower min

20%

24%

20%

20%

123

10  Electrical system

Parameter

PS (sw -2.28)

PS (sw 2.29-)

PSH

PSH with T mast

Lower max

50%

40%

80%

70%

Break point

35%

35%

35%

35%

Dead zone

10%

10%

10%

10%

Table 39. Pump settings

10.2.9.2

Parameter

PS (sw -2.28)

PS (sw 2.29-)

PSH

PSH with T mast

Speed Ctrl

Valve

Motor

Valve

Valve

Cont delay

0

0

0

0

Delay 1

5

0

6

6

Delay 2

8

6

6

6

Lower acc

10

6

3

3

Lower ret

9

11

9

9

Pump acc

100%

100%

100%

100%

Pump dec

100%

100%

100%

100%

Temp guard

No

Yes

No

No

Settings Under the Settings menu it is possible to select the language to be shown in the display. Swedish, English, German, French, and a “custom” language can be selected (preselected as Spanish). It is possible by using a PC and a special program to add on a “custom” language.

10.2.9.3

Total reset In the Total Reset menu it is possible to reset all parameters, accessories, users, calibrations and log on to the original values. • • •

All drivers: Removes all users and goes back to the original setting. Also the Service code and Local code will be reset to the original settings. Options: Resets all the accessories to their original values. Settings: Resets all the settings to their original values. NOTE! If executing a "Total reset" on Settings the truck type must be selected.

• •

Calibration: Removes all calibrated values. A new calibration procedure must be carried out for the truck to be capable of operation again. Logs: Clear all logs. The hour counters are not reset to zero.

In order to exit from the Total Reset menu the system must be restarted by switching off the power.

10.2.9.4

State the type of truck After all the settings have been removed, or a new ATC has been installed, the type of truck must be stated. When the truck is restarted after the intervention, the ATC will automatically open a menu where it is possible to select which type of truck the ATC is to be used in. PS settings => hydraulics => hvc setup. HVC 1: off v^

10.2.9.7

Selection of options There are several different selections under options. hey are used to tell the ATC which accessories the truck is equipped with. More information regarding the options and their functions are found under Section 10.2.9.29, page 138. In the first row of the display, the option's name and the status of the option (off or on) are indicated . Setting an option is done as follows: 1)

Step to the option that is to be set and press Enter. Lift stop: no 0: 1:yes

2)

Press the 0 key to turn off the option or 1 to turn it on. Lift stop: yes New value saved!

10.2.9.8

Calibrate the proportional buttons 1)

Open the Auth. service menu => Calibrate => Lift. The following display appears: Release lift and press ENT

2)

Make sure that no buttons are pushed and press ENT. Order full raise and press ENT

3)

Push the lift button completly and push ENT.

4)

Repeat the steps for the lowering button.

5)

The following display appears: Signal check: x.xx V Out: xxx% In this menu it is now possible to check that the calibration is correct. In the case of full lifting the signal check must show the following: • •

PS signal check: 5,2 V and 0%, (18% for ATC units older than version 2.18) PSH signal check: 5.2 V and 0%.

In the case of full lowering the voltage is not affected, but Out must show 100%. To proceed further press ENT. If this is not met, repeat the procedure until it corresponds.

126

6)

Press ENT to leave the menu.

7)

Disconnect the battery and then restart the truck.

8)

Perform a functional test for the lifting/lowering functions.

PS/PSH

10  Electrical system

Dual proportional buttons If the truck is equipped with dual proportional buttons, it is neccessary to activate Dual lift in the Auth. service menu => Options => Dual Lift => Yes.

10.2.9.9

1.

Enter the Auth. service menu => Calibrate => Channel 2. The following is displayed: Release k. 2 and press ENT

2.

Make sure that no buttons are pushed and press ENT. Order full + direction and press ENT

3. 4. 5.

Push the lift button completly and push ENT. Repeat the steps for the lowering button. Signal check as for the standard proportional buttons.

Calibrating the speed controller Under Calibrate it is possible to calibrate the speed controller. This is done as follows: 1)

Navigate to Service menu » Calibrate » Accelerator. Then press Enter. The following display appears: Release throttle press ENT

2)

Leave the speed controller in neutral, and press enter. The following display appears: Go to end points press ENT

3)

Give maximum speed in both directions, without pressing hard to the end position, and then press enter. The display shows whether the calibration was successful or not. (only software 2.23–) OK Press ENT Not successful Press ENT Press Enter

4)

The calibration is now finished. A window is shown where it is possible to test the response of the speed controller. Press enter to end. Signal check: 2.3V Out: 064% NOTE! The speed controller must be calibrated at each service.

10.2.9.10 Calibration of lifting and lowering controller (ATC T4mk2, 2007w28–) NOTE! The lifting and lowering controller must be calibrated for both ON/OFF and proportional regulation. 1)

PS/PSH

Navigate to Service menu » Calibrate » Lift. The following display appears:

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10  Electrical system

Lift settings to 0 press ENT 2)

Check that no controllers are activated. Then press ENT. The following display appears: Order full raise press ENT

3)

Press lift completely down on the right lifting and lowering control. Then press ENT.

4)

The following display then appears: Order full lower press ENT

5)

Press lower completely down on the right lifting and lowering control. Then press ENT.

6)

The display shows whether the calibration was successful or not. (only software 2.23–) OK Press ENT Not successful Press ENT

7)

The following display appears: Signal check: x.xV Out: xxx% In this menu it is now possible to check that the calibration is correct. The signal check must show the following values: • • •

With lifting activated: 4.7 V (± 0.1 V) Neutral (control not activated): 2.7 V (± 0.1 V) With lowering activated: 0.6 V (± 0.1 V)

Press ENT. 8)

Repeat the same calibration procedure for the left lifting and lowering control by selecting Channel 2, and performing steps 1-6. Finish after this with ENT.

9)

Exit the Auth. service menu by going to Exit and pressing ENT.

10) Disconnect the battery and then restart the truck. 11) Perform a functional test of the lifting/lowering functions.

10.2.9.11

Adding a new driver New drivers can be added via the Set Access menu. Select Operator to add a new driver. 1)

Select new/update, and press enter. OPERATOR: New/update v^

2)

Enter the driver ID to be altered or changed. Operator ID: ?

128

PS/PSH

10  Electrical system

3)

Select the driver category the driver is to belong to. Op category 3 ?

4)

Select the code applicable for the driver. If the code or category is to be changed for an existing driver, the code associated with this driver ID must be specified first. New code: ????

5)

To verify the code it must be entered one more time. Verify new code: ***?

6)

Press enter to end. OK Press ENT

10.2.9.12 Changing the format of the driver ID and access code In the submenu Set Access there is a function to set the number of digits in the driver ID and access code. Both these can be set from between one to seven digits. Note that drivers with longer codes will not be able to logon if the number of digits is reduced! On the other hand if the number of digits is increased the requisite number of zeros will be added to existing, shorter codes. 1)

The format of the code/ID is changed in Set access » Driver » Format. OPERATOR: Format v^

2)

A warning in two parts is shown. Press 2 to see the second part of the warning. Continue by pressing 1. CAUTION! Reduced length may lead-to lost entries 0:end 1:continue

3)

Changing the length of the ID or Code. ID length: 5 v Code length: 4 ^

4)

Step out by pressing a four, or the horn key.

10.2.9.13 Changing the access code for the Local or Authorised service menu The codes for both Local and Authorised service can be changed in Set Access. This is done in the same way for both, as follows: 1)

PS/PSH

Select Set access » Local and press enter.

129

10  Electrical system

SET ACCESS: Local v^ 2)

Specify the valid code. Old code: ****???

3)

Write in the new code. New code: ???????

4)

Verify the new code. Verify new code: ****???

5)

Press enter to end. OK Press ENT

10.2.9.14 Log functions and hour counter There are two different log functions in ATC, error log and temperature log. Both can be read and cleared in the Authorised Service . There are also a number of hour counters, and these can divided into two categories, total time and trip time. Both can be read in the Authorised Service , but only the trip category can be cleared. The times measured are: • • • •

Active time – the time the truck is used actively, or in other words the total of travel time and pump time. Log time – the time the system has been logged on. Travel time – the time the traction motor has been used. Pump time – the time the pump motor has been used.

The hour counters can also be read in external units, e.g. a TMC or HVC. The hour counter for total time can be set in the Auth. service menu => Logs/Counters => Hour meters. Note that the hour counter for total time can only be set to a value greater than the existing value. If a lower value is entered, there will be no error message, but the new value will not be saved.

10.2.9.15 Read hour counter 1)

Navigate to Service menu » Logs/counters » Hour meters LOGS/COUNTERS: Hour meters v^ Press Enter.

2)

Select Trip, Total or Read external. Hour meters: Total v^

130

PS/PSH

10  Electrical system

Hour meters: Trip v^ Hour meters: Read external v^ Press Enter. 3)

Navigate between the four different hour counters. TOTAL pump: 00001.246h

4)

Step back with the 4 key or with the horn key.

10.2.9.16 Temperature log The temperature log registers temperature measurements from the TMC at five different temperature intervals. The log saves the number of hours the different temperatures have been measured. A distinction is made between TMC and drive motor temperatures in different intervals, where TMC belongs to the lower intervals and the drive motor to the higher. Table 40. Temperature log Temperature levels:

Hours (the information is an example)

-40°C

436.53 h

41-50°C

271.28 h

51-60°C

42.74 h

61-70°C

3.61 h

>71°C

0.00 h

Table 41. High intervalls (Drive motor) Temperature levels:

Hours (the information is an example)

-60°C

137.63 h

61-80°C

41.77 h

81-100°C

24.88 h

101-120°C

2.6 h

>121°C

0.32 h

10.2.9.17 Error log ATC has an error log system that logs external and internal errors. External errors are errors that external units detect and report to ATC. Internal errors are errors that ATC detects itself. The error code, description of the error, date and time, are saved in the error log. The error log function is based on four error classes: • • • •

PS/PSH

A – Shown in the display and saved in the log. Only cleared after it has been read in the error log. B – Shown in the display and saved in the log. Cleared when the error has ceased. C – Saved in the log. Not shown in the display. Warning – Gives a text warning. Certain warnings are logged.

131

10  Electrical system

In addition to being shown in the display, also indicates an error through an audible signal. The signal is repeated every other minute as long as the error/warning is shown in the display. The warning is shown in the full top bar on the display, while the error is shown in the second bar position 5-8. The error log is divided into primary and secondary faults. A secondary error is an error that occurs 2 seconds after the first error occurred. If the last primary error is repeated without any other error occurring, this error will not be logged separately in the log. It will be added to a counter in the log of the last error instead.

Figure 73. ATC T4 fault log (example)

NOTE! If the log is reset, the fault code E027 is logged.

Figure 74. Fault log (primary log and secondary log)

132

PS/PSH

10  Electrical system

10.2.9.18 Read error log •

The error log is opened with Logs » Error log SERVICE MENU: < Logs >

•

The primary faults in the error log are navigated with the 8 and 2 keys. Information is read from the error log as follows:

•

The [i] key is used to access the secondary log. The secondary errors can then be navigated with the 2 and 8 keys. NOTE! The error log must not normally be cleared, since it contains the history of the machine, which may be critical during trouble shooting.

10.2.9.19 Performance parameters The performance parameters in ATC are divided into two levels, machine parameters and driver parameters. The machine parameters represent the basic setting of the machine. They are preset at the factory and can only be changed by using a special PC program. The driver parameters are percentages of the machine parameters.

10.2.9.20 Pump settings (2008w37–) Settings for the pump are located in the Auth. service menu –› Settings –› Pump. Delay1 and Delay2 Delay1 is used to set the required delay from pressing the button to initiate fork lifting until lowering is again permitted. The proportional valve is completely open until the delay has elapsed. Delay1 is set in steps of 100 ms. The time can be set between 0 and 255 seconds. (For the basic settings refer to the information that was delivered together with the truck) Delay2 is used to delay the closing of valves Y2 and Y5 when the buttons change from lifting/lowering to the neutral position. This gives a smoother braking movement for the forks. Delay2 is set in steps of 100 ms. The value can be set to between 0 and 255. (For the basic settings refer to the information that was delivered together with the truck.)

PS/PSH

133

10  Electrical system

ENT ->

Delay1: xxx%

Delay1: xxx New value: ?

^

Delay1: x New value saved!

^

Delay2: xxx%

Delay2: xxx New value: ?

^

Delay2: x New value saved!

^

Cont Delay: xr New value: ?

^

Cont Delay: xr New value saved!

^

Lower acc: xxx New value: ?

^

Lower acc: xxx New value saved!

^

Lower ret: xxx New value: ?

^

Lower ret: xxx New value saved!

^

Inputs, and then activating the different functions. The signal supply of approx. 5 V is on pin no. 1 in the following connectors: Connector

Functionality

XJ1.3

Lift PS

XJ2.3

Lower PS

XJ3.3

Lift (alternative)

XJ4.3

Lower (alternative)

XJ5.3

Creep drive (Tiller-up drive)

XJ14.4

Horn 1

XJ14.3

Horn 2

Comment

Supply 5 V pin no. 2

Digital inputs TMC, PS (–2011w15), PSH There are ten digital inputs in TMC, of which three are used for these truck models. Signal supply of 24 V is taken from pin no. X5.2.

142

PS/PSH

10  Electrical system

Connector

Functionality

Comment

X5.3

Brake switch

Closed in the upper and lower arm positions.

X5.7

Top position switch

Breaks at end position

X5.8

Open brake

Prevents driving when the brake is mechanically disconnected. The switch is closed during normal operation.

Digital inputs CMC, PS (2011w16–) There are eleven digital inputs in the CMC, of which two are used for these particular truck models. Connector

Functionality

Comment

X5.1

Brake switch

Closed in the upper and lower arm positions.

X5.19

Open brake

Prevents driving when the brake is mechanically disconnected. The switch is closed during normal operation.

Digital 24V outputs ATC All the outputs in ATC are of the “low side” type, which means that they close to B-. Only one output is used in these trucks. Signal supply of 24 V is on XJ11.3. Connector

Functionality

Comment

XJ11.4

Creep drive relay

Energises the creep drive relay K4 when the creep drive button is activated. The function of the relay is to release the brake when the arm is in its upper position and the Tiller-up drive function is used.

Digital 24V outputs TMC, PS (–2011w15), PSH There are five digital outputs in TMC. Four of these are of the “low side” type, which means that they close to B-. The fifth output is of the “high side” type, which means that it closes to B+. It is this fifth output that closes the lowering valve Y2. Connector

Functionality

Comment

X6.1

Energises main contactor K1

24 V supply from X6.2

X6.3

Energises the electric brake Y1

24V supply via brake switch

X6.4

Energises the lift contactor K2

24 V supply via X6.5

X6.6

Energises the horn H1

24 V supply via X6.5

X6.11

Energises the lowering valve Y2 0 V supply via X6.12. CAUTION! This output is not short-circuit-proof

Digital 24V outputs CMC, PS (2011w16–) There are seven digital outputs in the CMC. All of these are of the “low side” type, which means that they close to B-.

PS/PSH

143

10  Electrical system

Connector

Functionality

Comment

X5.2

Controlling of electric brake.

Controlled to B+.

X5.4

Controlling of electric brake.

Controlled to B-.

X5.9

Controlling of lowering valve.

+24V.

X5.12

Control of main contactor.

Controlled to B-.

X5.26

Controlling of horn.

Controlled to B-.

X5.33

Electrically operated valve, forks. Closes during fork lifting and lowering.

X5.34

Electrically operated valve, straddle legs.

Closes when the "straddle" option is selected and the straddle legs are raised or lowered.

Digital 24V outputs HVC, PS (–2011w15), PSH The HVC module consists of five outputs, of which one can also be used as a proportional output. All the outputs are of the “low side” type and close to B-. 24 V supply to the valves is taken from X23.7. Connector

Functionality

Comment

X23.4

Energises valve Y4

Activated together with the pump during lifting of the forks, and together with valve Y2 during lowering of the forks.

10.2.10.8 Cold resistance values, PS (-2011w15), PSH Component

Resistance (Ω)

Contactor K1

approx. 30

Contactor K2

approx. 30

Valve coil Y2

approx. 26

Valve coil Y3

approx. 23

Valve coil Y4

approx. 23

Brake Y1

approx. 23

Temperature sensor drive motor

approx. 940 Ω at room temperature. The sensor has a positive temperature coefficient

10.2.10.9 Cold resistance values, PS (2011w16–)

144

Component

Resistance (Ω)

Contactor K1

48

Valve coil Y2

40

Valve coil Y3

30

Valve coil Y4

-

Valve coil Y5

-

Brake Y1

21

Temperature sensor

940

PS/PSH

10  Electrical system

10.2.11

Fuses, PS (–2011w15), PSH Fuses F1

100 A

Traction motor

F2

125 A

Pump motor (PS)

160 A

Pump motor (PSH)

7.5 A

Manoeuvring

F3

10.2.12

Fuse, PS (2011w16–) Fuses F1

160 A

Traction motor/Pump motor

F3

7.5 A

Manoeuvring

F4

7.5 A

Valves/Horn

10.3

Diagnostics and trouble shooting

10.3.1

ATC fault code indications The error codes 1-33 are all memory errors that can occur in conjunction with program errors during unsuccessful reprograming or during electrostatic discharge. Fault code indications

Class

Explanation

E1 ATC invalid NVM access Warning B Attempt to write to invalid E2PROM address

Control/Procedure Settings lost. No action required.

E2 E3 E4 E6 ATC NVM (timer) access Warning B Time out under lost READ/WRITE access to E2PROM in timer module

Settings lost. No action required.

E7 ATC NVM (statistics) access lost

Settings lost. No action required.

Warning B Time out under READ/WRITE access to E2PROM in statistics module

E8

Not used

E9

Not used

E10

Not used

E11 ATC NVM parameters C partially reset during start-up

One or more parameters New settings may be (parameters/accessories/sett necessary. ings) out of range. This can also happen when the system starts up for the first time.

E12 ATC NVM local code reset during start-up

Local access code out of New settings may be range (0-9999999). This can necessary. also happen when the system starts up for the first time.

C

E13 ATC NVM Auth. service C code reset during start-up

PS/PSH

Auth. service access code out of range (0-9999999). This can also happen when the system starts up for the first time.

New settings may be necessary.

145

10  Electrical system

Fault code indications

Class

Explanation

Control/Procedure

E14 ATC NVM user entry cleared during start-up

C

User ID/code or profile outside area

New settings may be necessary.

E15 ATC NVM error log cleared during start-up

C

Error log corrupt

No action required.

E16 ATC NVM timer (timers) C cleared during start-up

Timer outside area

No action required.

E17

Not used

E18

Not used

E19

Not used

E20

Not used

E21 ATC NVM all users forced to reset

C

All users forced to reset in the reset menu

New settings may be necessary.

E22 ATC NVM all users forced to reset

C

Accessory parameters forced to reset in the reset menu

New settings may be necessary.

E23 ATC NVM setting of parameters forced to reset

C

Setting parameters forced to New settings may be reset in the reset menu necessary.

E24 ATC NVM calibration parameters forced to reset

C

Calibration parameters forced to reset in the reset menu

E25 ATC NVM all logs forced C to reset

All logs forced to reset in the No action required. reset menu

E26

C

Not used

E27 ATC NVM error log forced to reset

C

Error logs forced to be manually reset in the Auth. service menu

E28 ATC NVM temperature log forced to reset

C

Temperature log forced to be No action required. reset manually in the Auth. service menu

E29 ATC NVM trip meter time/utilisation forced to reset

C

Trip meter time/utilisation forced to be reset manually in the Auth. service menu

No action required.

E30 ATC NVM driver log forced to reset in the Local menu

C

driver log forced to resest in the LOCAL menu

No action required.

E31 ATC NVM effective time C forced to reset in the Local menu

Effective time forced to resest in the LOCAL menu

No action required.

E32 ATC NVM damage log forced to reset in the Local menu

C

Damage log forced to resest No action required. in the LOCAL menu

E33 ATC NVM collision log forced to reset in the Local menu

C

Collision log forced to resest No action required. in the LOCAL menu

E34 E35 ATC analogue speed input not within approved voltage range

146

New settings may be necessary.

B

No action required.

Not used

No action required.

Analogue speed input not within approved voltage range

Approved range approx. 0.3 – 4.8V 1.

Recalibrate

2.

Change the ATC

PS/PSH

10  Electrical system

Fault code indications

Class

Explanation

Control/Procedure

E36 ATC analogue brake input not within approved voltage range

B

Analogue speed input not within approved voltage range

Not used on these truck models. If the error code still comes up, check that the ATC is correctly connected, or else change it.

E37 ATC analogue lift input not within approved voltage range

B

Analogue lift input not within Not used on these truck approved voltage range models. If the error code still comes up, check that the ATC is correctly connected, or else change it.

E38 ATC analogue lower input not within approved voltage range

B

Analogue lower input not within approved voltage range

E39 ATC Analogue XJ3.3 (A-IN1) input not within approved voltage range

B

Analogue XJ.3 (A-IN1) input Not used on these truck not within approved voltage models. If the error code still range comes up, check that the ATC is correctly connected, or else change it.

E40 ATC Analogue XJ4.3 (A-IN1) input not within approved voltage range

B

Analogue XJ4.3 (A-IN1) input not within approved voltage range

Not used on these truck models. If the error code still comes up, check that the ATC is correctly connected, or else change it.

E41 ATC Analogue potentiometer input, low value not within approved range

B

Analogue potentiometer input, low value not within approved range

Not used on these truck models. If the error code still comes up, check that the ATC is correctly connected, or else change it.

E42 ATC Safety switch monitoring lost

A

Check of safety switch redundancy lost

If error recurs, change ATC.

E43 ATC speed controller monitoring lost

B

Analogue speed controller/check of speed controller signal in neutral position, lost

1.

Recalibrate

2.

Change the ATC

E44

Not used

E45

Not used

E46 ATC Error detected on servo input

A

E47

A

Not used on these truck models. If the error code still comes up, check that the ATC is correctly connected, or else change it.

Error detected on servo input Not used on these truck models.

E48 E49 E50 ATC/TMC low battery

C

Current battery status received from TMC is less than 20%

Charge the battery. In the case of repeated E50 logs, check the BDI settings (See Section 10.2.2.1, page 110)

E51 Error low common pot

B

Error low common supply range

1.

Replace the lift/lower switch.

2.

If the error still occurs replace the ATC.

E52

PS/PSH

Not used

147

10  Electrical system

Fault code indications

Class

Explanation

Control/Procedure

E53 Error high hydraulic pot

B

Error in supply range, high feed to hydraulic controller

1.

Replace the lift/lower switch.

2.

If the error still occurs replace the ATC.

•

Tiller with on/off buttons: Reset calibration of lift lower and aux 1.

•

Tiller with rocker switch: Check the inductive sensors and the connections.

E54

Not used

E55

Not used

E56 Lift range fault

10.3.2

Lift/lower signal outside permitted range

E57

Not used

E58

Not used

E59

Not used

Fault code indications, TMC (trucks with CMC) Fault code indications

Class

Explanation

E100 CAN error

B

CAN communication fault 1. in the TMC during start up

E101 TMC Watchdog

148

B

B

TMC monitoring has triggered

Control/Procedure Check that TMC receives voltage supply

2.

Check the CAN communication link between the ATC and the TMC to make sure there is no fault or short-circuit in the cables. Refer to the wiring diagram.

3.

There may be a short-circuit on the ATC, TMC or HVC communication port. Disconnect HVC and see if the error recurs, otherwise change TMC first and ATC as the other unit.

Try restarting the truck. If this does not help, change CMC.

PS/PSH

10  Electrical system

Fault code indications

Class

Explanation

Control/Procedure

E102 TMC logic error 1

B

Positive supply voltage to the logic is outside the range

1.

Try restarting

2.

Charge the battery if it is getting flat.

3.

Check that the thick cables between the motor and CMC are properly tightened and that they have a low ohm factor. Check also the supply cables to CMC, and the cable and voltage supply to contact X5.10.

4.

Change the CMC

5.

Change traction motor

E103 TMC logic error 2

E104 TMC logic error 3

E105 TMC emergency monitoring has tripped

PS/PSH

B

B

B

Error in the part of the 1. logic that handles the 2. return supply of the phase voltage 3.

Error in the part of the logic that handles the overlead protection

Try restarting. Charge the battery if it is getting flat. Check that the thick cables between the motor and CMC are properly tightened and that they have a low ohm factor. Akso check the supply cables to the CMC, and the cable and voltage supply to contact X5.10.

4.

Change the CMC

5.

Change traction motor

1.

Try restarting. If the error recurs, change CMC.

2.

Change the motor

Communication response 1. from TMC has not been 2. received in time

Restart Check the CAN bus cabling carefully, if the error occurs repeatedly, to make sure there is no play in the contacts and that the terminal resistance maintains 120 Ω +/- 5% 3. Check that the CAN bus is separated from the heavy duty cables. Interferance can give rise to the error.

149

10  Electrical system

Fault code indications

Class

Explanation

Control/Procedure

E106 TMC supply low

B

This test is done on start-up and when stationary. (No drive manoeuvre is given)

1.

Motor cable fault, connection fault, insulation fault in the motor or to chassis.

2.

Change the CMC

E107 TMC supply high

E108 TMC contactor closed

A

The main contactor contact tips are closed before voltage has reached the coil

Check main contactor K1 to make sure the contact tips are not welded, or that it is not short-circuited over the terminals via the cables.

The logic has low voltage to main contactor K1 but the contactor tips do not close

1.

Break in cables to the coil.

2.

Break in coil.

3.

The contactor tips do not close, or fail to connect with CMC.

E110 TMC current B measurement in the standby mode is not equal to zero

Check that the current is zero when truck is stationary

Change the CMC

E111 TMC capacitor charging

The capacitor in TMC does not charge up as it should during start-up

1.

Check that there is battery voltage to TMC, between Band contact X5.10. If not, check battery voltage, supply cables and their connections.

2.

Change the CMC

1.

Check that there is no short-circuit in main contactor K1, the coil, or that the freewheel diode is not reversed or short-circuited. Cut the diode and check that there is no short-circuit in the cables to the coil.

2.

Change the CMC

E109 TMC contactor open A

E112 TMC output short-circuited

E113 TMC contactor output

150

B

A

B

The output to the main contactor coil is short-circuited

The output for the main contactor does not function

Change the CMC

PS/PSH

10  Electrical system

Fault code indications

Class

Explanation

E114 TMC coil short-circuited

A

One of the outputs X5.10, 1. X5.12, X5.4/X5.2 or X5.26 is short circuited

There is a short-circuit in either the main contactor coil K1, the brake coil Y1, the lift contactor coil K2, or in the horn.

2.

There is a short-circuit in the cabling that connects to the components or in the freewheel diodes, or in the capacitor that suppresses the horn.

3.

Internal short-circuit in one of these outputs, change CMC

E115 TMC generic fault

B

TMC self-test failed

Control/Procedure

Try restarting a few times. If this does not rectify the problem, change TMC. NOTE! The fault is probably logged together with E123, but should normally never occur. If E115 or E123 still log, this should be reported to the service function at the truck manufacturer.

E116 TMC CAN bus

PS/PSH

A

Communication command 1. from ATC not received in time

If other CAN errors are logged, rectify these first

2.

There may be an error on ATC, interference on the CAN bus, or play in the CAN bus connector ring

E117 TMC wrong battery

B

Incorrect battery voltage

The TMC may be incorrectly configured. Change the CMC

E118 TMC pulse transducer error

B

Error on the signal from the transducer bearing in the traction motor

Check and measure the transducer in accordance with the trouble shooting chart for "Traction motor", see Section 10.3.6.5, page 167.

151

10  Electrical system

Fault code indications

Class

Explanation

Control/Procedure

E119 TMC Brake output

A

Brake output X5.4/5.2 is defective

1.

If there are other error codes logged, rectify these errors first

2.

Change the CMC

E120 TMC EEPROM error C

EEPROM set to default. Error in the range that includes adjustable values.

E121 TMC controller temperature

The internal temperature 1. monitor has exceeded the 75° C warning level. The current is limited in 2. relation to the temperature. TMC stops completely at 100°C.

Warning C

The battery settings have probably been lost. See Section 10.2.2.1, page 110 See Trouble shooting: Section 10.3.6.8, page 170 Change the CMC

E122 TMC motor temperature

Warning C

The drive motor temperature has exceeded the warning level.

See Trouble shooting: Section 10.3.6.7, page 169

E123 TMC generic

Warning C

Generic warning

Try restarting a few times. If the error does not disappear, change TMC. NOTE! The fault is probably logged together with E115, but should normally never occur. If E115 or E123 still log, this should be reported to the service function at the truck manufacturer.

E124 TMC PEV output

B

The output to lowering valve Y2 connection X5.9 is defective

First confirm that the valve coil is not short-circuited, that the freewheel diode short-circuits or is reversed, or that there is a short-circuit in the cabling. NOTE! This output connects to B+ and is not short-circuitproof. For this reason make sure to check that no external short-circuit exists before changing CMC.

152

PS/PSH

10  Electrical system

Fault code indications

Class

Explanation

Control/Procedure

E125 TMC temperature sensor

Warning C

The internal temperature sensor is defective

Change the CMC

E126 TMC Temperature sensor traction motor

Warning C

The drive motor temperature sensor is defective

First check trouble shooting for: Section 10.3.6.7, page 169

Current calibration in progress

Try restarting a few times. If this does not help, change the CMC.

E127 TMC Current sensor B error

10.3.3

PS/PSH

Fault code indications, TMC (trucks before CMC) Fault code indications Class

Explanation

Control/Procedure

E100 CAN error

CAN communication fault in the TMC during start up

1.

Check that the TMC is receiving a voltage supply.

2.

Check the CAN communication link between the ATC and the TMC to make sure there is no fault or short-circuit in the cables. Refer to the wiring diagram.

3.

The may be a short-circuit on the ATC, TMC or HVC communikation port. Disconnect HVC and see if the error recurs, otherwise change TMC first and ATC as the other unit.

B

E101 TMC Watchdog

B

TMC monitoring has triggered

Try restarting the truck. If this does not help, change TMC.

E102 TMC logic error 1

B

Positive supply voltage to the logic is outside the range

1.

Try restarting.

2.

Charge the battery if it is getting flat.

3.

Check that the thick cables between the motor and TMC are properly tightened and that they have a low ohm factor. Also check the supply cables to the CMC, and the cable and voltage supply to contact X5.1.

4.

Change TMC.

5.

Change the traction motor

153

10  Electrical system

Fault code indications Class

Explanation

Control/Procedure

E103 TMC logic error 2

Error in the part of the logic that handles the return supply of the phase voltage

1.

Try restarting.

2.

Charge the battery if it is getting flat.

3.

Check that the thick cables between the motor and TMC are properly tightened and that they have a low ohm factor. Also check the supply cables to the TMC, and the cable and voltage supply to connector contact X5.1.

4.

Change TMC.

5.

Change the traction motor

1.

Try restarting. If the error recurs, change TMC.

2.

Change the motor.

B

E104 TMC logic error 3

B

Error in the part of the logic that handles the overlead protection

E105 TMC emergency monitoring has tripped

B

Communication 1. response from TMC has 2. not been received in time

E106 TMC supply low

B

This test is done on start-up and when stationary. (No drive manoeuvre is given)

A

The main contactor contact tips are closed before voltage has reached the coil

E107 TMC supply high

E108 TMC contactor closed

154

Restart. Check the CAN bus cabling carefully if the error occurs repeatedly, to make sure that there is no play in the contacts and that the terminal resistance maintains 120 Ω +/- 5%.

3.

Check that the CAN bus is separated from the thick cables. Interferance can give rise to the error.

1.

Motor cable fault, connection fault, insulation fault in the motor or to chassis.

2.

Change TMC.

Check main contactor K1 to make sure the contact tips are not welded, or that it is not short-circuited over the terminals via the cables.

PS/PSH

10  Electrical system

Fault code indications Class

Explanation

Control/Procedure

E109 TMC contactor open

The logic has low voltage to main contactor K1 but the contactor tips do not close

1.

Break in cables to the coil.

2.

Break in coil.

3.

The contactor tips do not close, or fail to connect with TMC.

E110 TMC current measurement in the standby mode is not equal to zero

B

Check that the current is Change the TMC zero when truck is stationary

E111 TMC capacitor charging

B

The capacitor in TMC 1. does not charge up as it should during start-up

E112 TMC output short-circuited

E113 TMC contactor output

PS/PSH

A

A

B

The output to the main contactor coil is short-circuited

The output for the main contactor does not function

Check that there is battery voltage to TMC, between Band contact X5.1. If not, check battery voltage, supply cables and their connections.

2.

Change TMC.

1.

Check that there is no short-circuit in main contactor K1, the coil, or that the freewheel diode is not reversed or short-circuited. Cut the diode and check that there is no short-circuit in the cables to the coil.

2.

Change TMC.

Change the TMC

155

10  Electrical system

Fault code indications Class

Explanation

E114 TMC coil short-circuited

One of the outputs X6.1, 1. X6.3, X6.4 or X6.6 is short circuited

There is a short-circuit in either the main contactor coil K1, the brake coil Y1, the lift contactor coil K2, or in the horn.

2.

There is a short-circuit in the cabling that connects to the components or in the freewheel diodes, or in the capacitor that suppresses the horn.

3.

Internal short-circuit in one of these outputs, change the TMC.

A

E115 TMC generic fault B

TMC self-test failed

Control/Procedure

Try restarting a few times. If this does not rectify the problem, change the TMC. NOTE! The fault is probably logged together with E123, but should normally never occur. If E115 or E123 still log, this should be reported to the service function at the truck manufacturer .

E116 TMC CAN bus

E117 TMC wrong battery

156

A

B

Communication 1. command from ATC not received in time

If other CAN errors are logged, rectify these first.

2.

There may be an ATC error, interference on the CAN bus, or play in the CAN bus connector ring.

Incorrect battery voltage The TMC may be incorrectly configured. Change TMC.

PS/PSH

10  Electrical system

Fault code indications Class

Explanation

E118 TMC pulse transducer error

Error on the signal from Check and measure the the transducer bearing transducer in in the traction motor accordance with the trouble shooting chart: Section 10.3.6.5, page 167.

B

E119 TMC Brake output A

Brake output X6.3 is defective

Control/Procedure

1.

If there are other error codes logged, rectify those errors first

2.

Change TMC.

E120 TMC EEPROM error

C

EEPROM set to default. Error in the range that includes adjustable values.

The battery settings have probably been lost. See Section 10.2.2.1, page 110.

E121 TMC controller temperature

Warning C

The internal 1. temperature monitor has exceeded the 75° C warning level. The current is limited in 2. relation to the temperature. TMC stops completely at 100°C.

See Trouble shooting: Section 10.3.7.7, page 178. Change TMC.

E122 TMC motor temperature

Warning C

The traction motor temperature has exceeded the warning level.

1. See Trouble shooting: Section 10.3.6.8, page 170

E123 TMC generic

Warning C

Generic warning

Try restarting a few times. If the error does not disappear, change TMC. NOTE! The fault is probably logged together with E115, but should normally never occur. If E115 or E123 still log, this should be reported to the service function at the truck manufacturer .

PS/PSH

157

10  Electrical system

Fault code indications Class

Explanation

Control/Procedure

E124 TMC PEV output

The output to lowering valve Y2 connection X6.11 is defective

First confirm that the valve coil is not short-circuited, that the freewheel diode short-circuits or is reversed, or that there is a short-circuit in the cabling.

B

NOTE! This output connects to B+ and is not short-circuitproof. For this reason make sure to check that no external short-circuit exists before changing TMC.

158

E125 TMC temperature Warning C sensor

The internal temperature sensor is defective

Change TMC.

E126 TMC Temperature Warning C sensor traction motor

The traction motor temperature sensor is defective

First check trouble shooting for: Section 10.3.6.7, page 169.

E127 TMC Current sensor error

Current calibration in progress

Try restarting a few times. If this does not help, change TMC.

C

PS/PSH

10  Electrical system

10.3.4

Fault code indications, HVC (trucks with CMC) Fault code indications Class

Explanation

E130 HVC emergency monitoring fault

Communication 1. response from HVC has 2. not been received in time

B

Control/Procedure

3.

Restart. Check the CAN bus cabling carefully if the error occurs repeatedly, to make sure that there is no play in the contacts and that the terminal resistance is still 120 Ω +/- 5%. Check that the CAN bus is separated from the thick cables. Interference can give rise to the fault

E133 HVC proportional output is short-circuited

B

The proportional output is defective

This function is not used for these truck models. If the error still occurs, check that CMC has not been connected incorrectly. If not, change the CMC.

E134 HVC On/Off outputs short-circuited

B

One or more On/Off outputs short-circuited

1.

Check that there is no short-circuit in the cabling or freewheel diodes to valve coils Y3 and Y4. The resistance when cold must be approx. 23 Ω.

2.

Change CMC.

E135 HVC generic fault B

HVC self-test failed

Try restarting a few times. If this does not rectify the problem, change the CMC. NOTE! Should normally never occur. If E135 still logs anyway, this should be reported to the service function at the truck manufacturer .

PS/PSH

159

10  Electrical system

160

Fault code indications Class

Explanation

E136 HVC CAN bus

Communication 1. command from ATC has not been received in time 2.

B

Control/Procedure If other CAN errors are logged, rectify these first. There may be an error on ATC, interference on the CAN bus, or play in the CAN bus connector ring.

E139 HVC EEPROM error

C

EEPROM set to default

Log off and on, and note that the error codes disappear from the log book.

E140 HVC On/Off outputs not OK

C

On/Off outputs not OK

1.

If there are other error logs in conjunction with this error, trouble shoot these first.

2.

Do same trouble shooting as for error codes E134 and E138.

E141 HVC proportional output not OK

C

The proportional output is not OK

This function is not used for these truck models. If the error still occurs, check that HVC has not been connected incorrectly. If not, change the HVC.

E142 HVC ff coils

C

The proportional output is not OK

This output is not used for these truck models.

E144 HVC The B proportional valve is not connected

The proportional valve is not connected between X23.1 and X23.5 and the parameter EVP TYP in the SET menu is analogue or digital.

Check that the cabling to Y3 is correctly connected and that the wiring is not damaged.

E149 TMC Brake

The brakes are not working.

1.

Check that the brakes are correctly connected between connectors X5.2 och X5.4.

2.

Change the CMC.

B

E150 TMC Traction motor

B

The traction motor is not Change the CMC. working.

E151 TMC Key off signal is low

B

The Key off signal is low 1. at Key on.

Check the connection of the power cable from the battery terminals, positive and negative, to the contactor and CMC.

2.

Change the CMC.

PS/PSH

10  Electrical system

Fault code indications Class

Explanation

Control/Procedure

E152 TMC motor phases are open circuited

B

One of the motor phases is open circuited.

1.

Check that the motor wiring is correctly connected to the motor and regulator.

2.

Change the CMC.

E153 TMC Low voltage X5.3

B

X5.3 is not connected to 1. the battery or has a different voltage. 2.

Change the CMC.

E154 TMC Slip profile

B

Incorrect parameters for Check the hardware and the “slip” profile setting. the values in the settings menu for these parameters.

E155 TMC Program corrupted

B

The program or the flash memory in the CMC is corrupted.

Change the CMC.

E160 PMC CAN fault

B

CAN communication fault in the PMC during start up.

See E100.

E161 PMC Emergency monitoring has tripped

B

See E105.

See E105.

E162

C

Pump chopper. The Change the CMC. current sensor feedback is outside the permitted standby range.

E163 PMC VMN low

C

E164 PMC VMN high

E165 PMC CAN bus

C

B

E166 PMC Pump motor C temperature sensor

PS/PSH

Check that there is 24V at connector X5.3.

1.

Motor cable fault, connection fault, insulation fault beweeen the motor and chassis.

2.

Change the CMC.

1.

Motor cable fault, connection fault, insulation fault beweeen the motor and chassis.

2.

Change the CMC.

See E116.

See E116.

Pump motor temperature sensor faulty.

First check trouble shooting for: Section 10.3.6.4, page 167.

161

10  Electrical system

10.3.5

162

Fault code indications, HVC (trucks before CMC) Fault code indications

Class

Explanation

Control/Procedure

E130 HVC emergency monitoring fault

B

Communication response from HVC has not been received in time

1.

Restart.

2.

Check the CAN bus cabling carefully if the error occurs repeatedly, to make sure that there is no play on the contacts and that the terminal resistance maintains 120 Ω +/- 5%.

3.

Check that the CAN bus is separated from the thick cables. Interferance can give rise to the error.

E131 HVC Watchdog

B

HVC monitoring has triggered

Try restarting the truck. If this does not help, change HVC.

E132 HVC “hi side drivers”

B

24V supply to X22.2

1.

Check that the battery voltage is not low, also that it does not fall to less than 16 V when under load. Charge the battery and check that there is a good low-resistance connection between X16 and X19.1 and from X19.1 to X22.2. Check also the minus cable K2.4- to X19.4 and from X19.4 to X22.4.

2.

Change HVC.

E133 HVC proportional output is short-circuited

B

The proportional output is defective

This function is not used for these truck models. If the error still occurs, check that HVC has not been connected incorrectly. If not, change the HVC.

E134 HVC On/Off outputs short-circuited

B

One or more On/Off outputs short-circuited

1.

Check that there is no short-circuit in the cabling or freewheel diodes to valve coils Y3 and Y4. The resistance when cold must be approx. 23 Ω.

2.

Change HVC.

PS/PSH

10  Electrical system

Fault code indications

Class

Explanation

Control/Procedure

E135 HVC generic fault

B

HVC self-test failed

Try restarting a few times. If this does not rectify the problem, change the TMC. NOTE! Should normally never occur. If E135 still logs anyway, this should be reported to the service function at the truck manufacturer.

E136 HVC CAN bus

Communication command from ATC has not been received in time

1.

If other CAN errors are logged, rectify these first.

2.

There may be an error in the ATC, interference on the CAN bus, or play in the CAN bus contacts.

E137 HVC positive feed low

Warning C Positive logic supply is low

Check that the HVC receives approx. 12 V measured between X22.1 and X22.4. If not, check that TMC sends 12 V from X6.16 whether loaded or unloaded. If the voltage rises unloaded it may be HVC consuming too much current, or alternatively TMC that cannot drive the output specified for 100mA. If there is a voltage drop between TMC and HVC, check the low-resistance connection X6.16 to X19.1 and from X19.1 to X22.1, and also the minus side K2.4- to X19.4, and from X19.4 to X22.4.

E138 HVC short-circuit in coil

Warning C Short-circuit in one or more On/Off control units

1.

Check that there is no short-circuit in the cabling or freewheel diodes to valve coils Y3 and Y4, or that one of the coils is speed short-circuited. The resistance when cold must be approx. 23 Ω.

2.

Change HVC.

E139 HVC EEPROM error

PS/PSH

B

C

EEPROM set to default

Log off and on, and note that the error codes disappear from the log book.

163

10  Electrical system

Fault code indications

Class

Explanation

E140 HVC On/Off outputs not OK

Warning C On/Off outputs not OK

Control/Procedure 1.

If there are other error logs in conjunction with this error, trouble shoot these first.

2.

Do same trouble shooting as for error codes E134 and E138.

E141 HVC proportional output not OK

Warning C The proportional output is not OK

This function is not used for these truck models. If the error still occurs, check that HVC has not been connected incorrectly. If not, change the HVC.

E142 HVC ff coils

Warning C The proportional output is not OK

This output is not used for these truck models.

E143 HVC CAN communication error

Warning C No response from HVC on start-up

1.

If TMC also reports error E100, trouble shoot for this error first.

2.

Check the CAN communication connection between TMC and HVC.

3.

Check that HVC is actually supplied correctly from TMC. There must be 12 V measured between contacts X22.1 and X22.4 4. If the HVC is not supplied correctly by the TMC, the TMC must be changed. Otherwise the HVC must be changed.

10.3.6

Other trouble shooting (trucks with CMC)

10.3.6.1

Main contactor does not close There may be other reasons why the main contactor does not close. For this reason, start trouble shooting by rectifying the last logged primary error code. 1.

Have any related error codes been logged? Yes: Step 2

2.

No: Step 3

See trouble shooting for respective fault codes. Fault trace completed

3.

Is there 0 V out from TMC connection X5.12? Yes: Step 5

4.

No: Step 4

Change CMC. Fault trace completed

164

PS/PSH

10  Electrical system

5.

Is there 24 V as far as the main contactor plus connection K1.A1? Yes: Step 7

6.

No: Step 6

Check connection X5.10 - K1.A1 Fault trace completed

7.

Measure directly over the main contactor coil. Is there 24 V? Yes: Step 9

8.

No: Step 8

Check if cable connection K1.2 - X5.12 is OK and has low resistance by measuring the resistance to the front edge of X5, when the connector is pulled from TMC, to the front edge of the flat pin. If there is no connection, change or repair the cabling. Otherwise, change CMC Fault trace completed

9.

Replace contactor. *The normal cold contactor resistance is approx. 48 Ω. Fault trace completed Fault trace completed

10.3.6.2

The truck and ATC have total function loss – the display does not go on NOTE! If the truck is equipped with a charger there may be a fault on this. If the truck functions when X21 is toggled, the charge should be changed. All minus cables = blue All plus cables in machine housing = red/white All plus cables in steering arm = red NOTE! There may be an error in the display or display cable 1.

Is there voltage between F1.1 and E2.B-? Yes: Step 3

2.

No: Step 2

Check the battery, battery plug, electrical panel plug and their connections. Fault trace completed

3.

Is there voltage between X1.1 och E2.B-? Yes: Step 3

4.

No: Step 4

Check that there is 24 V at the following locations: X21.1, X21.2 and X8.2 Fault trace completed

5.

Is there 24 V between X1.1 and X1.5? Yes: Step 5

PS/PSH

No: Step 6

165

10  Electrical system

6.

Indicates break or poor connection in the blue minus cable between E2.B and X1.5. Fault trace completed

7.

Open the steering arm head. Is there 24 V between XJ10.1 and XJ10.5? Yes: Step 9

8.

No: Step 8

Change the steering arm cabling, or repair. Fault trace completed

9.

Change ATC. Fault trace completed Fault trace completed

10.3.6.3

Säkring The fuse for the drive motor (F1) is defective. The most likely reason is that the mean current exceeds the rated current of the fuse. In conjunction with the change, carefully check the motor cables and the plus and minus cables to the CMC to make sure they are correctly connected. Increased friction, increased load, high speed and rapid starting/stopping increase the average current for the controller. The truck may have been driven over its maximum performance. If the truck has been run with a heavy load and at a high speed and with many stops and starts, or in some other way has exceeded its limitations, try to reduce the speed, load, acceleration and retardation. 1.

Change the fuse (with correct fuse value) and restart. Continue with:Step 2

2.

Does the fuse blow just after the main contactor has closed? Yes: Step 3

3.

No: Step 4

Change CMC. If CMC is defective the most likely error is an exciter error with error codes E106 and E107. Fault trace completed

4.

Start the truck again. Fault trace completed

5.

Does the fuse blow again after the truck has been running for some time? Yes: Step 6

6.

No: Fault trace completed

Check that the mechanical torque in the gearbox is not excessive. Fault trace completed Fault trace completed

166

PS/PSH

10  Electrical system

10.3.6.4

High pump motor temperature, E166 If other error codes are logged, rectify those first. The pump motor may have become overheated because it has been run above its performance level for a long period. Check the motor. 1.

Is the warning also given when the motor is cold? Yes: Fault trace completed

2.

No: Step 2

The truck may have been driven over its maximum performance. There may be a fault in the motor. Temporarily reduce the lift performance. Fault trace completed

3.

Ensure that the temperature switch S36 is closed when the motor is cold. If it is not, this means that the switch is defective and must be changed. Ensure that there is 24 V DC at the connections X36.2 and X5.20. Did this solve the problem? Yes: Fault trace completed

4.

No: Step 4

Change the ATC Fault trace completed Fault trace completed

10.3.6.5

Traction motor The traction motor only runs at low speed and with a ticking sound, or alternatively the motor does not start or runs irregularly with a low torque. TMC encoder error E118 is probably logged. 1.

Pull out contact X9 that connects to the drive motor. Is there 12 V between pin X5.5 and X5.25 in the CMC? Yes: Step 3

2.

No: Step 2

Pull out the connector X5 and check that the connections X5.5 - X9.4 and X5.25 - X9 are intact and there is no short circuit in the wiring when measuring the resistance between X5.25 och X9.1. If the connections are OK, change the CMC. Fault trace completed

3.

Is there 12 V between pins 1 and 4 in connector X9? Yes: Step 5

4.

No: Step 4

Repair or change the cabling. Fault trace completed

5.

Replace the contacts and measure the voltage between X5.5 and X5.14 at the same time as the motor is run. An average value of 4-6 V must be read off when measuring the DC. OK? Yes: Step 7

PS/PSH

No: Step 6

167

10  Electrical system

6.

Carefully check that the cabling connection between X5.14 and X9.3 is OK and has a low resistance. If not, repair or change the cabling, otherwise change the drive motor. Fault trace completed

7.

Measure the voltage between X5.5 and X5.13 at the same time as the motor is run. An average value of 4-6 V must be read off when measuring the DC. OK? Yes: Step 9

8.

No: Step 8

Carefully check that the cabling connection between X5.13 and X9.2 is OK and has a low resistance. If not, repair or change the cabling, otherwise change the drive motor. Fault trace completed

9.

An oscilloscope is required for further trouble shooting to determine whether the pulses from the motor sensor bearing are OK and 90 degrees out of phase. The error can either be in the motor or in TMC. Try the motor if it has low insulation resistance to the chassis. Otherwise start with CMC. Fault trace completed Fault trace completed

10.3.6.6

Drive function The drive function does not work in one or two directions. NOTE! The brake switch input is tested for a coonection to X5.3 at every start. If there is no connection, a message is given to release up the arm before driving is permitted. 1.

NOTE! If the brakes are applied and correctly adjusted they will hold the truck in spite of full modulation. For this reason, always check if the controller is working. It can be heard as a slight humming sound. Can a noise be heard? Yes: Step 3

2.

No: Step 2

Reset the truck. Check that the safety switch has not temporarily jammed. If the error remains it will not be possible to restart the truck, and the question about the safety switch will still be in the display. Check also that the modulation from the ATC works from approx. 2.5 V in neutral position to close to 5 V when driving in the direction of the forks, and close to 0 V when driving in the opposite direction to the forks. Recalibrate if necessary. There may be an error on the brake switch. Check that the brake switch has not jammed by checking the input for this via the test menu. The switch is normally open when the arm is between its upper and lower position. If there is 24 V on the TMC contact X5.1 the controller will not modulate and the brake will not be electrically actuated. Check also that the brake open switch functions as it should do. The switch should normally be closed when the brake is not disconnected, and there should be 24 V to the CMC contact X5.19. If not, check the cables and switch.

168

PS/PSH

10  Electrical system

Fault trace completed 3.

Reset the truck. Is there 24V to brake contact X7 when the truck is manoeuvred? Yes: Step 5

4.

No: Step 4

Check that there is 24 V on the brake switch contact X4.3 when the arm is in drive position. Also check that there is a connection between X4.3 och X7.1. If not, repair or change the cabling, or alternatively change the brake switch S9 if this does not work. Fault trace completed

5.

There is either a mechanical or an electrical fault in the brake. The resistance must be approx. 23 Ω. Test if the brake functions if it is released from the motor. If not, change the brake. Fault trace completed Fault trace completed

10.3.6.7

High temperature in drive motor E122 If other error codes are logged, rectify those first. The drive motor may have become overheated because it has been run over its performance level for a long period. Check motor and gearbox. For information on temperature log, see Section 10.2.9.16, page 131. 1.

Is the warning also given when the motor is cold? Yes: Step 3

2.

No: Step 2

The truck may have been driven over its maximum performance. There may be a fault on the motor or gearbox. Temporarily reduce the drive performance. Fault trace completed

3.

Check that the cabling connection between X5.5 and X9.5 is OK and has low-resistance, and do the same for X5.22 and X9.6. If not, repair or change the cabling. If the cabling is OK there is a fault on the temperature sensor, and error code E126 has probably been logged. The temperature sensor resistance at room temperature must be approx. 940 Ω, with increased resistance at rising temperature. This means that a cable break or a break in the sensor causes a max temperature alarm. The temperature sensing can be temporarily removed by connecting an external resistance of 1 kΩ ½ W. To repair the temperature sensing the motor must be cooled. Did this solve the problem? Yes: Fault trace completed

4.

No: Step 4

Change the CMC Fault trace completed Fault trace completed

PS/PSH

169

10  Electrical system

10.3.6.8

The traction motor loses power and the speed slowly reduces High temperature in drive controller, error code E121 may be logged. A warning text is normally shown in the display. The CMC begins to linearly reduce the motor current at 75°C and stops it completely at 100°C. If the fault occurs with a cold controller there is probably an fault in the CMC internal temperature monitoring. If other error codes are logged, start the trouble shooting by rectifying these first. Otherwise, change the controller. For information on temperature log, see Section 10.2.9.16, page 131. 1.

Run the truck for an extended period in raised position and without load. Does the temperature in the controller still go over 75°C? Yes: Step 3

2.

No: Step 2

The truck may have been driven over its maximum performance. Try to reduce the speed, load, acceleration and retardation. Fault trace completed

3.

Try to confirm if there is something that is increasing the torque, such as worn or jamming gearbox, and if the motor is working normally. OK? Yes: Step 5

4.

No: Step 4

Rectify the gearbox or change the motor. Fault trace completed

5.

Change the CMC Fault trace completed Fault trace completed

10.3.6.9

Lowering of the forks does not work NOTE! If other pushbuttons for the hydraulic function are actuated at the same time as the lowering button, the lowering is stopped. “Release controls” comes up in the display. 1.

See Section 10.2.9.28, page 138. Does ATC read the input(s) in the menu “test inputs”? Yes: Step 3

2.

No: Step 2

Check that the pushbutton closes at approx. 5V to the ATC. Check also that 5 V is available, otherwise change the ATC. Fault trace completed

3.

Is there 24 V across the valve coil during lowering? Yes: Step 5

170

No: Step 4

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10  Electrical system

4.

Test the cable connections between X5.9 and Y2.2 and between X5.3 and Y2.1. If OK, change the CMC. Fault trace completed

5.

Check that there is no break in the valve coil. A normal resistance value is approx. 30-39 Ω. If not, change coil. Fault trace completed Fault trace completed

10.3.6.10 The top position switch for lifting does not work If the truck is equipped with top position switch for lifting this must normally be closed to enable lifting. The switch function can be checked in Section 10.2.9.5, page 125. 1.

Pull apart contact X15 and measure the resistance of the switch between pin 1 and 2 when the forks are completely lowered. OK? Yes: Step 3

2.

No: Step 2

Check that the switch is not in mechanically actuated position. If OK, change switch. Fault trace completed

3.

Check that there is 24 V to the switch and that the TMC receives 24 V at contact X5.7. OK? Yes: Step 5

4.

No: Step 4

Check the cabling and that the TMC supplies 24 V from contact X5.2. If not, change the TMC. Fault trace completed

5.

Remove the option for top position switch in the options menu, or alternatively change the TMC. Fault trace completed Fault trace completed

10.3.6.11

Tiller-up drive does not work 1.

See Section 10.2.9.28, page 138 Is the input read by ATC? Yes: Step 3

2.

No: Step 2

Check that the pushbutton switches, otherwise change pushbutton. Check that the ATC supplies approx. 5 V to the pushbutton. If not, change the ATC. Fault trace completed

3.

Measure if there is 24 V to relay K4 across the coil between K4.86 and K4.85. OK? Yes: Step 5

PS/PSH

No: Step 4

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10  Electrical system

4.

Check the arm cabling, and up to the relay. If defective, change cabling. Check that the ATC supplies 24 V between pins 3 and 4 in connector XJ11. If not, change the ATC. Fault trace completed

5.

Does relay K4 disconnect 24 V from connector pin K4.87? Yes: Step 7

6.

No: Step 6

Change relay. Fault trace completed

7.

Does relay K4 disconnect 24 V from the brake switch contact connection X4.3 when the arm is in its upper position? Yes: Step 9

8.

No: Step 8

Check the connection K4.87 - X4.3 Probably an open circuit or poor contact. Fault trace completed

9.

Check that 24 V goes to the brake connector pin X7.1. If not, check the wiring. Fault trace completed Fault trace completed

10.3.6.12 No hydraulic operations work The pump runs for lifting operations but no hydraulic operations function. The truck can be driven. 1.

Check that the HVC is set to “ON”. See Section 10.2.9.3, page 124. Is it? Yes: Step 3

2.

No: Step 2

Set HVC to “ON”. Fault trace completed

3.

Is the CMC supplying 24 V to the valve coils Y4 and Y5 from contacts X5.33 and X5.34? Yes: Step 5

4.

No: Step 4

Change CMC. Fault trace completed

5.

Check that the cabling is not damaged and that there is no break between X5.33 and Y5.1 or between X5.34 and Y4.2. OK? Yes: Step 7

6.

No: Step 6

Change or repair the cabling. Fault trace completed

172

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10  Electrical system

7.

Change CMC. Fault trace completed Fault trace completed

10.3.7

Other trouble shooting (trucks before CMC)

10.3.7.1

Main contactor does not close There may be many reasons why the main contactor does not close. For this reason, start trouble shooting by rectifying the last logged primary error code. *The normal cold contactor resistance is approx. 47 Ω. 1.

Have any related error codes been logged? Yes: Step 2

2.

No: Step 3

See trouble shooting for respective error codes. Fault trace completed

3.

Is there 24V from TMC connection X6.2? Yes: Step 5

4.

No: Step 4

Change TMC. Fault trace completed

5.

Is there 24 V as far as the main contactor plus connection K1.1? Yes: Step 7

6.

No: Step 6

Check connection X6.2 - K1.1 Fault trace completed

7.

Measure directly over the main contactor coil. Is there 24 V? Yes: Step 9

8.

No: Step 8

Check if cable connection K1.2 - X6.2 is OK and has low resistance by measuring the resistance to the front edge of X6, when the connector is pulled from TMC, to the front edge of the flat pin. If there is no connection, change or repair the cabling. Otherwise, change TMC Fault trace completed

9.

Replace contactor Fault trace completed Fault trace completed

10.3.7.2

The truck and ATC have total function loss – the display does not go on NOTE! If the truck is equipped with a charger there may be a fault on this. If the truck functions when X21 is toggled, the charge should be changed. All minus cables = blue

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10  Electrical system

All plus cables in machine housing = red/white All plus cables in steering arm = red NOTE! There may be an error in the display or display cable 1.

Is there 24 V between F1 (between the large fuses) and the large pump contactor connection K2.4? Yes: Step 3

2.

No: Step 2

Check the battery, battery plug, electrical panel plug and their connections. Fault trace completed

3.

Is there 24 V between insulation bolt X16 and the large pump contactor connection K2.4? Yes: Step 5

4.

No: Step 4

Check 7.5A fuse F3, and that there is 24 V to one side of the fuse holder. Only measured with the fuse pulled out of the holder. Fault trace completed

5.

Is there 24 V between X1.1 (the contact that connects to the steering arm) and the large pump contactor connection K2.4? Yes: Step 7

6.

No: Step 6

Check that there is 24 V on all the red/white cable connections in connector X21. Either there is a break or poor contact between X16 and X21.1, in toggle X21.1 X21.2, or in the connection X21.2 - X1.1 Fault trace completed

7.

Is there 24 V between X1.1 and X1.5? Yes: Step 9

8.

No: Step 8

Indicates break or poor connection in the blue minus cable between K2.4 and X1.5. Fault trace completed

9.

Open the steering arm head. Is there 24 V between XJ10.1 and XJ10.5? Yes: Step 11

10.

No: Step 10

Change the steering arm cabling, or repair. Fault trace completed

11.

Change ATC. Fault trace completed Fault trace completed

174

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10.3.7.3

Säkring The fuse for the drive motor (F1) is defective. The most likely reason is that the mean current exceeds the rated current of the fuse. In conjunction with the change, carefully check the motor cables and the plus and minus cables to the TMC to make sure they are correctly connected. Increased friction, increased load, high speed and rapid starting/stopping increase the average current for the controller. The truck may have been driven over its maximum performance. If the truck has been run with a heavy load and at a high speed and with many stops and starts, or in some other way has exceeded its limitations, try to reduce the speed, load, acceleration and retardation. 1.

Change the fuse (with correct fuse value) and restart. Continue with:Step 2

2.

Does the fuse blow just after the main contactor has closed? Yes: Step 3

3.

No: Step 4

Change TMC. If TMC is defective the most likely error is an exciter error with error codes E106 and E107. Fault trace completed

4.

Start the truck again. Fault trace completed

5.

Does the fuse blow again after the truck has been running for some time? Yes: Step 6

6.

No: Fault trace completed

Check that the mechanical torque in the gearbox is not excessive. Fault trace completed Fault trace completed

10.3.7.4

Traction motor The traction motor only runs at low speed and with a ticking sound, or alternatively the motor does not start or runs irregularly with a low torque. TMC encoder error E118 is probably logged. 1.

Pull out contact X9 that connects to the drive motor. Is there 12 V between pin X6.9 and X6.10 in the TMC? Yes: Step 3

2.

No: Step 2

Pull out the connector X6 and check that the connections X6.9 - X9.1 and X6.10 X9.4 are intact and there is no short circuit in the wiring when measuring the resistance between X9.1 och X9.4. If the connections are OK, change the TMC. Fault trace completed

3.

Is there 12 V between pins 1 and 4 in connector X9? Yes: Step 5

PS/PSH

No: Step 4

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10  Electrical system

4.

Repair or change the cabling. Fault trace completed

5.

Replace the contacts and measure the voltage between X6.10 and X6.19 at the same time as the motor is run. An average value of 4-6 V must be read off when measuring the DC. OK? Yes: Step 7

6.

No: Step 6

Carefully check that the cabling connection between X6.19 and X9.2 is OK and has a low resistance. If not, repair or change the cabling, otherwise change the drive motor. Fault trace completed

7.

Measure the voltage between X6.10 and X6.20 at the same time as the motor is run. An average value of 4-6 volt should be read off when measuring the DC. OK? Yes: Step 9

8.

No: Step 8

Carefully check that the cabling connection between X6.20 and X9.3 is OK and has a low resistance. If not, repair or change the cabling, otherwise change the drive motor. Fault trace completed

9.

An oscilloscope is required for further trouble shooting to determine whether the pulses from the motor sensor bearing are OK and 90 degrees out of phase. The error can either be in the motor or in TMC. Try the motor if it has low insulation resistance to the chassis. Otherwise start with TMC. Fault trace completed Fault trace completed

10.3.7.5

Drive function The drive function does not work in one or two directions. NOTE! The brake switch input is tested for a coonection to X5.3 at every start. If there is no connection, a message is given to release up the arm before driving is permitted. 1.

NOTE! If the brakes are applied and correctly adjusted they will hold the truck in spite of full modulation. For this reason, always check if the controller is working. It can be heard as a slight humming sound. Can a noise be heard? Yes: Step 3

2.

No: Step 2

Reset the truck. Check that the safety switch has not temporarily jammed. If the error remains it will not be possible to restart the truck, and the question about the safety switch will still be in the display. Check also that the modulation from the ATC works from approx. 2.5 V in neutral position to close to 5 V when driving in the direction of the forks, and close to 0 V when driving in the opposite direction to the forks. Recalibrate if

176

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10  Electrical system

necessary. There may be an error on the brake switch. Check that the brake switch has not jammed by checking the input for this via the test menu. The switch is normally open when the arm is between its upper and lower position. If there is 24 V on the TMC contact X5.1 the controller will not modulate and the brake will not be electrically actuated. Check also that the brake open switch functions as it should do. The switch should normally be closed when the brake is not disconnected, and there should be 24 V to the CMC contact X5.19. If not, check the cables and switch. Fault trace completed 3.

Reset the truck. Is there 24 V to brake contact X7 when the truck is manoeuvred? Yes: Step 5

4.

No: Step 4

Check that there is 24 V on the brake switch contact X4.3 when the arm is in drive position. Also check that there is a connection between X4.3 och X7.1. If not, repair or change the cabling, or alternatively change the brake switch S9 if this does not work. Fault trace completed

5.

There is either a mechanical or an electrical fault in the brake. The resistance must be approx. 23 Ω. Test if the brake functions if it is released from the motor. If not, change the brake. Fault trace completed Fault trace completed

10.3.7.6

High temperature in drive motor E122 If other error codes are logged, rectify those first. The drive motor may have become overheated because it has been run over its performance level for a long period. Check motor and gearbox. For information on temperature log, see Section 10.2.9.16, page 131. 1.

Is the warning also given when the motor is cold? Yes: Step 3

2.

No: Step 2

The truck may have been driven over its maximum performance. There may be a fault on the motor or gearbox. Temporarily reduce the drive performance. Fault trace completed

3.

Check that the cabling connection between X5.5 and X9.5 is OK and has low-resistance, and do the same for X5.22 and X9.6. If not, repair or change the cabling. If the cabling is OK there is a fault on the temperature sensor, and error code E126 has probably been logged. The temperature sensor resistance at room temperature must be approx. 940 Ω, with increased resistance at rising temperature. This means that a cable break or a break in the sensor causes a max temperature alarm. The temperature sensing can be temporarily removed by connecting an external resistance of 1 kΩ ½ W. To repair the temperature sensing the motor must be cooled. Did this solve the problem? Yes: Fault trace completed

PS/PSH

No: Step 4

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10  Electrical system

4.

Change the CMC Fault trace completed Fault trace completed

10.3.7.7

The traction motor loses power and the speed slowly reduces High temperature in drive controller, error code E121 may be logged. A warning text is normally shown in the display. The CMC begins to linearly reduce the motor current at 75°C and stops it completely at 100°C. If the fault occurs with a cold controller there is probably an fault in the CMC internal temperature monitoring. If other error codes are logged, start the trouble shooting by rectifying these first. Otherwise, change the controller. For information on temperature log, see Section 10.2.9.16, page 131. 1.

Run the truck for an extended period in raised position and without load. Does the temperature in the controller still go over 75°C? Yes: Step 3

2.

No: Step 2

The truck may have been driven over its maximum performance. Try to reduce the speed, load, acceleration and retardation. Fault trace completed

3.

Try to confirm if there is something that is increasing the torque, such as worn or jamming gearbox, and if the motor is working normally. OK? Yes: Step 5

4.

No: Step 4

Rectify the gearbox or change the motor. Fault trace completed

5.

Change the CMC Fault trace completed Fault trace completed

10.3.7.8

Lowering of the forks does not work NOTE! If other pushbuttons for the hydraulic function are actuated at the same time as the lowering button, the lowering is stopped. “Release controls” comes up in the display. 1.

See Section 10.2.9.28, page 138. Does ATC read the input(s) in the menu “test inputs”? Yes: Step 3

178

No: Step 2

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10  Electrical system

2.

Check that the pushbutton closes at approx. 5V to the ATC. Check also that 5 V is available, otherwise change the ATC. Fault trace completed

3.

Is there 24 V across the valve coil during lowering? Yes: Step 5

4.

No: Step 4

Test the cable connections between X6.11 and X2.1 and between X6.12 and Y2.2. If OK, change the TMC. Fault trace completed

5.

Check that there is no break in the valve coil. A normal resistance value is approx. 39 Ω. If not, change coil. Fault trace completed Fault trace completed

10.3.7.9

Lifting of the forks does not work NOTE! Certain trucks are equipped with end position stop. Before trouble shooting, temporarily set this option to “no”. If this solves the problem the top position switch should be checked in accordance with the trouble shooting chart for this. If the pump runs and the forks still do not lift there may be a fault in the hydraulics, a pump fault, or incorrectly connected hydraulic hoses. NOTE! • Remember to reset the option for end position switch lift. • If the battery is below 20% the lift stop will be actuated. Charge the battery. • If other pushbuttons for the hydraulic function are actuated at the same time as the lifting button, the lifting is stopped. “Release controls” comes up in the display. • The normal pump motor current value is approx. 38 A off-load, 105 A with 2500 kg and 125 A at the end stop. The end stop value can be checked via the option "lift limit" being temporarily set to "NO". See “Options menu” in Section 10.4.3, page 189. 1.

Does the lift contactor actuate without the pump running? Yes: Step 3

2.

No: Step 2

Check that the inputs for lift are read by ATC in the “inputs” menu in the test menu. If not, check that the pushbuttons work and close when actuated. Check that the pushbuttons receive approx. 5 V from the ATC. If not, change the ATC. Check that there is not a break to pump contactor K2 by checking the cabling, and that there is not a break in the connector coil. If there is +24 V as far as the contactor with B- as a reference and the contactor still does not pull, change the TMC. Fault trace completed

3.

Is the fuse F2 intact? Yes: Step 5

PS/PSH

No: Step 4

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10  Electrical system

4.

Change the fuse. Fault trace completed

5.

Check that 24 V goes to the motor terminal. OK? Yes: Step 7

6.

No: Step 6

The contact tips do not seem to conduct. Fault trace completed

7.

Check the brushes to the hydraulic unit, and that they are rest against the commutator. OK? Yes: Step 9

8.

No: Step 8

Change the brushes, or adjust. Fault trace completed

9.

Change the unit. Fault trace completed Fault trace completed

10.3.7.10 The top position switch for lifting does not function If the truck is equipped with top position switch for lifting this must normally be closed to enable lifting. The switch function can be checked in Section 10.2.9.5, page 125. 1.

Pull apart contact X15 and measure the resistance of the switch between pin 1 and 2 when the forks are completely lowered. OK? Yes: Step 3

2.

No: Step 2

Check that the switch is not in mechanically actuated position. If OK, change switch. Fault trace completed

3.

Check that there is 24 V to the switch and that the TMC receives 24 V at contact X5.7. OK? Yes: Step 5

4.

No: Step 4

Check the cabling and that the TMC supplies 24 V from contact X5.2. If not, change the TMC. Fault trace completed

5.

Remove the option for top position switch in the options menu, or alternatively change the TMC. Fault trace completed Fault trace completed

180

PS/PSH

10  Electrical system

10.3.7.11

Tiller-up drive does not work 1.

See Section 10.2.9.28, page 138. Is the input read by ATC? Yes: Step 3

2.

No: Step 2

Check that the pushbutton switches, otherwise change pushbutton. Check that the ATC supplies approx. 5 V to the pushbutton. If not, change the ATC. Fault trace completed

3.

Measure if there is 24 V to relay K4 across the coil between K4.86 and K4.85. OK? Yes: Step 5

4.

No: Step 4

Check the arm cabling, and up to the relay. If defective, change cabling. Check that the ATC supplies 24 V between pins 3 and 4 in connector XJ11. If not, change the ATC. Fault trace completed

5.

Does relay K4 disconnect 24 V from connector pin K4.87? Yes: Step 7

6.

No: Step 6

Change relay. Fault trace completed

7.

Does relay K4 disconnect 24 V from the brake switch contact connection X4.3 when the arm is in its upper position? Yes: Step 9

8.

No: Step 8

Check the connection K4.87 - X4.3 Probably an open circuit or poor contact. Fault trace completed

9.

Check that 24 V goes to the brake connector pin X7.1. If not, check the wiring. Fault trace completed Fault trace completed

10.3.7.12 No hydraulic operations work The pump runs for lifting operations, but no hydraulic operations work. The truck can be driven. 1.

Check that the HVC is set to “ON”. See Section 10.2.9.3, page 124. Is it? Yes: Step 3

2.

No: Step 2

Set HVC to “ON”. Fault trace completed

PS/PSH

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10  Electrical system

3.

Is HVC supplied with voltage? It should be possible to measure 24 V between X22.2 and X22.4, and there should be 12 V between X22.1 and X22.4. Are these voltages present? Yes: Step 5

4.

No: Step 4

If 24 V is missing, check the cabling. If 12 V is missing, check the cabling and that the TMC is actually supplying the HVC with 12 V. If not, change the TMC. Fault trace completed

5.

Is the HVC supplying 24 V to the valve coils Y3 and Y4 from contact X23.7? Yes: Step 7

6.

No: Step 6

Change HVC. Fault trace completed

7.

Check that the cabling is not damaged and that there is no break between X23.8 and Y3.2, nor between X23.4 and Y4.2. OK? Yes: Step 9

8.

No: Step 8

Change or repair the cabling. Fault trace completed

9.

Change HVC. Fault trace completed Fault trace completed

10.4

Appendix 1, Overview of the menu trees

10.4.1

General In the following section, Appendix 1, there are menu trees (version 2.28) for the following listed menus: • • • • • •

182

Menu tree, Local menu Menu tree, Service menu Menu tree, Monitor menu Menu tree, Reset Menu tree, Select language Menu tree, TRAC

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10  Electrical system

10.4.2

Local menu tree Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Remarks:

LOCAL MENU: < Exit > LOCAL MENU:

SET ACCESS:

OPERATOR :

Operator ID:

< Set access >

Operator ^ v

New/Chan ge ^ v

?

The level 3 displays are always followed in sequence. The no of question marks corresponds to the chosen id length (Authorised menu).

Operator categ:x ? This screens will only be displayed if the user ID exists and user code length > 0

Old code: ???? New code: ????

Verify new code: ????

The no of question marks corresponds to the chosen code length (Authorised menu). OK Press ENT

This screens will only be displayed if the user ID exists and user code length > 0 The no of question marks corresponds to the chosen code length (Authorised menu).

PS/PSH

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10  Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Invalid old code / verified code wrong / category out of range (1..4) / all 100 user IDs used / no access to E2PROM

Not successf ul! Press ENT

OPERATOR : Format

Remarks:

CAUTION! Reduced length may lead. v^ .to lost entries 0:escape 1:go on v1 ID length: x

ID length: x

ID length : x

v

New value: ?

New value saved! Input reject ed! Press ENT

Code length: x

Code length: x

Code length : x

^

New value: ?

New value saved! Input reject ed! Press ENT

184

SET ACCESS:

Operator ID:

Delete oper ^ v

?

The level 3 displays are always followed in sequence.

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10  Electrical system

Level 1

Level 2

Level 3 Delete op x? 0:No 1:Yes (No)

Level 4

Local ^ v

???????

Remarks:

Press ENT

Press ENT Old code:

Level 6

OK

Not successf ul!

SET ACCESS:

Level 5

invalid ID / 0:(No) pressed or input aborted/ no access to E2PROM The level 3 displays are always followed in sequence.

New code: ??????? Verify new code:

OK Press ENT

??????? Not successf ul! Press ENT

PS/PSH

LOCAL MENU:

FLEET MANAGER:

Unlock ^ v

invalid old code / verifyed code wrong / no access to E2PROM This menu entry resets the Impact Sensor actions. To be used by warehouse management to acknowledge impact.

FLEET MANAGER:

READ LOGS:

: [date]

Read logs ^ v

Operator log ^ v

[time] [time]

List of the 30 most recent operator sessions.

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10  Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

READ LOGS:

EFFICIEN CY:

: xx(mn)%

Efficien cy ^ v

Worst ^ v

Curr:iii (mn)A

EFFICIEN CY:

: xx(mn)%

Best ^ v

Curr:iii (mn)A

Operator ID:

: xx(mn)%

?

T:xx(mn) P:xx(mn)

Level 6

Remarks: List sorted from worst to best operator (Act). xx = active time / logged on time * 100; iii = mean main active current draw; mn = correspondin g mean value for all operators; Any operator's efficiency. = operator id (1 - 100) T = traction; P = pump; mn = correspondin g mean value for all operators;

ID not found! Press '

< Time & Date ^ v

Set time ^ v

11:39

hh:mm

New time: hh:mm

OK! Press ENT Input rejected ! Press ENT

TIME & DATE:

dd.mm.yy yy

2001-0918

Set date ^ v

New: yy-mm-dd

OK! Press ENT Input rejected ! Press ENT

TIME & DATE:

Select format:

Date format ^ v

2001-0918 ^ v 18-Sep01 ^ v 18.09.20 01 ^ v 09.18.20 01 ^ v

188

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Level 1

Level 2 SETTINGS : LCD contrast ^ v

Level 3 LCD contrast :

Level 4

Level 5

LCD contrast : x

LCD contrast : y

New value: ?

New value saved!

Level 6

Remarks: x = 0..9

Input rejected ! Press ENT SETTINGS : Key sound ^ v

Key sound: xxx

Key sound: xxxx

Key sound: yyy

0:no 1:yes

New value saved! Input rejected ! Press ENT

LOCAL MENU:

CARD READER:

smartcar d:xxx

smartcar d:xxx

smartcar d:yyy

< Card reader >

Enable/d isable

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

10.4.3

SERVICE menu tree Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Remarks:

SERVICE MENU: < Exit > SERVICE MENU: < Options >

Lift limit: xxx

Lift limit: xxx

Lift limit: yyy

xxx = currently used value.

^ v

0:no 1:yes

New value saved!

New value 'yyy' replaces the old 'xxx'.

Input rejected !

Screen stays on for 1 s.

Press ENT

PS/PSH

Displayed if value is out of range.

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10  Electrical system

Level 1

Level 2

Level 3

Level 4

Restart: xxx

Restart: xxx

Restart: yyy

^ v

0:no 1:yes

New value saved!

Level 5

Level 6

Remarks:

Input rejected ! Press ENT Safety syst:xxx

Safety syst:xxx

Safety syst:yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Effici log:xxx

Effici log:xxx

Effici log:yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Impact sens:xxx

Impact sens:xxx

^ v

0:no 1:yes

Imp sensor:y yy New value saved! Input rejected ! Press ENT

190

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10  Electrical system

Level 1

Level 2

Level 3

Level 4

Log level: xxx

Log level: xxx

Log level: yyy

^ v

New value: ?

New value saved!

Level 5

Level 6

Remarks: Appears only if Impact sensor is “yes” above!

Input rejected ! Press ENT Warning level: xxx

Warning level: xxx

Warning level :yyy

^ v

New value: ?

New value saved! Input rejected ! Press ENT!

Horn level :xxx

Horn level :xxx

Horn level :yyy

^ v

New value: ?

New value saved!

Appears only if Impact sensor is “yes” above!

Appears only if Impact sensor is “yes” above!

Input rejected ! Press ENT Stop level:xx x

Stop level:xx x

Stop level:yy y

^ v

New value: ?

New value saved!

Appears only if Impact sensor is “yes” above!

Input rejected ! Press ENT

PS/PSH

191

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Supervis lev: xxx

Supervis lev: xxx

Supervis lev: yyy

^ v

New value: ?

New value saved!

Level 5

Level 6

Remarks: Appears only if Impact sensor is “yes” above!

Input rejected ! Press ENT Damage rep:xxx

Damage rep:xxx

Damage rep:yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Time logoff:x xx

Time logoff:x xx

Time logoff:y yy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Del time a: xxx

Del time a:xxs

^ v

New value: ?

Delay time a:yys New value saved!

Appears only if Time logoff is “yes” above!

Input rejected ! Press ENT

192

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3

Del time b: xxx

Del time b:xxmin

^ v

New value: ?

Level 4 Delay time b:yymin New value saved!

Level 5

Level 6

Remarks: Appears only if Time logoff is “yes” above!

Input rejected ! Press ENT Dis tiller res:xxx

Dis tiller res:xxx

Dis tiller res:yyy

^ v

0:no 1:yes

New value saved!

Appears only if Time logoff is “yes” above!

Input rejected ! Press ENT Smartcar d:xxx

smartcar d:xxx

smartcar d:yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Damage rep:xxx

Damage rep:xxx

Damage rep:yyy

^ v

0:no 1:yes

New value saved!

Appears only if Time logoff is “yes” above!

Input rejected ! Press ENT

PS/PSH

193

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Disp log on:xxx

Disp log on:xxx

Disp log on:yyy

^ v

0:no 1:yes

New value saved!

Level 5

Level 6

Remarks:

Input rejected ! Press ENT Summer time:xxx

Summer time:xxx

Summer time:yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Keyswitc h :xxx ^ v

Keysw pwr off:xxx

Keysw pwr off:yyy

0:no 1:yes

New value saved! Input rejected ! Press ENT

Speed red:xxx

Speed red:xxx

Speed red:yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

194

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Cutback3 : xxxx%

Cutback3 : xxxx%

Cutback3 : yyyy%

^ v

New value: ?

New value saved!

Level 5

Level 6

Remarks: Appears only if Speed red is 'yes' above!

Input rejected ! Press ENT Service alrm:xxx

Service alrm:xxx

Service alrm:yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Interval : xxxxh

Interval : xxxxh

Interval : yyyyh

^ v

New value: ?

New value saved!

Appears only if Service alarm is 'yes' above!

Input rejected ! Press ENT Fixed platf: xxx

Fixed platf:xx x

Fixed Platf:yy y

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

PS/PSH

195

10  Electrical system

Level 1

Level 2

Level 3

Level 4

TillerUp D: xxx

TillerUp D: xxx

TillerUp D: yyy

^ v

0:no 1:yes

New value saved!

Level 5

Level 6

Remarks:

Input rejected ! Press ENT Reverse ind: xxx

Reverse ind: xxx

Reverse ind: yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

HVC1 :xxx

HVC1 :xxx

HVC1 :xxx

^ v

0:no 1:yes

New value saved!

Appears only if Revers ind is 'yes' above!

Input rejected ! Press ENT Raise steer: xxx

Raise steer: xxx

Raise steer: yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

196

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Stop on ramp: xxx

Stop on Ramp: xxx

Stop on ramp: yyy

^ v

0:no 1:yes

New value saved!

Level 5

Level 6

Remarks:

Input rejected ! Press ENT Straddle : xxx

Straddle : xxx

Straddle : yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Belly start: xxx

Belly start: xxx

Belly start: yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

Battery creep: xxx

Battery creep: xxx

Battery creep: yyy

^ v

0:no 1:yes

New value saved! Input rejected ! Press ENT

PS/PSH

197

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Charger: xxx

Charger: xxx

Charger: yyy

^ v

0:no 1:yes

New value saved!

Level 5

Level 6

Remarks:

Input rejected Press ENT OH Guard: xxx

OH Guard: xxx

OH Guard: yyy

^ v

0:no 1:yes

New value saved! Input rejected Press ENT

SERVICE MENU:

SETTINGS :

PERFORMA NCE:

< Settings >

Performa nce ^ v

Op category 1 ^ v

Fwd speed: xxx%

Fwd speed: xxx%

Fwd speed: yyy%

xxx = currently used value.

^ v

New value: ?

New value saved!

New value 'yyy' replaces the old 'xxx'.

Input reject ed!

Screen stays on for 1 s.

Press ENT Rev speed: xxx%

Rev speed: xxx%

Rev speed: yyy%

^ v

New value: ?

New value saved!

Displayed if value is out of range.

Input reject ed! Press ENT Tract accel:xx x%

acc to above!

^ v

198

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3

Level 4 Tract cutb1:xx x%

Level 5

Level 6

Remarks:

acc to above!

^ v Tract cutb2:xx x%

acc to above!

^ v Tract curr: xxx%

acc to above!

^ v Rdc brake: xxx%

acc to above!

^ v Neut brake: xxx%

acc to above!

^ v Rev brake: xxx%

acc to above!

^ v Brake pedal:xx x%

acc to above!

^ v PERFORMA NCE:

According to the above!

Op category 2 ^ v PERFORMA NCE:

According to the above!

Op category 3 ^ v PERFORMA NCE:

According to the above!

Op category 4 ^ v

PS/PSH

199

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

SETTINGS :

TRACTION :

Breakp lo: xxx%

Breakp lo: xxx%

Traction ^ v

Throttle map ^ v

^ v

New value: ?

Level 6 Breakp lo: yyy% New value saved!

Remarks: Defines the output signal level at 30% of the input signal 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Input reject ed! Press ENT Breakp hi: xxx%

Breakp hi: xxx%

^ v

New value: ?

Breakp hi: yyy% New value saved!

Screen stays on for 1 s. Displayed if value is out of range. Defines the output signal level at 70% of the input signal 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Input reject ed!

Screen stays on for 1 s.

Press ENT

Displayed if value is out of range.

Dead zone: xxx%

Dead zone: xxx%

Dead zone: xxx%

'xxx' = 'on' or 'off' (currently used)

^ v

New value: ?

New value saved!

New value 'yyy' replaces the old 'xxx'.

Input reject ed!

Screen stays on for 1 s.

Press ENT TRACTION :

Breakp lo: xxx%

Breakp lo: xxx%

Brake map ^ v

^ v

New value: ?

Breakp lo: xxx% New value saved!

Displayed if value is out of range. Defines the output signal level at 30% of the input signal 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

200

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

Level 6 Input reject ed! Press ENT

Breakp hi: xxx%

Breakp hi: xxx%

^ v

New value: ?

Breakp hi: xxx% New value saved!

Remarks: Screen stays on for 1 s. Displayed if value is out of range. Defines the output signal level at 70% of the input signal 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Input reject ed! Press ENT

Displayed if value is out of range.

Dead zone: xxx%

Dead zone: xxx%

Dead zone: xxx%

'xxx' = 'on' or 'off' (currently used)

^ v

New value: ?

New value saved!

New value 'yyy' replaces the old 'xxx'.

Input reject ed!

Screen stays on for 1 s.

Press ENT TRACTION : Motor type ^ v

Screen stays on for 1 s.

Motor: NN

Motor: NN

Motor: NN

0:Kordel 1:Sauer

New value saved!

Displayed if value is out of range.

Input reject ed! Press ENT SETTINGS : Brake ^ v

PS/PSH

201

10  Electrical system

Level 1

Level 2

Level 3

SETTINGS :

Speed ctrl: xx

Pump ^ v

^ v

Level 4

Level 5

Speed ctrl: xxxxx

Speed ctrl: xxxxx

0: valve 1: motor

New value saved!

Level 6

Remarks:

Input rejected ! Press ENT Cont Delay: xr

Cont Delay: xr

Cont Delay: xr

^ v

New value: ?r

New value saved! Input rejected ! Press ENT

Delay1: xxx

Delay1: xxx

Delay 1: x

^ v

New value: ?r

New value saved! Input rejected ! Press ENT

Delay2: xxx

Delay2: xxx

Delay 2: x

^ v

New value: ?r

New value saved! Input rejected ! Press ENT

202

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

Lower acc: xxx

Lower acc: xxx

Lower acc: xxx

^ v

New value: ?r

New value saved!

Level 6

Remarks:

Input rejected ! Press ENT Lower ret: xxx

Lower ret: xxx

Lower ret: xxx

^ v

New value: ?r

New value saved! Input rejected ! Press ENT

Pump acc: xxx

Pump acc: xxx

Pump acc: xxx

^ v

New value: ?

New value saved! Input rejected ! Press ENT

Pump dec: xxx

Pump dec: xxx

Pump dec: xxx

^ v

New value: ?

New value saved! Input rejected ! Press ENT

PS/PSH

203

10  Electrical system

Level 1

Level 2

Level 3 Temp guard: xxx ^ v

Level 4

Level 5

Temp guard

Temp guard

0:no 1:yes

New value saved!

Level 6

Remarks:

Input rejected ! Press ENT SETTINGS :

HYDRAULI CS:

HVC 1: xxx

HVC 1: xxx

HVC 1: yyy

Hydrauli cs ^ v

HVC Setup ^ v

^ v

0:off 1:on

New value saved! Input reject ed!

'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'. Screen stays on for 1 s.

Press ENT

Displayed if value is out of range.

HVC 1 PWM:xxxx Hz

HVC 1 PWM:xxxH z

HVC 1 PWM:yy yHz

'xxx' = 'on' or 'off' (currently used)

^ v

0:off 1:on

New value saved!

New value 'yyy' replaces the old 'xxx'.

Input reject ed!

Screen stays on for 1 s.

Press ENT HVC 2: xxx

Displayed if value is out of range.

acc to above!

^ v HVC 2 PWM:xxxx Hz

acc to above!

^ v HVC 3: xxx

acc to above!

^ v HVC 3 PWM:xxxx Hz

acc to above!

^ v

204

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3

Level 4 HVC4 :xxx

Level 5

Level 6

Remarks:

acc to above!

^ v HVC 4 PWM:xxxx Hz

acc to above!

^ v HYDRAULI CS: Lift ^ v

Raise ctrl:xxx xx

Raise ctrl:xxx xx

Raise ctrl:y yyyy

'xxx' = 'on' or 'off' (currently used)

^ v

0:OnOff 1:Speed

New value saved!

New value 'yyy' replaces the old 'xxx'.

Input reject ed!

Screen stays on for 1 s.

Press ENT Raise min: xxx% ^ v

Raise min: xxx New value: ?

Raise min: yyy New value saved! Input reject ed! Press ENT

Raise max: xxx%

^ v

PS/PSH

Refers to [ valve PWM ] or [ pump motor speed ] depending on choice above. Note that the min/max parameters only are used if speed control are selected. Appears only if speed control is selected above!

acc to above!

Appears only if speed control is selected above!

acc to above!

Appears only if speed control is selected above!

^ v Lower max: xxx%

Appears only if speed control is selected above!

acc to above!

^ v Lower min: xxx%

Displayed if value is out of range.

205

10  Electrical system

Level 1

Level 2

Level 3

Level 4 Breakp: xxx%

Level 5 acc to above!

^ v

Level 6

Remarks: Defines the output signal level at 50% of the input signal Appears only if speed control is selected above!

Dead zone: xxx%

acc to above!

Appears only if speed control is selected above!

acc to above!

Open delay of the proportional valve. Parameter range between 0-255. Unit s/20.

^ v Open delay: xxx ^ v

Appears only if speed control is selected above! Close delay: xxx

acc to above!

^ v

Close delay of the proportional valve. Parameter range between 0-255. Unit s/20. Appears only if speed control is selected above!

Dither freq: x ^ v

acc to above!

Dither frequency. Parameter range between 0-9. Appears only if speed control is selected above!

206

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3 HYDRAULI CS: Channel 2 ^ v

Level 4

Level 5

Level 6

Remarks:

Ch2 ctrl: xxxxx

Ch2 ctrl: xxxxx

Ch2 ctrl: yyyyy

''xxxxx' = currently used value

^ v

0:OnOff 1:Speed

New value saved!

New value 'yyyyy' replaces the old 'xxxxx'.

Input reject ed!

Screen stays on for 1 s.

Press ENT Speed ctrl:xxx xx

Speed ctrl:xxx xx

Speed ctrl:y yyyy

^ v

0:Valve 1:Motor

New value saved!

Displayed if value is out of range. Appears only if speed control is selected above!

Input reject ed! Press ENT Ch2 pos min:xxx%

Pos min: xxx

^ v

New value: ?

Pos min: yyy New value saved! Input reject ed! Press ENT

Ch2 pos max:xxx%

Appears only if speed control is selected above!

acc to above!

Appears only if speed control is selected above!

acc to above!

Appears only if speed control is selected above!

^ v

Ch2 neg max:xxx% ^ v

PS/PSH

Appears only if speed control is selected above!

acc to above!

^ v

Ch2 neg min:xxx%

Refers to [ valve PWM ] or [ pump motor speed ] depending on choice above.

207

10  Electrical system

Level 1

Level 2

Level 3

Level 4 Breakp: xxx%

Level 5

Level 6

Remarks: Defines the output signal level at 50% of the input signal

acc to above!

^ v

Appears only if speed control is selected above! Dead zone: xxx%

Appears only if speed control is selected above!

acc to above!

^ v HYDRAULI CS:

Hydra lock: xx

Hydra lock: xx

Hydraul lock ^ v

0:off 1:on

New value saved! Input rejected ! Press ENT

SETTINGS :

FB adjust

Adj FB mode

Steering ^ v

^ v

0:off 1:on

Plese wait, storing data.

Restar t system and adjust FB

This menu appears when FB adjust mode is 'On'

FB adj. Comple te

This menu appears when FB adjust mode is 'Off'

Restar t system EPS :xxx

EPS :xxx

EPS: yyy

^ v

0:off 1:on

New value saved! Input rejected ! Press ENT

208

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

Numbness x

Numbness x

Numbness x

^ v

New value: ?

New value saved!

Level 6

Remarks:

Input rejected ! Press ENT Steer ctrl:xxx xx

Steer ctrl:xxx xx

Speed ctrl:yyy yy

^ v

1:Speed 2:Posit

New value saved! Input rejected ! Press ENT

Lim. rough CW:

Lim. rough CW: x

^ v

New value: ?

Lim. rough: x New value saved! Input rejected ! Press ENT

Lim. rough CCW:

Lim. rough CCW: x

Lim. rough CCW: x

^ v

New value: ?

New value saved! Input rejected ! Press ENT

PS/PSH

209

10  Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

Limit fine CW: xx

Limit fine CW: x

Limit fine CW: x

^ v

New value: ?

New value saved!

Level 6

Remarks:

Input rejected ! Press ENT Limit fine CCW:

Limit fine CCW: x

Limit fine CCW: x

^ v

New value: ?

New value saved! Input rejected ! Press ENT

Steer hi spd:

Steer hi spd: xx

Steer hi spd: xx

^ v

New value: ?

New value saved! Input rejected ! Press ENT

SETTINGS : Battery ^ v

BATTERY: Battery type: ^ v

Battery type: x

Battery type: x

Wet:0 Gel:1 x

New value saved! Input rejected ! Press ENT

210

PS/PSH

10  Electrical system

Level 1

Level 2

Level 3 BATTERY: Wet battery ^ v

Level 4

Level 5

Wet battery:

Stepdown hi: x

Stepdown hi ^ v

New value: ?

Level 6

Remarks:

Stepdo wn hi: y New value saved! Input reject ed! Press ENT

Wet battery:

Stepdown lo: x

Stepdown lo ^ v

New value: ?

Stepdo wn lo: y New value saved! Input reject ed! Press ENT

BATTERY: Gel battery ^ v

Gel battery:

Stepdown hi: x

Stepdown hi ^ v

New value: ?

Stepdo wn hi: y New value saved! Input reject ed! Press ENT

Gel battery:

Stepdown lo: x

Stepdown lo ^ v

New value: ?

Stepdo wn lo: y New value saved! Input reject ed! Press ENT

PS/PSH

SETTINGS :

TRUCK TYPE

Truck type ^

XX

XX = trucktype

211

10  Electrical system

Level 1 SERVICE MENU: < Tests >

212

Level 2 TESTS: Inputs ^ v

Level 3

Level 4

TEST INPUTS:

11122233 3444555A

Overview ^ v

66677BCD EFGHIJK

TEST INPUTS:

Signal check:

Accelera tor ^ v

x.x V Out:syyy %

TEST INPUTS:

Signal check:

Brake ^ v

x.x V Out:syyy %

TEST INPUTS:

Signal check:

Lift ^ v

x.x V Out:syyy %

TEST INPUTS:

Signal check:

Aux AI 1 ^ v

x.x V Out:syyy %

TEST INPUTS:

Signal check:

Aux AI 2 ^ v

x.x V Out:syyy %

Level 5

Level 6

Remarks: Strings of the same digit are bar graphs for analogue/ste ering enc inputs. The digit identifies the input, the number of digits represents the input signal level. E.g "1" means: 10%