DOWNLOAD PDF TOYOTA Forklift 7SLL12.5 7SLL12.5F 7SLL16 7SLL16F Service Manual

Service Manual en

7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Valid from serial number: 711956-

Order number: 222641-040 Issued: 2004-12-20 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Issue date

Resp.

Changes

2004-12-20

ITS

Completely new issue

This manual covers following truck models:

T-code

Model

Serial number

789

7SLL12.5

711956-

789

7SLL16

711956-

791

7SLL12.5F

711956-

791

7SLL16F

711956-

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

Contents Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

1- Contents Presentation of the truck – M2

2-1

Intended application of the truck ................... 2 Forbidden application of the truck................. 2 Truck data..................................................... 3 Truck dimensions ......................................... 4 7SLL12.5/12.5F/16/16F ...................................... 4

Identification plate......................................... 6 Capacity plate............................................... 6 Addition and information plate ...................... 6 Capacity plate for double pallet handling ...... 7 Main components ......................................... 8 Warning and information plates ................... 10

Technical data – M4

3-1

General tightening torques ........................... 5

Destruction instructions - M6

4-1

General......................................................... 1 Procedure ..................................................... 1 Abbreviations................................................ 2 Sorting .......................................................... 2 Chassis (0300) ............................................. 3 4.5.1 Dismantling ......................................................... 3 4.5.2 Material handling ................................................ 3

Hoods, covers (0340) ................................... 4 4.6.1 Dismantling ......................................................... 4 4.6.2 Material handling ................................................ 4 © TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Fork structure (low-lifter) (0380).................... 5 4.7.1 Dismantling ......................................................... 5 4.7.2 Material handling ................................................ 5

Travel platform including mount (0560)......... 6 4.8.1 Dismantling ......................................................... 6 4.8.2 Material handling ................................................ 6

Overhead guard (option) (0810) ................... 7 4.9.1 Dismantling ......................................................... 7 4.9.2 Material handling ................................................ 7

Operator protective device (0840) ................ 8 4.10.1 Dismantling ......................................................... 8 4.10.2 Material handling ................................................ 8

Electric pump motor (1710)........................... 9 4.11.1 Dismantling ......................................................... 9 4.11.2 Material handling ................................................ 9

Electric travel drive motor (1760) ................. 10 4.12.1 Dismantling ....................................................... 10 4.12.2 Material handling .............................................. 10

Drive unit/gear (2550) .................................. 11 4.13.1 Dismantling ....................................................... 11 4.13.2 Material handling .............................................. 11

Wheels (3500) ............................................. 12 4.14.1 Dismantling ....................................................... 12 4.14.2 Material handling .............................................. 12

Steering arm (4110) ..................................... 13 4.15.1 Dismantling ....................................................... 13 4.15.2 Material handling .............................................. 13

Steering arm (4110) ..................................... 14 4.16.1 Dismantling ....................................................... 14 4.16.2 Material handling .............................................. 14

General electric equipment (5100)............... 15 4.17.1 Dismantling ....................................................... 15 4.17.2 Material handling .............................................. 15

Cabling (5590) ............................................. 16 4.18.1 Dismantling ....................................................... 16 4.18.2 Material handling .............................................. 16

1- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Steering and protective electronics (5700) .. 17 4.19.1 Dismantling ...................................................... 17 4.19.2 Material handling .............................................. 17

Lift/lowering sensor (5820) and safety sensor (5830) 18 4.20.1 Dismantling ...................................................... 18 4.20.2 Material handling .............................................. 18

Hydraulic unit (6100).................................... 19 4.21.1 Dismantling ...................................................... 19 4.21.2 Material handling .............................................. 19

Main mast (7100)......................................... 20 4.22.1 Dismantling ...................................................... 20 4.22.2 Material handling .............................................. 20

Chassis-mounted hydraulic oil lines (6230) (and main lift cylinder (6610) )

21 4.23.1 Dismantling ...................................................... 21 4.23.2 Material handling .............................................. 21

Battery charger connector (9380) ................ 22 4.24.1 Dismantling ...................................................... 22 4.24.2 Material handling .............................................. 22

Installation and maintenance instructions – P1 5-1 Truck installation........................................... 1 5.1.1 Lifting the truck ................................................... 1 5.1.2 Battery installation .............................................. 2 5.1.3 Putting into service ............................................. 2

Introduction, maintenance ............................ 4 5.2.1 Safety rules during maintenance work ............... 4

Cleaning and washing .................................. 6 5.3.1 External cleaning ................................................ 6 5.3.2 Cleaning the motor compartment ....................... 6 5.3.3 Electric components ........................................... 6

Safe lifting..................................................... 7

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Maintenance schedule – P2

6-1

Lubrication chart ........................................... 7

Oil and grease specification – P3

7-1

Tools – P4

8-1

Super Seal connectors ................................. 1 AMP connectors ........................................... 2 8.2.1 AMP Connectors, 040 series .............................. 3

Molex connectors.......................................... 3 Other tools .................................................... 4

Electric drive motor – 1760

9-1

Included components.................................... 1 Disassembly/assembly of the truck motor..... 3 9.2.1 Disassembly ....................................................... 3 9.2.2 Assembly ............................................................ 3

Service/repairs.............................................. 4 9.3.1 Disassembly of the motor ................................... 4 9.3.2 Motor installation ................................................. 5 9.3.3 Cleaning .............................................................. 5

Technical data .............................................. 6

Drive unit/gear – 2550

10-1

Included components.................................... 2 10.1.1 Technical data .................................................... 3

Leakage from top cover ................................ 3 Replacing the drive axle jointing ring ............ 3 10.3.1 Disassembly ....................................................... 4 10.3.2 Assembly ............................................................ 4

1- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Electromagnetic brake – 3370

11-1

Main components of the brake...................... 1 Maintenance ................................................. 2 11.2.1 Basic adjustment of the play .............................. 2 11.2.2 Brake disc replacement ...................................... 3

Electrical systems – 5000

12-1

Electrical equipment overview ...................... 1 Equipment list and electrical diagram ........... 3 Functional description.................................. 22 12.3.1 Description of steering system ......................... 28

Speed limitation ........................................... 29 Hour meter and battery condition................. 30 Diagnostic and troubleshooting ................... 32 12.6.1 Fault codes ....................................................... 32 12.6.2 Fault code history ............................................. 32 12.6.3 List of fault codes ............................................. 33 12.6.4 Transistor regulator troubleshooting and error codes 41 General ............................................................. 41 Transistor regulator errors ................................ 41 Resetting errors ................................................ 43 Safety ............................................................... 43 12.6.5 Built-in Test Function ....................................... 44 Digital inputs/outputs test mode ....................... 46 12.6.6 Display test mode ............................................. 49

Part numbers ............................................... 50 Parameters .................................................. 51 12.8.1 General ............................................................ 51 12.8.2 Viewing parameters -CAN key not connected . 51 12.8.3 Viewing parameters -CAN key connected ....... 52 12.8.4 Setting Driver parameters ................................ 53 12.8.5 Setting Service parameters .............................. 53 12.8.6 Summary of driver parameters ......................... 54 12.8.7 Description of driver parameters ...................... 55 # 2 - Maximum speed, high range .................... 55 # 3 - Maximum acceleration ............................. 55 © TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

# 4 - Neutral braking effect ............................... 55 # 6 - Maximum speed, low range ...................... 55 # 7 - Maximum speed, “Turtle” mode ................ 55 12.8.8 Summary of service parameters ...................... 56 12.8.9 Description of service parameters .................... 58 # 10 - PIN code ................................................. 58 To enter a new PIN-code: ................................. 58 To remove an existing PIN-code: ..................... 59 # 14 - Creep speed ........................................... 59 #15 - Non-configurable options ......................... 59 #16 - Configurable option #1 ............................ 59 #17 - Configurable option #2 ............................ 59 #18 - Configurable option #3 ............................ 59 #19 - Configurable option #4 ............................ 59 # 20 - Hour meter selection .............................. 60 # 21 - Battery size ............................................. 60 # 22 - Maximum fork lowering speed ................ 61 # 23 - Fork lower stop ramp .............................. 61 # 25 - Service interval ....................................... 61 # 35 - Log off ..................................................... 61 # 36 - Calibrate ................................................. 62 # 37 - Steering offset ........................................ 65 # 38 - Steer servo activated .............................. 65 # # 39 - Log-in method & operator parameter access .................................................................. 65 Extended keypad - General .............................. 66 Extended keypad - Programming ..................... 66 12.8.10 “Option” Parameters ....................................... 68 General ............................................................. 68 Parameter #15 Non-configurable options ......... 68 Setting Non-configurable options ...................... 69 Parameter #16 to #19 Configurable options ..... 70

Technical specifications – Curtis 1243......... 76

1- 6

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Hydraulic system – 6000

13-1

Hydraulic diagram......................................... 1 13.1.1 7SLL12.5F/16F ................................................ 1 13.1.2 7SLL12.5/16 ....................................................... 2 13.1.3 Main components ............................................... 3 13.1.4 Description ......................................................... 4 The PowerTrak system ....................................... 4 Working pressure ............................................... 5 Overflow valve .................................................... 5 Pressure sensor ................................................. 5

Main lift chain system – 7120

14-1

General......................................................... 1 Checking the chain setting............................ 1 Chain inspection ........................................... 1 14.3.1 Noise .................................................................. 1 14.3.2 Surface rust ........................................................ 1 14.3.3 Rusty links .......................................................... 1 14.3.4 Stiff links ............................................................. 2 14.3.5 Bolt rotation ........................................................ 2 14.3.6 Loose bolts ......................................................... 2 14.3.7 Outline wear ....................................................... 3 14.3.8 Stretching ........................................................... 4 14.3.9 Damage .............................................................. 5 14.3.10 Damaged discs ................................................ 5 14.3.11 Damaged bolts ................................................. 5 14.3.12 Dirty chain ........................................................ 6

Cleaning ....................................................... 6 Lubrication .................................................... 6

Control/computer equipment – 8700 15-1 General......................................................... 1 Connection ................................................... 1

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Layout ........................................................... 2 15.3.1 Main program screen ......................................... 2 15.3.2 Nodes ................................................................. 2 15.3.3 Icons ................................................................... 3 15.3.4 Tool buttons and menu bar ................................ 4 15.3.5 Information window ............................................ 4 15.3.6 Status bar ........................................................... 4

Connection function ..................................... 4 Disconnection function.................................. 5 Downloading program function ..................... 5 15.6.1 Normal downloading (truck with key) ................. 5 15.6.2 Normal downloading (truck with keypad) ........... 6 15.6.3 Emergency downloading (truck with keypad) ..... 6 15.6.4 Downloading in old versions of logic card .......... 7 15.6.5 Emergency downloading (truck with keypad) ..... 7

Truck report function ..................................... 8 Parameters function...................................... 9 Diagnostics function..................................... 11 15.9.1 Representation of signal colours ...................... 11 15.9.2 “Tiller arm” tab .................................................. 12 15.9.3 “Drive Controller” tab ........................................ 13

Other menu functions .................................. 14 15.10.1 Save to file ...................................................... 14 15.10.2 Download from file .......................................... 14 15.10.3 Reset CAN adapter ........................................ 14 15.10.4 Delete error code log ...................................... 14 15.10.5 Reset hour meter ............................................ 14 15.10.6 Read error code log ........................................ 14 15.10.7 Adjust date and time ....................................... 14 15.10.8 Adjusting the hour meter on older cards ........ 15 15.10.9 Help ................................................................ 15 About TruckCom ............................................... 15 15.10.10 Exit ............................................................... 15

Specifications .............................................. 15

1- 8

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Installation ................................................... 16 15.12.1 Installation on a PC with Windows® 95/98 .... 16 15.12.2 Installation on a PC with Windows XP/2000 .. 16 15.12.3 Installation on a PC with Windows NT ........... 22 15.12.4 In case of communication problems with CAN 22 15.12.5 To uninstall ..................................................... 22

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Contents T-code 789, 791 Date 2004-12-20

1- 10

© TIEE SARL

Valid from serial number 711956Order number 222641-040

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Presentation of the truck – M2 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

2- Presentation of the truck – M2 The truck is a battery driven support arm truck. The truck is equipped with a tiller arm for optional control: standing on the ride-on platform or walking. Best advantage can be taken of the truck’s properties by the operator standing on the ergonomically designed platform as this provides the operator with a clear view over the truck and load, allowing work to be carried out with ease and safety.

The truck is also equipped with protective gates to protect the operator when driving standing on the platform. When the gates are retracted the truck’s maximum speed is always 6 km/h. When the gates are raised and the operator is standing on the platform the truck’s maximum speed is 8 km/h.

The tiller arm is specially designed to provide the best possible operator ergonomy, having all the controls and buttons within easy reach without the operator needing to release the handle. The tiller arm is also equipped with a display showing running time and battery status among other things. The display is also used when the operator wishes to change any of the operator parameters with which the truck can be programmed.

The truck is equipped with the patented PowerTrak system, which means that the drive wheel pressure is adjusted according to the weight of the load and the wear on the drive wheel. This reduces the wear and tear on the drive wheel and ensures safer load handling.

The truck has a 24V electrical system and the speed is regulated by means of a transistor controller to provide gentle control of acceleration and speed while driving.

The forks are lifted using a compact, yet powerful hydraulic unit. Lifting is controlled by a transistorised variable speed controller. The truck's proportional valve is used to adjust the lowering speed and fork positioning during stacking.

The battery compartment is designed to allow the battery to be changed from either side as well as from above, which means the truck is well suited to most types of battery changing situations.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

2- 1

Presentation of the truck – M2 Intended application of the truck T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

The truck’s maximum speed is 6 km/h when the protective gates are retracted in the direction of the forks and the driver is standing on the platform.

The truck’s maximum speed is 8 km/h when the protective gates are retracted in the direction of the drive wheel and the driver is standing on the ride-on platform.

CAUTION! Pinch risk.

There is a risk of pinching if you drive the truck with the platform raised and the gates extended.

Always retract the gates when the platform is raised.

2.1 Intended application of the truck The truck is solely designed and manufactured to handle goods. The trucks should be fitted with the appropriate accessories relevant to the application.

2.2 Forbidden application of the truck The truck is designed for handling goods indoors. It is not permitted to use the truck for other purposes including the following: -

In areas that contain dust or gases which can cause fires or explosions As a tow-truck for trailers To tow other trucks To transport/lift passengers

- To drive on gravel or grass

2- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Presentation of the truck – M2 Truck data Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

2.3 Truck data The table provides information regarding some technical data, which is of value with daily use of the truck.

Table 1: Truck data Truck type

7SLL12.5 /12.5F

7SLL16/16F

Rated capacity, kg

1250

1600

Lift height, mm

2350-5400

2350-5400

Travel speed without load (<800kg), with gates Transporting position (Lh < 1,5 m), km/h

8

8

Travel speed with rated load (>800kg) with gates Transporting position (Lh < 1,5 m), km/h

7

7

Travel speed without gates Transporting position (Lh < 1,5 m), km/h

6

6

Travel speed Stacking position (Lh >1,5 m), km/h

5

5

Gradient with rated load, %

10

10

Weight without battery, kg

980

1130

Weight with battery, kg (Ah) *

1230

1390

Turning radius (Wa), mm (Small battery space, fork length 1150 mm, mast DX)

1755

1755

Continuous noise level, dB A

<70

< 70

Full body vibration value acc. to document N47E CEN/ TC150/WG8, m/s2

0,7

0,7

Permitted drive wheel, material

Power friction Tractothan siped rubber Rubber, non marking

The truck’s lifting capacity, lift height and weight can be found on the truck’s identification plate.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

2- 3

Presentation of the truck – M2 Truck dimensions T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

2.4 Truck dimensions The illustration shows external dimensions for the truck in its standard design.

7SLL12.5/12.5F/16/16F

C D

E A

F

B H J

I

G

K

L O M N

P

Q 2- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Presentation of the truck – M2 Truck dimensions Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 2: Truck dimensions Measure

7SLL12.5 (mm)

7SLL16 (mm)

7SLL12.5F (mm)

7SLL16F (mm)

A

1435

1435

1435

1435

B

150

150

150

150

C- Maximum lifting height dependant on mast type

2350-5400

2350-5400

2350-5400

2350-5400

D- Minimum mast height dependant on lifting height

1710-2365

1710-2365

1710-2365

1710-2365

E

600-1400

800-1400

800-1400

1150-1400

F- Minimum

90

90

90

90

F- Raised support arms (max)

-

-

210

210

G

85

85

85

85

H

24

24

17

17

I -Small battery space

1440

1440

1481

1481

I- Large battery space

1538

1538

1579

1579

J - Small battery space Dx Tele; Dx Hilo

860

907

901

948

J-Small battery space Tx

880

907

921

948

J - Large battery space Dx Tele; Dx Hilo

958

1005

999

1046

J- Large battery space Tx

978

1005

1019

1046

K- (E + J) fork length 1150, small battery space Dx

2010

2057

2051

2098

L - Small battery space

1716

1716

1755

1755

L - Large batteryspace

1813

1813

1852

1852

M

850/1150

850/1150

850/1150

850/1150

N

790

790

790

790

O

180

180

180

180

P

450-685

570-685

520-570

570

Q- (E + J+ 417) fork length 1150, small battery space Dx

2427

2774

2468

2515

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

2- 5

Presentation of the truck – M2 Identification plate T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

2.5 Identification plate The illustration shows the identification plate for the truck in CE-design.

Table 3: Item

Text

Unit

A

MODEL

B

SERIAL NO

C

RATED CAPACITY

kg

D

WEIGHT WITHOUT BATTERY

kg

E

BATTERY WEIGHT

F

BATTERY VOLTAGE

MAX MIN

kg kg V

2.6 Capacity plate The illustration shows the capacity plate used on the truck.

Table 4: Item

Text

Unit

H

SERIAL NUMBER

I

LIFTING HEIGHT

mm

J

ACTUAL CAPACITY

kg

K

LOAD CENTRE SPACING

mm

L

THE TRUCK MUST ALWAYS BE DRIVEN WITH LOWERED FORKS EXCEPT WHEN PLACING OR REMOVING LOAD

2.7 Addition and information plate M

2- 6

© TIEE SARL

Item

Text

M

WHEN STACKING, COMPLETELY LOWER THE SUPPORT ARMS

Unit

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Presentation of the truck – M2 Capacity plate for double pallet handling Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

2.8 Capacity plate for double pallet handling The picture shows the capacity plate that applies with double pallet handling.

Table 5:

© TIEE SARL

Permitted max. load on forks

Permitted max. load on support arms

Permitted min. load on support arms

M1 - M9

L1 - L9

V1 - V9

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

2- 7

Presentation of the truck – M2 Main components T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

2.9 Main components 1. Hydraulic control: For controlling lifting and lowering functions.

2. Tiller arm: The truck is manoeuvred by the driver while walking. 204 degree steering area.

The brakes are applied in the tiller arm’s upper and lower positions.

3. Identification plate: With model designation, serial number, year of manufacture, weight without battery, battery weight, rated capacity, battery voltage and manufacturer.

4. Emergency switch off 5. Side guards: The truck can travel at the higher speed of 8 km/h when the side guards have been raised. When the side guards are lowered, the truck can only travel at a maximum speed of 6 km/ h. When the side guards have been raised, the truck can lift the forks to a maximum height of 1800 mm. In order to lift to the maximum lifting height the side guards must be lowered.

6. Cover: Removable which provides good accessibility when servicing.

7. Battery disconnector and battery connector: The battery is charged via the permanently fitted charging connector.

8. Electric panel: With fuses and contacts positioned for easy access during service.

24 Volts transistor controlled system with regenerative feedback.

9. Drive unit with brake: Suspended drive unit with spring-loaded mechanical brake, travel motor, gears and drive wheel combined into a compact unit. Steering bearings between motor and gears.

10. Power steering unit (optional) 11. Support castor wheels: Two support castor wheels to ensure stability.

12. Serial number: The serial number plate fitted to the chassis.

13. Hydraulic unit: Pump motor, pump and oil tank are integrated in a compact unit.

14. Hydraulic valves: The valves are located to provide easy access.

15. Battey: 24V with different Ah values. The battery is automatically locked in the battery compartment.

16. Mast: Fitted with a finger guard to cover the driver's normal reach.

2- 8

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Presentation of the truck – M2 Main components Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

1 16

2 3

4

5

6 7

12 15

13

14

© TIEE SARL

11

10 9

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

8

2- 9

Presentation of the truck – M2 Warning and information plates T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

2.10 Warning and information plates The figure shows the position and significance of the plates and symbols located on the truck.

1. Hydraulic lever: Lifting/lowering of the forks 2. Hydraulic lever: Lifting/lowering of the support arms (7SLL12.5F/16F) 3. Travel direction 4. Signal/Horn 5. Capacity plate 6. Identification plate, A: CE, B: ASME, depending on market 7. Serial number 8. Hydraulic oil filling 9. Maximum height for rated lifting capacity 10. Do not walk under an elevated load 11. Lifting points

2- 10

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Presentation of the truck – M2 Warning and information plates Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

TOYOTA

TOYOTA INDUSTRIAL EQUIPMENT EUROPE S.A.R.L.

TOYOTA A B C D E E F G

TOYOTA INDUSTRIAL EQUIPMENT EUROPE S.A.R.L.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

2- 11

Presentation of the truck – M2 Warning and information plates T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

This page is intentionally left blank

2- 12

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Technical data – M4 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

3- Technical data – M4 Table 6: Technical data Model

7SLL12.5

7SLL12.5F 7SLL16

7SLL16F

Type

TSL140BDS41

TSL140BDS41

TSL140BDS41

TSL140BDS41

Output, kW

1,7

1,7

1,7

1,7

Duty cycle

S2,60 min

S2,60 min

S2,60 min

S2,60 min

Minimum carbon brush length, mm

13

13

13

13

Nominal commutator diameter, mm

63

63

63

63

Minimum commutator diameter, mm

60

60

60

60

Resistance, shunt field winding, Ω at 25 C°

0,498 (26C°)

0,498 (26C°)

0,498 (26C°)

0,498 (26C°)

Resistance armature winding, Ω at 24 °C

0,0161 (26C°)

0,0161 (26C°)

0,0161 (26C°)

0,0161 (26C°)

Insulation resistance between the windings and motor casing

>= 1Mohm

>= 1Mohm

>= 1Mohm

>= 1Mohm

Weight, kg

17

17

17

17

Type

BFK458-12

BFK458-12

BFK45812

BFK458-12

Braking force, Nm

32

32

32

32

Output, W

40

40

40

40

Resistance coil, Ω

14,4

14,4

14,4

14,4

Nominal play in actuated position, mm

0,3-0,5

0,3-0,5

0,3-0,5

0,3-0,5

Minimum thickness brake disc, mm

8.8

8.8

8.8

8.8

Thickness of a new brake disc, mm

10.0

10.0

10.0

10.0

Type

2-stage angle transmission

2-stage angle transmission

2-stage angle transmission

2-stage angle transmission

Gear ratio

16,29:1

16,29:1

16,29:1

16,29:1

Oil volume, litre

1,0

1,0

1,0

1,0

Oil type

Hypoid oil

Hypoid oil

Hypoid oil

Hypoid oil

Drive motor

Brake

Transmission/drive gear

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

3- 1

Technical data – M4 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 6: Technical data Model

7SLL12.5

7SLL12.5F 7SLL16

7SLL16F

Oil type at normal temperature

SAE 80W/ 90

SAE 80W/90

SAE 80W/ 90

SAE 80W/ 90

Oil type at temperature < -15oC

SAE 75W

SAE 75W

SAE 75W

SAE 75W

Drive wheel, mm

Dia 215x70

Dia 215x70

Dia 215x70

Dia 215x70

Axle pressure without load, kg

390

390

390

390

Axle pressure at rated load, kg

530

530

620

620

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

65 Nm

65 Nm

Fork wheel, mm

Dia 85x75

Dia 85x75

Dia 85x75

Dia 85x75

Axle pressure without load, kg

340

360

410

430

Axle pressure at rated load, kg

1420

1440

1810

1830

Support castors, mm

Dia 125x50

Dia 125x50

Dia 125x50

Dia 125x50

Axle pressure without load

600

620

640

660

Axle pressure at rated load, kg

630

650

610

630

Output, kW

3,0

3,0

3,0

3,0

Duty cycle,%

11

11

11

11

Minimum carbon brush length, mm

10

10

10

10

Minimum commutator thickness/diameter, mm

47

47

47

47

Pressure at rated load, bar

110

110

110

110

Overflow pressure, bar

200

200

200

200

Pump flow, at rated load, litre/minute

13

13

13

13

Tank volume, litre

12

12

12

12

Oil type

Hydraulic oil

Hydraulic oil

Hydraulic oil

Hydraulic oil

Oil type at normal temperature

ISO-LHM32

ISO-L-HM32

ISO-LHM32

ISO-LHM32

Oil type at temperature < -15oC

ISO-L-HV32

ISO-L-HV32

ISO-LHV32

ISO-LHV32

Wheels (See note 1)

Hydraulic system

3- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Technical data – M4 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 6: Technical data Model

7SLL12.5

7SLL12.5F 7SLL16

7SLL16F

Drive motor circuits, A

125

125

125

125

Pump motor circuits, A

160

160

160

160

Control circuits, A

7,5

7,5

7,5

7,5

Dimensions LxWxH, mm, small large

168x763x660 264x763x660

168x763x660 264x763x660

168x763x 660 264x763x 660

168x763x660 264x763x660

Capacity, Ah

250/450

250/450

250/450

250/450

Weigh, max./min. kg

200/320

200/320

200/320

200/320

Without load, km/t Without load, m/s

8,0 2,22

8,0 2,22

8,0 2,22

8,0 2,22

With rated load, km/t With rated load, m/s

7,0 1,94

7,0 1,94

7,0 1,94

7,0 1,94

Lifting without load, above free-lift, m/s (see note 2 &3)

TBA

0,32

TBA

0,26

Lifting without load, under free-lift, m/s (see note 2 &3)

TBA

0,28

TBA

0,24

Lifting with rated load, above free-lift, m/s (see note 2 &3)

TBA

0,19

TBA

0,15

Lifting with rated load, under free-lift, m/s (see note 2 &3)

TBA

0,17

TBA

0,14

Lowering without load, above free-lift, m/s (see note 2 &3)

TBA

0,44

TBA

0,36

Lowering without load, under free-lift, m/s (see note 2 &3)

TBA

0,16

TBA

0,15

Lowering with rated load, above free-lift, m/s (see note 2 &3)

TBA

0,57

TBA

0,45

Lowering with rated load, under free-lift, m/s (see note 2 &3)

TBA

0,43

TBA

0,37

Fuses

Battery compartment, Batteries

Driving speed

Lift/lowering speed

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

3- 3

Technical data – M4 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 6: Technical data Model

7SLL12.5

7SLL12.5F 7SLL16

7SLL16F

Driving without load, A

TBA

30

TBA

55

Driving with rated load, A

TBA

50

TBA

70

Lifting without load, above free-lift, A

TBA

100

TBA

100

Lifting without load, under free-lift, A

TBA

80

TBA

80

Lifting with rated load, above free-lift, A

TBA

215

TBA

215

Lifting with rated load, under free-lift, A

170

170

170

170

10%

10%

10%

10%

Small battery compartment Large battery compartment (See note 1)

880 978

921 1019

907 1005

948 1046

Turning radius WA (See note 1)

1716

1696

1716

1696

Max. lifting height depends on the mast type

2350-5400

2350-5400

2350-5400

2350-5400

960/1220

940/1200

1056/1340

1030/1320

Power consumption

Incline climbing ability With rated load

Measurement, L2

Weight Truck without battery, Max./min

Note 1 applies to the specification: Triplex mast 415, fork length 1150, small battery compartment, battery weight 220 kg, truck width 850.

Note 2 applies to the specification:Duplex hilo 415 mast.

Note 3 applies to the specification:Duplex hilo 335 mast.

TBA = (To Be Announced) will be determined later

3- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Technical data – M4 General tightening torques Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

3.1 General tightening torques Millimetre threads M3 to M24.

The following applies under ideal conditions, e.g. steel against steel.

Table 7: General tightening torques M3 B

M4 C

B

M5 C

B

M6 C

B

M8

M10

C

B

C

B

C

A

Tightening torque in Newtonmetre Nm

8.8

1.15

1.2

2.8

2.9

5.5

5.7

9.5

9.8

23

24

45

47

12.9

2.0

2.1

4.7

4.9

9.3

9.7

16.3

17.0

38.5

40.0

75.8

79.0

M12 B

M14 C

B

M16 C

B

M20 C

B

M24 C

B

C

A

Tightening torque in Newtonmetre Nm

8.8

77,7

81

123

128

189

197

369.6

385

638.5

665

12.9

130.5

136

208

217

319.7

333

623

649

1075

1120

A = Strength grade B = Galvanised, non-oiled bolts C = Untreated, oiled bolts NOTE! Experience has shown that if you adjust the torque wrench to the values for untreated bolts, you will get the correct torque value for galvanised bolts.Do not tighten more than the values set out in the table otherwise the bolts can be destroyed.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

3- 5

Technical data – M4 General tightening torques T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

This page is intentionally left blank

3- 6

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 General Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4- Destruction instructions - M6 4.1 General These instructions have been drawn up as a part of Toyota's environment management program. An important motive is, by taking nature into consideration, to economise with resources. In other words, you should try to recycle material as far as possible, thus minimising the discharge of environmentally hazardous substances.

These disassembly instructions are based on an F code (truck family) and are further divided into C codes (parts and functions on the truck).

These C-codes are: • 0000 Chassis • 1000 Motors • 2000 Transmission/drive gear • 3000 Brake/belt/wheel systems • 4000 Steering system • 5000 Electrical system • 6000 Hydraulics/pneumatics • 7000 Working function - lift mast • 8000 Auxiliary/installation equipment • 9000 Accessories/optional equipment The instructions do not tell you the type of material the parts are made of, but refer you to different material containers where the parts should be collected. Some plastics are marked, which means that some of the instructions refer to the marking to determine the collection container to use.

4.2 Procedure When sorting a component part you must know what plastic parts, liquids, environmentally hazardous substances and metals that it includes.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 1

Destruction instructions - M6 Abbreviations T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.3 Abbreviations The following abbreviations for Service Manuals and plastic materials are used in the dismantling instructions. Abbreviations used are: ABS = Acrylonitrile-butadiene-styrene PA = Polyamide PMMA = Plexiglass PP = Polypropylene SM = Service Manual

4.4 Sorting The sorting method for component parts is based on how the parts can be recycled and whether they must be taken care of in a special way.

• Plastics must first and foremost be sorted into recyclable and nonrecyclable plastics. Plastics that can be recycled must be subdivided to differentiate between the different types of plastics. Instructions either denote in which container the plastic should be placed or there is a reference to the material marking on the plastic component. In those cases where the collection container for the plastic part is indicated, the plastic type abbreviation code is also indicated.

Sorting is not necessary for non-recyclable plastics. These are placed in a container intended for combustible material.

• Place small plastic and rubber parts in a container intended for combustible material.

• Iron and steel scrap is sorted separately.

• Composite scrap that is difficult to dismantle and which contains different metals such as steel, aluminium, copper and other materials, e.g. plastics, should be sorted separately.

• Oil is collected in the intended container.

• Oil filters are collected in the intended container.

• Parts contaminated by oil, such as hydraulic hoses, should be sorted separately.

• Batteries should be returned to the manufacturer, either directly to the manufacturer or through Toyota.

• Electronic scrap should be sorted from other scrap.

• Cables should be removed and collected separately.

• Small parts such as screws, bolts, nuts, washers, etc. are not included in the dismantling instructions. These should be placed in a container intended for iron and steel scrap.

4- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Chassis (0300) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.5 Chassis (0300)

1

4.5.1 Dismantling • Disassemble the chassis from the truck (1).

4.5.2 Material handling All parts should be treated as iron and steel scrap.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 3

Destruction instructions - M6 Hoods, covers (0340) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.6 Hoods, covers (0340) 1

2

3

4

4.6.1 Dismantling • Remove the panel (1, 2).

• Remove the hood (3).

• Remove the plastic handle (4).

4.6.2 Material handling The hood should be treated as iron and steel scrap.

Place the plastic handle and the panel in a container intended for ABS.

4- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Fork structure (low-lifter) (0380) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.7 Fork structure (low-lifter) (0380) 1

For wheels see 3500

4.7.1 Dismantling • Remove the fork structure (1).

4.7.2 Material handling Place the fork structure in a container intended for iron and steel scrap.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 5

Destruction instructions - M6 Travel platform including mount (0560) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.8 Travel platform including mount (0560) 1 4 3

2

4.8.1 Dismantling • Remove the platform (1).

• Remove the mat (2).

• Remove the gas damper and destroy it by cutting it into two (3).

• Remove the switch (4).

4.8.2 Material handling Place the platform and the gas damper in a container intended for iron and steel scrap.

Place the mat in a container intended for combustible material.

Place the switch in a container intended for electronic scrap.

4- 6

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Overhead guard (option) (0810) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.9 Overhead guard (option) (0810)

1

4.9.1 Dismantling • Remove the overhead guard (1).

4.9.2 Material handling Place the overhead guard in a container intended for iron and steel scrap.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 7

Destruction instructions - M6 Operator protective device (0840) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.10 Operator protective device (0840)

1 2

4.10.1 Dismantling • Remove the operator protective device (1).

• Remove the plastic handles (2).

4.10.2 Material handling Place the operator protective device in a container intended for iron and steel scrap.

Place the plastic handles in a container intended for cables.

4- 8

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Electric pump motor (1710) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.11 Electric pump motor (1710)

4.11.1 Dismantling • Remove the hydraulic unit.

• Remove the hydraulic lines.

• Remove the pump motor including the pump (1).

4.11.2 Material handling All oil should be handled as hazardous waste.

Place the hydraulic oil lines in a container intended for oil-contaminated material.

Place the motor together with the pump in a container intended for hazardous waste.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 9

Destruction instructions - M6 Electric travel drive motor (1760) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.12 Electric travel drive motor (1760)

1

4.12.1 Dismantling • Remove the cables.

• Remove the travel drive motor including the electric parking brake from the gear (1).

4.12.2 Material handling Cables are placed in a container intended for cables. Place the motor and the electric parking brake in a container intended for hazardous waste.

4- 10

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Drive unit/gear (2550) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.13 Drive unit/gear (2550)

4.13.1 Dismantling • Drain the oil from the gearbox.

• Remove the gearbox from the drive motor (se SM).

• Remove the drive wheel.

4.13.2 Material handling The oil should be handled as hazardous waste.

The gearbox is placed in a container intended for iron and steel scrap.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 11

Destruction instructions - M6 Wheels (3500) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.14 Wheels (3500)

3

Chassis 850

2 1

4.14.1 Dismantling • Remove the drive wheel (1), swivel wheel (2) and fork wheels (3).

4.14.2 Material handling Place the vulcanised wheels in a container intended for vulcanised wheels.

4- 12

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Steering arm (4110) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.15 Steering arm (4110) 2 1 3

4

4.15.1 Dismantling • Remove the display (1).

• Remove the logic card (2).

• Remove the potentiometer (3).

• Remove the keypad (4).

• Remove the cable.

4.15.2 Material handling Place the display, logic card, potentiometer and keypad in a container intended for electronic scrap.

Place the cable in a container intended for cables.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 13

Destruction instructions - M6 Steering arm (4110) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.16 Steering arm (4110)

1

2

4.16.1 Dismantling • Remove the gas damper and destroy it by cutting it into two (1).

• Remove the switch (2).

4.16.2 Material handling Place metal parts and the gas damper in a container intended for metal scrap.

Place the switch in a container intended for electronic scrap.

4- 14

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 General electric equipment (5100) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.17 General electric equipment (5100)

4.17.1 Dismantling • Remove the cables.

• Remove the battery.

4.17.2 Material handling Cables are placed in a container intended for cables.

The battery (classified as hazardous waste within the EU) should be returned to the battery manufacturer or the manufacturer's representative (see the rating plate on the battery).

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 15

Destruction instructions - M6 Cabling (5590) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.18 Cabling (5590)

4.18.1 Dismantling • Remove the cables.

4.18.2 Material handling Cables are placed in a container intended for cables.

4- 16

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Steering and protective electronics (5700) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.19 Steering and protective electronics (5700)

1

4.19.1 Dismantling • Remove the electronic units (1).

4.19.2 Material handling Place the electronic units in a container intended for electronic scrap.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 17

Destruction instructions - M6 Lift/lowering sensor (5820) and safety sensor (5830) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.20 Lift/lowering sensor (5820) and safety sensor (5830)

1

2

4.20.1 Dismantling • Remove the height sensor (1).

• Remove the load sensor and the height reference sensor (2).

4.20.2 Material handling Place the sensors in a container intended for electronic scrap.

4- 18

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Hydraulic unit (6100) Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.21 Hydraulic unit (6100)

1

2

4.21.1 Dismantling • Drain the oil from the hydraulic system.

• Remove the hydraulic oil lines (see 6230).

• Remove the oil reservoir (2).

• Drain the oil from the reservoir.

• Remove the hydraulic unit (1) (motor + pump) (see 1710).

4.21.2 Material handling All oil should be handled as hazardous waste.

Place the hydraulic oil lines in a container intended for oil-contaminated material.

Place the tank in a container intended for PP. Place the motor together with the pump in a container intended for hazardous waste.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 19

Destruction instructions - M6 Main mast (7100) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.22 Main mast (7100)

A

A

A-A

4.22.1 Dismantling • See the SM for the disassembly procedure of the main mast.

• Remove the plastic components from the main mast.

4.22.2 Material handling The mast should be treated as iron and steel scrap.

Place the plastic components in a container intended for combustible material.

4- 20

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Destruction instructions - M6 Chassis-mounted hydraulic oil lines (6230) (and main lift cylinder Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

4.23 Chassis-mounted hydraulic oil lines (6230) (and main lift cylinder (6610) )

2

3

1

4.23.1 Dismantling • Remove the cylinder.

• Drain the cylinders of all oil.

• Destroy the cylinder by cutting it into two (1).

• Remove the hydraulic oil lines (see 2).

• Remove the hydraulic hoses (3).

4.23.2 Material handling The oil should be handled as hazardous waste.

Place the cylinder and hydraulic oil lines in a container intended for iron and steel scrap.

Place the hydraulic hoses in a container intended for oil-contaminated material.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

4- 21

Destruction instructions - M6 Battery charger connector (9380) T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4.24 Battery charger connector (9380)

2

1 4.24.1 Dismantling • The battery charger connector (1) is included with the battery.

• Remove the battery charger connector (2).

4.24.2 Material handling Place the battery charger connector (2) in a container intended for electronic scrap.

4- 22

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Installation and maintenance instructions – P1 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

5- Installation and maintenance instructions – P1 5.1 Truck installation

600+-100

5.1.1 Lifting the truck

600+-100

• Lift the truck at its centre of gravity using another fork lift truck.

• Fasten the truck to the forks of the lifting truck.

• Lift it very carefully.

WARNING! Risk of tipping.

The truck may tip over if it is lifted incorrectly.

Always lift the truck when it has been fastened to the forks of the lifting truck and its centre of gravity between the forks.

• Only lift the truck at the indicated lifting points using suitable lifting equipment.

WARNING! Risk of tipping..

The truck may tip over if it is lifted in the wrong places.

Always lift the truck at the indicated lifting points.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

5- 1

Installation and maintenance instructions – P1 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

5.1.2 Battery installation Check to make sure the battery cabling has been correctly connected to the battery.

VARNING! Risk of short-circuiting.

An incorrectly connected battery may cause short-circuiting.

The polarity must match. Compare the markings on the cables with those on the battery poles.

The battery can be replaced from the sides or from above.

5.1.3 Putting into service Prior to putting the truck into use, verify the items listed below.

Table 8: Pre-delivery inspection check-list

5- 2

Pos. no.

Inspection item

Measure

1

Hydraulic functions

Check its function

2

Operating control

Check its function

3

Switch for safety reversing

Check its function

4

Horn

Check its function

5

Steering

Check its function

5

Brakes

Check its function

6

Emergency switch off

Check its function

7

Hydraulic system

Inspect the oil level and check for oil leakage

8

Drive unit

Check for noise and oil leakage

9

Wheels

Check for damage, remove oil, chips, etc.

10

Chassis

Check for damage, remove dirt, etc.

11

Battery cover and locking

Check its function

11

Battery

Inspect the battery acid level and charge level

12

Fork carriage

Check for damage and wear

13

Lifting device

Check for damage, remove dirt, etc.

14

Finger guard

Check for damage and wear

15

Running time

Perform maintenance as described in the Maintenance section

16

Hydraulic cylinders

Look for damage and oil leakage

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Installation and maintenance instructions – P1 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

3

2

16

1

14

13

4

15

12

6

10

8

11

9

7

• Check to make sure all parameters are set to the desired values: - Maximum speed.

- Acceleration.

- Automatic speed reduction.

- PIN codes (option).

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

5- 3

Installation and maintenance instructions – P1 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

5.2 Introduction, maintenance To assure maximum safety and minimum downtime, all items in the service programme should be covered. The service intervals are only guidelines and need not be strictly followed. The operator of the truck should adapt these to local requirements, however, it is important that the minimum requirements as stated by Toyota are observed.

The service intervals are based on truck operating hours and can be adapted to most common 8-hour shifts. When calculating the service intervals, the following operating hours have been used: Day time:

08.00-17.00 (20 hours/week)

Double shift:

06.00-14.00, 14.00-22.00 (40 hours/week)

Triple shift:

06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hours/week)

Make sure the truck receives the necessary regular maintenance service according to the maintenance schedule. The truck's safety, efficiency and service life rely on the service and maintenance the truck receives.

For service and repairs, only use spare parts approved by Toyota.

5.2.1 Safety rules during maintenance work Only technicians who have received the necessary training for service and repairs of this truck type may carry out service and repair work.

• Do not perform any repair work on the truck unless properly trained and possessing the necessary skills to perform such work.

• Keep the service site clean. Oil and water on the floor could make it slippery.

• Never wear loose items and jewellery when working on the truck.

WARNING! Short-circuiting/Burn injuries.

When working on the truck's electrical system, short-circuiting/burn injuries may occur if metal objects come into contact with live electrical connections.

Remove any watches, rings and other metal jewellery.

• Unless otherwise indicated in this service handbook, always disconnect the battery connector prior to performing maintenance work on the truck.

• Prior to opening any covers to the drive unit and the electrical system, be sure to disconnect the power supply to the truck.

5- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Installation and maintenance instructions – P1 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

• Prior to commencing any work on the hydraulic system of the truck, be sure to slowly depressurize the system.

• Use paper or a thick paper board to inspect possible hydraulic oil leaks. Do NOT use your hand.

• Keep in mind that the transmission oil and hydraulic system oil may be burning hot.

WARNING! Risk of burn injuries.

Hot transmission and hydraulic oil.

Allow the truck to cool down prior to replacing the oil.

• Use only new and clean oil when refilling the hydraulic oil system WARNING! Risk of damaging the hydraulic system.

If the oil is contaminated, the hydraulic system components will be damaged.

Always use new and clean oil in the hydraulic system.

• Store and transport replaced oil in accordance with local regulations.

• Do not flush solvents, etc. used for cleaning into drains that are not specifically suited for this. Follow local regulations with regards to destruction of oil, solvents, etc.

• Disconnect the battery prior to performing welding work on the truck.

NOTE! The battery could become damaged.

When using an electric welding system, the welding current could reach the battery.

Be sure to first disconnect the battery.

• Prior to welding or grinding on painted surfaces, be sure to scrape off the paint at least 100 mm around the welding/grinding site using blasting or a paint remover.

CAUTION! Unhealthy gasses.

Paint, which is heated, generates unhealthy gasses.

Remove the paint 100 mm around the working place.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

5- 5

Installation and maintenance instructions – P1 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

5.3 Cleaning and washing Cleaning and washing of the truck is important to assure a high level of reliability.

• Clean and wash the truck once a week.

NOTE! Risk of short-circuiting.

The electrical system can become damaged.

Prior to washing, be sure to disconnect the battery by disconnecting the battery connector.

5.3.1 External cleaning • Remove dirt, chips, etc. from the wheels daily.

• Use a well-known degreasing agent, diluted to a suitable concentration.

• Wash off loose dirt using lukewarm water.

NOTE! Seizure, corrosion.

Mechanical parts could become damaged.

Following washing of the truck, lubricate it according to the lubrication schedule in the Maintenance section.

5.3.2 Cleaning the motor compartment • Prior to washing, cover all electric motors, connectors and valves.

NOTE! Risk of short-circuiting.

The electrical system can become damaged.

Electric components must not be washed with a high-pressure jet.

• Wash the motor compartment with a well-known degreasing agent diluted to a suitable concentration.

• Wash off loose dirt using lukewarm water.

5.3.3 Electric components • Use compressed air to blow clean the electric motors.

• Clean electric panels, logic cards, connectors, valves, etc. with a rag moistened with water and a suitable detergent.

NOTE! Risk of short-circuiting.

Electric components can become damaged.

Avoid breaking the warranty seals on the logic cards.

5- 6

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Installation and maintenance instructions – P1 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

5.4 Safe lifting Perform all lifts on level, slip-proof and firm surfaces. Avoid newly laid asphalt on warm summer days.

• Always apply the parking brake to prevent the truck from moving during lifting. If the brake wheel needs to be lifted, be sure to block the other wheels to make sure the truck will stand still.

• Select a lifting point that will make the lift as light as possible (one corner at a time). If the lifting point on the truck are indicated on the lower part of the chassis, be sure to use this to assure balanced lifting.

• Ensure that the surface where the jack is placed is clean and free from oil.

• Use clean hands and make sure the jack handle is free from grease and oil.

• Use the handle supplied with the jack. Too short a handle will require more strength than necessary. Too long a jack may result in overloading of the jack.

• Secure the truck with trestles, etc.: - As close to the lifted part of the chassis as possible in order to reduce the falling height if the truck should collapse.

- To prevent the truck from rolling.

- Never chock up the jack in order to achieve a higher lifting height.

- Never work under a lifted truck unless it has been securely chocked up.

WARNING! Risk of crushing.

A poorly chocked up truck may fall down.

Never work under a truck unless it has been securely chocked up using trestles or other safe hoisting gear.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

5- 7

Installation and maintenance instructions – P1 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

This page is intentionally left blank

5- 8

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Maintenance schedule – P2 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

6- Maintenance schedule – P2 Table 9: Maintenance schedule I:Inspect, rectify and change if necessary T: Tighten. C: Clean L: Lubricate.

M:Control measurement, rectify if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to appli- 5 cation

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1w

1m

6m

12m

36m

1d

0000

Chassis

0000.1

Inspect all shafts, links and clamping pins

I

0000.2

Inspect possible damage on the chassis; open the battery cover and use it as an aid

I

0000.3

Check the cover locks

I

0000.4

Check finger guard

I

0000.5

Check signs and stickers

I

0000.6

Inspect the operator platform

I

0380.3

Press grease into grease nipples (Note 6)

I/L

0380

Fork carriage

0380.1

Check for crack formation and damage

I

0380.2

Check clearance in bushes and links

I

0380.3

Press grease into grease nipples (Note 6)

0380.4

Check the lift limit switch

0380.5

Inspect the guides for wear and lubricate them (Note 6)

I/L

0380.6

Inspect the load support (Option)

I

0450

Frame-mounted components

0450.0

Inspect the motor plate links and turning pipe

© TIEE SARL

I/L I

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

I

6- 1

Maintenance schedule – P2 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 9: Maintenance schedule I:Inspect, rectify and change if necessary T: Tighten. C: Clean L: Lubricate.

M:Control measurement, rectify if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

I/T1

I/T

1700

Drive motors

1700.1

Check clearance in connections

1700.2

Inspect the carbon brushes in the drive motor and lift motor

M

1700.3

Clean the drive motor and lift motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

2550

Drive unit

2550.1

Check for leakage

2550.2

Check the oil level

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in steering bearing

I

2550.5

Change the oil in the drive gear

2550.6

Lubricate the gear rim

3100

Brake

3100.1

Clean and verify correct operation of the service brake and parking brake

3100.2

Inspect brake disc weak and verify correct tightening torque (32 Nm)

M

3100.3

Check the clearance in disengaged position.

(0,2-0,3 mm)

M

6- 2

© TIEE SARL

T2 I I

I3

L

L4 L C/I

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Maintenance schedule – P2 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 9: Maintenance schedule I:Inspect, rectify and change if necessary T: Tighten. C: Clean L: Lubricate.

M:Control measurement, rectify if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to appli- 5 cation

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1w

1m

6m

12m

36m

1d

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts New wheel: Tread thickness = 30 mm Tightening torque = 65 Nm) (3500,2)

M

3500.3

Check whether the castor wheel rotates and swings freely; lubricate the horizontal bearing.

Inspect the castor wheels for wear and correct installation. New wheel: Tread thickness = 10 mm)

I

4110

Tiller arm

4110.1

Check the mountings

I

4110.2

Inspect the steering couplings for excessive play and the return spring

I

4110.3

Inspect the gear of the steering servo unit. (Option)

I

5000

Electrical functions

5000.1

Inspect brake switch operation

I

I

5000.2

Inspect correct operation of the emergency stop switch

I

I

5000.3

Check the function of the collision safety switch

I

I

5000.4

Inspect lifting/lowering operation of the forks (and support arms 7SLL12.5F/7SLL16F)

I

I

5000.5

Inspect correction operation of the platform switch

I

I

5000.6

Inspect the side guard switch for correct operation

I

I

5000.7

Check the function of the horn

I

I

5000.8

Check for wear on cabling

I

I

© TIEE SARL

I

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

6- 3

Maintenance schedule – P2 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 9: Maintenance schedule I:Inspect, rectify and change if necessary T: Tighten. C: Clean L: Lubricate.

M:Control measurement, rectify if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

5000.9

Check the function of the driver’s control

I

I

5000.10

Inspect the error code log, operating hours and all segments in the display panel

I

I

5110

Battery

5110.1

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

M

5110.2

Check connections to battery, truck and charge

I

5110.3

Check that the cell and pole guards are undamaged

I

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

5400

Power system

5400.1

Clean and inspect the mounting devices

C/T

5400.2

Re-tighten cable connections

T

5400.3

Check the contactor points on K10

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

6000

Hydraulic system

6000.1

Check hoses and connections for wear

I

6000.2

Check hoses for wear and damage

I

6000.3

Check the oil tank for cracks, leakage and damaged mountings

I

6000.4

Check that the oil level is correct

6000.5

Replace the oil and clean the reservoir

6- 4

© TIEE SARL

I

I

I L5

L

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Maintenance schedule – P2 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 9: Maintenance schedule I:Inspect, rectify and change if necessary T: Tighten. C: Clean L: Lubricate.

M:Control measurement, rectify if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to appli- 5 cation

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1w

1m

6m

12m

36m

1d

6600

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

7100

Mast

7100.1

Check for any cracks and other damage

I

7100.2

Tighten the mast mounting bolts (tightening torque = 197 Nm)

T

7100.3

Inspect the play between the mast member and the mast stabiliser rollers inside the mast

I

7100.4

Inspect lateral play in the mast stabiliser

I

7100.5

Inspect the lifting chains and chain rollers for wear

I

7100.6

Inspect correct adjustment of the lifting chains

I

7100.7

Inspect the chain pin shafts and split cotters

I

1 = The connections are re-tightened for the first time after 500h and then every 1000 /h.

2 = The attachment bolts are re-tightened after 500h to 45 Nm. 3 = Check for leakage in conjunction with the first oil change 4 = The oil is changed for the first time after 500h/6 month and then every 3000 h/36 months.

5 = Replace the oil and clean the reservoir the first time after 80 hours/ 1 month, and then every 1000 hours/12 months.

6 = If the truck is used in cold stores or other severe conditions, perform this item every 250 hours.

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

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

6- 5

Maintenance schedule – P2 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

5000

7100 6600

4110

5000

5000

3500 0450 5100

1700

3100

6000

2550 3500

6- 6

© TIEE SARL

5400

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Maintenance schedule – P2 Lubrication chart Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

6.1 Lubrication chart Table 10: Lubrication chart Pos no

Service point

Interval/Running hours 500h

1 2 3 4 5 6 7

Wheel bearing, bushings Mast beam Lifting chains Hydraulic system Steering bearings Drive gear Bushings

1000h

3000h

L L L C C L

Lubricant

O L O

A F D B G C A

L= Lubrication C = Check O= Oil change

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

6- 7

Maintenance schedule – P2 Lubrication chart T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

3

2

1

4 7

5

6

6- 8

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Oil and grease specification – P3 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

7- Oil and grease specification – P3 Table 11: Oil and grease specification Lubricant

Specification > - 15°C < - 15°C

Application area

A

Grease

Bearings and bushings

B C

Hydraulic oil Transmission oil

D F G

Grease Grease Grease

S213366 Q8 Rubens WB ISO-L-HM32 Hypoid oil SAE 80W/90 See table below 055-70111 Staburags NBU 8EP

S213366 Q8 Rubens WB ISO-VG32 Hypoid oil SAE 75W See table below 055-74320 Staburags NBU 8EP

Hydraulic system Gears Chains Mast Steering bearings

Ambient temperature

Viscosity class

Recommended products ( Similar products

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5 °C

VG 68

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA

> + 5 °C < +45°C

VG 150

Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

© TIEE SARL

from other manufacturers may be used)

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

7- 1

Oil and grease specification – P3 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

This page is intentionally left blank

7- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Tools – P4 Super Seal connectors Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

8- Tools – P4 8.1 Super Seal connectors 1 3

3 2

Figure

© TIEE SARL

Number

Application

159232

Tools for fitting pins/sleeves

159229

Tools for loosening locks (1)

159230

Tool for fitting secondary locks 1-2 poles (2)

159231

Tool for fitting secondary locks 3-6 poles (2)

159228

Tools for removing pins/sleeves (3)

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

8- 1

Tools – P4 AMP connectors T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

8.2 AMP connectors PT = Power Timer (4,8. 5,8. 6,3 mm) JPT = Junior Power Timer (2,8 mm) MPT = Micro Power Timer (1,5 mm)

Figure

2

1

Number

Application

151080 (PT)

Tools for removing pins/sleeves

213296 (JPT)

Tools for removing pins/sleeves

213298 (MPT)

Tools for removing pins/sleeves

1=163787 2=163788

Tools for fitting sleeves

1=213336 (MPT) 2=213337 (MPT)

1=213336 (JPT) 2=213549 (JPT)

2 8- 2

© TIEE SARL

Tools for fitting pins For 0,5-2,5 mm2

1

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Tools – P4 Molex connectors Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

8.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

8.3 Molex connectors 16 9 8 1 Figure

© TIEE SARL

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

8- 3

Tools – P4 Other tools T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

8.4 Other tools Figure

8- 4

© TIEE SARL

Number

Application

179915

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

08-13022

Driving gear puller

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electric drive motor – 1760 Included components Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

9- Electric drive motor – 1760 9.1 Included components 16 21 14

18

13

19

20

17 10

15

12 11

8

9

7 5

6

4 3 1 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

9- 1

Electric drive motor – 1760 Included components T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 12: Included components

9- 2

© TIEE SARL

Pos.

Name

Notes

1

Screw

M6x25

2

Bearing plate

3

Groove ring

4

Bearing

5

Carbon brush bridge

6

Screw

M5x12

7

Screw

M5x20

8

Carbon brush

9

Rotor

10

Wedge

11

Plug

12

Armature

13

Cable

14

Cable

15

Bearing plate

16

Screw

17

Seal

18

Bearing

19

Washer

20

Groove ring

21

Groove ring

M6x25

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electric drive motor – 1760 Disassembly/assembly of the truck motor Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

9.2 Disassembly/assembly of the truck motor 9.2.1 Disassembly • Switch off the truck and disconnect the battery connector.

• Remove the motor compartment covers.

• Disconnect the cables from the motor and the tiller arm.

• Loosen the four nuts from the motor mounts on the driving gear.

• Disconnect the cables for the start switch and the emergency stop switch. At the same time, remove all cables from the cable recess in the cover.

• Remove the cover that covers the motor compartment and the tiller arm mount from the motor. Remove the cover that covers the motor compartment together with the tiller arm.

• Carefully lift the motor straight up while being careful not to damage the driving gear sealing surfaces, and place the motor on a clean surface.

• Protect the driving gear against contamination by covering all ports with suitable means, e.g. a plastic sheet.

It is now possible to commence with the necessary service and repairs of the motor.

9.2.2 Assembly • Assembly is done in reverse.

• Carefully lower the motor into the drive gear while making sure the seals and gear wheels are not damaged.

• Tighten the pin bolt nuts to the prescribed torque of 27 Nm. • Install and adjust the brake according to the instructions. Secure the cover and tiller arm with screws and connect the cables that were previously disconnected. Verify that the polarity is correct.

• Following completed installation, perform operational testing of the brake before the truck is operated again.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

9- 3

Electric drive motor – 1760 Service/repairs T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

9.3 Service/repairs 9.3.1 Disassembly of the motor 16 21 14

18

13

19

20

17 10

15

12 11

8

9

7 5

6

4 3 1 2

• Loosen the brake disc tappet by first removing the groove ring together with the washer at the end of the rotor shaft. It is then possible to remove the tappet by lifting it. It may be necessary to use a suitable tool to free it.

• Us the four plugs that cover the carbon brushes, fold away the carbon brush springs and pull out the carbon brushes.

• Disassemble the bearing plate (2) at the end of the commutator together with the carbon brush bridge (5) and the carbon brushes (8) by removing the eight screws (1). Then set down the motor, arrest it properly to the edge of the bearing plate and carefully knock at the end of the rotor shaft with a rubber mallet.

• Disassemble the drive end of the bearing plate (15) together with the rotor (9). Be careful not to damage the motor windings when the rotor is remove from the motor cover.

9- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electric drive motor – 1760 Service/repairs Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

• Once the motor bearing plates have been disassembled and the rotor has been removed from the motor cover, loosen the gear wheel at the rotor drive end. This is done by loosening the gear wheel nut and then pulling out the gear wheel with a puller. Please note that the gear wheel has been secured to the rotor shaft with Loctite.

• Then loosen the inner groove ring together with the washer below the ring. Pull out the rotor shaft from the bearing (18).

• Loosen the outer groove ring together with its washer, and remove the bearing from the bearing plate.

• Remove the bearing plate seal (17) and carefully clean the bearing plate.

• Install a new seal in the bearing plate.

9.3.2 Motor installation Install the motor in reverse.

• Carefully check whether the rotor can move freely when rotating and that the carbon brushes press against the commutator.

• Check the insulation resistance of the motor (between each winding and the motor cover). On a new motor, the measured value should be 2 - 3 MOhm. When the motor has become dirty, an insulation resistance down to approx. 1 MOhm is acceptable.

• Install a new O-ring on the bearing plate at the drive shaft end and a new seal on the bearing plate collar.

9.3.3 Cleaning Keep the motor as clean as possible since this is a decisive factor for correct operation. Regularly inspect the motor and motor compartment for build-up of dust, oil and other contaminants.

If the motor windings and internal compartments are dry, use a vacuum cleaner with a suitable nozzle to clean the motor. Compressed air can be used together with a vacuum cleaner for cleaning. If this is the case, make sure the compressed air is clean and dry.

If deposits have formed on the windings, use a lint-free cloth to remove them. If required, moisten the cloth with an organic, volatile grease solvent that will not damage the windings. However, do not use too much cleaning agent as it could penetrate into the motor parts.

If grease deposits are left on the surface, use a suitable solvent to remove cleaning agent remains.

If the motor components are heavily contaminated, it may be necessary to use a solvent that is sprayed onto the parts. It is especially important for the rotor that the cleaning agent is applied in a manner that avoids contaminants from penetrating into the motor section. © TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

9- 5

Electric drive motor – 1760 Technical data T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

One method to clean the rotor is to submerge it in solvent. If this method is used, be sure to later dry the motor using a heat source. During the drying process, arrange good ventilation and allow the components to dry until repeated insulation resistance measurements show similar and approved values.

9.4 Technical data Table 13: Technical data Machine type

9- 6

© TIEE SARL

Type

TSL140B-DS41

Power (kW)

1,7

Intermittence

S2 60 min.

Minimum carbon brush length (mm)

13

Minimal commutator diameter (mm)

60

Resistance, shunt field winding Ω at 26°C

0,498

Resistance, armature winding Ω at 26°C

0,0161

Insulation resistance between windings and motor cover

>= 1 MOhm

Weight (kg)

17

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Drive unit/gear – 2550 Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

10- Drive unit/gear – 2550

18 2 1

3 4 5 6

15

10

7

16 17

8 9

14

11 12

13

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

10- 1

Drive unit/gear – 2550 Included components T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

10.1 Included components Table 14: Included components

10- 2

© TIEE SARL

Pos.

Name

Notes

1

Motor gear wheel

2

Locking nut

3

Primary gear wheel

4

Tapered roller bearing

5

Shim

6

Shim

7

Tapered roller bearing

8

Tapered roller bearing

9

Locking nut

10

Cover

11

Screw

12

Shim

13

Pinion/crown wheel

14

Drive axle

15

Wheel screw

Tightening torque 65 Nm Lock using Loctite 270

16

Jointing ring

Fill the jointing ring with grease Seal using Loctite 574

17

Tapered roller bearing

18

Cover with gear ring

Tightening torque 70 Nm Centre punch to lock

Tightening torque 300 Nm Centre punch to lock Tightening torque 26,6 Nm Secure using Loctite 242 Gear play 0,09-0,15 mm. Pretighten the bearing by 2-5/100. The punched measure in the pinion should be adjusted using shims.

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Drive unit/gear – 2550 Leakage from top cover Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

10.1.1 Technical data Table 15: Technical data Truck type

7SLL12.5/12.5F/16/16F

Gear type

2-stage angle gear

Gear ratio

14,20:1

Oil volume, litres

1,75

Oil type

Hypoid oil

Viscosity, normal temperature

SAE 80W/90

Viscosity, <-15°C

SAE 75W

10.2 Leakage from top cover Disassembly • Lift up the truck and properly secure it using trestles.

• Unscrew the drive wheel.

• Using a box wrench, unscrew the M8 nuts which secure the gear unit to the motor. Hold the gear unit to prevent it from falling down.

• Using a 6 mm Allen key, loosen the M8 screws which secure the cover.

• Replace the seal.

Assembly is done in reverse.

• Tighten the four M8 screws and the four M8 nuts to a torque of 27 Nm. Secure with Loctite 242.

• Tighten the 5 screws of the drive wheel to a torque of 65 Nm.

10.3 Replacing the drive axle jointing ring When replacing the drive axle jointing ring, the gear unit can remain installed on the truck.

If the drive axle leaks oil, follow the instructions below.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

10- 3

Drive unit/gear – 2550 Replacing the drive axle jointing ring T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

10.3.1 Disassembly • Unscrew the drive wheel.

• Remove the bottom cover and drain all oil (10).

• Loosen the drive axle nut. Remove the nut and washer (9).

• Carefully knock out the drive axle using a brass mandrel and hammer (14).

• Pull out the bearing from the drive axle using the bearing removal tool 08-13022 (17).

• Verify that the bearing plates are free from damage. If the plates have been damaged by the bearing puller, then measure the total thickness of the spacing washers and replace them prior to assembly (12) • Remove the jointing ring from the drive axle (16).

10.3.2 Assembly Assembly of the gear unit after replacement of the drive axle jointing ring is done in reverse compared to disassembly.

Pay special attention to the following during assembly: • Fill the jointing ring with grease after setting it on the drive axle.

• Ensure that only undamaged spacing washers of equal total thickness as the original spacers are set on the drive axle.

• Press on the bearing on the drive axle, making sure not to damage the bearing spacing washers.

• During assembly of the drive axle with attached bearing, spacing washers and jointing ring, make sure the placement of the axle wedges coincide with the crown wheel wedges and that the bearing and jointing ring are properly positioned in the gear housing prior to pressing the axle completely into the opening.

• Place the spacer ring on the drive axle end and then screw on the axle nut. Always be sure to use a new nut. Tighter the axle nut to a torque of 300 Nm, and lock it with one centre punch. Lubricate the drive axle nut prior to setting it on the axle.

• Before installing the bottom cover, replace the seal. Make sure it is not damaged. Install the cover and tighten the screws to a torque of 26.6 Nm. Lubricate the screws prior to mounting. Fill with oil according to the oil filling instructions.

Fit the drive wheel and tighten the screws to a torque of 65 Nm.

10- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electromagnetic brake – 3370 Main components of the brake Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

11- Electromagnetic brake – 3370 11.1 Main components of the brake 9

1

8 2

7

3

6

4

5

Table 16: Main components of the brake

© TIEE SARL

Pos. no.

Description

1

Magnet coil

2

Electric cable

3

Pressure plate

4

Pressure spring

5

Friction plate

6

Adjusting locking nut

7

Brake disc

8

Mounting bolts

9

Hub

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

11- 1

Electromagnetic brake – 3370 Maintenance T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

11.2 Maintenance In normal use, the brake should not require any maintenance. The preventive maintenance diagram, however, recommends regular inspection of the brake disc for wear and also to ensure the play between the magnet coil housing and pressure plate is correct.

11.2.1 Basic adjustment of the play 9,5 Nm

0,3

The specified play between the magnetic coil housing and the pressure plate should be 0.3 mm when applying the brake. The maximum play prior to adjustment becoming necessary is 0.8 mm.

Adjustment • Slightly loosen the tightening of the three mounting bolts.

• Turn the locking nuts counter-clockwise and lightly tighten the bolts while at the same time checking the play in three places using a 0.3 feeler gauge.

• Tighten the mounting bolts to a torque of 9.5 Nm and reverify the play using the feeler gauge.

11- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electromagnetic brake – 3370 Maintenance Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

11.2.2 Brake disc replacement Replace the brake disc when its entire thickness has become 8,8 mm.

• Disconnect the electric cables from the brake.

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

• Replace the brake disc on the hub and inspect the friction plate for wear. If the surface is uneven, then replace the friction plate.

• Unscrew the locking nuts on the coil at least 6 mm to assure there is a large play between the coil and the pressure plate when the coil is later reinstalled.

• Attach the coil to the motor end and adjust the play as described in the section ”Basic adjustment of the play”.

• Reconnect the electric cables.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

11- 3

Electromagnetic brake – 3370 Maintenance T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

This page is intentionally left blank

11- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Electrical equipment overview Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

12- Uklad elektryczny 12.1 Widok ogolny - rozmieszczenie elementow A2:S17

A17

KOMPONENT ÖVERSIKTSBILD

A6

S18:1

S18:2

A2

A2:S20 A2:S19 R14

L1

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 1

Electrical systems – 5000 Electrical equipment overview T-code 789, 791

Valid from serial number 711956-

Date 2004-12-20

Order number 222641-040

S53 S56

S31

S90 S33

Y59 Y58 Y41

M3

KOMPONENT B4 ÖVERSIKTSBILD

S10 S21

X1

G1

B5

Y52 X41

A3

Y10

F3

A1

S19 S59

F50 R2

F52 F53 K10

M1 S65

12- 2

© TIEE SARL

F1 H1

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

12.2 Wyjasnienie skrotow schematow elektrycznych

Tabela 17: Zestawienie grup podzespolow Symbol

Funkcja

Wyjasnienie

Associated signal names

Inf.

A1:OUT MAIN CONTACTOR

7

Zrodla zasilania wozka G1

Glowne zrodlo zasilania

Bateria trakcyjna 24 V

X1

Wtyczka baterii / isolation

Zlacze

K10

Stycznik glowny

Zlacze

Elementy zabezpieczajace F1

Zabezpieczenie silnika jazdy

Bezpiecznik 125 A

F3

Zabezpieczenie silnika pompy

Bezpiecznik 160 A

F 50

Zabezp. obwodu sterowania, A2

Bezpiecznik 7,5A

F 51

Zabezp. obwodu sterowania, A1

Bezpiecznik 7,5 A

F 52

Zabezpieczenie ukladu wspomagania

Bezpiecznik 30 A

F 53

Zabezp. obwodu sterowania, A5

Bezpiecznik 3 A

A5:INPUT ENABLE B+

A5:POWER SUPPLY 24VDC 3

Kontrola i przetwarzanie sygnalow A1

Uklad jazdy i urzadzenia peryferyjne Regulator tranzy storowy (CURTIS) kontroli zasilania

A2

Kontrola wszystkich funkcji wozka

Karta elektroniki

A3

Kontrola ukladu podnoszenia

Regulator tranzy -storowy (CURTIS)

A5

Uklad wspomagania

Karta elektroniki

3, 2

A6

Wyswietlanie funkcji wozka

Wyswietlacz

1

A17

PIN-kody (wprowadzanie danych)

Klawiatura

1

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

1

12- 3

Electrical systems – 5000 Equipment list and electrical diagram T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 17: Zestawienie grup podzespolow Symbol

Funkcja

Wyjasnienie

Associated signal names

Inf.

Hamowanie, Zabezpieczenia & zarzadzanie S21

Wylacznik awaryjny

Wylacznik

A1:INP.SUPPLY 24VDC

S10

Ramie kierownicy w pozycji do jazdy Inductive proxi(Aktywowanie hamulca) mity switch

A1:INP.TILLER ARM IN DRIVE POS

7, 10

Y1

Cewka hamulca

Electromechanical brake

A1:OUT.BRAKE A

7

A2:S17

Awaryjna jazda do przodu

Hall sensor

A2:BELLY BUTTON

5

S19

Platform staying down supervision

Inductive proximity switch

A1:INP.MAN ON PLATFORM

7, 3

S59

Platform not up supervision

Inductive proximity switch

A1:INP.PLATFORM NO T FOLDED UP

7, 10

S53

Gates up supervision

Inductive proximity switch

A1:INP GATES UP

7, 10

S56

Gates down supervision

Inductive proximity switch

A1:INP GATES DOWN

7, 10

S33/1

Supervision -Max. permitted lift height for powertrak

Magnetic switch

A1:INP LIFT LIMIT POWER TRAC 1,< 1.8M

7,9

S33/2

Supervision -Max. permitted lift height with gates up

Magnetic switch

A3:INP.LIFT LIMIT <1,8 M

7,9

H1

Audible warning signal -Horn

Horn

A1:OUT.SIGNAL HORN

7

S18:1

Wlaczenie klaksonu

Switch

A2:INP.HORN1

7, 4

S18:2

Wlaczenie klaksonu

Switch

A2:INP.HORN2

7, 4

Uklad jazdy & kontrola jazdy L1

Kontrola jazdy i wybor kierunku jazdy (manetka)

Czujniki Halla

S113

“Turtle” function

Switch

M1

Truck traction

Motor

Y58

Powertrak drain-hydraulic control

Y59 B5 12- 4

6, 7 A2:TURTLE

3

Magnetic valve

A1:OUT.POWERTRAK DRAIN VALVE

7

Powertrak open-hydraulic control

Magnetic valve

A1:OUT.POWERTRAK FILL-UP VALVE

7

Powertrak pressure supervision

Pressure sensor

A3:INP.PRESSURE PT

7

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 17: Zestawienie grup podzespolow Symbol

Funkcja

Wyjasnienie

Associated signal names

Inf.

Wspomaganie R2

Steering angle signal

Potentiometer

A5:A_IN0 , A_IN1

3

S65

Drive wheel in centre reference

Inductive proximity switch

A5:REF

3

M6

Drive wheel steering

Motor

3,2

Podnoszenie widel R14

Fork lift/ lower control

Hall sensor unit

A2:A_IN

7

Y10

Fork lower -hydraulic control

Proportional magnetic valve

A3:OUT MAGNET VALVE PWM

7,8

B4

Load supervision

Pressure sensor

A3:INP.PRESSURE LIFT

7

M3

Hydraulic pressure

Motor

Support arm lift (7SLL12.5F/16F) A2:S19

Support arm lift control

Hall sensor

5,7,8

A2:S20

Support arm lower control

Hall sensor

5,7.8

Y41

Support arm lower -hydraulic control

Magnetic valve

A3:OUT.SUPPORT ARM LOWER VALVE

7,8

Y52

Support arm / fork lift selection

Magnetic valve

A3:OUT. FORK/ SUP.ARM VALVE

7,8

S31

Support arms at top supervision

Inductive proximity switch

A1:INP.SUPPORT ARM AT TOP

7,8 10

S90

Support arms at bottom supervision

Inductive proximity switch

A1:INP.SUPPORT ARM AT BOTTOM

7,8,10

Pozostale R1

Power supply

PTC-resistor 10 Ohm

X41

CAN communication (external)

Connection point

X9

CAN communication (extra I/O)

Connection point

Footnotes to the table above: 1. Situated in the tiller arm handle and communicates via the CAN bus 2. The steering servo controller, servo motor and mechanics are integrated into one single unit.

3. Optional function © TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 5

Electrical systems – 5000 Equipment list and electrical diagram T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

4. S18:1 represents the left side button and S18:2 represents the right side button.

5.These inputs signals are processed directly via Hall effect sensors mounted on the A2 card and are handled via the CAN bus.

6. Speed control signals from L1 are processed by Hall element sensors mounted on the A2 card. Sensors A2:S1-9 control speed control signals for driving in fork direction. Sensors A2:S10-18 control speed control signals for driving in drive wheel direction.

7. Signals to/ from these elements can be checked via the Built-in Test function. See “12.6.5Built-in Test Function” on page 44 8. Only valid for truck with support arm lift 9. Output is low when sensor is activated.

10. Output is high when sensor is activated.

12- 6

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.1 Schematy elektryczne 1 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 7

Electrical systems – 5000 Equipment list and electrical diagram T-code 789, 791

Valid from serial number 711956-

Date 2004-12-20

Order number 222641-040

12.2.2 Schematy elektryczne 2 z 15

12- 8

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.3 Schematy elektryczne 3 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 9

Electrical systems – 5000 Equipment list and electrical diagram T-code 789, 791

Valid from serial number 711956-

Date 2004-12-20

Order number 222641-040

12.2.4 Schematy elektryczne 4 z 15

12- 10

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.5 Schematy elektryczne 5 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 11

Electrical systems – 5000 Equipment list and electrical diagram T-code 789, 791

Valid from serial number 711956-

Date 2004-12-20

Order number 222641-040

12.2.6 Schematy elektryczne 6 z 15

12- 12

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.7 Schematy elektryczne 7 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 13

Electrical systems – 5000 Equipment list and electrical diagram T-code 789, 791

Valid from serial number 711956-

Date 2004-12-20

Order number 222641-040

12.2.8 Schematy elektryczne 8 z 15

12- 14

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.9 Schematy elektryczne 9 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 15

Electrical systems – 5000 Equipment list and electrical diagram T-code 789, 791

Valid from serial number 711956-

Date 2004-12-20

Order number 222641-040

12.2.10 Schematy elektryczne 10 z 15

12- 16

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.1 Schematy elektryczne 11 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 17

Electrical systems – 5000 Equipment list and electrical diagram T-code 789, 791

Valid from serial number 711956-

Date 2004-12-20

Order number 222641-040

12.2.12 Schematy elektryczne 12 z 15

12- 18

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.13 Schematy elektryczne 13 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 19

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.14 Schematy elektryczne 14 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 20

Electrical systems – 5000 Equipment list and electrical diagram Order number 222641-040

Date 2004-12-20

Valid from serial number 711956-

T-code 789, 791

12.2.15 Schematy elektryczne 15 z 15

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

12- 21

Electrical systems – 5000 Functional description T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.3 Functional description means constantly on

means flashing.

This section gives basic electrical descriptions of the truck’s main functions in tabular form. It describes, in simple terms, what happens when performing any of the truck’s main operations.

• Event - The main stages in performing any of the truck’s main functions are referred to as “Events”. Each event is numbered.

• Prior events - Indicates the event number which must have taken place immediately before in order for current event function correctly.

• Action(s) - A required action from the operator for the event to occur • Influencing elements - conditions which must be fulfilled in order for the event to occur. Certain parameter settings may also affect the outcome of the event.

• Resulting conditions - Describes key occurrences which can be checked to confirm operation.

Note that “resulting conditions” show what is expected when no error conditions are present. Items shown in square brackets [ ] refer to electrical component designations as stated in the electrical wiring diagrams.

Unless otherwise stated, high ≈ 24 V and low ≈ 0 V

12- 22

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Functional description Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 18: Functional description Event:

1. Battery connected

Action(s)

Connect the traction battery [X1, G1]

Influencing elements

Main power fuses ok [F1, F3] Operating circuit fuses ok [F50, F51, F52, F53] PTC resistor ok [R1]

Resulting conditions

24V (control) supplied directly to [A2], [A5] and via R1 to [A1], [A3], [A5] Curtis status LED blinks once every 5 seconds.[A1]

Event:

2. Switch on (PIN-code entry)

Prior event(s)

1

Action(s) Enter valid PIN-code and press

[A17]

Influencing elements

Emergency switch-off closed [S21] [INP.SUPPLY +24V] high Tiller arm in drive not activated [S10] [INP.TILLER ARM IN DRIVE POS] low

Resulting conditions

Power lamp and

lights. Main display shows hour meter reading for 4 seconds followed by battery condition as a per-

centage of full charge and

[A6]

Mechanical brake remains on [Y1, A1:OUT.BRAKE] high Main contactor output remains high [A1:OUT.MAIN CONTACTOR] and Main contactor remains open [K10]

Event:

3. Tiller am lowered for driving

Prior event(s)

2

Action(s)

Lower tiller arm handle

Influencing elements

Tiller arm in drive sensor [S10]

Resulting conditions

Tiller arm in drive sensor activates [S10] [INP.TILLER ARM IN DRIVE POS.] high Brake solenoid control [A1:OUT.BRAKE] remains high Brake remains on [Y1] Main contactor output [A1:OUT.MAIN CONTACTOR] goes low Main contactor closes [K10] 24V (power) supplied to [A1],[A3] & [A5]

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 23

Electrical systems – 5000 Functional description T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 18: Functional description Event:

4. Traction, forks first

Prior event(s)

3

Action(s)

Move butterfly [L1] in forks drive direction.

Influencing elements

Butterfly Hall sensors [A2:S10-18] Platform staying down sensor [S19]. Platform not up sensor [S59] Gates up sensor [S53], Gates down sensor [S56] Fork load supervision sensor [B4] Parameter settings. See “12.4Speed limitation” on page 29

Resulting conditions

[A1:OUT.BRAKE A] goes low Brake solenoid control [A1:OUT.BRAKE] goes low & brake coil [Y1] energises, mechanical brake releases Current fed to traction motor field winding (S2 +ve and S1 -ve) Pulsed current fed to traction motor armature proportional to butterfly deflection

Event:

5. Traction, drive wheel first

Prior event(s)

3

Action(s)

Move butterfly [L1] in drive wheel drive direction.

Influencing elements

Butterfly Hall sensors [A2:S1-9] Platform staying down sensor [S19]. Platform not up sensor [S59] Gates up sensor [S53], Gates down sensor [S56] Fork load supervision sensor [B4 See “12.4Speed limitation” on page 29

Resulting conditions

[A1:OUT.BRAKE A] goes low Brake solenoid control [A1:OUT.BRAKE] goes low & brake coil [Y1] energises Current fed to traction motor field winding (S2 -ve and S1 +ve) Pulsed current fed to traction motor armature proportional to butterfly deflection

Event:

6. Neutral braking

Prior event(s)

4 or 5

Action(s)

Let butterfly [L1] return to neutral position.

Influencing elements

Fork load supervision sensor [B4] Parameter settings

Resulting conditions

Traction motor [M1] acts as generator and via transistor controller [A1] converts the trucks energy of motion into electrical energy thus reducing the truck’s speed. The excess electrical energy is fed back to the battery helping to recharge it [G1].

The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes to a complete stand still

12- 24

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Functional description Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 18: Functional description Event:

7. Reverse braking

Prior event(s)

4 or 5

Action(s)

Move butterfly [L1] so as to reverse the direction of travel

Influencing elements

Man-on platform switch [S19] Fork load supervision sensor [B4]

Resulting conditions

Traction motor [M1] acts as generator and via transistor controller [A1] converts the trucks energy of motion into electrical energy thus reducing the truck’s speed. The excess electrical energy is fed back to the battery helping to recharge it [G1]. The braking effect increases the more the butterfly is deflected The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes to a complete stand still

Event:

8. Mechanical brake operation

Prior event(s)

4 or 5

Action(s)

Move tiller arm handle to upper or lower position

Influencing elements

Tiller arm in drive sensor goes low [S10]

Resulting conditions

The mechanical brake [Y1, A1:OUT.BRAKE A] activates

Event:

9. Steering

Prior event(s)

3

Action(s)

Steer tiller unit handle to left or right

Influencing elements

Steering angle potentiometer [R2] Steering reference switch [S65, A5:INP.REFERENCE SWITCH] Man on platform switch [S19, A1:INP.DRIVER ON PLATFORM]

Resulting conditions

Steer servo motor positions drive wheel according to tiller handle’s deflection [A5, M6] (See section “12.3.1 Description of steering system” )

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 25

Electrical systems – 5000 Functional description T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 18: Functional description Event:

10. Fork lifting

Prior event(s)

2

Action(s)

Operate fork lift control [R14] in lifting direction

Influencing elements

Forks lift control [R14] Battery status ok (>20% charge left) Gates up sensor [S53], Gates down sensor [S56] Max permitted lift height with gates up sensor [S33/2] Support arms at bottom sensor [S90] Fork load supervision sensor [B4]

Resulting conditions

Current fed to lift motor [M3] field winding (S2 -ve and S1 +ve) Pulsed current fed to lift motor armature proportional to lift control deflection Pump motor [M3] operates

Event:

11. Fork lowering

Prior event(s)

2

Action(s)

Operate fork lift control [R14] in lowering direction

Influencing elements

Forks lift control [R14]

Resulting conditions

[A1:OUT.MAGNET VALVE PWM] sends pulsed signal to fork lowering hydraulic valve [Y10]. Valve opens proportionally to signal allowing a variable lower speed.

Event

12. Support arms lifting (7SLL12.5F/16F))

Prior event(s)

2

Action(s)

Operate support arm lift button [A2:S19] i

Influencing elements

Support arm lift button [A2:S19] Battery status ok (>20% charge left) Support arm at top sensor [S31] Fork load supervision sensor [B4]

Resulting conditions

[A3:OUT.FORK/SUP:ARM VALVE] goes low & valve Y52 operates A set current is fed to lift motor [M3] field winding (S2 -ve and S1 +ve) Pulsed current fed to lift motor armature Pump motor [M3] operates & hydraulic pressure fed to support arm lift circuit

12- 26

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Functional description Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 18: Functional description Event

13. Support arms lowering (7SLL12.5F/16F)

Prior event(s)

2

Action(s)

Operate support arm lower button [A2:S20] i

Influencing elements

Support arm lower button [A2:S19] Support arm at bottom sensor [S90]

Resulting conditions

[A3:OUT.SUPPORT ARM LOWERING VALVE] goes low & valve Y41 operates support arm lift circuit pressure is drained to tank and support arms lower.

Event

14. Powertrak operation

Prior event(s)

10 / 11 / 12 / 13

Action(s)

Lift a load on forks and/or support arms

Influencing elements

Max permitted lift height for Powertrak sensor [S33/2]

Resulting conditions

[A1:OUT POWERTRAK FILL-UP VALVE] low & [A1:OUT POWERTRAK DRAIN] high while fork lift height <1,8 m Lift pressure applied to Powertrak cylinder.

Fork lift height goes over 1.8m and [S33/2] [A3:INP LIFT LIMIT, <1,8M] goes low [A1:OUT POWERTRAK DRAIN VALVE] then goes low and valve [Y58] opens thus draining pressure from Powertrak cylinder

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 27

Electrical systems – 5000 Functional description T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.3.1 Description of steering system The servo steering system on this truck comprises a synchronous DC motor [M6] with permanently magnetized rotor which is also brushless.

This type of motor is ideal for truck steering applications due to light weight and high torque even from stand still. The motor directly drives the drive wheel gear unit, via an integrated 2 stage planetary gear. The steer motor is controlled by a fully electronic 4-quadrant regulator [A5] which is mounted directly in the servo motor casing. Hall sensors (H) in the servo motor provide timing information for commutation control.

The sensors also provide the steer servo with position information.

A double potentiometer [R2] situated below the tiller arm mounting provides steer angle information from the operator. Every time the traction battery is connected and the truck switched on the steer system performs a reference search for "straight ahead" position. An inductive proximity switch [S65] mounted in the final drive gear mounting plate registers a change in state (either ON to OFF or OFF to ON depending on drive wheel's initial position) and feeds this signal back to the steer servo. From this point on, the steer servo "knows" the position of the drive wheel. Only after the traction battery is next disconnected, is a new reference search carried out.

The steer servo communicates fully via the CAN bus. All steer servo errors codes are transmitted to the truck's control system and displayed on the tiller unit's display.

12- 28

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Speed limitation Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

12.4 Speed limitation The truck’s maximum speed is limited by a combination of, fork lift height, fork load and operator’s driving position. Driver parameter settings also affect maximum speed. See “12.8.6Summary of driver parameters” on page 54 for more information. The table below summarises the speed limitations and assumes that all relevant driver parameters are set to 100%. Note that the speeds given are nominal.

Table 19: Summary of speed limitations Load (kg)

Fork lift height (mm)

Driver position or mode

Max. speed (km/h)

<800

<1800

Platform down, gates up (transportation mode)

8

Platform down, gates down

6

Platform up, gates down (pedestrian mode)

6

Platform up, gates up

0

Platform down, gates up

0

Platform down, gates down

5

Platform up, gates down (pedestrian mode)

5

Platform up, gates up

0

Platform down, gates up (transportation mode)

8 - 7a

Platform down, gates down

6

Platform up, gates down (pedestrian mode)

6

Platform up, gates up

0

Platform down, gates up (transportation mode)

0

Platform down, gates down

5

Platform up, gates down (pedestrian mode)

5

Platform up, gates up

0

<800

>800

>800

>1800

<1800

>1800

-

-

Turtle mode is controlled by parameter # 7

-

-

Snail speed mode

≈ 1,6

-

-

Error / Warning code mode

≈ 2,5

a.Max. speed determined by actual load and will ramp between 8 & 7 km/h

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 29

Electrical systems – 5000 Hour meter and battery condition T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.5 Hour meter and battery condition At switch on, the hour meter is displayed and the hour meter symbol lights for 4 seconds. Fig. 1 The display will then change to show the battery’s remaining capacity expressed as a percentage of full charge and the battery symbol lights.

Fig. 2

Fig. 1

Fig. 2

The truck’s control system stores 5 different elapsed time values in units of hours. The time value normally shown depends on the setting of service parameter #20. (See “# 20 - Hour meter selection” on page 60). However, any of these time values can be temporarily displayed on the hour meter. To choose which value to display carry out the following procedure: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold S18 depressed until “H” is displayed, then release S18. Fig. 3

Hour meter symbol lights.

Fig. 3

12- 30

The different hour meter modes are displayed by repeatedly operating speed control L1. The actual time value will be displayed momentarily after the mode is selected.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Hour meter and battery condition Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 20: Hour meter modes Description

Display

Key time: Total time truck has been switched on Activity time: Combined time either pump or drive motor has been in operation (Default display mode) Drive motor time: Total time drive motor has been in operation Pump motor time: Total time pump motor has been in operation Remaining time to next service (Parameter #25 controls the initial value) See “# 25 - Service interval” on page 61 for more information.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 31

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.6 Diagnostic and troubleshooting means constantly on

means flashing.

12.6.1 Fault codes

Fig. 4

The trucks’s electronic control system incorporates built-in fault code display and logging. This capability works as a powerful complement in assessing the cause of eventual truck malfunctions. When a fault code occurs the code number is displayed and the fault condition LED flashes. Fig. 4.

The codes can be broadly divided into two groups: • Caution codes - denoted by prefix “C”. These codes alert the operator to the presence of a caution condition. Caution codes in the range C50 to C99 will limit the truck’s maximum speed to creepspeed. The conditions which cause such codes can usually be easily remedied without further attention. Caution codes C19 to C43 are not stored in the code history log.

• Error codes - denoted by prefix “E”. These codes alert the operator to the presence of a fault condition in the truck. Error codes E100 and higher will stop all truck driving functions until the error code is cleared.

The first time any fault code is displayed it is advisable to check if the condition persists by switching the truck off completely. i.e. disconnect the battery and then switch back on. Check to see if the fault code is again displayed.

12.6.2 Fault code history Up to 50 of the most recently occurred fault codes will be stored in a log along with the hour meter reading when the fault occurred. When the fault code log is displayed, it shows the fault codes in chronological order with the newest code first.

Carry out the following to display the fault code log: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press Fig. 5 12- 32

© TIEE SARL

on the keypad.

• Hold S18 depressed until “E” is displayed, then release S18. Fig. 5 Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Fault symbol lights.

The most recently occurred error will be displayed. The display will alternate between the fault code and the hour meter reading when the fault occurred. If the fault code log contains more than one fault code, these can be displayed by repeatedly operating the speed control L1.

12.6.3 List of fault codes NOTE! The text “Restart the truck!” in the following tables always means switching the truck off completely by removing the battery connector [X1], reconnecting and then switching the truck on again.

Table 21: List of fault codes Code

Description

Possible cause / Hint or Solution

C3

TLS: Shock sensor values above limit

A shock sensor has reported values above limit.

Driving may be too tough Make sure that the shock sensor limits are correct.

Make sure that the shock sensor is correct located./Brake activates and stops the truck. A TLS reset command activates the truck.

C4

TLS: Truck set out of use

Possibility to set the truck “out of use” with a TLS command. / Truck can´t be used before a TLS command sets the truck “in use”

C19

Default parameter value warning

"Certain parameter value(s) may be outside their normal maxmin range. These parameter values will be reset to their default values. / " It may be necessary to check the settings of all parameters if this code is displayed

C20

Butterfly warning

Problem with butterfly sensor [L1].

Butterfly may have been activated during start up or faulty sensor(s).[A2] / Check action of butterfly

C21

Lift/Lower control warning

Lift / Lower control for the forks may have been activated during start up or faulty sensor / Check action of Lift / Lower control

C28

Emergency switch warning

Emergency switch activated [S21] No voltage supply to Traction transistor regulator [A1].

Harness problem. / Check emergency switch is not depressed.

Check wiring.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 33

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 21: List of fault codes Code

Description

Possible cause / Hint or Solution

C29

Service time warning

Next service is due / Check service counter. It may not be reset after latest service See “# 25 - Service interval” on page 61 for setting of parameter #25.

C30

Max.fork load exceeded

The load on the forks has exceeded the truck’s classified lift capacity. / Ensure the load to be lifted does not exceed the classified lift capacity Check that lifting is not performed against the mechanical stop.

This applies to both fork lifting and support arm lifting.

Ensure the mast sections and lifting chains move freely Check pressure sensor o/p [B1:INP.PRESSURE LIFT] voltage ≈ 0,5V with no load & lowered forks / support arms Perform a Max. load calibration See “# 36 - Calibrate” on page 62

C35

Steer servo -Internal temperature warning

The internal temperature of the steer servo[A5] has exceeded +68° C / Steering may be too intensive

C41

Battery undervoltage warning -traction transistor regulator

Traction transistor regulator[A1] has detected battery voltage < 17V Battery parameter not correctly adjusted. See “# 21 - Battery size” on page 60 for setting of parameter #21 Battery due for charging

C42

Battery overvoltage warning -traction transistor regulator

Traction transistor regulator[A1] has detected battery voltage > 33V / Can be caused by fully-charged battery and energy return feed to the battery during heavy reverse braking

C43

Traction transistor regulator thermal cutback

Driving may be too intensive Defective Traction transistor regulator [A1]

C47

Battery under voltage warning -pump transistor regulator

Pump transistor regulator[A3] has detected battery voltage < 17V / Battery parameter not correctly adjusted. See “# 21 - Battery size” on page 60 for setting of parameter #21 Battery due for charging

C48

Battery overvoltage -pump transistor regulator

Pump transistor regulator[A3] has detected battery voltage > 33V

C49

Pump transistor regulator thermal cutback

Lifting may be too intensive Defective pump transistor regulator [A3]

C60

Pressure sensor error, Lift system

Voltage at i/p [B4:INP.PRESSURE LIFT] outside range +0,3V to +7,7V / Check pressure sensor [B4] wiring and function Defective pressure sensor [B4]

12- 34

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 21: List of fault codes Code

Description

Possible cause / Hint or Solution

C61

Pressure sensor error powertrak

Voltage at i/p [B5:INP.PRESSURE PT] outside range +0,3V to +7,7V / Check pressure sensor [B5] wiring and function Defective pressure sensor [B5]

C62

Powertrak error

Unexpected pressure level in Powertrak system / Check wiring & connections to Powertrak related components [Y58], [Y59], [B4] & [B5] Mechanical failure in powertrak valves

C63

Powertrak valve output error

Valve defective [Y59] or fault in o/p from traction transistor regulator [A1:OUT.POWERTRAK FILL UP VALVE]

C64

Powertrak valve output error

Valve defective [Y58] or fault in o/p from traction transistor regulator [A1:OUT.POWERTRAK DRAIN VALVE]

C 70

Pump motor field circuit open

Shunt field open [M3], harness broken, pump transistor regulator defective [A3]./ Check wiring and connections to shunt field [M3]

C 71

M minus error - Pump transistor regulator [A3]

Problem with switch transistor in armature circuit inside Pump transistor regulator [A3] Defective Pump transistor regulator [A3].

C 72

Current sensor error Pump transistor regulator [A3]

Armature current sensor fault in pump transistor regulator [A3] Defective pump transistor regulator [A3]

C73

CAN timeout error -Pump transistor regulator [A3]

Pump transistor regulator [A3] reports unexpected loss of data flow from tiller head [A2]./ Check CAN bus signal cables and connections.[A3, A2] Restart the truck

C74

Data not received - Pump transistor regulator [A3]

Data from [A3] not received by [A2] Broken CAN wire / Check CAN bus signal cables and connections.[A3, A2] Restart the truck

C75

Transmission to Pump transistor controller[A3] failed

Data from [A2] not received by [A3] Broken CAN wire Defective Pump transistor regulator [A3] /Check CAN bus signal cables and connections.[A3, A2] Restart the truck

C76

Pump transistor regulator [A3] incompatible with the type of truck

Incorrect type of pump transistor regulator is fitted / Check correct transistor regulator type is fitted

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 35

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 21: List of fault codes Code

Description

Possible cause / Hint or Solution

C77

Lift potentiometer [R14] connection error

Analogue potentiometer control not detected. / Check wiring & connections between potentiometer [R14] & [A2]

C80

Steer servo - Reference sensor current error

Steer servo reference current < 0,1A Supply fault to home reference sensor [S65] Defective home reference sensor [S65] / Check wiring to sensor

C81

Steer servo - Reference sensor supply error

Sensor supply from Defective home reference sensor [S65] / Check supply voltage is 12V between wires 95-97 / Check Wiring to sensor Check condition of [F50]

C82

Steer servo - drive current warning

Steer servo drive current is exceeding 80% of maximum.

Steering activity may be too intensive See also code E132

E90

Extra I/0 (0) CAN communication error

Data from extra I/0 box (0) not received by [A2] / Check CAN bus cables and connections. [A2] Restart the truck

E91

Extra I/0 (1) CAN communication error

Data from extra I/0 box (1) not received by [A2] / Check CAN bus cables and connections. [A2] Restart the truck

E92

Configuration error Extra I/0 (0)

Faulty configuration of option in extra I/0 box (0) / Check allocation of outputs in I/0 extension box (0).

E93

Configuration error Extra I/0 (1)

Faulty configuration of option in extra I/0 box (1) / Check allocation of outputs in I/0 extension box (1).

E100

Steer servo - configuration error

Presence of steer servo and parameter #38 setting do not match/ Ensure parameter #38 is set correctly

E101

Traction transistor regulator [A1] incompatible with the type of truck

Incorrect type of traction transistor regulator is fitted / Check correct transistor regulator type is fitted

E104

Brake switch transistor output in Traction transistor regulator [A1] shorted

Defective Traction transistor regulator [A1] / Check cables and magnetic coil to the brake [Y1] Check parameter 22

E106

Digital output fault or field current limit

Attempting to drive more current than specified from outputs.

OR problem regulating field current.

Internal Traction transistor regulator fault. [A1]

12- 36

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 21: List of fault codes Code

Description

Possible cause / Hint or Solution

E107

Main contactor not activated [K10]

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

Contactor control wire not connected.

Contactor drive output in controller faulty (off) / Check main contactor tips. Check control wires to main contactor.

Check contactor drive output goes low. [A1]

E108

Main contactor tips welded or open circuit in coil.[K10]

Main contactor tips welded.

Contactor drive output in controller faulty (on) / Check main contactor tips Check contactor drive output goes high. [A1]

E110

Fault in armature current reading

Possible defect in the transistor regulator [A1].

Can be caused by excessive moisture inside regulator. / Restart the truck

E112

Steer servo- wheel position error

Error when comparing actual wheel position (reference sensor signal) with steer servo’s calculated position. / Check reference sensor[S65] functions correctly Check steer servo pinion is not loose and in contact with drive unit’s gear ring Restart the truck

E113

Unspecified steer servo fault

Control system has detected a fault condition but is unable to ascertain the exact cause. / Restart the truck

E114

Steer servo phase error [A5, M6]

Loss of motor phase to steer servo motor. / Check internal motor cable connections in steer servo[A5, M6]

E115

Steer servo initialisation error [A5]

Faulty Servo [A5] Internal logical fault Wrong parameters / Restart the truck

E116

Steer servo checksum error [A5]

Can occur after new firmware has been loaded into truck / Restart the truck

E117

Steer servo communication error

Shall not occur under normal conditions./ Contact support organisation

E118

Command mode error

Shall not occur under normal conditions./ Contact support organisation

E119

Steer servo error during homing operation (Time out)

Home position (steering straight) not achieved within preset time.

Home reference sensor [S65] not adjusted correctly Faulty reference sensor / Check reference sensor gap is adjusted correctly, check wiring to sensor

E120

Steer servo- potentiometer error

Comparison of voltages between IN_0 & IN_1 is out of range. / Check potentiometer inputs

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 37

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 21: List of fault codes Code

Description

Possible cause / Hint or Solution

E121

Steer servo error -steering angle value check

Restart the truck Check that sum of voltages between wire nos.

92-94 and 93-94 ≈ 5V Re calibrate steering (See “# 36 - Calibrate” on page 62)

E122

Steer servo -reference supply out of range

Defective steer servo [A5] / Check voltage between wire nos.

91-94 = 4,5 to 5,5 V

E123

Steer servo - Hall sensor fault

Intermittent contacts inside steer servo Defective steer servo [A5] / Check internal connections from Hall sensors to main circuit board in steer servo [A5]

E124

Steer servo - overvoltage [A5]

May occur when performing heavy reverse braking on newly charged battery (Voltage exceeded 39V) / Restart the truck

E125

Steer servo - internal short circuit [A5, M6]

Defective steer servo [A5,M6] / Check wiring for short-circuit Restart the truck

E126

Steer servo - current offset error [A5, M6]

Defective steer servo [A5,M6] / Restart the truck

E127

Steer servo - temperature error[A5, M6]

Steer servo internal temperature outside range -40 to +85º C Steering activity may be too intensive Defective steer servo [A5,M6] / Restart the truck (See also code C35)

E128

Not applicable in this truck

-

E129

Steer servo - supply undervoltage

Battery charge too low Intermittent connection in servo supply circuit [A5] Steer servo fuse [F52] faulty or blown. / Check condition of Fuse [F52] Charge battery

E130

Steer servo - analogue steer signal input fault

Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5] / Check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.

E131

Steer servo - analogue steer signal input 0 fault

Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN0] / Check 0,4 to 4.8V between wires 94-93, check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.

12- 38

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 21: List of fault codes Code

Description

Possible cause / Hint or Solution

E132

Steer servo - current limit reached

Output current to steer motor exceeding 80% of maximum for longer than 5 seconds.

Steered portion of drive unit not moving freely./ Check for free movement of drive wheel on floor. Check steering drive train is free of dirt or other foreign objects.(See also code C82)

E133

Steer servo - analogue steer signal input 1 fault

Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires 94-92 , check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.

E134

Steer servo - analogue steer signal input short circuit

Faulty steer angle potentiometer [R2] or wiring short circuit between [A5:INP.A_IN1 and INP.A_IN0] / Check wiring to potentiometer [R2], Move tiller handle in all directions to ensure no wiring problems exist.

E135

Steer servo - offset value error

Voltage difference between [A5:INP.A_IN1 and INP.A_IN0] is too great Requires re calibration / Re calibrate steering (parameter #36) See “# 36 - Calibrate” on page 62

E136

Steer servo - steer angle potentiometer error

Calibrated neutral position value is out of range.

Defective potentiometer [R2] / Ensure potentiometer is fitted correctly.

Re calibrate steering (parameter #36). See “# 36 - Calibrate” on page 62

E137

Steer servo - checksum error on received data

Faulty wiring / Check CAN bus signal cables and connections.[A5, A2] Restart the truck

E138

CAN data not received

Data from traction transistor regulator not received by [A2] Faulty wiring / Check CAN bus signal cables and connections.[A1, A2] Restart the truck

E139

Steer servo - data transmission to servo failed

Faulty wiring / Check CAN bus signal cables and connections.[A5, A2] Restart the truck

E140

Checksum error

Faulty internal micro controller [A2], faulty software

E141

Software problem

Faulty internal micro controller [A2], faulty software / New software may need loading via CAN

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 39

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 21: List of fault codes Code

Description

Possible cause / Hint or Solution

E150

Data not received - Traction transistor controller

Traction transistor regulator [A1] does not answer, bad connections or faulty Traction transistor regulator [A1].

E151

Transmission to traction transistor regulator failed

Broken CAN-wire.

Traction transistor regulator [A1] defective

E157

Bus off error

CAN-bus problem, wiring harness or hardware problem.[A2] / Check CAN wiring

E159

Over-run error

CAN-bus problem, wiring harness or hardware problem.[A2] / Check CAN wiring

E160

Error -safety switch against collision

Error in Hall sensor for safety switch against collision “belly button”/ Check switch is not activated.

E200

Drive motor field circuit open

Shunt field open [M1], harness broken, Traction transistor regulator defective [A1]. / Check wiring and connections to shunt field [M1]

E201

M minus error

Problem with switch transistor in armature circuit inside Traction transistor regulator [A1] Defective Traction transistor regulator [A1].

E202

Current sensor error - traction transistor regulator [A1]

Armature current sensor fault in Traction transistor regulator [A1].

Defective Traction transistor regulator [A1].

E214

CAN-timeout error - traction transistor regulator [A1]

Traction transistor regulator reports unexpected loss of data flow from tiller head [A2]./ Check CAN bus signal cables and connections

12- 40

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

12.6.4 Transistor regulator troubleshooting and error codes

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

General Curtis 1243 is a regulator [A1] & [A3] 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.

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

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.

Transistor regulator errors The table below depicts the error codes that may be shown by the STATUS LED or read using the hand-held terminal.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 41

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 22: Transistor regulator error code STATUS LED

Hand-held terminal display

Explanation

Possible cause

LED off

-

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

-

Defective regulator

Defective regulator

1,1

¤¤

CURRENT SHUNT FAULT

Built-in current shunt defective

Armature current sensor fault in motor controller.

1,2

¤ ¤¤

HW FAILSAFE

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs.

Problem to regulate field current.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shunt field open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

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

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

1. Battery voltage > 33 volts

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Over-/under-temperature reduction

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

12- 42

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Resetting errors To reset an error turn S17 to off and then on again.

Error

Reset when

OVERVOLTAGE

Battery voltage falls below 33 V

THERMAL CUTBACK

The temperature is within allowed range

THROTTLE FAULT 1, 2

Error has been fixed

LOW BATTERY VOLTAGE

When battery voltage exceeds 16 V

Safety 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.

WARNING! Risk of short-circuiting.

Remove all watches, jewellery and always use insulated tools only.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 43

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.6.5 Built-in Test Function The truck’s control system provides a number of useful built-in test functions • Connect CAN-key in X41 and press

[A17].

• Battery status is shown.

• Press Horn S18 repeatedly to choose Built-in Test mode.

NOTE! All truck functions operate as normal in this mode. Care should be taken when operating the truck and reading the display at the same time!

Table 23: Built-in test modes Flashing symbol

Displayed data

Unit

Speed reference value sent to traction transistor controller.

-

Lift / lower command value sent to pump transistor controller.

12- 44

© TIEE SARL

Main control card signals [A2) See Table 26:

-

Inputs / outputs traction transistor regulator & pump transistor regulator. See Table 24: & Table 25:

-

Battery voltage

V

Armature current to traction motor [M1]

A

Field current to traction motor [M1]

A

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 23: Built-in test modes Flashing symbol

© TIEE SARL

Displayed data

Unit

Armature PWM to traction motor [M1]

%

Armature current to pump motor [M3]

A

Field current to pump motor [M3]

A

Armature PWM to pump motor [M3]

%

Signal from pressure sensor [B4] (Hydraulic pressure in lift circuit)

bar

Signal from pressure sensor [B5] (Hydraulic pressure in powertrak circuit)

bar

Maximum lift pressure setting.

bar

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 45

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Digital inputs/outputs test mode In the digital inputs/outputs mode, the operation of both inputs and outputs can be checked by checking the individual segments of the main display as given in the following tables.

Table 24: Transistor regulator inputs Function

Segment

Tiller arm in drive pos.[S10], input A1:INP.TILLER ARM IN DRIVE POS: Platform not folded up switch [S59], input A1:PLATFORM NOT FOLDED UP Man on platform switch [S19], input A1:INP.MAN ON PLATFORM Gates up switch [S53], input A1:GATES UP

Gates down switch [S56], input A1:GATES DOWN Support arms at top switch [S31], input A3:INP.SUPPORT ARM AT TOP (7SLL12.5F/16F) Support arms at bottom switch [S90], input A3:INP.SUPPORT ARM AT BOTTOM (7SLL12.5F/16F) Forks < 1800mm [S33/2] magnetic switch , input A3:LIFT LIMIT <1,8M Powertrak lift limit [S33/1] magnetic switch, input A1:LIFT LIMIT POWERTRAK 1,<1,8M Powertrak fill up valve watchdog (Senses whether Y59 is drawing current correctly should normally show the inverse of output signal) Powertrak drain valve watchdog (Senses whether Y58 is drawing current correctly should normally show the inverse of output signal)

12- 46

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 25: Transistor regulator outputs Function

Segment

Signal horn [H1], output A1.SIGNAL HORN

Brake solenoid [Y1], output A1.BRAKE RELEASE Main contactor [K10], output OUT.MAIN.CONTACTOR Powertrak fill up valve [Y59], output A1:OUT.POWERTRAK FILL UP VALVE Powertrak drain valve [Y58], output A1:OUT.POWERTRAK DRAIN VALVE Fork / support arm valve [Y52], output A3.OUT.FORK SUP.ARM VALVE (7SLL12.5F/16F) Support arm lower valve [Y41], output A3.SUPPORT ARM LOWERING VALVE (7SLL12.5F/16F)

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 47

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 26: Main control card signals [A2] Function

Segment

Support arms up [A2:S19] 7SLL12.5F/16F)

Support arms down [A2:S20] (7SLL12.5F/16F)

Signal horn [S18]

Option switch -lefthand left

Option switch -lefthand middle

Option switch -lefthand inner

Option switch -righthand inner

Option switch -righthand middle

Option switch -righthand outer

12- 48

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Diagnostic and troubleshooting Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

12.6.6 Display test mode The digital display [A6] itself can be tested to verify all the segments of the display function correctly.

To select Display test mode carry out the following procedure: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press Fig. 6

on the keypad.

• Hold S18 depressed until “d” is displayed, then release S18. Fig. 6 All number segments on the display and symbol lamps should flash sequentially. Fig. 7

Fig. 7

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 49

Electrical systems – 5000 Part numbers T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.7 Part numbers To select part number display mode carry out the following procedure: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold S18 depressed until “Pn” is displayed, then release S18. Fig. 8 Fig. 8

The display will now show the part numbers for the control program, the hardware part number and hardware serial number.

The part numbers are displayed by repeatedly operating speed control L1. The display will first show the starting portion of the number then the ending portion.

Table 27: Part numbers Display

Meaning Software (Control program) part number

Hardware part number

Hardware serial number

12- 50

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

12.8 Parameters 12.8.1 General The truck’s control system stores a number of parameters. These parameters are used to configure the truck for correct operation in the particular application for which it was designed. The parameters are divided into two groups, Driver parameters and Service parameters.

• Driver parameters (2 to 7) - These parameters are used to tailor the driving characteristics of a truck for a specific driver or operation. Up to 10 sets of driver parameters can be stored. Driver parameters can be adjusted directly without the requirement for a suitable CAN service key.1 • Service parameters (10 to 39) - These parameters are used to tailor the truck’s performance / operation characteristics and include all other parameters not designated as driver parameters. Service parameters can ONLY be adjusted when a suitable CAN service key is plugged into the truck.2

12.8.2 Viewing parameters -CAN key not connected To select Parameter display mode carry out the following procedure: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold S18 depressed until “P” is displayed, then release S18. Fig. 9

Fig. 9

Parameters symbol lights.

The different parameters are now displayed by repeatedly operating speed control L1. Driver parameters can be both viewed and changed.1

1.Driver parameters can only be set without a CAN key if parameter #39 is set to value 3. See “# # 39 - Log-in method & operator parameter access” on page 65 2.Service parameters can be viewed without a CAN key being plugged in but they cannot be adjusted. © TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 51

Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.8.3 Viewing parameters -CAN key connected • Ensure the battery is connected.

• Connect a suitable CAN-service key to X41.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second and then press on the keypad.

• Hold S18 depressed until “P” is displayed, then release S18. Fig. 10

Fig. 10

Parameters symbol lights.

Operating speed control L1 in the forward direction causes the display to show the first set of driver parameters. Continued operation of speed control L1 in the forward direction will then cause display to show the next set of driver parameters (for driver no.2) and so on, up to the last driver (Driver no. 10). See Fig. 11

Driver parameter no.

Parameter set no.

Fig. 11

After the ten sets of driver parameters have been displayed, the trucks service parameters will be displayed when operating the speed control L1 in the forward direction The truck’s service parameters can be displayed first by operating speed control L1 in the backward direction. This will cause parameter #40 to be displayed and then parameter #39 etc.1

1.Certain parameters numbers displayed are not active in this truck model.

12- 52

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

12.8.4 Setting Driver parameters To change the value of a particular driver parameter carry out the following: • Switch on the truck and log in with the appropriate PIN-code. This is important if the truck has more than one set of Driver parameters active. Any changes made will only be in effect when that particular “driver” is logged in.

• Select the required parameter using [L1].

• Press Horn button S18.

Parameter symbol flashes.

.

• Set parameter value by repeatedly operating speed control L1 up or down • Press Horn button S18 once to confirm the new setting.

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing

on the keypad

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

For detailed descriptions and effects of these parameters.see the section “12.8.6Summary of driver parameters” on page 54

12.8.5 Setting Service parameters To set any of the Service parameters, a suitable CAN service key must be plugged into the truck’s external CAN connector [X41]. Service parameters are not driver specific. When a CAN service key is plugged in, it is not necessary to enter a PIN-code prior to pressing on the key pad. Once the CAN service key is plugged in, the procedure is the same as setting Driver parameters.

For detailed descriptions and effects of these parameters see the section “12.8.8Summary of service parameters” on page 56.

NOTE! Truck handling.

Modifying specific truck parameters will change the driving characteristics of the truck.

Do not change any parameters without the necessary know how.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 53

Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.8.6 Summary of driver parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in sections “12.8.2Viewing parameters -CAN key not connected” on page 51 and “12.8.6Summary of driver parameters” on page 54

See also section “12.4Speed limitation” on page 29 for information regarding the maximum speeds of the truck.

Parameter

Table 28: Summary of driver parameters Name

Unit

Min. Max. Step Std. Note

02

Maximum speed, high range

%

10

100

5

100 S 10:

100:

S= maximum speed 03

Maximum acceleration

%

10

100

5

80 A 10:

100:

A= maximum acceleration 04

Neutral braking effect

%

5

100

5

70 F 5:

100:

F= neutral brake force 06

Maximum speed -low range

%

10

100

5

100 S 10:

100:

S= maximum speed 07

Maximum speed- “Turtle”

%

10

100

5

60 S 10:

100:

S= maximum speed

12- 54

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

12.8.7 Description of driver parameters # 2 - Maximum speed, high range Allows adjustment of the maximum speed of the truck in the high speed range. The high speed range is active when the gates are folded out, the platform is down and the forks are below 1,8 m.

# 3 - Maximum acceleration Allows adjustment of the truck’s maximum acceleration. The lower the value of the parameter the longer it takes to accelerate the truck to the demanded speed control lever position [L1].

# 4 - Neutral braking effect Allows adjustment of the neutral braking force applied when speed control lever [L1] returns to the neutral position. The lower the value of the parameter the longer it takes to bring the truck to a standstill.

# 6 - Maximum speed, low range Allows for adjustment of the maximum speed of the truck in the low speed range. The low speed range is active when the gates are folded down and ptatform folded up. This parameter also affects the stacking speed mode when the forks are above 1,8 m.

# 7 - Maximum speed, “Turtle” mode Allows for adjustment of the maximum speed of the truck in the “Turtle” mode.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 55

Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.8.8 Summary of service parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in sections “12.8.3Viewing parameters -CAN key connected” on page 52 and “12.8.8Summary of service parameters” on page 56

Service Manual The CAN service key must be connected to the external CAN connector [X41] before adjusting any Service parameters

Parameter

Table 29: Summary of service parameters Name

Unit Min.

Max.

Step Std. Note

10

PIN-code

-

0

9999

1

1

14

Creep speed

%

-10

10

1

0

PIN code assignment.

NOTE: Not applicable if Parameter #39 has been set to the value 5, 6, 7 or 8.

S -10:

+10:

S= Speed at first sensor 15

Non-configurable options 0 to 9

See Service Manual“12.8.10“Option” Parameters” on page 68

16

Configurable option #1

See “12.8.10“Option” Parameters” on page 68Service Manual

17

Configurable option #2

18

Configurable option #3

19

Configurable option #4

20

Hour meter selection

-

1

5

1

2

Select which hour meter is normally displayed

21

Battery size

-

1

20

1

5

Battery size selection

22

Maximum fork lowering speed

-

64

255

5

180 L 1:

255:

L= max. lowering speed 12- 56

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Parameter

Table 29: Summary of service parameters Name

Unit Min.

Max.

Step Std. Note

23

Fork lower stop ramp

-

20

1

1

7 T 1:

20:

T= Stop ramp time 25

Service interval

h

0

2000

50

100

Setting of service intervaltimer.

35

Log off

min.

0

20

1

20

Time interval to automatic log off

36

Calibrate

-

0

4

1

0

Calibrate fork lift OR steer servo

37

Steering offset

1/10°

-300

300

1

0

Trim steering -300:30° to left 300:30° to right

38

Steer servo activated

-

0

1

1

0

Activates steer servo, when fitted

39

Access code

-

1

12

1

3

State which level of authorization the driver has to the driver parameters. Odd values indicate open operator parameters, while even values indicate that the operator parameters must be opened with a CAN key.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 57

Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.8.9 Description of service parameters # 10 - PIN code NOTE: The functionality of parameter #10 is ignored if the value of parameter #39 has been set to 5, 6, 7 or 8. PIN code input is facilitated via the extended keypad. For detailed information, see the section Extended keypad - General on page 66.

The parameter stores the truck’s active PIN-codes. The truck can store up to ten PIN-codes. Each PIN-code has a set of parameters associated with it, called driver Parameters. Entering a particular PIN-code at start-up will make the selected PIN-code’s driver parameters active.

This allows up to ten operators to individually adjust the characteristics of the truck.

On delivery the truck has one default PIN-code stored which is “1“.

To enter a new PIN-code: • Operate L1 repeatedly in the forward direction to select parameter #10. After one second, the display will show the PIN-code for this driver.

• Repeat the step above until parameter#10 for the next driver is displayed, the display will either show PIN-code for that driver OR “0”(zero).

• Repeat the step above until the PIN-code displayed is “0”(zero) • Press Horn button S18

Parameter symbol flashes.

.

• Operate L1 to set the desired value of the new PIN-code.1 • Press Horn button S18

Parameters symbol lights. (stops flashing).

The new PIN-code has now been entered.

1.Operating L1 lightly will step the value in increments of 1.

Operating L1 fully will step the value in increments of 100 Valid values are 1 to 9999 12- 58

© TIEE SARL

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Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

To remove an existing PIN-code: • Operate L1 repeatedly in the forward direction to select parameter #10. After one second, the display will show the PIN-code for this driver.

• Repeat the step above until the PIN-code to be removed is displayed.

• Press Horn button S18

Parameter symbol flashes.

.

• Operate L1 to set the PIN-code value to “0”(zero).

• Press Horn button S18

Parameters symbol lights. (stops flashing).

The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in Table 18, “Functional description,” on page 23Service Manual (Event 2 -Switch on (PIN code entry) Parameter #10 cannot be displayed without the CAN service key.

# 14 - Creep speed This parameter allows adjustment of the initial speed when the first Hall sensor is activated in the speed control [L1].

#15 - Non-configurable options See “12.8.10“Option” Parameters” on page 68Service Manual

#16 - Configurable option #1 See “12.8.10“Option” Parameters” on page 68Service Manual

#17 - Configurable option #2 See “12.8.10“Option” Parameters” on page 68Service Manual

#18 - Configurable option #3 See “12.8.10“Option” Parameters” on page 68Service Manual

#19 - Configurable option #4 See “12.8.10“Option” Parameters” on page 68Service Manual © TIEE SARL

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Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

# 20 - Hour meter selection This parameter determines which hour meter mode to display during normal use.

Table 30: Hour meter parameter selection Value

Description

Display

1

Key time: Total time truck has been switched on

2

Activity time: Combined time either pump or drive motor has been in operation (Default display mode)

3

Drive motor time: Total time drive motor has been in operation

4

Pump motor time: Total time pump motor has been in operation

5

Remaining time to next service (Parameter #25 controls the initial value) See “# 25 - Service interval” on page 61 for more information

# 21 - Battery size This parameter matches the discharge indication to the characteristics of the battery fitted.

To adjust the disconnection point of the battery discharge indicator, measure 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 1,15 not less.

The acid concentration can vary depending on battery brand.

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© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 31: Battery size parameter Value

Function

4

¦

5

Less discharged

Battery (Ah) 450 Ah

6 7

More discharged

8

∅

250 Ah

9 WARNING! Ensure you have set the parameter correctly.

The battery may otherwise be irreparably damaged.

# 22 - Maximum fork lowering speed This parameter allows adjustment of the maximum fork lowering speed

# 23 - Fork lower stop ramp This parameter adjusts the time interval between releasing the fork lower control and fork lower valve completely closing. Decreasing the parameter value will shorten the time interval resulting in a “harder” fork stop. Increasing the parameter value will make the fork stop more “gentle”

# 25 - Service interval This parameter determines the time value in hours to the next service from 0 to 2000 hours in steps of 50 hours. Whenever this value is changed the timer is reset and will start counting activity time up to the set value. On reaching the set value caution code 29 (C29) will be shown on the display.

# 35 - Log off This parameter determines the time interval before the truck automatically logs off when truck has been idle. A value of “0”(zero) disables the function.

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Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

# 36 - Calibrate This parameter is used to perform calibration of fork lift start point, automatic calibration of maximum load, manual calibration of maximum load and steering servo: NOTE: During calibration, the CAN key must have been connected and the brake applied. The gates and support arms should be in the lowered position.

- Value 0 : No calibration value active (default value) - Value 2 : Valve startpoint for fork lower To optimize the fork lowering function it is necessary to “trim” the control signal for the proportional lowering valve. The point when the valve just starts to open is called the valve start point.

To calibrate the valve start point perform following procedure: • Select parameter #36 and set its value to 2.

• Switch off the truck by pressing

Press

on the keypad.

on the keypad. The display shows

• With a load on the forks (between 300 kg & max. load) lift to approximately 1 m above the floor.

• Press and hold depressed the horn button [S18].

The display will show a counter value representing the valve control signal. After a delay, the forks will begin to lower.

• Release the horn button [S18] immediately the forks begin to lower.

SAFETY NOTE! Releasing the horn button [S18] before the calibration is complete stops all truck’s functions and therefore functions as a “dead man’s handle”

The display will show the calibration value for 3 seconds followed by .

• Switch off the truck by pressing

on the keypad.

• Press on the keypad. Valve start point calibration is now complete - Value 3 : Automatic calibration of maximum load • Select parameter #36 and set its value to 3.

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

• Switch off the truck by pressing

• Press

T-code 789, 791 Date 2004-12-20

on the keypad.

on the keypad. The display shows

• With truck’s rated load + 100 kg on the forks, lift the forks above the initial lift height.

• Press and hold depressed the horn button [S18].

The calibration sequence will now commence. The lift pump motor will start and the forks will lift. During this procedure the system pressure is analysed and the calibrated value is shown on the display. The whole procedure lasts approximately 6 seconds. After the lift pump motor stops the display will show the calibration value for 3 seconds followed by

.

• Release the horn button [S18].

SAFETY NOTE! Releasing the horn button [S18] before the calibration is complete stops all truck’s functions and therefore functions as a “dead man’s handle”

• Switch off the truck by pressing

on the keypad.

Press on the keypad. Automatic max. load calibration is now complete - Value 4 : Manual calibration of maximum load SAFETY NOTE! Under no circumstances shall the maximum load setting be increased above the truck’s rated load capacity + 100 kg.

The maximum load can be set manually in this mode without the requirement of a test load on the forks. It is necessary, therefore to establish the correct value to be entered. See Table 32: below • Select parameter #36 and set its value to 4.

• Switch off the truck by pressing • Press stored.

on the keypad.

on the keypad. The display shows the present value

• Press the horn button [S18]

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

• Set parameter value by repeatedly operating speed control [L1] up or down. See Table 32: • Press the horn button [S18] to store the new value. The display will .

show

Table 32: Man. max.load calibration values Mast

1250

1600

DxTele

≈ 270-280

≈ 270-280

DxHiLo

≈280-290

≈280-290

TxHiLo

≈ 280-290

≈ 280-290

NOTE! The values given in the table above are nominal and based on brand new, cold machines. Minor adjustment of these values may be necessary to compensate for stiffness in mast guides, chains etc.

- Value 1 : Calibrate the steer servo.

The calibration establishes the steering centre position (straight ahead). The system calculates the steering straight position by measuring the difference between “steer full left” and “steer full right”.

Situations which may require that this calibration be performed are: • The truck deviates from a straight line when tiller arm is in neutral position.

• Occurrences of error codes E121 or E135 Before performing this calibration, ensure the drive wheel in centre sensor [S65] is functioning and correctly adjusted.

To calibrate the steer servo perform following procedure: • Select parameter #36 and set its value to 1.

• Switch off the truck by pressing

• Press

on the keypad.

on the keypad. The display shows

• Turn the tiller arm fully to the left until end stop is reached.

• Press horn button [S18]. Display now shows • Turn the tiller arm fully to the right until end stop is reached.

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

• Press horn button [S18]. Display now shows • Switch off the truck by pressing • Press

.

on the keypad.

on the keypad. Steering calibration is now complete

# 37 - Steering offset This parameter can be used to “trim” the actual steering position of the drive wheel in relation to the position of the steering tiller. It should only be adjusted after having performed a steering calibration (parameter #36) A situation which may require that this parameter be adjusted is if the truck tends to drift away from a straight ahead course when driving over longer distances Many factors can contribute to this. It is therefore advisable to make adjustments to this parameter on a trial and error basis.

Whenever this parameter is adjusted, it is necessary to restart the truck. (Disconnect and reconnect battery)

# 38 - Steer servo activated If the truck is equipped with steer servo it must be activated by setting this parameter.

Value 0 - Steer servo not activated (default) Value 1 - Steer servo activated

# # 39 - Log-in method & operator parameter access This parameter determines which function will used for log-in and whether or not the operator is allowed to adjust the operator parameter settings.

• Value 1 - Key switch installed - Operator parameters accessible (without CAN service key).

• Value 2 - Key switch installed - Operator parameters NOT accessible (without CAN service key).

• Value 3 - Keypad (standard 10 PIN codes) - Operator parameters accessible (without CAN service key). NOTE: This is the default setting.

• Value 4 - Keypad (standard 10 PIN codes) - Operator parameters NOT accessible (without CAN service key).

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

• Value 5 - Extended keypad (100 PIN codes) - Operator parameters accessible (without CAN service key).

• Value 6 - Extended keypad (100 PIN codes) - Operator parameters NOT accessible (without CAN service key).

• Value 7 - Extended keypad (100 PIN codes) + TLS - Operator parameters accessible (without CAN service key).

• Value 8 - Extended keypad (100 PIN codes) + TLS - Operator parameters NOT accessible (without CAN service key).

Extended keypad - General The truck can be programmed with a maximum of 10 operator profiles.

The extended keypad then enables a maximum of 10 PIN codes to be assigned to each operator profile. This makes it possible to handle up to 100 different PIN codes.

If the extended keypad is activated, handling of standard PIN codes that are normally accessible via parameter #10 is ignored.

Extended keypad - Programming A group of PIN codes can be made accessible by defining them as a block. Block no. 0 is activated in the default setting. This means that 3 different operator profiles can be accessed from the very start. Activation of other blocks will make all the PIN codes for that block accessible (see Table 34:). If all 10 blocks have been activated, then 10 PIN codes will be accessible for the operator profile.

The truck firmware stores a standard PIN code set as depicted in Table 34: These PIN codes can be adjusted to any value, however, it is advisable to avoid identical PIN codes in different operator profiles.

Starting programming using the extended keypad: • Connect a suitable CAN service key to X41.

• Enter code 341671 and depress

on the keypad.

• Select a programming command from Table 33.

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© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 33. Programming commands - extended keypad Programming

Function

Note

Reset to default settings

Blocks 1 - 9 are disabled. The original PIN codes are reset according to Table 34: B = Block no. 0 - 9

Depress “2” + B +

The PIN codes in the block can be used

B = Block no. 0 - 9

Depress “3” + B +

The PIN codes in the block cannot be used

Depress “4” + B + F + NNNN +

Programming of a new PIN code

B = Block no. 0 - 9 F = Operator profile no. 0 - 9 NNNN = PIN code

Depress “1” +

• Switch off the truck by pressing

on the keypad.

Programming of the extended keypad is now complete.

Parameter #39 must be set to the value 5, 6, 7 or 8 in order for the new PIN codes to take effect.

Perform a test by logging in with one of the new PIN codes. It is important to verify that the correct operator profile is enabled when a specific PIN code is entered, especially if an operator profile has been programmed for a specific application or special goods handling.

Table 34: The table shows the standard PIN codes in the firmware.

These can be activated for use or changed according to the preferences of the operator.

One or more of these blocks can be activated.

When logging in normally, an operator profile is activated when any of the PIN codes in an activated block is entered.

The truck firmware will deny log-in if PIN code “0000” is used.

Service technicians are requested to keep notes on activated blocks, PIN code changes and special operator profile settings.

NOTE: If the extended keypad is reset, this does NOT affect the operator profile settings.

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 34: Standard Pin-code assignment with extended keypad Driver Profile no

Profile 0

Profile 1

Profile 2

Profi le3

Profile 4

Profile 5

Profile 6

Profile 7

Profile 8

Profile 9

Block 0

0000

0001

0002

0003

0000

0000

0000

0000

0000

0000

Block 1

5421

7901

1437

3731

1049

9439

7265

1322

2869

1574

Block 2

1787

4854

2907

9175

5799

1490

3031

7392

5622

5023

Block 3

4659

3174

1026

3815

6703

1179

5152

7514

5668

3215

Block 4

9197

7110

5477

3846

9491

5918

8222

6923

8139

7025

Block 5

2549

6276

9879

9658

1690

4042

5201

9807

4332

9715

Block 6

7474

4142

8620

3754

8432

8788

7430

1948

2595

8527

Block 7

1930

1482

7135

2395

7365

7092

4611

2831

4185

6067

Block 8

2876

4731

1022

5377

3257

7334

9009

7881

8843

7436

Block 9

3242

3162

5878

2828

1910

6907

2136

5730

2957

7691

12.8.10 “Option” Parameters WARNING! Do not attempt to make any adjustments to these parameters unless you have sufficient knowledge of the truck’s options/ modified functions. This manual only covers the truck’s standard equipment. Specially modified trucks may require that you have access to special service information. Improper adjustment of the option service parameters may result in a malfunction.

General Parameters #15 to #19 are reserved in the truck’s control system for extra truck options and/or special product modifications. Normally, these parameters are configured by the manufacturer when the truck is modified or customized. It is advisable to up-load the parameter settings from trucks which are modified. In the event the main control card[A2] is changed, the original parameter settings can be transferred to the new card thus ensuring the special option functions correctly.

Parameter #15 Non-configurable options Up to 16 so called sub-parameters are stored and accessed via parameter #15.These options are either switched ON or switched OFF and require no other adjustments. They are therefore called non-configurable options.

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© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Setting Non-configurable options • Ensure the truck is in parameter mode.

Parameters symbol lights.

• Select parameter #15 using [L1].

The first sub-parameter will be displayed Continued operation of the speed control L1 will display the next subparameter. Note also that only relevant sub-parameters will be displayed.

After 1 second the value of the sub-parameter will be displayed • Press Horn button S18.

Parameter symbol flashes.

.

• Set sub-parameter value by repeatedly operating speed control L1 up or down. See Table 35: for details.

• Press Horn button S18 once to confirm the new setting.

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing

on the keypad

The non-configurable option shall now be activated.

• Ensure the option operates correctly before returning the truck for normal use.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

12- 69

Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

P

Sub-parameter No.

Option name Function ON

Function OFF

Default setting

Table 35: Parameter #15 Non-configurable options Value

Note

0

Snail function

1

0

0

1

Turtle function

1

0

0

2 to 9

N/A at present

-

-

-

Parameter #16 to #19 Configurable options Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a maximum of 4 preprogrammed functions to be activated and configured to suit a specific special option or customization. See “Table 36:Configurable option list” on page 73. They are therefore called configurable options.

• Each parameter can be designated to hold a particular option.

• Each designated option has up to 4 arguments associated with it.

• Each argument holds a value which configures that option.

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

16 - 0 - 1

T-code 789, 791 Date 2004-12-20

Parameter no. (range 16-19) Argument: #0 holds option designator Argument value (range 0 - 63) 0= no option is activated for this parameter 1 to 63 = Preprogrammed option no. See separate table)

OPTION ASSIGNATION

16 - 1- 1

Argument: #1, #2, #3 & #4 hold configurable values for the option Argument value (range depends on argument) Value depends on option and argument selected See separate table OPTION CONFIGURATION

Fig. 12Configurable option layout

Setting Configurable options To activate a configurable option it must first be assigned to one of the parameters #16 to #19. This is achieved by setting argument #0 to the pre-programmed option no. Once it is assigned, the option’s arguments must be configured. This is achieved by setting a value for arguments #1, #2, #3 and #4.

• Ensure the truck is in parameter mode.

Parameters symbol lights.

• Select parameter #16, #17, #18 or #19 using [L1].

Argument #0 will be displayed After 1 second the argument value will be displayed. A value of “0” indicates no option is assigned to this parameter, in which case continued operation of the speed control L1 will display the next parameter • Press Horn button S18.

Parameter symbol flashes.

© TIEE SARL

.

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

• Set argument #0 value by repeatedly operating speed control L1 up or down. Refer to Table 36: • Press Horn button S18 once to confirm the new setting.

Parameters symbol lights. (stops flashing).

• Select argument #1 by operating speed control L1.

After 1 second the value of argument #1 will be displayed.

• Press Horn button S18.

Parameter symbol flashes.

.

• Set argument #1 value by repeatedly operating speed control L1 up or down. Refer to option list Table 36: • Press Horn button S18 once to confirm the new setting.

Parameters symbol lights. (stops flashing).

Adjust arguments #2, #3 and #4 using the same method as above.

• Switch off the truck by pressing

on the keypad

The special option shall now be activated.

• Ensure the special option operates correctly before returning the truck for normal use.

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 36: Configurable option list Argument #1

Argument #2

Argument #3

Argument #4

Argument #0 = 1: Option button controls Spider output 0:Spider 0 1:Spider 1

0:Digital out 1 1:Digital out 2 2: Digital out 3 3: Digital out 4

1-6:option button 1-6

Type of function: 0:momentary 1:toggling

Argument #0 = 2:Reduced drive speed controlled by Spider digital input 0:Spider 0 1:Spider 1

0-7:Digital in 1-8

0-12:reduced speed 40-100% (i.e. 40+5*arg3 e.g.

4: 40+5*4=60%)

0:high speed range 1:low speed range 2: both ranges

Argument #0 = 3:Activate Spider output at certain machine movements 0:Spider 0 1:Spider 1

0:Digital out 1 1:Digital out 2 2: Digital out 3 3: Digital out 4

To select activating movement, see Table 37:

Output mode: 0: steady on 1: flashing 1Hz 2: flashing 2Hz

Argument #0 = 4:Pull main contactor controlled by Spider digital input 0:Spider 0 1:Spider 1

0-7:Digital in 1-8

0-30:Hold time 0-30 minutes

Not used

Argument #0 = 5: Lift/Lower controlled by Spider digital inputs 0:Spider 0 1:Spider 1

0: Lift, digital in 1 Lower, digital in 2 Lower inhibit, in 3 1: Lift, digital in 2 Lower, digital in 3 Lower inhibit, in 4 2: Lift digital in 3 Lower digital in 4 Lower inhibit in 5 3: Lift digital in 4 Lower digital in 5 Lower inhibit in 6 4: Lift digital in 5 Lower digital in 6 Lower inhibit in 7 5: Lift digital in 6 Lower digital in 7 Lower inhibit in 8

0: Lower inhibit disabled 1: Lower inhibit enabled

0: Fork lift/lower 1: Support arm lift/lower

Argument #0 = 6:Lift height restriction with override 0:Spider 0 1:Spider 1 © TIEE SARL

0-7: Restriction switch at digital in 1-8

1-6: Override, option switch 1-6

Not used

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Electrical systems – 5000 Parameters T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Table 37: Option 3 - Movement selection

12- 74

© TIEE SARL

Selected movement

Argument #3

-

0

Driving forward

1

Driving backward

2

Driving forward or backward

3

Lifting forks

4

Lifting forks or driving forward

5

Lifting forks or driving backward

6

Lifting forks or driving forward or backward

7

Lowering forks

8

Lowering forks or driving forward

9

Lowering forks or driving backward

10

Lowering forks or driving forward or backward

11

Lifting forks or lowering forks

12

Lifting forks or lowering forks or driving forward

13

Lifting forks or lowering forks or driving backward

14

Lifting forks or lowering forks or driving forward or driving backward

15

All other movements (AOM)

16

Driving forward or AOM

17

Driving backward or AOM

18

Driving forward or backward or AOM

19

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Electrical systems – 5000 Parameters Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 37: Option 3 - Movement selection

© TIEE SARL

Selected movement

Argument #3

Lifting forks or AOM

20

Lifting forks or driving forward or AOM

21

Lifting forks or driving backward or AOM

22

Lifting forks or driving forward or backward or AOM

23

Lowering forks or AOM

24

Lowering forks or driving forward or AOM

25

Lowering forks or driving backward or AOM

26

Lowering forks or driving forward or backward or AOM

27

Lifting forks or lowering forks or AOM

28

Lifting forks or lowering forks or driving forward or AOM

29

Lifting forks or lowering forks or driving backward or AOM

30

Lifting forks or lowering forks or driving forward or driving backward or AOM

31

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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Electrical systems – 5000 Technical specifications – Curtis 1243 T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

12.9 Technical specifications – Curtis 1243 Table 38: Technical specification -Curtis 1243 Item

Traction

Rated operating voltage

24

24

Volts

Overvoltage limit

33

33

Volts

Undervoltage limit

16

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

500

V AC

Minimum

PWM frequency

16

16

kHz

Max. current of armature winding 1)

200

300

Amps

for 2 minutes

100

100

Amps

for 1 hour

25

35

Amps

for 2 minutes

20

20

Contactor voltage

24

24

Volts

Same as battery voltage

Contactor current

2

2

Amps

Max (current limit at 2.5 amps)

KSI2) input voltage, Min.

16.8

16.8

Volts

KSI2) input current

50

50

mA

Logic input voltage

>7.5; High <1; Low

>7.5; High <1; Low

Volts

Logic input current

15

15

mA

Operating temperature

-40 to +50

-40 to +50

°C

Overtemperature, reduction

85

85

°C

Undertemperature, reduction

-25

-25

°C

Max. current of field winding

Lift

Unit

Explanation

for 1 hour

1 During specific test conditions.

2 Key Switch Input

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Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Hydraulic system – 6000 Hydraulic diagram Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

13- Hydraulic system – 6000 13.1 Hydraulic diagram 13.1.1 7SLL12.5F/16F

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

13- 1

Hydraulic system – 6000 Hydraulic diagram T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

13.1.2 7SLL12.5/16

13- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Hydraulic system – 6000 Hydraulic diagram Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

13.1.3 Main components 1+2 12

11 3

10 4

9 5 8 6

7

Table 39: Main components

© TIEE SARL

Pos. no.

Name

Remarks

1

Motor

Pump motor

2

Pump

3

Pressure sensor B4

Fork lifting/support arm lifting

4

Pressure sensor B5

PowerTrak

5

Overflow valve

Max. 200 bar

6

Air bleeder

Oil replenishment

7

Brake valve for lowering action

8

Proportional valve Y10

Fork lowering

9

Lowering valve Y41

Support arm lowering (7SLL12.5F/16F)

10

Switching valve Y52

Forks/Support arms (7SLL12.5F/16F)

11

PowerTrak valve Y58

Draining of PowerTrak cylinder

12

PowerTrak valve Y59

Replenishment of PowerTrak cylinder

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

13- 3

Hydraulic system – 6000 Hydraulic diagram T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

13.1.4 Description 13.1.1. Lifting system The pump motor (M) features speed control for continuous adjustment of the fork lifting speed. Two non-return valves (CV1,CV2), one for fork lifting and one for support arm lifting, are installed to prevent leakage through the pump. The routing valve (Y52) controls selection of support arm lifting or fork lifting. An overflow valve (RV) prevents overpressure in the system. The pressure sensor (B4) detects the cylinder pressure, providing data about the load on the forks, and it is also used to monitor possible overloading. This allows limitation of the speed when carrying loads heavier than 800 kg and also serves as a warning in case the max. load is exceeded. The proportional valve (Y10) enables stepless adjustment of the speed when lowering the forks. The maximum fork lowering speed is adjusted by a flow limiting valve (SB1). The lowering valve (Y41) controls lowering of the support arms. The maximum support arm lowering speed is adjusted by a flow limiting valve (SB2).

When lifting the forks, if internal leakage via the support arm lifting valve (Y52) should occur this is drained by using the check valve (OR3) and fluid is returned to the reservoir. This prevents unintended support arm movement.

There is no return filter in the hydraulic system.

The PowerTrak system The truck is equipped with the patented PowerTrak system,

which adapts the drive wheel pressure in accordance with the load on the forks and the drive wheel wear. This results in less wear on the drive wheel and promotes safer load handling.

The PowerTrak cylinder operates when the forks have been lifted to maximum 1800 mm, however system operation varies depending on the mast type. The pressure sensor (B5) detects the pressure and is used to control and monitor the PowerTrak system. This prevents excessive drive wheel pressure when handling loads at lifting heights >1800 mm. The PowerTrak system uses two valves (Y58,Y59), one for filling and another for draining. When the machine receives no power, both valves are shut off in order to maintain the pressure in the PowerTrak cylinder. Replenishment and draining are done by switching on the power to either valve. A load sensing valve (LS) controls the amount of pressure applied on the PowerTrak cylinder. The check valve (OR2) operates to dampen cylinder movement.

13- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Hydraulic system – 6000 Hydraulic diagram Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Working pressure The working pressure shows the classified weight.

• 7SLL12.5: 110 bar • 7SLL16: 110 bar • 7SLL12.5F:110 bar.

• 7SLL16F:110 bar.

Overflow valve The overflow valve opens at the following pressure: • 7SLL12.5/12.5F: 200 bar.

• 7SLL16/16F: 200 bar.

Pressure sensor The pressure sensor is used to adjust the speed and is affected by the load.

Load < 800 kg. Travel speed = 8.0 km/h Load >800 kg. Travel speed = 7.0 km/h (Declines linearly to 7.0 km/h at maximum load)

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

13- 5

Hydraulic system – 6000 Hydraulic diagram T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

This page is intentionally left blank

13- 6

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Main lift chain system – 7120 General Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

14- Main lift chain system – 7120 14.1 General Applies to all machines with a mast.

14.2 Checking the chain setting The lift chains must be adjusted at regular periods due to stretching, see below. The chain setting is checked during servicing as set out in the maintenance schedule.

Any adjustment is made with the chain mounting bolts.

Adjust the fork height according to C code 7100, 7420, 7700 and 7800 as applicable.

14.3 Chain inspection The chains are exposed to two types of wear, outline wear and stretching. Wear to the bolts and disc holes is caused by stretching. The chains are also affected by the environment they are used in.

14.3.1 Noise If lubrication has been insufficient there will be metallic friction on the chain and this will result in noise.

The chain should be replaced.

14.3.2 Surface rust Surface rust is easy to recognize as the chain will be reddish brown.

Deep-seated rust has generally started and the chain has impaired strength.

The chain should be replaced

14.3.3 Rusty links Fretting corrosion results in a reddish brown powder being visible by the outer discs. It can also appear as if the chain is bleeding when lubricated.

The chain should be replaced.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

14- 1

Main lift chain system – 7120 Chain inspection T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

14.3.4 Stiff links If it is not possible to pull out the chain to its normal position this can be because of link rust or seizing.

The chain should be replaced.

14.3.5 Bolt rotation Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when comparing with a new chain.

The chain should be replaced .

14.3.6 Loose bolts If a bolt is loose it will protrude from the side of the chain, which is due to a stiff link or bolt rotation.

The chain should be replaced.

14- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Main lift chain system – 7120 Chain inspection Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

14.3.7 Outline wear P

H2

H3

P = Pitch H2 = Nominal disc height.

H3 = Minimum disc height.

A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is define as H3 in the figure and denotes the minimum permitted value of the disc height.

Maximal permitted outline wear is 5% of the height H2. If a lift chain reaches the maximum level of wear, the chain should be replaced.

The nominal and minimum disc heights for respective lift chains are stated in the table in the chapter “Stretching”.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

14- 3

Main lift chain system – 7120 Chain inspection T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

14.3.8 Stretching The amount of stretch on a lift chain is measured on the part of the chain that runs over the chain sprocket. The amount of stretch may, at the most, be 2% on the most worn section of the chain. Measurement is suitably made over 300-1000 mm of the chain.

The nominal and maximum permitted chain lengths for lift chains are stated in the table below.

Table 40: Stretching Type of chain

Nominal disc height H2 ( mm)

Minimum disc height H3 (mm)

Pitch P (mm)

Nominal chain length for 20/30/ 50 discs (mm)

Maximum permitted chain length for 20/ 30/50 discs (mm)

3/4”, 2x3

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 3x4

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 4x6

17.8

16.9

19.05

381/572/953

389/583/972

1”, 4x4

23,6

22,4

25,4

508/762/1270

518/777/1295

1”, 6x6

23,6

22,4

25,4

508/762/1270

518/777/1295

Wear to the bolts and around the holes on the discs are a reason why the chain stretches. The chain should be replaced if stretching is more than 2%.

14- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Main lift chain system – 7120 Chain inspection Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

14.3.9 Damage

The chain should be replaced if damaged in any way.

14.3.10 Damaged discs If a disc has broken on the chain, this can be due to overloading or corrosion.

The chain should be replaced.

14.3.11 Damaged bolts It can be difficult to discover whether a bolt has broken. It can appear as bolt rotation and/or that the outer disc is loose.

The chain should be replaced.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

14- 5

Main lift chain system – 7120 Cleaning T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

14.3.12 Dirty chain If a chain is very dirty it is first and foremost recommended that it is replaced. It can also be dismantled and cleaned as set out in the chapter “Cleaning”.

14.4 Cleaning If a chain is very dirty it is recommended that it is replaced.

Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol.

The chain should be blown dry using compressed air and lubricated directly after cleaning NOTE! Exercise care with degreasing agent as these can contain abrasives.

14.5 Lubrication Mineral and synthetic oils can be used to relubricate Rexnord chains.

NOTE! Lubricant must not contain substances such as molybdenum disulphide, PTFE or the like.

A lift chain should be offloaded from the weight of the fork carriage (hanging free) when lubricated.

• Lubrication intervals: - 500 hours with normal operations - 100 hours when driving in rugged environments such as cold stores and corrosive environments.

The chains are sprayed with lubricant. Note the entire chain must be lubricated, even the fastening bolts. It is especially important that the part of the chain which runs over the chain sprocket is well lubricated.

The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below. The following lubricants are recommended:

14- 6

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Main lift chain system – 7120 Lubrication Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Table 41: Recommended Product Ambient temperature

Viscosity class

Recommended Products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5°C

VG 68

> + 5°C < + 45°C

VG 150

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette Klüberoil 4UH 1-220N, Klüber Lubrication

VG 220 >+ 45°C <+ 80°C * Equivalent products from another manufacturer may be used.

NOTE!

Do not use a special rust protective agent to prevent rust on the lift chains.

These agents impair the lubrication of the chains. Regular lubrication is the best method to prevent rust attack.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

14- 7

Main lift chain system – 7120 Lubrication T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

This page is intentionally left blank

14- 8

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 General Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

15- Control/computer equipment – 8700 TruckCom 3.4 User Manual -for trucks using the “PowerDrive” platform.

This Manual is valid for version 3.4 of TruckCom p/n 182145-007.

15.1 General TruckCom is a communication program which communicates with trucks equipped with CAN (Controller Area Network) communication.

It enables the following tasks to be performed: • downloading truck control software.

• viewing and adjusting driver / truck parameters and hour meters. Additionally, the truck’s parameter set (including hour meter values) can be saved to file and reloaded later.

• viewing diagnostic data for various digital inputs / outputs and analogue data including voltages, currents and certain temperatures.

The program is a Windows program running under Windows® 95/98, Windows® XP/2000 and Windows® NT.

15.2 Connection 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.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

15- 1

Control/computer equipment – 8700 Layout T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

15.3 Layout 15.3.1 Main program screen Information window

Menu bar

Tool buttons

Nodes Icons

Status bar

Fig. 13Main TruckCom program screen A main window opens when the program is started, consisting of menu bar, tool buttons, workspace, log window and status window.

15.3.2 Nodes Devices which are connected to and communicate via the CAN interface are called nodes. The nodes detected on the bus are shown in the node window. The current node status and input component/information is shown with different icons.

Fig. 14A typical node window display

15- 2

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Layout Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

15.3.3 Icons Icon

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

Node not connected is shown when there is no contact with a node in the network.

Node not OK is shown when an error has been reported by a node. Click on node to obtain more information.

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

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

Truck report See “15.7Truck report function” on page 8 Parameters is shown when a node has information on a parameter.

Diagnostics

Exit

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

15- 3

Control/computer equipment – 8700 Connection function T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

15.3.4 Tool buttons and menu bar The tool button bar allows direct access to the program’s most common functions. The menu bar allows access to all the program functions.

Explanations of each menu bar item are given in the relevant section.

Search for units

Disconnect Download from PC

Truck report

Parameters Diagnostics Information

Exit

Fig. 15Tool button bar

15.3.5 Information window 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.

15.3.6 Status bar There is a status bar at the bottom of the main window, which shows variable status when the program is run.

REC

MACHINE

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.

15.4 Connection function 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.

15- 4

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Disconnection function Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

15.5 Disconnection function 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. This enables connection to another truck without having to close the program.

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

Type 123456

15.6.1 Normal downloading (truck with key) 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. © TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

15- 5

Control/computer equipment – 8700 Downloading program function T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

15.6.2 Normal downloading (truck with keypad) To open the file to be downloaded to a node, select Open… The file name, file type and version number are displayed in the "File information" dialog box. If the file is intended for a controller, be sure to indicate which type of controller should receive the file. Start downloading by depressing and then releasing the red key on the keypad.

The truck must be restarted within 20 seconds from the time the Start key has been actuated.

When downloading has been completed, close the download dialog box and then disconnect the PC from the network. It is now possible to reconnect to verify the new application.

15.6.3 Emergency downloading (truck with keypad) • Disconnect the battery connector.

• Select OK in the dialog box.

• Keep the red key on the keypad depressed while reconnecting the battery connector.

• Release the red key to commence downloading.

15- 6

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Downloading program function Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

15.6.4 Downloading in old versions of logic card 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.

15.6.5 Emergency downloading (truck with keypad) 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.

On some trucks, a counter, which continuously counts up, is displayed.

NOTE! Once programmed, the logic cards in some trucks can only be upgraded with the same basic firmware. In other words, it is not possible to replace the basic firmware (other machine type).

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

15- 7

Control/computer equipment – 8700 Truck report function T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

15.7 Truck report function 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.

NAME

Example of information generated in the truck report: [GENERAL] REPORT DATE-TIME=2004-01-19 11:11:58 CPC-PP SERIAL No=8002041 MACHINE NUMBER=555555 CUSTOMER=CUSTOMER 1 TECHNICIAN=NONAME COMPANY=Other NOTES=Test report [CAN NODES] MAIN CARD=0 CURTIS DRIVE CONTROLLER=16 [MAIN CARD CONFIGURATION] SOFTWARE=181179-001 HARDWARE=167833-004 SERIAL NO=53676 [DRIVE CONTROLLER CONFIGURATION] SOFTWARE=5 DRIVE CURRENT LIMIT (A)=300 FIELD MAXIMUM (A)=34 SERIAL NO=52857 MFG Date:=26/05/03 HOUR METERS] A IGNITION TIME=81 B TOTAL MOVEMENT=7 C DRIVE MOTOR TIME=7 D PUMP MOTOR TIME=0 S SERVICE TIME=7

[ERROR LOG] 01=104 00007.5 02=104 00007.5 03=104 00007.5 04=104 00007.5 05=104 00007.5 09=104 00005.0

[DRIVER PARAMETERS] 1=100 2=100 3=75 100=0

[TRUCK PARAMETERS] 11=0 12=0 13=0

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

15- 8

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Parameters function Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

15.8 Parameters function 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].

NOTE! The truck must in Normal mode (i.e. not Parameter mode) when connecting TruckCom. Otherwise TruckCom will report “Unable to determine truck brand”

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

Fig. 16, Fig. 17 and Fig. 18 show one example.

Fig. 16Driver tab

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

15- 9

Control/computer equipment – 8700 Parameters function T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Fig. 17Truck tab

Fig. 18Time tab

15- 10

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Diagnostics function Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

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

NOTE! If the value “---” is shown in a field, or a “read status LED” is red, the communication has been interrupted for some reason and error data will not be able to be shown.

NOTE! The tab information displayed in diagnostics mode depends on the type of truck connected.

15.9.1 Representation of signal colours The screen dumps shown in the following section have been modified to improve legibility in black & white print.

BLACK GREEN RED

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

15- 11

Control/computer equipment – 8700 Diagnostics function T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

15.9.2 “Tiller arm” tab

Clicking on the tiller arm tab will display a dialog showing the following: • Speed lever -the status of the speed control and travel direction selector. The status of each individual hall element is displayed.

• Buttons -the status of the control buttons is displayed. “Sxx” refers to the switch designations as given in the circuit diagram.

• Option -the status of the optional function buttons • Battery -The measured battery voltage • R14 / R15 -Not used at present

15- 12

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Diagnostics function Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

15.9.3 “Drive Controller” tab

Clicking on the Drive Controller tab will display a dialog showing the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM - The effective drive output supplied to the field circuit as a percentage.

• Armature PWM -The effective drive output supplied to the armature circuit as a percentage • Field current - The current flowing in the field circuit in Amperes.

• Armature current -The current flowing in the Armature circuit in Amperes • Raw throttle data - The received speed control signal as a percentage.

• Temperature - The temperature of the output stage of the transistor controller in degrees Celcius • Inp pin 10 -The input voltage from the pressure sensor “digital o” indicates the digital status of the input.

• Inp pin 11-The input voltage from the man-on platform sensor. “digital o” indicates the digital status of the input © TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

15- 13

Control/computer equipment – 8700 Other menu functions T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

15.10 Other menu functions 15.10.1 Save to file 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 >.

15.10.2 Download from file 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 >.

15.10.3 Reset CAN adapter 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 >.

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

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

15.10.6 Read error code log To show the truck’s error code log, select < Tools | Read error log >.

15.10.7 Adjust date and time 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.

NOTE! This does not apply to trucks without a real-time clock.

15- 14

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Specifications Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

15.10.8 Adjusting the hour meter on older cards 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.

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

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

15.11 Specifications Table 42: Can interface specification

© TIEE SARL

Description

Value

Unit

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

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

C

15- 15

Control/computer equipment – 8700 Installation T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

15.12 Installation Note The program must be installed from the hard disk.

Note The software application in the computer can be damaged, which is why the PC installation should be performed by someone with the required knowledge. Toyota does not accept any responsibility for any errors that occur during the installation.

Note All references to PC operating system actions, menus and commands are based on the English language version of Windows®.

15.12.1 Installation on a PC with Windows® 95/98 If a previous version of the TruckCom application has been installed on the PC, it will be necessary to edit the System.ini file.

Start the Msconfig.exe application by selecting the Start button, selecting Run and then typing msconfig.

Click on System.ini and open the folder (386Enh).

Unmark the option at Device=C:\Windows\Cpcppvd.vxd.

Save the change and close the application.

Now continue with installation The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.

Then follow the on-screen instructions.

15.12.2 Installation on a PC with Windows XP/2000 To make the application work, it is necessary to first enter a value in the Windows® Registry and then make a few changes in the Windows® Control panel.

Due to the built-in Windows® security, this must be done manually.

The instructions below provide step-by-step guidance to enable these changes and make the interface operate under Windows XP and Windows 2000.

The changes can be made either before or after TruckCom is installed.

• Open the Registry Editor. To do this, select the Start button, then Run, type regedit and hit Enter.

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© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

• Mark the Enum folder which can be found under HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the Registry Editor.

Select the Edit option, then Find and type PortName to search for the correct folder.

NOTE! The location of the folder differs between different computers (some may be .. \Enum\Root\.., while others could be ...\Enum\ACPI\... etc.).

Thus be sure to search for the correct folder.

When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in the PortName data field and that the folder name is Device Parameters.

Right-click with the mouse in the right box to enter a new value of the DWORD type and with the name

EnableConnectInterruptIoctl.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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Control/computer equipment – 8700 Installation T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

Change the value in data field 1 by right-clicking on the name and selecting Modify.

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© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

EnableConnectInterruptIoctl

The Device Parameters folder should look like the one in the picture.

The Registry change is now complete. Close the Registry Editor.

Changes in Windows® Control Panel Select the Start button. Choose Settings, then Control Panel and double-click on System, then select Hardware.

Click on Device Manager and open Ports (Com & LPT).

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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Control/computer equipment – 8700 Installation T-code 789, 791 Date 2004-12-20

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© TIEE SARL

Valid from serial number 711956Order number 222641-040

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

Double-click on the LPT port to be changed, and select the Port Settings tab. Check the "Use any Interrupt assigned to the port" option and click on OK.

The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.

Then follow the on-screen instructions.

© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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Control/computer equipment – 8700 Installation T-code 789, 791 Date 2004-12-20

Valid from serial number 711956Order number 222641-040

15.12.3 Installation on a PC with Windows NT The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.

Then follow the on-screen instructions.

15.12.4 In case of communication problems with CAN Make sure the computer settings for the printer port in the BIOS Setup are as follows: Port address: 0378 IRQ:

7

Mode:

Output only

For detailed information on how to change the Setup settings, refer to the User's Guide supplied with the computer.

15.12.5 To uninstall To uninstall TruckCom under Windows®, select the Start button, Settings, Control Panel, Add/Remove Programs. To uninstall you must then select the TruckCom Program and click Change/Remove.

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© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16FApproved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 711956Order number 222641-040

T-code 789, 791 Date 2004-12-20

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© TIEE SARL

Service Manual 7SLL12.5/7SLL12.5F/7SLL16/7SLL16F Approved by: L-G Andersson

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©TOYOTA Industrial Equipment Europe SARL Ancenis, France