BT W18 W20 Service Manual 178825-040 - PDF DOWNLOAD

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Safety regulations with maintenance work

1

Cleaning and washing ................................................... 3 Safe lifting ......................................................................... 4

0DLQWHQDQFH /XEULFDWLRQ VFKHGXOH Maintenance schedule

1

Lubrication schedule ...................................................... 7

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Super Seal connectors

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Component parts

1

Service/Repairs ............................................................... 4 Technical data ................................................................. 6

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Component parts

2

Leakage from top cover ................................................. 4 Changing of the drive shaft’s sealing ring ................. 4

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Main components of the brake

1

Maintenance ..................................................................... 2

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Component parts, tiller arm

1

Adjustments ...................................................................... 4 Tiller arm handle .............................................................. 5

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Electrical parts

1

List of symbols and electrical wiring diagram .................................................................. 3 Functional description .................................................. 11 Hour meter ...................................................................... 13 Fault codes ..................................................................... 13 Parameters ..................................................................... 18 Part numbers .................................................................. 27 Transistor panel ............................................................. 27 Diagnostic and troubleshooting ................................. 28 Technical specifications – Curtis 1243 ..................... 30

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Hydraulic chart and list of symbols

1

Adjustments W18 ............................................................ 2 Adjustments W20 ............................................................ 4

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General

1

Charging

1

Troubleshooting and service ........................................ 1 Technical data ................................................................. 2 Charging settings ............................................................ 3

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Connection ....................................................................... 1 Layout ................................................................................ 2 Function ........................................................................... 4 Specifications ................................................................. 12

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Type

TSL140S-DS20

TSL140S-DS30

Output, kW

1.2

1.4

Duty cycle

S2, 60 min

S2, 60 min

Minimum carbon brush length, mm

13

13

Nominal commutator diameter, mm

50

50

Minimum commutator diameter, mm

47

47

Resistance, shunt field winding, Ω at 25 C°

0.49

0.49

Resistance armature winding, Ω at 24 °C

0.0156

0.0156

Insulation resistance between the windings and motor casing

>=1 Mohm

>=1 Mohm

Weight, kg

14

14

Type

BFK457-08

BFK457-08

Braking force, Nm

16

16

Output, W

25

25

Resistance coil, Ω

23

23

Nominal play in actuated position, mm

0.2-0.4

0.2-0.4

Minimum thickness brake disc, mm

5.5

5.5

Thickness of a new brake disc, mm

7.0

7.0

Type

2-stage angle transmission

2-stage angle transmission

Gear ratio

19,14:1

19,14:1

Oil volume, litre

1.0

1.0

Oil type at normal temperature at temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

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Drive wheel, mm

Dia 215x70

Dia 215x70

Axle pressure without load, kg

200

254

Axle pressure at rated load, kg

650

710

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

Fork wheel, mm

Dia 85x75

Dia 85x75

Axle pressure without load, kg

2x40 (240)

2x55 (240)

Axle pressure at rated load, kg

2x710 (240)

2x775 (240)

Support castors, mm

Dia 125x40

Dia 125x40

Axle pressure without load

2X70 (240)

2x75 (240)

Axle pressure at rated load, kg

2x80 (240)

2x130 (240)

Output, kW

1.2

2.2

Duty cycle,%

10

10

Minimum carbon brush length, mm

7.5

12

Minimum commutator thickness/diameter, mm

4.75

4.75

Pressure at rated load, bar

110

125

Overflow pressure, bar

130

140

Pump flow, litre/minute

4.7

5.1

Tank volume, litre

0,5

1,0

Oil type: at normal temperature at temperature < -15oC

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Drive motor circuits, A

125

125

Pump motor circuits, A

125

125

Control circuits, A

7,5

7,5

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Dimensions LxWxH, mm

193x642x450

193x642x510

Capacity, Ah

160-320

240-320

Weigh, kg

165-250

210-250

Without load, km/t

6,0

6,0

With rated load, km/t

6,0

6,0

Lift without load, s

2.2

1.7

Lift with rated load, s

3.4

2.3

Lowering without load, s

2.6

1.6

Lowering with rated load, s

3.1

1.7

Driving without load, A

38

30

Driving with rated load, A

45

45

Lift without load, A

39

46

Lift with rated load, A

80

92

8%

8%

Short Medium Long

519 565 613

590 638

Turning radius WA

1466

1491

Lift height

205

205

295

335

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Truck without battery, Medium

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All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter. The operator may adapt them to local conditions, but it is important that the intervals comply with BT’s minimum requirements.

The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations. The following running times have been used when calculating the intervals:

- Day time:

08.00-17.00 (20 hr./week)

- 2-shifts:

06.00-14.00, 14.00-22.00 (40 hr./week)

- 3-shifts:

06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)

Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.

Only use BT approved spare parts when service and repair work are carried out.

6DIHW\ UHJXODWLRQV ZLWK PDLQWHQDQFH ZRUN Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work.

• Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so • Keep the area where you carry out the service clean. Oil or water makes the floor slippery • Never wear loose objects or jewellery when working on the truck :$51,1* 6KRUW FLUFXLWLQJ %XUQV :KHQ ZRUNLQJ ZLWK WKH WUXFN¶V HOHFWULFDO V\VWHP VKRUW FLUFXLWLQJ EXUQV FDQ RFFXU LI D PHWDO REMHFW FRPHV LQWR FRQWDFW ZLWK OLYH HOHFWUL FDO FRQQHFWLRQV 5HPRYH ZDWFKHV ULQJV RU RWKHU W\SHV RI PHWDO MHZHOOHU\

• Always disconnect the battery by pulling out the battery isolator when carrying out maintenance work on the truck unless otherwise stated in this Service Manual • Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system Service Manual W18/W20

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• Relieve the system pressure slowly before starting work on the truck’s hydraulic system • Use paper or a rigid sheet of cardboard when checking for oil leakage. 1HYHU use your hand • Bear in mind that the oil in the transmission or the hydraulic system can be hot :$51,1* 5LVN RI EXUQV +RW WUDQVPLVVLRQ DQG K\GUDXOLF RLO /HW WKH WUXFN FRRO EHIRUH FKDQJLQJ WKH RLO

• Only fill the hydraulic system with new and clean oil :$51,1* 7KH K\GUDXOLF V\VWHP FDQ EH GDPDJHG ,I WKH RLO LV FRQWDPLQDWHG K\GUDXOLF FRPSRQHQWV FDQ EH GDPDJHG $OZD\V XVH QHZ DQG FOHDQ RLO LQ WKH K\GUDXOLF V\VWHP

• Store and dispose of changed oil in accordance with local directives • Do not release solvents and the like, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local directives that apply for disposal • Disconnect the battery when welding on the truck 127( 7KH EDWWHU\ FDQ EH GDPDJHG :KHQ ZHOGLQJ XVLQJ DQ HOHFWULF SRZHU VRXUFH WKH ZHOGLQJ FXUUHQW FDQ HQWHU WKH EDWWHU\ 7KH EDWWHU\ VKRXOG WKHUHIRUH EH GLVFRQQHFWHG

• Remove at least 100 mm of paint around the welding/grinding area through sand-blasting or the use of a paint stripper when welding or grinding on painted surfaces &$87,21 +DUPIXO JDVHV 3DLQW WKDW LV KHDWHG JLYHV RII KDUPIXO JDVHV 5HPRYH PP RI SDLQW IURP WKH ZRUN DUHD

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&OHDQLQJ DQG ZDVKLQJ Cleaning and washing of the truck is important to ensure the truck’s reliability.

• Carry out general cleaning and washing weekly 127( 5LVN RI VKRUW FLUFXLWLQJ 7KH HOHFWULFDO V\VWHP FDQ EH GDPDJHG 'LVFRQQHFW WKH EDWWHU\ EHIRUH ZDVKLQJ E\ SXOOLQJ RXW WKH EDWWHU\ FRQQHFWRU

([WHUQDO FOHDQLQJ • Remove rubbish, etc. from the wheels daily • Use a well-known degreasing agent, diluted to a suitable concentration • Rinse off loose grime using tepid water 127( -DPPLQJ FRUURVLRQ 0HFKDQLFDO FRPSRQHQWV FDQ EH GDPDJHG $IWHU ZDVKLQJ WKH WUXFN VKRXOG EH OXEULFDWHG DV VHW RXW LQ WKH FKDS WHU 0DLQWHQDQFH DQG OXEULFDWLRQ FKDUW

&OHDQLQJ WKH PRWRU FRPSDUWPHQW • Cover the electric motors, connections and valves before washing 127( 5LVN RI VKRUW FLUFXLWLQJ 7KH HOHFWULFDO V\VWHP FDQ EH GDPDJHG (OHFWULFDO FRPSRQHQWV PXVW QRW EH FOHDQHG ZLWK D KLJK SUHVVXUH ZDVKLQJ XQLW

• Clean the motor compartment using a well-known degreasing agent, diluted to a suitable concentration • Rinse off loose grime using tepid water

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(OHFWULFDO FRPSRQHQWV • Blow electric motors down using compressed air • Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent 127( 5LVN RI VKRUW FLUFXLWLQJ (OHFWULFDO FRPSRQHQWV FDQ EH GDPDJHG 'R QRW EUHDN WKH JXDUDQWHH VHDO RQ WKH HOHFWURQLF ERDUG

6DIH OLIWLQJ All lifting must be carried out on a flat, non-slip and firm surface. Avoid new laid asphalt or asphalt on a hot summer’s day.

• Activate the parking brake to prevent the truck from moving during the lift. If the lift applies to the brake wheel, chock the other wheels so that the truck stands still • Select a lifting point so that the lift is as easy as possible (one corner at a time). If the truck has marked lifting points on the under side of the chassis these can be used to obtain a well balanced lift • Ensure that the surface under the jack is clean and free from oil and grease • Ensure that your hands and the jack’s lever are free from oil and grease • Use the lever that belongs to the jack. A lever that is too short requires more force than is necessary. If the lever is too long there is a risk of the jack being overloaded • Support the truck: - as close as possible to the part of the chassis that is to be lifted.

This reduces the risk of the truck tipping over - so that the truck cannot roll •

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0DLQWHQDQFH VFKHGXOH I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary 3RV 1R

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0000.1

Check all links and locking pins

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0000.2

Check wear on cover/battery locking

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0000.3

Check of cracking and damage

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0000.4

Check the cover locks

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0000.5

Check finger guard

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0000.6

Check signs and stickers

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0380.1

Check for crack formation and damage

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0380.2

Check clearance in bushes and links

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0380.3

Press grease into grease nipples (Option)

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0380.4

Check the lift limit switch

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1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

Service Manual W18/W20

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I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary 3RV 1R

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2550.1

Check for leakage

2550.2

Check the oil level

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2550.3

Check for abnormal noise

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2550.4

Check the attachment and clearance in steering bearing

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2550.5

Change the oil in the drive gear

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3100.1

Clean

3100.2

Check for wear on the brake disc

M

3100.3

Check the clearance in disengaged position

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3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts

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3500.3

Check that the support wheel turns and rotates freely

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3500.4

Check for wear on the support wheel

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4110.1

Check the mountings

4110.2

Check the power in the gas damper

4–2

I3

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Service Manual W18/W20

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I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary 3RV 1R

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5000.1

Check the operation of the brake microswitch in the upper and lower brake positions. Lubricate the switch head

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5000.2

Check the function of the collision safety switch

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5000.3

Check the function of the horn

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5000.4

Check for wear on cabling

5000.5

Check the function of the driver’s control

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5000.6

Check the error code log and operating times

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5110.1

Check the electrolyte level, 10-15 mm over the cell plates

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5110.2

Check connections to battery, truck and charger

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5110.3

Check that the cell and pole guards are undamaged

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5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

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5400.1

Cleaning and checking of mounting in chassis

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5400.2

Re-tighten cable connections

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5400.3

Check the contactor points on K10 and K30

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5400.4

Check the movement of the contactors

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5400.5

Check the cable insulation

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5700.1

Check connectors and cables

5700.2

Check all segments on display

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6100.1

Check hoses and connections for wear

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6100.2

Check hoses for wear and damage

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6100.3

Check the oil tank for cracks, leakage and damaged mountings

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6100.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

4–4

Service Manual W18/W20

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I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary 3RV 1R

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6600.1

Check for leakage

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6600.2

Check the mountings

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= The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months.

= The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm.

= Check for leakage in conjunction with the first oil change.

= The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months

= The oil is changed and the filter cleaned for the first time after 80 h/ 1 month, and then every 1000 h/12 months

When points with higher hour intervals are carried out the points with lower hour intervals should also be carried out unless otherwise specified above.

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5000

5000

5700

4110 5110

5400

5000 3100 1700 6100 2550

6600

0380

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Service Manual W18/W20

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= The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months

= The oil is changed and the filter cleaned for the first time after 80 h/1 month, and then every 1000 h/12 months.

6100

2550 0380

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BT 26777 (Spray)

BT 26777 (Spray)

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B

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ISO-L-HM32

ISO-VG32

Hydraulic system

C

Transmission oil

Hypoid oil SAE 80W/90

Hypoid oil SAE 75W

Gears

D

Grease

BT 26778 (Spray)

BT 26778 (Spray)

Chains

E

Grease

BT 73942XX5 TOTAL N3942

BT 73942XX5 TOTAL N3942

Lubricating nipples, Contact pressure spring

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Service Manual W18/W20

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Tool for release of lock (1)

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Tool for application of secondary locking 2-pole (2)

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Service Manual W18/W20

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When ordering 155619-001 both cables are received

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4

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M5x12

7

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M5x20

8

Carbon brush

9

Rotor

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Washer

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'LVPDQWOLQJ RI PRWRU IURP WUXFN • Switch off the truck and pull out the battery plug.

• Remove the covers for the motor compartment.

• Release the cables for the motor and tiller arm.

• Unscrew the four nuts for the attachment of the motor to the drive gear.

• Loosen the cables for the key switch and emergency switch. Pull out all the cables from the cover’s cable duct.

• Loosen the cover over the motor compartment and the tiller arm’s mounting from the motor. Remove the cover over the motor compartment together with the tiller arm.

• Carefully lift the motor straight up, without damaging the sealing surfaces to the drive gear and place the motor on a clean surface.

• Protect the drive gear from impurities by covering over its opening in an appropriate manner, e.g. with a piece of plastic.

The requisite service and repair of the motor can now be carried out.

7–2

Service Manual W18/W20

Approved by: L-G Andersson

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$VVHPEOLQJ • Assembling is carried out in the reverse order.

• Carefully lift down the motor in the drive gear to avoid damaging the seals and gear wheels.

• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm. • Fit and adjust the brakes as per the instructions. Screw tight the cover and tiller arm, and connect the cables that were previously removed. Check that the polarity is correct.

• The function of the brakes should be checked before the truck is moved.

Service Manual W18/W20

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17 10

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12 11

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7 6 5 4 3 1 2

• Release the brake disc’s companion flange by first removing the locking ring together with the washer in the end of the rotor shaft.

The companion flange can now be lifted off. It may be necessary to unclamp it with an appropriate tool.

• Remove the four plugs that cover the carbon brushes, move the springs on the carbon brushes to one side and pull out the carbon brushes.

• Dismantle the commutator end’s bearing shield (2) together with the carbon brush bridge (5) and carbon brushes (8) by unscrewing the eight screws (1). Now put down the motor with a firm resting point against the edge of the bearing shield, and carefully tap on the rotor shaft’s end with a rubber mallet.

• Dismantle the drive end’s bearing shield (15) together with the rotor (9). Make sure not to damage the motor windings when the rotor is removed from the motor housing.

7–4

Service Manual W18/W20

Approved by: L-G Andersson

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• After dismantling the motor’s bearing shields and removing the rotor from the motor housing, the gear wheel in the rotor’s drive end is removed. This is done by unscrewing the nuts on the gear wheel and then pulling the gear wheel off with a puller. Note that the gear wheel is locked with Loctite to the rotor shaft.

• Now release the inner locking ring together with the underlying washer. Pull out the rotor shaft from the bearing (18).

• Release the outer locking ring together with its washer, and remove the bearing from the bearing shield.

• Remove the bearing shield’s seal (17) and carefully clean the bearing shield.

• Fit a new seal in the bearing shield.

$VVHPEOLQJ RI PRWRU Assemble the motor in the reverse order.

• Carefully check that the rotor can move freely in the direction of rotation and that the carbon brushes are flush with the commutator.

• Check the motor’s insulation resistance (between respective winding and the motor housing). For a new motor this should lie between 2 - 3 Mohm. When a used motor has been exposed to impurities an insulation resistance down to approx. 1 Mohm is acceptable.

• Fit a new O-ring in the drive shaft end’s bearing shield and a new seal on the collar of the bearing shield.

&OHDQLQJ An extremely critical factor to ensure correct functioning of the motor is that it is kept as clean as possible. The motor and the motor compartment must be regularly checked for dust, oil, and other impurities.

A vacuum cleaner with an appropriate nozzle can be used to clean the motor if the motor windings and inner compartment are dry Compressed air can be used in combination with a vacuum cleaner. In which case the compressed air must be clean and dry.

A cloth of non-fluffing material should be used if the windings have a coating. The cloth can also be moistened with a grease-dissolving, organic and volatile detergent that does not damage the windings. Use detergent sparingly to avoid it penetrating into the parts of the motor.

Residual detergent should be removed with an appropriate solvent, if it leaves a greasy surface.

If the parts of the motor are heavily fouled it may be necessary to use a solvent that is sprayed onto the parts. It is important that the detergent is applied in a way to prevent dirt from penetrating into the parts of the motor, especially for the rotor.

Service Manual W18/W20

Approved by: L-G Andersson 7 – 5

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One method of cleaning the rotor is to dip it in solvent. If this is done then the rotor must always be dried with the application of heat. There must be adequate ventilation during the drying process, and the drying should continue until a number of measurements of the insulation resistance provide equivalent and approved results.

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:

:

Type

TSL140S-DS20

TSL140S-DS30

Output (kW)

1,2

1,4

Intermittence

S2 60 min.

S2 60 min.

Minimum length of carbon brush (mm)

13

13

Minimum commutator diameter (mm)

47

47

Resistance, shunt field winding Ω at 26 C°

0,49

0,49

Resistance, armature winding,Ω at 26C°

0,0156

0,0156

Insulation resistance between windings and motor housing

>= 1Mohm

>= 1Mohm

Weight (kg)

14

14

Service Manual W18/W20

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15

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31

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Service Manual W18/W20

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3

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7

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9

Gear wheel

10

Conical roller bearing

11

Shims

12

Screw

13

Shims

14

Conical roller bearing

15

Pinion/ Crown gear

Cog clearance 0.09-0.15 mm Pretension bearing with 2-5/100 Stamped size on pinion adjusted with shims

16

Nut

Tightening torque 300 Nm Locked with punch mark

17

Shims

18

Conical roller bearing

19

Shims

20

Screw

Service Manual W18/W20

1RWH

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Primary gear

Top cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

Bottom cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242 Approved by: L-G Andersson

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25

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26

Nut

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27

Screw

Motor and gear housing

28

Nut

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29

Conical roller bearing

30

Shims

31

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32

Drive shaft

Motor gear

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: 3

Type of gear

2-step angle gear

Gear ratio

14,20:1

Oil volume, litres

1,75

Oil type

Hypoid oil

Viscosity, normal temperature

SAE 80W90

Viscosity, <-15°C

SAE 75W

Service Manual W18/W20

Approved by: L-G Andersson 8 – 3

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• Lift up the truck, and block up to ensure that it is stable.

• Unscrew the drive wheel.

• Unscrew the M8 nuts (28), that hold the gear and motor, with a box wrench. Support the gear so that it does not drop.

• Release the M8 bolts (12), that hold the cover (3), with a 6 mm hex socket wrench.

• Change the gasket (6). $VVHPEOLQJ LV FDUULHG RXW LQ WKH UHYHUVH RUGHU

• Tighten the four M8 bolts and the four M8 nuts to a torque of 26.6 Nm Lock with Loctite 242.

• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.

&KDQJLQJ RI WKH GULYH VKDIW¶V VHDOLQJ ULQJ The drive shaft’s sealing ring can be changed with the gear mounted in the truck.

Follow the instructions below if oil is leaking from the drive shaft.

'LVPDQWOLQJ • Unscrew the drive wheel 1).

• Remove the lower cover and drain off the oil (22).

• Release the drive shaft nut. Remove the nut and washer (16,17).

• Carefully tap out the drive shaft with a brass drift and hammer (32).

• Pull off the bearing from the drive shaft with tool 08-13022 (29).

• Check that the bearing washers are not damaged. If they have been damaged by the puller tool, measure the total thickness of the shim washers and change them before assembling (30).

• Remove the sealing ring from the drive shaft (31).

8–4

Service Manual W18/W20

Approved by: L-G Andersson

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$VVHPEOLQJ Assembling of the gear after changing the drive shaft’s sealing ring is carried out in the reverse order to dismantling.

Pay special attention to the following during assembling: • Fill the sealing ring with grease after fitting it on the drive shaft.

• Make sure that only undamaged shim washers with the same total thickness as the originals are put on the drive shaft.

• Press the bearing on the drive shaft and make sure not to damage the bearing’s shim washers.

• When fitting the drive shaft with bearing, shim washers and seal, make sure that the shaft keys correspond with the crown gear’s keys and that the bearing and seal are correctly positioned in the gear housing before the shaft is pressed in completely.

• Put the distance ring on the drive shaft end, and put on the shaft nut.

Always XVH a new nut. Tighten the shaft nut to a torque of 300 Nm and lock it with a punch mark in the middle. The drive shaft nut should be lubricated before it is put on the shaft.

• Change the gasket before fitting the bottom cover. Make sure that it is not damaged. Fit the cover and tighten the bolts to a torque of 26.6 Nm. The bolts should be lubricated before they are fitted. Fill up with oil in accordance with the instructions for replenishing the oil.

Fit the drive gear and tighten the bolts to a torque of 65 Nm.

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2

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3

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4

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5

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6

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7

Flange

8

Mounting bolts

9

Brake disc

10

Hub

Service Manual W18/W20

Approved by: L-G Andersson 9 – 1

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0DLQWHQDQFH Basically the brake is maintenance free in normal work environments.

However it is recommended according to the preventive maintenance schedule to check the brake disc for wear and the gap between the magnetic coil housing and the pressure plate on a regular basis.

%DVLF $GMXVWPHQW RI JDS 5,5 Nm

0,2

The QRPLQDO JDS between the coil housing and the pressure plate, in applied position, shall be PP. The PD[LPXP JDS before readjustment is necessary is PP. Adjustment procedure: Loosen the tension of the three adjustment bolts .

Turn the lock nuts anti-clockwise and tighten the bolts slightly while checking the gap RQ WKUHH SRLQWV with a 0.2 mm feeler gauge.

Tighten the lock nuts 5,5 Nm and recheck the gap with the feeler gauge.

([FKDQJH RI EUDNH GLVF The brake disc shall be exchanged when its total thickness has been reduced to 5,5 mm.

• Disconnect the electrical wires of the brake.

• Loosen and remove the three mounting bolts and remove the brake coil.

9–2

Service Manual W18/W20

Approved by: L-G Andersson

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• Replace the brake disc on the hub and make a visual inspection of the wear of the friction plate. Replace the friction plate if the surface is worn uneven.

• Unwind the lock nuts on the coil at least 6 mm to make sure there is a gap between the coil and the pressure plate when the coil is refitted.

• Mount the coil on the motor end and carry out adjustment of the gap according to chapter “Basic Adjustment of gap”.

• Reconnect the electrical wiring.

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2

6

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7

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8

Gas damper

9

Bracket

10

Stop screw

11

Screw

12

Ball joint

13

Screw

14

Distance

15

Bush

2

16

Damper

2

17

Axle

18

Cam

19

Distance

20

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21

Distance

22

Distance

23

Switch

Service Manual W18/W20

4

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9

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10

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11

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12

Screw

13

Distance

14

Bush

2

15

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2

16

Axle

17

Cam

18

Distance

19

Screw

20

Distance

21

Distance

22s

Switch

4

S 10

$GMXVWPHQWV $GMXVWLQJ RI EUDNH PLFURVZLWFK Switch (23) is always adjusted to its lowest position.

• Unscrew the screws (13, 20) that hold the switch and the distance.

• Press down the switch and tighten the screws.

• Check that the switch is actuated by the cam (18) in the arm’s top and bottom position.

10 – 4

Service Manual W18/W20

Approved by: L-G Andersson

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27 26 24 25

14 23 22

17 18

21

16

20

19

15 14 14

30 31 10 9 8

32

35

14

12 11

13

33 34 5

6

7

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Screw

2

Cover

3

Handle

4

Electronic circuit board

5

Screw

6

Display card

7

Top cover

8

Pushbutton

9

Signal switch

10

Signal button

11

Display glass

12

Arm

13

Pushbutton

14

Plate

Service Manual W18/W20

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Keyboard option

Option

Lift/Lower

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15

Spring

16

Pushbutton

17

Arm

18

Holder

19

Spring

20

Control switch

21

Axle

22

Sliding bearing

23

Control stop

24

Arm

25

Spring holder

26

Spring

27

Spring holder

28

Sliding bearing

29

Control switch

30

Button for safe reversing

31

Arm

32

Spring

33

Lower cover

34

Screw

M4x40

35

Screw

2xM5x45 - 2xM5x60

Service Manual W18/W20

1RWH

Not used

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'LVPDQWOLQJ $VVHPEOLQJ • Dismantle cover (2), (keyboard option).

• Remove the screws (35), hold top cover firm (7).

• Disconnect the cable connected to the electronic circuit board (4).

• Remove the screws (34).

• Carefully lift off the lower cover (33), and place a finger between the lower cover (33) and button (30) to hold the button (30) in place.

Assembling is carried out in the reverse order.

127( 6WDWLF HOHFWULFLW\ 5LVN RI VWDWLF GLVFKDUJH WKDW FDQ GDPDJH WKH HOHFWURQLFV 0DNH VXUH WR WDNH WKH QHFHVVDU\ SUHFDXWLRQV EHIRUH ZRUNLQJ ZLWK WKH HOHFWURQLFV

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• Connect the CAN-key to the truck • Enter parameter mode (P) • Change parameter 39 to value = 3 or 4 • Set the required PIN-code by using parameter 10 • Switch off the truck • Dismantle the cover(2) on the tiller arm • Fit the keyboard • Remove the ignition key, fit the strap • Fit the cover in the key hole • Start the machine using the chosen PIN-code • Change from keyboard to ignition key (2) • Connect the CAN-key to the truck • Enter parameter mode (P) • Change parameter 39 to value = 1 or 2 • Switch off the truck 5HPRYH WKH NH\ ERDUG RQ WKH WLOOHU DUP

• Fit the cover • Remove the strap • Remove the cover • Fit the ignition key • Start the truck Service Manual W18/W20

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• Dismantle the button as per the diagram.

• Disconnect the connection for the switch on the electronic circuit board (4).

• Press out the switch from its mounting.

Assembling is carried out in the reverse order.

10 – 8

Service Manual W18/W20

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• Remove the button by placing a screwdriver in the hole (A) as per the diagram below.

A

A

• Unscrew the holder (18) so that the arm (12) comes loose.

Assembling is carried out in the reverse order. &KDQJLQJ RI SXVKEXWWRQ

• Press the button by hand sideways.

• Place a screwdriver as per the diagram and carefully pry the button loose.

• Unscrew the button’s holder and arm.

Assembling is carried out in the reverse order.

Service Manual W18/W20

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S17 S31

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F50 M3

F51 F1

Y41

R1 K10 F3

M1

K30 A1 H1

Service Manual W18/W20

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Transistor regulator

A5

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A6

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A7

Keypad

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Option

F1

Fuse

Drive motor circuit

125 A

F3

Fuse

Pump motor circuit

125 A

F 50

Fuse

Operating circuit A5

7,5 A

F 51

Fuse

Operating circuit A1

7,5 A

F 52

Fuse

Optional equipment

Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

M1

Motor

Drive motor

M3

Motor

Pump motor

R1

PTC-resistor

Power supply

S1

Switch

Option

S2

Switch

Option

S3

Switch

Option

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Service Manual W18/W20

15 Ohm

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Switch

Option

S5

Switch

Option

S6

Switch

Option

S10

Switch

Travel brake

S17

Switch

Key

S18

Switch

Horn button

S20

Switch

Safety reversing

S21

Switch

Emergency switch off

S31

Switch

Lift height limiter

S34

Switch

Fork lifting

S41

Switch

Fork lowering

Y1

Brake

Y41

Magnetic valve

Fork lowering

X1

Connector

Battery

X41

Connection point

CAN-communication

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Service Manual W18/W20

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Service Manual W18/W20

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)XQFWLRQDO GHVFULSWLRQ 6WDUWLQJ WKH WUXFN • Battery connector plugged in.

• S21 closed.

• S17 on.

'ULYLQJ VSHHG ≤ 6 km/h

A1 BS1 T1

Ish

• S59 open.

• S10 closed .

A2

A

• L1 activated in any direction.

A1

T2

K10

B+

1HXWUDO VSHHG UHGXFWLRQ • L1 to neutral position, motor starts to work as generator. Brake energy comes back to battery.

• Y1 will be applied when the truck comes to a stand still even if the tiller is in drive position.

3LFWXUH Energy back to the battery.

The transistors (T2) for the generated brake current are not live.

A1 BS1

T1 Ish + Ia

S2

MShunt

Ia

MShunt

+

S2

A2

A A1

T2 K10

B+

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Service Manual W18/W20

Approved by: Joakim Carleborn

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1HXWUDO VSHHG UHGXFWLRQ RQ VORSHV If the driver release the speed leaver (L1) on a slope and the truck doesn’t come to a stop within a certain time the electrical brake will be applied by the system.

%UDNLQJ The brake is always applied when the truck is started with the tiller in it’s upper or lower position (S10 open). The brake is released in the same moment as the conditions for driving are fulfilled and the truck starts to move.

Conditions to brake the truck: • S10 open.

/LIWLQJ WKH IRUNV • S34.

• S31 closed.

• Battery status OK (if battery capacity >20% left).

/RZHULQJ WKH IRUNV • S41activated.

+RUQ • S18 activated.

11 – 12

Service Manual W18/W20

Approved by: Joakim Carleborn

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+RXU PHWHU • Press S18 and turn S17 to on at the same time.

• Press S18 until you read H= hour meters.

• You have now choosen H=hourmeters the symbol “B” will be highlighted.

• You can now choose type of hourmeter by pressing L1.

1 (A)= Key time.

2 (b)= Drive motor time.

3 (c)= Pump motor time.

4 (d)= Activity time.

5 (s)= Time to service.

A

)DXOW FRGHV • Press S18 and turn S17 to on at the same time.

E

D

C

B

• Press S18 until you read E= fault codes.

• By choose E the symbol “E” will be highlighted to indicate what’s currently shown on display.

• The last 50 fault codes will be stored. The latest fault will be shown first. The display first show the error code and then wich hour the fault occured.

• The fault codes are devided into two groups C = caution and E = error.

• The C will not be stored. It’s only a caution and will be highlighted on display as long as the fault exists. &RGH

&

Description

Default parameter warning.

Possible fault reason

Parameter area is probably corrupt.

Default values have been down loaded, i.e special parameter settings must be restored.

&RGH

&

Description

Butterfly warning

Possible fault reason

Problem with butterfly sensor.

Butterfly may have been activated during start up or faulty sensor.

Service Manual W18/W20

Approved by: Joakim Carleborn

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Description

Service time warning

Possible fault reason

Time to make service Service counter not reset after latest service

&RGH

&

Description

Pressure switch warning

Possible fault reason

A problem with the pressure switch. Check that the voltage is approximately 24 V between the cables 24 and 40 connected to the pressure sensor.

Check the voltage between cable 40 and 63 connected to the pressure sensor. The output voltage should be 0.5 Volt (unloaded machine) - 5 Volt (max load)

&RGH

&

Description

Battery undervoltage warning

Possible fault reason

Battery voltage < 17 volt Battery parameter not correct adjusted Time to charge battery

&RGH

&

Description

Battery overvoltage warning

Possible fault reason

Battery voltage > 33 volt Fully-charged battery and energy return feed to the battery during motor braking.

&RGH

&

Description

Power amplifier thermal cutback

Possible fault reason

Too intensive driving Defect motor controller

Service Manual W18/W20

Approved by: Joakim Carleborn

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&RGH

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Description

Motor controller does not correspond with the type of truck

Possible fault reason

Check that the right type of motor controller is fitted

&RGH

(

Description

Brake switch transistor shorted

Possible fault reason

Defect motor controller Check the cables and magnetic coil to the brake

&RGH

(

Description

Digital output or field over current

Possible fault reason

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault.

&RGH

(

Description

Contactor off

Possible fault reason

Problem with main contactor tips or cabling (open circuit).

Contactor control wire not connected.

Contactor drive output in controller faulty (off).

&RGH

(

Description

Contactor welded

Possible fault reason

Main contactor tips welded.

Contactor drive output in controller faulty (on).

&RGH

(

Description

System error.

Possible error cause

Possible defect in the motor controller.

Restart the machine.

Service Manual W18/W20

Approved by: Joakim Carleborn

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&RGH

(

Description

Checksum error

Possible fault reason

Internal microcontroller fault (tiller head), faulty software or pcb.

&RGH

(

Description

Software problem

Possible fault reason

Internal microcontroller fault (tiller head),faulty software or pcb.

&RGH

(

Description

Drive communication error

Possible fault reason

Broken CAN-cable.

Motor controller broken

&RGH

(

Description

Drive communication Tx error

Possible fault reason

Motor controller does not answer, bad connections or faulty motor controller.

&RGH

(

Description

Bus off error

Possible fault reason

CAN-bus problem, harness or hardware problem.

&RGH

(

Description

Over run error

Possible fault reason

CAN-bus problem, harness or hardware problem.

w

11 – 16

Service Manual W18/W20

Approved by: Joakim Carleborn

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(

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Error in safety reversing

Possible fault reason

Critical sensor element faulty

&RGH

(

Description

Field open

Possible fault reason

Shuntfield open, harness broken, motor controller defect.

&RGH

(

Description

M minus error

Possible fault reason

Problem with switch transistor in armature circuit inside motor controller.

&RGH

(

Description

Power amplifier sensor error

Possible fault reason

Armature current sensor fault in motor controller.

&RGH

(

Description

Power amplifier CAN-timeout

Possible fault reason

Motor controller reports unexpected loss of data flow from tiller head.

Service Manual W18/W20

Approved by: Joakim Carleborn

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3DUDPHWHUV • Press S18 and turn S17 to on at the same time.

• Press S18 until you read P= parameters.

A

• You have now choosen P=parameters the symbol “C” on display will be highlighted to indicate what’s currently shown on display.

• Scroll to the parameter you want to change or look at by pressing the L1 up or down.

E

D

C

B

• Press S18 ones to get access to the parameter.

• Set parameter value by pressing L1 up or down.

• Press S18 ones to confirm change.

• Turn S17 to off.

You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid.

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Service Manual W18/W20

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02

Speed

%

10

100

5

100

10:low Speed 100:full Speed

03

Acceleration

10

100

5

75

10:low acceleration 100:full acceleration

04

Neutral speed reduction

5

100

5

80

Defines motor speed reduction force when lever goes to neutral position.

5: low reduction force 100: full reduction force

05

Logg off

0

20

1

0

The time until the truck will be switched off when a key pad is used.

Time is counted from when the latest power consumer is used.

1min

3DUDPHWHU GHVFULSWLRQ 3DUDPHWHU

The maximum speed can be adjusted.

3DUDPHWHU

The lower value of the parameter the longer time it takes to accelerate the truck to top speed.

3DUDPHWHU

Defines motor brake force when lever (L1) goes to neutral position.The lower value of parameter the longer time to reduce speed.

3DUDPHWHU

The time until the truck will be switched off when a key pad is used.

Time is counted from when the latest power consumer is used.

Service Manual W18/W20

Approved by: Joakim Carleborn

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3DUDPHWHU

1DPH

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1

Speed, low speed

%

10

100

5

100

Speed, low speed 10: low speed 100: highest speed

2

Maximum Speed

%

10

100

5

100

Maximum Speed 10:low Speed 100:full Speed

03

Acceleration

10

100

5

50

10:low acceleration 100:full acceleration

04

Neutral speed reduction

5

100

5

50

Defines motor speed reduction force when lever goes to neutral position.

5: low reduction force 100: full reduction force

05

Logg off

0

20

1

0

The time until the truck will be switched off when a key pad is used. Time is counted from when the latest power consumer is used

1min

3DUDPHWHU GHVFULSWLRQ 3DUDPHWHU

Possibility to adjust the speed in the low speed range (when the safety gates are not used).

3DUDPHWHU

Possibility to adjust the speed in the high speed range (when the safety gates are used).

3DUDPHWHU

The lower value of the parameter the longer time it takes to accelerate the truck to top speed.

3DUDPHWHU

Defines motor brake force when lever (L1) goes to neutral position.The lower value of parameter the longer time to reduce speed.

11 – 20

Service Manual W18/W20

Approved by: Joakim Carleborn

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3DUDPHWHU

The time until the truck will be switched off when a key pad is used.

Time is counted from when the latest power consumer is used.

6HUYLFH SDUDPHWHUV • Connect CAN-key in X41 • Choose parameter KKK

3DUDPHWHU

1DPH

10

8QLW

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0D[

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PIN code

0

9999

1

0

Possibility to state up to 10 PIN codes (10 different drivers)

14

Creep speed

-10

10

1

0

This defines how much output the controller gives when you reach the first speed sensor.

-10 : low speed when reaching first speed sensor.

10:high speed when reaching first speed sensor.

20

Hour meter selection

1

5

1

2

Select hour meter

21

Battery size

1

20

1

9

Battery size selection

25

Service interval

0

2000

50

100

Possible to set servicetimer.

28 - Machine n° W18432800AA-/ W20432865AA-

Lift button selection

1

3

1

1

Button selector

39

Access code

1

4

1

1

State which level of authorization the driver has to the parameters

40 - Machine n° 364690AAW18432800AA/ W20432864AA

Display code

0

1

1

0

Defines what should be shown on display.

1h

Service Manual W18/W20

Approved by: Joakim Carleborn

11 – 21

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3DUDPHWHU GHVFULSWLRQ 3DUDPHWHU

10 drivers can have it’s own PIN-code to get access to the truck. Each driver have possibility to set all the driver parameters individual.

Possibility to adjust the speed in the high speed range (when the safety gates are used) Code 0 is not accepted as a solitary code.

When you wish to start the truck enter your code and press the green button with the number 1.

To turn the truck to off press the red no.0 button.

When you have the CAN-key connected you can turn the truck on by just pressing the green no. 1 button. You turn it to off by pressing the red no. 0 button.

3DUDPHWHU

Defines the speed you will get when you reach the first speed sensor.

3DUDPHWHU

You choose wich hour meter you want to display.

1A = Key time.

2b =Activity time.

3c = Drive motor time.

4d = Pump motor time.

5s = Time to service.

3DUDPHWHU

You must give data about with wich battery the truck is equipped.

To adjust the disconnection point of the battery discharge indicator meassure according to : • Acid concentration when fully charged battery. To check quality of battery. Shall be between 1,27-1,29.

• When you get lift cut out (80 % discharged of battery capacity) you shall have close to 1,14 not less.

11 – 22

Service Manual W18/W20

Approved by: Joakim Carleborn

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The acid concentration can vary depending of battery brand.

9DOXH

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1 2 3 4 5 6 7

140

8

240

9

↑

10 11

Less discharged

12 13

More discharged

14

↓

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3DUDPHWHU

With this parameter you can set a time limit to next service from 0 to 2000 hours in step of 50 hours. When it’s time for service you will get caution 29 (C29) on the display.

Service Manual W18/W20

Approved by: Joakim Carleborn

11 – 23

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Using this parameter you can select which button is to be used for lift/ lower.

1 = Lower lift/lower button activated (default) 2 = Upper lift/lower button activated 3 = Both lift/lower buttons are activated 3DUDPHWHU

This parameter can be adjusted like: 1 = Key connected, driver parameters open.

2 = Key connected, driver parameters must be opened with can-key.

3 = Key pad connected, driver parameters open.

4 = Key pad connected, driver parameters must be opened with CAN key.

3DUDPHWHU ² 6HULDO QXPEHU $$ : $$ : $$

• Set parameter to value 1.

• Turn S17 to off and then on again.

• Press S18 to choose display mode.

A

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• Connect CAN-key in X41 and start the machine.

• Battery status is shown and symbol “D” is lit.

E

D

C

B

• Press S18 to choose display mode.

See table below.

11 – 24

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B

Speed reference value sent to Curtis.

C

Digital inputs to Curtis and hallelements. * See explanation below

BC

Battery voltage (V)

D

Armature current (A)

BD

Field current (A)

CD

PWM Armature in %

BCD

Status Curtis

Service Manual W18/W20

Approved by: Joakim Carleborn

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*They are displayed by high lighting segments of three of the figures (A).

• The most significant figure active (marked with arrow).

• Power amplifier inputs.

A

T

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A

E

D

B

C

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%

B C

S31 , input A1:15

D

S10 , input A1:12

E F

(

& '3

'

G

S10 , input A1:5

DP

• The second most significant figure active (marked with arrow).

A

• Power amplifier outputs.

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E D

C

B

$ ) * % ( '

& '3

B C

Y41 , output A1:2

D

Y1 , output A1:3

E

K10, output A1:4

F

H1 , output A1:7

G

Y1 , output A1:5

DP

K30 , output A1:6

Service Manual W18/W20

Approved by: Joakim Carleborn

11 – 25

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• The third most significant figure active (marked with arrow) • Digital input from control sensors.

A

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A

E

D

B

C

B C

$ ) * % (

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D

Forks up

E

Forks down

F

Support arms up

G

Support arms down

DP

• The fourth most significant figure active (marked with arrow).

A

E

D

C

B

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Extra function 6

B

Extra function 5

C

Extra function 4

D

Extra function 3

E

Extra function 2

F

Extra function 1

G DP

11 – 26

Service Manual W18/W20

Approved by: Joakim Carleborn

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3DUW QXPEHUV • Press S18 and turn S17 to on at the same time.

A

• Press S18 until you Pn= partnumbers.

• You have now choosen Pn= part numbers the symbol “D” on display will be highlighted to indicate what’s currently shown on display. In the start the Pn = part number complete unit will be shown.

E

D

C

• By scrolling with the L1 you can get the following information:

B

• SPn= Software part number.

• HPn= Hardware part number.

• HSn= Hardware serial number.

7UDQVLVWRU SDQHO

STATUS

B+

A1

VOLTAGE

SERIAL

CURRENT

*HQHUDO

M-

M

MODEL

Curtis 1243 is a regulator for controlling shunt motors. Varying the voltage applied through the armature primarily controls the speed. The voltage is varied through use of pulse-width modulation (PWM). This involves varying the “on” time of the MOS-FET transistors regulating the armature current.

A2

Switching of the rotational direction is achieved by switching the polarity on the field winding (S1-S2). The regulator is fitted with a four-quadrant transistor bridge for the field winding and a single-quadrant transistor bridge for the armature winding.

S1

S2 Service Manual W18/W20

Approved by: Joakim Carleborn

11 – 27

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STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The table below describes the error codes that may be shown by the STATUS LED or read using the handheld terminal.

67$786 /('

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LED off

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

Defective regulator

Defective regulator

1,1

&855(17

Built-in current shunt defective

Armature current sensor fault in motor controller.

¤¤

6+817 )$8/7

1,2

¤ ¤¤

+: )$,/6$)(

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

1,3

¤ ¤¤¤

0 6+257('

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller.

3,1

¤¤¤ ¤

&217 &2,/ )/'

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault.

6+257

3,3

¤¤¤ ¤¤¤

),(/' 23(1

Open field winding

Shuntfield open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

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Low battery voltage

1. Battery voltage <17 volts 2. Corroded battery terminals 3. Loose battery or regulator connections

Overvoltage

1. Battery voltage > 33 volts

92/7$*(

4,2

11 – 28

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Service Manual W18/W20

Approved by: Joakim Carleborn

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1. Temp. >85oC or < - 25oC 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions

PLQDO GLVSOD\

4,3

¤¤¤¤ ¤¤¤

7+(50$/ &87%$&.

5HVHWWLQJ HUURUV To reset an error turn S17 to off and then on again.

(UURU

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29(592/7$*(

Battery voltage falls below 33 V

7+(50$/ &87%$&.

The temperature is within allowed range

7+5277/( )$8/7

Error has been fixed

/2: %$77(5< 92/7$*(

When battery voltage exceeds 16 V

6DIHW\ The regulator is a high-power component. When working on a battery operated vehicle, necessary precautions should be taken. This includes, but is not limited to, correct training, use of eye protectors, avoiding use of lose-fitting clothes, removal of watches and jewellery, and use of insulated tools only. :$51,1* 5LVN RI VKRUW FLUFXLWLQJ 5HPRYH DOO ZDWFKHV MHZHOOHU\ DQG DOZD\V XVH LQVXODWHG WRROV RQO\

Service Manual W18/W20

Approved by: Joakim Carleborn

11 – 29

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Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

Undervoltage limit

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature winding *

150

Amps

for 2 minutes

100

Amps

for 1 hour

20

Amps

for 2 minutes

Max. current of field winding

20

([SODQDWLRQ

for 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

2

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

Volts

KSI input current

50

mA

Logic input voltage

>7.5; High <1; Low

Volts

Logic input current

15

mA

Operating temperature

-40 to +50

°C

Overtemperature, reduction

85

°C

Undertemperature, reduction

-25

°C

* During specific test conditions.

11 – 30

Service Manual W18/W20

Approved by: Joakim Carleborn

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1

A Y41

4

2 3

M3

P

5 T

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1

Lift cylinder

Lifting the forks

2

Preasure relief valve

3

Flow control valve

4

Non-return valve

5

Filter

M3

Motor

P

Pump

T

Tank

Y41

Valve

5HPDUNV

Pump motor

1,2 litre (B20 0,5 litre) Lowering valve for the forks

Service Manual W18/W20

Approved by: L-G Andersson 12 –

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$GMXVWPHQWV : $GMXVWLQJ WKH SUHVVXUH OLPLW YDOYH The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The machine should be capable of lifting a load of between 1850-1900 kg.

1

2 3

1. Locking nut. Use special tool, see drawing in chapter “Tools”.

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

3. Pressure limit valve. Use special tool, see drawing in chapter “Tools”.

• Loosen the locking nut (1) using a special tool (see drawing 3.2).

Place a load of 1800 kg on the forks and check that the machine can lift it.

• If the machine lifts 1800 kg, place a further 100 kg on the forks.

Check whether the machine can lift the load.

• If the machine lifts 1900 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the machine cannot lift the load.

12 – 2

Service Manual W18/W20

Approved by: L-G Andersson

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7RROV • Use a 22 mm standard socket and turn it down to the values shown below in drawing A, when you wish to loosen or tighten the pressure limit valve.

• Use a 10 mm standard socket and turn it down to the values shown below in drawing B, when you wish to loosen or tighten the locking nuts.

A

26,5

Service Manual W18/W20

8

12

B

13,5

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$GMXVWPHQWV : $GMXVWLQJ WKH SUHVVXUH OLPLW YDOYH The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The machine should be capable of lifting a load of between 2050-2100 kg.

1. Locking nut.

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

• Loosen the locking nut (1) using a 13 mm spanner.

• Place a load of 2000 kg on the forks and check that the machine can lift it.

• If the machine lifts 2000 kg, place a further 100 kg on the forks.

Check whether the machine can lift the load.

• If the machine lifts 2100 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the machine cannot lift the load.

12 – 4

Service Manual W18/W20

Approved by: L-G Andersson

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SMCI is a battery charger intended for valve-regulated or freely ventilated lead acid batteries. It is adapted for batteries from about 100 Ah up to 320 Ah. The charger which uses advanced switch techniques is connected to a normal (grounded 230 V single phase) socket (B) and the built-in micro controller then controls charging following the pre-set charging curve.

During charging the charging process is displayed with a status indicator on the standby housing (A).

The micro controller also controls charging with respect to charging time and temperature in the charger so that charging can be limited, e.g. if a fault occurs in some cell in the battery or when there is insufficient cooling of the charger.

SMCI 300 is delivered pre-set for 24 v and with software intended for charging valve-regulated or freely ventilated lead acid batteries.

&

The size and type of the battery are selected using the switch on the side of the fan(C) which is accessible via a slotted head screwdriver.

&KDUJLQJ Connect the charger to the mains. When charging starts after a few seconds, the orange status indicator on the standby housing(A) lights up. Yhis indicator remains lit until the battery is fully charged and the indicator turns to green.

Charging time varies depending on the type of battery and the degree of discharge. Normally the charger is started after working hours and the battery is fully charged the next morning. A highly discharged freely ventilated battery of 320 Ah may need up to 14 hours re-charging time, a VR battery even longer.

Some time after charging (depending on, for example, type of battery) SMCI 300 switches to maitenance charging. The green indicator remains lit to show that the battery is fully cgarged.

When charging is completed, the mains plug is placed in the standby housing.

7URXEOHVKRRWLQJ DQG VHUYLFH First check whether the charger indicates an error. A red, blinking indicator means that the charger cannot detect that any battery is connected.Check the cables, pole terminals and other connections to the batteries. Measure battery voltage.

If the charger still doesn´t work, send it to your supplier for repair.

Service Manual W18/W20

Approved by: L-G Andersson 13 –

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13 – 2

Size

250x115x67 mm

Weight

1,6 kg

Ambient temperature

-25°C till +40°C

Mains voltage

90-255 V AC 45-400 Hz (Reduced charging current for mains voltage below 200 V

Rated voltage

24 V DC

Rated current

30 A

Max output

750 W

Efficiency

> 86%

Battery type

Freely ventilated lead batteries (with water refilling). Valve regulated (VR) lead batteries.

Protection

IP 20

General

Temperature regulated cooling fan, protected against faulty polarisation

Service Manual W18/W20

Approved by: L-G Andersson

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2XWSXW

, FXU

0D[ FXUUHQW PDLQ

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UHQW

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0

No charging (red LED is lit)

-

-

-

1

100-119 Ah

30 A

5,5 A

0,5 A

2

120-144 Ah

30 A

6,6 A

0,6 A

3

145-174 Ah

30 A

8A

0,8 A

4

175-209 Ah

30 A

9,6 A

1,0 A

5

210-249 Ah

30 A

11,5 A

1,2 A

6

250-299 Ah

30 A

13,7 A

1,4 A

7

300-350 Ah

30 A

16,2 A

1,6 A

9DOYH UHJXODWHG EDWWHULHV 6ZLWFK

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, FXU

0D[ FXUUHQW PDLQ

FXUUHQW

UHQW

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8

No charging (red LED is lit)

-

-

-

9

300-350 Ah

30 A

3,9 A

1,6 A

A

250-299 Ah

30 A

3,3 A

1,4 A

B

210-249 Ah

30 A

2,75 A

1,2 A

C

175-209 Ah

30 A

2,3 A

1,0 A

D

145-174 Ah

25 AA

1,9 A

0,8 A

E

120-144 Ah

21 A

1,58 A

0,6 A

F

100-119 Ah

17 A

1,32 A

0,5 A

Service Manual W18/W20

Approved by: L-G Andersson 13 –

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Service Manual W18/W20

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*HQHUDO TruckCom is a communication program which communicates with trucks equipped with CAN (Controller Area Network) communication. It enables functions such as downloading programs, adjusting parameters and displaying measuring data etc. to be carried out.

This Manual is valid for program number 182145-xxx.

The program is a Windows program run under Windows® 95/98.

&RQQHFWLRQ A CAN interface of the CPC-PP type is needed to connect it to the truck, with attendant cable. The interface is connected to the printer port on a PC, and the cable is connected between the interface and truck’s CAN connection.

The CAN interface is supplied with power from the truck electronics and is protected from any high voltages in the truck if a fault should occur.

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/D\RXW 0DLQ ZLQGRZ A main window opens when the program is started, consisting of menu bar, tool buttons, workspace, log window and status window.

1RGHV The nodes detected on the bus are shown in the node window.

The current node status and input component/information is show with different icons.

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is shown when contact is made with a node and no errors have been reported.

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is shown when there is no contact with a node in the network.

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is shown when an error has been reported by a node. Click on node to obtain more information.

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is shown when information is available on which software is installed. Click to obtain more information.

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is shown when a node has information on, for example, error codes. ,QIRUPDWLRQ

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is shown when a node has information on a parameter.

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7RRO EXWWRQV Search for units, disconnect from PC, download, truck report, parameters, diagnostics, information and exit.

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,QIRUPDWLRQ ZLQGRZ The right section of the main window contains a status window where different messages are shown.

To see previous messages, use the scroll arrows in the right margin.

6WDWXV EDU There is a status bar at the bottom of the main window, which shows variable status when the program is run.

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The following are shown from the left: Help text "pop-up" via the mouse cursor, connected/not connected to network, truck type connected, initiation result of CAN interface and the present time.

)XQFWLRQ &RQQHFWLRQ To connect the PC the network, select the "Scan units" function.

This can be done with the menu <Nodes | Scan units> or with the tool button [Scan nodes].

This should also be done when the truck is supplied with voltage and in normal drive mode.

The program will now run a check and installation of the CAN interface. A diagnosis will also be carried out to check which units are connected in the system. The result of this diagnosis is shown in the Node window.

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'LVFRQQHFWLRQ Select the Disconnect function to disconnect from the network.

This can be done with the menu <Nodes | Set PC off-Line > or with the tool button [Set PC off-Line].

The CAN interface is then reset and the CAN cable can be disconnected if so required.

The objective is to enable connection to another truck without having to close the program.

'RZQORDGLQJ SURJUDP To download a new program to one of the nodes, select the Download function. This can be done with the menu <Tools | Download software... > or with the tool button [Download].

Type 123456

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Select Open.. to open the file to be downloaded into a node. The file name, file type and version number are shown in the window for “file information”. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by selecting Start... and by restarting the truck by turning the key off and on twice.

Restart must be made within 20 seconds from when the Start button has been activated.

Close the download window when the download is ready, and then disconnect the PC from the network. A new connection can now be made to verify the new program.

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To download to older versions of electronic cards which do not support restart with key, the button Old card... should be used instead of Start...

Downloading is carried out in the same way, except that restart is done by using the battery lug instead of the key.

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E141 will be shown in the truck’s display when starting, if for any reason there is no program in the electronics card (interrupted downloading). Communication with the truck via the PC will then be minimised. Use “E141” to download the program in the card. : :

If there is no program a counter will be shown in the display, which continuously counts up.

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7UXFN UHSRUW It is possible to generate a report to a file or disk with the truck’s configuration and status. Select menu <Tools | Generate truck report...> or with the tool button Truck report. Save the report in Report.file.

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Example of information generated in the truck report: [GENERAL] REPORT DATE-TIME=1999-12-09 07:42:14 CPC-PP SERIAL No=8002008 MACHINE NUMBER=392179 CUSTOMER=CUSTOMER 1 TECHNICIAN=NONAME COMPANY=COMPANY 1 NOTES=Test report [CAN NODES] MAIN CARD=125 FORK CARD=-1 TRUCK TRACKER=-1 ACC LIFT CONTROLLER=0 ACC DRIVE CONTROLLER=0 CURTIS LIFT CONTROLLER=-1 [MAIN CARD CONFIGURATION] SOFTWARE=169942-001 HARDWARE=169937-001 SERIAL NO=12112 [HOUR METERS] A IGNITION TIME=1 B TOTAL MOVEMENT=0 C DRIVE MOTOR TIME=0 D PUMP MOTOR TIME=0 S SERVICE TIME=9

[ERROR LOG] 01=55 99-12-09 06:11 02=55 99-12-08 20:54 03=55 99-12-08 14:26 04=231 99-12-08 14:16 05=55 99-12-08 14:11 . . .

50=55 99-12-08 14:40 [DRIVER PARAMETERS] 1=3 2=100 3=100 . . .

100=0 [TRUCK PARAMETERS] 11=100 12=80 13=10

The contents of certain rows can vary according to truck type.

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3DUDPHWHUV To change the truck parameters, select the Parameter function.

This can be done with the menu <Tools | Change parameters > or with the tool button [Parameters].

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This must therefore be done when the truck is in parameter mode. When the truck is in normal drive mode the parameter window is locked and no information can be changed.

Nevertheless, it is possible to unlock the window by restarting the truck in parameter mode and then selecting Unlock... without closing the window first.

The parameter numbers follow the description in the respective truck Service Manuals.

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'LDJQRVWLFV To access diagnostics, select the Diagnostic function. This can be done with the menu <Tools | Diagnostic...> or with the tool button [Diagnostic].

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Several analogue values will be shown on the Analogue side: Inputs, outputs and the drive/lift converter values. The input/ output values are read directly from the in/out directory in the main card and are then shown as voltages and number of revolutions.

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“Cmd” is the requested number of revolutions from the main card sent to the drive/lift converters via the CAN bus.

“Actual” is the number of revolutions the drive/lift converters have detected and sent back to the main card.

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The actual temperatures of the electronic units and motors are shown. The values are shown in degrees Celsius.

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The digital inputs are read directly from the input directory on the main card. It is assumed that the input is activated if the colour of the LED is green. If the LED is white/transparent the input is not activated.

The digital outputs are read directly from the out-directory on the main card and are shown with red LEDs.

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The truck parameters can be saved in the PC for downloading at a later date.

Select <File | Save to file | Parameters >. All parameters in the nodes which are connected to the bus will be scanned in and saved in a file.

If only the hour meters are needed, select <File | Save to file | Hour meters >.

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A set of parameters can be downloaded from the PC to the truck.

Select <File | Load from file | Parameters >. The parameters in the file will be copied to the nodes connected to the bus. If only the hour meter settings are needed, select <File | Load from file | Hour meters >.

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If problems should occur when resetting the CAN adapter connected to the PC, this can normally be done manually by making sure that the adapter is supplied with voltage and then selecting <Nodes | Reset CPC-PP >.

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To delete the truck’s error code log, start the truck in parameter mode and then select < Tools | Erase error log >.

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To reset the truck’s hour meter, start the truck in drive mode and then select < Tools | Reset hour meters >.

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To show the truck’s error code log, select < Tools | Read error log >. $ GMXVW GDWH DQG WLPH

To quickly adjust the truck’s data and time, select < Tools | Adjust date & time >. The time given in the PC will now be downloaded into the truck.

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To adjust the hour meter on trucks with older cards, select < Tools | Adjust Hour meters >. The time in the PC will then be downloaded to the truck.

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To see program information, select <Help | About TruckCom... > or tool button [About].

([LW To exit the program, select <File | Exit > or the tool button [Exit].

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Power consumption

40-120

mA

Supply voltage

11-28

V

Transfer rate

125

kbit/s

Storage temperature

-20-80

0C

Operating temperature

0-60

0

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,QVWDOODWLRQ The program is delivered on disks or over the network, and the installation is started by running A:\SETUP.EXE. Follow the instructions shown on the screen.

Make sure that the computer settings for the printer port in setup (BIOS) are as follows: Port address:

0378

IRQ:

7

Mode:

Output only

For information on how the settings in setup are changed, see the user manual from the computer manufacturer.

7R XQLQVWDOO If you wish to uninstall TruckCom this can be done from Windows < Setup| Control Panel| Add/delete program > .

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