Atlet Forklift PLP SERVICE MANUAL 2013B

PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

01

GENERAL INFORMATION AND TECHNICAL DATA 2013B

1.1

Introduction 1.1.1 1.1.2 1.1.3 1.1.4

1.2

1.3

1.5

1.6

6

We respect the environment.............................................................................................. 6

7

1.4.1 1.4.2

Service............................................................................................................................... 7 Trouble shooting ................................................................................................................ 7

Data

7

1.5.1 1.5.2 1.5.3

Designations...................................................................................................................... 7 Dimensions and weights.................................................................................................. 10 Component specification ................................................................................................. 12

Recommended consumable materials

13

Oil and grease types........................................................................................................ 13

Standards and abbreviations 1.7.1 1.7.2 1.7.3 1.7.4 1.7.5 1.7.6

PLP

General.............................................................................................................................. 3 Truck modification.............................................................................................................. 4 Lifting the truck .................................................................................................................. 5 Welding on the truck.......................................................................................................... 6 Gas spring ......................................................................................................................... 6

Preparations

1.6.1

1.7

3

Environmental considerations 1.3.1

1.4

General.............................................................................................................................. 3 The trucks.......................................................................................................................... 3 Structure of the Manual ..................................................................................................... 3 Symbol key ........................................................................................................................ 3

Safety 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5

3

14

Screws............................................................................................................................. 14 Standard abbreviations and units .................................................................................... 16 Screw types and tensile grades....................................................................................... 16 Colour coding according to NCS ..................................................................................... 17 Colour codes for wiring diagrams .................................................................................... 17 Designations for electrical components........................................................................... 18

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

2

PLP

PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

01

GENERAL INFORMATION AND TECHNICAL DATA

1.1

Introduction

1.1.1

General This manual describes the service procedures for UniCarriers PLP low lifters. Use the manual for quick and correct service of respective truck models.

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 UniCarriers Service Manual Change.

1.1.2

The trucks The manual covers the low lifters PLP 200 and PLP 250.

1.1.3

Structure of the Manual The manual is arranged in accordance with the same principles as the Atlet spare part catalogues, i.e. 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 placed in Chapter 12 "Miscellaneous". For this reason Chapter 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:

PLP

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PLP Service Manual — D001981, C, GBR, Translated

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 trouble shooting, 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.

To prevent injuries caused by crushing the battery plug should always be removed when working on and around the mast and hydraulic unit. The mast or hydraulic unit can be actuated and move due to an electrical fault or a mistake while working. 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!

• •

• • • •

•

1.2.2

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 using a jack, make sure you secure it with blocks. The truck must not rest on the jack, while work is carried out.

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

Always use UniCarriers 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.

Only service personnnel who have been authorised by UniCarriers, shouldcarry out servicing and maintenance. UniCarriers cannot accept responsibility for servicing or maintenance that is carried out by personnel who have not been authorised.

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

4

PLP

PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

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: • • • •

1.2.3

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; 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 1. Permitted PLP lifting points

WARNING! The machine must never be lifted in any other points than the ones shown.

PLP

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

Figure 2. Lifting point, jack

1.2.4

Welding on the truck •

•

1.2.5

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.

Gas spring The functioning of the platform and steering arm should be checked. The gas springs in both of these functions are a very critical factor for their correct functioning.

During service and preventive maintenance it is important if the truck is a model with a suspended platform to check that the platform is raised up automatically when the driver gets off 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! 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.

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PLP

PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

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 •

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.

• • •

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 Truck designation Table 1. Truck designations Truck Type Load capacity

PLP

PLP 200

Low lifter

PLP 250

Low lifter

PLP 200

2000 kg

PLP 250

2500 kg

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

Type designation

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

2.

Model designation.

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

3.

4.

8

Year of manufacture, week, and warranty period in months (only Sweden). (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).

PLP

PLP Service Manual — D001981, C, GBR, Translated

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 (only Sweden). (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.

PLP

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

Table 2. Explanation of Model designation: Example: PLP 200 160 30

1.5.2

Truck Type

PLP

Load capacity/10

200

Battery Ah/5

160

Charger Ampere

30

Dimensions and weights Dimensions PLP

10

PLP

PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

Machine specification No. 1

Lifting capacity, rated

Q

1a

Distance to centre of gravity

D

2

Lifting height

H4

2a

Mast height

H3 H5

2b

Transport free lift

2c

Full free lift

2d

Straddle lift

4

Lifting speed without load – with rated load

4a

Lifting time without load – with rated load

5

Lowering speed without load – with rated load

kg

PLP

PLP 250

2000

2500

600

600

200

200

2,0-2,5

2,0-2,7

2,5

2,5

mm

H2

m/s, s

Lowering time without load – with rated load 6

PLP 200

Driving speed without load – with rated load

km/h

10,0-8,5

12,0-9

Driving speed without load – with rated load

m/s

2,77-2,36

3,3-2,77

8

Reversing capacity without load – with rated load

Max

%

10-10

10-10

10

Turning radius

R2

mm

770 + L2

835 + L2

11

Minimum aisle width Ast incl. 200 mm R2- L2 + load length + 200

mm

Load length 800 mm

Ast

mm

Load length 1000 mm

Ast

mm

Load length 1,200 mm

Ast

mm

13

Height over protective roof

H6

mm

14

Truck length

L

mm

750 + L1

825 + L1

15

Truck width

B

mm

770

770

16

Fork length, std

L1

mm

1000 / 2375

1000 / 2375

17

Width over forks, std max-min

V

680 / 460

680 / 480

17a

Width between fork shanks

V - 350

V - 350

19

Truck length to fork support area

L4

750

825

20

Fork arm, width – thickness

B1

175 - 55

175 - 55

20a

For height, min

H1

mm

85

85

21

Straddle lift height

H7

mm

22

Width between fork straddle lift

B2

mm mm mm mm

mm

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

No.

1.5.3

PLP 200

PLP 250

785 - 1765

785 - 1465

551 + L2

626 + L2

W - 175/526

W - 175/526

30 - 145

30 - 145

23

Dim. for front axle – fork support area

L2

24

Wheelbase

L3

25

Wheel track – front, back centre of wheel

mm

26

Ground clearance, half wheelbase load

mm

27

Service weight with/without battery

860 - 530

925 - 545

28

Max axle pressure, load wheel with/without rated load

212 / 1828

212 / 2238

705 - 1110

715 - 1215

mm mm

kg

29

Max axle pressure, drive wheel with/without rated load

39

Battery capacity

kWh

4,8-9,6

7,5-14,4

39a

Battery voltage

Ah

200-400

300-600

V

24

24

kW

2.2/2.4 AC

2.2/2.4 AC

Transistor

Transistor

41

Traction motor

42

Speed controlling

43

Lift motor

kW %/min

2,2 - 12/10

2,2 - 12/10

43a

Hydraulic pressure

MPa

9

11

44

Wheel type

Vulkollan

Vulkollan

44a

Number of drive/castor/load wheels

3-4

3-4

45

Wheel dimensions

45a

Load wheel D* width

(4x) 85x75

(4x) 85x75

45b

Drive wheel D* width

(1x) 230x90

(1x) 230x90

45c

Caster wheel

(2x) 150x60

(2x) 150x60

46

Steering system

Tiller arm

Tiller arm

47

Main brake, type – actuated part

El. drive mech.

El. drive mech.

48

Parking brake, type – actuated part

El. drive mech.

El. drive mech.

mm

Component specification Table 3. Component specification Component Traction motor

Specification Drive voltage

24V

Output standard

2.2/2.4 kW 60 min.

Gearbox Hydraulic system

12

Gear ratio (standard)

15:1

Oil volume

0.85 litre

Max pressure

21 MPa

Oil volume

max 1.6 litre

PLP

PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

Component

Specification

Hydraulic unit (motor and pump)

Output

2.2 kW

Control system for traction motor

Type FZ2007

AC1 CAN

Voltage

24 V

Max. current

250A (RMS) for 2 min

Control fuse 1

5A

Pump motor fuse 1

250 A

Traction motor fuse 1

250 A

Fuses

1.6

Recommended consumable materials

1.6.1

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 follow the Atlet requirements for 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. If this takes place the oil becomes black (due to the build-up of sediment) and must be changed to prevent jamming of the hydraulic valves. We currently have grounding of all the truck models that may be affected by this problem. It is important that different products and brands are not mixed, particularly synthetic and mineral oils.

Refer to the purchasing documentation for more information about the products.

CAUTION! Never mix different lubricants, and definitely not synthetic oil with mineral oil!

Product

Brand name and type Part no.

Class

Standard

Mobil DTE 10 Exel

107173

ISO VG 46, viscosity index 150 or greater.

Cold store

Mobil Univis HVI 26

008936

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

Biodegradable oil

Mobil EAL Hydraulic 32 014160

Hydraulic oil

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.

PLP

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

Product

Brand name and type Part no.

Oil for the food industry Mobil DTE FM 32

Class

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

Mobilube HD-A 85w-90 116444

Class GL5, 85W-90.

For ZF drive units the oil must be approved in the ZF list of TE-ML 17B lubricants.

Cold store

Mobile Devac synthetic 116447 Gear Oil 75W-90

Class GL5, 75W-90. For ZF drive units the oil must be approved in the ZF list of TE-ML 17B lubricants.

Standard/Cold stores

Molykote G-4501

014163 180 kg

Fully synthetic, lithium complex, NLGI grade 1.5. viscosity 220.

-40°C till +180°C.

Standard

Mobilux EP 2

001197 0.4 kg tube

-20°C to +110°C.

Cold store

Molykote G-4501

014164 0.4 kg tube

-40°C to +180°C.

Grease, ball bearings

SKF grease

001207

Grease for bearings.

High performance grease

Molycote, Multilube

014165 0.4 kg tube

Good load capability, water-resistant.

Electronics grease; electrical system. Only for cold stores.

Kryotox El 2

124525 30 g tube

Tool for tube, part no. 110782.

Electrical grease specification.

-50°C to +270°C.

Tectyl/Dinitrol

014162

No specification.

Chain spray

001196

No specification.

Electronics spray

001198

No specification.

Lubrication spray

001195

No specification.

Degreasing compound

112268

No specification.

Biodegradable oil Grease

Miscellaneous Rust protection

1.7

Standards and abbreviations

1.7.1

Screws

1.7.1.1

Tightening torques for screws and nuts Table 4. Tensile grade

14

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

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

DIM

4,6 Nm

8,8 Nm

10,9 Nm

12,9 Nm

M8

8,9

24

33

40

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.

1.7.1.2

Tightening torques for hydraulic couplings Table 5. 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.

1.7.1.3

PLP

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

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

1.7.1.4

1.7.1.5

1.7.2

1.7.3

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

Description

Tensile grade

M6S

Hexagon screw

8,8 10,9

MC6S

Hexagon hole screw

8,8 10,9 12,9

16

MF6S

Hexagon hole screw, countersunk

10,9

MCS

Slotted screw

4,6

PLP

PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

Screw type

Description

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.

1.7.4

1.7.5

PLP

Colour coding according to NCS Machine colour

Designations

Yellow

NCS 0070-Y20R

Medium grey

NCS 7000

Dark grey

NCS 8000

Colour codes for wiring diagrams Code

Cable colour

BL

Blue

BN

Brown

GN

Green

GR

Grey

OR

Orange

P

Pink

R

Red

SB

Black

VO

Violet

W

White

Y

Yellow

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PLP Service Manual — D001981, C, GBR, Translated

01 General information and technical data

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.

1.7.6

Designations for electrical components Electrical components normally have a designation of two letters: Table 6. First letter Code

Description

Designation (Eng)

A

Component or function without its own letter in the list

Component or function without its own letter below

C

Kondensator

Capacitor

D/V

Diod

Diode

E

Elektronikkomponent

Electrical component

F

Säkring

Fuse

I

Indikator

Indicator

K

Kontaktor/relä

Contactor/relay

L

Spole/induktivt element

Coil/inductive element

M

Motor

Motor

P/X

Koppling

Connection

R

Motstånd

Resistor

S

Switch

Switch/Change-over switch

T

Terminalanslutning

Terminal

Y

Ventil/broms

Valve/brake

H

Ljudvarning/lampor/ljus

Audible warning unit/lamps/lights

G

Battery

Battery

Code

Description

Designation (Eng)

B

Brake Assembly

Brake

C

Kontrollsystem

Control system

E

Nödfunktion

Emergency function

F

Framåt

Forward

H

Tidsenhet

Hour

K

Nyckel

Key

L

Lower

Lower

M

Manöver

Manoeuvre

P

Pump

Pump

R

Reverse

Reverse

S

Speed

Speed

Table 7. Second letter

18

PLP

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2007B

2 Special tools Special tools PLP ........................................................................................................... 2.3 Introduction .......................................................................................................... 2.3 List of tools .......................................................................................................... 2.3

SERVICE MANUAL

2.2

SERVICE MANUAL

Special tools / Special tools PLP / Introduction

2.3

Edition 2007B

2 Special tools Special tools PLP Introduction All special tools can be ordered from Atlet AB.

List of tools Table 2.1 List of tools Designation

Part number

Applications

Cleaning fluid

P/N 112268

Cleaning of electric motors from gearbox oil and other dirt

Chain spray

P/N 001196

Lubrication of chains

Crimping tool Molex

P/N 006454

Cable connections

Pin extractor

P/N 006456

Cable connector

Lifting eye

P/N 104737

Lifting eye for drive unit.

P/N 118515

Lifting tool

Lifting device

Figure

2.1

For detailed information on the above products, please contact Atlet.

SM_PLP_02_0001A.eps Bild 2.1 Lifting device

SM_PLP_02_119002_2007B.fm

SERVICE MANUAL

2.4

Special tools / Special tools PLP / List of tools

SERVICE MANUAL

SERVICE MANUAL Macine:

Manual No:

PLP

119002

Edition 2011A 3 Service

Regular maintenance 3

Introduction .......................................................................................................... 3.3 Safety .................................................................................................................. 3.3 Recommendation ................................................................................................ 3.3 Daily service ........................................................................................................ 3.3 Weekly service (30 operating hours) ................................................................... 3.3 First service ......................................................................................................... 3.4 Main service ........................................................................................................ 3.4 Extra service inspections ..................................................................................... 3.4 Check list, service inspection .............................................................................. 3.6 Code explanation ............................................................................................... 3.10 Lubrication chart ................................................................................................ 3.14 PLP ............................................................................................................................... 3.14 Symbol key, lubrication chart ....................................................................................... 3.15

Specific instructions 16

Traction motor ................................................................................................... 3.16 Preventive maintenance ............................................................................................... 3.16

Gearbox ............................................................................................................. 3.16 First service .................................................................................................................. 3.16 Preventive maintenance ............................................................................................... 3.16

Lift chains and forks ........................................................................................... 3.17 Check ........................................................................................................................... 3.17

Hydraulic oil ....................................................................................................... 3.18 First service .................................................................................................................. 3.18 Intervals ........................................................................................................................ 3.18

Emergency stop ................................................................................................. 3.18 Recommended replacement ............................................................................. 3.19 Storage of machines and motors ....................................................................... 3.19

SERVICE MANUAL

3.2

SERVICE MANUAL

Service / Regular maintenance / Introduction Edition 2011A

3.3

3 Service

Regular maintenance 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.

Safety Important!

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 function tests of the safety system should be made with the speed controller in neutral position, see section 10.

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 investment in your truck we advise you to contact your local Atlet representative and to sign up for a service contract for regular inspection.

Daily service For instructions, refer to the Operators Manual.

Weekly service (30 operating hours)

For instructions, refer to the Operators Manual.

SERVICE MANUAL

03_SM_PLP_En_119002_2011A.fm

3.4

Service / Regular maintenance / First service First service

The first service should be carried out after 200 hours. This service has the purpose of ensuring the function of the truck and its component parts.

• Change the oil in the gearbox.

• Change the hydraulic oil filter.

• Test the function of the entire machine in accordance with the following list.

Main service

Tightening torque: 195Nm

EN-1726 and ISO 3691 specify that regular preventive maintenance should be carried out on the truck. To guarantee high quality, operation reliability and personal safety, this maintenance should be carried out by Atlet Service or by personnel specially trained by Atlet. To comply with this requirement Atlet has prepared the following main service points (A service), which should be checked every 500 hours of operation.

• Check for external damage on chassis.

• Check of weld joints at vital points.

• Check of lifting devices.

• Check of component attachments.

• Function test, lever (lever bolts195 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.

• Oil and filter change according to 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.

SERVICE MANUAL

Service / Regular maintenance / Extra service inspections

None of the above mentioned inspection can be debited to Atlet Products.

SERVICE MANUAL

3.5

3.6

Service / Regular maintenance / Check list, service inspection 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: Chassis Inspection points

Symptom

Inspection

Service code

Signs/Decals

None, illegible

Visual

1024, 1101

Panels

Attachment, damage

Visual, tools

1102, 1032

Load wheel, Castor wheel

Damage, wear

Visual

1108, 1109

Noise

Listen, tool

Attachment

Visual, tools

Rubber mats, Rub- Damage ber protectors Attachment Chassis, general Tightening torque: 195Nm

Driving seat, seat

Visual

1105, 1058

Visual, tools

Appearance

Visual

1001, 1033, 1112

Damage

Visual

Loose screws, bolts

Tools (lever bolts 195 Nm)

Settings, tilt, load and angle adjustments, attachment to the chassis, damage, lubrication, seat switch (10w46 - )

Visual

1107

Mast Inspection points

Symptom

Inspection

Service code

Pull rods

Locking.

Tools

2105

Damage

Visual

Cracks, damage

Visual

Wear

Visual

Angle, deformation

Visual, tools

Cracks, damage

Visual

Play, damage, wear on rollers

Visual, operating test

Angle, deformation

Visual

Attachment rollers

Visual, tools

Forks

Fork carriage

SERVICE MANUAL

2026

2007, 2004

Service / Regular maintenance / Check list, service inspection Mast Inspection points

Symptom

Inspection

Service code

Mast sections

Cracks, damage

Visual

2101

Wear, cracks

Visual

Drive unit Inspection

Inspection points

Symptom

Gearbox

Oil level

Visual, filling

Oil leakage

Visual, tools

Function, noise

Listen, tool

Cable connections

Visual, tools

7028, 7113, 7039, 7027, 7112

Noise

Listen, tool

3002, 3005

Damage, wear

Visual

Attachment, play

Visual, tools

Sliding bearing

Noise

Listen, lubricate

3103

Drive shaft

Noise

Listen, tool

3104

Gear

Noise

Listen, tool

3102, 3106

Traction motor Drive wheel

Service code 3006, 3101, 3107

Steering Inspection points

Symptom

Inspection

Service code

Guide bearing

Noise

Listen, lubricate

4101

Tiller arm attachment

Play

Visual

4103

Attachment

Tools

Guide belt

Play

Visual

4005

Brake Inspection points

Symptom

Inspection

Service code

Braking force

Malfunction

Function test, tools

5012

Parking brake

Malfunction

Function test, tools

5014

Brake cable

Abrasion

Visual

5002

Brake disc

Wear

Visual, tools

5104

SERVICE MANUAL

3.7

3.8

Service / Regular maintenance / Check list, service inspection

Inspection points

Hydraulic system Symptom Inspection

Service code

Hydraulic tank

Oil level

Visual, filling

6012, 6102

Damage, leakage contamination

Visual, cleaning

Filter blocked

Visual, replace

Function

Function test, stopwatch

Damage

Visual, replace

Leakage

Visual, tools, replace

Weld damage

Visual, tools, replace

Damage, chain attachments

Visual, tools

Leakage, damage

Visual, tools

Attachment

Visual, tools

Nipples

Leakage

Visual, tools

6019

Pump motor

Function, noise

Listen, tool

7030, 7029

Cable connections

Visual, tools

Leakage

Visual, tools

Damage

Visual, tools

Noise

Listen

Malfunction

Test

Leakage

Visual, tools

Malfunction

Test

Leakage

Visual, tools

Malfunction

Test

Leakage

Visual, tools

Cylinders

Hoses

Hydraulic pump

Relief valve Solenoid valve Prop. valve

6001, 6017

6007, 6008

6109

6105 6018 6018

For more information regarding the hydraulic system, also see section 8 and lift cylinders section 9.

SERVICE MANUAL

Service / Regular maintenance / Check list, service inspection

Inspection points

Electrical system Symptom Inspection

Service code

Contactors

Malfunction

Visual, tools, replace

7107

Cable break

Visual, tools

Contactor tip

Visual, tools

Charging

Tools

Low acid level

Tools

Low acid weight

Tools

Damage

Visual

Transistor system AC

Cable break

Visual, tools

7025

Cabling

Damage, break

Visual, tools

7007, 7009 7010, 7039 7104, 7112

Horn

Malfunction

Function test

7014

Speed controller

Attachment

Visual, tools

7011, 7106

Malfunction

Function test

Battery

7032

Calibration Fuses

Blown

Visual, replace

7103

Battery plug

Malfunction

Function test, tools

7008

Hour meter

Malfunction

7012

Battery indicator

Malfunction

7013

Safety switch

Emergency stop

Malfunction

7020

Microswitch

Function

Function test

7017

ATC T4

Function Cable connections

Visual

7004

SERVICE MANUAL

3.9

3.10

Service / Regular maintenance / Code explanation

Code explanation

Chassis Code

Designation

Check

Reference to section

1001

Machine housing

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

1024

Machine plate

Attachment: text should correspond with 1 machine type, and symbols and warning decals should be fitted.

1032

Panels

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

4

1033

Colour

Peeling of paint and attachment/lack of decals.

1

1042

Load guard

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

1

1058

Rubber strips

Attached with glue or screws/weld bolts

-

1101

Decals

Damage

-

1102

Chassis, covers

Damage, battery cover

4

1108 1109

Load wheel bearing Castor wheel bearing

The operation is frictionless, remove any string, 4 plastic bands etc. that have stuck.

6 Vulkollan wheel wear. Dirt.

1112

Accessories

User Manual, areometer and battery water bot- tle.

1

Mast Code

Designation

Check

Reference to section

2004

Frame section

Attachment of the mast in machine housing.

1

2007

Rollers in fork carriage

Washers. Lubrication of roller surfaces.

1 6

2026

Forks

Cracks, damage, parallelism, height over floor.

6

2101

Mast play

Check max play, Cams. Lubricate slide surfaces.

6

2102

Lift chains

Check wear.

4

2105

Push rods / Pull rods

Locking, damage

6

SERVICE MANUAL

Service / Regular maintenance / Code explanation

3.11

Drive unit Code

Designation

Check

Reference to section

3002

Drive wheel

Wear, damage, clean

5

3005

Drive wheel bolt

Attachment.

5

3006

Oil leakage

Leakage from axles, joints, plugs or material.

5

3101

Oil level

Oil level. Oil change.

1 5

3102

Noise

Gears.

5

3103

Sliding bearing

Noise, lubrication

5

3104

Drive shaft

Tightening, play

5

3106

Gears

Gear ratio

5

3107

Gear housing

Check wear.

5

Steering Code

Designation

Check

Reference to section

4103

Tiller arm attachment Play, bushings, attachment

7

4104

Guide bearing

1 7

Play, lubrication

Brake unit Code

Designation

Check

Reference to section

5002

Brake cable

Attachment, damage

11

5012

Braking force

Braking distance

11

5014

Parking brake

Function, cable connections

11

5104

Brake discs

Friction surface> min level all round

11

SERVICE MANUAL

3.12

Service / Regular maintenance / Code explanation

Code

Designation

Hydraulic system Check

Reference to section

6001

Lift cylinders

Leakage at attachments, weld joints, scraper, piston rod

9

6007

Couplings

Leakage.

-

6008

Hoses

Cracks, wear, damage.

1

6012

Oil level in tank

Oil level between min and max.

1 8

6017

Lowering

Check lowering speed.

8

6018

Solenoid valve

Leakage in slide, connections, tightening.

-

6019

Nipples

Leakage. Tightening.

-

6102

Filter

Replace if necessary.

8

6105

Relief valve

Function, adjustment as per max lifting capacity. Locking.

8

6109

Hydraulic pump

Leakage between pump and motor.

-

SERVICE MANUAL

Service / Regular maintenance / Code explanation Electrical system Check

Code

Designation

7004

Truck computer

Error log.

10

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

Function. Oxide deposits.

-

7017

Microswitch

Function. Attachment.

-

7020

Emergency switch

Function.

-

7025

Transistor system

Dirt, moisture. Cable connections, oxide.

-

7029

Pump motor carbon brushes

Wear.

8

7030

Pump motor

Attachment. Cleaning.

5

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.

10

7103

Fuses

That they are not brittle, oxidised.

1

7104

Cabling

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

-

7106

Speed controller

Attachment and function.

11

7107

Contactors

Contact surfaces, cable connections, dust guard.

-

7112 7039

Traction motor cables Attachment, damage, insulation, oxidation.

-

7113

Housing, traction motor

5

Noise, grease, play.

SERVICE MANUAL

3.13

Reference to section

3.14

Service / Regular maintenance / Lubrication chart Lubrication chart Note!

For recommended oil and grease types, see section 1.

PLP

A

B D C

E F

1 2

G Figure 3.1

Lubrication chart PLP. For explanation of symbols, see table 3.2

1. 500 h service 2. Annual service All the panels must be removed when lubricating the truck, see section 4. The electric panel should also be released and folded back to improve access. The electric panel is fitted with two socket head cap screws to the battery wall. When lubricating the mast sections, push out the battery slightly and brush grease on the roller and slide surfaces.

Service on an Atlet truck can be divided into service that should be carried out regardless of how severely the truck is loaded and used (see "Check list, service inspection" on page 3.6) and an annual recurrent service:

SERVICE MANUAL

Service / Regular maintenance / Lubrication chart Table 3.1

Components to lubricate, PLP

Positioning

Explanation

A

Mast section – roller surfaces and slide surfaces

B

Gates – bearing surfaces lubricated

C

Spring-mounted drive unit – link bearings, 12 grease nipples

D

Hydraulic oil

E

Castor wheel - sliding bearings, 2 grease nipples

F

Gearbox oil

G

Platform, 2 grease nipples

Symbol key, lubrication chart Table 3.2

Symbol key for lubrication chart

Symbol

Explanation

Symbol

Explanation

Hydraulic oil

Hydraulic oil, 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 / lubrication.

• Filled symbol – Change.

SERVICE MANUAL

3.15

3.16

Service / Specific instructions / Traction motor

Specific instructions

Note!

For recommended oil and grease types, see section 1.

Traction motor Preventive maintenance Preventive maintenance is implemented in accordance with the recommended intervals in 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.

• Listen for abnormal noise from the bearings when the motor is run. Check that it does not vibrate abnormally.

• The motor is blown clean with dry compressed air, or cleaned with a vacuum cleaner. A cleaning fluid should be used to drive out oil and dirt, if oil has leaked from the gearbox into the motor.

• Check the insulation resistance for the motor, see specification in section 1 for correct value.

Gearbox First service First oil change after 200 hours

• •

The first oil change should be made after approx. 200 hours.

Use a recommended type of oil, see section 1.

Preventive maintenance Oil level checked during each service

•

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.

Note!

Remember to fill up the gearbox after changing the oil or changing the gearbox. See section 5 for procedure.

SERVICE MANUAL

Service / Specific instructions / Lift chains and forks

3.17

Note!

Spent oil should be taken care of and recycled according to the applicable legislation in respective countries.

Lift chains and forks

Check For safety reasons the forks should be checked during each service, see "Check list, servThe forks

ice inspection" on page 3.6

should be checked during each service

SERVICE MANUAL

3.18

Service / Specific instructions / Hydraulic oil

Hydraulic oil Note!

For recommended oil and grease types, see section 1.

First service

Hydraulic oil filer change after 500

•

Oil filters should be changed after 500 hours.

hours

Intervals

After 500 hours of operation: The hydraulic oil filter and air filter to the hydraulic oil

tank should be changed after no more than 500 hours of operation. This refers to those types of trucks that have replaceable filters. Clean the suction filter.

After every 1000 hours of operation: Change the hydraulic oil, oil filter and air filter after 1000 hours of operation, or once every year (which ever comes is first).

If the hydraulic oil has been heated over 60 degrees Celsius the oil and the filter should be immediately replaced since its lubricating properties can have been changed.

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.

It can also be checked with the following simple test: 1. Use protective glasses, gloves and clothes, and observe the fire instructions for the premises.

Warning!

Risk for burn injuries on the skin.

2. Take a little hydraulic oil in a teaspoon and heat the spoon with a cigarette lighter – if there is a crackling sound this proves that it contains water and should be changed.

The hydraulic oil should be filtered when filling, by pouring the oil through the filter.

Emergency stop Special emphasis should be placed on the inspection of the emergency stop. Of the contactor tip seems to be worn during a visual inspection, it should be replaced on a preventive basis. Applies to emergency stop SE. Warning!

The unit should be replaced if the emergency stop has been used in a dangerous situation.

SERVICE MANUAL

Service / Specific instructions / Recommended replacement

3.19

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

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.

SERVICE MANUAL

3.20

Service / Specific instructions / Storage of machines and motors

SERVICE MANUAL

SERVICE MANUAL Machine : PLP Manual no: 119002

Edition 2010B

4 Chassis

4.1 Design and function .....................................................................................................4.3 4.1.1 Scope ..............................................................................................................4.3 4.1.2 Machine housing .............................................................................................4.3 4.1.3 “Friction force” system .....................................................................................4.4 4.1.4 Covers and panels ..........................................................................................4.4 4.1.5 Castor wheel ...................................................................................................4.4 4.2 Repair and maintenance instructions .........................................................................4.5 4.2.1 Covers and panels ..........................................................................................4.5 4.2.2 Castor wheel ...................................................................................................4.6 4.2.3 Mechanical “friction force” (–2010w21) ...........................................................4.7 4.2.4 Hydraulical “friction force” (2010w22–) ...........................................................4.8 4.2.5 Battery .............................................................................................................4.9

SERVICE MANUAL PLP

4.2

SERVICE MANUAL PLP

Chassis / Design and function

4.3

Edition 2010B

4 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 castor wheel.

The straddle lift and load wheel could be considered to be part of the chassis, but since they are part of the mast the instructions for these are to be found in chapter 6, Mast, instead.

4.1.2

Machine housing

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

Figure 4.1 Machine housing PLP, mechanical “friction force” (-2010w21)

SERVICE MANUAL PLP

4.4

Chassis / Design and function

Figure 4.2 Machine housing PLP, hydraulical “friction force” (2010w22-)

4.1.3

“Friction force” system

A “friction force” system will increase the pressure on the drive wheel as more load is placed on the forks, providing greater traction and minimizing the risk of sliding when turning corners with a load. The latest system is hydraulically controlled as opposed to the previously mechanically controlled system.

4.1.4

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.

4.1.5

Castor wheel

The caster wheel is a fully turning, non-driven wheel placed under the machine housing. PLP has two castor wheels.

SERVICE MANUAL PLP

Chassis / Repair and maintenance instructions

4.2

4.5

Repair and maintenance instructions 4.2.1

Covers and panels

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

4.2.1.1 1.

2.

3.

4.

Dismantling of panels

Loosen the two screws to the side panels (pos 1), from the outside. Remove the panels.

Loosen the plate bolts (pos 2).

To remove the panels pos 3, you must first unscrew the knob on the emergency stop button. Press in the emergency stop. Pick off the small plastic plug that is located in the plastic cover on the battery. Insert a round bar or similar with a diameter of around 3 mm. Turn the emergency stop button until the hole in the axle is identified. Then remove the emergency stop button by turning anti-clockwise. Remove the two retaining screws and lift out the panels by unfolding the gates to 3/4 and work the panels over the gates.

The battery cover, pos 4 and 5, has four screws that can be accessed by opening the cover. Loosen these and lift off the cover and plastic panel.

4

5

1

3

1

2

Figure 4.3

Clean the panels with soapy water. White impact marks may appear in the case of minor damage to the plastic panels. These marks can be removed by carefully heating with a hot air gun.

SERVICE MANUAL PLP

4.6

Chassis / Repair and maintenance instructions

4.2.2

Castor wheel 12 15

17

1

14

13

2 3 16

4

5

6

7 11

8 9

10

8

9

Figure 4.4

4.2.2.1 • • • • •

Dismantling the castor wheel/bearing

Remove the plastic cover from the machine housing.

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

Loosen the bolts, pos. 12, see Figure 4.4.

Take out the castor wheel unit and support the fork in a vice.

Tap out the retaining pin, pos. 11, drive out the wheel axle, pos. 7, and remove the wheel from the fork.

Note!

Take care of the spacers, pos. 8.

• Support the wheel in the vice instead of the fork.

• Pull out the bearings with a bearing extractor.

SERVICE MANUAL PLP

Chassis / Repair and maintenance instructions

4.2.2.2

4.7

Assembling the castor wheel/bearing

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

• Place the wheel fork with the side facing down.

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

• Fit the wheel axle, pos. 7.

• Tap in the retaining pin, pos. 11.

• Bring up the complete castor wheel under the machine housing, and fit the screws, pos. 12.

Note!

Check the positioning to make sure the grease cup comes in the right direction.

• Tighten to the correct torque.

• Fit the plastic cover and lift down the machine to the floor.

4.2.3

Mechanical “friction force” (–2010w21)

The mechanical “friction force” system has two mechanical springs.

4.2.3.1

Adjusting the “friction force” tension

• Adjust the tension of the mechanically adjusted springs by loosening the top nut (A) and adjust the spring height to 169 mm (PLP 200) /157 mm (PLP 250) with the inner nut (B). Secure with the top nut.

A B

Figure 4.5 Mechanical “friction force”

SERVICE MANUAL PLP

4.8

Chassis / Repair and maintenance instructions

4.2.4

Hydraulical “friction force” (2010w22–)

The hydraulical “friction force” system has two springs, one mechanically adjusted spring and one which is hydraulically adjusted.

The left hand spring (red) is attached to the drive unit housing and is mechanically adjusted at the top of the spring.

The right hand spring (yellow) is mounted to a pull cylinder which is connected to the hydraulic lift system. The screw positioned on top of the cylinder is equipped with a air breather and locks the spring to the guide bracket.

Tightening torque: 36 Nm

When mounting the hydraulical spring make sure the hydraulic hose has free movement from the drive unit housing to make sure it is free from contact. Tighten the top screw with 36 Nm.

D

A B

C

Figure 4.6 Hydraulical “friction force”

4.2.4.1

Adjusting the “friction force” tension

Note!

When adjusting the tension the truck must stand on the floor.

• Adjust the tension of the mechanically adjusted spring by loosening the top nut (A) and adjust the spring height to 169 mm (PLP 200) /157 mm (PLP 250) with the inner nut (B). Secure with the top nut.

Note!

The hydraulical spring is mounted with no tension.

SERVICE MANUAL PLP

Chassis / Repair and maintenance instructions

4.2.4.2

4.9

Adjusting the position of the drive unit housing

To achieve a more stable traction the sideway movement of the drive unit housing can be adjusted.

• Loosen the two locking screws (C) located on either side of the drive unit housing.

• Fully tighten the two adjusting screws (D), then turn the adjusting screws ¼ turn counterclockwise.

• Secure with the locking screws.

4.2.5

Battery

4.2.5.1

Changing the battery

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.

A battery trolley must be used when changing the battery.

1. Separate the battery plug.

Figure 4.7 Illustration of changing the battery

2.

3.

Release the battery lock.

Roll out the battery onto the battery trolley.

Warning!

Observe care to avoid “splashing” waste acid or oxide from the battery.

4.2.5.2

Replacing the battery rollers 0

1.

Remove the battery.

SERVICE MANUAL PLP

4.10

Chassis / Repair and maintenance instructions

Warning!

Observe care to avoid “splashing” waste acid or oxide from the battery.

2. The battery rollers are loose in their seats. Lift up the rollers in the back edge, and pull backwards and upwards.

SERVICE MANUAL PLP

SERVICE MANUAL Machine : PLP Manual no: 119002

Edition 2010B

5 Drive unit

5.1 Design and function .....................................................................................................5.3 5.1.1 Introduction .....................................................................................................5.3 5.1.2 Traction motor .................................................................................................5.3 5.1.3 Gearbox ..........................................................................................................5.3 5.2 Repair and maintenance instructions .........................................................................5.4 5.2.1 Preparations ....................................................................................................5.4 5.2.2 Dismantling the drive unit housing (–2010w21) ..............................................5.4 5.2.3 Assembling the drive unit housing (–2010w21) ..............................................5.5 5.2.4 Dismantling the drive unit housing (2010w22–) ..............................................5.6 5.2.5 Assembling the drive unit housing (2010w22–) ..............................................5.7 5.2.6 Traction motor .................................................................................................5.7 5.2.7 Gearbox ..........................................................................................................5.7 5.2.8 Drive wheel .....................................................................................................5.9 5.3 Diagnostics and trouble shooting .............................................................................5.10 5.3.1 Trouble shooting chart ...................................................................................5.10

SERVICE MANUAL PLP

5.2

SERVICE MANUAL PLP

Drive unit / Design and function

5.3

Edition 2010B

5 Drive unit 5.1

Design and function 5.1.1

Introduction

The drive unit is mounted in a vertically moving assembly containing the brakes, traction motor, gearbox and drive wheel.

PLP is equipped with a technical solution for five-wheel pedestrian trucks, designated Friction Force, which efficiently ensures that an optimum drive wheel pressure is always available.

Friction Force utilises the principle of increasing the force on the load wheel with an increasing effective force on the forks. The load wheel force is transferred via a link system to the vertically moving suspended drive wheel, so that the wheel forces are concentrated there. The suspension also includes compression springs, which make the wheel insensitive to irregularities in the floor and ensure an optimum drive wheel pressure even when the truck is not loaded.

Friction Force also ensures improved ergonomics in that a cushioning effect is also achieved at the load wheel and also by reducing rattling noise in the lifting system.

For technical data regarding component parts, see section 1.

5.1.2

Traction motor

The traction motor on PLP is a three-phase induction motor. A pulse transducer is enclosed in the bearing on the non-driving end of the motor and this provides speed return to the traction controller, see section 10.

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.

SERVICE MANUAL PLP

5.4

5.2

Drive unit / Repair and maintenance instructions

Repair and maintenance instructions 5.2.1 1.

2.

Preparations

Separate the battery plug.

Remove the panels on the machine housing, see section 4.

5.2.2

Dismantling the drive unit housing (–2010w21) 3

2 1

Figure 5.1

1.

2.

3.

4.

5.

Dismantle the gates. Start with the gas spring.

Release all the electrical connections to the traction motor and brake.

Release the electric panel and fold back.

Release the gas spring to the platform.

Unscrew the eight socket head cap screws holding the traction motor, and lift it out.

Important!

Protect the motor shaft and the hole in the gearbox, e.g. with rags.

6. Unscrew the three socket head cap screws holding the motor bed to the gearbox. Lift out the motor bed.

7. Release the two springs pressing down the drive wheel when it is unloaded by completely screwing off the four nuts. Use a long socket.

8. The two long bolts to the springs must be taken out from underneath. Lift up the truck to a suitable height and secure with blocks. Remove the two bolts.

SERVICE MANUAL PLP

Drive unit / Repair and maintenance instructions

5.5

9. Release and remove the cable duct on the top of the machine housing.

10. Release the electrical connections to the tiller arm, and release and lift out the complete assembly with steering axle, tiller arm head and guide belt.

11. Release and drive out the two shafts (pos. 1 in fig. Figure 5.1) in the lower link arms as far as is possible. The shafts must not be completely removed.

12. Release and drive out the four shafts (pos. 2 and 3. in fig. Figure 5.1) in the upper link arms.

13. The drive unit housing can now be lifted out from the truck. Mark the position of the gearbox in the drive unit housing before removing the gearbox from the housing.

5.2.3 1.

Assembling the drive unit housing (–2010w21)

Assemble in reverse order. Adjust the spring tension, as described in Section 4, “Adjusting the spring tension friction force”.

Important!

Note that the spring tension is to be set when the truck is lowered so that the drive wheel and caster wheel are on the same level.

Important!

When you refit the guide belt, it is important that the drive wheel is straight and has wheel nuts on the left side as seen from behind, and the stop lug on the steering axle is pointing straight backwards. If this is incorrect the steering's zero position will be wrong.

SERVICE MANUAL PLP

5.6

Drive unit / Repair and maintenance instructions

5.2.4

Dismantling the drive unit housing (2010w22–) 5

3

4

1

4

2 Bild 5.2

1.

2.

3.

4.

5.

Disconnect the gates. Start with the gas spring.

Disconnect all electrical connections to the drive motor and brake.

Remove the electrical panel and fold it aside.

Remove the gas spring to the platform.

Loosen the eight Allen screws that secure the drive motor and lift it out.

Important!

Protect the motor shaft and the hole in the gearbox with rags etc.

6. Loosen the three Allen screws that attach the motor bed to the gearbox. Lift out the motor bed.

7. Disconnect the hydraulic hose connected to the traction cylinder (pos 1 Bild 5.2). Make sure the hydraulic system is depressurised by checking the blades are lowered.

8. Lift the truck high enough to secure with blocks.

9. Remove the nuts that attach the traction cylinder and the right-hand spring (yellow) on the underside of the drive unit housing (pos 2 Bild 5.2).

10. Remove the two Allen screws that attach the holder with the traction cylinder to the drive unit housing (pos 3 Bild 5.2).

11. Remove the spring (yellow), traction cylinder and holder.

Important!

Avoid turning the top screw on the traction cylinder as the plate in the holder may end up in the wrong position in relation to the hydraulic coupling.

SERVICE MANUAL PLP

Drive unit / Repair and maintenance instructions

5.7

12. Remove the left spring (red) by unscrewing the nuts (pos 4 Bild 5.2) with a long sleeve. Take out the long bolt downwards.

13. Disconnect and remove the cable duct on the top of the machine housing.

14. Remove the electrical connections to the steering arm, loosen and lift out the whole assembly with the steering axle, steering arm head and guide belt.

15. Loosen and drive out the four axles in the link arms (pos 5 Bild 5.2).

16. You can now remove the drive unit housing from the truck. Mark the position of the gearbox in the drive unit housing before removing the gearbox from the housing.

5.2.5 1.

Assembling the drive unit housing (2010w22–)

Assemble in reverse order. Adjust the spring tension on the left spring (red), as described in Section 4, “Adjusting the spring tension friction force”.

Important!

Note that the spring tension is to be set when the truck is lowered so that the drive wheel and caster wheel are on the same level.

Important!

Fit the hydraulic spring (yellow) without preloading.

Important!

When you refit the guide belt, it is important that the drive wheel is straight and has wheel nuts on the left side as seen from behind, and the stop lug on the steering axle is pointing straight backwards. If this is incorrect the steering's zero position will be wrong.

5.2.6

Traction motor

The traction motor is mounted on the top of the inner ring in the guide bearing, with a total of six screws. When assembling and dismantling the traction motor the contact surfaces between the motor and gearbox must be thoroughly cleaned. It is also important that the pinion teeth are in line with the drive teeth so that the tooth flanks are not damaged.

5.2.6.1

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 with waxed paper or the like, and a moisture absorbing material.

5.2.7

Gearbox

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

SERVICE MANUAL PLP

5.8

Drive unit / Repair and maintenance instructions

5.2.7.1

Motor mounting

The motor mounting is screwed in the gearbox with three socket head cap screws.

These should be treated with Loctite 243 or the equivalent when fitted.

5.2.7.2

Changing the wheel studs

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 243 or the equivalent before the new wheel stud is screwed in.

5.2.7.3

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.

5.2.7.4

Guide bearing

The guide bearing is protected by rubber rings and is maintenance-free as long as not special cleaning has been carried out with a high-pressure jet.

5.2.7.5

Gear collar and drive pinion

The guide gear collar and drive pinion on the gearbox should be greased with standard grease.

5.2.7.6

Checking the oil level and filling up with oil

Oil is poured in through the upper filler screw hole. The correct level is at the lower edge of the hole.

The oil level should be regularly checked to avoid damaging the gearbox.

5.2.7.7

Oil change

The oil is drained out through the lower oil plug hole. 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.

Before screwing in the oil plug again it should be cleaned.

SERVICE MANUAL PLP

Drive unit / Repair and maintenance instructions

5.2.8

Drive wheel

5.2.8.1

Replacing the drive wheel

5.9

0

1.

2.

3.

4.

Loosen the wheel nuts.

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

Separate the battery plug.

Turn the drive wheel 45°.

Figure 5.3 Loosen the nuts on the drive wheel.

5.

6.

7.

8.

Remove the wheel nuts.

Replace the drive wheel.

Tighten the wheel nuts to 84 Nm. Start the truck and test drive in both directions. The wheel must not catch or jam.

SERVICE MANUAL PLP

5.10

5.3

Drive unit / Diagnostics and trouble shooting

Diagnostics and trouble shooting 5.3.1

Trouble shooting chart Table 5.2 Symptom

Cause

Action

The wheel has a flapping sound when driving.

The tyre has separated due to impact.

1. Change the wheel.

The wheel squeaks continuously when driving.

Bearing is damaged.

1. Replace bearing.

The wheel is flat after long breaks, but becomes round after driving for a while.

The wheel mass has become warm while driving and deforms when parked.

Try a different type of wheel.

The wheel has a deformity that does not disappear when driving.

A “blow out” has taken place due to overheating and changed the molecular structure of the wheel mass.

Change the wheel.

The truck seems to jerk when driving.

Hard foreign object has fastened in the drive wheel.

1. Remove the object or change the wheel.

2. Examine the floor for any irregularities.

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

2. See also items above.

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

The wheel is oval.

1. Change the wheel.

2. Check/adjust the brake.

3. See also items above.

The wheel has transverse cracks, and small bits have fallen out of the tyre.

The wheel has been heated.

Small cracks appear with hard acceleration and reversing.

1. Lower the acceleration and reversing rate.

The wheel has one or more small deformations.

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

1. Remove objects on the floor.

Leaking seal around the drive axle.

•

Oil on the floor.

SERVICE MANUAL PLP

2. Change the wheel if necessary.

2. Tell the driver to brake more smoothly.

Replace seal

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

Drive unit / Diagnostics and trouble shooting

5.11

Table 5.2 Symptom

Cause

Action

Grating noise when accelerating or using the reversing brake.

1. Defective gear wheel in the drive unit.

Check the teeth by removing the cover.

2. Too little oil in the gearbox.

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

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

Faulty bearing in the traction motor.

Dismantle and renovate the traction motor.

The truck rolls "sluggishly".

1. The brakes are applied.

•

Replace brake disc.

If this does not help: •

replace the complete brake unit.

2. 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: •

The drive unit pulls at an angle which is felt in the tiller arm. This makes it difficult maintaining the right course when accelerating and braking.

(Applies to ma-chines without servo)

Change the wheel.

1. Too much slack in control belt.

1. Tighten the control belt, see Chapter 7.

2. The drive unit leans.

2. The bushings in the links for the drive unit housing should be replaced.

3. The machine housing leans.

4. Drive wheel camber missing. Or track is worn.

3. The caster wheels are unevenly worn. Replace both caster wheels, or use shims.

4. Replace drive wheel. See also Parts and Service News 2093.

SERVICE MANUAL PLP

5.12

Drive unit / Diagnostics and trouble shooting

SERVICE MANUAL PLP

PLP Service Manual — D001981, C, GBR, Translated

06 Mast system

06

MAST SYSTEM 2013B

6.1

Design and function 6.1.1

6.2

6.3

59

Inspection of welded fork carriages ................................................................................. 59 Replacing the fork carriage.............................................................................................. 61 Replacing pressure plates (2010w22-)............................................................................ 61 Adjusting the fork carriage............................................................................................... 62

Diagnostics and trouble shooting 6.3.1

PLP

Lift system ....................................................................................................................... 59

Repair and maintenance instructions 6.2.1 6.2.2 6.2.3 6.2.4

59

63

Troubleshooting chart ...................................................................................................... 63

57

PLP Service Manual — D001981, C, GBR, Translated

06 Mast system

58

PLP

PLP Service Manual — D001981, C, GBR, Translated

06 Mast system

06

MAST SYSTEM

6.1

Design and function

6.1.1

Lift system The truck variants PLP 200 and PLP 250 have low-lifting fork carriages.

6.2

Repair and maintenance instructions

6.2.1

Inspection of welded fork carriages

6.2.1.1

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

The purpose of the inspection is to detect damage, faults, deformation, etc. A fork carriage showing this kind of damage may not be used until it has been repaired.

6.2.1.2

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. If the fork blade is bent too much, the fork carriage must be straightened or replaced. l= fork blade length in mm. k= measurement in mm between the fork blade tips and a ruler.

Measurement when a blade must be straightened: greater than k=l/33. Example: k=1150/33= 34 mm.

NOTE! Repairs must be carried out by a licensed welder.

PLP

59

PLP Service Manual — D001981, C, GBR, Translated

06 Mast system

6.2.1.3

Crack formation

1.

Front welded joints

2.

Rear welded joints

Check whether the forks are cracked. Take extra care when welding joints at the front (item 1) and rear (item 2). If cracks are detected, the fork carriage must be replaced or repaired.

NOTE! Repairs must be carried out by a licensed welder.

6.2.1.4

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 60, otherwise the forks must not be used.

Table 25. Fork angle

6.2.1.5

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.

NOTE! Repairs must be carried out by a licensed welder.

60

PLP

PLP Service Manual — D001981, C, GBR, Translated

06 Mast system

6.2.2

Replacing the fork carriage

6.2.2.1

Dismantling the fork carriage 1)

Separate the battery plug.

2)

Remove the covers over the machine housing.

3)

Release and drive out the four shafts, pos. 1 and 2.

4)

Mechanical steering: Lift the fork carriage straight up. Hydraulical steering: Lift the fork carriage straight up to detach it.

NOTE! Observe great caution!

6.2.2.2

Fitting the fork carriage 1)

Mount the fork carriage in reverse order.

6.2.3

Replacing pressure plates (2010w22-)

6.2.3.1

General For the hydraulically controlled friction force system there are pressure plates mounted between the chassis and the pull bars.

6.2.3.2

6.2.3.3

Removing the pressure plate 1)

Unscrew the nuts holding the pressure plate.

2)

Remove the pressure plate.

Mounting the pressure plate 1) 2)

PLP

Push the pressure plate through the chassis holes and lock in place with washer and nut.

Torque Tighten with 9,8 Nm.

61

PLP Service Manual — D001981, C, GBR, Translated

06 Mast system

6.2.4

Adjusting the fork carriage

6.2.4.1

General The truck must stand on a level surface. Lower the forks and check the height from the floor to the top of the forks. The height must be 85-90 mm, with a difference of 5 mm between the four measuring points, see Figure 13, page 62. If the forks are too high, or too low, this is adjusted with the adjusting screw over the lift cylinder.

Figure 13. Adjusting the fork carriage

62

PLP

PLP Service Manual — D001981, C, GBR, Translated

06 Mast system

6.3

Diagnostics and trouble shooting

6.3.1

Troubleshooting chart Table 26. Symptom/Action table Symptom

PLP

Possible cause

Procedure

Play to mast.

Mast rollers not shimmed enough.

Adjust the side supports.

The fork carriage lowers unevenly, jumps.

Side supports adjusted too hard. Adjust the side supports.

No lubrication on the mast roller surfaces.

Grease the roller surfaces.

The fork carriage squeaks.

No lubrication on the mast roller surfaces.

Grease the roller surfaces.

63

PLP Service Manual — D001981, C, GBR, Translated

06 Mast system

64

PLP

PLP Service Manual — D001981, C, GBR, Translated

07 Steering

07

STEERING 2013B

7.1

Design and function 7.1.1 7.1.2 7.1.3 7.1.4

7.2

7.3

69

Cleaning .......................................................................................................................... 69 Tiller arm head (-2007w27).............................................................................................. 70 Tiller arm head (2007w28-).............................................................................................. 70 Tiller arm (2007w28-)....................................................................................................... 76 Replacing the steering belt .............................................................................................. 76 Adjusting the steering belt ............................................................................................... 77 Adjusting the end position switch .................................................................................... 77 Adjustment, electronic steering ....................................................................................... 77 Servo steering (2006w15-) .............................................................................................. 80

Diagnostics and trouble shooting 7.3.1 7.3.2

PLP

General............................................................................................................................ 67 Steering ........................................................................................................................... 67 Servo unit (-2005w19) ..................................................................................................... 67 Servo unit (-2005w20-) .................................................................................................... 68

Repair and maintenance instructions 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 7.2.9

67

83

Steering that is too light or stiff ........................................................................................ 83 Uneven or jerky steering.................................................................................................. 83

65

PLP Service Manual — D001981, C, GBR, Translated

07 Steering

66

PLP

PLP Service Manual — D001981, C, GBR, Translated

07 Steering

07

STEERING

7.1

Design and function

7.1.1

General The steering movement is transferred mechanically from the tiller arm to the drive unit with a drive belt.

7.1.2

Steering The truck is steered by turning the complete tiller arm, which via a drive belt 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.

This electronic steering system is designed to be an auxiliary system to assist the mechanical steering. This means that the servo provides assistance when the mechanical steering is operated. The servo unit uses 2 voltage-controlled signals for regulation, and if one of the signals is not present, the servo is switched off. In the case of a single fault, a red fault indication lamp is lit on the servo unit and the servo assistance function is lost. The truck then operates in the same way as a normal PLP without a servo.

All the sensor inputs are short-circuit proof against short-circuits to the ± Battery. The motor connections are not short-circuit-proof. A contactor is needed in series with the servo motor so that the servo motor will be able to generate voltage itself. The truck's electrical system will be damaged if the battery is not connected, and a rapid movement is made, and if the servo motor generated voltage exceeds 35 Volts.

7.1.3

Servo unit (-2005w19)

7.1.3.1

General The position sensors must send identical signals to the servo; 6.0 V in the neutral position. If there is greater than 0.5 V difference between the position sensor signals, the servo is switched off (red LED on the PSA servo box).

The servo has a dead zone of ±0.5 V around 6.0 V. Full steering output is provided at ±1.7 V. The centre position of the dead zone can be adjusted by ±0.3 V by means of a small hole at the right underside of the PSA servo box (max. 300 degrees turning angle).

The servo function can be blocked by an external 24 V signal, which is ± 95 degrees steering angle; there is also a mechanical block at ± 105 degrees steering angle. When the servo is blocked, the same red LED that indicates an incorrectly adjusted position sensor is lit. The end position sensor also opens the contactor to the servo motor.

7.1.3.2

Servo steering unit, diagnostics (-2005w19) Power connections from the battery Table 27. 2-pole pins AMP gray connector Position

PLP

Cable colour

Description

#1

Red

Battery + 16-32 V

#2

Blue

Battery - 0 V

67

PLP Service Manual — D001981, C, GBR, Translated

07 Steering

Motor power connections Table 28. 2-pole pins AMP black connector Position

Cable colour

#1

Description Motor +

#2

Black 250 mm

Motor -

Sensor 1 Table 29. 4-pole minifit pin Position

Cable colour

Description

#1

Grey

Plus feed to the sensor 12 VDC ±5%

#2

White

Signal sensor

#3

Not connected

#4

Black

0V

Sensor 2 Table 30. 4-pole minifit pin Position

Cable colour

Description

#1

Grey

Plus feed to the sensor 12 VDC ±5%

#2

White

Signal sensor

#3

Not connected

#4

Black

0V

Blocking signal from brake operation Table 31. 2-pole minifit pin Position #1 #2

7.1.4

Servo unit (-2005w20-)

7.1.4.1

General

Cable colour Yellow

Description Blocking 16-32 V Not connected

The position sensors must send identical output signals to the servo; 6.0 V in the neutral position. If there is greater than 1 V difference between the position sensor signals, the servo is switched off (red LED lit on the PSA servo box).

The servo has a dead zone of ±0.5 V around 6.0 V. Full steering output is provided at 1.9 V. The servo function can be blocked by an external 24 V signal. This signal is controlled by a switch in the arm, which is activated when the arm is in its activated state. On older models, an end position switch can also block the servo function. When the servo is blocked, the same red LED that indicates an incorrectly adjusted position sensor is lit.

68

PLP

PLP Service Manual — D001981, C, GBR, Translated

07 Steering

7.1.4.2

Servo steering unit, diagnostics (-2005w20-) Power connections from the battery Table 32. Connector X22, 5-pole pins AMP Position

Cable colour

Description

# 1, X22.1

Red/Blue

Battery +24 V

# 2, X22.2

Blue

Battery - 0 V

X22.2

Pink/White

Blocking signal +24 V

Motor power connections Table 33. Connector X22, 5-pole pins AMP Position

Cable colour

Description

# 4, X22.4

Red

Motor +

# 5, X22.5

Black

Motor -

Sensor 1 and Sensor 2 Table 34. Connector X24, 8-pole minifit pins Position

Cable colour

Description

# 1, X24.1

Orange

Plus feed to sensor 1, 12 VDC ±5%

# 2, X24.2

Green

Signal sensor

# 3, X24.3

Black

0V

# 4, X24.4

Black

0V

# 5, X24.5

-

# 6, X24.6

Orange

Plus feed to sensor 2, 12 VDC ±5%

# 7, X24.7

Green

Signal sensor

# 8, X24.8

Black

0V

7.2

Repair and maintenance 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.

NOTE! High-pressure washing must not be used.

PLP

69

PLP Service Manual — D001981, C, GBR, Translated

07 Steering

7.2.2

Tiller arm head (-2007w27)

7.2.2.1

Replacement

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.

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 1.6, page 13.

7.2.3

Tiller arm head (2007w28-)

7.2.3.1

Removal and installation of the tiller arm head

70

1)

Adjust the arm to its shortest length and unscrew the adjusting lever. (Only applies to trucks with adjustable arms)

2)

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

3)

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

4)

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

PLP

PLP Service Manual — D001981, C, GBR, Translated

07 Steering

5)

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.

6)

Refit in the reverse order.

CAUTION! Ensure that no cables are trapped when the head is assembled.

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 70

2)

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

Figure 14. Dismantling of the lift/lower buttons

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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.

Screw Wing

3.

4.

Mechanical spring Bearing

1.

2.

3.

4.

5.

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.

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.

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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 15. Cable routing, standard version

Cable routing, options

Figure 16. Cable routing, options

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Table 35. Cable routing, options

7.2.3.5

Position

Descriptions

1

Smart card

2

Heat resistance

3

Tiller Up Drive

Fitting the main cabling and brake switch Securing the tiller arm main cabling (trucks with fixed arms) The cabling is secured by cable clips to the tiller arm head. The cabling is run down and through the tiller foot, at the right of the steering shaft. The cabling is secured inside the truck by cable ties to the cable strip.

Cabling from the brake switch is run to the left of the steering shaft and secured by cable ties to the cable strip.

CAUTION! Ensure that the cabling cannot chafe against any sharp edges.

CAUTION! The cabling must have enough slack so that the arm can be lowered to its lowest position and turned to its maximum extent left and right without straining the cable.

It must also be possible to open the upper part of the tiller head without being restricted by the cabling.

CAUTION! The main cabling must not be so long that the programming cable takes the load when the upper part is hanging on the cabling.

Securing the tiller arm main cabling (trucks with adjustable arms) The cabling is secured by cable clips to the tiller arm head. The cabling is run down and through the tiller foot, in front of the steering shaft towards the forks. The cabling is secured inside the truck by cable ties to the cable strip.

CAUTION! The cabling must be almost fully extended when the arm (adjusted to its full length) is at its lowest position and turned to its maximum right or left. If this is done correctly, the length of the cabling will be such that it is possible to open the upper part of the tiller head in such a way that the programming cable is not put under any strain.

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Cable routing, standard version

Cable routing, options

Table 36. 7.9 Cable routing, options Position

PLP

Descriptions

1

Smart card

2

Heat resistance

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7.2.4

Tiller arm (2007w28-)

7.2.4.1

Removing the gas spring

Figure 17. Tiller arm

WARNING! Take care while removing and installing the gas spring not to get crushed fingers.

1)

Remove the screw (14).

2)

Remove the cam (12) by turning the arm through about 45º and then moving the cam forwards.

3)

Slacken the stop screw (6).

4)

Lift up the rubber damper (31) along the piston while at the same time angling the tiller arm upwards.

5)

Release the gas spring by first opening the clip on the bearing holder (32) with a screwdriver. Then pull the gas spring away from the ball roller screw.

6)

Refit in the reverse order.

NOTE! Apply grease to the bearing holder (32) and the fork (30).

7.2.5

Replacing the steering belt 1)

76

Separate the battery plug.

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7.2.6

2)

Remove the panels on the machine housing, see Section 04, page 37.

3)

Release all the electrical connections to the traction motor and brake.

4)

Unscrew the eight socket head cap screws holding the traction motor, and lift it out.

Protect the motor shaft and the hole in the gearbox, e.g. with rags.

5)

Unscrew the three socket head cap screws holding the motor bed to the gearbox. Lift out the motor bed.

6)

Completely unscrew the two bolts holding the belt tensioner in the bottom of the steering axle, and the two bolts holding the steering axle upper bearing.

7)

Replace the belt.

8)

Refit in the reverse order.

Adjusting the steering belt 1)

Separate the battery plug.

2)

Roll out the battery.

3)

Slightly release the two bolts holding the belt tensioner.

4)

Use the adjusting screw to tension the belt, only enough so that it can still be pushed in by finger pressure.

5)

7.2.7

Torque Tighten the two bolts holding the belt tensioner to 9.8 Nm.

Adjusting the end position switch If the end position switch needs to adjusted, check the following: • •

7.2.8

That the microswitch in its pressed in position is not also mechanically pressed into its bottom position.

That the end position is not reached before it should be actuated (>95 degrees). This is checked by swinging the tiller arm backwards and forwards to its extreme positions, in which case the end position switch must only be actuated with the tiller arm at >95 degrees.

Adjustment, electronic steering Checks and, if necessary, adjustments, must always be performed after adjusting the belt tension. When adjusting the belt tension, the tension levels in the neutral positions of the potentiometers must be checked and if necessary adjusted, see Section 7.2.8, page 78.

The belt tension is checked by measuring the play in the tiller arm. This play must be approximately 30 mm on a servo-equipped truck.

There are several reasons why the steering can seem to be stiff: • • •

Belt tension too tight.

The steering shaft bearing can be binding.

The shaft that changes the potentiometer voltage can be rubbing against the body of the potentiometer.

There are 2 alternative methods of adjusting the PSA servo.

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Alternative 1 - Change the dead zone. (Max. 300 degrees of turning)

Figure 18. Adjusting the dead zone

If adjustment of the dead zone is required: The dead zone is adjusted with the aid of a small flat blade screwdriver through a screw hole on the right underside of the PSA servo box.

Remove the securing screw from the underside and pull on the servo box until the screw hole can be seen.

CAUTION! When adjusting the dead zone in the servo box, do not push the screwdriver in too hard.

Clockwise adjustment of the dead zone means that the arm moves more easily to the left and less easily to the right. Continue adjusting until the tiller arm moves just as easily in both directions.

Alternative 2 - Position sensor adjustment 1. Adjust the position sensor to obtain 6.0 V in the neutral position. Ensure that the shafts to the potentiometer arms are at the same distance on both sides.

Figure 19. Adjusting the position sensors

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2.

To adjust the position sensors, remove the 2 screws at the bracket for the potentiometers at the rear of the drive unit housing.

Figure 20. Removing the screws on the bracket

3.

4.

Carefully move the tiller arm slightly to the right and left without affecting the tiller arm switch. Stop with the tiller arm in the centre of the play that is present before the drive wheel is moved. Measure the signals from the position sensors, at X23.2 and X24.2 to B -.

Adjust one potentiometer at a time to obtain 6.20 V ±0.10 V. NOTE! It is important to adjust both position sensors for equal deviation, e.g. (6.13 and 6.10 V) or (5.85 and 5.9 V). NOT 5.8 and 6.2 V.

If 6.0 V cannot be achieved on both sides, because one of the potentiometers comes to its end position, then either remove or add an additional shim plate (118016).

Figure 21. Fitting a shim plate

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Figure 22. Adjusting the position sensors

• •

Left hand switch: Turn the potentiometer clockwise to obtain a higher voltage.

Right hand switch: Turn the potentiometer clockwise to obtain a lower voltage.

7.2.9

Servo steering (2006w15-)

7.2.9.1

Adjusting the steering force Function: The steering force can be adjusted with the aid of slackening or tightening the guide belt. In general it can be said that a looser guide belt results in a greater potentiometer angle, and the amplification to the steering motor increases, so that the truck will respond more easily to being steered. If stiffer steering is desired, the guide belt can be tightened which results in a lesser potentiometer angle, and the amplification to the steering motor decreases as a result.

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Figure 23. Servo steering

PLP

1)

Adjusting the guide belt: Disconnect the battery plug and pull out the battery far enough for the adjuster screw and locking screws to be accessible from the battery space. Secure the battery so that it cannot roll out.

2)

Slightly slacken the two locking screws (item 35, see Figure 7.12) for belt tensioning and use the adjuster screw (33) to obtain the desired value. As a starting point the belt tensioner can be adjusted so that it lies edge to edge with the drive unit housing in accordance with Figure A, Figure 24, page 82.

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Figure 24. Adjusting the steering belt

3)

Figure B, Figure 24, page 82 shows the adjustment to obtain a looser belt, which gives more steering force, whilst Figure C shows a tighter belt which gives less steering force.

4)

Depending on the characteristics of the floor and the type of wheel, the steering force can be affected and may need to be adjusted to alter its effect.

5)

Adjusting the potentiometers: Connect to the battery and measure with a voltmeter between B-, X24.4 and X24.7. The value must be 6 V in the neutral position. I.e. the drive wheel must be in the straight forward position and the guide belt not influenced by the potentiometer mechanism.

6)

If the value is not 6 V the bracket on which the potentiometer is mounted must be twisted until this value is obtained, see Figure 25, page 82. If the steering is stiff during clockwise movement, the bracket must be adjusted clockwise. Similarly, if the steering is stiff during counterclockwise movement, the bracket must be adjusted counterclockwise.

Figure 25. Adjusting the potentiometer

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7)

Check by turning the steering arm to right and left within the amount of play while at the same time reading the voltage shown on the multimeter. This play allows the steering arm to be turned a few centimetres to left and right before any resistance is felt. During this movement the drive wheel position should not change. Turn the steering arm to the left until some resistance is felt. The measured value must be approximately 4 V. Turn the steering arm to the right until some resistance is felt. The value should now be approximately 8 V.

8)

Depending on the characteristics of the floor and the type of wheel, the steering force can be affected and may need to be adjusted to alter its effect.

7.3

Diagnostics and trouble shooting

7.3.1

Steering that is too light or stiff 1.

Is the steering too stiff or too light?

Yes: Step 2

2.

No: Fault trace completed

In the first instance adjust the steering force with the belt tension. (see Section 7.2.9.1, page 80) Continue with: Step 3

3.

Is the steering uneven in either direction, or jerking?

Yes: Step 4

4.

No: Fault trace completed

Adjust the balance of the steering forces with the potentiometers. (see Section 7.2.9.1, page 80 "Adjusting the potentiometers") Fault trace completed Fault trace completed

7.3.2

Uneven or jerky steering 1.

Is the steering uneven in either direction, or jerking?

Yes: Step 2

2.

Is the steering also too stiff or too light?

Yes: Step 4

3.

No: Fault trace completed

No: Step 3

Adjust the balance of the steering forces with the potentiometers. Check that the bearing between the steering shaft and the belt sensor moves smoothly without jerking.

Fault trace completed

4.

In the first instance adjust the steering force with the belt tension. (see Section 7.2.9.1, page 80) Continue with: Step 5

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5.

Then adjust the balance of the steering forces with the potentiometers. (see Section 7.2.9.1, page 80 "Adjusting the potentiometers") Fault trace completed Fault trace completed

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08 Hydraulic system

08

HYDRAULIC SYSTEM 2013B

8.1

Design and function 8.1.1 8.1.2 8.1.3 8.1.4

8.2

8.3

91

Hydraulic system ............................................................................................................. 91 Hydraulic oil, changing/draining....................................................................................... 92 Hydraulic unit motor......................................................................................................... 93 Adjusting the level limit position switch (-2010w21) ........................................................ 96 Solenoid........................................................................................................................... 97 Installation instruction for pipe couplings......................................................................... 97

Diagnostics and trouble shooting 8.3.1

PLP

General............................................................................................................................ 87 Electric solenoid valve ..................................................................................................... 87 Level limit position switch ................................................................................................ 87 Hydraulic diagram............................................................................................................ 88

Repair and maintenance instructions 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6

87

99

Symptom and Action ....................................................................................................... 99

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08 Hydraulic system

08

HYDRAULIC SYSTEM

8.1

Design and function

8.1.1

General

8.1.1.1

Lift The driver activates a switch which starts the lift motor by means of a contactor. The electric motor drives the hydraulic pump, which pumps hydraulic oil to the lift cylinders.

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. If the relief valve is adjusted it must be resealed.

8.1.1.2

Lower There is a fixed restrictor valve in the hydraulic unit, which regulates the lowering speed by restricting the return flow of hydraulic oil.

8.1.2

Electric solenoid valve

8.1.2.1

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.

8.1.2.2

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.

8.1.2.3

Lowering function The solenoid valve 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.

8.1.3

Level limit position switch The function of the electrical level limit position switch is to switch off the hydraulic motor when the fork carriage reaches its top position. This will protect the hydraulic motor from overheating. For adjustments, see Section 8.2.4, page 96.

The electrical level limit position switch has been replaced by an inductive sensor (2010, week 22) which is set to activate before the top of the end stroke. The purpose of this is to avoid self-locking of the forks in the top position.

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8.1.4

Hydraulic diagram

8.1.4.1

List of hydraulic diagrams for PLP Table 37. 8.1 List of hydraulic diagrams for PLP Description

88

Reference

Reference

PLP hydraulic schematic diagram (-2010w21)

108011

Section 8.1.4.2, page 89

PLP hydraulic schematic diagram (2010w22-)

108423

Section 8.1.4.3, page 90

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8.1.4.2

PLP

PLP hydraulic schematic diagram (-2010w21)

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8.1.4.3

90

PLP hydraulic schematic diagram (2010w22-)

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08 Hydraulic system

8.2

Repair and maintenance instructions

8.2.1

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

Dirt particles must not get into components.

Do not use cloths that release fibres or particles.

Only use clean tools.

Carefully clean tanks, pipes and hoses before installation.

Welded or hot-bent pipes must be pickled (cleaned in an acid bath) and washed before they are built in.

The oil tank must be closed and provided with an efficient air filter to prevent dirt contaminating the hydraulic oil.

Sealing compounds such as flax, cement or thread tape are not permitted.

Take into consideration the specified operating data.

Do not exceed the permitted pressures and volume flows.

Do not exceed or go below the specified temperature range.

Pay attention to specified electrical voltages and power consumption.

NOTE! All work with the hydraulic system should be carried in a pressureless state and in a clean environment.

Installation To prevent dirt and corrosion in the hydraulic system all hydraulic components must be provided with plastic plugs blocking the connections before they are delivered. Only remove these plugs just before the component is to be installed in the machine. Retaining screws and connections must correspond with those on the drawing. Retaining screws should not be tightened with a higher torque than what is specified on the drawing. If such information is missing, the torque should not exceed that specified in Section 1.7.1.1, page 14.

Connections Couplings must be fitted in accordance with the tightening torques specified in the table at Section 1.7.1.2, page 15. 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.

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.

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8.2.2

Hydraulic oil, changing/draining

8.2.2.1

Equipment that is required • •

8.2.2.2

New oil, or purifying equipment for the old oil.

A tray to collect the oil in.

Procedure: 1)

Lower the forks and disconnect the battery plug electrical.

2)

Remove the panels enclosing the area where the hydraulic unit is placed.

3)

Check how much oil needs to be filled by marking the existing level. e.g. with a strip of tape. Before marking the level the lift cylinder should be run several times to check that the pump does not suck air (screaming noise at the end). If this should be the case the marking should be moved correspondingly so that this does not happen when new oil has been filled.

4)

Remove the cap from the hydraulic oil tank,.

5)

Suck up the oil with a pump, and pump over the old oil to a suitable container.

NOTE! Avoid spilling oil outside the container. The oil should be handled in accordance with the applicable environmental legislation and local directives.

6)

Fill up with oil to the previously marked level. If possible, filter the new oil when filling. To obtain the correct oil, follow the recommendations in Section 01, page 1.

7)

The lift cylinder should be run several times to check that the oil level is correct and so that any air will disappear, and also to check for excess oil. Excess oil runs the risk of the oil overflowing.

Wipe up any oil spillage and refit the panels.

8.2.2.3

Air filter There is an air filter in the refilling plug on the hydraulic tank, which during service/oil change must be cleaned. The filter is cleaned with a suitable grease solvent that will not damage the rubber, e.g. turpentine.

Pull out the filler plug from the tank and remove the red cap fixed with three barbs. Wash the foam rubber filter and blow clean, or squeezze dry with paper. Refit in the reverse order. The filter should be replaced if the foam rubber is damaged.

8.2.2.4

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 should be used in the truck.

The hydraulic oil used in the the truck should comply with the following quality requirements: • • • • • • • • •

92

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.

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• •

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 UniCarriers if the warranty it to be valid.

NOTE! For recommended oil and grease types, see Section 1.6, page 13.

8.2.2.5

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 8.2.2.4, page 92 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.

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 an assembly consisting of the brush, brush holder and spring. Installation is in accordance with the following instructions.

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Figure 26. Replacing the brushes

1)

Release the cables from the terminals on the motor (item 1, Figure 26, page 94).

2)

Remove the through bolts from the rear end of the motor (item 2, Figure 26, page 94).

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 26, page 94). If the motor has an earth return, the earth connection on the rear end of the motor should also be detached (item 4, Figure 26, page 94).

6)

Remove the rear end (item 5, Figure 26, page 94). Make sure that the terminals remain in their positions.

Figure 27. Replacing the brushes

94

7)

Disconnect all four carbon brushes by releasing the screws (item 6, Figure 27, page 94) - A. Then press each brush 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 27, page 94), to approx. 1.3-1.8 Nm. PLP

PLP Service Manual — D001981, C, GBR, Translated

08 Hydraulic system

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 (item 12, Figure 27, page 94) and that the attachment is held in place by a lug and a slot on the casing and 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 26, page 94).

12) Replace the cables to the motor terminals.

8.2.3.4

Tips for prolonging the service-life of the motor •

• •

• •

• • •

PLP

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.

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.

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8.2.4

Adjusting the level limit position switch (-2010w21)

Figure 28. Adjusting pressure

96

1)

Unscrew the connector securing screw (indicated by the arrow).

2)

The pressure can be adjusted with the connector still connected using an Allen key (size 2) through the hole were the screw in point 1 is fitted.

3)

Put the maximum rated load on the forks and make fine adjustments to the limit position switch setting to allow continuous movement during lifting and to stop the movement directly when the top position is reached.

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8.2.5

Solenoid

8.2.5.1

General instructions when working with solenoid valve

8.2.5.2

8.2.6

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.

• 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)

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.

NOTE! The pipe must not follow round.

2)

PLP

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 29, page 98).

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08 Hydraulic system

Figure 29. 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 30, page 98). If not, give it another short turn. It is of no importance whether the pipe olive can still be turned.

Figure 30. 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.

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.

98

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08 Hydraulic system

Figure 31. 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.

Table 38. 8.2 Symptom

Possible fault

Procedure

The lift motor continues to run The switch is not adjusted despite the fork carriage being at correctly. the top and against the mechanical stop. NOTE! Only applies to trucks with a switch as a lift stop.

Adjust the switch so that it opens 20 mm before the fork carriage reaches its top position.

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 relief 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 lift motor continues to run The pressure switch is not despite the fork carriage being at adjusted correctly. the top and against the mechanical stop.

The pressure switch cannot be

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.

Lower the pressure in the pressure switch, see Section 8.2.4, page 96.

Change the pressure switch.

adjusted.

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Symptom

Possible fault

The lift motor stops when the The pressure switch is not maximum load or a lesser load is adjusted correctly. to be lifted.

Procedure Increase the pressure in the pressure switch, see Section 8.2.4, page 96.

The pressure switch cannot be adjusted so that the pump stops when at the top position.

Change the pressure switch.

The lift motor runs intermittently when ender load.

The limit values between the overflow valve and the pressure switch are too close to each other.

Check and if necessary adjust the overflow valve towards maximum load and then adjust the pressure switch in accordance with the instructions.

If this still does not work, change the pressure switch.

The fork carriage will not lower.

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

Dismantle the valve and clean it.

The fork carriage lowers too slowly.

The lowering valve is dirty or defective.

Dismantle the valve and clean, or alternatively replace defective parts.

The oil filter is blocked and dirty.

Change filter.

Dirt in the fixed restrictor in the hydraulic unit.

Dismantle and clean the dirt from the restrictor.

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.

The hydraulic oil has become too 1. hot.

2.

Change the oil and oil filter.

Motor oil has been used and caused the hydraulic oil to emulsify with water and then rot.

100

Check the breaking function of the lift stop.

PLP

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2003

9 Lift cylinders Design and function ....................................................................................................... 9.3 Introduction .......................................................................................................... 9.3 Lift cylinder .......................................................................................................... 9.3 Dismantling and assembling .......................................................................................... 9.3

SERVICE MANUAL

9.2

SERVICE MANUAL

Lift cylinders / Design and function / Introduction

9.3

Edition 2003

9 Lift cylinders Design and function Introduction The lift cylinder consists of a single-acting hydraulic cylinder, where hydraulic oil is pumped into the cylinder and presses 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 cylinder. This is then pushed together by the weight of the forks and the load, at the same time as the oil returns to the hydraulic tank.

Lift cylinder Dismantling and assembling 1.

Move the battery out of the way.

2.

Remove the hydraulic hose and hydraulic coupling on the cylinder.

3.

Plug the hydraulic hose to avoid dirt getting into the hydraulic system.

1

Figure 9.1

4.

Remove the plate in the fork carriage (pos. 1 in Figure 9.1). Keep the spacers in a safe place.

5.

Lift out the cylinder.

6.

Assemble in the reverse order.

SM_PLP_09_119002_2003.fm

SERVICE MANUAL

9.4

Lift cylinders / Design and function / Lift cylinder

SERVICE MANUAL

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

10

ELECTRICAL SYSTEM 2013B

10.1 Design and function 10.1.1

General.......................................................................................................................... 107

10.2 Repair and maintenance instructions 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9

107

General.......................................................................................................................... 107 Battery ........................................................................................................................... 109 General handling ............................................................................................................110 Contactors in cold storage rooms...................................................................................112 Drive and valve controller ...............................................................................................112 Insulation resistance.......................................................................................................113 Main controller unit ATC, operation ................................................................................114 ATC Logic ...................................................................................................................... 128 Downloading.................................................................................................................. 128

10.3 Diagnostics and trouble shooting

132

10.3.1

Error codes .................................................................................................................... 132

10.3.2

Other trouble shooting ................................................................................................... 141

10.4 Appendix 1, Overview of the menu trees 10.4.1 10.4.2 10.4.3 10.4.4 10.4.5 10.4.6 10.4.7

PLP

107

149

General.......................................................................................................................... 149 Local menu tree............................................................................................................. 150 SERVICE menu tree...................................................................................................... 158 Monitor menu................................................................................................................. 201 Reset menu ................................................................................................................... 203 Language tree ............................................................................................................... 204 TRAC............................................................................................................................. 204

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10 Electrical system

10

ELECTRICAL SYSTEM

10.1

Design and function

10.1.1

General

10.1.1.1

Description of components

Figure 32. Components 1.

2.

3.

10.1.1.2

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

4.

5.

6.

Emergency Stop Switch ATLET truck computer, ATC Battery plug

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.

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• •

•

•

•

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).

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

108

Acronyms and abbreviations Acronym

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.

DC

Direct Current

Direct current

ELCB

Electronically Load Compensated Brake

Brake with electronic load compensation.

EPS

Electric Power Steering

Electric servo steering

GND

Ground

Ground.

PSA

Powered Steering Assistance

Servo steering

TMC

Traction Motor Controller

Traction motor controller.

WG

Wire Guidance

Wire guidance

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PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

10.2.2

Battery

10.2.2.1

Battery capacity

Figure 33. 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.

When the battery capacity falls to 20%, there will be a lift stop within 3 minutes of active time and fault code E50 is logged.

Table 39. 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.

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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 40. 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 111.

Used to accept the shown value.

110

Service mode:

-

Used to select the shown menu alternative.

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PLP Service Manual — D001981, C, GBR, Translated

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 34. 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".

PLP

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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.

10.2.5

Drive and valve controller

10.2.5.1

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 41. 10.3 Connector X6 traction motor controller AC1 Pin

Description

Comment

X6.1

Control of main contactor.

Controlled to B-.

X6.2

Supply to main 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.

+24 V

X6.6

Controlling of horn.

Controlled to B-.

X6.7

CAN communication.

CAN Low.

X6.8

-

-

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.

112

X6.14 -

-

X6.15 -

-

X6.16 +12 V supply to the HVC.

+12 V (Not used as standard)

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.

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10 Electrical system

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

Table 42. 10.4 Connector X5 traction motor controller AC1 Pin

10.2.5.2

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

Input from gate switch.

Closes with the gates in their upper positions.

X5.6

Input from platform switch.

Closes with the platform in its lowered position.

X5.7

Input from lift switch.

The lift stop switch opens at lift stop.

X5.8

Input from platform switch.

Closes with the platform in its raised position.

X5.9

Input from switch, fixed platform.

Closes when the driver stands on the platform.

X5.10 -

-

X5.11 -

-

X5.12 -

-

Wiring diagram All the wiring diagrams can be found in a separate “Wiring diagram handbook”, contact UniCarriers for further information.

The relevant wiring diagrams are specified in the table below.

Table 43. 10.5 Description

Machine

Reference

Document code

Wiring diagram

PLP

108007 (–2005w17) 118270 (2005w18–) 118222 (2007w28–)

Circuit diagram

PLP

108186 (–2005w17) 118275 (2005w18–)

10.2.6

Insulation resistance

10.2.6.1

Insulation test 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.

WARNING! The instrument has a dangerous voltage across the measuring terminals. Do not touch the terminals during testing.

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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.

10.2.7

Main controller unit ATC, operation

10.2.7.1

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.

User ID: ?

2.

3.

Local code: ????

4.

5.

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 horizontally, and keys two and eight to step vertically. 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. Logging on takes place by selecting the driver ID and entering a password. In the Operational mode it is possible to use the truck and all its functions.

Local Service

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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.

Service menu Atlet Service includes all the functions used by Atlet authorised service personnel. A password is needed to access the Atlet Service menu. The Atlet Service menu is built up as shown in fig.

1.

2.

3.

4.

5.

6.

7.

8.

• • • • • • • •

10.2.7.2

SERVICE MENU: < Exit > SERVICE MENU: < Options > SERVICE MENU: < Settings > SERVICE MENU: < Test menu > SERVICE MENU: < Calibrate > SERVICE MENU: < Logs > SERVICE MENU: < Authorisation > SERVICE MENU: < Reset menu > Exit – selected to exit the 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.

Test menu - tests inputs and outputs, along with software and hardware versions in the system menus.

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 Service and Local service.

Total Reset menu - possibility to reset all parameters, accessories, users, calibrations and log on to the factory settings.

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.

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10.2.7.3

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.

10.2.7.4

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.

PLP 200 <PLP 250 Mark the appropriate type of truck and press Enter. If the wrong type of truck is selected, use the Rest menu to reset all the settings and try again.

10.2.7.5

Monitor menu By pressing the Enter and 7 key at the same time it is possible to access the Monitor menu from the Operational mode.

WARNING! As the monitor menu is active, the truck reacts physically by activating the controls.

The Monitor menu shows the rotation speed, power consumption, motor temperature and TMC temperature.

1.

2.

3.

4.

5.

116

Monitor menu Driving Monitor menu Pump Monitor menu Steering Monitor menu Sling steering Monitor menu In/Out

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10 Electrical system

Driving Under the Traction menu it is possible to control the motor speed in real time and the power consumption or motor and TMC temperatures.

C: 025 deg C M: 027 deg C 1800 RPM 56 A Pump: Not relevant to PLP. Steering: Not relevant for PLP. Wire guidance Not relevant to PLP. In/Out Under In/Out it is possible to check all inputs to ATC, TMC and HVC in real time. It is also possible to check the ATC internal interlock functions. The function to check the inputs is built up as shown in fig: 1.

2.

3.

4.

5.

ATC inputs: TMC inputs: HVC inputs: EPS inputs: ATC in/out:

Note that the truck is in Operational mode when the Monitor menu is shown. In other words the truck can be driven, and therefore it is appropriate to block it up in accordance with the safety instructions.

10.2.7.6

Selection of options There are several different options under Options. These are used to tell the ATC which options the truck is equipped with. More information concerning which options are available and their functions are in Section 10.2.7.26, page 126.

The option name and which status the option has (off or on) is specified in the first bar in the display. Setting an option is done as follows: 1)

Step forward to the option to be set, and press enter.

Lift stop: no 0:no 1:yes

2)

Press the 0 key to switch off the option, or 1 to set it.

Lift stop: yes Replace!

10.2.7.7

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

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1)

Select Speed controller, and press Enter.

CALIBRATE: Speed control v^

2)

Leave the speed controller in neutral, and press enter.

Speed control to 0 press ENT

3)

Give maximum speed in both directions, without pressing hard to the end position, and then press enter.

Give max signals press ENT

4)

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

5)

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.

10.2.7.8

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)

Navigate to Service menu » Calibrate » Lift/Lower. The following display appears: Lift control to 0 press ENT

2)

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

3)

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

4)

The following display then appears: Give full lowering press ENT

5)

118

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

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10 Electrical system

6)

The display shows whether the calibration was successful or not. (only software 2.23–) OK! Press ENT Not accepted 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 Atlet menu by going to Exit and pressing Enter.

10) Disconnect the battery and then restart the truck.

11) Perform a functional test of the lifting/lowering functions.

10.2.7.9

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.

DRIVER: New/update v^

2)

Enter the driver ID to be altered or changed.

User ID: ?

3)

Select the driver category the driver is to belong to.

Driver 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: ***?

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6)

Press enter to end.

OK! Press ENT

10.2.7.10 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.

DRIVER: Format v^

2)

A warning in two parts is shown. Press 2 to see the second part of the warning.

Continue by pressing 1.

WARNING! Shortened length can lead-to loss 0:end 1:continue

3)

Changing the length of the ID or Code.

ID no. of chars 5 v Code length: 4 ^

4)

10.2.7.11

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

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

Select Set Access » Local, and press Enter.

AUTHORISATION: Local v^

2)

Specify the valid code.

Old code: ****???

3)

Write in the new code.

New code: ???????

4)

120

Verify the new code.

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Verify new code: ****???

5)

Press enter to end.

OK! Press ENT

10.2.7.12 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 Atlet 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 Atlet 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 drive 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 Atlet menu => Log => Hour counter. 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.

10.2.7.13 Read hour counter 1)

In Log, select Hour counter.

LOG BOOK: Hour meter v^

2)

Select Trip, Total or External.

HOUR METER: Total v^ HOUR METER: Trip v^ HOUR METER: Extern v^

3)

Navigate between the four different hour counters.

TOTAL pump: 00001.246h

4)

PLP

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

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10.2.7.14 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.

Table 44. 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

10.2.7.15 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: • • • •

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.

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.

Example of how the error log works: Primary log

Secondary log

01:030122 07:49+ Drive controller Low voltage #3 +01:030122 07:49 Drive controller No 030215 18:09 communication +01:030122 07:49 Valve system No communication

The fault “Drive controller, Low voltage” has occurred three times. The first time at 07:49 220103 and the third time at 18:09 150203. There are two secondary faults associated with the first fault, which are shown by the plus character after the time 07:49.

10.2.7.16 Read error log •

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

•

122

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

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•

The [i] key is used to access the secondary log. The secondary errors can then be navigated with the 2 and 8 keys.

10.2.7.17 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.

10.2.7.18 Driver categories The software in ATC supports four different driver categories. These are used to give different drivers difference performances. One example is the possibility to have a category for experienced drivers and one for beginners. All driver IDs must be associated with a driver category.

Parameter

Descriptions

Limits

Forward speed

Maximum speed forward

20-100%

Reverse speed

Maximum speed in reverse

20-100%

Accel

Acceleration

20-100%

Speed red. 1

Creep speed

0-90%

Speed red. 2

Tiller up drive speed

0-90%

Current limit

Current limit

20-100%

Brake red.

Braking torque for reducer brake

0-100%

Neut brake s

Braking torque for neutral position brake

0-100%

Brake reverse

Braking torque for reversing brake

50-100%

Brake pedal

Braking torque for the ELCB brake

50-100%

10.2.7.19 Set driver parameters 1)

Select Settings » Performance. Select in which category the driver parameters are to be changed.

PERFORMANCE: Driver category:1 v^

2)

Navigate amoung the different driver paraemeters with the 2 and 8 keys. Press Enter to select parameter. speed. redn. 2 20% v^

3)

Write in a new value and press enter. speed. redn. 2 25% Replace!

10.2.7.20 Pin code ATC uses a pin code instead of a key switch. Each driver is defined with a unique ID number.

A pin code is linked to each driver ID, which can be 1-7 digits in length. Up to 100 driver IDs can be saved. The driver ID and code are used together to access the truck, thereby replacing the key switch.

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10.2.7.21 Safety checks When logging into the truck there is a safety check of the brake switch, lift system, safety switch and speed controller. The lifting and speed controllers must be inactivated while logging on and the brake switch must previously have been in its neutral position before logging on. If any of these safety tests fail a warning is shown in the display, with a request to reset the activated control to neutral position. Depending on which control is activated, an interlock function will be actuated to prevent the use of certain of the truck functions.

Table 45. 10.8 Warning text in display Speed control to 0

Cause

Interlock function actuated

The speed controller is actuated Speed interlock during logon. This warning can also be shown if the steering arm is moved to operational mode with excessive throttle application.

The brake switch was not in neutral position during start-up.

Release tiller Release controls

Release controls

Safety interlock

One of the keys for Lift interlock lifting/lowering was actuated during logon. Also shown if more than one lifting/lowering control is actuated simultaneously.

The safety switch has returned to Safety interlock neutral position after logon.

Table 46. 10.9 Interlock function

System in the truck obstructed

Speed interlock

Drive system

Safety interlock

Drive system

Lift interlock

Lift system

10.2.7.22 Speed limits In ATC there is the possibility of achieving a reduction in speed during the operation of the truck, to creep speed. Creep speed is selected by switching with the 2 key between creep speed and full speed (key 8 to go straight to full speed). The actual position is shown in the display with a symbol representing a tortoise or a hare.

For safety reasons the maximum speed is determined by the positions of the gates and platform. See below for a description of the various gate and platform positions that are possible.

Gates out

124

Platform up

Driver on the platform

Permitted speed

see fig.

0

0

0

No driving

A

0

0

1

6

B

0

1

0

6

C

0

1

1

Incorrect position

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Gates out

Platform up

Driver on the platform

Permitted speed

see fig.

1

0

0

Driving not permitted

D

1

0

1

Maximum speed

E

1

1

0

Driving not permitted

F

1

1

1

Incorrect position

10.2.7.23 General functional description For the truck to be in neutral position the following is necessary: • • • • • • • •

The tiller arm must be raised.

The drive wheel must point straight forwards.

Forks in bottom position.

Battery plug disconnected.

Truck in room temperature (20°C).

The side gates are folded down.

The platform is raised.

The emergency stop switch is in its uppermost position.

10.2.7.24 Truck position The truck can be in four different positions: • •

PLP

OFF: Voltage disconnected.

Logged on/Operational mode: To be compared with the battery plug connected and the key in the lock, key in "on" position.

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• •

Logged off: To be compared with the battery plug connected but the key removed.

Standby: To be compared with the battery plug connected and the key in the lock, but in off position.

In Operational mode all the truck functions such as lifting/lowering and travel can be used.

Logon with ID and pin code is required to access the Operational mode. In the Operational mode the driver can utilise a lot of information via the display, such as date, time, battery status, error codes and warning messages, etc.

• • • • • •

Date - shows ATC date.

Time - shows ATC time.

Field for error codes – an error code is shown when an error occurs. When a warning is shown it is shown in the full upper bar instead.

Symbol for creep speed/full speed - shows if the truck is in full speed or creep speed mode.

Hour counter – shows active or logged on time, depending on which selection was made in the options menu.

Battery indicator – shows battery status. When 20% battery status is reached the lift system ceases to be available.

10.2.7.25 Temperatures The TMC measures the temperatures and if necessary sends a signal to the ATC. The temperatures that are measured are those of the controller and traction motor. The traction motor temperature is only measured as two levels; above or below 125°C. If a value exceeding 125°C is measured, the TMC reduces the current and the warning “Mot. temp. warning” is shown on the display.

The controller temperature is only measured and handled as two levels. If the temperature exceeds 75°C the TMC reduces the maximum current. If the temperature exceeds 100°C the current is reduced to zero and the truck stops. If the controller temperature exceeds 75°C a warning is shown in the display "Reg. temp. warning”.

10.2.7.26 Options Options

Descriptions

Lifting stop

Lift stop for fork lift. Shuts off pump as lift stop switch affected. Lift stop is connected to a digital input on the TMC.

Restart

Restart of fork lifting, activated by pressing 2 on the keyboard.

Safety system

Safety system S3 (only full servo). When the safety system is switched in, the speed is reduced while turning. The safety system is included in Fleet management.

Efficiency

Efficiency log. Included in Fleet management.

Collision detection

Collision sensor. Included in Fleet management. The collision sensor is based completely on software. The speed is monitored and sudden and rapid reductions in speed are interpreted as various grades of collision. *Log level -Setting for logging collisions. *Warning levels-Settings for collision warnings on the display. *Signal level-Setting for a collision that will sound the horn. *Stop level-Setting for a collision that will stop the truck. *Foreman level-Setting for a collision that will require the truck to be unlocked using a code.

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Options

Descriptions

Damage log

Damage log. 10 seconds after logging on, the truck goes down to creep speed and the driver is asked a number of questions concerning possible damage. If the driver answers in the negative, the truck goes to Operational, i.e. it can be driven in the normal manner. Otherwise, questions are asked about damage to various parts of the truck. Included in Fleet management.

Log off time

Time for automatic logging off. *Time segment a -Time to go to Standby. *Time segment b -Time to log off. *Dis tiller res (Disable tiller reset)-If this parameter is set to “Yes”, log on from Standby to Operational by pressing the “I” button twice. If the parameter is set to “No”, log on by activating the tiller arm brake switch.

Smart card

The Smart card is a unit which is mounted on the machine housing (PP Servo) or the tiller arm.With the Smart card, logging on is with a card instead of a PIN code. *Damage log-Smart card damage log.

Display the log

If the option is activated, the logged time is shown on the display. Otherwise, total active time is displayed.

Summer time

Automatically sets the clock to summer time.

key switch

If this option is activated, the key switch is to be used instead of the PIN code for logging on.

Speed red

Speed reduction, which is connected to a digital input on the TMC.

Service alarm

Automatic service reminder. *Range-Time for service intervals.

Fixed platf

Activated when a fixed platform is used (only PLP).

TillerUpD

By pressing and holding in a button on the tiller arm, the truck can be driven at creep speed, without the tiller arm brake switch being activated (only PLL/PSD/PS).

Foot switch

Activates the foot switch surveillance (only PP). On trucks with operator lift the access to the foot switch is limited. In case of a failure of the foot limit switch the operator lift can still be raised during service if the option is set to NO. Note!The option must be returned to YES after service.

Reversing warning

Reversing warning that is switched in by the HVC (only PP).

Asociated controls

Associated controls (only PP).

Dual lift

Dual proportional buttons (only PS/PSH)

Vert. adj. straddle legs

Vertically adjustable straddle legs (only PSH). Cannot be combined with Dual lift.

Belly start

If this parameter is set to “Yes”, the belly switch must be activated in order to be able to log on (used as an “Enter” button). If the parameter is set to “No”, log on immediately after entering the code.

*Only shown if the option is activated.

WARNING! Those options where it is stated that they are only used on a specific type of truck must under no circumstances be activated on any type of truck other than those stated. This is because the software uses the same digital inputs for different functions on the different types of truck.

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10.2.8

ATC Logic

10.2.8.1

General The truck control logic is nowadays mainly generated in the ATC software, and not as previously with cabling and the series and parallel connection of switches. For this reason it is no longer possible to measure all the logical conditions by means of a multimeter. This can now be done with the help of the Monitor menu function for input control. There is no circuit diagram for the software. Instead, a graphic description of the software conditions required for ATC to request procedures has been generated.

The condition does not rule if it is true. This can be compared to an NC contact.

The condition rules if it is true. This can be compared to an NO contact.

Two conditions after each other generate an “and”condition, i.e both conditions must rule for the objective to be achieved. Two parallel conditions generate an"or" condition, which means that it is sufficient for one of the conditions to rule for the objective to be achieved.

Below is an example of how the horn works: It is thus sufficient for one of the horn buttons to be activated for the horn to sound.

10.2.8.2

Direction selector An explanation of the different interlock conditions is available under Section 10.2.7.21, page 124.

10.2.8.3

Brake-System An explanation of the different interlock conditions is available under Section 10.2.7.21, page 124. Note that the brake will be automatically engaged after 500 ms on a stationary truck with the speed controller in neutral position.

10.2.8.4

Lift system An explanation of the different interlock conditions is available under Section 10.2.7.21, page 124.

10.2.9

Downloading

10.2.9.1

Downloading of service data and logs to a PC 1)

Log off the truck and pull out the battery plug.

2)

Start the PC

3)

Connect a COM serial port on the PC to computer connector X3 in the tiller arm head.

Use a PC downloading cable, part no. 108005.

4)

Reconnect the battery plug.

PC

128

5)

Start Windows HyperTerminal.

6)

Create a new HyperTerminal connection.

7)

Connect directly to the COM serial port.

8)

Set the communication parameters as follows:

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• • • • • 9)

Baud Rate (transfer speed): 9600 Data Bits: 8 Parity: None Stop Bits: 1 Flow Control: None

Activate the function “Capture text” in the “Transfer”menu.

Truck

10) Log on to the Atlet menu.

11) Select “LOGS/COUNTERS“ and “Download“.

12) The servicing information will now be transferred to the PC. Disconnection 13) Close HyperTerminal and switch off the PC, log off the truck and disconnect the battery plug.

14) Disconnect the PC downloading cable.

10.2.9.2

Downloading of "Truck Manager" and statistics logs to a PC 1)

Log off the truck and pull out the battery plug.

2)

Start the PC

3)

Connect a COM serial port on the PC to computer connector X3 in the tiller arm head.

Use a PC downloading cable, Atlet part no. 108005.

4)

Reconnect the battery plug.

PC

5)

Start Windows HyperTerminal.

6)

Create a new HyperTerminal connection.

7)

Connect directly to the COM serial port.

8)

Set the communication parameters as follows: • • • • •

9)

Baud Rate (transfer speed): 9600 Data Bits: 8 Parity: None Stop Bits: 1 Flow Control: None

Activate the function “Capture text” in the “Transfer”menu.

Truck

10) Log on to the Local menu.

11) Select “FLEET MANAGER“ and “Download“.

12) The servicing information will now be transferred to the PC. Disconnection 13) Close HyperTerminal and switch off the PC, log off the truck and disconnect the battery plug.

14) Disconnect the PC downloading cable.

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10.2.9.3

ATC connector ATC, connector and pin numbering. Connections seen from above.

Figure 35. Cortex card

10.2.9.4

Digital I/Os Digital inputs ATC There are 12 digital inputs on the ATC card, of which seven are used for the pushbuttons on the tiller arm. The pushbuttons control the lift/lower and horn functions. The signal voltage is 5V. The other five digital inputs are not used in these truck models.

The fact that the inputs are read by the ATC can easily be confirmed in the Atlet service menu by selecting Test => Inputs, and then activating the different functions.

The signal supply of approx. 5V is on pin no 1 in the following connectors: Table 47. 10.11 Connector

130

Functionality

XJ1.3

Lift

XJ2.3

Lower

XJ3.3

Lift

Comment

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Table 48. 10.11 Connector

Functionality

XJ4.3

Lower

XJ8.1

Horn 1

XJ14.1

Horn 2

Comment Supply 5V pin no 2

Digital inputs TMC There are ten digital inputs in the TMC, of which seven are used for these particular truck models.

Signal supply 24V is taken from pin no X5.2.

Table 49. 10.12 Connector

Functionality

Comment

X5.3

Brake switch

Closes in the upper and lower arm positions.

X5.5

Gates

Closes with the gates in their extended positions.

X5.6

Platform switch

Closes with the platform in its lowered position.

X5.7

Top position switch

Breaks at end position

X5.8

Platform switch

Closes with the platform in its raised position.

X5.9

Fixed platform switch

Closes with the driver on the platform

X6.14

Speed reduction switch

Opens at low speed and must be selected in the Options menu

Digital 24V outputs TMC 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.

Table 50. 10.13 Connector

10.2.9.5

Functionality

Comment

X6.1

Energises main contactor K1

24V supply from X6.2

X6.3

Energises the electric brake Y1

24V supply via brake switch

X6.4

Energises the lift contactor K2

24V supply via X6.5

X6.6

Energises the horn H1

24V supply via X6.5

X6.11

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

Cold resistance values Table 51. 10.14 Component

PLP

Resistance

Contactor K1

approx. 47 Ohm

Contactor K2

approx. 19 Ohm

Valve coil Y2

approx. 26 Ohm

Brake Y1

approx. 20 Ohm

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10.2.9.6

PLP fuses Table 52. Fuses Designations

Heavy current (A)

Use

F1

250

Traction motor

F2

250

Pump motor

F3

7,5

Manoeuvring

F4

5

For additional equipment. Max. 120 W

F5

25

Servo steering

10.3

Diagnostics and trouble shooting

10.3.1

Error codes

10.3.1.1

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.

Table 53. 10.16 Fault code indications E1 ATC invalid NVM access

132

Class Warning B

Explanation Attempt to write to invalid E2PROM address

E2

Not used

E3

Not used

E4

Not used

Control/Procedure Settings lost. No action required.

E5 ATC NVM Efficiency log is full

C

The efficiency log is full (all Settings lost. No action 100 posts are used) => the required. first post will be overwritten.

E6 ATC NVM Efficiency log reset on starting

C

The efficiency log is corrupted.

Repaired/erased during the start checks.

Settings lost. No action required.

E7 ATC NVM C Chronological collision log reset on starting

Chronological collision log Settings lost. No action corrupted. required.

Repaired/erased during the start checks.

E8 ATC NVM C Chronological collision log reset on starting

Chronological damage log Settings lost. No action corrupted. required.

Repaired/erased during the start checks.

E9 ATC NVM Temperature C log reset on starting

Temperature log corrupted.

Repaired/erased during the start checks.

Settings lost. No action required.

E10 ATC NVM Operator log reset on starting

Operator log corrupted.

Repaired/erased during the start checks

Settings lost. No action required.

C

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Fault code indications

Class

Control/Procedure

E11 ATC NVM parameters C partially reset during start-up

One or more parameters New settings may be (parameters/accessories/s necessary. ettings) 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

C

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

E13 ATC NVM ATLET code reset during start-up

C

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

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) cleared during start-up

C

Timer outside area

No action required.

E17

Not used

E18

Not used

E19

Not used

E20 ATC NVM Atlet/Local code forced to reset

C

Atlet/Local code forced to reset in the Reset menu

E21 ATC NVM all users forced to reset

C

All users forced to reset in New settings may be the reset menu necessary.

E22 ATC NVM Accessory C parameters forced to reset

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

E23 ATC NVM setting of C parameters forced to reset

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

E24 ATC NVM calibration C parameters forced to reset

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

E25 ATC NVM all logs forced to reset

All logs forced to reset in the reset menu

C

E26

PLP

Explanation

New settings may be necessary.

No action required.

Not used

E27 ATC NVM error log forced to reset

C

Error logs forced to resest No action required. in the ATLET menu

E28 ATC NVM temperature log forced to reset

C

Temperature logs forced to No action required. resest in the ATLET menu

E29 ATC NVM trip meter time/utilisation forced to reset

C

Trip meter time/utilisation forced to resest in the ATLET menu

No action required.

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

driver log forced to resest in the LOCAL menu

No action required.

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Fault code indications

Class

Explanation

Control/Procedure

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

C

Effective time forced to No action required. resest in the LOCAL menu

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

C

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

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

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

E34

Not used

E35 ATC 1721 Analogue Common Pot Low Input Range Fault

B

“ADC PotLowOutput” > ADC COMMON POT LOW SUPERVISION LEVEL

E36 ATC 1721 Analogue Common Pot High Input Range Fault

B

“ADC PotHighOutput” > ADC COMMON POT HIGH SUPERVISION LEVEL

E37 ATC 1721 Analogue Brake Input Range Fault

B

“ADC BrakeOutput” > ADC MAX BRAKE SUPERVISION LEVEL or “ADC BrakeOutput” > ADC MIN BRAKE SUPERVISION LEVEL

E38 ATC 1721 Analogue Raise Input Range Fault

B

“ADC Raise Output” > ADC MAX RAISE SUPERVISION LEVEL or “ADC Raise Output” > ADC MIN RAISE SUPERVISION LEVEL

E39 ATC 1721 Analogue Lower Input Range Fault

B

“ADC Lower Output” > ADC MAX LOWER SUPERVISION LEVEL or “ADC Lower Output” > ADC MIN LOWER SUPERVISION LEVEL

E40 ATC 1721 Analogue A-IN1 Input Range Fault

B

“ADC Aln1 Output” > ADC MAX AIN1 SUPERVISION LEVEL or “ADC Aln1 Output” > ADC MIN AIN1 SUPERVISION LEVEL

E41 ATC 1721 Analogue A-IN2 Input Range Fault

B

“ADC Aln2 Output” > ADC MAX AIN2 SUPERVISION LEVEL or “ADC Aln2 Output” > ADC MIN AIN2 SUPERVISION LEVEL

E42 ATC Safety switch monitoring lost

B

Check of safety switch redundancy lost

E43 ATC speed controller monitoring lost

B

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

E44

Not used

E45

Not used

No action required.

E46

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Fault code indications

Class

Explanation

Control/Procedure

E47 E48 E49 E50 ATC/TMC low battery C

Current battery status Charge the battery. In the received from TMC is less case of repeated E50 logs, than 20% check the BDI settings (See Section 10.2.2.1, page 109).

E51 Com pot low fault

Common low supply range 1. fault

Replace the lift/lower switch.

2.

If the error still occurs replace the ATC.

High supply to hydraulic 1. controls supply range fault

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.

B

E52 E53 Hyd pot high fault

B

E54

Not used

E55

Not used

E56 Lift range fault

PLP

Not used

B

Lift/lowering signal out of allowed range

E57

Not used

E58

Not used

E59

Not used

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10.3.1.2

TMC fault code indications Table 54. 10.17 Fault code indications E100 CAN error

136

Class B

Explanation CAN communication fault in the TMC during start up

Control/Procedure 1.

Check that TMC receives voltage supply

2.

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

3.

There may be a short-circuit in the ATC or TMC communication port. Change first the TMC and the AMC as the other unit.

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 TMC, and the cable and voltage supply to connector contact X5.1.

4.

Change the TMC

5.

Change drive motor

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Fault code indications E103 TMC logic error 2

E104 TMC logic error 3

E105 TMC emergency monitoring has tripped

PLP

Class B

B

B

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

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

Control/Procedure 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 the TMC

5.

Change drive motor

1.

Try restarting. If the error recurs, change the TMC.

2.

Change the motor

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

E106 TMC supply low E107 TMC supply high

B

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

E108 TMC contactor closed

A

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

Restart Check the CAN bus cabling carefully if the error occurs repeatedly, to make sure 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.

1.

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

2.

Change the 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.

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Fault code indications E109 TMC contactor open

138

Class A

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

Control/Procedure 1.

Break in the wiring to the coil

2.

Break inside the 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 the TMC does not charge up as it should during start-up.

E112 TMC output short-circuited

A

The output to the main contactor coil is short-circuited

E113 TMC contactor output

B

The output for the main contactor does not function

1.

Check that there is battery voltage to TMC, between Band contact X5.1.

2.

If not, check the battery voltage, supply cables and their connections

3.

Change the 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 the TMC

1.

Change the TMC

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Fault code indications E114 TMC coil short-circuited

Class A

E115 TMC generic fault B

Explanation

Control/Procedure

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 TMC

1.

Try restarting a few times. If this does not rectify the problem, change TMC.

TMC self-test failed

NOTE! The fault is probably logged together with E123, but should normally never occur. If E135 or E123 still logs, this should be reported to the service function at UniCarriers E116 TMC CAN bus

E117 TMC wrong battery

PLP

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 error on ATC, interference on the CAN bus, or play in the CAN bus connector ring

Incorrect battery voltage The TMC may be incorrectly configured.

Change the TMC

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Fault code indications E118 TMC pulse transducer error

Class B

E119

Explanation

Control/Procedure

Error on the signal from Check and measure the the transducer bearing transducer in in the drive motor accordance with the trouble shooting chart: Section 10.3.2.4, page 144.

Not used

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 109.

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 10.3.2.7, page 146.

See Trouble shooting: Section 10.3.2.6, page 146

Change the TMC

E122 TMC motor temperature

Warning C

The drive motor temperature has exceeded the warning level.

1.

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 E135 or E123 still logs, this should be reported to the service function at UniCarriers

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Fault code indications E124 TMC PEV output

Class B

Explanation

Control/Procedure

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.

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.

E125 TMC temperature Warning C sensor

The internal temperature sensor is defective

Change the TMC

E126 TMC Temperature Warning C sensor traction motor

The drive motor temperature sensor is defective

1.

E127 TMC Current sensor error

Current calibration in progress

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

C

10.3.2

Other trouble shooting

10.3.2.1

Main contactor does not close

See Trouble shooting: Section 10.3.2.6, page 146

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

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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

10.3.2.2

The truck and the ATC have total function loss – the display does not appear 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 on the display or display cable 1.

Is there 24 V between F1 (between the large fuses) and the insulation point 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 24 V between insulation bolt X16 and the insulation point B-?

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 insulation point B-?

Yes: Step 7

142

No: Step 6

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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 a break or a poor connection in the blue minus cable between insulation point B- 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

10.3.2.3

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 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.

Continue with: Step 5

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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

10.3.2.4

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

Remove connector X6 and check the connections between X6.9 - X9.1 and X6.10 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

4.

No: Step 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 X9.3 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 X6.10 and X6.20 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 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

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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

10.3.2.5

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.

See also in the table at Figure 10.7 under which circumstances the truck has faults which prevent it from being driven.

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.

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 X5.3 the controller will not modulate and the brake will not be electrically actuated.

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. 20 Ω. Test if the brake functions if it is released from the motor. If not, change the brake.

Fault trace completed Fault trace completed

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10.3.2.6

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 10.2.7.14, page 122.

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.

There is an internal thermal switch connected between X8.1 and X8.2. If the internal temperature of the motor is below 125°C this switch is closed, but above 125°C it opens. Check this switch when the motor is cold, and note that the cable connector X8 must be disconnected from the motor during measurement. If the thermal switch seem so be OK, check that there is no break in the cable or a poor connection. This can be checked with the current on and with a cold motor by measuring that there is 24 V on both X8.1 and 8.2, with B- as a reference.

Continue with: Step 4

4.

Did this solve the problem? If not, change the TMC. Fault trace completed Fault trace completed

10.3.2.7

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 TMC 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 TMC 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 10.2.7.14, page 122.

1.

Check that the fan that cools TMC is working as it should and that the cooling fins on TMC are not blocked by dust and dirt. OK? Yes: Step 3

2.

No: Step 2

Check the fan cabling and that there is 24 V to the fan. Otherwise, change the fan and clean up dust and dirt.

Fault trace completed

3.

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 5

146

No: Step 4

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4.

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

Fault trace completed

5.

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 7

6.

No: Step 6

Rectify the gearbox or change the motor.

Fault trace completed

7.

Change TMC. Fault trace completed Fault trace completed

10.3.2.8

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 10.2.7.5, page 116.

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

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. 19 Ω. If not, change coil.

Fault trace completed Fault trace completed

10.3.2.9

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.

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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 158.

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

4.

No: Step 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

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10.3.2.10 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 10.2.7.5, page 116.

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

10.4

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: • • • • • •

PLP

Menu tree, Local menu Menu tree, Service menu Menu tree, Monitor menu Menu tree, Reset menu Menu tree, Language Menu tree TRAC

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10.4.2

Local menu tree Level 1

Level 2

Level 3

Level 4

Level 5

Remarks:

LOCAL MENU: < Exit > LOCAL MENU:

SET ACCESS:

OPERATOR:

Operator ID:

< Set access >

Operator ^ v

New/Chang e ^ v

?

Operator categ:x ?

Old code: ????

New code: ????

Verify new code: ????

Ok! Press ENT Not successfu l!

Press ENT

OPERATOR:

CAUTION! Reduced length may lead.

Format

v^ .to lost entries 0:escape 1:go on v1

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Level 1

Level 2

Level 3

Level 4

Level 5

Id length: x

Id length: x

v

New value: ?

Remarks:

Id length: x New value saved!

Input rejected!

Press ENT Code length: x

Code length: x

^

New value: ?

Code length: x New value saved!

Input rejected!

Press ENT The level 3 displays are always followed in sequence.

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Level 1

Level 2

Level 3

SET ACCESS:

Operator ID:

Delete oper ^ v

?

Delete op x?

Level 4

Level 5

Remarks: invalid ID / 0:(No) pressed or input aborted/ no access to E2PROM

0:No 1:Yes (No) OK! Press ENT Not successfu l!

Press ENT SET ACCESS:

Old code:

Local ^ v

???????

New code: ???????

The level 3 displays are always followed in sequence. invalid old code / verifyed code wrong / no access to E2PROM

Verify new code: ???????

Ok! Press ENT Not successfu l!

Press ENT

152

LOCAL MENU:

FLEET MANAGER:

<Fleet manager >

Unlock ^ v

This menu entry resets the Impact Sensor actions. To be used by warehouse manegement to acknowledge impact.

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Level 1

PLP

Level 2

Level 3

Level 4

Level 5

Remarks: List of the 30 most recent operator sessions.

FLEET MANAGER:

READ LOGS:

<o>: [date]

Read logs ^ v

Operator log ^ v

[time] [time]

READ LOGS:

EFFICIENC Y:

<o>: xx(mn)%

Efficienc y ^ v

Worst ^ v

Curr:iii( mn)A

EFFICIENC Y:

<o>: xx(mn)%

Best ^ v

Curr:iii( mn)A

Operator id::

<o>: xx(mn)%

?

T:xx(mn)P :xx(mn)

READ LOGS:

DAMAGE LOG:

<o>: xxx(mn)

Damage log ^ v

Worst ^ v

<o>: xxx(mn)

List sorted from worst to best operator (Act). xx = active time / logged on time * 100; iii = mean main active current draw; mn = corresponding mean value for all operators; List sorted from worst to best operator (Act). xx = active time / logged on time * 100; iii = mean main active current draw; mn = corresponding mean value for all operators; Any operator's efficiency. <o> = operator id (1 - 100) T = traction; P = pump; mn = corresponding mean value for all operators; <o> = operator who used the truck immediately before damage was reported. xxx = number of reported damages. List sorted from greatest to smallest no of reported damages.

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Level 1

Level 2

Level 3

Level 4

Level 5

DAMAGE LOG:)

<o>: xxx(mn)

Best ^ v

<o>: xxx(mn)

DAMAGE LOG:

30:[date] [time]

Chronolog ical ^ v

<o>: <dc> v v v

Remarks: <o> = operator who used the truck immediately before damage was reported. xxx = number of reported damages. List sorted from smallest to greatest no of reported damages.

List sorted in chronological order. <o> = operator who used the truck immediately before damage was reported. <dc> = damage code (max two characters long).

1:[date] [time] <o>: <dc> not implemented yet !

154

READ LOGS:

IMPACT LOG:

<o>: ^xx(mn)

Impact log ^ v

Worst ^ v

IOM:xxx Mn:xxx%

IMPACT LOG:

<o>: ^xx(mn)

Best ^ v

IOM:xxx Mn:xxx%

Top = peak impact value; mn = mean impact value for all operators; IOM = number of impacts over mean (mn); Mn = operator's mean value.

Top = peak impact value; mn = mean impact value for all operators; IOM = number of impacts over mean (mn); Mn = operator's mean value.

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

IMPACT LOG:

30:[date] [time]

Chronolog ical ^ v

<o>: <il> v v v

Remarks: List sorted in chronological order. <o> = operator who used the truck immediately before damage was reported. <il> = impact level (max two characters long).

01:[date] [time] <o>: <il> 01:[date] [time]

Send fleet manager data to serial port.

<o>: <il> FLEET MANAGER:

RESET LOG:

Reset ^ v

Operator log ^ v

Reset optr log?

0:No 1:Yes (No)

RESET LOG:

Resetthis log?

Effic/Dmg /Imp

0:No 1:Yes (No)

RESET LOG:

Time stamp

Time stamp ^ v

xxx days

11:39

LOCAL MENU:

SETTINGS:

TIME & DATE:

< Settings >

< Time & Date ^ v

Set time ^ v

number of days since last reset

New time: hh:mm hh:mm Ok! Press ENT Input rejected!

Press ENT

PLP

155

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4

TIME & DATE:

dd.mm.yyy y

Set date ^ v

New: yy-mm-dd

Level 5

Remarks:

2001-0918 Ok! Press ENT Input rejected!

Press ENT TIME & DATE:

Select format:

Date format ^ v

2001-0918 ^ v 18-Sep-01 ^ v 18.09.200 1 ^ v 09.18.200 1 ^ v

SETTINGS: LCD contrast ^ v

LCD contrast:

LCD contrast: x

x = 0..9

New value: ?

LCD contrast: y New value saved!

Input rejected!

Press ENT

156

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2 SETTINGS: LCD contrast ^ v

Level 3 Key sound: xxx

Level 4

Level 5

Remarks:

Key sound: xxxx 0:no 1:yes Key sound: yyy New value saved!

Input rejected!

Press ENT

LOCAL MENU:

CARD READER:

smartcard :xxx

smartcard :xxx

< Card reader >

Enable/di sable

^ v

0:no 1:yes smartcard :yyy New value saved!

Input rejected!

Press ENT

PLP

157

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

10.4.3

SERVICE menu tree Level 1

Level 2

Level 3

Level 4

Level 5

Remarks:

SERVICE MENU: < Exit > SERVICE MENU: < Options >

Lift limit: xxx

Lift limit: xxx

^ v

0:no 1:yes Lift limit: yyy New value saved!

Input rejected!

Press ENT

Restart: xxx

Restart: xxx

^ v

0:no 1:yes Restart: yyy New value saved!

Input rejected!

Press ENT

158

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Safety syst:xxx

Safety syst:xxx

^ v

0:no 1:yes

Level 4

Level 5

Remarks:

Safety syst:yyy New value saved!

Input rejected!

Press ENT Effici log:xxx Effici log:xxx

Effici log:xxx 0:no 1:yes

^ v Effici log:yyy New value saved!

Input rejected!

Press ENT Impact sens:xxx

Impact sens:xxx

^ v

0:no 1:yes Imp sensor:yy y New value saved!

Input rejected!

Press ENT

PLP

159

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Log level: xxx

Log level: xxx

^ v

New value: ?

Level 4

Level 5

Remarks: Appears only if Imp sensor is 'yes' above!

Log level: yyy New value saved!

Input rejected!

Press ENT Horn level :xxx

Horn level :xxx

^ v

New value: ?

Appears only if Impact sensor is “yes” above!

Horn level :yyy New value saved!

Input rejected!

Press ENT Warning lev :xxx

Warning lev :xxx

^ v

New value: ?

Appears only if Imp sensor is 'yes' above!

Warning lev :yyy New value saved!

Input rejected!

Press ENT

160

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Stop level:xxx

Stop level:xxx

^ v

New value: ?

Level 4

Level 5

Remarks: Appears only if Imp sensor is 'yes' above!

Stop level:yyy New value saved!

Input rejected!

Press ENT Supervis lev :xxx

Supervis lev :xxx

^ v

New value: ?

Appears only if Imp sensor is 'yes' above!

Supervis lev :yyy New value saved!

Input rejected!

Press ENT Damage rep:xxx

Damage rep:xxx

^ v

0:no 1:yes Damage rep:yyy New value saved!

Input rejected!

Press ENT

PLP

161

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Time logoff:xx x

Time logoff:xx x

^ v

0:no 1:yes

Level 4

Level 5

Remarks:

Time logoff:yy y New value saved!

Input rejected!

Press ENT Del time a: xxx

Del time a:xxs

^ v

New value: ?

Appears only if Time logoff is 'yes' above!

Delay time a:yys New value saved!

Input rejected!

Press ENT Del time b: xxx

Del time b:xxmin

^ v

New value: ?

Appears only if Time logoff is 'yes' above!

Delay time b:yymin New value saved!

Input rejected!

Press ENT

162

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Dis tiller res:xxx

Dis tiller res:xxx

^ v

0:no 1:yes

Level 4

Level 5

Remarks: Appears only if Time logoff is 'yes' above!

Dis tiller res:yyy New value saved!

Input rejected!

Press ENT Smartcard :xxx

smartcard :xxx

^ v

0:no 1:yes smartcard :yyy New value saved!

Input rejected!

Press ENT

Damage rep:xxx

Damage rep:xxx

^ v

0:no 1:yes

Appears only if Time logoff is 'yes' above!

Damage rep:yyy New value saved!

Input rejected!

Press ENT

PLP

163

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Disp log on:xxx

Disp log on:xxx

^ v

0:no 1:yes

Level 4

Level 5

Remarks:

Disp log on:yyy New value saved!

Input rejected!

Press ENT Summer time:xxx

Summer time:xxx!

^ v 0:no 1:yes Summer time:yyy New value saved!

Input rejected!

Press ENT Keyswitch :xxx

Keysw pwr of:xxx

^ v

0:no 1:yes Keysw pwr of:yyy New value saved!

Input rejected!

Press ENT

164

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Speed red:xxx

Speed red:xxx

^ v

0:no 1:yes

Level 4

Level 5

Remarks:

Speed red:yyy New value saved!

Input rejected!

Press ENT Cutback3: xxxx%

Cutback3: xxxx%

^ v

New value: ?

Appears only if Speed red is 'yes' above!

Cutback3: yyyy% New value saved!

Input rejected!

Press ENT Service alrm:xxx

Service alrm:xxx

^ v

0:no 1:yes Service alrm:yyy New value saved!

Input rejected!

Press ENT

PLP

165

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Interval: xxxxh

Interval: xxxxh

^ v

New value: ?

Level 4

Level 5

Remarks: Appears only if Service alrm is 'yes' above!

Interval: yyyyh New value saved!!

Input rejected!

Press ENT Fixed platf. :xxx

Fixed platf.:xx x

^ v

0:no 1:yes Fixed Platf:yyy New value saved!!

Input rejected!

Press ENT

TillerUpD :xxx

TillerUpD :xxx

^ v

0:no 1:yes TillerUpD :yyy New value saved!!

Input rejected!

Press ENT

166

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Reverse ind :xxx

Reverse ind :xxx

^ v

0:no 1:yes

Level 4

Level 5

Remarks:

Reverse ind :yyy New value saved!!

Input rejected!

Press ENT Raise steer :xxx

Raise steer :xxx

^ v

0:no 1:yes Raise steer :yyy New value saved!!

Input rejected!

Press ENT

Stop on ramp :xxx

Stop on Ramp :xxx

^ v

0:no 1:yes Stop on ramp :yyy New value saved!!

Input rejected!

Press ENT

PLP

167

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Straddle :xxx

Straddle :xxx

^ v

0:no 1:yes

Level 4

Level 5

Remarks:

Straddle :yyy New value saved!!

Input rejected!

Press ENT Belly start :xxx

Belly start :xxx

^ v

0:no 1:yes Belly start :yyy New value saved!!

Input rejected!

Press ENT

Battery creep :xxx

Battery creep :xxx

^ v

0:no 1:yes Battery creep :yyy New value saved!!

Input rejected!

Press ENT

168

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

SERVICE MENU:

SETTINGS:

PERFORMAN CE:

< Settings >

Performan ce ^ v

Op category 1 ^ v

Level 4

Level 5

Fwd speed: xxx%

Fwd speed: xxx%

^ v

New value: ?

Remarks:

Fwd speed: yyy% New value saved!

Input rejected!

Press ENT Rev speed :xxx%

Rev speed :xxx%

^ v

New value: ?

Rev speed: yyy% New value saved!

Input rejected!

Press ENT

Tract accel:xxx %

acc to above!

^ v Tract cutb1:xxx %

acc to above!

^ v Tract cutb2:xxx %

acc to above!

^ v

PLP

169

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4 Tract curr :xxx%

Level 5

Remarks:

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:xxx %

acc to above!

^ v PERFORMAN CE:

According to the above!

Op category 2 ^ v PERFORMAN CE:

According to the above!

Op category 3 ^ v PERFORMAN CE:

According to the above!

Op category 4 ^ v

170

PLP

PLP Service Manual — D001981, C, GBR, Translated

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: ?

Breakp lo: yyy% New value saved!

Input rejected!

Press ENT

Breakp hi: xxx%

Breakp hi: xxx%

^ v

New value: ?

Breakp hi: yyy% New value saved!

Input rejected!

Press ENT

Deadzone: xxx%

Deadzone: xxx%

^ v

New value: ?

Deadzone: xxx% New value saved!

Input rejected!

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'.

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'.

Screen stays on for 1 s.

Displayed if value is out of range. 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Press ENT

PLP

171

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

TRACTION:

Breakp lo: xxx%

Breakp lo: xxx%

Brake map ^ v

^ v

New value: ?

Breakp lo: xxx% New value saved!

Input rejected!

Press ENT

Breakp hi: xxx%

Breakp hi: xxx%

^ v

New value: ?

Breakp hi: xxx% New value saved!

Input rejected!

Press ENT

Deadzone: xxx%

Deadzone: xxx%

^ v

New value: ?

Deadzone: xxx% New value saved!

Input rejected!

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'.

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'.

Screen stays on for 1 s.

Displayed if value is out of range. 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Press ENT

172

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3 TRACTION:

Level 4 Motor: NN

Motor type ^ v

Level 5

Remarks:

Motor: NN 0:Kordel 1:Sauer Motor: NN New value saved!

Input rejected!

Press ENT

SETTINGS: Brake ^ v SETTINGS: Pump ^ v

Cont Delay: xr

Cont Delay: xr New value: ?r Cont Delay: xr New value saved!

Input rejected!

Press ENT

PLP

173

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3 Delay1:

Level 4

Level 5

Remarks:

Delay1: xxx New value: ?r Delay 1: x New value saved!

Input rejected!

Press ENT

Delay2:

Delay2: xxx New value: ?r Delay 2: x New value saved!

Input rejected!

Press ENT

Lower acc:

Lower acc: xxx New value: ?r Lower acc: xxx New value saved!

Input rejected!

Press ENT

174

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3 Lower acc:

Level 4

Level 5

Remarks:

Lower ret: xxx New value: ?r Lower ret: xxx New value saved!

Input rejected!

Press ENT

SETTINGS:

HYDRAULIC S:

HVC 1: xxx

HVC 1: xxx

Hydraulic s ^ v

HVC Setup ^ v

^ v

0:off 1:onr HVC 1: yyy New value saved!

Input rejected!

'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Press ENT HVC 1 PWM:xxxxH z

HVC 1 PWM:xxxHz

'xxx' = 'on' or 'off' (currently used)

^ v

0:off 1:onr

New value 'yyy' replaces the old 'xxx'.

HVC 1 PWM:yyyHz

Screen stays on for 1 s.

New value saved!

Displayed if value is out of range.

Input rejected!

Press ENT HVC 2: xxx

acc to above!

^ v

PLP

175

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4 HVC 2: xxx

Level 5

Remarks:

acc to above!

^ v HVC 2: xxx

acc to above!

^ v HVC 2: xxx

acc to above!

^ v HVC 2: xxx

acc to above!

^ v HVC 2: xxx

acc to above!

^ v HYDRAULIC S: Lift ^ v

Raise ctrl:xxxx x

Raise ctrl:xxxx x

^ v

0:OnOff 1:Speed Raise ctrl:yyyy y New value saved!

'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Input rejected!

Press ENT

176

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

Speed ctrl:xxxx x

Speed ctrl:xxxx x

^ v

0:Valve 1:Motor

Remarks:

Speed ctrl:yyyy y New value saved!

Input rejected!

Press ENT Raise min: xxx% ^ v

Raise min: xxx New value: ?

Raise min: yyy New value saved!

Input rejected!

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.

Press ENT Raise max: xxx%

acc to above!

^ v Lower min: xxx%

acc to above!

^ v Lower max: xxx%

acc to above!

^ v Breakp: xxx% ^ v

PLP

acc to above!

Defines the ouput signal level at 50% of the input signal

177

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4 Deadzone: xxx%

Level 5

Remarks:

acc to above!

^ v HYDRAULIC S:

Ch2 ctrl: xxxxx

Ch2 ctrl: xxxxx

Channel 2 ^ v

^ v

0:OnOff 1:Speed Ch2 ctrl: yyyyy New value saved!

Input rejected!

'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Press ENT Speed ctrl:xxxx x

Speed ctrl:xxxx x

^ v

0:Valve 1:Motor Speed ctrl:yyyy y New value saved!

Input rejected!

Press ENT

Ch2 pos min:xxx%

Pos min: xxx

^ v

New value: ?

Refers to [ valve PWM ] or [ pump motor speed ] depending on choice above.

Pos min: yyy New value saved!

Input rejected!

Press ENT

178

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4 Ch2 pos max:xxx%

Level 5

Remarks:

acc to above!

^ v Ch2 neg min:xxx%

acc to above!

^ v Ch2 neg max:xxx%

acc to above!

^ v Breakp: xxx%

acc to above!

^ v Deadzone: xxx%

acc to above!

^ v HYDRAULIC S:

acc to above!

Channel 3 ^ v HYDRAULIC S:

acc to above!

Channel 4 ^ v HYDRAULIC S:

Hydra lock: xx

Hydraul lock ^ v

0:off 1:on Hydra lock: xx New value saved!

Input rejected!

Press ENT

PLP

179

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4

SETTINGS:

FB adjust

Adj FB mode

Steering ^ v

^ v

0:off 1:on Adj FB mode xx Press '<' key Input rejected!

Press ENT

EPS: xxx

EPS: xxx

^ v

0:off 1:on

Level 5 Plese wait, storing data.

Restart system and adjust FB

Remarks: This menu appears when FB adjust mode is 'On' This menu appears when FB adjust mode is 'Off'

FB adj.

Complete Restart system

EPS: yyy New value saved!

Input rejected!

Press ENT Numbness ^ v

Numbness x New value: ?

Numbness x New value saved!

Input rejected!

Press ENT

180

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4

Steer ctrl:xxxx x

Steer ctrl:xxxx x

^ v

1:Speed 2:Posit

Level 5

Remarks:

Speed ctrl:yyyy y New value saved!

Input rejected!

Press ENT Limit rough:

Limit rough: x

^ v

New value: ?

Limit rough: x New value saved!

Input rejected!

Press ENT

Limit fine CW: xx

Limit fine CW: x

^ v

New value: ?

Limit fine CW: x New value saved!

Input rejected!

Press ENT

PLP

181

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4

Limit fine CCW:

Limit fine CCW: x

^ v

New value: ?

Level 5

Remarks:

Limit fine CCW: x New value saved!

Input rejected!

Press ENT Steer hi spd:

Steer hi spd: xx

^ v

New value: ?

Steer hi spd: xx New value saved!

Input rejected!

Press ENT

SETTINGS: Battery ^ v

BATTERY: Battery type:

Battery type: x Wet:0 Gel:1 x Battery type: x New value saved!

Input rejected!

Press ENT

182

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3 BATTERY: Calibrate ^

Level 4

Level 5

Remarks:

Measured: xxx New value: ?

Measured: yyy New value saved!

Input rejected!

Press ENT

BATTERY: Wet battery ^ v

Wet battery:

Stepdown hi: x

Stepdown hi ^ v

New value: ?

Stepdown hi: y New value saved!

Input rejected!

Press ENT

Wet battery:

Stepdown lo: x

Stepdown lo ^ v

New value: ?

Stepdown lo: y New value saved!

Input rejected!

Press ENT

PLP

183

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3 BATTERY: Gel battery ^ v

Level 4

Level 5

Gel battery:

Stepdown hi: x

Stepdown hi ^ v

New value: ?

Remarks:

Stepdown hi: y New value saved!

Input rejected!

Press ENT Gel battery:

Stepdown lo: x

Stepdown lo ^ v

New value: ?

Stepdown lo: y New value saved!

Input rejected!

Press ENT

184

SETTINGS:

TRUCKTYOE

Trucktype ^

XX

XX = trucktype

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1 SERVICE MENU: < Tests >

PLP

Level 2 TESTS: Inputs ^ v

Level 3

Level 4

TEST INPUTS:

111222333 444555A

Overview ^ v

66677BCDE FGHIJK

TEST INPUTS:

Signal check:

Accelerat or ^ 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

Remarks: Strings of the same digit are bar graphs for analog/steering enc inputs. The digit identifies the input, the number of digits represents the input signal level. E.g "1" means: 10%<spd cmd<50%, "11" means: 50%<spd cmd<90%, "111" means: spd cmd>90%.

Single letters means digital input activated. s' = sign

s' = sign

s' = sign

s' = sign

s' = sign

185

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

TESTS: Outputs ^ v

Level 3

Level 4

TEST INPUTS:

Signal check:

Aux AI 3 ^ v

x.x V Out:syyy%

TEST INPUTS:

Steering rpm:

Steering ^ v

syyy

TEST INPUTS:

SP pot: x.xxV

EPS sensors

FB pot: x.xxV

Level 5

Remarks: s' = sign

s' = sign

If "ENT" is pressed, the currently displayed output will be engaged as long as the key is kept pressed

TEST OUTPUT: LED 1 ^ v

TEST OUTPUT: LED 2 ^ v TEST OUTPUT: LED 4 ^ v TEST OUTPUT: HEATER ^ v TEST OUTPUT: ANALOG OUT TESTS: Versions ^ v

READ VERSION:

HW: SW:

Traction ^ v READ VERSION:

HW: SW:

HVC ^ v

186

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3 READ VERSION:

Level 4

Level 5

Remarks:

HW: SW:

Power steering^ v READ VERSION:

HW: MM.mm

ATC ^ v

VCL SW: MM.mm ^v OS date: yy-mm-dd OS ver: MM.mm ^v

TESTS:

Disable?

TM encoder ^ v

0:no 1:yes: enc disabled Press ENT

TESTS:

Disable?

PP footswitc h ^

0:no 1:yes: Footsw. disabled Press ENT

PLP

SERVICE MENU:

CALIBRATE :

< Calibrate >

All ^ v

187

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2 CALIBRATE : Accelerat or ^ v

Level 3 Release throttle and press ENT Go to end points and press ENT

Level 4

Level 5

Remarks: Covers both butterfly and pedal type throttle The level 3 displays are always followed in sequence. s = sign (+ raise, - lower)

OK!: Press ENT Not successfu l!

Press ENT Signal check: x.x V Out:syyy%

CALIBRATE : Brake ^ v

Release brake and press ENT

The level 3 displays are always followed in sequence.

Order full brake and press ENT OK!: Press ENT Not successfu l!

Press ENT Signal check: x.x V Out:syyy%

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PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2 CALIBRATE : Lift ^ v

Level 3 Release lift and press ENT Order full raise and press ENT

Level 4

Level 5

Remarks: Covers both combined and separate raise/lower controls.

The level 3 displays are always followed in sequence. s = sign (+ raise, - lower)

Order full lower and press ENT OK!: Press ENT Not successfu l!

Press ENT Signal check: x.x V Out:syyy%

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Level 1

Level 2 CALIBRATE : Channel 2 ^ v

Level 3

Level 4

Level 5

Remarks:

Release ch2 and press ENT Order full +dir and press ENT Order full -dir and press ENT OK!: Press ENT Not successfu l!

Press ENT Signal check: x.x V Out:syyy%

CALIBRATE :

According to “Channel 2”

Channel 3 ^ v CALIBRATE :

According to “Channel 2”

Channel 4 ^ v

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10 Electrical system

Level 1

Level 2

Level 3

CALIBRATE :

Level 4

Level 5

Remarks:

Center steering and press ENT

Steering ^ v

Calibrati on done press ENT Calibrati on failed press ENT CALIBRATE :

Update angle

Update angle ^ v SERVICE MENU:

LOGS/COUN TERS:

<Logs/cou nters >

Error log ^ v

30: Exxx

+01: Exxx

[date] [time]

Offset: zzz ms

v^

Latest error is shown first.

The [i] key can be used to jump directly to the next error (primary and secondary error log) xxx is the error code yyy is the number of errors occured "+" idicates that there is a secondary error

[error text line 1]

[error text line 1]

[error text line 2]

[error text line 2]

v^

v^ #yyy occurred: [date] [time]

+02: Exxx Offset: zzz ms v^

v^

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Level 1

Level 2

Level 3

Level 4

next primary error…

Level 5

Remarks:

[error text line 1] [error text line 2] v^

Appears only if VCL (or the error is a OS) VCL or OS ERROR ERROR instead of the 2 screens Module above! No id: mmm secondary log v^ is possible.

+03: Exxx Offset: zzz ms v^

Error id: eee

[error text line 1]

Line: LLL

[error text line 2] v^ +04: Exxx Offset: zzz ms v^ [error text line 1] [error text line 2] v^

LOGS/COUN TERS:

Tract motor temp

Temp log ^ v

60C:xxxx. xh v v v

192

Temperatures for traction motor, traction controller, pump motor, pump controller, hydr oil, power steering motor, power steering controller, all in five intervals.

Intervals differs depending on the objects working temperature range.

PLP

PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3

Level 4

Level 5

Remarks:

Tract motor temp 121 :xxxx.xh LOGS/COUN TERS:

HOUR METER:

TOTAL Active:

Hour meters ^ v

Total ^ v

xxxxx.yyy h

xxxxx -> hours yyy -> 1/1000 hours

TOTAL Logged on: xxxxx.yyy h TOTAL Traction: xxxxx.yyy h TOTAL Pump: xxxxx.yyy h HOUR METER:

TRIP Active:

Trip ^ v

xxxxx.yyy h

xxxxx -> hours yyy -> 1/1000 hours

TRIP Logged on: xxxxx.yyy h TRIP Traction: xxxxx.yyy h TRIP Pump: xxxxx.yyy h

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Level 1

Level 2

Level 3

Level 4

HOUR METER:

READ Traction:

Read external ^ v

xxxxx h

Level 5

Remarks:

READ Pump: xxxxx h READ Pwr Steer: xxxxx h LOGS/COUN TERS: Utilisati on ^ v

LOGS/COUN TERS: Reset ^ v

"iii" is the calculated "mean main active current", "xx" is calculated as: [active time] / [calendar time since last reset].

Tract: iii A xx% Pump: iii A xx%

RESET: Error log ^

Reset error log?

0:no 1:yes Successfu l reset Press ENT Reset aborted!

Press ENT

RESET: Temp log ^

Reset temp log?

0:no 1:yes Successfu l reset Press ENT Reset aborted!

Press ENT

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PLP Service Manual — D001981, C, GBR, Translated

10 Electrical system

Level 1

Level 2

Level 3 RESET: Trip meters/Ut il^

Level 4

Level 5

Remarks:

Reset trip/util log?

0:no 1:yes Successfu l reset Press ENT Reset aborted!

Press ENT

RESET: Service alarm ^ v

Reset service?

0:no 1:yes Successfu l reset Press ENT Reset aborted!

Press ENT

LOGS/COUN TERS:

SET HOURS:

Set hour mtrs ^v

Logged on ^ v

Logged on xxxh

Logged on: xxx New value: ?

Hour meters can only be set to a higher value than before.

Logged on: yyy New value saved!

Input rejected!

Press ENT

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Level 1

Level 2

Level 3 SET HOURS:

Level 4 Active: xxxh

Active ^ v

Level 5

Remarks:

Active: xxx New value: ?

Active: yyy New value saved!

Input rejected!

Press ENT

SET HOURS:

Traction:

Traction ^ v

Traction: xxx New value: ?

Active: yyy New value saved!

Input rejected!

Press ENT

SET HOURS: Pump ^ v

Pump:

Pump: xxx New value: ?

Active: yyy New value saved!

Input rejected!

Press ENT

LOGS/COUN TERS:

Send all above logs to serial port truck serial no, versions and settings (not fleet manager statistics)

Download ^ v

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10 Electrical system

Level 1

Level 2

Level 3

Level 4

SERVICE MENU:

SET ACCESS:

OPERATOR:

Operator ID:

< Set access >

Operator ^ v

New/Chang e ^ v

?

Level 5

Remarks: The level 3 displays are always followed in sequence.

The no of question marks corresponds to the chosen id length (ATLET menu).

Operator categ:x ?

Old code:

invalid old code / verifyed code wrong / category out of range (1..4) / all 100 user ID's used / no access

????

New code: ????

Verify new code: ????

Ok! Press ENT Not successfu l!

Press ENT OPERATOR:

CAUTION! Reduced

Format ^ v

length may lead. v^

Id length: x New value: ?

Id length: x New value saved!

Input rejected!

Press ENT

PLP

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Level 1

Level 2

Level 3

Level 4

v

Level 5

Id length: x

Code length: x

v

New value: ?

Remarks:

Code length: x New value saved!

Input rejected!

Press ENT SET ACCESS:

Old code:

Local ^ v

???????

invalid old code / verifyed code wrong / no access to E2PROM

New code: ???????

Verify new code: ???????

Ok! Press ENT Not successfu l!

Press ENT

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10 Electrical system

Level 1

Level 2

Level 3

SET ACCESS:

Old code:

Service ^ v

???????

Level 4

Level 5

Remarks: invalid old code / verifyed code wrong / no access to E2PROM

New code: ???????

Verify new code: ???????

Ok! Press ENT Not successfu l!

Press ENT SERVICE MENU:

Go to Reset menu

< Total reset >

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10 Electrical system

Table 55. Hydraulic Control Channels Lift channel Selection is done 'semiautomatically' during CALIBRATION between: 1. Combined raise/lower control (e.g. joystick) 2.

Channel 2

Channel 3

Channel 4

Selection is decided in SETTINGS between: 1. On/Off control.

2.

Speed control. a) Valve PWM control.

Individual raise and lower controls (e g b) Pump motor pushbuttons in the tiller Every unique VCL sw speed control. head) variant includes rules for: 1. which inputs are Selection is done Selection is decided in allowed to be used to 'semiautomatically' during SETTINGS between: each channel. The final 1. On/Off control.

CALIBRATION between: decision to determine 1. Combined raise/lower 2. Speed control. which of these allowed control (e.g. joystick) a) Valve PWM inputs will be used is 2. Individual raise and control. made by the lower controls (e g b) Pump motor 'auto-sense' feature pushbuttons in the tiller speed control. during calibration. head) 2. which outputs will be Selection is done Selection is decided in used: 'semiautomatically' during • if on/off control is SETTINGS between: CALIBRATION between: 1. On/Off control. selected 1. Combined raise/lower 2. Speed control.

• if valve PWM is control (e.g. joystick) a) Valve PWM selected 2. Individual raise and control.

• if motor speed lower controls (e g b) Pump motor control is selected. pushbuttons in the tiller speed control. head) 3. which interlocks should exist between the Selection is done Selection is decided in different channels. 'semiautomatically' during SETTINGS between: CALIBRATION between: 1. On/Off control.

1. Combined raise/lower 2. Speed control. control (e.g. joystick) a) Valve PWM 2.

Individual raise and lower controls (e g pushbuttons in the tiller head)

control. b)

Pump motor speed control.

Example 1 - tiller application Lift channel is analog, with valve PWM output. Inputs are decided in Atlet menu/Calibrate/Lift menu. When the display requests "full raise" the proportional pushbutton connected to J9 (lift) is activated by the engineer followed by ENT. Cortex then recognises this input as the raise input. The display requests "full lower" and the operator pushes the button connected to J8 (lower). Cortex has now detected which inputs are used for raise and lower, and has also stored at which input levels full output should be given. Output type is selected in Atlet menu/Settings/Hydraulics/Lift. First of all, speed control is selected. Now, further settings are needed. In this case, a porportional valve will be controlled by HVC 1. The engineer selects valve speed control. Fixed outputs for contactor prop valve and dir valve are hardcoded.

Output relations to dead zone passing and to calibrated maximum input are entered.

Channel 2 is 'digital', with onoff valve control. No input calibrations need to be done, since output is defined as 'onoff'. Hardcoded definitions for input and output associations take effect.

Example 2 - rider stacker Lift channel is analog, with joystick and pump motor speed control. Input calibration is carried out as in example 1. Cortex recognizes the a 'combined' raise/lower control from the voltage

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10 Electrical system

levels read during calibration. Output setting s are set to 'speed control' and 'motor'. Raise command is sent to hardcoded adress in PMC, lower command is sent to HVC 1.

10.4.4

Monitor menu Level 1

Level 2

Level 3

Remarks

MONITOR MENU: < Exit > MONITOR MENU:

TRACTION:

xxxxrpm

< Traction >

Drive Monitor ^ v

+/-iii A

TRACTION:

C: +/-ttt degC

Temp Monitor ^ v

M: +/-TTT degC

MONITOR MENU:

xxxxrpm

< Pump >

+/-iii A

"xxxx" = motor speed in rpm; "iii" = motor current "ttt" = controller temperature; "TTT" = motor temperature

v^ C:ttt M:TTT degC MONITOR MENU:

Adjust FB

< Steering >

v^

Steer 90deg left and press ENT Steer 90deg right and press ENT Adjustment done

Jumps to 'Exit' when pressing ENT

Press ENT Read sensors

SP pot: n.nnV

v^

FB pot: n.nnV

"n.nn"= Read value in Volts

FB pot: n.nnV FB pot: n.nnV Angle: xx Set steer 0-pos

"nnnn"= 0-position in mV, ENT escape button instead of key 4.

<4 nnnnmV 6> Record angle

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10 Electrical system

not implemented yet

MONITOR MENU: < Wire guide > MONITOR MENU:

IN/OUT:

< In/Out >

ATC inputs: ^ v

Accelerator xxx Raise1 xxx Raise2 xxx Lower1 xxx Lower2 xxx Belly x BellyInv x TillerUpD x Horn x Dig_in1 x Dig_in2 x Dig_in3 x Dig_in4 x Dig_in5 x

IN/OUT:

Dig_in1 x

TMC inputs: ^ v

Dig_in2 x Dig_in3 x Dig_in4 x Dig_in5 x Dig_in6 x Dig_in7 x

IN/OUT:

Dig_in1 x

HVC inputs: ^ v

Dig_in2 x Dig_in3 x A_in 1 xxx

IN/OUT: EPS inputs: ^ v v IN/OUT:

Lift int x

ATC int/out: ^ v

Speed int x Safety int x Max spd xxx Forward x Reverse x Brake x Liftstop x

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10 Electrical system

10.4.5

Reset menu Level 1 RESET: All users ^ v

Level 2

Level 3

Level 4

Level 5

Remarks:

Reset all users?

0:no 1:yes Successfu l reset Press ENT Reset aborted!

Press ENT

RESET: Options ^ v

Reset options?

0:no 1:yes Successfu l reset Press ENT Reset aborted!

Press ENT

RESET: Settings ^ v

Reset settings?

0:no 1:yes Successfu l reset Press ENT Reset aborted!

Press ENT

RESET: Calibrati on ^ v

PLP

Reset calib?

0:no 1:yes

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10 Electrical system

Successfu l reset Press ENT Reset aborted!

Press ENT RESET: Logs ^ v

Reset logs?

0:no 1:yes Successfu l reset Press ENT Reset aborted!

Press ENT

10.4.6

Language tree Level 1

Level 2

Level 3

Level 4

Level 5 Remarks :

SELECT LANGUAGE: English ^ v Svenska Deutsch Francais Custom

10.4.7

TRAC TRAC MENU: < Exit > TRAC MENU:

Initphone

< Initphone > TRAC MENU:

Answer call

< Answer call >

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SERVICE MANUAL Machine:

PLP

Manual No:

119002

Edition 2009B

11 Speed control and Brake system Design and function ..................................................................................................... 11.3 Electric brake ......................................................................................................11.3 Repair and maintenance instructions ........................................................................ 11.4 Electric brake ......................................................................................................11.4 Service ......................................................................................................................... 11.4 Replacing the brake disc (–2006w46) .......................................................................... 11.4 Replacing the brake disc (2006w47–) .......................................................................... 11.5 Emergency release ...................................................................................................... 11.6

SERVICE MANUAL

11.2

SERVICE MANUAL

Speed control and Brake system / Design and function / Electric brake

11.3

Edition 2009B

11 Speed control and Brake system Design and function Electric brake PLL is equipped with an electric brake. The electric brake is a safety brake with two friction surfaces. The braking torque is produced by spring pressure. The brake is activated when the voltage over the coil is lost, i.e. the truck is braked when it is without voltage.

When the brake is activated the springs press on the plate, which is pressed axially to the rotor. When the brake is to be released the coil is supplied with battery voltage. The magnetic field created between the plate and the magnetic part allows the rotor to rotate freely.

The brake is activated by the TMC and EPS via the ATC (see also wiring diagram).

11_SM_PLP_En_119002_2009B.fm

SERVICE MANUAL

11.4

Speed control and Brake system / Repair and maintenance instructions / Electric brake

Repair and maintenance instructions Electric brake Service The brake does not need adjusting.

When serviced the gap between the magnetic parts should be measured to ensure that the brake disc is not worn.

A

Figure 11.1

The gap A can be measured with the brake fitted (figure 11.1).

Warning!

The brake disc is worn out and should be replaced if the measured gap is greater than 0.6 mm!

Replacing the brake disc (–2006w46) 1.

Disconnect the electrical connection to the magnetic part.

2.

Release the three retaining screws holding the magnetic part, and carefully lift off.

Clean the magnetic part.

3.

Lift off the brake disc and clean all the surfaces.

4.

Fit the new brake disc and refit the magnetic part. Tighten the three retaining screws to 9.5 Nm.

5.

Reconnect the electrical connection to the magnetic part.

Warning!

Check that you have a safe braking capacity.

SERVICE MANUAL

Speed control and Brake system / Repair and maintenance instructions / Electric brake

11.5

Replacing the brake disc (2006w47–)

C B Figure 11.2 Electric brake (2006w47–)

1.

Disconnect the electrical connections to the magnetic part.

2.

Undo the three retaining screws, pos B in figure11.2.

3.

Dismantle the brake by unscrewing 3 screws, pos C.

4.

Lift out the brake disc and clean the magnetic part and brake plate.

5.

Mount the new brake disc and refit the magnetic part. Tighten the three retaining screws at 9.5 Nm.

6.

Reconnect the electrical connections to the magnetic part.

Warning!

Check that you have a safe braking capacity.

SERVICE MANUAL

11.6

Speed control and Brake system / Repair and maintenance instructions / Electric brake

Emergency release The brake can be released manually if necessary.

Note!

If the brake is released manually there will be no functioning parking or emergency brake. Never leave a machine with a manually released brake!

Figure 11.3

To manually release the brake, screw in two screws (M6x55) in the two marked holes (figure 11.3).

SERVICE MANUAL