37 2 6MB
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.
PS/PSH
69
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
PS/PSH
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
PS/PSH
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
85
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
PS/PSH
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.
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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.
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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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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: ?
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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.
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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^
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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.
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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)
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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
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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.
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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
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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
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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.
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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
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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.
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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.
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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.
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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
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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
PS/PSH
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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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
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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
PS/PSH
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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
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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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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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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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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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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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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
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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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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
PS/PSH
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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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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.
PS/PSH
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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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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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
PS/PSH
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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
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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
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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
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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%