Still Forklift Truck Su Sd Sv Factory Service Repair Workshop – PDF DOWNLOAD

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Workshop manual

SU/SD/SV

SD

SV

First issued: Last updated:

SU

09/03

Workshop Manual

SU/SD/SV

Id. no. W8 054 311

Foreword Foreword This workshop manual (WM) is a collection of technical data and functional descriptions for the standard vehicle.

It is intended as a guide which should be kept at hand at all times, to help explain the technical features of the vehicle and consequently ensure that maintenance and repair are carried out correctly.

5/0002new

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The workshop manual is updated on a regular basis with additional sheets.

Updating workshop manuals Our range of equipment is subject to continuous development and improvement. A consequence of this is that components or assemblies are sometimes replaced or their function changed.

5/0003

In order to guarantee that the owner of a workshop manual is always in possession of up-to-date and relevant documentation, the manual must be updated using the method described overleaf.

5/0004

1/0096

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Sheet no.

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Foreword Updating workshop manuals 1. Replacing incorrect sheets

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If a sheet contains an error, e.g. if adjustment values have been altered, the sheet in question must be replaced.

The new sheet can be identified by the information at the left-hand side of the page footer (1). The date of issue is updated here in the Issue line (2). The date of issue of the sheet which needs replacing is specified in the Replaces issue line (3). The sheet no. remains the same (4).

Every time a change is made, the cover sheet is replaced. The date of first issue and the date of the last update are shown in field 9. This means that the workshop manual edition is immediately obvious.

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A Manual

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3 Page footer of a cover sheet Workshop SU/SD/SV Manual

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9 2. Inserting new sheets If new, altered or additional components are introduced to the series, it may be necessary to insert one or more additional sheets.

An additional sheet can be identified by the changes at the left and right of the page footer (5 + 6).

At the left, in the Issue line, is the current date of issue (7). At the right, the additional sheet is marked with the sheet no. with a consecutive index (8).

The list of contents for the assembly in question must also be replaced.

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5 Page footer of an additional sheet Workshop Sheet no.

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Foreword Updating workshop manuals We send new sheets, whether they are replacement or additional sheets, and new lists of contents, to all the workshop manual owners we know of by mail.

Notes, Imprint We can accept no liability for warranty claims relating to work carried out in accordance with the instructions in this workshop manual.

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The warranty terms remain unaffected.

STILL WAGNER works continuously on the development of its industrial trucks. We would ask for your understanding that we reserve the right to make alterations and that errors cannot be excluded, and that no warranty claims may be based on the information, illustrations or descriptions contained in this workshop manual.

Published by STILL WAGNER GMBH & CO KG Trainingszentrum (Training Centre) Ernst-Wagner-Weg 1-5 72766 Reutlingen-Mittelstadt Germany

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Guide to chapters Chapter

1:

Drive wheel

Chapter

2:

Gear

Chapter

3:

Drive motor

Chapter

4:

Speed sensor

Chapter

5:

Steering

Chapter

6:

Brake

Chapter

7:

Mast

Chapter

8:

Vehicle control

Chapter

9:

Component panel

Chapter 10:

ABÜ - braking monitor

Chapter 11:

Curtis display unit

Chapter 12:

Battery

Chapter 13:

Valve driver

Chapter 14:

Block diagram of hydraulics

Chapter 15:

Pump assembly

Chapter 16:

Pressure sensor

Chapter 17:

Valve block

Chapter 18:

Steering software

Chapter 19:

Travel control software

Chapter 20:

Summary of errormessages

Chapter 99:

Maint

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List of contents Sheet no.

Chapter 1: Drive wheel • Changing the drive wheel .....................................................................1-01 - Removal .............................................................................................1-01 - Installation ..........................................................................................1-01 • Information table: ID numbers of drive wheel .......................................1-02

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Chapter 2: Gear • Removing the gear ...............................................................................2-01 • Commissioning the travel drive (after replacement) .............................2-02 - Lubricating the bogie bearing .............................................................2-02 • Oil change.............................................................................................2-03 Chapter 3: Drive motor • Removing the gear ...............................................................................3-01 • Carbon brushes ....................................................................................3-02 - Replacing the carbon brushes............................................................3-02 • Technical data ......................................................................................3-03 • Maintenance .........................................................................................3-04 - General...............................................................................................3-04 - Cleaning .............................................................................................3-04 - Visual inspection, replacing damaged parts .......................................3-05 - Checking the brush unit, replacing the carbon brushes .....................3-06 - Commutator........................................................................................3-07 - Bearings .............................................................................................3-08 Chapter 4: Speed sensor • General .................................................................................................4-01 • Testing the speed sensor .....................................................................4-02 Chapter 5: Steering • Block diagram of steering SU ...............................................................5-01 • Block diagram of steering SD/SV .........................................................5-02 • Pin assignment .....................................................................................5-03 • Setpoint potentiometer..........................................................................5-05 • Actual value potentiometer ...................................................................5-06 • Quick start adjusting the steering .........................................................5-07 • Travel on curves function......................................................................5-08 Chapter 6: Brake • Electromagnetic spring brake ...............................................................6-01 - Function..............................................................................................6-01 - Removal .............................................................................................6-02 - Replacing the brake lining ..................................................................6-04 - Adjusting the brake clearance ............................................................6-05 - Adjusting the braking force .................................................................6-06 - Measuring the brake deceleration ......................................................6-07 Issue Replaces issue

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List of contents Sheet no.

- Checking the brake deceleration ........................................................6-10 - Maintenance .......................................................................................6-12

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Chapter 7: Mast • Removing the mast...............................................................................7-01 • Removing the lift carriage .....................................................................7-03 • Exchange Guiderollers .........................................................................7-04 • Sideplay ................................................................................................7-04 Chapter 8: Travel control • Block diagram for "Travel" ....................................................................8-01 • Pin assignment .....................................................................................8-03 • General .................................................................................................8-06 • Braking modes......................................................................................8-07 • Table of operating modes .....................................................................8-07 • Travel on curves ...................................................................................8-08 • Hour meter............................................................................................8-09 • Service hour meter ...............................................................................8-09 • Battery discharge indicator ...................................................................8-09 • Self test.................................................................................................8-10 • Error display..........................................................................................8-11 • Test procedure......................................................................................8-11 Chapter 9: Component panel • Arrangement of the components on comonent panel for SU................9-01 • Arrangement of the components on comonent panel for SD................9-02 Chapter 10: ABÜ - Braking monitor • Block diagram of braking monitor ABÜ (U50).....................................10-01 • Pin assignment ...................................................................................10-02 • General ...............................................................................................10-04 • Functions ............................................................................................10-05 -Wheel position display (optional).....................................................10-05 -Adjust the display ............................................................................10-05 -Driving while curve ..........................................................................10-06 -Flashing error codes........................................................................10-07 Chapter 11: Curtis display unit • General ...............................................................................................11-01 • Pin assignment ...................................................................................11-02 • Function ..............................................................................................11-03 • Error display........................................................................................11-03 • Battery discharge indicator .................................................................11-03 • Hour meter..........................................................................................11-04

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List of contents Chapter 12: Battery • General

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• • • • • • •

Sheet no.

12-01 Durability and lifetime .........................................................................12-01 Handling and maintenance .................................................................12-02 Maintenance intervals.........................................................................12-03 Acid density test..................................................................................12-04 Prevention of damage and accidents .................................................12-05 Commissioning unfilled battery with charged plates...........................12-06 Changing the battery ..........................................................................12-07 - Lifting and removing the battery .......................................................12-07 - Installing the battery .........................................................................12-08

Chapter 13: Valve driver • Block diagram .....................................................................................13-01 • Pin assignment ...................................................................................13-02 • General ...............................................................................................13-03 • Removal..............................................................................................13-05 • Flashing error codes ...........................................................................13-06 • Table of functions ...............................................................................13-07 Chapter 14: Hydraulics • Block diagram of hydraulics................................................................14-01 • Filter....................................................................................................14-02 - Maintainens ....................................................................................14-02 • Lowering brake valve..........................................................................14-03 - General...........................................................................................14-03 - Exchange........................................................................................1403 Chapter 15: Pump assembly • Individual components ........................................................................15-01 • LIFTING function ................................................................................15-02 • LOWERING function...........................................................................15-03 • Electrically pilot controlled non-return valve (2/2-way valve) ..............15-04 • Replacing carbon brushes on the SU .................................................15-05 • Replacing carbon brushes on the SD .................................................15-06 • Removing the pump motor .................................................................15-07 • Hydraulic pump...................................................................................15-08 - General.............................................................................................15-08 - Removing the hydraulic pump ..........................................................15-09 • Adjusting the pressure relief valve on the SU.....................................15-10 • Adjusting the pressure relief valve on the SD/SV ...............................15-11 - Proportional valve.............................................................................15-11 • Changing the hydraulic oil ..................................................................15-12 • Pumpassembly SV tecnical datas ......................................................15-13 - Removal .........................................................................................15-13 - Exchange of Carbonbrush..............................................................15-13 • Pumpcontaktor 2Y1 ............................................................................15-14 • Tankvolume ........................................................................................15-14 Issue Replaces issue

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List of contents Sheet no.

Chapter 16: Pressure sensor • Pressure sensor..................................................................................16-01

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Chapter 17: Valve block • General SD .........................................................................................17-01 • Hydraulic connections SD...................................................................17-01 • Electrical values..................................................................................17-01 • General SV .........................................................................................17-02 • Hydraulic connections SD...................................................................17-02 • Electrical values SD............................................................................17-02 • Other Valves SD .................................................................................17-02

Chapter 18: Steering software • General ...............................................................................................18-01 • Making a connection...........................................................................18-02 • Errors ..................................................................................................18-03 • Teaching in .........................................................................................18-04 - Setpoint potentiometer .....................................................................18-04 - Actual value potentiometer ...............................................................18-06 • Tester..................................................................................................18-07 - Speed measurement ........................................................................18-10 - Amplifier data....................................................................................18-11 - Digital inputs and ouputs ..................................................................18-12 - Potentiometer voltages.....................................................................18-14 • Settings...............................................................................................18-15 - Wheel distance .................................................................................18-15 Chapter 19: Travel control software • General ...............................................................................................19-01 • Setting parameters .............................................................................19-02 • Test.....................................................................................................19-03 • Diagnosis ............................................................................................19-03 • "File" menu .........................................................................................19-03 • Setting parameters with the hand-held programming unit ..................19-05 • Summary of the parameters that have to be set.................................19-19 • Battery discharge curves ....................................................................19-20 • List of parameters 1 ............................................................................19-21 • List of parameters 2 ............................................................................19-22 • List of parameters 3 ............................................................................19-23 • List of parameters 4 ............................................................................19-24 • List of parameters 5 ............................................................................19-25 • Description of parameters...................................................................19-26 • Errors displayed with flashing code ....................................................19-32 • List of flashing error codes..................................................................19-33 • Tester table.........................................................................................19-34 Issue Replaces issue

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List of contents Sheet no.

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Chapter 20: Summary of errormessages • Errormessages of the Travel control...................................................20-01 • Errormessages of the ABÜ-Braking monitor......................................20-01 • Errormessages of the Steering controler ...........................................20-01 • Errormessages of the Valve driver ....................................................20-01

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Chapter 1

Drive wheel

Changing the drive wheel Dimensions of new wheel: Change at residual diameter:

ř 250 x 80 mm ř 225 mm

The drive wheel must be replaced when: • • • •

the running surface is very pitted, the running surface is out of round, the running surface is cracked, the diameter of the tyre has decreased by 10%.

Removal

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1. Pull out the battery plug.

1

2. Jack up the vehicle safely on both sides and secure it to prevent it rolling away.

3. Remove the covers.

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4. Move the drive wheel into the straight-on position.

5. Loosen the 5 drive wheel nuts (1) and unscrew them.

6. Pull off the drive wheel, taking care not to damage the threaded bolts.

Installation 1. Before installing the drive wheel, clean the area where the wheel is seated on the axis and ensure that it is in perfect condition.

2. Push on the drive wheel and tighten the 5 wheel nuts by hand.

3. To secure the new drive wheel, tighten the wheel nuts diagonally in several passes with a torque wrench.

Tightening torque for the wheel bolts: 140 Nm

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Chapter 1

Drive wheel

Information table ID numbers of drive wheels Id. no. Ĺ™ 250/100

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Design Solid rubber tyre, press-fit

8 305059

Solid rubber tyre, tread press-fit

8 305060

Solid rubber tyre, natural rubber

8 329012

Solid rubber tyre, with tread

8 329013

Solid rubber tyre, electrically conductive

8 340792

Vulkollan tyre, vulcanized in place Vulkollan tyre, press-fit

8 305063

Vulkollan tyre, profile press-fit

8 305064

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Chapter 2

Gear

Removing the gear 1. Jack up the vehicle and secure it to prevent it rolling away (distance of approx. 10cm between drive wheel and floor).

2

2. Turn the drive wheel to one side so that the gear is visible.  It is more practical not to remove the drive wheel to start with when you want to take out the gear.

8-0518

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3. Pull out the battery plug.

4. Position a fork-lift truck or a low-lift truck under the drive wheel so that the weight of the gear is supported (clear distance between forks approx.

220 mm).

3

5. Support the gear safely from below.

3

6. Raise the fork-lift truck or low-lift truck until there is a slight pressure applied to the drive wheel.

7. Remove the 6 gear screws M10x40 (2).

8. Raise the motor with a rope (special tool, cable pull, see the section entitled "Removing the drive motor") and underlay it in at least 2 places with flat steel bars approx 20 mm thick (3).

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min. 10cm

9. Slowly lower the fork-lift truck and remove the gear at the front. 

Floor

Cover the gear opening to prevent dirt entering. Support the gear with a taut rope or chock it up from below with wood to prevent it tilting over to the rear or side.

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Chapter 2

Gear

Commissioning the travel drive (after replacement) The following types of gear oil are used: Standard oil: Ambient temperature: Id. no. W8 036 925

SAE 80 0°C to 40°C

Low temperature oil: Partly synthetic Ambient temperature: Id. no. W8 036 929

SAE 75 W-90

oil level

to -30°C 1

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For vehicle use in special conditions, please contact the manufacturer for further information.

Oil volume: approx. 1.5 l Transmission: i = 15.18

6/2016

 The given amount of oil is a guideline only.

The correct amount of oil is that required for the level to reach the lower edge of the filling hole (1). This means that the spur gear is submerged in oil by about 1/3 of its height (1).

Overfilling must be avoided, otherwise oil can escape at the gear bleeder screw, the seals may be damaged and it is possible that the operating temperature may not be maintained.

Check that the gear bleeder screw is clean.

2

3

Lubricating the bogie bearing 6/2014

The bogie bearing should be lubricated once a year through the two lubricating nipples at opposite sides (2 and 3). This is particularly important every time the gear has been cleaned (e.g. with steam jets).

The bearing play at the bogie bearing must be checked whenever maintenance is carried out.

Grease type: All-purpose grease

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Chapter 2

Gear

Oil change The first oil change must be carried out after approx.

1000 operating hours.

All subsequent oil changes should be carried out after approx. 2000 operating hours or at least once a year.

Between the oil change intervals, the oil level should be checked once a quarter and topped up if necessary. 

The gear oil must be drained off when the vehicle is warm.

The maximum permissible operating temperature is 80°C.

4 1 6/2013 Fig. 1

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Changing the oil 4

Remove the filler screw (1). Check the oil level with a dipstick through the threaded hole of the filler screw. The gear oil level should be at the lower edge of the filler hole. Top up if necessary (Fig. 1). or: • Jack up the vehicle and secure it to prevent it rolling away.

• Move the gear into the drainage position.

• Set an oil catchment vessel under the oil drainage screw (3) (should have a vol. of approx. 1.5l).

• Remove the oil filler screw (1).

• Remove the oil drainage screw (1) and allow the oil to run out.

1 2 3 6/2012

 Risk of scalding!

The oil temperature may be as high as 80°C!

Oil level

• Clean the magnet on the oil drainage screw (3) • Screw the oil drainage screw back in place, using a new sealing ring (2).

• Fill with new gear oil up to the lower edge of the threaded hole for oil filler screw (approx.1.5l).

• Screw the oil filler screw back in place, using a new sealing ring (4).

Sealing rings: Id. no. W8 006 172 

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Tightening torque for the oil filler (1) and drainage screw (3) MA= 22Nm. 09/03

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Chapter 3

Drive motor

Removal 

Once the drive motor has been removed, the vehicle is no longer braked. Secure the vehicle to prevent it rolling away!

• Pull out the battery plug.

• Mark and disconnect the field coil connections.

• Mark and disconnect the armature coils.

• Mark and disconnect the speed sensor and brake connector.

• Unscrew the supports for the component panel (1).

20408

1

• Unscrew the 8 M6 screws (2).

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• Screw a screw-fit eyebolt (3) into the motor shaft and hitch to the rope and lifting bar.

• Lay the lifting bar on the arm console and lever the motor out of its guide by lifting.

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2

20408

3

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Chapter 3

Drive motor

Carbon brushes Replacing the carbon brushes The carbon brushes must be replaced when they have reached a residual length of 16 mm.

• Pull out the battery plug.

• Remove the drive motor (please see Drive motor, Removal).

• Lever out the black plastic cap (1).

• Shape a loop out of a piece of wire and use it to pull off the carbon brush spring (2).

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1

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• Pull carbon brush out of the guide shaft.

• Unscrew the carbon brush connecting screw (3) and, if necessary, replace the carbon brushes.



Always replace the full set of carbon brushes (4 brushes).

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Chapter 3

Drive motor

Technical data Model...................................GF 114-F4 Excitation type .....................Shunt motor Voltage ................................24 V Rated current ......................104 A Rated output........................2000 W Rated speed ........................2700 rpm

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Direction of rotation .............right / left

6110003

Protection class ...................IP 00/20 Insulation class....................F Clockwise Switching-on time ................S 2 = 60 min

+ A1

A2

F2

+ F1

+ F2

F1

Drive motor terminals Designation at the motor

M

Meaning

A1

rotor coil; B+

A2

rotor coil; B -

F1

shunt field coil,

F2

shunt field coil,

Anti-clockwise + A1

A2

M

Direct current motor with separately excited field coil (without commutation poles)

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Chapter 3

Drive motor

Maintenance General Maintenance work between major overhauls should consist of the following: • • • • •

Cleaning General visual inspection Replacing damaged parts Checking the brush unit and commutator Replacing the carbon brushes (if necessary)

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This work should be carried out at least every 500 operating hours or once a quarter.

We recommend having major motor overhauls carried out by a specially equipped workshop, as special tools and specialist knowledge are required. 

Before carrying out any work on the motor, always first pull out the battery plug to avoid short circuits or injury.

Cleaning • Remove the cover and take out the brushes.

• Clean the motor thoroughly using compressed air, taking care not to breathe in any dust (wear a protective mask).

• Clean soiled commutators and brush unit using a clean cloth (not cleaning wool) moistened with benzine and dry well. 

Do not lift the brush springs more than is necessary and do not bend them to the side.

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Chapter 3

Drive motor

Maintenance Visual inspection, replacing damaged parts • Check that the gear ventilation channels (1) are clean. Soiling impairs the air circulation, which leads to increased temperatures in the motor and possibly irreparable damage to the motor.

1

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• Clean the gear bleeder screw.

• Check the field and armature coils for signs of overloading (e.g. overheating): dark coloration, brittle or burned insulation, unsoldered commutators.

Motors with this kind of damage must be replaced without delay.

6/2008

• If you discover oil or grease in the motor (usually a paste made up of oil, oil vapour mixed with dust and carbon abrasions), investigate the cause immediately and remedy it.

The motor must be cleaned extremely thoroughly. 

Rapid carbon brush or commutator wear is generally due to the effect of oil.

The oil/grease burns in the brush sparks, leaving behind a sharp-edged oil ash which has an abrasive effect.

This can lead to inadmissibly high levels of carbon brush wear before the next scheduled maintenance date is reached.

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Chapter 3

Drive motor

Maintenance Checking the brush unit, replacing the carbon brushes After the carbon brush unit has been cleaned, it should be possible to move the carbon brushes easily in their guide with the spring raised.

If one or more of the carbon brushes jam, they must not be sanded down with emery paper or any other abrasive.

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In this case, the entire carbon brush unit must be replaced, as it is possible that the brushes were thermally overloaded.

It is also important that the carbon brushes are not broken or chipped at the running edges.  • Always replace the entire brush set, basing your assessment on the shortest brush.

• Only use original replacement carbon brushes (see spare parts list!).

• Do not allow the carbon brush springs to knock against the carbon brushes when you are inserting the brushes.

• If the minimum length has not quite been reached, replace the brushes anyway, as the remaining running time may be shorter than the next maintenance interval.

• A maximum of 3 carbon brush sets should be replaced in succession before a general overhaul of the motor is carried out (by a specialist workshop).

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Chapter 3

Drive motor

Maintenance Commutator The running surface of the commutator should be even and smooth with a grey-black appearance.

The commutator must not be worn, scored or out of round. Ensure there are no protruding segments (jagged brush running edges).

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Should one of the above conditions occur, the commutator must be reworked (major overhaul).

There are special regulations for reworking commutators.

Special tools are required for the purpose, since the armatures must not be held between the points in the centres of the axes (axes are finish-ground without points).

The max. permissible deviation from concentricity after reworking in accordance with the regulations is 0.03 mm (when armature is held at the bearing points).  The service life of the carbon brushes depends not only on the conditions under which they are used, but also to a great extent on the condition of the commutator (degree of wear). For this reason, the service life of the sets of carbon brushes grows shorter with successive sets. This may make it necessary to shorten the inspection interval between Commut. diam. new Commut. diam. min. major overhauls.

33 mm 31 mm Commutators cannot be re-turned an infinite number 36 - 64 mm 33 - 61 mm of times. They must not measure less than a certain 67 - 100 mm 63 - 96 mm minimum diameter. Re-turning them a little and often 107 mm 102 mm is more conducive to a long service life than re126 mm 116 mm turning them by a large amount but not very often.

For this reason, you should always have the commutator re-worked every 3 sets of carbon brushes, at the latest (major overhaul).

Never attempt to achieve the necessary finish with a file, emery paper or similar.

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Chapter 3

Drive motor

Maintenance Bearings The ball bearings do not need to be re-lubricated (they are maintenance-free!). The volume of grease in the bearings is sufficient for the maintenance periods between major overhauls.

The bearings must be replaced: • without fail on the occasion of every major overhaul,

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• after they have been in use for 2000 operating hours, at the latest, • if the vehicle is only used for short operating times, then after 5 years at the latest.

Only use the bearings specified in the spare parts list (to guarantee the service life of the bearings).

  If the speed of the motors drops noticeably, work must be stopped immediately. Check the battery without delay, then recharge it if necessary.

Never drive the vehicle if the battery voltage is too low!

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Chapter 4

Speed sensor

General The speed sensor is supplied with 12V by the brake monitoring board (ABÜ). At its outputs, it delivers voltages of approx. 1V or 11V, depending on its switching status.

The speed sensor uses two internal proximity switches to determine the speed of the drive motor.

The speed sensor is monitored constantly by the ABÜ (brake monitoring board).

10069

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

If an error occurs (e.g. if a channel is faulty), this is recognised by the ABÜ board and electromagnetic braking is initiated immediately.

In the event of failure, the ABÜ board generates a flashing error code which is shown on the fault LED (please see ABÜ/Flashing error code).

Terminals block connector X2 X2 : 1

pink

12V

X2 : 2

purple

Signal A1

X2 : 3

yellow

GND

X2 : 4

orange

Signal A2

Signal sequence U(V)

Phase shift 90°

11V

1V

t(s)

Signal A2

U(V)

30 pulses/revolution/channel

t(s)

Signal A1

Assembly: The mounting distance between the counting wheel and the sensor should be between 1 and 2 mm.

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Sheet no.

4 – 01

Chapter 4

Speed sensor

Testing the speed sensor Note: Secure the vehicle to prevent it rolling away!

1. Jack up the vehicle far enough to free the drive wheel.

2. Switch on the vehicle.

Speed sensor 12V

Signal A2

Signal A1

X2 1

X2 2

X2 4

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Copyright reserved.

X2 3

approx.9.5V

3. Check the power supply of the speed sensor between X2:1 (12V) and X2:3 (0V).

Remark: If less than 12V or no voltage is applied between X2:1 and X2:3, a further voltage measurement must be taken between X1:1 and X21:2 of the ABÜ.

If the measurement taken here is 10V, the line connections between the ABÜ and the sensor must be checked (line breakage, poor contact connection).

0V

V

approx. 9.5V

V

12V V

rs

vl

X1 1

X1 4

ov

X1 3

ge

X1 2

ABÜ

4. Press the deadman switch.

5. Accelerate the drive wheel very slowly. If this is not possible, turn the drive wheel by hand.

6. Check the sensor signals. The voltage between X2:2 (Signal A2) and X2:3 (0V), and the voltage between X2:4 (Signal A1) and X2:3 (0V) should be approx. 10V. If significantly less or no voltage is applied, the speed sensor is faulty.

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Chapter 5

+

Steering

Battery

1F3

Setpoint

Actual value

5-speed potentiometer endless

5-speed potentiometer endless

2.2K Emergency stop

2.2K

R1

2.2K

R2

Wheel position display

2.2K

R1

X1 3

R2

Key switch o X2 12 X1 19 6

X1 8

0V

X1

22

X1 10

8.6-0.4V

2.5-6.5V

X2 13

>20°

X1 16 out in

9,2V

0.4-8.6V Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

20

ABÜ

6.5-2.5V

X1:24

Diagnosis notebook

24V

Steering control

X1 25 Power supply

X1:1 0V X1:8 9V

X2 4 X1 4

X1:13

Controller

M

3F1

X2 4 ABÜ 0V

X3 5

X210

0V

X1 15 23 2

No function

Contact test response signal

Main contactor K1

Steering contactor ON

Battery

X1 5

Steering OK

X1 11 X1 9

Travel speed

X2 3 X1 3 X2 2

Enable

X21

Steering OK 0V

Coding input

X1:7

EEPROM

Contactor driver

X3 9 K

3K1

6 X3 4

X2 3

24V

1 X2 10 A

D

X2:11

24V X2

1F11

X1 4 X1 3 X3 1

Travel controller 0V

X1:14

24V

X1 8

Deadman

El. magn. brake

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Chapter 5

Steering

Block diagram of steering +

Battery

1F3

Setpoint

Actual value

5-speed potentiometer endless

5-speed potentiometer endless

2.2K Emergency stop

2.2K

R1

2.2K

R2

Wheel position display

2.2K

R1

X1 3

R2

Key switch o X2 12 X1 19 6

X1 8

0V

X1

22

X1 10

8.6-0.4V

2.5-6.5V

X2 13

>20°

X1 16 out in

9,2V

0.4-8.6V Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

20

ABÜ

6.5-2.5V

X1:24

Diagnosis notebook

24V

Steering control

X1 25 Power supply

X1:1 0V X1:8 9V

X2 4 X1 4

X1:13

Controller

M

Contact test response signal

Main contactor K1

Steering contactor ON

Battery

3F1

X2 4 ABÜ 0V

X1 5

X3 5

X1 6

3K1

X2 3

24V

1 X2 10 D

X2:11

24V 6 X3 4

1F11

A

0V

X2

X1 15 23 2

Steering OK

X1 11 X1 9

Travel speed

X2 3 X1 3 X2 2

Enable

X21

Steering OK 0V

Coding input

X1:7

EEPROM

Contactor driver

X1 4 X1 3

Travel controller 0V

X1:14

24V

X1 8

Deadman

El. magn. brake

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1K34

Chapter 5

Steering

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Pin assignment X1:1 E

0V power supply for the Diagnosisplug of the steering controller.

X1:2 E

Supply voltage for releasing the brake.

If no +24V power is applied to X1:2 the brake cannot be released. The ABÜ detects an error. There is a 1K resistor between 1+24V and X1:2 for the contact testing of the internal safety relay.

X1:3 A

0V power for switching on the steering contactor 3K. Is switched when the power supply for the steering controller is applied, setpoint and actual value are in the correct range and there are no internal errors.

X1:4 E

Coding input.

0V must always be applied here = Coding SU. The coding determines the characteristics, vehicle dimensions and current limitation. If 0V is removed, FE24 appears.

X1:5 E

Travel speed As long as impulses are received at this input, the steering remains 100% active, even if the deadman switch is released. Without impulses, the antiwalk function is activated when the deadman switch is removed.

X1:6 A

0V power supply for setpoint and actual value potentiometer

X1:7 E/A Diagnosis lead for PC This is needed to read out errors, set parameters, etc.

X1:8 A

Positive power supply for setpoint and actual value pot. approx. 9-10V.

X1:9 E

Enable steering As soon as there is a difference between the setpoint and actual value, the steering is activated, even without the enable steering signal. If the deadman switch is released without a setpoint/actual value difference (when the vehicle is at a standstill), the power to the steering amplifier is switched off. In this way, a continuous flow of power caused by twisting of the drive wheel can be prevented when the vehicle is at a standstill. Without a setpoint/actual value difference, the drive wheel can be moved out of the home position by up to 15° by external influences.

X1:10

Steering actual value R2 If the voltage is not within a range of 6.5 - 2.5V, K1 and 3K1 drop out (cable breakage fuse).

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Chapter 5

Steering

Pin assignment

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

X1:11 A Steering OK (0V) If any of the following errors occur, the 0V signal is switched off: 1. Setpoint / actual value potentiometer faulty 2. Undervoltage for setpoint/actual value potentiometer 3. Contact test of internal safety relay negative 4. Internal error X1:12

Not used

X1:13

Diagnosis lead for PC

X1:14

Not used

X1:15 A Steering ok (24V) If any of the following errors occur, the 24V signal is switched off: 1. Setpoint / actual value potentiometer faulty 2. Undervoltage for setpoint/actual value potentiometer 3. Contact test of internal safety relay negative 4. Internal error X1:16 A Signal for steering angle >20°, for the "Slow travel on curves" function X1:17 X1:18

Not used Not used

X1:19

Setpoint R1 If the voltage is not within a range of 0.4-8.6V, the internal safety relay and 3K1 drop out (cable breakage fuse)

X1:20 E Setpoint R2 If the voltage is not within a range of 8.6-0.4V, the internal safety relay and 3K1 drop out X1:21

Not used

X1:22 E Actual value R1 If the voltage is not within a range of 2.5-6.5V, the internal safety relay and 3K1 drop out (cable breakage fuse) X1:23 E Switchover from sensity to rough steeringmode.(No working steering while stoping) X1:24 E Output X1:16 is read back. Monitoring of whether output X1:16 is actually active.

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Chapter 5

Steering

Setpoint potentiometer Mounting Switch off the vehicle.

Remove the setpoint potentiometer (3). To do so, unscrew the screw (1) and release the threaded pin (2).

Turn the steering wheel as far to the right as it goes and from this point turn it back again by 2 1/8 turns to the left. The steering mechanism is now in the centre position.

Switch the vehicle on again.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Note:

Since a difference has been made between the setpoint and actual value by turning the actual value potentiometer, uncontrolled steering movements may occur!

Set the test device for voltage measurement and measure the voltage between X1:2 (red) and X1:4 (white/red). The voltage range should be between 0 and 8.6V. Now turn the shaft of the potentiometer until a value of 0V is set. The potentiometer values for R1 and R2 are now equal.

1 2 10100

3

Remark: The shaft of the setpoint potentiometer is flattened on one side. It is important to ensure that the threaded pin (2) comes into contact with this flat area when it is screwed in.

Install the setpoint potentiometer in the steering mechanism again without turning either. Tighten the threaded pin (2) again.

The upper and lower voltage limits must now be taught in with the notebook (please see Steering software / Teaching in).

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Chapter 5

Steering

Actual value potentiometer Mounting

Set the drive to straight-on (drive wheel parallel to the forks) Switch off the vehicle Remove the actual value potentiometer (3). To do so, unscrew the screw (1) and release the other screw (2).

Switch the vehicle on again.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Note:

Since a difference has been made between the setpoint and actual value by turning the actual value potentiometer, uncontrolled steering movements may occur!

Set the test device for voltage measurement and measure the voltage between X1:2 (red) and X1:4 (white/red). The voltage range should be between 0 and 8.7V. Now turn the shaft of the potentiometer until a value of 0V is set. The potentiometer values for R1 and R2 are now equal.

Remark: The shaft of the actual value potentiometer is flattened on one side. It is important to ensure that the threaded pin (2) comes into contact with this flat area when it is screwed in.

10101

2

3

1

Install the actual value potentiometer again without turning its shaft. Tighten the threaded pin (2) again.

The upper and lower voltage limits must now be taught in with the notebook.

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Chapter 5

Steering

Quick start 1. Set the drive wheel to the straight-on marking.

2. Remove fuse 3F1.

3. Set mechanical centre of steering wheel.

Set the steering wheel to the mechanical centre position, i.e. turn back by 2 1/8 turns, starting from the end stop.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

4. Set electrical centre of setpoint potentiometer.

Tester window, setpoint voltages at steering wheel: turn the setpoint potentiometer until the voltages at Potentiometer 1 and Potentiometer 2 are equal and install them without turning.

5. Set electrical centre of actual value potentiometer.

Tester window, Actual value voltages at drive wheel: turn the actual value potentiometer until the voltages at Potentiometer 1 and Potentiometer 2 are equal and install them without turning.

6. Set maximum steering distance for steering wheel.

Setpoint for end stops: Teaching in window, Setpoint potentiometer: turn the steering wheel to the left-hand end stop, then press CONTINUE. Turn the steering wheel to the right-hand end stop, then press CONTINUE. 7. Install fuse 3F1 again.

8. Set the maximum steering distance actual value and 90° angle.

Teaching in window, Actual value potentiometer.

Turn the steered wheel into the straight-on position by turning the steering wheel or tapping the fine adjustment keys. Carry out travel test to check this setting. Press CONTINUE, then move the steered wheel fully to the right and press CONTINUE. 9. Test the steering.

10. Delete the error memory.

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Chapter 5

Steering

Travel on curves function As soon as the steering is turned to an angle of more than 20°, the output signal of the steering controller at pin X1:16 is reduced from approx. 7.1V to a value of <3.2V. This signal is converted to a 0V signal in the ABÜ and sent on to the travel control. This causes the travel control to change from travel mode 2 to travel mode 1.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

However, since there is a lower parameter value set in Mode 1 than in Mode 2, the travel speed is reduced to approx. 60% of Vmax in the SU and approx. 80% of Vmax in the SD.

Steering controller

OUT >20°

IN >20°

X1 16

X1 24

<3.2V or >7.1V X2 10

ABÜ

In In <3.2V --> Out 0V In >7.1V --> Out 24V

Out

As soon as the steering angle changes back to 15°, the vehicle is switched back to its normal speed.

Remark: The function "Speed reduction on curves" can be removed at the customer's request. To do so, set the parameters "Max FWD SPD" and "Max Rev SPD" to 100%.

X2 11 0V or 24V X2 14

Travel control

Mode input 1

0V = Mode 1 24V = Mode 2

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Chapter 6

Brakes

Electromagnetic spring brake Function The drawing to the right shows the brake when it is currentless, i.e. when it is in the braking position.

5

1

When no current is supplied (deadman not actuated), the braking moment is generated by several compression springs which create a frictional grip.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

This takes place as follows: the compression springs (1) press axially on the armature disk (2) against the brake lining (3). This in turn is now pressed between the motor housing (4) and armature disk, which blocks the drive = braked condition.

The brake is released electromagnetically (deadman switch actuated).

a

6/0072

4

2

3

When the deadman switch is actuated, the coil in the magnetic brake is excited with direct current and the magnetic circuit between the armature disk (2) and the magnetic section/coil (1) is closed.

When the magnetic coils (5) are supplied with current, they become magnetic and pull the armature disk (2) against the spring force.

The armature disk (2) moves axially in the direction of the fixed magnetic section, the gap "a" is reduced to "zero" and the brake lining (3) can move freely = unbraked condition.

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a

Chapter 6

Brakes

Electromagnetic spring brake Removal 

Once the brake has been removed, the vehicle is no longer braked. For this reason, always secure the vehicle to prevent it rolling away before removing the brake.

1 2

• Pull out the battery plug.

• Disconnect the lead to the magnet at the connector.

4

6

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Release the 3 hexagon socket screws (1) gradually in several passes.

5

• The complete magnetic section (2), armature disk (3) and adjusting sleeves (4) can now be lifted off.

• The brake lining (5) lies loosely on the motor pinion (6), which is screwed to the armature shaft of the motor.

3

• To reinstall the brake, follow the instructions above in reverse order. 

Once the brake has been installed, the brake clearance must be checked without fail and adjusted if necessary.

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Chapter 6

Brakes

Electromagnetic spring brake 4

Removal • Unscrew the 3 adjusting sleeves (1).

• Remove the 4 compression springs (2).

• Remove the 4 pressure elements (3).

• Unscrew the adjusting ring (4).

The pressure elements (3) are rounded on one side. When reassembling, ensure that the rounded side faces towards the adjusting ring (4).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.



2

3

1

6/0075

4

6/0072



When reassembling and installing the spring brake, it is important to ensure that the rotor and armature disk are absolutely clean and free of oil.

6/0076

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Chapter 6

Brakes

Electromagnetic spring brake Replacing the brake lining The brake lining (1) must be replaced when the gap "a" has increased to approx. 0.7 mm due to wear.

Further adjustments should then no longer be carried out with the adjusting sleeves.

If this measurement is exceeded, proper clearance by the magnetic section is then no longer possible and there is a risk that the vehicle may be driven with the brake linings applied.

The brake lining must also be replaced in the event of cracks or non-radial wear.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

In order to replace the brake lining, the electromagnetic brake must be removed.

3

1  The brake lining (1) must be seated on the motor pinion (3) so that it can be moved freely by hand around its axis.

A brake lining that does not move will unavoidably become cracked and cause noise during operation.

For this reason, the motor pinion must be checked for scratches or soiling. If necessary, copper paste must be used to make the brake lining move freely on the pinion.

Whenever the linings are changed, you must check: • that the brake lining moves easily on the motor pinion (3) • that it is seated firmly on the motor pinion without play (3)

a

• the condition of the lining surface (porous, cracked)

Thickness of a new brake lining:

10 mm

Replace when thickness reaches: (when worn symmetrically)

8 mm

6/0072

2

1

 If the rotor causes noises during travel, check the concentricity and bearing clearance of the armature shaft of the drive motor.

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a

Chapter 6

Brakes

Electromagnetic spring brake Adjusting the brake clearance General 1

In order to measure the clearance, the electromagnetic brake must be active (vehicle at a standstill and deadman switch not actuated).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Correct adjustment of the spring brake is on the one hand intended to guarantee a minimum clearance so that the brake lining is sure to run freely when the brake is released, while on the other allowing the largest possible degree of wear on the brake lining (2).

a B

A

6/0072

Fig. 1

The dimension "a" (Fig. 1) shows the gap which must be set to 0.4 mm when the brake is set or readjusted (brake clearance).

3

2

1 Adjustment process 4

• Release the three fastening screws (1).

Do not remove them.

• Use an open-ended spanner to turn the adjusting sleeves (3) in or out of the magnet section until you measure a clearance of 0.4 mm with a feeler gauge between the magnet section (4) and the armature disk (5).

• Check dimension "a" (clearance) with a feeler gauge in at least 3 different places close to the screws.

0.4 mm 6/0148

Fig. 2

5

3

• Tighten the adjusting sleeves (3) down again and check the clearance. Repeat steps 2-4 if necessary. Tighten the adjusting screws (1) again and check the play again, readjusting if necessary.

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Chapter 6

Brakes

Electromagnetic spring brake Adjusting the braking force Correct adjustment of the braking force affects the length of the braking distance. For this reason, its adjustment must be checked after maintenance work or when the brake has been replaced.

2

1

2

3 6

The braking force can be checked with a dynometer. a

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Turning the adjusting ring (1) with a hook spanner alters the amount of pressure exerted on the pressure elements (2), the compression springs (3) and the armature disk (4).

6/0072

As a result, the brake lining (5) is pressed against the end shield of the drive motor with a greater or lesser degree of force during the braking process.

Turning the adjusting ring anti-clockwise: --> Reduces the braking force (braking distance longer) Turning the adjusting ring clockwise: --> Increases the braking force (braking distance shorter)

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4 5

Chapter 6

Brakes

Electromagnetic spring brake Measuring the brake deceleration

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

General The brake deceleration value is measured with the dynometer Id. no. W8 050 605.

This works on the principle of the pendulum, which registers irregular movements with great precision.

During travel at a steady speed over an even surface, the pendulum always hangs vertically and shows zero on the dial . On acceleration, the pointer deflects to the right (clockwise) and on braking (deceleration), it moves to the left.

6 3

Preparations for measurement Moisten the rubber sucker on the underside of the dynometer (ideally with glycerine) then use the lever (1) to fasten it onto a horizontal surface.

1 5/0115

The dial must face towards the driver's seat and be mounted in the direction of travel.

Before every deceleration measurement, the measuring case ( 3) must be tipped to move the measuring pointer ( 4) to zero.

2

The dynometer has been set to the correct zero position when the measuring pointer can move almost a full turn to the left from the zero position (anti-clockwise) and almost half a turn to the right when the case is tipped.

The maximum pointer (5) is moved round to the measuring pointer from the right by hand with the knob ( 6), until it reaches about the zero position.

4 5 5/0116

6 Deceleration in %

During the braking process, the maximum pointer moves to the maximum deflection point together with the measuring pointer and remains there when the measuring pointer moves back to the zero position.

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Chapter 6

Brakes

Electromagnetic spring brake Measuring the brake deceleration Evaluating the measurement • Calculate the maximum vehicle speed (V = distance/time).

• Mount the dynometer on the vehicle where it is clearly visible and set it to zero.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Accelerate the vehicle to Vmax. in the direction of the forks (reverse).

• Stop the vehicle with the full braking force (release the deadman switch) and read the braking deceleration value "F" in % off the dynometer (position of the maximum pointer).

• The braking deceleration value required for the calculated speed is shown in the graph below.

 Measured speed: Required braking deceleration

7km/h 7%

% Deceleration

9 7 4

2

4

6

8

10 11

12

13

km/h 6/0079

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Chapter 6

Brakes

Electromagnetic spring brake Measuring the brake deceleration Braking distances The values provided in this table of braking distances are for guidance only. The exact braking force must be determined by measuring the braking deceleration value with a measuring device.

Vehicle speed v

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

in km/h

Time in s for 10 m test distance (flying start)

m/s

Minimum permissible braking distance in metres with nominal load

1

0.28

36.00

0.21

2

0.56

18.00

0.42

3

0.83

12.00

0.63

4

1.11

9.00

0.84

5

1.39

7.20

1.05

6

1.67

6.00

1.26

7

1.94

5.14

1.48

8

2.22

4.50

1.69

9

2.50

4.00

1.90

10

2.78

3.60

2.11

11

3.06

3.27

2.32

12

3.33

3.00

2.53

13

3.61

2.77

2.74



The values provided above only apply for Group A trucks as specified by DIN 15161 with a design-specific maximum speed of 13.4 km/h.

The measurement must always be taken in the direction of the forks!

Minimum braking value Z in % with nom. load zmin = 1.86 x v Example v = 10 km/h = 1.86 x 10 km/h = 18 %

Example:

At a speed of 5 km/h, the test distance of 10 m is covered in a time of 7.2 seconds. At this speed, a minimum braking distance of 1.05 m must be achieved with a nominal load.

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Chapter 6

Brakes

Electromagnetic spring brake Checking the brake deceleration The brake deceleration of the electromagnetic brake must be checked so that: • the vehicle is not braked too hard in an emergency situation (the stability of the vehicle must be guaranteed in every situation), • the vehicle has the shortest possible braking distance needed to come to a standstill in an emergency situation.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The electromagnetic brake is activated when: • the deadman switch is released and the vehicle is at a standstill (no pulses from speed sensor), • the vehicle decelerates too slowly or not at all when a deceleration operation is initiated, • a manual or emergency stop is initiated.

When the vehicle is braked as normal (travel lever is let go and deadman switch is released) or during reverse travel, only the generator brake system is active.

To test the brake deceleration of the electromagnetic brake, it is easiest to accelerate the vehicle to maximum speed and then press the emergency-stop button on the operating console (main contactors drop out, electromagnetic brake becomes operative).

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Chapter 6

Brakes

Electromagnetic spring brake Checking the brake deceleration Checking the brake stage • Drive the vehicle with a load.

• Check that it is possible to drive the vehicle at maximum speed.

1

• Mount the dynometer (1) where it can be seen clearly and set it to zero.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Accelerate the vehicle and initiate an emergency braking operation when the vehicle is at maximum speed (press emergency-stop button on the operating console).

• Read the deceleration value off the dynometer: The permissible value is 8% ±2%, which represents a deceleration of approx. 0.8m/s2.

5/0115

 If the brake deceleration value is not achieved when the brake clearance is set correctly, the brake must be replaced.

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Chapter 6

Brakes

Electromagnetic spring brake Maintenance The following steps must be carried out or taken into account during maintenance work:

2

• Adjustment of the brake clearance.

1

• Adjustment of the braking force.

• Replace brake linings (1) if chipped or worn down on one side.

6/0073.2

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• The brake lining (1) must run easily up and down on the motor pinion (2).

• Clean all the oil from the brake with compressed air.

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Chapter 7

Mast

Removing the mast If the guide rollers are worn or damaged, they must be replaced.

In order to carry out this work, the mast must be removed.

• Tie the lift carriage to a crane (1) and extend the mast hydraulically to its maximum extent. Hold the mast taut with the crane.

20208

1

• Release the pair of lock nuts (2) and pull both chain anchors (3) out of the guide.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Slowly lower the lift carriage with the crane and let it slide down and out of the profile of the inner mast. Lay the lift carriage on a pallet.

• Release the lock ring (4). The piston rod is now free.

• Tie the crane to the crossbar of the inner mast and tension (the mast is still extended as far as it goes).

20209

• Press the operating button for lowering and hold it down for a while so that the pressure can be released from the cylinders.

2

3

20210

4

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Chapter 7

Mast

Removing the mast • Disconnect the main connection (4) for the main lift.

Catch any oil that runs out.

• Release the two screws (5) • Carefully raise the inner mast (6) with the crane until the two mast sections bump together with the guide rollers (7).

20211

5

• Lift the mast clear and lay it down on a pallet.

4 6

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Copyright reserved.

• The inner mast can now be pulled down out of the profile of the outer mast. The rollers are now freely accessible.

20212

20213

7

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Chapter 7

Mast

Removing the lift carriage • Raise the lift carriage hydraulically to a height of 1.3m.

• Attach the lift carriage to a crane and pull it up by about 20 cm. The chains are now slack.

• Release the stop screws (1).

• Release the roller cover (2) and pull out the roller (3).

20214

1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Slowly raise the lift carriage up and out of the mast profile with the crane (5) and lay it down on a pallet.  During this process, the lifting chain remains in contact with the lift carriage, i.e. the cotter bolt (4) does not have to be removed.

2

5

3

20218

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20216

20317

7 – 03

Chapter 7

Mast

Guide rollers Replacement The guide rollers on the mast and fork carriers are subject to very heavy wear. The same aplies for the mast profiles and running tracks which the guide rollers slide up and down continuously.

Because, due to their design, dimensional tolerances in the mast profiles must be taken into account, the guide rollers are availalbe in different diameters.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Particularly after the running-in time (approx. 6 months), the profile diameter "A" and consequently dimension "X" will have increased, since the guide roller compacts the running track heavily along its entire length.

In order to prevent the mast becoming unstable and causing clattering noises, guide rollers must be installed that are slightly too large.

The following roller diameters are available: 75.2 mm 75.7 mm

2

76.2 mm Remark: Dimension "A" must be measured at the point where the guide roller and mast profile come into contact. Dimension "X" should measure 0.35 mm maximum.

1

Lateral play The lateral play (1) between the outer and inner mast and the fork carrier and inner mast should be between 0.4 and 1.4 mm.

The lateral play can be varied by adding adjusting shims (2).

These are available in thicknesses of 0.3 and 1.0 mm.

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Chapter 8

Travel control

Block diagram for "Travel"

Steering controller 1F11 1F3

K1

1k

X1 2

<3.2V

X1 16

>7.1V X1 24

Steering angle > 20°

Emergency-stop Steering OK

S2

X1 11

3F1

Key switch

Steering OK

24V

0V 1F1

X1 15

3K1 Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

24V

U50 ABÜ

X2 10 X3 9 1K34

K1

X2:11 X2:4 V8

X2:6

travel contactor

X2:3 X2:14 X3 4

5k

Steering angle related deceleration

Travel direction

Travel control 1A10 I

12

15

X1 8

X1:1

5 amps or t > 3 sec.

Current sensor B-

X1 11

Enable

Setpoint 0 =Vmax

X1 7

Load sensor

Contactor contact test

FE 3.2 3.4

Mode Input 1

Travel dir. DWS

X1 6

X1 16 X1 14

Travel dir. LS

X1 4

X3 1

Deadman

0V 24V

Power supply

Control of

Travel transducer Type=1

1.6-3.4V

1

M-

B+

D1

D2

M

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Chapter 8

Travel control

Block diagram for "Travel"

Steering controller 1F11 1F3

K1

1k

X1 2

<3.2V

X1 16

>7.1V X1 24

Steering angle > 20°

Emergency-stop Steering OK

S2

X1 15

X3:9

X3:1 Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

X1 11

3F1

Key switch

Steering OK

24V

0V 1F1

24V

3K1

U50 ABÜ

X2 10 X3 9

U50 1K34

X3: 1

X2:11 X2:4

V8

X2:6

travel contactor

X2:3 X2:14 X3 4

5k

Steering angle related deceleration

Deadman

0V 24V

Travel direction

Travel control 1A10 I

12

15

X1 8

X1:1

5 amps or t > 3 sec.

Current sensor B-

X1 11

Enable

Setpoint 0 =Vmax

X1 7

Load sensor

Contactor contact test

FE 3.2 3.4

Mode Input 1

Travel dir. DWS

X1 6

X1 16 X1 14

Travel dir. LS

X1 4

Power supply

Control of

Travel transducer Type=1

1

M-

B+

D1

D2

M

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Chapter 8

Travel control

Pin assignment E = Input A = Output

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Connector X1 Pin 1E Pressure sensor The pressure sensor is connected to the vehicle's initial-lifting cylinder with a T-piece. The greater the load on the forks, the more voltage is generated by the pressure sensor. The voltage range is between 1 and 4 volts. The braking you initiate with the deadman is influenced according to this voltage. More voltage means stronger deadman braking. The aim of this system is to achieve braking that is not influenced by the load.

If line breakage occurs, the strongest braking possible is initiated.

2E Hour meter for lifting and lowering 3A Lift stop battery discharge indicator.

If the 0V signal is removed from this output, the battery has discharged down to 20%.

4A Negative control of travel contactor 1K34.

In order for 0V to be issued at this output, there must be 24V applied at X1:16, there must be no internal errors and the contactor contact test 1K34 must be positive.

5A Not in use

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Chapter 8

Travel control

Pin assignment Connector X1 Pin 6E Setpoint The voltage between X1:6 and X1:7 or negative must be approx. 3.3V when the travel transducer is in the neutral position and approx. 0V when fully deflected.

The resistance between the above pins should be approx. 4.75K in the neutral position and approx. 0K when fully deflected.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

7A Setpoint supply (0Volt) 24V should be measured against positive at this pin.

8A 0V is applied to this pin when the deadman switch is actuated and a travel direction is selected. If the vehicle is already in motion and the deadman switch is released, the 0V voltage is not removed until the vehicle comes to a standstill or if the braking time extends beyond 3 secs. (e.g. if the vehicle were to roll down a ramp).

9E Mode selection 2 There are four parameter modes in total. Which mode is activated depends on the connection at pins X1:9 and 14. Which mode is selected with which connection variant is illustrated in the "Tabel of operating modes" (please see Vehicle control system/Description of functions).

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Chapter 8

Travel control

Pin assignment Connector X1 Pin 10 Not in use 11E Travel direction reverse 12E Travel direction forwards 13

Not in use

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

14E Mode selection 1 please see Pin X1:9 15E Enable When the deadman switch has been actuated, there should be 24V applied at this pin. The effect of this is that when the travel signal arrives, the electro-magnetic brake is released.

If the vehicle is already in motion, removal of the enable signal causes the generator brake to be initiated. When the vehicle is at a standstill, the electro-magnetic brake is applied.

16E Positive power supply for the control section 24V

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Chapter 8

Travel control

General

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The travel control can be adapted to meet customer requirements by changing the parameters.

The following can be adjusted: • Speed • Braking characteristics • Start-up behaviour and more.

A hand-held programming unit or notebook is needed for this work (please see Software/Vehicle control system)

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Chapter 8

Travel control

Description of functions Braking modes

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The connected motor can be braked as the result of 5 different conditions: • Removal of the deadman switch signal: generator braking on removal of the deadman switch is proportional in strength to the carried load (pressure sensor query).

• Removal of the travel direction signal (neutral braking).

• Change-over of the travel direction signal (reversing braking).

• Internal fault or external line breakage (electromagnetic brake).

• Travel on a curve.

Table of operating modes The operating mode is determined by the switching of pins X1:9 and X1:14.

4

3

16

9

2

1

8

1

By varying these two terminal pins, 4 different operating modes can be set.

Since a different parameter value can be programmed in each mode, the performance of the vehicle may be unfamiliar if an operating mode that was not wanted is selected due to a wrong connection.

10396

Mode

Speed

Operating mode

X1:14

X1:9

SU

SD

1

0V

0V

60,0 %

80,0 %

2

24V

0V

100,0 %

100,0 %

3

0V

24V

60,0 %

80,0 %

4

24V

24V

100,0 %

100,0 %

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Chapter 8

Travel control

Description of functions Travel on curves As soon as a steering angle of more than 20° is set, the output signal of the steering controller at pin X1:16 changes down from approx. 7.1V to a value of <3.2V. This signal is converted into a 0V signal in the ABÜ and sent on to the travel control. As a result, the travel control changes from Travel mode 2 to Travel mode 1.

Steering controller

OUT >20°

IN >20° X1 24

X1 16

<3.2V or >7.1V

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

However, since there is a smaller parameter value set in Mode 1 than in Mode 2, the travel speed is now reduced to approx. 60% of Vmax.

X2 10

ABÜ

As soon as the steering angle changes back to 18° again, the vehicle is returned to the normal speed.

Steering output = <3.2V

X2 11

--> ABÜ output = 0V 0V or 24V

Steering output = >7.1V --> ABÜ output = 24V

X2 14

Travel control

Mode input 1

If 0V are applied at the input of the travel control, Mode 1 is active = deceleration.

If 24V are applied at the input of the travel control, Mode 2 is active = Vmax

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Chapter 8

Travel control

Description of functions Hour meter There are two hour meters integrated in the travel control. They count the hours that pass a. while the key switch is switched on and b. during travel, lifting or lowering.

Which type of operating hours are shown can be set with parameters.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Service hour meter

1

SRVC TOTAL HRS

There are two service hour meters "Operation" (1 and 2) and two service hour meters "Emergency" (3 and 4) integrated in the travel control. They count downwards from a previously set number (the maintenance interval) to zero. The hours that have passed are counted a. while the key switch is switched on (1) and b. during travel, lifting or lowering (2).

When zero hours is reached, FE 23 and "SERVICE" appears on the display , The red LED under the spanner symbol lights up, the speed is not reduced jet, the two service hour meters "Emergency" (3 or 4) starts to run.

If the emerencycounter (3 and 4) also is reached zero hours, emergency operating mode is initiated, i.e. the vehicle is reduced in accordance with the parameter value Trac Fault SPR.It is set to a default value of 100%, i.e. no reduction. The red LED under the spanner symbol flashes up. FE 23 and "SERVICE" appears on the display .

2

0 hrs

3

DIS TOTAL HRS

4

0 hrs

There is a battery discharge indicator integrated in the travel control. In order for this to function correctly, the cut-off voltage, end charging voltage and charging factor must be programmed. If the battery voltage drops below a certain value (20% residual capacity), the lifting function is switched off.

In this case, the display shows 0% and the yellow LED on the display lights up.

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FE23,"SERVICE",Red LED lights up Vmax

DIS TRAC HRS

FE23,"SERVICE",Red LED flashes V trak fault spr

Counter Keyswitch

Battery discharge indicator

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SU/SV/SD

Counter Drive, Lift, Lower

30284

Sheet no.

8 â&#x20AC;&#x201C; 09

Chapter 8

Travel control

Description of functions Selbsttest Every time the vehicle is switched on, the travel control carries out a self-test. This test consists of: • Setpoint potentiometer monitoring • Test of travel contactor coils and contacts • Excess temperature +85°C • Low temperature

-25°C

• Low voltage

(16V)

• Amplifier short-circuit Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Excess voltage

(45V)

• Drive motor short-circuit

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Chapter 8

Travel control

Error display The travel control can recognise certain internal or external errors. If an error is detected, the travel function is interrupted, braking is initiated and the error is shown on the status LED (1) and the Curtis display unit. Errors are displayed continuously in the form of a 2-figure flashing code.

If no errors are detected, the status LED flashes about once every 5 seconds.

The code is displayed until the error is reset by switching the control off and then on again (enable or key switch), on condition that the error has been rectified (please see Travel control software/Error messages).

10394

1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Remark:

Only one error is ever shown at one time, and this is the last error to have occurred.

Example: Code"3.2" - Main contactor melted / stuck *** **

3

_

*** **

2 __

3

_

*** **

2 __

3

_ 2

10395

Test procedure If the relevant voltage potential is applied to the following terminals, the connected motor will start. If not, either the motor or the travel control is faulty.

X1:6

Resistance reading between X1:6 and X1:7 < 5K X1:7 Setpoint 0.4 - 8.6V X1:11 24V Travel direction LS X1:15 24V Enable via deadman X1:16 24V Power supply B0V Power supply B+ 24V Power supply

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Chapter 9

Component panel

Arrangement of the components on component panel for SU

-2F1

3F1 1F3 1F11

-1F1 U50

1K34

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

K1 2K1 3A20 3K1

W210 1A10

1A10 3A20 3K1 K1 2K1 1K34 1F3 2F1 3F1 1F11 1F1 U50

Travel control Steering controller Steering motor contactor Main contactor Pump contactor Drive motor contactor Fuse for control Main fuse for pump Fuse for steering controller Fuse for control Fuse for drive motor ABĂ&#x153; braking monitor

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Sheet no.

9 â&#x20AC;&#x201C; 01

Chapter 9

Component panel

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Arrangement of the components on component panel for SD

20418

1A10 3A20 3K1 K1 2K1 1K34 1F3 2F1 3F1 1F11 1F1 U50 X

Travel control Steering controller Steering motor contactor Main contactor Pump contactor Drive motor contactor Fuse for control Main fuse for pump Fuse for steering controller Fuse for control Fuse for drive motor ABĂ&#x153; braking monitor Connector for control current

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Chapter 10

ABÜ - Braking monitor

Block diagram of braking monitor ABÜ (U50)

X1:15

Enable steering 0V = OK

.

Travel control Enable 1A10 Travel or generator brake X1 8 Deadman Electro-magn. brake

ABÜ

.

X X2 14 Response signal V8 on

.

V8

.

Steering motor

X2 3

Enable deadman

X1 9 SU Steering OK = 0V

3K1

.

.

X3 1 X2 3X3 4

.

24V

X3 5

X1 11

X2 6

.

0

Actual value potentiometer steering

n.c.

4

5

12

1

..

.

P2

Switch-on test K1

X2:13 P3

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

PIC Relay, release brake

K1

X2:10

0V 24V

1

Wheel position display

Lift stop

.

.

.

K2

Power supply

Power supply 1A10

Mode 2

.K1

Travel direction

Standstill detection for steering

.

residual battery cap. reached

Switch-on test K1

0V K2

Rev. polarity diode X3 9 X1 6

2

1

X1 3

4

Travel direction

X1 14 Steering OK K =24V

.

24V

.

Speed sensor

2+24V

.

X1 16 > 20° X1 24

.

7 8

X3 10 X2 9 X2 11

1A10 Deceleration

.

1F11

3

2K1

.

Mech. lift stop

24V

O

X1 2

X3 2 Lifting button

Pump contactor

1+24V Key switch < 3.2V => 0 > 7.1V => 1

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Chapter 10

ABÜ - Braking monitor

Pin assignment *A = Output *E = Input X1 X1:1 A* X1:2 A X1:3 E* X1:4 E X1:5 A X1:6 A

12V power supply, speed sensor 0V power supply, speed sensor Channel 1 signal; speed sensor Channel 2 signal; speed sensor Not occupied Standstill detection for steering controller. As long as pulses are received at the steering controller, the steering remains active, even if the steering enable signal is removed.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

X2 X2:1 X2:2 X2:3 E X2:4 E

X2:5 E

X2:6 E X2:7 E X2:8 E X2:9 E X2:10 E

X2:11 A

X2:12 E X2:13 A X2:14 E

1+24V power supply for ABÜ.

0V power supply for ABÜ.

Travel enable for 1A10 and supply voltage for travel direction switch via deadman switch.

Steering controller OK=0V. This is applied as soon as supply voltage is applied at the steering controller and there are no internal steering controller errors.

Steering controller OK=24V. Applied as soon as supply voltage is applied at the steering controller and there are no internal steering controller errors.

Steering contactor 3K1 closed, i.e. steering contactor contact test is OK. Travel direction DWS Travel direction LS Signal from 1A10 to ABÜ to activate lift stop.

Signal from steering controller: Steering angle is < or > than 20°. At >20°, deceleration is initiated.

0V are applied at this output when the voltage at X2:10 is <3.2V. 24V are applied when the voltage is >7.1V. Steering actual value for the wheel position display Converted value for the wheel position display.

If two deadman switches are fitted - query whether both deadman switches are pressed.

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Chapter 10

ABÜ - Braking monitor

Pin assignment X3

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

X3:1 A

If 24V are applied at X3:9 and K1 is closed, 24V should be applied here.

X3:2 E Supply for potential-free normally open contact K2 (selection of pump contactor) X3:3 A If K2 is closed, the same potential should be applied here as at X3:2 X3:4 A Power supply for deadman switch.

Condition is: K1 closed, X3:9=24V, switch-on test for K1 positive, 3K1 closed, steering OK signal=0V X3:5 A Inverted output of X2:3 for enable steering=0V X3:6 E Start for the hour meter during lifting X3:7 E Start for the hour meter during lowering X3:8 A Connection of X3:6 and 7 via diodes for the hour meter in the travel control X3:9 E Foot contact of K1, is supplied by the steering controller output "Steering OK" X1:14 X3:10 A Power supply for the travel control. 24V if the reverse polarity diode in the ABÜ is in order.

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Chapter 10

ABÜ - Braking monitor

General Apart from monitoring the braking process, the ABÜ has the following functions: • Weel position display • Signal adaptation for the "Slow travel on curves" function The ABÜ monitors generator braking of the vehicle.

If the generator braking is not strong enough, the ABÜ opens internal relay K1, which causes the electromagnetic brake to be activated immediately.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The actual vehicle speed is detected by a speed sensor. These speed sensor impulses are offset against the braking time, which gives a delay time in m/ss.

The required delay time is stored as software in the ABÜ and is then continually compared with the actual delay time.

If there is a deviation downwards which is too large, relay K1 drops out and mechanic braking is initiated.

A differentiation is made between two delays: 1. 0.5 m/s2 SU when the travel direction signal is removed --> Neutral braking is monitored, not reversing braking 2. 1.5 m/s2

SU

1/0355

when the deadman signal is removed

K1 opens when: • The deadman is (no longer) actuated (X2:3=0V) and the speed is higher than 2.5km/h or the delay time is not within the range specified above.

• The travel direction is (no longer) selected (X2:7 and X2:8=0V) and the speed is higher than 2.5 km/h or the delay time is not within the range specified above.

• One of the speed sensor channels is faulty.

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Chapter 10

ABÜ - Braking monitor

Functions Wheel position display (optional) The steering angle of the steered wheel is measured by the actual value potentiometer and sent to the ABÜ at X2:2. Here, the value is converted and controlled with two potentiometers P2/P3, so that the display unit can be adjusted.

30043

Adjusting the display

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Teach in the steering actual value (see "Steering actual value").

1

2

• Move the drive wheel into the "straight-on position".

• Turn potentiometer P2 (1) until the display also shows "straight-on".

• Move the drive wheel into the 90° position.

1/0355

• Turn potentiometer P3 (2) until the display also shows 90°. The display for the steering angle on the other side is then set automatically.

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Chapter 10

ABÜ - Braking monitor

Functions Travel on curves Signal adaptation

Steering controller

As soon as a steering angle of more than 20° is set, the output signal of the steering controller at pin X1:16 changes down from approx. 7.1V to a value of <3.2V. This signal is converted into a 0V signal in the ABÜ and sent on to the travel control. As a result, the travel control changes from Travel mode 2 to Travel mode 1.

OUT >20°

IN >20° X1 24

X1 16

<3.2V or >7.1V

X2 10

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

ABÜ However, since there is a smaller parameter value set in Mode 1 than in Mode 2, the travel speed is now reduced to approx. 60% of Vmax.

As soon as the steering angle changes back to 18° again, the vehicle is returned to the normal speed.

X2 11 0V 24V

Steering output = <3.2V --> Output ABÜ = 0V

X2 14 Mode input 1 Travel control

Steering output = >7.1V --> Output ABÜ = 24V

If 0V are applied at the input of the travel control, Mode 1 is active = deceleration.

If 24V are applied at the input of the travel control, Mode 2 is active = Vmax

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Chapter 10

ABÜ - Braking monitor

Flashing error codes There is a red LED (1) on the ABÜ board. In the event of an error, this lights up in a certain rhythm. This rhythm is also an error code.

If an error has occurred, this can be recognised from a longer switching-on impulse.

Example: To indicate error 5: Error 1 2 impulses

3

4

5

6

7

8

long pause

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Copyright reserved.

Several errors can also be shown at once.

Example: Error 2 and Error 4:

Error 1 2 Pulses

Error 3

4

5

6

7

8 long

1

pause

The following errors can be displayed: Impulse 1: Speed too high on brakingImpulse 2: No voltage at X3:9 (foot contact relay K1) Impulse 3: Relay K1 faulty Impulse 4: Output transistor V8 for X3:4 faulty

0/0167

Impulse 5: Internal transistordriver is defect Impulse 6: Deadman 1(X2:3) and Deadman 2 (X2:14) have different signals at input.

Impulse 7

Speed too high (e.g. speed sensor is producing unclear impulses).

Impulse 8: Speed sensor faulty

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 If there are no errors, the red error LED shows the speed sensor impulses.

Once an error has been rectified, a key-switch reset must be carried out.

SU/SD/SV

Sheet no.

10 – 07

Chapter 11

Curtis display unit

General The Curtis display unit displays the following data from the travel control: • Operating hours • Maintenance date • Remaining battery capacity • Error codes There are also three LEDs which display the following information: Red LED (1):

Service interval finished 10397

Yellow LED (2): Flashes when battery discharged 3

2

1

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Copyright reserved.

Green LED (3): Hour meter, is only shown for the first 3 seconds after switching on.

During this time, the green LED is illuminated.

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Chapter 11

Curtis display unit

Pin assignment Pin 5 = B+ Operating voltage (15V) min Pin 8 = B - (0V) Pin 6 = Data input

8

5

4

1

Pin 1, 2, 3, 4, 7 not occupied

Technical data 15V min -10°C to +70°C

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Copyright reserved.

Operating voltage Operating temperature

10398

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Chapter 11

Curtis display unit

Function When the vehicle is switched on at the key switch, all 3 LEDs (green, yellow, red) light up for 3 seconds, then the operating hours are shown for 3 seconds and the green LED is on.

Then the red and green LEDs go out and only the yellow LED continues to be lit up continuously. In place of the operating hours, the remaining battery capacity is now shown in %.

10397

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Copyright reserved.

Error display If an error has occurred, the red service LED flashes.

At the same time one of the errors from the error code table of the travel control is shown on the display. The error code appears every 3 seconds alternating with the remaining battery capacity. Any maintenance intervals that have come to an end are also treated as errors. The word "SERVICE" appears on the display every 60 seconds for a period of 5 seconds.

Battery discharge indicator The yellow LED is illuminated continuously after the switching-on test and when the hour meter display has gone out. When a remaining battery capacity of 20% is reached, this LED starts to flash. At the same time, the lifting function is interrupted.

When there are no errors, the remaining battery capacity is displayed as a %age.

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Chapter 11

Curtis display unit

Hour meter When the vehicle is switched on at the key switch, the green LED lights up for about 5 seconds and then goes out. This means that the hour meter is working.

Whether the total hours or the travel, lifting and lowering hours are displayed depends on how the travel control is programmed (parameter settings).

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Copyright reserved.

Between 0 and 999 999 hours can be displayed. When the maximum is reached, the display is automatically reset to 000 000 hours.

The operating hours can be set to a value of your choice. In order to do this, the following parameters in the travel control must be set accordingly ADJ HRS high ADJ HRS mid ADJ HRS low and adopted with SET TOTL HRS or SET TRAC HRS (ON/ OFF).

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Chapter 12

Battery

General It is essential to ensure that only batteries that comply with the data sheet requirements for nominal voltage and minimum weight are used in the vehicle.

Durability and lifetime The durability is the minimum number of charging cycles (1500) that can be carried out without the capacity dropping below 80 % of the nominal value.

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Copyright reserved.

The actual lifetime may be longer or shorter than the durability, since numerous influences in practical operation place completely different strains on the battery than it is subjected to under laboratory conditions.

Influences that extend the battery life are, for example: • Good maintenance and care • Low loads • Normal operating temperatures (30-40° C) • Good recharging practice • Avoidance of total battery discharge and prompt rectification of faults Influences that shorten the battery life are, for example: • Frequent total battery discharge • Continuous higher temperatures (> 40° C) • Charging with unadmissibly high current when the voltage at the beginning of gassing has been reached (2.4V/cell) • Leaving the battery to stand when it is discharged • Overloading or short-circuits • Impurities entering into the electrolyte

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Chapter 12

Battery

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Handling and maintenance • The best operating temperature is between 25° C and 40° C. In order to avoid permanent damage to the battery, the highest permissible electrolyte temperature of 55° C should never be exceeded.

• In situations where the battery is subjected to heavy loads and/or used in winter temperatures, the battery should be charged every day, even if less than 80 % of the standard capacity has been used.

• The tray lid or battery cover must be removed or opened without fail before charging and for intermediate charging.

• A temperature rise of between 10° and 12° C can be expected during charging of the battery. With batteries that are subjected to heavy loads, this can cause a rise in the electrolyte temperature to above 55° C. If necessary, allow the battery to cool down and interrupt the charging process.

• The cell stoppers can be left in place during charging.

• The tray lid or battery cover should not be closed for at least 1/2 hour after charging is complete.

• Always connect the battery charger with the correct polarity, otherwise the battery and/or the charger may be damaged (+ to +).

• Only charge with direct current.

• In order to prevent leak currents, batteries should always be kept clean and dry (Neutralo spray).

• The terminals and connectors should always be sprayed with terminal spray to prevent oxidation and sulphate formation.

• Lifting devices that are not compatible cause damage to the battery (tray distortion and damage to insulation).

• Protect the battery from impurities, such as metal dust and ammonia vapours.

• If in doubt, consult the customer service department of the battery supplier.

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Chapter 12

Battery

Maintenance intervals Daily work: charge the battery Weekly work: Check the electrolyte level. If necessary, top up with demineralised water towards the end of the charging time. It should be topped up at the latest when the electrolyte level has dropped to the level of the baffle.

Monthly work:

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Copyright reserved.

Check all cells for equal gassing towards the end of the charging time. Measure the acid density and temperature once charging is complete, and register any deviations from the set values.

Quarterly work: When charging is complete, check the electrolyte temperature of all cells. If one cell gives significantly different results from the others, it must be checked separately.

The insulation resistance of the battery must be measured in accordance with VDE regulations with the external circuit disconnected. The bottom limit is 50 Ohm per V of nominal voltage.

However, the measurement must not be less than 1000 Ohm. If the insulation resistance is lower, the cells and case must be cleaned.

6-monthly work: Check the function of the charger, in particular the level of the charging current at the start of serious gassing (2.4 V/cell).

The connectors and connector devices must be checked to ensure that they function correctly. 

In addition to these basic specifications, the specifications of the battery manufacturer should also be complied with.

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Chapter 12

Battery

Acid density test When the acid is well mixed, the acid density is an indication of the degree to which the battery is charged. It does not, however, increase more acutely until towards the end of charging. This is due to the gassing, which starts at about 2.4 V/cell.

Acid pipette

1 Areometer

The acid density is measured with an areometer (pipette acidity tester) (1).

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Copyright reserved.

During the measuring process, the floater must not stick to the side or knock against the top. A correct measurement of the acid density can be obtained if the measurement is taken about 1/2 hour after completion of the charging process.

To guarantee a correct reading, you should avoid taking a measurement directly after the water has been topped up, since the water and acid must be mixed.

1/0399 + 1/0400

The battery temperature should not deviate significantly from 30° C during the measurement.

Acid density when the battery is fully charged: 1.27 kg/l Acid density when the battery is discharged: 1.13 kg/l

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Chapter 12

Battery

Prevention of damage and accidents Handling batteries is potentially very hazardous. For this reason, the following points must be observed without fail:

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Copyright reserved.

a) Danger: Charging gases can cause deflagration or explosion.

Preventative measures: Good ventilation, prevention of electrical sparks, no bare flames in battery compartments, do not smoke

Space for battery manufacturer's name and logo

No. of cells

Type

Capacity

b) Danger: Acid can cause injuries and cause corrosive damage to parts.

Preventative measures: Always wear protective clothing that is resistant to acid, rubber gloves and protective goggles.

Keep a neutralising agent at the ready. Keep water at hand for rinsing out the eyes if necessary (in the event of eye injuries, call a doctor immediately).

Weight

Tray no.

Nominal voltage Battery no.

Delivery date

c) Danger: Voltages of more than 40 V can be damaging to the health.

Preventative measures: Do not touch any live parts, and inform personnel about the same. Compliance with VDE regulations 0100 and 0105. d) Danger: Lead and lead compounds are a health hazard when they are taken up by the human body.

Preventative measures: Eating and drinking is prohibited in the battery charging station. Always wash your hands after working on batteries. e) Danger: Batteries can cause damage if they fall over or drop out of lifting gear.

Preventative measures: Only use suitable and safe lifting equipment.

Provide the necessary securing devices to prevent the battery falling over or slipping off the loading surface of the means of transport.

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Chapter 12

Battery

Commissioning unfilled battery with charged plates After removing the stoppers, all the cells must be filled equally with sulphuric acid with a density of 1.25 kg/l. They should be filled to the lower acid level mark (use a cell filler or plastic funnel).

The acid should have a temperature of + 15°C when it is poured in. After an interval of 5-6 hours, the acid should be topped up slightly if necessary.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The temperature increase must be measured with a thermometer, which should be immersed in the electrolyte in one of the cells in the middle of the battery. If the temperature rise is less than 10° C, the battery can be connected to the charger for recharging.

The recharging time is between 6 and 12 hours until the control switch of the charger switches off automatically. A longer charging time (up to 20 hours) is needed for I-h charging (without automatic switching off).

The temperature must be monitored during charging. It must not exceed 55°C, otherwise the charging process must be interrupted so that the battery can cool down.

When the charging process is complete, the acid density should be 1.27 kg/l ± 0.01 kg/l. If this is not the case, you must continue charging until a uniform acid density of 1.27 kg/l is reached.

The battery is now ready for operation. If necessary, top up the electrolyte to the nominal level with distilled water. If the acid density is too high, draw off some of the acid and top up with distilled water. 

If the electrolyte temperature rises by more than 10°C after filling or if the density of the acid that has been added has reduced by more than 0.03 kg/l, the plate material has lost some of its charge during previous storage. A longer commissioning time is then required. In addition to these instructions, it is important to adhere to the instructions of the battery manufacturer!

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Chapter 12

Battery

Changing the battery Lifting and removing the battery When the battery compartment cover is opened with its swivelling brackets, which secure the battery, the battery can be freely accessed from above.

Pressing the battery free-lift button causes the 4 ball bearings, which act as rollers, to rise by 10 cm to the max. lifting height (120 mm). This makes it easier to install and remove the battery.

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Copyright reserved.

The battery is now no longer locked in place, and can be guided out over the rollers at either side with a battery changing frame.

20420

Before taking this step, please ensure that the frame is suitable for the battery weight (this information is provided on the battery nameplate).  Battery type: 3PzS 420L in special tray The dimensions of the battery tray do not comply with DIN standard: width = 790 mm, DIN width = 830 mm)

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Chapter 12

Battery

Changing the battery Installing the battery Before installing the battery, please check the following: • Tray type, tray size with anchor • Minimum weight (see vehicle nameplate) • Voltage (24 V) • Correct polarity on connection

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Any damage to the battery Once the battery has been replaced, it must be secured in place again by pressing the lowering button and closing the battery compartment cover.

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Chapter 13

Valve driver

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Copyright reserved.

Block diagram

Demand

+24V

Lifting/lowering, initial lift

Ventiltreiber

Enable Hydraulic

Lifting

Lowering

0V

20190

20190

Proportionalvalve Lift/Lower Mainlift and Initiallift

Solonoid Lower Mainlift and Initiallift SD

Pumpcontaktor

Solonoid Lift/Lower Mainlift

Solonoid Lift/Lower Initiallift

Proportionalvalve Lower Mainlift SV

Remark: The Valvedriver for SD and SV is different.The Reason is that we have only one Proportionalvalve for SD but we have got two for SV.(please see Valvedriver/Pinassignment) ID-Nr.SD: 427 557 ID-Nr.SD: 428 814 Issue Replaces issue

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Chapter 13

Valve driver

Pin assignment Connector X1 1 E Signal for lifting main and initial lift from throttle 2 E Signal for lowering main and initial lift from throttle 3 E Signal for lifting or lowering initial lift (not main lift) 4 A Power supply for throttle potentiometer, 10 volts 5 E Setpoint from throttle, 0.4 - 3.4 volts 20189

6 A Throttle power supply, 0 volts

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Copyright reserved.

7 E Hydraulic enable.No hydrauliv funktion without this signal

E = Input signal; A = Output signal

Connector X2 1 E Board power supply, 24 volts 2 E Board power supply, 0 volts 3 E Board power supply, 0 volts 4 A +selection of proportional valve, 250-800 mA currentless closed 5 A -selection of proportional valve 6 A SD: +selection of B/W valve for lowering mainand initiallift, 24 volts Remark: The Valvedriver for SD and SV SV: +selection of proportionalvalve lowering is different.The Reason is that mainlift, 2Y21 we have only one Proportio7 A +selection of B/W valve for lifting main lift, nalvalve for SD but we have 24 volts got two for SV.(please see Valvedriver/Pinassignment) 8 A +selection of B/W valve for lifting initial lift, 24 volts ID-Nr.SD: 427 557 9 A +selection of pump contactor, 24 volts ID-Nr.SD: 428 814 10 Not in use 11 E Switch signal 2S30 battery free lift 12 E Switch signal 2S5 mechanical lift stop, initial lift 13 E Switch signal 2S46 release of intermediate lift stop (option) 14 E Switch signal 2S26 function of intermediate lift stop Issue Replaces issue

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Chapter 13

Valve driver

General The purpose of the valve driver is to control the three black and white valves in the valve block and the proportional valve in the pump unit.

The valve driver receives the following input signals from the throttle:

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• X1:5 : Setpoint for lifting/lowering the main lift and initial lift • X1:3

Enable signal for initial lift

• X1:7

Enable signal for hydraulics

• X1:1

Signal for "lifting main and initial lift"

• X1:2

Signal for "lowering main and initial lift"

20187

With the help of these input signals, the following valves are selected: Proportional valve 2Y01 (4) Lifting/lowering main lift, lowering initial lift

3

1

B/W valve 2Y21 (2) 2

Lowering main and initial lift B/W valve 2Y37 (1)

4

Lifting main lift B/W valve 2Y47 (3) Lowering initial lift 

Under which conditions which output is set is shown in the table of functions on the following page.

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Sheet no.

13 – 03

Chapter 13

Valve driver

General The purpose of the valve driver is to control the two black and white valves in the valve block , the proportional valve in the pump unit and the external propvalve.

The valve driver receives the following input signals from the throttle:

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• X1:5 : Setpoint for lifting/lowering the main lift and initial lift • X1:3

Enable signal for initial lift

• X1:7

Enable signal for hydraulics

• X1:1

Signal for "lifting main and initial lift"

• X1:2

Signal for "lowering main and initial lift"

20187

With the help of these input signals, the following valves are selected: Proportional valve 2Y01 (4) Lifting main lift, lifting/lowering initial lift Propvalve lowering mainlift 2Y21 (2) B/W valve 2Y37 (1) Lifting/lowering main lift B/W valve 2Y47 (3) Lifting/lowering initial lift



2

Under which conditions which output is set (please see valvedriver/Table of functions)

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30276

Sheet no.

13 – 04

Chapter 13

Valve driver

Removal The valve driver is located underneath the steering wheel cover (1). This cover can be removed by unscrewing the two hexagon socket screws (2).

The valve driver box is screwed to the chassis with two screws (3).

The cover can be taken off by removing the four Phillips screws (4).

20187

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

3

1

2 20183

20188

4

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Chapter 13

Valve driver

Flashing error codes There is a red LED (1) on the valve driver board. This LED indicates errors that occur with a flashing code.

In normal operation, the LED is illuminated permanently.

Wire breakage or short-circuit of valve coil: Flash pulse Pause

20187

1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Internal error Flash pulse Pause

Potentiometer supply from setpoint generator is faulty Flash pulse Pause



If an error is detected by the valve driver box, all the outputs are switched off. .

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Chapter 13

Valve driver

Table of functions SD

INPUTS Terminal Function

X1:5

X1:7

Lifting/ Enable Setpoint lowering hyinitial lift draulics

Lifting main lift Lowering main lift

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Copyright reserved.

X1:3

OUTPUTS

X

X

X

X

Lifting initial lift

X

X

Lowering initial lift

X

X

X1:1

X1:2

X2:9 X2:4

Lifting Lowering Pump

X

Proport ional valve

X

X2:8

X2:6

Main lift

initial lift

Lowering

X

X X

X2:7

X

X

X

X

X

X

X

SV

INPUTS Terminal Function

X1:5

X1:3

OUTPUTS

X1:7

Lifting/ Enable Setpoint lowering hyinitial lift draulics

Lifting main lift Lowering main lift

X

X

X

X

Lifting initial lift

X

X

Lowering initial lift

X

X

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X1:1

X1:2

X2:9 X2:4

Lifting Lowering Pump

X

X

Proport ional valve

X2:7

X2:8

X2:6

Main lift

initial lift

Lowering

X

X X

X

X

X

SD/SV

X

Sheet no.

13 â&#x20AC;&#x201C; 07

Chapter 14

Hydraulics

Block diagram of hydraulics Power supply X1.16

1A10

Battery controller 0V = Batt.ok.

When 20% remaining X1 3 capacity is reached, the 0V signal is removed.

X2 9

1F3

ABĂ&#x153; Emergency stop

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

PIC

key switch K2

Lifting X3 3

2

K1 Battery free lift Lowering Pressure sensor

2F1

2K1

Lowering valve

2M1 M

P

1/0402

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14 â&#x20AC;&#x201C; 01

Chapter 14

Hydraulics

Filter The purpose of the mainliftfilter (1) is to filter the hydroulicoil that flowes to the maincylinders.

Der It is placed onHaupthubölfilthe backside of the batterieroom between mast and loadchain.

2 1 3 4

Size of filter: 100µ /6cm

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Copyright reserved.

Maintainens 30282

The oilfilter must be maintained like the maintainensplan it says (please see Maintainens/hydraulictank/filter) .

Lower the mainlift completely down,unscrew nut (2),and take the filter out.Collect the oil thats runing out of the pipes.

Reassembly the filter by unscrew the hexagonalscrew (4) ,take filtersieve (5) out and clean it with pressureair.

Remark: Filterinstallation only in direction downwards (3).

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Chapter 14

Hydraulics

Lowerbreakvalve General The lowerbreakvalve prevents the abrupt lowering of the mainlift in case of a brocken hydraulictube.

In the moment if the loweringspeed increases to 0,6 m/ sec, the lowerbreakvalve will be aktiv and prevents a further rise of the lowerspeed.

The lowerbreakvalve is placed on the backside of the batterieroom between mast and loadchain, underneadh the oilfilter (please see Hydrauliks/Filter) 30283

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Copyright reserved.

Typ: 25 l/s

1

Removal • Lift the mainlift to app. two meters and secure the liftingdevice against lower down with some adequate wood.

• Be prepared with a container against oil that runs out of the hydraulictubes and loose the hexagonalscrew (1).

• Save the oil.

• Loose the second hexagonalscrew at the Tcrossing of the Cylindersupply and take the lowerbrackevalve out.

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Chapter 15

Pump unit

Individual components

1

The pump assembly is made up of the following components (1) Compound motor 24V/2KW

8

7

(2) Gear pump, externally toothed (3) Hydraulic suction filter

4

(4) Lowering valve (5) Tank (6) Air filter (7) Carbon brushes

3

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Copyright reserved.

(8) Pressure relief valve

8/0064

2 5

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6

Chapter 15

Pump unit

LIFTING function P When the pump motor (1) is driven, it starts the externally toothed pump (2), which immediately causes oil to flow from the tank via the suction filter (3) and the non-return valve (4) to the pressure port "P".

4

1

There is a pressure line connected at pressure port "P" that is connected to the lifting cylinder.

8/0065

If the pressure rises at the "P" port, the pressure at the pressure relief valve (5) increases --> the pressure relief valve opens and the oil flows back to the tank.

.

3

2

5

Excess pressure

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Working pressure

Oil pressure from pump

P

4

.. .. ...... .. .. . .. . ..

8/0066

Return flow to tank

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Chapter 15

Pump unit

LOWERING function

1

For the load to be lowered again, the electrically pilot controlled non-return valve (directional valve, 1) must be supplied with current by the "Lowering" key.

2

The electrically pilot controlled non-return valve then changes its switching position.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

So that the load is not lowered too quickly, the lowering brake valve (2) is fitted after the non-return valve. This only allows a certain volume of oil to flow through in a certain time, so that a controlled lowering speed is achieved (11 l/min).

.

Return flow

8/0067

. ....... .

P

2

.. .. .

8/0066

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Chapter 15

Pump unit

Electrically pilot controlled nonreturn valve (2/2-way valve) The 2/2-way valve is a bevel-seated valve.

The directional valve that is illustrated here is a socalled OPENER valve, i.e. when the coil (1) is not excited, the taper pin (2) presses on the slider (3) and therefore closes the control hole (A --> B).

1

2

If the coil (1) is then excited, the taper pin (2) is pulled upwards. The oil pressure that is then applied causes the slider (3) to move upwards, and the oil can flow unobstructed from A --> B. 8/0068

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Copyright reserved.

3 Coil resistance = 40 Ohm

B

A

1

8/3122

2

8/0069

Ohm

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Chapter 15

Pump unit

Replacing carbon brushes on the SU

3

1

2

4

The carbon brushes must be replaced when they reach a residual length of 11mm. At this length, they are worn down by 50 %.

Length of a new carbon brush: 22mm The entire set of brushes must always be replaced (4 brushes).

Removal • Pull out the battery plug.

• Unscrew the 2 hexagon screws (1).

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8/0070

• Screw in a hexagon screw (5 x 30 mm) (2) to help pull off the carbon brush lid (4) until you feel some resistance.

7

• Continue pulling the carbon brush lid off the motor (3) with a screwdriver.

6

• Alternately screw in the puller screw and lift the carbon brush lid (4) with the screwdriver and pull out the carbon brushes.

• Slowly release the carbon brush spring (7).

• Unscrew the fastening screw (6) of the carbon brush connecting lug and remove the carbon brush.

• Clean out the commutator compartment (blow it out with oil-free compressed air).  Never inhale carbon dust!

To replace the brushes follow the instructions above in reverse order.

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Sheet no.

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Chapter 15

Pump unit

Replacing carbon brushes on the SD The carbon brushes must be replaced when they reach a residual length of 16 mm.

• Pull out the battery plug.

• Remove the pump assembly (please see "Pump assembly, Removal").

• Remove the red plastic cap (1).

20193

1

• Unscrew and remove the threaded pins (2).

• Screw one of these threaded pins into the opening (3) to push off the carbon brush cover (4).

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• Lift the carbon brush spring with a wire loop and lift the carbon brushes out of the guide shaft.

• Release the Phillips screw (5) and replace the carbon brush if necessary.

20194

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4

3

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Chapter 15

Pump unit

Removing the pump motor • Pull out the battery plug.

2

• Unscrew the 2 nuts (2).

• Disconnect the connecting cable (1) at the motor (mark the cable).

1

• Carefully take down the motor.  There is a mounting pin (3) in the lower part of the motor housing. Take note of this when re-installing. The mounting pin is generally on the side of the electrically pilot controlled non-return valve.

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Copyright reserved.

8/0072

To install, follow the instructions above in reverse order, taking care to comply with the following points: • See the remark above.

• Push the motor shaft correctly onto the cross coupling (4).

3

8/0073

8/0041t

4

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Chapter 15

Pump unit

Hydraulic pump General The hydraulic pump is an externally toothed gear pump.

Die Pumpe besteht im wesentlichen aus dem Zahn The pump consists essentially of a pair of gear wheels, which is mounted in 4 bearing bushes, and a housing with a cover at the front and back. A drive shaft sealed with a rotary shaft seal is inserted through the front cover.

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Copyright reserved.

The bearing forces are taken up by sliding bearings.

These are designed for high bearing pressures and have good emergency running properties, especially at low speeds.

Internal sealing of the pressure compartments is pressure dependent, which gives ideal operational efficiency.

A

A

B

B

C

C

Pressure side

At the front end, the movable bearing bushes are subjected to operating pressure and are pressed against the gear wheels to form a seal.

Suction side

8/0075

The pressure fields that are applied are limited by special seals.

The seal around the edge of the gear wheels is guaranteed with a tiny gap that adjusts when the gear wheels are pressed against the housing as pressure is applied.

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Chapter 15

Pump unit

Removing the hydraulic pump Suction side End cover Housing 3 parallel grooves

Drive wheel end cover Grooves for leaking fluid Radial grooves

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Copyright reserved.

8/0077

Sealing and supporting element Openings Drive shaft High-pressure seal Gearwheels Radial seal

Pressure side

Dismantling • Pull the drive wheel off the shaft.

Front rest

• Release the hexagon socket screws.

Housing Drive gearwheel

• Lift off the cover over the drive shaft.

• On a piercing press, push the shaft, together with the ball bearing, out of the bearing cap.

Mark the driven gearwheel and rest.

• By pulling on the housing, draw the shaft with the drive gearwheel, driven gearwheel and the front rest out of the housing (use a protective jaw).

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Sheet no.

15 – 09

Chapter 15

Pump unit

Adjusting the pressure relief valve on the SU The maximum pressure of the pump assembly is preset in the factory to 150bar and should not normally need to be adjusted.

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Copyright reserved.

When it is set to this pressure, the vehicle can lift 2100kg .

However, should adjustment still be necessary, proceed as follows:

4

• Unscrew the cover sleeve (1).

• Unscrew the pressure adjusting screw (2) almost all the way out.

• Unscrew the closure stopper (3) and connect a manometer (4) with a measuring range of at least 200bar at this point.

• Open the battery cover and press the "battery free lift" switch, which is now accessible, until the pump reaches the end stop.

• Now screw in the pressure adjusting screw (2) until the manometer displays 150bar.

• Disconnect the manometer and screw in the closure stopper again (3).

Tightening torque: 23 Nm.

30044

1

3

Recommended values for pressure adjustment: 8/0079

Maximum pressure ....approx. 150bar Working pressure without load .................approx. 50bar Working pressure with load ......................approx. 100bar Current consumption without load. ................approx. 75A Current consumption with load. .....................approx. 125A

2

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Chapter 15

Pump unit

Adjusting the pressure relief valve on the SD/SV The maximum pressure of the pump assembly is preset in the factory to 190bar SD and 200bar SV should not normally need to be adjusted.

When it is set to this pressure, the vehicle can lift 2000kg with just the basic lift, 1000kg with just the main lift, and 200kg with the basic and main lift.

However, should adjustment still be necessary, proceed as follows:

20199

1

• Unscrew the cover sleeve (1)

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Copyright reserved.

• Unscrew the pressure adjusting screw (2) almost all the way out.

• Unscrew the closure stopper (3) and connect a manometer with a measuring range of at least 200bar at this point.

• Open the battery cover and press the "battery free lift" switch, which is now accessible, until the pump reaches the end stop.

20200

2

• Now screw in the pressure adjusting screw (2) until the manometer displays 190/200bar.

• Disconnect the manometer and screw in the closure stopper again (3).

Tightening torque: 23Nm.

Proportional valve 2Y1 The proportional valve (4) processes an analogue current of 250 to 800mA. This is equivalent to a setpoint from the throttle of 0.4 to 3.4volts.

3

This makes it possible to vary the lifting and lowering speed of the main lift.

In order to guarantee start-up without jerking, a ramp is initiated on acceleration and deceleration of the valve driver box.

With the basic lift function, the proportional valve is switched on and off  a ramp.

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Sheet no.

15 – 11

Chapter 15

Pump unit

Changing the hydraulic oil Frequency: Oil type:

every 12 months HLP46 DIN 51524

Oil volume:

SU 1,4l SD 4,0l SV 6,0l

Procedure 1. Carry out the steps described on sheet A6.

2

2. Dispose of the oil hydraulic oil in accordance with the regulations.

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Copyright reserved.

3. Clean the oil tank (1).

4. Replace the hydraulic suction filter (2) if necessary.

5. Fill the tank with hydraulic oil.

6. Mount the oil tank.

7. Check the hydraulic system for leaks.

8. Attach the oil information card.

8/0076

9. Replace the cover.

1

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Chapter 15

Pump unit

Tecnical datas Performance rating Nominal current Nominal voltage Protection

3 KW 125 Amp 24 Volt IP 54

Removal

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Copyright reserved.

30279

The best way to remove the oiltank or the motor is to remove the hold pump unit.

Therefor unscrew both ellenscrews (1) at the footroom of the driver.

Dont forget to loosen al kables from the valveblock,pumpcontaktor and pumpmotor before.

1

Exchange the Carbonbrush on SV The Exchange of the Carbonbrush is necessary if the Carbonbrush reached a length of less than 16 mm.

30280

3

• Pull the batteryplug out.

2

• Remove the pumpunit (please see pumpunit/removal).

• Unscrew screw and nut (2).

• Remove cover plate (3) • Take a wirepuller and pull the carbonbrush at the brushcable out of the shaft.

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Chapter 15

Pump unit

Pump contactor 2K1 In the SD, the pump contactor is not on the component panel, as it is in the SU, but is located directly on the pump assembly. It is secured to the pump motor here with a hose clip.

The pump contactor 2K1 is controlled by valve driver 2A3. The pump contactor is switched on when either the lift main lift or lift basic lift function is selected.

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Coilresistor: 27 Ohms Measuring on pins (2)

20197

Tank volume The SD-Tank underneath the pumpunit have a volume of 4 Litres.

Only 3,5 Litres are aktually used.That means that 0,5 Litres remain in the Tank if all cylinders are extended.

The SD-Tank underneath the pumpunit have a volume of 6 Litres.

Only 4,9 Litres are aktually used.That means that 1,1 Litres remain in the Tank if all cylinders are extended.

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Chapter 16

Pressure sensor

Pressure sensor

1

The pressure sensor (1) measures the pressure applied to the forks and converts it into a voltage signal of 1 - 3.4V. The higher the pressure, the higher the voltage. A higher voltage means stronger braking.

This means that the generator braking is not load dependent.

The minimum and maximum values for the sensor voltage must be determined and programmed as a parameter (please see "Travel control software, List of parameters").

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Copyright reserved.

For information about determining the minimum and maximum sensor voltage value, please see Travel control software, Description of parameters.

If the pressure sensor voltage drops below the value entered in the parameter, the system identifies this as cable breakage, i.e. maximum braking is then always used.

1/0403

Technical data Maximum pressure: Voltage range: + power supply: - power supply:

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0-220bar 1-5V Terminal 3B23:3 9-30V Terminal 3B23:1 0V Terminal 3B23:2

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Chapter 17

Valve block

General SD 1 The valve block is made up of three separate valves.

Black/white valve for lifting basic lift 2Y47 (1)

B

Black/white valve for lifting main lift 2Y37 (2) Black/white valve for lowering 2Y21 (3)

H

Neither valve coils nor individual segments of the valve block can be replaced.

2

P

Hydraulic connections SD Connection P: Pressure lead, from pump assembly

20184

Connection H: Oil lead to the main cylinders

3

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Copyright reserved.

Connection B: Oil lead to the basic lift cylinders

Technical data Resistance value of a valve coil:

30 ohms

Voltage:

24 volts

Current:

0.8 amps

 There is a free wheel diode in the valve connector (connections 1 and 2).

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1 3

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Chapter 17

Valve block

General SV The valve block is made up of two separate valves.

3

I

Black/white valve for lifting/lowering initiallift 2Y47 (3) 1

Black/white valve for lifting main lift 2Y37 (1)

H

Neither valve coils nor individual segments of the valve block can be replaced.

P

Hydraulic connections SV Connection P: Pressure lead, from pump assembly 30277

Connection H: Oil lead to the main cylinders

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Connection I: Oil lead to the initial lift cylinders

Technical data Resistance value of a valve coil:

30 ohms

Voltage:

24 volts

Current:

0.8 amps

 There is a free wheel diode in the valve connector (connections 1 and 3).

5

External valves 30276

External proportionalvalve 2Y21 (5) Controlls the speed for mainlift lowering Proportionalvalve inside the pumpunit 2Y1 (4) Controlls the speed of mainlift lifting and initiallift lowering.(please see valvedriver/blockdiagram)

5

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Chapter 18

Steering software

General Diagnosis and settings are carried out with a notebook, an adapter cable and the relevant service software: ParaDigLS24.

The adapter cable (1) Id. no. W8 409 559 is connected directly to the notebook COM1 at connector X99 (2) on the other side.

The service software has the following functions: • Setting up a connection For communication between the notebook and steering

2

20223

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Copyright reserved.

• Errors Reading out current or stored errors.

• Teaching-in set and actual values Teaching in the middle and end positions of the set and actual value potentiometers.

• Tester menu Inputs and outputs, speeds, potentiometer voltages and amplifier can be checked.

• Settings Setting different wheel distances.

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Chapter 18

Steering software

Making a connection Prerequisites: Battrey plug plugged in.

Switch lock "On".

Adapter cable Id. no. W8 409 559 connected at both ends.

Start Service Software ParaDigLS24 The start page of the steering service software now opens  The relevant data will only be shown in the Vehicle type, Program version and Controller fields if a connection has really been made with the vehicle. If the connection has not been successful, these fields will be empty.

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Copyright reserved.

Click on "Connect"

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Chapter 18

Steering software

Errors Current errors Clicking on the "Error display" button opens the "Current errors" field. This is not updated until you click on the "Update values" button.

All errors that are currently registered are then displayed.

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Copyright reserved.

For a summary of the errors: please see Steering software/Errors

20226

Stored errors Clicking on the "Error memory" button opens the "Error memory" button.

Here, all the errors that have been stored since the errors were last deleted are displayed. The error at the bottom of the list is the last error that occurred.

Under "Error frequency", you can read out how often an error has occurred since the errors were last deleted.

Once all maintenance work is complete, the error memory should be deleted by clicking on the "Delete error memory" button.

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Chapter 18

Steering software

Teaching in Setpoint potentiometer Teaching in is needed when: • Setpoint or actual value potentiometer has been replaced • The reduced speed on curves function is initiated differently at each side • The steering controller has had to be replaced 1

Procedure:

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Copyright reserved.

• Connect the notebook to the steering controller.

• Switch on the key switch.

• Click on "Connect".

• Click on "Setpoint and actual value potentiometers".

• The "Delete potentiometer settings" window opens (1).

If the query "Carry out teaching in?" is answered with yes, all the values that have been taught in for the setpoint are deleted.

2

• The "Reversed steering" window (2) opens 

Reversed steering is a steering system in which the steering directions have been swapped over, i.e. turning the steering wheel to the right initiates a left-hand curve.

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Chapter 18

Steering software

Teaching in Setpoint potentiometer

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Copyright reserved.

• As instructed in the dialogue field, first turn the steering wheel to the  as far as the mechanical stop and then click on "Continue". The value is now adopted and stored as long as it is within the permissible range. This can be seen from the fact that the arrow for the direction of rotation (1) disappears.

• Now, as instructed in the dialogue field, turn the steering wheel to the as far as the mechanical stop and then click on "Continue". The value is now adopted and stored as long as it is within the permissible range. This can be seen from the fact that the arrow for the direction of rotation (1) disappears.

• If the value that is to be stored is not within the permissible range, the setpoint potentiometer must be set better mechanically, i.e. more accurately (see Steering/Setpoint potentiometer).

1

Teaching in of the setpoint potentiometer is now complete, but because adjustment of the actual value potentimeter is affected by the setpoint, when the "Continue" button is pressed, the option for setting the actual value potemtiometer is displayed automatically.

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Chapter 18

Steering software

Teaching in Actual value potentiometer • Connect the notebook to the steering controller • Switch on the key switch • Click on "Connect" • Click on "Actual value potentiometer" • The "Delete potentiometer settings" window opens (1)

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Copyright reserved.

If the query "Carry out teaching in?" is answered with yes, all the values that have been taught in for the actual value are deleted.

1

• The "Reversed steering" window (2) opens 

Reversed steering is a steering system in which the steering directions have been swapped over, i.e. turning the steering wheel to the right initiates a left-hand curve.

2

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Chapter 18

Steering software

Teaching in Actual value potentiometer • When the above question is answered, the "Set actual value potentiometer for steering" window opens.

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Copyright reserved.

• Straighten up the vehicle in the direction of the forks, i.e. move the drive wheel exactly into the straight-on position by driving and turning the steering wheel at the same time. This is a quick method of determining the straight-on position.

• Make an aligning mark on the drive wheel toothed gear ring (1) and the bolster (2), to mark the centred straighton position.

• Move the steering wheel (setpoint) into the centre position as instructed. This is equivalent to 2 1/8 revolutions, since the total turning distance is 4 1/4 revolutions. Mark this position with a pencil and adopt the setting with "Continue".

2

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18 – 07

Chapter 18

Steering software

Teaching in Actual value potentiometer

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• As instructed, bring the drive into the measured and marked position with the fine adjustment keys (1) and adopt the setting with "Continue".

•

As instructed in dialogue field (2), turn the steering wheel to the right and adopt the value with a mouse click on the "Complete" button.

•

Teaching in is now complete.

1

Since the old settings have now been overwritten, it is important to check the steering settings, as instructed (3).

2

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Chapter 18

Steering software

Teaching in Actual value potentiometer • Check initiation of the deceleration function: measured from the straight-on position (1), the speed should be reduced after 20° (equivalent to three teeth of the toothed gear ring below).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The reduction should be initiated at the same point on both sides. If this is not the case, the straight-on position must be corrected by the appropriate amount using the fine adjustment keys (2) and saved again. To do this, the vehicle must be jacked up and the deadman switch actuated.  The value is only adopted and saved by the system if it is within the permissible range.

You can see this from the "Continue" button (2), which will be shaded grey. If the value you want to save is outside the permissible range, the actual value potentiometer must be set better mechanically (please see Steering/Actual value potentiometer).

2

250001

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Chapter 18

Steering software

Tester Speed measurement The current and the maximum speeds are shown in the "Speed measurement" window.

The speed is determined by the speed sensor, which is connected directly to the steering system.

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Copyright reserved.

To display the maximum speed, the "Reset maximum speed" button must first be pressed, so that the relevant display field shows "0.0 km/h".

Clicking on the "Start measurement" button starts the speed measurement, while "Stop measurement" stops it. The highest speed measured in this period is shown in the "Maximum speed" display field.

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Chapter 18

Steering software

Diagnosis and adjustment Tester Amplifier data Supply voltage Supply voltage for the steering.

24 volts ± 3.5V

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Copyright reserved.

Mean motor current a higher or lower motor current is set, depending on how fast the steering wheel is turned.

The maximum current is approx. 35 amps.

Amplifier temperature The temperature sensor integrated in the steering measures the temperature of the steering amplifier. If this rises above 95°C, the output power is reduced to 50%.

PWM ratio The steering motor is clocked by the amplifier transistors of the steering system. If the speed of the steering motor changes, the PWM (pulse width modulation) must also change proportionally.

100% PWM is equivalent to a fully opened amplifier transistor. In this case, the steering motor is supplied with 100% of the electrical power. 

None of the data shown in this field is updated until the "Start measurement" button is pressed. The measuring process is completed with the "Stop measurement" button.

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Chapter 18

Steering software

Diagnosis and settings Tester Digital inputs and outputs Travel on curves active

If a steering movement of >20° is made, the travel speed should be reduced. When the steering is turned back to "straight-on", the vehicle should be returned to maximum speed again when the steering angle is <18°.

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Copyright reserved.

In short, the "Travel on curves active, Output" signal indicates that the steering has recognised that the vehicle is on a curve (3A20 X1:16 = approx. 7 volts).

The "Travel on curves active Input" signal is the response input. It is for safety purposes only (3A20 X1:24).

Deadman

(3A20 X1:9) Without the "Enable steering" signal, the steering motor is not clocked.

The enable steering signal is generated by the deadman and ABÜ OK. This signal is inverted, i.e. 0 volts = enable steering.

Steering OK 3A20 X1:11 The "Steering OK" signal is sent when the power supply is applied, there is no internal excess temperature and no internal or external steering errors are registered.

Without this signal, the deadman switch cannot be supplied with power and consequently the brake cannot be released. Travel is not possible.

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Chapter 18

Steering software

Diagnosis and settings Tester Digital inputs and outputs Steering motor contactor

3A20 X1:3 The steering contactor 3K1 is selected at negative with this output, if the contactor contact test has a positive result.

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Copyright reserved.

Contactor contact test: When the steering is switched on, a test is carried out to check whether there is already a 24 V signal applied at X2:2 although the contactor coil is not selected. If this is the case, it means that the contactor contact has melted (error). If this is not the case, a negative signal is sent to X1:3 to switch on the steering contactor. The measurement at X2:2 should now be 24V volts.

If an internal steering error occurs, the "steering motor contactor" output is switched off immediately.

Safety relay The internal safety relay closes when there are no internal faults (excess temperature, contactor driver OK, EPROM OK).

If the contact of the safety relay is closed, there should be 24V applied at 3A20/X1:15, on condition that terminal 3A20/X1:2 is supplied with 24V.

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Chapter 18

Steering software

Diagnosis and settings Tester Potentiometer voltages Supply voltage of actual and setpoint values

3A20 X1:8 positive

approx. 9.3 volts

3A20 X1:6 negative

approx. 0 volts

Setpoint voltage at the steering wheel

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Copyright reserved.

The slider contact of potentiometer 1 and potentiometer 2 must always add up to the supply voltage. The actual total voltage is shown in the "Total" field (1).

1

The potentiometer consists of two anti-parallel coils with sliders. If the shaft of the potentiometer is turned, one slider moves up and the other moves down by the same proportion. The two potentiometer voltages are only the same at the electrical centre of the potentiometer (approx. 550 ohms).

For this reason, a coil defect or wire breakage is detected immediately, since one coil monitors the other.

Actual value voltages at the drive wheel (please see Steering software/Setpoint voltage at the steering wheel).

The setpoint and actual value potentiometers for the steering are identical!

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Chapter 18

Steering software

Diagnosis and settings Settings Wheel distance The wheel distance is defined as the distance between the driven wheel and the drive wheel.

Since there are different fork lengths, there are also different wheel distances.

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If the wheel distance changes, the distance between the point around which the driven wheels turn and the centre of the drive wheel also changes. The result is that the compensation angles also change.

The compensation angle is defined as the additional angle needed in a vehicle with a drive that is mounted off-centre in order to let the vehicle turn on the spot.

Fork length

Distance

By changing the "wheel distance" parameter, this compensation angle can be adapted for the vehicle conditions.

1000

1473

1150

1623

There is a total of seven wheel distance lengths available because there are seven different wheel distances.

1200

1673

1400

1873

1600

2073



2020

2493

2390

2863

The standard setting for this parameter is 1623. For this reason, it is important when replacing a steering controller to ensure that the "wheel distance" parameter is set correctly for the fork length of the vehicle.

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Chapter 18

Steering software

Table of errors Error no.

19

20 21

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Copyright reserved.

22

23

Description

Cause

An error 20, 22, 23, 24, 25, 26 was registered briefly during switching-on of the steering controller (STG) STG internal error Vehicle type has • STG has been changed installed in a different vehicle to SU, SV or SD Data in parameter • Parameter assignment set is inconsistent for STG start does not work correctly No parameter set • There is no parameter found for cable set in the software code. version for the vehicle type read out of the cable coding

Rectification • If this error occurs sporadically and the controller goes into its normal operating condition, no reaction is necessary

• Replace STG. • Check whether STG number matches vehicle type.

• Re-start.

If error remains, replace STG • Check whether STG number matches vehicle type.

• If OK: re-start.

• If error remains: vehicle code to 3X1:4, Check 3X1:18 and 3X1:21.

Must measure GND or 24V, depending on vehicle type If error remains: replace STG • Check potential at pins X1:4, X1:18 and X1:21

24

Invalid vehicle code after switching-on

• Cable coding: Pin: 21 18 4 0 0 1 1: GND (X1:1) 0: open (STG internally to +24V)

25

Vehicle code (hardware coding) unreliable

• When the vehicle code • Check potential at pins 3X1:4, is read out repeatedly, 3X1:18 and 3X1:21 for loose it is not always the contacts. same.

26

Control has not been checked by manufacturer

• The control has not • If this occurs in a STG that is been marked as straight from the factory, having been checked please uninstall it again and by the manufacturer. A send it to our customer service certain entry is missing department. from the EEPROM

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Chapter 18

Steering software

Table of errors Error no.

27

Description

Cause

Internal safety • Output X1:15 shorted relay is closed to 24V. during switching-on • Relay contact is stuck • Relay driver faulty

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Copyright reserved.

28

29

Internal safety relay opens during running time

Steering contactor 3K1 is already closed during switching-on

• Relay driver faulty

• Relay itself is faulty • Short to battery negative in the supply leads • Short-circuit between X2:2 and 24V.

• Contact has melted

Rectification • Use the diagnosis software / digital inputs and outputs/ safety relay to check whether the safety relay is driven.

• Check whether the relay contact has melted: • Switch off the vehicle • Pull out connector X1 of the STG • Connect ohmmeter to pins X1:15 and X1:2 • If relay open, resistance should be "infinite" • Check cable connections of outputs X1:15 and X1:2 (e.g. short to battery negative)

• Check short-circuit between X2:2 and +24V.

• Switch off the vehicle Voltmeter at X2:2 • Switch on the vehicle. If error 29 is displayed again and 24V are applied at X2:2, the cause may be a short in the cable harness or a melted steering contactor • Check coil 3K1

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Chapter 18

Steering software

Table of errors Error no.

30

Description Driver of steering contactor 3K1 is faulty

Cause

Rectification

• Output X1:3 is not connected at relay pin 85 or 86.

• Switch off the vehicle and measure the resistance between X1:3 and 3K1 pin 85 or 86. If the reading is more than 500 ohms there is a poor connection • Switch off the vehicle. There should not be a short-circuit between pin X1:3 and battery negative.

• Switch off the vehicle, disconnect the cable from 3K1 and measure the resistance between pins 85 and 86. If the resistance is > 300 ohms, the coil is in order.

• Output X1:3 shorts to battery negative

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Copyright reserved.

• The coil of 3K1 has shorted.

31

32

Contact of 3K1 cannot be closed

Motor connections confused

• The internal contactor driver is faulty.

• No 24V at one of the two motor leads X2:1, X2:3 after the contactor is switched on • One of the two motor supply leads X2:1, X2:3 has shorted to battery negative • Motor connection cables X2:1 and X2:3 have been confused.

• Switch off the vehicle: Check that the motor leads are properly connected.

• Switch off the vehicle. Measure the resistance between 3K1 pin 30 and 24 volts: resistance should be almost 0 ohms.

• Swap the motor connection leads X2:1 and X2:3 (Manufacturer's comment: if this error occurs sporadically but the STG still works properly otherwise, do not change anything

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Chapter 18

Steering software

Table of errors

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Error no.

33

Description

Cause

The power section has shorted or is disconnected from the motor

34

Potentiometer supply voltage not in permissible range

35

Setpoint potentiometer voltage has shorted against battery negative or 24V or 9.3V

Rectification

• One of the two motor supply leads X2:1 or X2:3 is not connected

• Check motor connections X2:1 and X2:3

• One of the two motor supply leads X2:1 or X2:3 has shorted to battery negative • If the motor is correctly connected, it is possible that the power section is faulty • The supply voltage for potentiometer X1:8 has shorted to 24V or battery negative.

• The battery voltage exceeds 32 V for longer than 2.5 sec. after switching on • One of the pins X1:19 and/or X1:20 has shorted against battery negative or 24V or 9.3V.

• Check the carbon brushes

• The supply leads of pins X1:19 and/or X1:20 have been interrupted

• Can occur as consequential error of errors 30 and 31

• Switch on the vehicle and measure the voltage at pin X1:8. The voltage should be 9.3V ± 0.1 V. • Check leads for short-circuits

• When the vehicle is switched on, the voltage displayed in the "Potentiometer voltages" window should be between 0.15V and 9.85V. These values also apply for measurement with a voltmeter at pins X1:19 and X1:20.

• Check the connecting leads between the setpoint potentiometer and STG for cable breakage and faulty plug-in connectors.

• In the event of a short-circuit against 24V, the setpoint potentiometer must also be replaced once the error has been rectified.

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Chapter 18

Steering software

Table of errors

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Error no.

36

37

38

Description

Cause

Rectification

Actual value potentiometer voltage has shorted against battery negative or 24V or 9.3V

• One of the pins X1:10 • When the vehicle is switched and/or X1:22 has on, the voltage displayed in the shorted against battery "Potentiometer voltages" negative or 24V or window should be between 9.3V. 0.15V and 9.85V. These values also apply for measurement with a voltmeter at pins X1:10 and X1:22.

• The connecting leads • Check the connecting leads of pins X1:10 and/or between the setpoint X1:22 have been potentiometer and STG for interrupted cable breakage and faulty plug-in connectors.

• In the event of a short-circuit against 24V, the actual value potentiometer must also be replaced once the error has been rectified.

Temperature of the • The temperature of the • Check how the STG has been power section is power section has installed. Is it cooled too high exceeded 85°C. adequately?

• Has the power section shortcircuited?

STG output "Travel • The STG output X1:16 • Check the cable harness and on curves" has has shorted to battery ABÜ input X2:10 for shortshort-circuited negative or 24V for circuit. longer than 300ms.

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Chapter 18

Steering software

Table of errors

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Error no.

39

40

Description Both setpoint potentiometers show implausible values

Both actual value potentiometers show implausible values

Cause • The voltages of the twin setpoint potentiometer at pins X1:19 and X1:20 do not match Loose contact

•

•

•

•

Rectification • Check potentiometer connections for faulty cables and/or plug-in connectors

• In the event of a short-circuit against 24V, the actual value potentiometer must also be replaced once the error has been rectified Fault in potentiometer. • With the vehicle moving, steer If error 35 is also very slowly from one steering displayed at the same end stop to the other. If the time, please rectify this error always appears at the error first same steering position, this indicates that the potentiometer is faulty.

The voltages of the • Check potentiometer twin setpoint connections for faulty cables potentiometer at pins and/or plug-in connectors X1:10 and X1:22 do not match Loose contact • In the event of a short-circuit against 24V, the actual value potentiometer must also be replaced once the error has been rectified Fault in potentiometer • With the vehicle moving, steer very slowly from one steering end stop to the other. If the error always appears at the same steering position, this indicates that the potentiometer is faulty.

If error 35 is also displayed at the same time, please rectify this error first

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Chapter 18

Steering software

Table of errors Error no.

41

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

42

43

44

Description

Cause

Rectification

The "Steering OK" signal has shorted against battery negative during switching on

• Signal X1:11 has • Switch off the vehicle. Check shorted against battery the resistance between X1:11 negative during and battery negative. The switching on resistance should be in the megohm range.

• Check the cable harness for short-circuits (also sporadic short-circuits) The "Steering OK" • Signal X1:11 has • Check output X1:11. It should signal at X1:11 shorted against a be 0-active when the travel does not match the foreign potential during controller is enabled. Voltage internal control travel at X1:11 approx. Ubatt response signal • X1:11 should be at "1" when STG stopped. Voltage at X1:11 < 0.5 V. • Check the cable harness for short-circuits. (also sporadic short-circuits) The actual value • The steering wheel • If this message appears potentiometer was has been moved when continuously, check whether outside the switched off. the steering positions for the permissible voltage left/right-hand steering angle range during and straight-on are correct switching-on • If this is not the case, teachingin of the steering must be repeated This condition is corrected automatically on switching on. This error message is for information only.

The output to 3K1 • The output to 3K1 X1:3 • Check the cable harness for was shorted short-circuited for at permanent or sporadic against 24V least 110ms against shorting of X1:3 against 24V. 24V

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Chapter 18

Steering software

Table of errors Error no.

46

Both battery voltage and potentiometer supply voltage are far below the permissible value

Faulty signal for "Travel on curves"

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Copyright reserved.

50

Description

Cause

Rectification

• The conditions must be as follows for 400ms:

• Check the cable harness for permanent or sporadic shorting of X1:8 and X1:25 against battery negative

• Battery voltage at X1:25 below 13V • Potentiometer supply voltage at X1:8 below 7.9 V • Output X1:16 emits an incorrect logical level: e.g.: STG switches driver "On" Actual condition at pin is "Off" (or vice versa)

• Check charging and age of vehicle battery • Check for shorting of a different electrical assembly against battery negative.

On - level at X1:16: 0.96V Off - level at X1:16: 7.56 V

Signal can be checked in the "Digital inputs and outputs/ Travel on curves active" window

• Driver is faulty • Lead for returning • Check connecting cable from signal to X1:24 is faulty X1:16 to X1:24 for breakage, shorting against 24V and battery negative and foreign potential • Foreign potential on • Check connecting cable from one of the cables X1:24 to travel controller for leading out of X1:24 or breakage, shorting against travel controller 24V and battery negative and for foreign potential • If the cables are in order and the displays in the "Digital inputs and outputs/Travel on curves active" window are different, the driver is faulty.

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Chapter 18

Steering software

Table of errors

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The errors 70 up to 85 are internal controller errors. If they only occurs sporadically, no Error Description Cause Rectification reaction no. is necessary, otherwise replace the controller

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Chapter 18

Steering software

Table of errors Error no.

86

Description

Cause

Safety processor:

• The signal at X1:16 does not match the current steering angle

• If errors 34 or 35 are registered, please rectify these first • Troubleshooting as for error 50 to ascertain generation of faults by foreign voltage

• Error number 90...99 displayed sporadically

• If this error occurs sporadically and the controller goes into its normal operating condition, no reaction is necessary • If this error occurs sporadically and the controller goes into its normal operating condition, no reaction is necessary • If one of these error combinations is registered continuously, carry out troubleshooting as for errors 27 and 28 (see above) • If one of these error combinations is registered continuously, and also any of errors 72, 73 or 74, the controller must be replaced • If this error occurs sporadically and the controller goes into its normal operating condition, no reaction is necessary • If one of these error combinations is registered continuously, carry out troubleshooting as for errors 29, 30 and 31 (see above) • If one of these error combinations is registered continuously, and also any of errors 72, 73 or 74, the controller must be replaced

Faulty signal for "Travel on curves"”

89

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Copyright reserved.

9x

Error message registered briefly during start-up of the controller Error found in internal safety relay during startup of the controller

and

27

9x

• Function test of the internal safety relay after switching-on the STG was faulty: • Control by one of the two processors not possible

• Relay does not open/ close

An error at 3K1 or its driver found during start-up of the controller

and

30

Rectification

• Function test of the internal safety relay after switching-on the STG was faulty: • Control by one of the two processors not possible

• 3K1 does not open/ close

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Chapter 18

Steering software

Table of errors Error no.

9x

Description Error found in the power section of the controller during start-up of the controller

and

Cause

Rectification

• Function test of the internal safety relay after switching-on the STG was faulty:

• If this error occurs sporadically and the controller goes into its normal operating condition, no reaction is necessary

• Switching off by one of the two processors is not possible

• If one of these error combinations is registered continuously, carry out troubleshooting as for errors 29, 30, 31 and 33 (see above) • If one of these error combinations is registered continuously, and also any of errors 72, 73 or 74, the controller must be replaced

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

31

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Chapter 19

Travel control software

General The travel control parameters can be set and diagnosis carried out either with the hand-held programming unit or a notebook.

Prerequisites for working with the notebook: Service software STEDS-Version 6.0 or later Adapter (1) Id. no. 4 498 916 Adapter cable (2) Id. no. 5 456 433 1/0135

The adapter cable connects the notebook and vehicle control with each other. It is plugged in at the point where the display unit is usually connected during normal operation (3).

On the other side the Com 1 connection is used.

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Copyright reserved.

Making a connection

1

2

3

• Check that the battery plug is plugged in.

• Check that the emergency-stop switch is not pressed.

4

5

20403

• Check that the switch lock is switched on (the electrical power supply is guaranteed when there are 0 volts applied at B- (4) and 24 volts at X1:16 (5)).

• After starting the STEDS program, make the following mouse clicks: DIAGNOSIS/MULTI-FUNCTIONAL PROGRAMS/ TRAVEL CONTROL SU, SD, SV, EK10.

The start page of the travel control software now opens (6).

• Click on the (7) "Load parameters from the control into the PC" button.

The entire parameter set is now loaded from the travel control into the notebook, where it can be altered.

6

• If the connection has not been made correctly, this may be due to a faulty cable, adapter or control system. The error message (8) is displayed.

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Chapter 19

Travel control software

Setting parameters • Click with the mouse on "Setting parameters" (1) • Select the parameters you are looking for with the mouse pointer. Use the scroll bar (2) to run through the parameters more quickly.

For lift of parameters, please see Travel control Software, List of parameters).

• Mark a line with a mouse click. The background to the line turns blue.

1

2

10145

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Under the table, either the selection option OFF/ ON (3) is displayed, or a horizontal scroll bar (4), which can be used to change the marked value by clicking on it with the mouse.

• When the parameter value has been changed, a button labelled "Undo" (5) appears, which can be used to reset the original value.

Remark: Altered values are entered in the control system immediately and do not have to be saved or transferred with an extra command.

10141

3

10142

4

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Chapter 19

Travel control software

Test In the "Test" submenu, the input and output signals of the travel control can be checked (please see Travel control software, Tester table).

The button labelled "zoom" (1) can be used to enlarge the selected parameter on the display (2).

Diagnosis

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Copyright reserved.

1

10144

In the "Diagnosis" submenu, the saved and current errors can be read out.

The button labelled "Delete error memory" (3) can be used to reset the error memory.

For a full list of all possible errors, please see Travel control software, Table of errors).

2

"File" menu Clicking on the File menu (4) opens the following selection of functions:

20417

• Load from the control system: The parameters set stored in the travel control is loaded into the notebook.

• Save in the control system: The file that is already open or a file opened with the "Open file" command is loaded into the travel control. In this way, a parameter set that is stored in the data memory can be loaded into any vehicle of choice.

3

10143

4

10138

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Travel control software

"File" menu • Open file: A parameter set stored in the data memory of the notebook can be selected with this function and saved in any vehicle of choice.

• Save file under: With this command, a parameter set can be stored in any directory on the notebook under a customer name, so that it can be loaded into any vehicle of choice at any time.

1/0138

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Copyright reserved.

• Print: A selected parameter set file can be printed with this function.

• Exit: This command closes the PC programmer program.

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Chapter 19

Travel control software

Setting parameters with the handheld programming unit 1

The following functions can be carried out with the hand-held programming unit (1):

2

• Programming the parameters for the travel control (PROGRAM).

• Online querying of statuses of the inputs and outputs and temperature of the travel control (TEST).

• Displaying current errors and errors that have occurred since the last time the diagnosis history was deleted (DIAGNOSTICS).

3

• Copying the control parameters.

4

5

7

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Copyright reserved.

6

The programming unit is made up of the following components: 8

• Display (2).

• PROGRAM button (3) for programming the parameters.

8/0087

9

• TEST button (4) for online querying of statuses.

• DIAGNOSTICS button (5) for troubleshooting.

• SCROLL DISPLAY buttons (6) for scrolling the display up and down.

• CHANGE VALUE buttons for changing the values.

• MORE INFO button (8).

• Socket (9) for plugging in the connecting cable that leads to the control system.

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Travel control software

Setting parameters with the handheld programming unit

1 2

Switching on • Plug the connecting cable (10) into the socket (9).

• Plug the connector at the other end of the cable into the socket (11) of the Highpulse control (12).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Remark:

The deadman switch must not be actuated either during the vehicle switching-on process or during selection of the Special Diagnostics menu. If it is, the following message appears on the display (2): ERROR CONNECTING TO THE CONTROL. TO RETRY PRESS SCROLL DOWN

5

3

4 7

6

9 8 8/0087

10

Fig. 2

4

3

2

1

11 12

1/0396

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Chapter 19

Travel control software

Setting parameters with the handheld programming unit

1 2

Switching on • Switch on the vehicle with the key switch.

Display: for approx. 7 seconds:

5

3

CURTIS PMC 1307 - 2102 4 7

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Copyright reserved.

6

9 8

Language selection 8/0087

The default language can be changed to German, English or numeric by pressing the VALUE UP or VALUE DOWN buttons in the special program.

10

WITH VALUE UP OR VALUE DOWN GERMAN (ENGLISH) (NUMERIC)

4

3

2

1

11 12

CONTROL NO. 1243 - 43xx DATE OF MANUF. 03/00 a) SOFTWARE VERS. 00•04

Remark:

1/0396

The data after the texts may differ from the examples shown here.

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Travel control software

Setting parameters with the handheld programming unit b)

PRINT

2

PROGRAM TEST OR DIAGNOSTIC

TO MENU SELECTION 4

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Copyright reserved.

Remark:

The display texts shown here in sections a) and b) are displayed alternately until a selection is made.

3

PROGRAM menu Fig. 1

8/0087

Setting the parameters Press the "PROGRAM" button (3). The LED (4) in the top left-hand corner of the button lights up.

All the parameters are displayed with their values.

There are always 4 parameters shown on the display (see Fig. 3)

TRAVEL STRBG -> 250 SLOW TRAVEL STRBG 250 BRAKING STRBG 120 SLOW BRAKING STRBG 120 Fig. 3

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Chapter 19

Travel control software

Setting parameters with the handheld programming unit Only the parameter that is currently on the top line of the display can be changed.

The value can be changed with the "CHANGE VALUE" buttons (1).

Remark:

The LEDs at the tips of these buttons (2) indicate whether the value is at the upper or lower limit.

If one of the diodes goes out, the adjusting limit has been reached.

2

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Copyright reserved.

8

The "MORE INFO" button shows an expanded version of the parameter display. A bar graph (4), the entered value (5), and the maximum (6) and minimum (7) possible values are displayed (Fig. 2).

1 9 2

To scroll the list of parameters up or down, press the "SCROLL DISPLAY" buttons (8 and 9).

Fig. 1

8/0087

5

4

Remark:

The values entered here are intended purely as examples. In the actual adjustment process, the relevant values for the vehicle in question must be set.

SLOW TRAVEL GESEH %

60

MIN

40

MAX

100

Fig. 2

6

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Chapter 19

Travel control software

Setting parameters with the handheld programming unit 4

Special program menu The following functions can be carried out with the special program:

RESET SETTINGS SET CONTROL -> PROG SET PROGRAM-> CONTROL DELETE DIAG. HISTORY

• Resetting to initial settings.

• Loading control parameters into programming unit.

• Loading settings from the programming unit into the control system.

• Deleting the diagnosis data.

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Copyright reserved.

• Adjusting the display contrast.

3 1

• Language selection.

• Displaying information about the programming unit.

• Displaying information about the control.

To enter the special program menu, press the PROGRAM (1) and MORE INFO (2) buttons at the same time.

2

The LED (3) on the PROGRAM button lights up.

8/0087

The first 4 functions are shown on the display (4).

Only the function that is in position one on the display can be altered.

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Chapter 19

Travel control software

Setting parameters with the handheld programming unit 5

Special program menu To carry out a function, you must press the MORE INFO button (1).

RESET SETTINGS SET CONTROL -> PROG SET PROGRAM -> CONTROL DELETE DIAG. HISTORY

1. Resetting to initial settings

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Copyright reserved.

Use the SCROLL DISPLAY buttons (2) to move RESET SETTINGS to the 1st position on the display (5).

Press MORE INFO (1).

The display text shown in Fig. 1 appears.

Fig. 1

When the VALUE UP button (3) is pressed, the display text shown in Fig. 2 appears.

RESET TO INITIAL SETTINGS? YES: VALUE UP CANCEL: VALUE DOWN

When the VALUE DOWN button (4) is pressed, the display text shown in Fig. 3 appears.

PLEASE WAIT ...

automatic Fig. 2

.

ALL SETTINGS HAVE BEEN RESET TO INITIAL VALUES

Fig. 3

3

2

2

FUNCTION NOT CANCELLED

4 1

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Travel control software

Setting parameters with the handheld programming unit Special program menu 2. Loading settings from the control system into the programming unit.

Use the SCROLL DISPLAY buttons (2) to move SET CONTROL -> PROG to the first position on the display.

Press MORE INFO (1).

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Copyright reserved.

The display text shown in Fig. 1 appears.

Fig. 1

When the VALUE UP button (3) is pressed, the display text shown in Fig. 2 appears.

When the VALUE DOWN button (4) is pressed, the display text shown in Fig. 3 appears.

SAVE ALL SETTINGS IN PROG? YES: VALUE UP CANCEL: VALUE DOWN

PLEASE WAIT ...

automatic Fig. 2

ALL SETTINGS FOR THE CONTROL STORED IN THE PROGRAMMING UNIT Fig. 3

FUNCTION NOT CANCELLED 3

2

2

4 1

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Travel control software

Setting parameters with the handheld programming unit Special program menu 3. Loading settings from the programming unit into the control system.

Use the SCROLL DISPLAY buttons (2) to move SET PROGRAM -> CONTROL to the first position on the display.

Press MORE INFO (1).

The display text shown in Fig. 1 appears.

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Copyright reserved.

Fig. 1

When the VALUE UP button (3) is pressed, the display text shown in Fig. 2 appears.

When the VALUE DOWN button (4) is pressed, the display text shown in Fig. 3 appears.

LOAD SETTINGS FROM PROGRAMMING UNIT? YES: VALUE UP CANCEL: VALUE DOWN

PLEASE WAIT ...

automatic Fig. 2

ALL SETTINGS HAVE BEEN LOADED FROM THE PROGRAMMING UNIT INTO THE CONTROL Fig. 3

FUNCTION NOT CANCELLED 3

2

4

2

1

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Chapter 19

Travel control software

Setting parameters with the handheld programming unit Special program menu 4. Deleting the diagnosis data Use the SCROLL DISPLAY buttons (2) to move DELETE DIAG HISTORY to the first position on the display.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Press MORE INFO (1).

The display text shown in Fig. 1 appears.

Fig. 1

When the VALUE UP button (3) is pressed, the display text shown in Fig. 2 appears.

DELETE CONTROL DIAGNOSIS HISTORY? YES: VALUE UP CANCEL: VALUE DOWN

When the VALUE DOWN button (4) is pressed, the display text shown in Fig. 3 appears.

PLEASE WAIT ...

automatic Fig. 2

DIAGNOSIS HISTORY IN CONTROL HAS BEEN DELETED

Fig. 3

FUNCTION NOT CANCELLED 3

2

2

4 1

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Chapter 19

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Setting parameters with the handheld programming unit Special program menu 5. Adjusting the display contrast Use the SCROLL DISPLAY buttons (2) to move DISPLAY CONTRAST to the first position on the display.

Press MORE INFO (1).

The display text shown in Fig. 1 appears.

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Copyright reserved.

When the VALUE UP button (3) is pressed (held down), the display turns darker.

When the VALUE DOWN button (4) is pressed (held down), the display turns brighter.

Fig. 1

ADJUST THE DISPLAY CONTRAST DARKER: VALUE UP BRIGHTER: VALUE DOWN

3

2

4

2

1

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Chapter 19

Travel control software

Setting parameters with the handheld programming unit Special program menu

3

2

2

4

1

8/0087

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

6. Language selection

Fig. 1

The default language can be changed to German, English or numeric (Fig. 1) by pressing the VALUE UP or VALUE DOWN buttons in the special program.

7. Displaying information about the programming unit

Fig. 2

Use the SCROLL DISPLAY buttons (2) to move INFO PROGRAM UNIT to the first position on the display.

Press MORE INFO (1).

The display text shown in Fig. 2 appears.

Remark:

PROGRAM UNIT 1307 - 2102 DATE OF MANUF. 20 APR 95 SOFTWARE VER. 00 - 08

The data shown here is intended purely as an example.

3

2

8. Displaying information about the control 4

2 DISPLAY buttons (2) to move Use the SCROLL 1 CONTROL INFO to the first position on the display.

Press MORE INFO (1).

8/0087 The display text shown in Fig. 3 appears.

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SELECT LANGUAGE WITH VALUE UP OR VALUE DOWN GERMAN (ENGLISH) (NUMERIC)

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Fig. 3

CONTROL 1243 - xx DATE OF MANUF. MAR 00 SOFTWARE VER. xx -xx

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Setting parameters with the handheld programming unit Test menu In this menu, the real time information about the statuses of the inputs and outputs and the temperature of the control are displayed.

1

The MORE INFO button (2) can be used to display the information in the first position on the display on a larger scale.

2

The following information is shown: (Figs. 1, 2 and 3) Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

8/0087

3 Travel switch signal as a %age of the maximum speed

Fig. 1

4 Battery voltage

3 4 5 6

5 Heat sink temperature 6 Deadman switch on/off

TRAVEL SWITCH % BATTERY VOLTAGE CONTROL TEMP BRAKE INPUT

0 23 21 OFF

7 Mode switch on/off 8 Belly switch

Fig. 2

9 Forwards switch on/off

7 8 9 10

10 Reverse switch on/off 11 Forwards contactor on/off

FAST TRAVEL BELLY SWITCH FORWARDS INPUT REVERSE INPUT

ON OFF OFF OFF

12 Reverse contactor on/off 13 Maximum measured heat sink temperature 14 Minimum measured heat sink temperature

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11 12 13 14

FORW. CONTACTOR OFF REVERSE CONTACTOR OFF MAX TEMP °C 28 MIN TEMP °C -10

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Chapter 19

Travel control software

Setting parameters with the hand-held programming unit Displaying current errors 1

When the DIAGNOSTIC button (1) is pressed, all the errors that are currently registered are shwon on the display (Table 1).

Pressing the DIAGNOSTIC (1) and MORE INFO (2) buttons at the same time takes you into the special diagnostic menu.

2

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Here, a list of errors is displayed that have been detected by the control system since the last time the errors were deleted.

Each error is only displayed once.

For the text shown on the display, please see Table 1.

8/0087

BELLY ERROR CONT. DRV. EX. CURR. DIR. CONT. STUCK START-UP PROT. HPD

Switching off

FAILURE FUSE

Switch off the vehicle and disconnect the connection between the programming unit and the control.

U BATT TOO LOW M SHORT-CIRCUIT CONTACTOR INTERRUPTION NO ERROR EXCESS VOLTAGE START-UP PROT. SRO TEMPERATURE ERROR TRAVEL SW. ERROR 1 TRAVEL SW. ERROR 2

Error on checking the belly switch Current through contactor driver too high Contacts of the direction contactor are stuck Start-up protection for travel switch triggered Hardware failure fuse triggered Battery voltage too low (< 16V) Short-circuit at M output to BInterruption of contactor control circuit Control has not detected an error Battery voltage too high (> 45V) Start-up protection for dir. switch triggered Reduction due to excess or low temperature Travel switch error, incorrect value Travel switch error, interruption in cable

Table 1

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Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Summary of the parameters that have to be set

Display

Explanation

Brake C/L

Max. braking current in amps

Accel Rate

Acceleration rate in seconds

Decel Rate

Deceleration rate in seconds

Max F Speed

Maximum forwards speed as a %

Max R Speed

Maximum reverse speed as a %

Creep Speed

Creep speed as a %age of maximum speed

Full Volts

Battery monitoring

Empty Volts

Battery monitoring

Reset Volts

Battery monitoring

ADJ HRS low

Operating hours input

ADJ HRS mid

Operating hours input

ADJ HRS high

Operating hours input

SET Total HRS

Operating hours, key switch on/off

SET Trac HRS

Operating hours, lifting, lowering, travel on/off

HOUR METER Type

Total hours with key switch on/off

SRVC Total HRS

Service counter with key switch ON

SRVC Trac HRS

Service counter with lifting, lowering, travel

SRVC Total

Restart Service counter keyswitch on/off

SRVC Trac

Restart service counter workinghours on/off

Max Load Volts

Maximum output voltage, pressure sensor

Min Load Volts

Minimum output voltage, pressure sensor

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Battery discharge curves Full Volts

- cell voltage when 100% charged

Empty Volts - cell voltage when 20% charged Reset Volts - cell voltage for resetting the discharge indicator to 100%

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Battery type Lead - acid - wet PzS Lead - acid - wet CMS Increased capacity Hagen ,PWF,CWF,PzV Sonnenschein dryfit Varta Carat gel battery Gel batteries in general Data Dryflex Drypower 8WF 800 HL 48

Full Volts U/cell 1.93 1.95

Empty Volts U/cell 1.70 1.69

Reset Volts U/cell 2.06 2.06

1.99 2.00 2.00 2.00 1.99 1.97

1.82 1.86 1.86 1.86 1.84 1.73

2.06 2.06 2.06 2.06 2.06 2.06

 In the control, the values are entered as 3-figure number sequences, e.g.: 199 for 1.99 The values given in the table are the settings for standard loads.

In special cases with higher loads (high current consumption in a short time or cold store operation) deviations may occur, depending on the area of application. In cases of this kind, the battery manufacturer should be consulted directly.

The capacity of the battery does not have any effect on the parameters specified above.

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Chapter 19

Travel control software

List of parameters 1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

No. Display

Explanation

Range

Value

1

M1 DRIVE CURRENT LIMIT

Maximum travel current Mode 1

50A to Rated

250

2

M2 DRIVE CURRENT LIMIT

Maximum travel current Mode 2

50A to Rated

250

3

M3 DRIVE CURRENT LIMIT

Maximum travel current Mode 3

50A to Rated

250

4

M4 DRIVE CURRENT LIMIT

Maximum travel current Mode 4

50A to Rated

250

5

M1 BRAKING CURRENT LIMIT

Maximum braking current Mode 1

50A to Rated

180

6

M2 BRAKING CURRENT LIMIT

Maximum braking current Mode 2

50A to Rated

180

7

M3 BRAKING CURRENT LIMIT

Maximum braking current Mode 3

50A to Rated

180

8

M4 BRAKING CURRENT LIMIT

Maximum braking current Mode 4

50A to Rated

180

9

M1 ACCELERATION RATE

Acceleration rate Mode 1

0.1 to 3

3

10

M2 ACCELERATION RATE

Acceleration rate Mode 2

0.1 to 3

3

11

M3 ACCELERATION RATE

Acceleration rate Mode 3

0.1 to 3

3

12

M4 ACCELERATION RATE

Acceleration rate Mode 4

0.1 to 3

3

13

M1 DECELERATION RATE

Deceleration on neutral braking Mode 1

0.1 to 10

1,1

14

M2 DECELERATION RATE

Deceleration on neutral braking Mode 2

0.1 to 10

1,1

15

M3 DECELERATION RATE

Deceleration on neutral braking Mode 3

0.1 to 10

1,1

16

M4 DECELERATION RATE

Deceleration on neutral braking Mode 4

0.1 to 10

1,1

17

THROTTLE DECEL

Potentiometer throttling on change-over from travel to braking

0.1 to 1.0

0,1

18

M1 BRAKING RATE

Deceleration on reverse braking Mode 1

0.1 to 3

3

19

M2 BRAKING RATE

Deceleration on reverse braking Mode 2

0.1 to 3

3

20

M3 BRAKING RATE

Deceleration on reverse braking Mode 3

0.1 to 3

3

21

M4 BRAKING RATE

Deceleration on reverse braking Mode 4

0.1 to 3

3

22

INTERLOCK BRAKE RATE

Braking factor dependent on pressure sensor

0.1 to 3

0,1

23

QUICK START

Throttle sensitivity

0 to 10

5

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List of parameters 2

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

No. Display

Explanation

Range

Value SU

SD/SV

24

TAPER RATE

Change-over from braking to rolling

1 to 20

10

10

25

M1 MAX FWD SPEED LIMIT

Maximum forward travel speed Mode 1

0% to 100%

60

80

26

M2 MAX FWD SPEED LIMIT

Maximum forward travel speed Mode 2

0% to 100%

100

100

27

M3 MAX FWD SPEED LIMIT

Maximum forward travel speed Mode 3

0% to 100%

60

80

28

M4 MAX FWD SPEED LIMIT

Maximum forward travel speed Mode 4

0% to 100%

100

100

29

M1 MAX REV SPEED LIMIT

Maximum reverse travel speed Mode 1

0% to 100%

60

80

30

M2 MAX REV SPEED LIMIT

Maximum reverse travel speed Mode 2

0% to 100%

100

100

31

M3 MAX REV SPEED LIMIT

Maximum reverse travel speed Mode 3

0% to 100%

60

80

32

M4 MAX REV SPEED LIMIT

Maximum reverse travel speed Mode 4

0% to 100%

100

100

33

CREEP SPEED LIMIT

Speed that is set with the smallest throttle deflection

0% to 25%

15

15

1

1

0% to 40%

14

14

60% to100%

93

93

5K-0(1), 0-5V SE(2), 0-5K(3), 0-5V WW(4)

34

THROTTLE TYPE

Throttle type

35

THROTTLE DEADBAND

Width of neutral position of throttle

36

THROTTLE MAX. OUTPUT P. Width of maximum setting of throttle

37

THROTTLE MAP

Throttle sensitivity at low speed

20% to 80%

40

40

38

MINIMUM FIELD CURRENT L.

Smallest permissible field current, affects the maximum speed

1.6A to 50A

6,4

8,2

39

MAXIMUM FIELD CURRENT L

Largest permissible field current, affects the maximum speed

Min Field C/ L to Rated

25

25

40

FIELD MAP START

Affects the armature current and consequently the torque with load on starting-up

25A to Full Drive C/L

75

60

41

FIELD MAP

Affects the armature current and consequently the torque with load at Vmax

0% to 100%

70

100

42

CURRENT RATIO

Factor of current increase in proportion to specification from throttle

1, 2, 3, 4

1

1

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List of parameters 3

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

No. Display

Explanation

Range

Value

43

M1 RESTRAINT

How strongly vehicle should be braked when throttle setpoint is reduced slightly. Mode 1

Min Field C/ L to Rated

10

44

M2 RESTRAINT

How strongly vehicle should be braked when throttle setpoint is reduced slightly. Mode 2

Min Field C/ L to Rated

10

45

M3 RESTRAINT

How strongly vehicle should be braked when throttle setpoint is reduced slightly. Mode 3

Min Field C/ L to Rated

10

46

M4 RESTRAINT

How strongly vehicle should be braked when throttle setpoint is reduced slightly. Mode 4

Min Field C/ L to Rated

10

47

LOAD COMPENSATION

Load compensation

0% to 25%

0

48

HIGH PEDAL DISABLE (HPD)

No travel setpoint or deadman before switch lock switched on

Off (0), Brake (1), KSI (2)

2

49

Switching-on sequence STATIC RETURN TO OFF (SRO) Switch lock, deadman, travel direction required

Off (0), Brk(1), KSI(2), KSI, Brk&Fwd only(3)

0

50

SEQUENCING DELAY

Delay while switching-on sequence is evaluated

0 to 3

0

51

MAIN CONTACTOR INTERLOCK

1K34 is not switched on until deadman is pressed; X1:15

On/Off

52

MAIN OPEN DELAY

1K34 drops out xx secs. after deadman is released

0-40

53

CONTACTOR DIAGNOSTICS

Contact test 1U34 Switching on or off

On/Off

54

AUXILIARY DRIVER TYPE

Output driver X1:8 is active low or high

Types 0-5

2

55

AUX. DRIVER TURN OFF DELAY

Delay between throttle neutral and switching off output driver X1:8

0-30

3

56

VARIABLE BRAKING

Generator braking dependent on throttle position or not

On/Off

ON

57

ANTI TIEDOWN

Prevents vehicle rolling back when brake released. Dependent on Mode 2 or 4

On/Off

OFF

58

POT LOW FAULT

"Potentiometer error" error active or inactive

On/Off

ON

59

FULL VOLTS *

Volts/cell when battery 100% charged

Empty Volts to Reset volts

193

ON 20 ON

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List of parameters 4

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

No. Display

Explanation

Range

Value

60

EMPTY VOLTS *

Volts/cell when battery discharged

0 to Full Volts

170

61

RESET VOLTS *

Volts/cell that have to be reached so that battery discharge indicator shows 100% again

Full Volts to 3

206

62

BATTERY ADJUST

Factor for battery capacity calculation

0.1 to 20.0

16,2

63

BDI DISABLE

Deceleration when batt. cap. <20%. Depends on value entered under "BDI Limit Speed"

On/Off

ON

64

ADJUST HOURS LOW

Setting of hour meter, last 2 figures

0 to 99

0

65

ADJUST HOURS MID

Setting of hour meter, middle 2 figures

0 to 99

0

66

ADJUST HOURS HIGH

Setting of hour meter, first 2 figures

0 to 99

0

67

SET TOTAL HOURS

Programming of hour meter switch lock with value of no. 64, 65, 66

On/Off

ON OFF

68

SET TRACTION HOURS

Programming of hour meter for travel, lifting, lowering with value of no. 64, 65, 66

On/Off

ON OFF

69

HOURMETER TYPE

Which of the two hour meters specified above should be shown on the display

On/Off

OFF =FHS

70

SERVICE TOTAL HOURS

Service hour meter, switch lock

0.0 to 50

71

SERVICE TRACTION HOURS

Service hour meter set to count with travel, lifting, lowering

0.0 to 50

72

SERVICE TOTAL

Reset service hour meter, switch lock

On/Off

OFF

73

SERVICE TRACTION

Reset service hour meter for travel, lifting, lowering,

On/Off

OFF

74

DISABLE TOTAL HOURS

Service hour meter, switch lock, emerg. operation 0 to 250

75

DISABLE TRACTION HOURS

Service hour meter for travel, lifting lowering, emergency operation

0 to 250

76

TRACTION FAULT SPEED

Travel speed reduced to an entered percentage when counter level for emergency operation reached

0 to 100%

100

77

BDI LIMIT SPEED

When BDI Disable to "ON", travel is reduced to the value entered here when batt. cap. 20%

0 to 100%

100

10

=1000h

5

=500h

120

=1200h

100

=1000h

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Chapter 19

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List of parameters 5

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

No. Display

Explanation

Range

Value

78

WARM SPEED

Max. travel speed when the value entered in the "MOTOR WARM" parameter is reached

0 to 100%

25

79

MOTOR WARM x 10m

When 98 = approx. 130°C is reached, the travel speed is reduced to the value entered in the "WARM SPEED" parameter

Motor Warm to 250

98

80

MOTOR HOT x 10m

When 102 = 150°C is reached, travel is switched off

Motor Warm to 250

102

81

MOTOR

Temperature evaluation ON/OFF

On/Off

ON

82

MAX-REV REGEN

Maximum current used for braking in a braking operation actuated with deadman switch in DWS travel direction

Min Rev to Rated

300

83

MAX-FWD REGEN

Maximum current used for braking in a braking operation actuated with deadman switch in LS travel direction

Min FWD to Rated

300

84

MIN-REV REGEN

Minimum current used for braking in a braking operation actuated with deadman switch in DWS travel direction

25A to Max Rev.

180

85

MIN-FWD REGEN

Minimum current used for braking in a braking operation actuated with deadman switch in LS travel direction

25A to Max Fwd.

180

86

MAX LOAD VOLTS

Maxiumum output voltage from pressure sensor

0.2 to 5.5

3

87

MIN LOAD VOLTS

Minimum output voltage from pressure sensor

0.2 to 5.0

0,8

88

INT BRAKE DELAY

Delay until magnetic brake is activated after vehicle comes to a standstill

0.0 to 8.0

3

89

MAIN CONTACTOR INITIAL

Switching on of 1K34 with switch lock without enabling by deadman

Off

Off

90

PUMP METER

Error output 1 can be switched over to "Pump running" input

On/Off

ON

COMPENSATE

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Description of parameters Brake C/L • Maximum armature braking current The brake current set here is not exceeded.

If braking is induced by removing the travel direction signal (neutral braking), the maximum braking current is composed of brake C/L (armature current) and 6A field current. If braking is induced by reversing the travel direction (reversing braking), the maximum braking current is composed of brake C/L and 25A (field current).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Accel Rate How fast the throttle reaches maximum speed when it is fully deflected.

Minimum Field Current This parameter determines the maximum speed of the vehicle. The parameter set here specifies the minimum value for the field current. The smaller the field current in a series wound motor, the faster the vehicle runs (field weakening). For this reason, the parameter set here must not be smaller than 6.4A in the SU and 8.2A in the SD. The parameters Max F Speed and Max R Speed determine the speed of the vehicle in travel on curves (i.e. in Mode 1 or 3) and then only with dependence on the Minimum Field Current parameter.  Parameter Min Field Cur. = 8.2 Parameter Max F Speed = 80 --> The vehicle travels straight on at 11km/h = Vmax, on curves at 80% of 11km/h = approx. 9km/h

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Travel control software

Description of parameters Accel Rate delay Speed with which the vehicle is regulated down to the lower speed when the travel setpoint signal is removed.

Max F Speed • Maximum forwards speed

Max R Speed • Maximum reverse speed

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Creep Speed Maximum travel speed when throttle is deflected to 1st step.

Full Volts • Factor for battery capacity calculation So that the remaining battery capacity can be calculated for different types of battery, the relevant factor must be selected from the table headed "Factors for calculating the remaining battery capacity".

Empty Volts • Lift stop This determines the cell voltage level at which the lift stop should be activated. Please see the table specified above.

Reset Volts • Reset voltage for the battery discharge indicator This determines the cell voltage level at which the battery display is reset to 100% again after charging.

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Travel control software

Description of parameters ADJ HRS Low • Entry of operating hours This parameter displays the last 2 figures on the 6figure hour meter display.

ADJ HRS mid • Entry of operating hours This parameter displays the middle 2 figures on the 6-figure hour meter display.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

ADJ HRS High • Entry of operating hours This parameter displays the first 2 figures on the 6figure hour meter display.

SET Total Hours • Program the entered operating hours to switch lock The operating hours entered under ADJ HRS low, mid and high can be programmed to the hour meter for "Key switch ON" with this parameter. To do so, set this parameter to "ON" and then to "OFF" again.

SET Trac Hours • Program the entered operating hours to travel, lifting and lowering The operating hours entered under ADJ HRS low, mid and high can be programmed to the hour meter for "Travel, lifting and lowering" with this parameter.

To do so, set this parameter to "ON" and then to "OFF" again.

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Chapter 19

Travel control software

Description of parameters

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Hour meter type This parameter is used to select which of the hour meters should appear on the display. If this parameter is set to "ON", the key switch hours are displayed, and if it is set to "OFF", travel, lifting and lowering are displayed.

SRVC total HRS â&#x20AC;˘ Setting maintenance interval for key switch This parameter is used to set the maintenance interval for the "Key switch" service counter.

The system counts downwards from the figure entered here to zero as soon as the key switch is switched on. The value entered is multiplied by 100.

Example: You want the display to indicate that maintenance is due after 500 hours: Enter this number: 5

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Travel control software 1 SRVC TOTAL HRS

Description of parameters SRVC Trac HRS • Set maintenance interval for "Travel, lifting and lowering" This parameter is used to set the maintenance interval for the "Travel, lifting and lowering" service counter.

The system counts downwards from the figure entered here to zero as soon as travel, lifting or lowering are selected. The value entered is multiplied by 100.

Example: You want the display to indicate that maintenance is due after 500 hours: Enter this number: 5

2 SRVC TRAC HRS

0 hrs

3 DIS TOTAL HRS

FE23,"SERVICE",Red LED lights up Vmax

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4 DIS TRAC HRS

SRVC Total • Reset service counter for key switch When the "key switch" service counter has run down to zero, the maintenance symbol lights up. To return to the normal status, this parameter must be set to "ON" and then "OFF".

SRVC Trac • Reset service counter for travel, lifting and lowering When the "Travel, lifting and lowering" service counter has run down to zero, the maintenance symbol lights up.To return to the normal status, this parameter must be set to "ON" and then "OFF".

0 hrs

Counter keyswitch schalter

FE23,"SERVICE",Red LED flashes V trak fault spr

Counter Drive,Lift, Lower

Service hour meter There are two service hour meters "Operation" (1or 2) and two service hour meters "Emergency" (3 or 4) integrated in the travel control. They count downwards from a previously set number (the maintenance interval) to zero. The hours that have passed are counted a. while the key switch is switched on (1) and b. during travel, lifting or lowering (2).

When zero hours is reached, FE 23 and "SERVICE" appears on the display , The red LED under the spanner symbol lights up, the speed is not reduced jet, the two service hour meters "Emergency" (3 or 4) starts to run.

If the emerencycounter (3 or 4) also is reached zero hours, emergency operating mode is initiated, i.e. the vehicle is reduced in accordance with the parameter value Trac Fault SPR.It is set to a default value of 100%, i.e. no reduction. The red LED under the spanner symbol flashes up. FE 23 and "SERVICE" appears on the display .

30284 30284

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Chapter 19

Travel control software

Description of parameters

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Max load Volts â&#x20AC;˘ Maximum pressure sensor output voltage When the maximum load (approx. 2 tonnes) is held on the forks, the pressure sensor delivers a voltage of approx. 3.4 volts. The voltage must be read out from the "TEST" menu under full load and then stored in this parameter. If this pressure sensor voltage value is different from in reality, the vehicle is braked too hard or too gently with deadman braking.

Min load Volts â&#x20AC;˘ Minimum pressure sensor output voltage When there is no load on the forks, the pressure sensor delivers a voltage of approx. 1V. The voltage must be read out from the "TEST" menu without a load and then stored in this parameter. If this voltage value is different from in reality, the vehicle is braked too hard or too gently with deadman braking.

If the pressure sensor voltage drops below the value entered in this parameter, the system detects this as cable breakage, i.e. maximum braking is always initiated.

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Sheet no.

19 â&#x20AC;&#x201C; 31

Chapter 19

Travel control software

Errors displayed with flashing code When an error is detected, a status LED (1) indicates the type of error continuously in the form of a two-position flashing code.

When no errors have been detected, the status LED flashes about once every 5 seconds.

The LED is located in the housing on the factory nameplate.

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The code is indicated with this flashing signal until the error is reset by switching the control off/on (enable or key switch). This is on condition that the error has been rectified.

1/0394

1

Comment: Only one error is displayed at once, and this is always the last error to have occurred.

1/0395

Example: Code"3.2" - Main contactor melted/stuck *** **

3

_

*** **

2 __

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Sheet no.

19 â&#x20AC;&#x201C; 32

Chapter 19

Travel control software

List of flashing error codes

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Code Designation

Description Reduction due to excess temperature (120°C) or under temperature (-35°C) of the travel control

43

THERMAL CUTBACK

14

SRO

Start-up protection. Setpoint comes before travel dir. switch

23

HPD

Start-up protection. Setpoint comes before deadman

23

SERVICE TOTAL

23

SERVICE TRAC

23

TOTAL DISABLED

23

TRAC DISABLED

13

M-SHORTED

Short-circuit at M output to B-

11

CURRENT SHUNT FAULT

Error at internal current sensor

33

FIELD OPEN

Motor field coil interrupted

32

MAIN CONTACT WELDED

Contact of 1K34 welded

42

OVERVOLTAGE

Battery voltage too high / emergency-stop pressed during travel or emergency-stop due to steering error

44

ANTI TIEDOWN

MODE input 1 active on switching-on

31

CONT COIL. / FLD SHORT

Contactor coil 1K34 has shorted

12

HW FAILSAFE

Internal error

41

LOW BATTERIE VOLTAGE

Battery voltage too low

22

EMR REV WIRING

Internal error

34

MISSING CONTACTOR

Contactor coil 1K34 interrupted

21

THROTTLE WIPER HI

Throttle wiper error

44

MOTOR HOT

Motor temperature >160°C

44

MOTOR WARM

Motor temperature <90°C

20

BD LOW

Battery discharge indicator registering less than 20% capacity

24

TR. WIPER LO

Travel potentiometer voltage(wiper) too low

21

TR. WIPER HI

Travel potentiometer voltage(wiper) too high

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1st "key switch" service counter has run down.

Parameter 70 1st "Travel, lifting and lowering" service counter has run down. Parameter 71 2nd "Emergency operation, key switch" has run down. Parameter 74 2nd "Emergency operation, lifting, lowering, travel" has run down. Parameter 75

Workshop Manual

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Sheet no.

19 – 33

Chapter 19

Travel control software

Tester table Designation TRAVEL SWITCH % FIELD CURRENT ARM CURRENT FIELD PWM ARM PWM BDI % LOAD VOLTAGE BATT. VOLTAGE MOT RES X 10 m

Description Throttle signal as %age of maximum speed Motor field current Motor armature current Motor field current Motor armature current Remaining battery capacity Pressure sensor voltage Battery voltage Temperature dependent resistance value of field coil Current heat sink temperature 1st service counter, key switch.

Value must be multiplied by 25 (please see example) 1st service counter, key switch.

Value must be added to the value above (please see example) 1st service counter, travel, lifting, lowering.

Value must be multiplied by 25 1st service counter, travel, lifting, lowering.

Value must be added to the value above Travel direction switch, FORWARDS Travel direction switch, REVERSE Mode input 1 active Mode input 2 active Deadman switch Belly switch (not fitted) Main contactor (1K34) active Auxiliary driver (brake output) active Control system operating modes

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HEATSINK °C TOT SRVCX25 TOT SRVC SRVC X25 TRAC SRVC FORWARD INPUT REVERSE INPUT MODE INPUT A MODE INPUT B INTERLOCK EMR REV INPUT MAIN CONT AUX DRIVER SYS MODE

Display % A A % % % V V 58 22

on/off on/off on/off on/off on/off on/off on/off on/off 0-5

Example for parameters TOTSRVC X25 / SRVC X25: TOT SRVC X25 = 17 TOTSRVC = 10 With an entered maintenance interval of 500 hrs.:

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-> 17 x 25 ->

=

425 + 10 435 hrs.

500 - 435 = 65 hrs. until next maintenance.

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Sheet no.

19 – 34

Chapter 20

Summary of Error messages

Error messages of the Travel control (see Travel control/ Error display) sheet no. 08-11 (see Travel control software/List of flashing error codes) sheet no. 19-33 (see Displayunit/Errordisplay) sheet no. 11-03

Error messages of the ABÜ- Braking monitor (see ABÜ- Braking monitor/Flashing error codes) sheet no. 10-07

Error messages of the steering controler (see Software steering/Errors) sheet no. 18-03

Error messages of the Valve driver

Urheberrechtlich geschützt. Jede Form der Vervielfältigung, auch auszugsweise, ist untersagt.

Copyright reserved.

(see Valve driver/Flashing error codes) sheet no. 13-06

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Sheet no.

20 –

Chapter 99

Maintenance

General Maintenance work must be carried out when the period specified in the maintenance instructions comes to an end or is exceeded, or when the maintenance symbol (spanner symbol) on the display (1) lights up.

Before and during all maintenance work, appropriate measures must be taken to ensure that work is carried out safety.

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Before carrying out work on the hydraulic system, ensure that the pressure has been released from the system by lowering the load bearing device to the floor.

00191

1

Before carrying out work on the drive system, ensure that the vehicle is securely jacked up and supported from below in order to prevent it rolling away or starting up when not intended.

In operating conditions where there is more dust in the atmosphere or the floors and aisles are heavily soiled, the maintenance intervals must be shortened.

The same applies for conditions with severe temperature fluctuations or continuous extreme temperatures.

Remark:

After all maintenance work, a test of the vehicle functions and condition must be carried out!

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Sheet no.

99 â&#x20AC;&#x201C; 01

Chapter 99

Maintenance

Safety instructions Handling fuels and lubricants

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Copyright reserved.

The following fuels and lubricants are used in the vehicle: • Gear oil • Hydraulic oil • Battery acid.

There are comprehensive safety specifications prescribed for the use and handling of these substances. The most important points are: For gear oil and hydraulic oil • Avoid contact with the skin. It is particularly important not to let oil that escapes under pressure come into contact with the skin.

• Do not breathe in oil mist.

• Oils are a potential hazard for water. For this reason, always transport and collect oil in containers that conform with regulations.

• Do not spill oil if possible. If spillage does occur, bind the spilt oil with suitable materials.

• Dispose of waste that contains oil in accordance with environmental regulations.

For battery acid • Battery acid is poisonous, so never breathe in its vapours.

• Battery acid is caustic, so avoid contact with the skin without fail.

• Always rinse off any battery acid that is spilt or splashes onto the skin with copious amount of clear water.

• When handling battery acid, use safety clothing like protective gloves and clothing and a face mask. In the event that acid still comes into contact with the skin, wash it off immediately with copious amounts of cold water and call a doctor.

• An explosive mixture of gases can be produced during battery charging which may still be present once the charging process is complete. For this reason, ensure that the charging bay is well ventilated.

• Smoking and naked flames are prohibited within a range of 2 m around the charged battery.

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Sheet no.

99 – 02

Chapter 99

Maintenance

Brake Functional check of the deadman brake If the deadman switch is released during travel, the vehicle should be generator braked immediately.

Once it comes to a standstill, the mechanical brake should be applied automatically.

If the deadman switch is released at a standstill, the mechanical brake should be applied immediately.

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Functional check of the neutral brake If the travel switch is released during travel, it should return automatically to the neutral position. The vehicle should be brought to a standstill with generator braking. Once it has been at a standstill for two seconds, the mechanical brake is applied.

30020

1

Functional check of the reversing brake If the travel switch is moved into the opposite direction during travel, the vehicle should be braked immediately with generator braking.

Maximum wear on the brake lining 30021

The brake lining (1) must be replaced when it reaches a residual thickness of 8 mm (please see the chapter on the Brake/Brake lining).

2

Brake clearance The brake clearance (2) increases by the same amount as the brake lining decreases. If the brake clearance is too large, the brake cannot be released any more. For this reason, it must be checked without fail whenever maintenance is carried out (please see the chapter on the Brake/Setting the brake clearance).

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Sheet no.

99 â&#x20AC;&#x201C; 03

Chapter 99

Maintenance

Battery Checking the electrolyte level The electrolyte level (battery fluid) must reach the baffle (plastic grid under the stopper) but not rise above it.

Always check the electrolyte level in several cells, since it can differ greatly.

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Copyright reserved.

Checking the electrolyte density The electrolyte density is an indication of the degree to which the battery is charged, i.e. the greater the density, the higher the battery capacity. The electrolyte density is measured with an aerometer (1).

The electrolyte density must be tested  the battery has been charged. The electrolyte density should be between 1.22 and 1.27 kg/l after the battery is charged. A lower reading is not acceptable.

It may be necessary to top up the acid.

30022

1

Battery lock The battery lock mechanism must not be bent.

The sealing lips and rubber pads that hold the battery in its end position should be undamaged.

The battery should be held securely in its end position, even during fast travel around bends (please see chapter on Battery/Lifting and removing the battery).

Cleaning the battery The battery must be kept dry and clean. Any battery acid that runs out into the battery tray must be removed with a suction device (2).

Any verdisgris that has formed on the terminals should be removed.

Clean any oil smears, dust or other soiling off the surface of the battery with a clean, dry cloth.

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Chapter 99

Maintenance

Battery Battery lock The battery lock mechanism must not be bent.

The sealing lips and rubber pads that hold the battery in its end position should be undamaged.

The battery should be held securely in its end position, even during fast travel around bends.

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Battery charger The output voltage of the battery charger must match the battery voltage.

The insulation on the battery connecting cable must not have any bare patches. The charger should switch on automatically when it is connected with the battery. The charger must be set up in a place where good through-ventilation is guaranteed.

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Sheet no.

99 â&#x20AC;&#x201C; 05

Chapter 99

Maintenance

Operating elements 2

4

Ease of movement

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Copyright reserved.

The operating elements include: • Emergency-stop switch (1) • Key switch (2) • Steering wheel (3) • Travel switch (4) • Lifting button (5) • Lowering button (6) • Horn button (7) • Deadman switch (8) All the operating elements must move smoothly and return automatically to their neutral position. Lubricate if necessary.

30024

7 5 6

1

Switches must click firmly into position. Covers or cladding must not scrape against the operating elements.

Check all operating elements to ensure that they function correctly.

Replace contacts that are burnt out.

The symbols on the operating elements must be clearly legible.

30025

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Sheet no.

99 – 06

Chapter 99

Maintenance

Steering Ease of movement It must be possible to turn the steering wheel without exerting any force. However, the steering wheel must not move out of its home position of its own accord.

The ease of movement can be adjusted. To do this, remove the cover (1). The adjusting nut (2) is located under the steering wheel.

Once the hexagon socket screw (3) has been released, the nut (2) for adjusting the steering wheel ease of movement can be varied.

1

20183

Reversed steering

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Copyright reserved.

30026

If the vehicle is fitted with reversed steering, the relevant information notice (6) must be fixed to the vehicle.

2

Steering angle

3

The maximum steering angle is set correctly when the vehicle travels in a circle around the so-called turning radius point, which is no larger than 100 mm in diameter.

The turning radius point is between an imaginary centre line of both forks at the height of the load wheels.

Switching-off in the event of error If there is an internal or external error in the steering controller, travel should be switched off.

This cut-out function must be checked during maintenance.

To do this, pull out block connector X5 of the actual value potentiometer. The steering should now be out of action and the mechanical brake activated.

6 30027

Toothed gear ring The toothed gear ring (4) and the steering motor pinion (5) must be lubricated.

4 5 30028

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Sheet no.

99 â&#x20AC;&#x201C; 07

Chapter 99

Maintenance

Lifting chains

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Copyright reserved.

General The lifting chains used for the main lift are multi-link chains, also known as flyer chains. Flyer chains are dimensioned in inches.

Chains tend to elongate during the course of time as a result of wear on the chain link pins. When a specified tolerance measurement is exceeded, the chain must be replaced (please see Lifting chains/ Checking the chain elongation).

In order to keep wear to a minimum, please always ensure that: • The chains are cleaned regularly and then sprayed with a special chain spray.

• The chains are checked regularly to ensure they are correctly adjusted (tension).

• Any imbalance due to incorrect chain tension or faulty mechanical elements is avoided.

Note:

Chains are safety components. They must therefore be checked with particular care.

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Sheet no.

99 – 08

Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage The lifting chains on the main lift must be checked for the following signs of damage: •

Surface rust

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Copyright reserved.

20132

•

Rust in the joints

20133

•

Stiff links

20134

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Sheet no.

99 – 09

Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage •

Twisted link pins

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Copyright reserved.

20135

•

Loose link pins

20136

•

Unacceptable external wear

20137

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Sheet no.

99 – 10

Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage •

Damage

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20138

•

Broken link plates

20139

•

Broken link pins

20140

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Sheet no.

99 – 11

Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage •

Soiling

20141

Wear in the link plate holes

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Copyright reserved.

•

20142

•

Wear on a link pin

If any of these signs of damage are found, the chain must be replaced immediately, since damage of this kind can cause the chain to break before the wear limit for permissible chain elongation is actually reached (please see Lifting chains/Replacing the lifting chains).

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Sheet no.

99 – 12

Chapter 99

Maintenance

Lifting chains Checking the chain elongation

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Copyright reserved.

Main lift Caution:

Even if the wear limit has not yet been reached, we recommend that all chains for safety reasons.must be replaced at the following intervalls becouse its very difficult to ascertain, due to ageing and material fatigue:

Mainlift:

If elongation of the load or controllchains is more than 2%

Initiallift:

If elongation of the chains is more than 2% or they have been working more than 5000 hours.

The chains must be tested with the chains installed and with at least 10% of the rated load. They must not be elongated by more than 2%. The chain must be cleaned before the measurement is taken. The measurement must be made in the working area of the chain.

2% are 17mm of a lenght of 17 dubblelinks.This means that the chain is weared out if 17 dubblelinks are longer then 560mm instead of 543mm.

1 double link

17 double links of a elongated chain = 560mm

61049

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Sheet no.

99 â&#x20AC;&#x201C; 13

Chapter 99

Maintenance

Replacing the lifting chains Note:

Always use original spare parts when replacing lifting chains!

When the lifting chains are replaced, the connecting bolts (1) between the chain anchor (2) and chain (3) must also be replaced.

The lifting chains for the main lift must always be replaced at the same time.

This is the only way to guarantee an even distribution of weight over both chains.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Repairing the lifting chains Repairs should not be carried out on the lifting chains.

If, however, repairs are unavoidable, you must proceed with extreme caution.

Before the lifting chains are removed, the rivet heads must be ground down so that the movable inner plates in the holes are not damaged.

Pins and plates that have been removed must not be used again.

It is important to ensure that the outer plates are not damaged in any way, as this can cause chain breakage.

When riveting, only a slight deformation of the pin head is necessary, since the pins are held primarily in place by the force fit in the outer plates.

Attaching additional chain links is not allowed, since the links that are added are not pre-stretched.

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3

Sheet no.

99 â&#x20AC;&#x201C; 14

Chapter 99

Maintenance

Lubricating the lifting chains

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Copyright reserved.

How often lubrication is required depends on what the vehicle is used for and on the conditions in which it is used. With normal use in single-shift operation, the chains must be re-lubricated every quarter or every 500 operating hours.

In tougher and/or multi-shift operation, and in situations where heavy soiling occurs or in humid conditions, lubrication must be carried out more often.

The intervals must be shortened as appropriate for the situation, e.g. if the vehicle is used in two-shift operation, the intervals should be halved.

Note: If the outside of the chain is so soiled that penetration of the lubricating oil cannot be guaranteed, the chain must be cleaned before lubrication. Please see "Cleaning the chains"!

"Stabylan 2001" lubricant (Id. no. W8 010 100) should be used for lubricating the lifting chains.

Remark:

If the vehicle is used in a cold store environment (-30°C), the lubrication intervals should be reduced to half the length, and in multi-shift cold store operation, intervals should be shortened to 1/4 or 1/6 of the standard length, according to the amount of use.

"Syntesco" lubricant should be used for lubricating the lifting chains of vehicles used in cold store conditions (Id. no. W8 036 220).

Remark:

Dirt should not adhere to the outside of the chains.

The chains are correctly lubricated if your finger is covered with a film of oil when you touch the chain and if the lubricant does not drip off the chain.

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Sheet no.

99 â&#x20AC;&#x201C; 15

Chapter 99

Maintenance

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Copyright reserved.

Cleaning the chains If chains are covered with a layer of grease on the outside or if they are heavily soiled, new lubricant cannot penetrate through the layer of grease or dirt into the chain. This causes wear and allows corrosion to occur, which subsequently makes the chain links stiffen.

For this reason, it is essential to clean soiled chains before they are lubricated.

Chains should only be cleaned with paraffin derivates like diesel fuel, petroleum, cleaning naphtha, etc.

Cleaning with steam jets in combination with cold solvent cleaners or any kind of agents containing caustic or acidic substances is strictly prohibited. This kind of treatment can cause direct damage to the chains.

If cleaning the chains with steam jet equipment is absolutely unavoidable, you should proceed as follows: • Cleaning Only use steam jet equipment without adding any cleaning agents.

• Blowing out Immediately after a chain has been cleaned, all the water left on its surface and in the chain links should be removed with a compressed air blower.

The chain should be moved several times during this process.

• Spraying The chain should then be sprayed immediately with one of the preserving and lubricating agents recommended by us. The chain should also be moved often enough during this process to ensure that the preserving and lubricating agent does actually penetrate into the chain links.

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Sheet no.

99 – 16

Chapter 99

Maintenance

Hydraulic tank Volume The hydraulic tank volume is as follows for the different vehicles SU Nom./Usable 1.4 / 1.1 Litres SD Nom./Usable 4.0 / 3.5 Litres SV Nom./Usable 6.0 / 4.9 Litres

Seals

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Copyright reserved.

The tank and pump assembly are connected to each other with a screw-fit connection.

For additional protection around the joint, a hose clamp is fitted that must be checked for leaks (1).

30029

1

Filter The paper air filter (2) lets air flow into or out of the tank.

Hydraulic oil that has leaked out of the oil tank gums up gradually in the filter and blocks it off. When this happens, the filter must be replaced.

Mainliftfilter The purpose of the mainliftfilter (3) is to filter the hydroulicoil that flowes to the maincylinders.

It is placed on the backside of the batterieroom between mast and loadchain(please see hydraulic/Filter)

30030

2

Size of filter: 100µ /6cmcm

Soiled oil

3

The hydraulic oil can become soiled by different materials: • Condensation water • Rubber that rubs off the hydraulic hoses • Metal splinters off the valve block • Other dirt For this reason, the hydraulic oil must be replaced to schedule, or at the latest when the colour of the oil has turned darker than honey yellow.

Please displose of used oil correctly.

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Sheet no.

99 – 17

Chapter 99

Maintenance

Wheels Wear The drive wheel must be replaced when the diameter has worn down to 225 mm.

It must also be replaced when: • The running surface is very pitted • The running surface is out of round • The running surface is cracked The tightening torque for the wheel bolts is 140Nm. 30031

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Copyright reserved.

Wheel bearings

1

When replacing the drive wheel, always check the wheel bearing.

To do so, jack up the vehicle, and chock it up securely, then take hold of the drive wheel with both hands and jiggle it. You should be able to feel that it is fitted firmly without any play.

Castor wheels Castor wheels must be replaced when the diameter has worn down to 65mm.

They must also be replaced when: • The running surface is very pitted • The running surface is out of round • The running surface is cracked.

When the load wheels are replaced, the lubricating nipples (1) in the load wheel axles must be lubricated.

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99 – 18

Chapter 99

Maintenance

Motor Carbon brushes The carbon brushes must be replaced when they have worn down to the following length: Drive motor: 20mm Pump motor: 16mm Steering motor: 14mm The entire brush set (4 brushes) must always be replaced (please see Drive motor/carbon brushes).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Remark:

30039

The motor should not be placed under a full load immediately after the carbon brushes have been replaced. The carbon brushes run in relatively quickly under a minimum load.

Checking the brush springs Brush springs that are not adequately pre-tensioned can cause the commutator to burn. Ensure that the carbon brushes move easily in the shaft.

Other maintenance work As well as replacing the carbon brushes, motor maintenance includes the following points: • Cleaning (see Travel drive/Maintenance) • Visual inspection (see Travel drive/Maintenance) • Replacing damaged parts (see Travel drive/ Maintenance) • Checking the brush assembly and commutator (see Travel drive/Maintenance).

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Sheet no.

99 – 19

Chapter 99

Maintenance

Gear Changing the gear oil The oil must be drained off when the vehicle is warm.

The maximum permissible operating temperature is 80C°.

Use new seals on the oil drainage screw. Tightening torque: 22Nm. The filling volume is about 1.5 litres (see Travel drive/ Oil change).

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Noises Noises are a sign of excessive wear or an internal fault. The problem may be that there is not enough oil in the gear or the wrong type, but it is more commonly due to mechanical action (driving over floor joints or rails) (please see Travel drive/Maintenance).

Leaks Check the gear for leaks at the inlet and outlet screws, the screw holes, at the shaft outlet and the back cover.

If necessary, replace the seal or shaft ring.

Gear bearing The gear bearing (1) is located between the motor and gear (1). A lubricating nipple (2) is fitted here.

This must be lubricated every time maintenance work is carried out on the gear, at the latest.

30032

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Sheet no.

99 â&#x20AC;&#x201C; 20

Chapter 99

Maintenance

Mast Mast rollers The mast rollers (2) must not be worn out or cracked.

Mast rollers with lubricating nipples must be lubricated with all-purpose grease.

Guide rollers of the fork holder 1

The guide rollers (1) must not be worn out or cracked.

Guide rollers with lubricating nipples must be lubricated with all-purpose grease.

30040

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Windscreen The windscreen is on the one hand designed to protect the driver from drops of chain grease and draughts, and on the other hand to guarantee him a clear view of the forks. For this reason, the windscreen must be kept clean at all times.

30041

Lifting cylinder

2

The lifting cylinder must be inspected for leaks. If necessary, replace the set of seals.

Guides, surfaces The surfaces of the mast profiles that the guide and mast rollers run up and down continuously, must be cleaned regularly and then greased again, in order to keep wear to a minimum.

Forks The welded seams of the forks on the fork holder must be inspected for cracks.

Chain adjustment The chain tension must be adjusted with the main lift fully lowered. Tighten both chain tensioners (4) until a slight tension can be felt.

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Sheet no.

99 â&#x20AC;&#x201C; 21

Chapter 99

Maintenance

Pump assembly Carbon brushes The carbon brushes must be replaced when they have worn down to 16 mm. Never replace single carbon brushes - always replace the entire set.

Please refer to the instructions on "Replacing the carbon brushes" (sheet 15-05).

Oil level The oil level cannot be measured until all the cylinders have been retracted. The oil level should be between the minimum and maximum mark.

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Noises Screeching,whining or scraping noises caused by faulty bearings, if the oil level is too low or scuffing toothed gears in the pump must be rectified by replacing the worn parts.

20412

Soiling A mixture of abrasive dust from the carbon brushes and a fine oil vapour makes a very good electrically conductive connection. If this connection forms between the chassis and the positive or negative battery pole, this is referred to as a short to ground. It can cause various different faults. For this reason, clean all surface dust off the motors every time maintenance work is carried out.

Filter The filter (1) in the pump assembly is designed to prevent particles of dust or other substances entering the tank unfiltered. This air filter can gum up with leaking hydraulic oil. If, then, a large volume of hydraulic oil is removed from the tank to extend the cylinders, air cannot flow into the tank, a vacuum is formed and the tank distorts and can drop off.

30034

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99 â&#x20AC;&#x201C; 22

Chapter 99

Maintenance

Lubrication plan Lubricants The following lubricants should be used: Hydraulic oil HLP DIN 51524/T2 Id. no. 8 036 912 The refill opening for the hydraulic oil is marked with a symbol (1).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Gear oil SAE 80 Id. no. 8 036 925

30035

All-purpose grease ESSO Beacon 2 Id. no. 8 010 107

1

Chain lubricant Stabylan 2001 Id. no. 8 010 100

Disposal If the vehicle described here has to be taken out of service, it is important to ensure that all the components are disposed of in accordance with the regulations (relevant components are marked with the symbol shown here (2)).

In particular the fuels used in the vehicle must be either recycled or disposed of in the correct manner.

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SU/SD/SV

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2

Sheet no.

99 â&#x20AC;&#x201C; 23

Chapter 99

Maintenance

Lubrication plan Grease the toothed gears in the steering with all-purpose grease (1): Every 3 months.

Grease bolster bearings with all-purpose grease (2): Every 12 months.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Lubricate the load wheel axle with allpurpose grease (3): Every 12 months.

Lubricate all moving parts with oil: Every 3 months.

30042

4

5

2

1

Change the hydraulic oil (4): Every 12 months.

Change the gear oil (5): Every 12 months.

Lubricate all the guide rollers in the battery compartment with oil (6).

30037

3

30038

6 Issue Replaces issue

09/03

Workshop Manual

SU/SD/SV

Sheet no.

99 â&#x20AC;&#x201C; 24