STILL STED forklift EGU-18 EGU-20 EGU-20S EGU-H Electric Pallet Truck Workshop Manual

EGU-18 / EGU-20 / EGU-20S / EGU-H Electric Pallet Truck

Workshop Manual Valid from Series No.: 71 0117 0 00020 71 0119 0 00028 71 0125 0 00048 71 0201 0 00010 4498854 - 01.2000

Workshop Manual

EGU 18/20/20S

Instructions on Use of Manual Structure

System diagnostics

The Workshop Manual "EGU 18/20/20S" is divided into two sections:

The system diagnostics help to speedily pinpoint faults in the electrical installation and to find out their exact cause. They are made up as follows:

- Repair hints Index 00 bis 30 - Fault diagnostics 31 and special tools 32 Both sections consist of a compilation of single sheets which can be supplemented and which are filed into a STILL & SAXBY file according to index number.

- Use of the programming unit - Parametrisation of the pulse control - Menus The wiring diagrams (in DIN A3 format) are located in chapter 08. The related legends are on the respective pages.

Repair hints

)

Where necessary, a table has been added which displays important data for the STILL Maintenance Service which must be consulted also by the experienced service engineer.

Issue: 01.2000

To enable quick reference to be made to the individual Functional Groups, the number of the relevant group figures in each case at the top of each page, in the right or left corner.

(Replaces issue:

The entire contents of this manual are split up in compliance with the system applied to the Parts Catalogue which is divided into Functional Groups.

The manual contains a description of the construction features and operation of the different assemblies/functional groups.

II

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Copyright reserved.

Regarding the sequence of operations these are supplemented by instructions, hints and diagrams or figures/illustrations.

Workshop Manual

EGU 18/20/20S Instructions on Use of Manual

Purpose of the manual The user will in future receive Workshop Manuals for every specific type of truck (in this case EGU 18/20/20S models).

These are meant to replace the service information bulletins formerly used.

The Workshop Manual incorporates the following advantages:

Reliable updating causing no problems: The break-down of the manual into single sheets results in the association of information, reducing errors to a minimum.

Together with the updated sheets the addressee will in each case also receive instructions advising him how to file the new sheets and whether old sheets must be removed from file and if so, which ones.

If sheets must be replaced, the places which comprise the change with regard to the previous sheets will be identified with an asterisk (*).

Updating

(Replaces issue:

Issue: 01.2000

)

Easy to use: Easy, speedy and unerring use of the workshop manual, eliminating the need for timeconsuming searching.

3. Supplements/repeated supplements Additional sheets which are valid from a given serial number or from a certain production date are printed on coloured paper, in such a case the old sheets must remain in the manual as they still remain valid for the first serial numbers (e.g. in the event of several product improvements).

Should single sheets or groups of sheets no longer correspond to the latest engineering design or know-how, updating sheets will be dispatched.

Due to organizational reasons this is feasible only within the STILL & SAXBY Organization.

Updating exists in the forms shown below:

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Copyright reserved.

1. Substituting a sheet You remove the previous sheet and substitute the new one (e.g. in the event of printing errors, changes in illustrations etc.)

2. Inserting additional sheets These sheets carry the page number of the page which must precede the sheets to be inserted. For example, the sheet with page numbers 6a and 6b must be filed directly behind page 6 which must be followed by page number 7 (e.g. in the case of additions or product improvements).

III

Workshop Manual

EGU 18/20/20S

Instructions on Use of Manual When working with the present manual please observe the following: In this workshop Manual the standard designs of the corresponding truck models, as well as some widely used variants are dealt with.

Working in compliance with the instructions contained in this manual does not entitle to warranty claims. The STILL & SAXBY warranty conditions remain unaffected.

Publisher: STILL & SAXBY rue des Frères Lumière F-77107 Meaux STILL & SAXBY are constantly striving to improve their products and we therefore reserve the right to change truck specifications and design without notice.

Issue: 01.2000

(Replaces issue: )

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

Copyright reserved.

IV

Workshop Manual

EGU 18/20/20S/H

Table of contents

Issue: 12.2001

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

Copyright reserved.

(Replaces issue: 01.2000)

Synoptic Table on Functional Groups 00 01 02 03 04 05 06 07 08 09 10 11 20 22 28 31 32

General Chassis Running axle Gear drive Wheels and tyres Driving controls Steering Brakes Electric equipment Lighting equipment and instruments Hydraulic system Power unit Mast Fork carriage Built-in charger Diagnostics Special tools

V

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Copyright reserved.

Issue: 12.2001 (Replaces issue: 01.2000)

Workshop Manual

EGU 18/20/20S/H

00

General

Contents Page

Technical data EGU-18/20/20S 2

Technical data EGU-H 3

1

00

EGU 18/20/20S

Workshop Manual

General Technical data Identification Manufacturer Model designation

EGU 20-S

battery

battery

walkie

walkie

walkie

walkie, stand-on

walkie, stand-on

Q (kg) c (mm) x (mm) y (mm)

1800 600 968 1320

2000 600 968 1390

2000 600 968 1454

2000 600 968 1390

2000 600 968 1454

Weights Dead weight Axle load Axle load Axle load Axle load

with load with load without load without load

kg kg kg kg kg

285 880 1400 390 90

293 960 1545 405 100

310 1010 1570 455 125

348 995 1565 440 120

365 1045 1590 490 145

Wheels, chassis Tyres, superelastic (SE), pneumatic (L), polyurethane (P) Vullkollan (V) Tyre dimensions Tyre dimensions Dimension of stabiliser wheels Wheels, number front (x=driven) Track width, front Track width, rear

V

V

V

V

V

b 10 (mm) b 11 (mm)

230 x 75 85 x 100 2 x Ø 100 x 40 1x-2/2 0 390

230 x 75 85 x 80 2 x Ø 100 x 40 1x-2/1 0 390

230 x 75 85 x 80 2 x Ø 100 x 40 1x-2/1 0 390

230 x 75 85 x 80 2 x Ø 100 x 40 1x-2/2 0 390

230 x 75 85 x 80 2 x Ø 100 x 40 1x-2/4 0 390

Overall dimensions Lift Tiller height Fork height Overall length Length Overall width Fork thickness Fork width Fork length Outside fork distance Ground clearance Aisle width with pallets 800 x 1200 long Turning radius

h 3 (mm) h 14 (mm) h 13 (mm) l 1 (mm) l 2 (mm) b 1 (mm) s (mm) e (mm) l (mm) b 5 (mm) m 2 (mm) Ast3 (mm)

120 692/1254 85 1660 510 700 52 180 1150 560 33 1952

120 692/1254 85 1732 582 700 52 180 1150 560 33 2022

120 692/1254 85 1794 644 700 52 180 1150 560 33 2086

120 668/1117 85 1817/2207 582 700 52 180 1150 560 33 2092/2462

120 668/1117 85 1880/2270 728 700 52 180 1150 560 33 2154/2524

Performances Driving Driving Lifting Lifting Lowering Lowering Rated tractive force Rated tractive force Service brake

Wa (mm)

1533

1603

1667

1660/2031

1722/2095

with load without load with load without load with load without load with load without load

km/h km/h m/s m/s m/s m/s % %

5.8 6 0.04 0.054 0.04 0.04 10 20 electromechanical

5.8 6 0.04 0.054 0.04 0.04 10 20 electromechanical

5.8 6 0.04 0.054 0.04 0.04 10 20 electromechanical

5.08.2000 6 0.04 0.054 0.04 0.04 10 20 electromechanical

5.8 6 0.04 0.054 0.04 0.04 10 20 electromechanical

Electric motors Drive motor Lift motor

performance S2 = 60 min performance S 3 = 15%

kW

1.2

1.2

1.2

1.2

1.2

kW

2

2

2

2

Battery acc. to DIN 43531/35/36 A, B, C, no Battery voltage

2

no

DIN 43535 B

DIN 43535 B

DIN 43535 B

DIN 43535 B

U (V)

24

24

24

24

Battery capacity Battery weight

24

K 5 (Ah) kg (+/- 5%)

180 195 -

240 220 -

330 270 -

240 220 -

330 270 -

Energy consumption acc. to VDI cycle Other specifications Speed control type Noise level

pulse control -

pulse control -

pulse control -

pulse control -

pulse control -

2

without battery driver's side load side driver's side load side

driver's side load side driver's side front/rear

min/max traction unit

centre wheel base

depending on supplier

at driver's ear

kWh/h

dB (A)

Issue: 01.2000

EGU 20-S

battery

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Copyright reserved.

EGU 20

battery

)

EGU 20

battery

(Replaces issue:

EGU 18

Drive: Battery, Diesel, petrol, LP gas, mains Operation: Manual, walkie, stand-on, driver seated, order picker Load capacity/hoisted load Load centre Load distance Wheel base

Workshop Manual

00

EGU 18/20/20S/H

General General Technical data Identification Manufacturer Manufacturer’s model designation Drive: Batter y, Diesel, petrol, LP gas, mains Operation: Manual, walkie, driver standing, driver seated, order picker Load capacity/hoisted load Load centre Load distance Wheel base Weights Dead weight Axle load with load (800/2000kg) Axle load with load (800/2000kg) Axle load without load Axle load without load Wheels, chassis Tyres, superelastic (SE), pneumatic (L), polyurethane (P) Vullkollan (V) Tyre dimensions Tyre dimensions Dimension of stabiliser wheels Wheels, number front (x = driven) Track width, front Track width, rear Overall dimensions Lift Initial lift Tiller height Fork height Overall length Length Overall width Fork thickness Fork width Fork length Fork carriage width Outside fork distance Ground clearance Aisle width with pallets 800 x 1200 long Turning radius Performances Driving Driving Lifting (Main lift) Lifting (Main lift) Lifting (Initial lift) Lifting (Initial lift) Lowering (Main lift) Lowering (Main lift) Lowering (Initial lift) Lowering (Initial lift) Rated tractive force Rated tractive force Service brake Electric motors Drive motor Lift motor Battery acc. to DIN 43531/35/36 A, B, C, no Battery voltage Battery capacity Battery weight Energy consumption acc. to VDI cycle Other specifications Speed control type Noise level

EGU-H Battery walkie

without batterie driver's side load side driver's side load side

Q (kg) c (mm) x (mm) y (mm)

2000/800 600 695 1158

kg kg kg kg kg

470 558 / 688 898 / 1968 474 182 V

driver's side load side driver's side front/rear

230 x 75 2 x ( 2x Ø 85 x 60) 2 x Ø 100 x 4 1x-2/4 b 10 (mm) b 11 (mm)

min/max drive section

centre wheel base

h 3 (mm) h 5 (mm) h 14 (mm) h 13 (mm) l 1 (mm) l 2 (mm) b 1 (mm) s (mm) e (mm) l (mm) b 3 (mm) b 5 (mm) m 2 (mm) Ast3 (mm) Wa (mm)

560 120 765 / 1255 91 1783 633 700 55 184 1150 625 564 20 2061 1356

with load without load with load without load with load without load with load without load with load without load with load without load

km/h km/h m/s m/s s s m/s m/s s s % %

6 6 0.28 0.16 3 2.4 0.16 0.14 2.2 2.3 10 20 electro-magnetic

performance S2 = 60 min performance S3 = 15%

kW kW

1,2 2 no 24 190 185 -

depending on supplier

at driver’s ear

U (V) K 5 (Ah) kg (+/- 5%) kWh/h

dB (A)

Pulse control 68

3

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Copyright reserved.

Issue: 01.2000 (Replaces issue:

)

Workshop Manual

EGU 18/20/20S

01

Chassis

Contents Page

General 2

Removal of covers 3

1

01

Workshop Manual

EGU 18/20/20S/H

Chassis General The truck frame is machine-welded.

The hood is manufactured using the RMI polyurethane injection technique, making it highly shock-resistant.

1

Load chassis

2

Motor chassis

3

Cover

Platform support

2

Lowerable platform

3

Gas-filled strut (automatic return to vertical position)

Note: The platform is optional for the EGU-H.

1

Mast chassis

2

Motor chassis

2

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The EGU-H is provided with a small mast welded to the chassis.

Issue: 12.2001

1

(Replaces issue: 01.2000)

The EGU 20S is also equipped with a lowerable platform comprising the following elements:

Workshop Manual

01

EGU 18/20/20S

Chassis Removal of covers 1

The covers must be removed to gain access to the electric equipment.

-

Disconnect the battery.

Pull the cover (1) up and remove it.

Remove the 2 screws on the hinged cover (2) and remove the cover.

Remove the 2 screws on the instrument panel cover (3).

Remove the 2 screws on the contactor cover (4).

2

4

-

Set the levers to the braking position.

NOTE: The cover (1) can only be installed if the brake release is in the braking position.

(Replaces issue:

-

Refit the cover.

NOTE: The cover is clipped onto the manual electromagnetic brake release.

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

Copyright reserved.

Issue: 01.2000

)

Installation Installation is in the reverse order of removal.

3

EGU 18-20S/01-03

3

Workshop Manual

02

EGU 18/20/20S

Page

Preparation of the truck

2

Maintenance supports

2

Attaching the supports

2

Removing the free lift mechanism

4

Removing the pressure rods

4

Removing the articulated lever

6

Installation

10

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Issue: 01.2000

Contents

(Replaces issue:

)

Running axle

1

02

Workshop Manual

EGU 18/20/20S

Running axle Preparation of the truck Maintenance supports (see special tools, group 32) If the truck has to be positioned on the drive section (vertically) to perform maintenance work, the maintenance supports described here must be installed for safety reasons.

Attaching the supports - Remove the battery.

- Install a special plug, part no. 4498851 (1) in place of the hydraulic system filler plug.

3 2

- Turn back the star handle (5) until the screw head (3) projects around 10 mm.

5 7

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2

2

4

6

)

- Push the screw head (3) and stop lug (6) into the cut-out (4) in the drive section as far as they will go. This ensures positive locking of the screw head.

350 mm

Issue: 01.2000

- Position a wooden block (7) (about 35 mm thick) at a distance of 1000 mm from the drive section (to protect the tiller head).

(Replaces issue:

- Underlay the drive section with cardboard (2) (to protect the paintwork).

Workshop Manual

EGU 18/20/20S/H

02 Running axle

- Lock the spider nut and ensure that the spider is supported fully by the maintenance supports.

- Seize the truck at the fork ends (8) and raise the truck carefully.

CAUTION: Deposit the tiller slowly and carefully on wood (7).

Issue: 12.2001

- When tilting the truck back onto the fork rollers, hold it on the side of the forks (8) (danger of crushing).

NOTE: In the raised state, the maintenance supports are 2 mm shorter than the drive section. This is necessary for other services.

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Copyright reserved.

(Replaces issue: 01.2000)

CAUTION: For the EGU-H remove the fork carriage (see group 22).

3

02

Workshop Manual

EGU 18/20/20S

Running axle Removing the free lift mechanism

1

Removing the pressure rods - Remove the battery.

- Put maintenance supports in place and lift the truck up.

- Drive out the clamping sleeve (1).

- Drive out the pin (2).

Issue: 01.2000

(Replaces issue:

2

)

- Drive out 2 clamping sleeves (3).

4

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Copyright reserved.

3

Workshop Manual

02

EGU 18/20/20S

Running axle NOTE: The driven-out clamping sleeve remains positioned in a recess in the forks (4) and it can be taken out after removing the roller fork.

)

4

)

- Drive out the pin (1) with a drift punch until the hole for the clamping sleeve is accessible.

Issue: 01.2000

(Replaces issue:

- Insert the punch (diam. 4 mm) into the hole for the clamping sleeve (2).

5

- Carefully pull out the pin to the side step by step by turning it. If the pin sticks, drive it out with a hammer and a drift punch.

CAUTION: If the pin is pulled out completely, the spacer tube (3), roller (4) and roller fork (5) will drop out.

Therefore: - Using your other hand, grip the spacer tube (3) and roller (4) and hold them.

4

3

2

1

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- Put both parts down in a safe place.

- Grip the fork roller (6) and lift.

- Pull out the pin (1) completely.

6

- Take out the roller fork with a pressing linkage.

Installation

1

The installation is in the reverse order of removal.

5

02

EGU 18/20/20S

Workshop Manual

Running axle Removing the articulated lever - Take off the covers (1 - 4).

- Disconnect the electrical connection to the key-operated switch and the battery discharge display (mark the cables accordingly).

- Disconnect and remove the battery.

6

Issue: 01.2000

(Replaces issue:

- Disconnect and mark the cables of the pulse control (6) and remove the control, the battery connector and the 2 clamps (5).

)

5

- Remove the motor-pump unit. Remove 2 screws (7), supporting the pump unit from the underneath. Deposit the pump unit with the venting filter pointing upwards, otherwise oil will flow out.

NOTE: The removal of the pump unit is absolutely essential for other work steps.

- Drive out the clamping sleeve (8) with a drift punch (diam. 8 mm) through the hole in the battery compartment.

6

8

7

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- Disconnect the electric (and mark) and hydraulic connections.

Workshop Manual

02

EGU 18/20/20S

Running axle - Remove the pressure rods (see group 02, pages 2 to 5).

- Using wooden wedges or similar objects (1) (7 mm), fasten the fork carriage frame and the drive section.

1 )

1

2

(Replaces issue:

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

Copyright reserved.

Issue: 01.2000

)

- Drive out the pin (2) with a bronze / aluminium drift punch (3).

3

- Pull out the pin and hold the articulated lever in the top position (4).

4

7

02

Workshop Manual

EGU 18/20/20S

Running axle - Lower the articulated lever (5).

- Remove the retaining pin on the piston rod.

5

Issue: 01.2000

(Replaces issue:

- Put two Europallets or similar objects in position (6), height approx. 300 mm.

)

6

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- Shift the fork frame (7) approx. 50 mm to separate the connection to the lift cylinder.

7

8

Workshop Manual

EGU 18/20/20S

02 Running axle

- Lower the fork frame (1) on the Europallets.

Issue: 01.2000

(Replaces issue:

)

)

1

CAUTION: Before depositing the fork ends, only touch them at the sides to avoid the risk of crushing

- Remove the maintenance supports.

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- Drive out the clamping sleeve (2).

2

9

02

Workshop Manual

EGU 18/20/20S

Running axle - Drive out the pin (1) with a drift punch (diam. 16 x 250 mm).

- Remove the spring type pin.

1

Installation Installation is in the reverse order of removal.

Issue: 01.2000

(Replaces issue:

- Remove the articulated lever (2).

)

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

Copyright reserved.

10

Workshop Manual

03

EGU 18/20/20S

Page

Lubrication, bogie bearing

2

Removing the gearbox

3

Assembly of the gearbox

3

Oil change for gearbox

4

Checking the transmission oil level

5

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Issue: 01.2000

Contents

(Replaces issue:

)

Gear drive

1

03

Workshop Manual

EGU 18/20/20S

Gear drive Lubrication, bogie bearing

1

2

General To achieve optimum operation and maximum service life from the bogie bearing, lubricate the bogie bearing once every three months.

Procedure - Remove the covers.

- Lubricate the grease nipples (1 and 2) through the holes in the drive section.

EGU 18-20S/03-03.eps

Grease type: All-purpose grease

Issue: 01.2000

(Replaces issue: )

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

Copyright reserved.

2

Workshop Manual

EGU 18/20/20S

03 Gear drive

Removing the gearbox NOTE: When the drive motor is dismantled, the truck is not braked, so it must be chocked to prevent it from moving.

- Remove the battery plug.

- Place the truck on chocks approximately 230 mm high.

- Remove the drive wheel (3).

- Remove the drive motor (1).

)

NOTE: The leads must not be disconnected!

- Drain the oil from the gearbox (4) (see page 03-04) - Loosen the 6 remaining screws (2) and lower the gearbox carefully.

- Remove the gearbox.

(Replaces issue:

Issue: 01.2000

- Block the gearbox securely.

NOTE: Cover the gearbox orifice (to prevent dirt from entering it).

Assembly of the gearbox

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Copyright reserved.

Assembly is in the reverse order of removal.

NOTE: Before assembling the gearbox, make sure that its intake and ventilation holes are clean.

3

03

Workshop Manual

EGU 18/20/20S/H

Gear drive Oil change for gearbox The first oil change should take place after approx. 50 - 100 operating hours.

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

NOTE: The gear oil must be drained at operating temperature.

CAUTION: Danger of burning!

The maximum permissible operating temperature is 80°C. Viscosity: SAE80.

- Install the filler plug with a new sealing ring.

NOTE: In a cool room the gear oil has a viscosity of SAE90 or higher.

4

Issue: 12.2001

NOTE: The gearbox oil can also be filled and checked at the upper gearbox opening.

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

Copyright reserved.

- Jack up the truck safely and secure against rolling.

- Position an oil collecting tray with a capacity of 2.0 litres under the oil drain plug (2) of the gearbox.

- Turn the tiller clockwise as far as possible.

- Using a 6 mm hexagonal wrench, remove the filler plug (1) through the hole in the chassis (3).

- Remove the oil drain plug (2) and drain the oil.

- Install the oil drain plug with a new sealing ring.

- Fill the gearbox with transmission oil through the opening in the frame (3) (approx. 1,5 l).

The correct oil level is reached when the oil is at the base of the filler opening (1).

(Replaces issue: 01.2000)

Changing the oil

Workshop Manual

03

EGU 18/20/20S

Gear drive Checking the transmission oil level

Issue: 01.2000

- Remove the filler plug (2). The oil level is correct if the oil flows out of the hole.

(Replaces issue:

)

)

- Pull out the battery plug (1).

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

Copyright reserved.

- If the oil level is correct, the spur wheel (3) should be immersed approx. 1/3 in oil.

3

Oil level MA = 55 +10 Nm

5

Workshop Manual

04

EGU 18/20/20S

Page

Replacing the drive wheel

2

Swivel rollers

3

Adjusting the swivel rollers

3

Removing the swivel roller

3

Support rollers

4

General

4

Simple support rollers

4

Tandem support rollers

4

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

Copyright reserved.

Issue: 01.2000

Contents

(Replaces issue:

)

Wheels and tyres

1

04

Workshop Manual

EGU 18/20/20S

Wheels and tyres Replacing the drive wheel New dimensions: 230 x 75 mm The drive wheel must be replaced if: - the running surface is badly damaged or out of round - the diameter of the tyre has been worn down by 10% (minimum acceptable tyre diameter: 207 mm) Types of tyres: - Smooth polyurethane wheel - Treaded polyurethane wheel - Smooth rubber wheel - Treaded rubber wheel - Smooth natural rubber wheel - Treaded natural rubber wheel

230 mm EGU 18-20S/03-01.eps

- Remove the battery plug.

- Place the machine on chocks and block it so that it cannot roll (raise by 230 mm).

- Turn the drive wheel (2) so that you can loosen the 5 wheel nuts (1).

- Position the drive wheel crossways.

- Remove the wheel nuts.

- Remove the drive wheel.

1

Issue: 01.2000

(Replaces issue:

Removal

)

Assembly

Nut dimensions: Tightening torque for the nuts:

2

(A12x1.5 Din 74361).

83 Nm.

2 EGU 18-20S/04-02.eps

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Copyright reserved.

- Before assembling the drive wheel, clean the seat and make sure that it is in perfect condition.

- Put the drive wheel in place and tighten all 5 nuts by hand.

- Use a torque wrench to lock the nuts, tightening opposite nuts alternately.

Workshop Manual

04

EGU 18/20/20S

Wheels and tyres Swivel rollers 1

3

Adjusting the swivel rollers - Drive the traction wheel on a 3mm thick metal plate.

2

- Release the clamping screw (1) on the roller support.

- Loosen the socket head screw (2).

- Lower both swivel rollers (4) until the swivel rollers touch the ground.

Issue: 01.2000

(Replaces issue:

)

- Tighten the screw (1) to a torque of 125 Nm.

4

- Tighten the socket head screw with its washer (3) until the washer is clamped against the bearing housing.

NOTE: After assembling the rollers, you must check that they work properly. When you change the travel direction, the supporting rollers must pivot by 180° after travelling a short distance.

EGU 18-20S/04-01.eps

4

7 5

6

Removing the swivel roller - Remove the hex head screws (2).

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Copyright reserved.

The swivel roller with the wire-cover and the collared spacers can then be removed.

- Release the clamping screw (1) on the roller support.

- Remove the protective cover (4).

- Remove the bearings (5 and 6) and the sleeve (7). These two parts can be removed with a bearing extractor.

Reassembly Reassembly is in the reverse order or removal.

EGU 18-20S/04-03.eps

- Remove the circlips.

3

04

Workshop Manual

EGU 18/20/20S

Wheels and tyres Support rollers General Initial dimension: 85 mm.

The support rollers must be replaced - When they are damaged or out of round - When their diameter is worn down to 76.5 mm - When their bearings are faulty Depending upon the model, the EGU can be equipped with two different types of load rollers:

3

1

Simple support rollers

Issue: 01.2000

Reassembly Reassembly is in the reverse order or removal.

(Replaces issue:

Removal - Raise the forks until the bearing is separated from the load roller to allow the shaft to be driven out.

- Drive out the roll pin (1) downwards.

- Use chocks to securely raise the side to be replaced by approximately 100 mm.

- Then drive out the shaft (2).

- If necessary, replace the roller (3), bearings and rings.

2 EGU 18-20S/04-04.eps

)

Tandem support rollers

NOTE: After removal check the free movement of the rocker arms (4).

Reassembly Reassembly is in the reverse order or removal.

Torque for screws: 70 Nm. 4

5

4

8 9

6 4 8

7 6

5 7 EGU 18-20S/04-05.eps

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Copyright reserved.

Removal - Use chocks to securely raise the side to be replaced by approximately 100 mm.

- Pivot the supports (4).

- Loosen then remove the screws (5).

- Extract both rollers (9).

- If necessary, replace the rollers, bearings, shafts (6) and rings (7).

- Grease the supports rocker arm (4) at the grease nipples (8)

Workshop Manual

05

EGU 18/20/20S/H

Issue: 12.2001

Contents

Page

Tiller

2

General

2

Arrangement of the tiller head components EGU-18/20/20S

2

Arrangement of the tiller head components EGU-H

2a

Dismantling the tiller head

3

Dismantling the tiller circuit board block

3

Dismantling the butterfly handles

3

Operating principle

4

Safety microswitch

5

Travel direction

5

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

Copyright reserved.

(Replaces issue: 01.2000)

Driving controls

1

05

Workshop Manual

EGU 18/20/20S

Driving controls Tiller

1

General The tiller head is composed of a moulded housing containing an electronic circuit board, 3 push-buttons (raise, lower and horn), 2 butterfly handles for traction and a safety microswitch with a push-button.

3

If the tiller head malfunctions, the whole circuit board block must be changed.

4

When the butterfly handles are used, a combination of resistors is activated and causes the index value to vary according to the angle of rotation of the butterfly handles. The three push-buttons are on-off switches.

5

2

1 Safety microswitch.

2 Circuit board.

EGU 18-20S/05-02.tif

Issue: 01.2000

(Replaces issue:

Arrangement of the tiller head components

6

3 Butterfly handle for traction movements.

5 Push-button for lifting the forks.

)

4 Push-button for the horn.

7

6 Push-button for lowering the forks.

EGU 18-20S/05-01.eps

2

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

Copyright reserved.

7 Tiller safety button.

05

Workshop Manual

EGU 18/20/20S/H

Driving controls Arrangement of the tiller head components EGU-H 1 : Safety microswitch 2 : Circuit board 3 : Traction control 4 : Horn pushbutton 5 : Fork lift pushbutton 6 : Fork lowering pushbutton 7 : Belly switch 8 : Lowering pushbutton (initial lift) 9 : Lift pushbutton (initial lift)

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

Copyright reserved.

NOTE : The EGU-H circuit board is identical to the one installed in the EGV 14-16 equipped with initial lift. (The progressive lifting and lowering function is not used.)

Issue: 12.2000

(Replaces issue: 01.2000)

2a

Workshop Manual

EGU 18/20/20S

05 Driving controls

Dismantling the tiller head

Dismantling the tiller circuit board block

(Replaces issue:

- Remove the BTR screw (DIN 912, M6x20-88) (2).

- Extract the block (3) secured on 3 studs located at the back of the block.

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

Copyright reserved.

Issue: 01.2000

)

- Unplug the battery.

- Remove the four BTR (DIN 912, M6x12 8.8) screws (5) from the housing on the tiller.

Remove the housing (1).

- To extract the safety push-button, simply pull it upwards. This push-button (7) is embedded.

- Disconnect the tiller circuit board plug (located at the bottom), after first noting which way round it was connected.

- Then take off the second housing (6) by removing the three BTR (FHC M8xI2xI2) screws (8) - The tiller head is now disassembled.

Dismantling the butterfly handles - Pull hard, in a single movement, to extract each butterfly handle (4).

The butterfly handles can only be removed once the circuit board has been extracted from its housing.

Reassembly Reassembly follows the reverse order.

CAUTION: When reassembling, the 2 butterfly handles must be clipped back onto the 2 positioning and securing studs.

3

05

Workshop Manual

EGU 18/20/20S

Driving controls Operating principle One side of the control circuit board is covered with a plastic film under which you can see several white areas. These areas are conductive and each cover 2 strips which activate the functions (forward travel, reverse travel, lift, lower and horn) when they come into contact.

The lift, lower and horn control buttons are equipped with two small white plastic studs which press on the conductive areas and link the strips of the circuits controlling the different functions. Only the traction control butterfly handles are equipped with 4 white plastic studs (2 for travel direction and 2 for speed).

2 1

3

4

1 Back

3 Accelerator

5 Lifting - 2S2

Issue: 01.2000

5

4 Horn

(Replaces issue:

2 Forward

6 Lowering - 2S1 7 Direction control buttons

4

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

Copyright reserved.

7

)

6

Workshop Manual

05

EGU 18/20/20S

Driving controls Safety microswitch The tiller safety microswitch (1) activated by the housing (2) is a safety device that must operate in accordance with accident prevention regulations.

This is why you must always check that it works correctly during each maintenance operation.

After the safety microswitch is actuated, the direction of travel changes automatically to reverse. As soon as the microswitch is released, the machine remains at a standstill.

1

2

)

To restart the machine, there are only two possible solutions: - Turn the key switch to stop and then back to start.

EGU 18-20S/05-05.eps

(Replaces issue:

Travel direction

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

Copyright reserved.

Issue: 01.2000

- Return the tiller to the braking position.

Reverse

Forward

5

Workshop Manual

06

EGU 18/20/20S

Steering

Page

Removing the tiller

2

Removing the tiller microswitch

3

Dismantling the spring

3

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

Contents

1

06

Workshop Manual

EGU 18/20/20S

Steering Removing the tiller

EGU 18-20S/06-02.eps

Before doing anything else, remove the tiller cable.

1

- Disconnect the battery.

- Remove the cover (1) clipped on the 2 brake release levers for the electromagnetic brake.

- Remove the tiller head (see group 05, page 3).

- Disconnect the cable plug on the tiller head PCB.

- Slide the cable downwards inside the tiller arm.

- Mark and remove the two plugs on the tiller microswitches.

Issue: 01.2000

(Replaces issue:

- remove the 3 screws (2) on the tiller head and remove the lever.

)

3

- Remove the mechanical assembly.

Reassembly Reassembly is in the reverse order of removal.

3

2

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Copyright reserved.

- Remove the 4 BTR screws (3) fastening the tiller assembly onto the motor. These are mounted using Loctite

Workshop Manual

EGU 18/20/20S/H

06 Steering

Removing the tiller microswitch - Disconnect the battery.

- Remove the front cover and round cover.

- Remove the 2 microswitch power supply plugs (2).

- Unscrew the 2 socket head screws and remove the microswitch support assembly.

- Unscrew the 2 screws (1) on the microswitch.

Issue: 12.2001

(Replaces issue: 01.2000)

Dismantling the spring CAUTION: The spring (2) located inside the tiller arm is under high pressure. When dismantling it, place the tiller in the neutral position.

- Remove the screw (1) on the tiller arm.

- Drive out the pin (3).

Reassembly Reassembly is in the reverse order of removal.

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

Copyright reserved.

The gas compression springs mounted on the standard trucks have a force of 400 N. NOTE : The gas compression springs installed on the coldstore trucks (in appearance identical to standard trucks) have a force of 400 N at ambient temperature (for at –30°C the loss is about 10 – 12 % of the gas efficiency).

3

Workshop Manual

07

EGU 18/20/20S

Issue: 01.2000

Contents

Page

Electromagnetic brake

2

Function

2

Removal

3

Instructions for adjustment of the air gap

3

General

3

Adjustment procedure

3

Maintenance

4

Checking the air gap

4

Checking the braking force

4

Adjusting the electromagnetic brake locking levers

5

Functional check of the levers

5

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

Copyright reserved.

(Replaces issue:

)

Brakes

1

07

Workshop Manual

EGU 18/20/20S/H

Brakes Electromagnetic brake Function The illustration below shows the brake in the non-operated state, ie in the braking position.

The compression springs (2 and 3) press the brake anchor plate (6) axially against the brake lining (4) and this in turn against the motor flange (5).

If the tiller is lowered from the neutral position to the travel position, the safety microswitch of the electromagnetic brake is operated by a control cam.

The coil (1) of the electromagnetic brake is excited with direct current and the magnetic circuit between the anchor plate (6) and the coil is closed.

The anchor plate rises to the magnetised part, causing the air gap "a" to become "zero" again and to release the rotor (4).

7 Threaded piece

2 Compression spring

5 Flange

8 Stainless steel plate

3 Compression spring

6 Anchor plate

The stainless steel plate prevents the brake disk from seizing (particularly in a humid environment).

2

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Copyright reserved.

4 Rotor

Issue: 12.2001

(Replaces issue: 01.2000)

1 Coil

Workshop Manual

EGU 18/20/20S

07 Brakes

Removal - Unplug the battery.

- Block the machine to stop it rolling.

- Disconnect the power cable from the electromagnetic brake.

- Remove the tiller.

- Mark the initial radial position of the electromagnetic brake.

- Unscrew the 3 socket head screws (2).

- Remove the brake unit.

To reinstall, follow the same procedure in reverse order.

)

ATTENTION: Do not operate the truck if the electromagnetic brake is defective.

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

Instructions for adjustment of the air gap General Correct adjustment of the electromagnetic brake should ensure a minimum travel to free the lining and should allow the greatest possible wear on the lining.

Dimension "a" (1) indicates the air gap which must be set to 0.2 mm when it is readjusted (brake travel).

Adjustment procedure - Using the adjustment screws (2), adjust dimension "a" to 0.2 mm.

- Use the thickness gauge to check dimension "a" at three points (next to the screws (1)).

NOTE: Every time the lining is changed, check its mobility on the hub.

Replace when the residual thickness is: 4 mm.

3

07

Workshop Manual

EGU 18/20/20S

Brakes Maintenance Checking the air gap - Release the brake.

- Measure the air gap with a gauge.

Air gap............................ 0.15 bis 0.30 mm Minimum brake lining thickness.... 4 mm ATTENTION: Replace the whole brake if the air gap can no longer be adjusted.

ATTENTION: Keep the braking track clear and ensure that there is a sufficient safety distance.

5 km/h )

- Accelerate the pallet truck to 5 km/h.

- Apply the brake and measure the braking distance.

Max. braking distance: 1.05 m - The brake must be replaced if the distance is any longer.

1,05 1 .0 5 m

Issue: 01.2000

(Replaces issue:

Checking the braking force - Put a rated load on the pallet truck.

ATTENTION: Do not operate the pallet truck with a defective brake.

EGU 18-20S/07-02

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

Copyright reserved.

4

Workshop Manual

07

EGU 18/20/20S

Brakes Functional check of the levers

Adjusting the electromagnetic brake locking levers

- Put the two levers in the position shown in the illustration.

- It should be possible to move the pallet truck when the electromagnetic brake is released.

- Turn the two levers 3/4 of a turn anti-clockwise.

- The brake should now be applied and the powerless pallet truck no longer be able to move. The round cover can only be removed in this position.

- Remove the tiller.

- Put the traction wheel to the straight ahead position.

- Tighten the two levers (1 and 4) clockwise.

- This simulates the locking of the electromagnetic brake, allowing the truck to be moved in the powerless state.

- Mark the position ( A, B, C, ...) of the left and right levers as illustrated.

- Select the appropriate shim from the table below.

- Remove the left lever (1) and install the selected shim (6) between the lever and brake (2).

Shim Thickness

A

0.2

B

0.4

C

0.6

D

0.8

E

1.0

F

1.2

G

1.4

Issue: 01.2000

(Replaces issue:

6

E

G

D

A

C B

B

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Copyright reserved.

3

C

A

D

G

Table of shim dimensions - Remove the right lever (4) and install the selected shim (3) between the lever and the brake (2).

- Tighten the levers. They should now be in the position indicated in the illustration.

2

F

)

Lever Position

1

E F

5

4

1 Left lever (in specified position) 2 Brake 3 Shim 4 Right lever (in specified position) 5 Position of traction wheel 6 Shim

5

Workshop Manual

08

EGU 18/20/20S/H

Issue: 12.2001

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

Copyright reserved.

(Replaces issue: 01.2000)

Electric equipment Contents

Page

Technical data for maintenance

2

Traction control unit

3

General

3

Power section - connections

4

Input and output signals

5

Description of the two modes

5a

Fault display

7

Flashing fault code

8

List of errors

8

Tiller microswitch

9

End-of-lift microswitch

9

Fuses

10

Contactors

10

Lowering solenoid valve

11

Wiring diagram legend

12

Wiring diagram EGU-18/20/20S

13

Wiring diagram EGU-H

21a

Battery

23

PzS battery (standard lead battery)

23

Handling and maintenance

23

Maintenance intervals

24

Acid density measurement

24

Avoiding damage and accidents

25

Activation of unfilled battery, plates charged

26

Changing the battery

27

Maintenance staff

27

Fire precautions

27

Safe parking

27

Battery replacement

28

Battery replacement with crane

28

Battery replacement with battery removal frame

28

Changing the battery with a battery trolley

29

1

08

Workshop Manual

EGU 18/20/20S

Electric equipment Technical data for maintenance

Traction control unit Voltage range

24 V - 36 V

Minimum voltage limit

16.8 V

Maximum voltage limit

45 V

Casing electrical insulation

500 V

Armature circuit current

200 A for 2 mn 30A for 1 h

Field winding current

25 A for 2 mn 15 kHz

Ambient temperature range

-40°C to +50°C

Weight

1,45 kg

Dimensions

168x114x68 (l x w x h) in mm

Issue: 01.2000

Commutation frequency

(Replaces issue:

10 A for 1 h

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

Copyright reserved.

2

Workshop Manual

EGU 18/20/20S

08 Electric equipment

Traction control unit General The Traction Control Unit (1) is a unit controlled by a microprocessor using proven MOSFET technology.

The microprocessor has direct control on the input signal of the starting switch, for all signal processing, up to the integration of current limiting.

The control unit has internal and external safety monitoring, which stops the unit if an anomaly appears.

(Replaces issue:

Fault diagnosis is simple to carry out with a light emitting diode (LED) (2) placed under the control section.

Control unit adjustment operations must be carried out by the programmer or the Notebook.

To reach the control unit or any other electrical component, you must first remove the covers.

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

Copyright reserved.

Issue: 01.2000

)

To control the speed and power of the travel motor from 0 to 100%, the excitation of the transistor cadence is changed.

3

08

Workshop Manual

EGU 18/20/20S

Electric equipment Power section - connections Terminal B+ (1) is connected to the positive pole of the battery via the line contactor and to the armature terminal (A1).

Terminal B- (2) is connected to the negative pole of the battery. Internally it is connected to the MOSFET power source and to the capacitors.

Terminal M- (3) is connected to the armature (A2). Internally it is connected to the MOSFET power source.

Terminal S2 (5) is connected to the other end of the exciting winding (S2).

ATTENTION: The polarity of S1 and S2 affects the sense of rotation of the motor if the travel direction (forward/reverse) is changed or if the belley switch on the tiller head is activated.

5

3

1 6

7

Issue: 01.2000

2

EGU 18-20S/08-13.eps

(Replaces issue:

4

Terminal S1 (4) is connected to the exciter winding terminal (S1).

8 )

10

Power unit wiring diagram 1 Terminal B+

6 Line contactor

2 Terminal B-

7 Fuse 125 A

3 Terminal M-

8 Battery

4 Terminal S1

9 Field winding of traction motor

5 Terminal S2

10 Armature

4

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9

Workshop Manual

EGU 18/20/20S

08 Electric equipment

Input and output signals

Inputs Pin 16: Supply of +24V voltage through key switch. Initialise the controller in this way and an internal monitoring circuit starts up. When the controller is powered up, follow the circuit sequence: key switch--> operating direction of microswitch.

Pin 15: Tiller input microswitch +24V. Pin 14: MODE (1) selection input.

Pin 13 : Tiller head safety input +24V. As long as this input is on circuit, the control takes the motor traction current to 60% of power and the operating direction changes.

Pin 12 : Operating direction input +24V (forward).

Pin 11 : Operating direction input +24V (reverse).

Inputs 12 and 11 activate the control unit power stage.

(Replaces issue:

Issue: 01.2000

)

The input and output signals are grouped on 16pole connector X1 which is directly inserted in the control section of the control unit (1).

Voltage control: between terminals 6(+) and 7(-).

- Accelerator switch in neutral about 3.5 V - Traction control about 0V (between 0 and 0.1V).

Pin 6: Pin 7:

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

Copyright reserved.

Pin 8: Pin 5:

Acceleration instruction (from 5 kOhm to 0 kOhm).

Power supply (low value) for traction potentiometer.

Control of electromagnetic brake (0 V).

Power supply (high value) for potentiometer (option). Not used.

Output Pin 10: Switch inspection output for tiller head safety.

Pin 9: MODE selection input (2) (not used).

Pin 4: Negative control for line contactor.

Pin 3: FAULT 1 output (not used).

Pin 2: FAULT 2 output (not used).

Pin 1: Not used.

Connector X1, 16-pin, controller

5

Workshop Manual

08

EGU 18/20/20S/H

Electrical equipment Description of the two modes Modes 1 and 2 influence two parameters: - acceleration ( mode 1 = 2.5 seconds, mode 2 = 1 second) - braking opposite to the direction of travel (mode 1 = 3 seconds, mode 2 = 1 second) These values are set in the factory to allow for two choices of parameters depending on the use. This is possible without having to connect to the programming unit or computer.

(Replaces issue: 01.2000)

Terminal 14

Terminal 9

Mode 1

0V

0V

Mode 2

+ 24 V

0V

See group 31 for a description of the parameters.

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

Copyright reserved.

Issue: 12.2000

These modes are activated via terminals 14 and 9 of connector X1.

5a

08

Workshop Manual

EGU 18/20/20S

Electric equipment 2

1

3

4

5

6

7

8

9

10

12

11

Issue: 01.2000

(Replaces issue:

Belly switch test option de la sécurité timon Option de vérification EGU 18-20S/08-14.eps

)

Standard wiring diagram, traction controller 7 Brake switch

2 Belly switch (microswitch)

8 Key switch

3 Forward input

9 Line contactor coil

4 Reverse input

10 False polarity protection diode

5 Selection of mode 1

11 Control fuse 7.5 A

6 Selection of mode 2

12 Traction control

6

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

Copyright reserved.

1 Curtis programmer

Workshop Manual

08

EGU 18/20/20S

Electric equipment Fault display

1

If a fault is detected, a LED STATUS (1) indicates the fault type by means of a flashing code. The LED is on the front panel of the controller (2).

The code flashes until the controller is reinitialised (turn off / on – the braking switch is sometimes sufficient), provided that the fault has been cleared.

EGU 18-20S/08-18.tif

2

(Replaces issue:

The following troubleshooting information is generated by the command. The troubleshooting LED, in the control unit section, flashes to indicate the diagnostic code.

The illustration shows an example: One flash - short pause - two flashes - long pause, etc.

The code of this example is: 1,2

Short Pause

Long Pause

The following table gives an interpretation of the flashing codes.

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

Copyright reserved.

Issue: 01.2000

)

Flashing fault code

7

08

Workshop Manual

EGU 18/20/20S/H

List of errors NOTE: The last detected fault is always displayed first. During normal operation the code of the LED is 1,0.

LED CODE

MESSAGE ON PROGRAMMER SCREEN

0,1

NO KNOWN FAULTS

Correct operation

1,1

CURRENT SHUNT FAULT

Current shunt error

- Controller defective

1,2

HW SAFE

Hardware problem

- Controller defective - Wiring problem

1,3

M-SHORTED

Connection Mshorted

- Connection M- shorted to earth.

MEANING

CAUSE OF FAULT

- Motor problem - Improper sequencing of switch key / brake / selection of travel direction

1,4

SRO

SRO fault

- incorrect SRO configuration - Open brake circuit or travel selection circuit - Operational delay too short

Potentiometer

- Connection accelerator to controller broken

slider faulty

- Throttle leads shorted to earth or B+ - Potentiometer defective

2,2

EMR REV WIRING

Tiller safety circuit cut out

- Tiller safety circuit open - Vertification circuit for tiller safety circuit open

HPD

Safety pedal high activated

- Improper sequencing switch key / brake / travel direction selection

2,3

- Incorrect configuration of throttle type used as programmer - Potentiometer out of adjustment (low value)

2,4

3,1

3,2

THROTTLE FAULT 2

CONT COIL/FIELD SHORT

Low value potentiometer shorted or cut

- Open circuit of low value potentiometer - Low value potentiometer shorted

Overcurrent in contactor coil or armature

- Line contactor coil shorted

Line contactor MAIN CONT WELDED welded

Issue: 12.2001

THROTTLE FAULT 1

(Replaces issue: 01.2000)

2,1

- Incorrect configuration of throttle type used - Shunt winding shorted - Electromagnetic brake shorted or resistance low - Line contactor welded - Contactor control defective - Cables on 2 line contactor power terminals interchanged

FIELD OPEN

3,4

MISSING CONTACTOR

4,1

LOW BATTERY VOLTAGE

4,2

4,3

OVERVOLTAGE

Armature current cut - Armature or armature cable broken out - Controller defective Line contactor welded

- Line contactor coil open

Battery

- Battery voltage below minimum

voltage low

- Battery terminals corroded

- Contactor missing - Contactor wiring broken

- Voltage drop at battery terminals Battery overvoltage

- Maximum battery voltage exceeded - Charger set connect to truck

Temperature -high THERMAL CUTBACK -low

- Temperature above 85°C or below –25°C - Truck overloaded - False installation of controller - Operation under extreme conditions

4,4

8

ANTI-TIEDOWN

Mode 2 or 4 selected - Multi-mode inputs shorted to B+ permanently selected after starting

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

Copyright reserved.

3,3

Workshop Manual

EGU 18/20/20S/H

08 Electric equipment

Tiller microswitch Microswitch –S3 is activated by the position of the tiller. When the tiller is in the home position (position 1 and 3), traction is inhibited as lifting remains enabled.

Travel is only possible in position 2 of the tiller, the position which disengages the mechanical brake.

Issue: 12.2001

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

Copyright reserved.

(Replaces issue: 01.2000)

End-of-lift microswitch The microswitch (1) is activated when the forks of the EGU-18/20/20S are in the high position or the EGU-H forks are in the high initial lift position.

If the latter is activated, it cuts off the coil power from lift contactor K3.

End-of-lift inductive sensor on EGU-H This inductive sensor (2) is located in the battery compartment.

When the inductive sensor detects the passage of the fork carriage, it stops the pump motor. To change the sensor, it is necessary to remove the battery.

NOTE : The magnet situated on the fork carriage is mounted with the green side facing the inductive sensor. To remove it, it is necessary to take off the fork carriage (see group 22).

9

08

Workshop Manual

EGU 18/20/20S/H

Electric equipment Fuses Position of fuses: power and control F1: pump motor power fuse

= 125 A

F2: travel motor power fuse

= 125 A

F3: main control fuse

= 7.5 A

F4: Curtis combi control fuse

=3A

NOTE : For EGU-H

F1 : pump motor power fuse = 150 A

Contactors Line contactor -K1 is driven by the position of the tiller. It is of the type SW80-105/24V and its coil has a resistance of about 50 ohms.

Issue: 12.2001

(Replaces issue: 01.2000)

Pump contactor -K3 is of the type SW180-491/24V and its coil has a resistance of about 30 ohms.

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

Copyright reserved.

10

Workshop Manual

08

EGU 18/20/20S

Electric equipment Lowering solenoid valve Lowering solenoid valve Y1 (1) allows the hydraulic oil to flow back to the tank as soon as it is actived by lower push-button 2S2 on the tiller head (also see section on hydraulic system, group 10).

1

Issue: 01.2000

EGU 18-20S/08-04.tif

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

Copyright reserved.

(Replaces issue:

)

The resistance of the solenoid valve coil as measured between terminals 1 and 2 is 40 ohms.

11

08

Workshop Manual

EGU 18/20/20S

Electric equipment Wiring diagram legend

A11

Battery charger

A111

Test card

F1

Pump fuse

F2

Traction fuse

F3

Controller fuse

F4

Composite instrument fuse

G1

Battery

4H1

Horn

K1

Directional relay

K3

Pump relay

M1

Traction motor

M2

Pump motor

6P20

Curtis Combi Controller

S1

Key switch

1S1

Reverse microswitch

2S1

Lift microswitch

4S1

Horn microswitch

1S2

Forward microswitch

2S2

Lower microswitch

S3

Tiller microswitch

S5

Lift limiting microswitch

1S30

Belly switch

Y1

Solenoid valve

Y2

Electromagnetic brake

12

Issue: 01.2000

Tiller housing P.C.B.

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

Copyright reserved.

A2

)

Traction control

(Replaces issue:

A1

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

Copyright reserved.

Issue: 01.2000 (Replaces issue:

)

Workshop Manual EGU 18/20/20S

13

Wiring diagram No. 467757 / 16.12.1998

Electric equipment

08

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

Copyright reserved.

Issue: 01.2000 (Replaces issue:

)

Workshop Manual EGU 18/20/20S

15

Wiring diagram No. 467757 / 05.05.1999

Electric equipment

08

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

Copyright reserved.

Issue: 01.2000 (Replaces issue:

)

Workshop Manual EGU 18/20/20S

17

Wiring diagram No. 467757 / 11.06.1999

Electric equipment

08

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

Copyright reserved.

Issue: 01.2000 (Replaces issue:

)

Workshop Manual EGU 18/20/20S

19

Wiring diagram No. 467757 / 23.06.1999

Electric equipment

08

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

Copyright reserved.

Issue: 01.2000 (Replaces issue:

)

Workshop Manual EGU 18/20/20S

21

Wiring diagram No. 467757 / 17.08.1999

Electric equipment

08

Workshop Manual

EGU 18/20/20S/H

08 Electrical equipment

(Replaces issue: 01.2000)

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

Copyright reserved.

Issue: 12.2000

Legend for wiring diagram A1 A11 A111 A2 F1 F2 F3 F4 G1 4H1 K1 K3 K4 M1 M2 6P20 Rc S1 1S1 2S1 4S1 2S2 S3 S5 S6 S8 1S30 2S80 2S81 Y1 Y2 Y5 Y6

Controller Battery charger Diode panel Tiller head Pump fuse Traction motor fuse Controller fuse Composite instrument fuse Battery Horn Traction contactor Pump contactor EGDS relay Traction motor Pump motor Composite instrument Heating resistor Key switch Forward travel pushbutton Lowering pushbutton Horn pushbutton Lifting pushbutton Tiller inclination transmitter Upper initial lift transmitter Main lift transmitter Initial lift pressure switch Belly switch Initial lift pushbutton Lowering pushbutton Lowering solenoid Brake Lifting device solenoid valve Lowering solenoid valve

21a

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Copyright reserved.

Wiring diagram EGU-H

(Replaces issue: 01.2000)

Issue: 12.2000

Workshop Manual EGU 18/20/20S/H

08

Electrical equipment

21b

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

Copyright reserved.

(Replaces issue: 01.2000)

Issue: 12.2000

Workshop Manual EGU 18/20/20S/H

08

Electrical equipment

21c

Workshop Manual

08

EGU 18/20/20S

Electric equipment Battery PzS battery (standard lead battery) Handling and maintenance - Preferable operating temperature is between 25°C and 40°C. To avoid permanent damage to the battery, the maximum permissible electrolyte temperature of 55°C should never be exceeded.

Issue: 01.2000

- Always remove or open the tray lid or battery cover before charging and for intermediate charging.

- When charging the battery, a temperature increase of 10° – 12° may be expected.

With heavily used batterys, the electrolyte temperature may increase to over 55°C. If this occurs, leave the battery to cool and interrupt the charging process.

- The cell plugs may remain in place during charging.

- Always connect the charger correctly poled, otherwise the battery and charger may be irreparably damaged (+ to +).

- Only charge with direct current.

- To avoid creep currents, always keep batterys dry and clean (Neutralospray).

- Poles and connectors should always be sprayed with pole spray in order to avoid oxidisation and sulphate formation.

- Unsuitable lifting gear may damage the battery (twisting of tray and damage to insulation).

- Protect the battery from contamination, e.g. metal dust, ammonia vapours.

- If in doubt, call the battery supplier's aftersales service.

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(Replaces issue:

)

- For heavy duty and when used at winter temperatures, the battery should be charged daily; even if less than 80% of the standard capacity has been used.

- Do not close the tray lid or battery cover until ½ hour after charging is completed.

23

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EGU 18/20/20S

Electric equipment PzS battery Maintenance intervals

Acid density measurement

Daily maintenance: Charging the battery

The acid density is an indication of a battery's charge condition, provided the acid is well mixed. However, the acid density only increases towards the end of the charging process.

This is due to the gassing, which starts at approx. 2.4 V per cell.

Weekly maintenance: Check the electrolyte level. If necessary: top up with distilled water towards the end of the charging process. It should always be topped up when the electrolyte level falls to the level of the baffle.

24

The battery temperature must remain close to 30°C during measurement.

Issue: 01.2000

NOTE: Beyond these basic instructions, always comply with the battery manufacturer's instructions.

To ensure a correct reading, avoid measuring immediately after topping up with water, as the water and acid must be mixed.

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

Copyright reserved.

Half-yearly maintenance work: Ensure that the charger is working properly, particularly the level of the charging current when strong gassing begins (2.4 V per cell).

Ensure that the plugs and connectors are working properly.

During measurement, the float switch must not jam against the sides or knock the top. The correct value for acid density is obtained by measuring around ½ an hour before the end of charging.

)

Quarterly maintenance: After termination of charging, measure the electrolyte temperature in all the cells. If one of the cells registers a substantial difference compared with its neighbours, check it separately.

Measure the battery's insulation resistance with a separate external circuit, as per VDE. 50 Ohm per V of rated voltage is the lowest limit.

The value must not, however, fall below 1000 ohms. If the insulation resistance is lower, clean the cells and the containers.

Acid density with fully charged battery:....................... 1.27 kg/l Acid density with discharged battery:.......................... 1.13 kg/l (Replaces issue:

Monthly maintenance: Check all cells towards the end of the charging process for even gassing. Measure acid density and temperature after completion of charging and register any deviations from required values.

Acid density is measured with an hydrometer (acid siphon).

Workshop Manual

EGU 18/20/20S

08 Electric equipment

PzS battery Avoiding damage and accidents Working with batterys its not without its dangers. However, these can be avoided by following the procedures below:

a) Hazard: Charging gases can cause explosions.

Avoidance: Ensure good ventilation, avoid electric sparks or naked flames in battery rooms, no smoking. b) Hazard: Acid can cause injuries and corrosive damage to parts.

Issue: 01.2000

c)

Avoidance: Eating and drinking is not permitted at the battery charging station, always wash your hands after handling batterys. e) Hazard: Batteries can cause damage if tipped over or if they fall out of the lifting gear.

Avoidance: Only use suitable, safe lifting gear; during transportation, provide necessary safeguards against tipping over or slipping off the transport vehicle's loading surface.

Hazard: Voltages above 40V can cause a health risk.

Avoidance: Never touch live parts and instruct staff accordingly.

Observe VDE 0100 and VDE 0105.

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(Replaces issue:

)

Avoidance: Wear protective acid-proof clothing and rubber gloves, as well as protective goggles, keep neutralisation agent close at hand. Keep water ready for rinsing eyes (in the event of accident, particularly to eyes, call a doctor immediately).

d) Hazard: Lead and lead compounds are health hazards if absorbed by the human body.

25

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Workshop Manual

EGU 18/20/20S

Electric equipment PzS battery Activation of unfilled battery, plates charged After removing the plugs, all components must be filled steadily with sulphuric acid with a density of 1.25 kg/l, up to the lower acid level marker (use a component filling system for or a plastic sieve).

The filling acid must have a temperature of no less than 15°C. After a rest period of 5-6 hours, add some acid if necessary.

The temperature must be monitored during charging. It must not exceed 55°C; otherwise the charging process must be suspended to let the battery cool.

26

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

Copyright reserved.

The battery is then ready to operate. If necessary, bring the electrolyte to reference level, using distilled water. If the acid density is too high, remove acid and add distilled water.

)

At the end of the charging process, acid density must be 1.27 kg/l plus/minus 0.01 kg/l. If not, continue charging until a uniform acid density of 1.27 kg/l is reached.

Issue: 01.2000

Recharging time, until automatic stop by the charger control switch, is 6-12 hours. In the case of a "l-h" charging (without automatic stop), a longer charging time is required (up to 20 hours).

(Replaces issue:

Temperature increase must be measured using a thermometer dipped in electrolyte, in a component in the centre of the battery. If the temperature increase is less than 10°C, the battery may be connected to the charger for recharging.

NOTE: If the electrolyte temperature increases by more than 10°C after filling, or the acid density used has dropped by more than 0.03 kg/l, it means that the material making up the plates has lost part of its charge following prior storage. A longer activation time is then required. In addition to these instructions, the indications of the battery manufacturer must also be observed.

Workshop Manual

08

EGU 18/20/20S

Electric equipment Changing the battery Maintenance staff Batteries may only be changed by specially trained personnel and in accordance with the instructions of the manufacturer of the battery, charger and truck. Follow the battery handling instructions.

WARNING: Smoking and naked flames are not permitted when handling batterys. No inflammable or spark-producing materials may be located within at least 2 metres of the truck to be charged and the charger.

The room must be well ventilated. Fire extinguishers must be kept ready.

EGU 18-20S/08-05.eps

1 2

Safe parking (Replaces issue:

Issue: 01.2000

)

Fire precautions

When the battery is being worked on, the truck must be properly parked and it may only be started when the battery cover is closed and the battery plug connected.

- Park the truck, set the tiller (1) to the vertical position.

3

- Remove the switch key (3).

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- Disconnect the battery socket (2).

EGU 18-20S/08-06.eps

27

08

EGU 18/20/20S

Workshop Manual

Electric equipment Battery replacement

3

EGU 18-20S/08-07.eps

There are three possibilities of replacing the battery: 1 Vertically with a lifting tackle (all trucks) 2. With a battery removal frame* (trucks with rear cover (5) only) 3. With a lateral battery removal trolley* (trucks with side cover only) To avoid short circuits, cover batterys with unprotected terminals or connectors with a rubber mat.

Battery replacement with crane

4

- The lifting tackle should exercise a vertical pull so that the battery tray is not squeezed together. Hooks must be attached in such a way that they cannot fall onto the battery cells when the lifting tackle is slack.

)

- Carefully lift the battery out of the truck.

Issue: 01.2000

- Attach the battery (3) to a suitable lifting tackle (4).

(Replaces issue:

- Open the battery cover.

EGU 18-20S/08-08.eps

5

- Lift the forks.

- Remove the front cover (5) from the battery compartment.

- Place the removal frame (6) in front of the battery.

- Lower the forks. The battery rests on the frame base.

* Option

28

EGU 18-20S/08-09.eps

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

Copyright reserved.

Battery replacement with battery removal frame*

Workshop Manual

08

EGU 18/20/20S

Electric equipment Changing the battery with a battery trolley*

1

3

2

CAUTION: When removing or installing the battery keep your hands away from chassis and battery! There is a higher risk of squeezing your hands!

- Open the battery cover.

- Remove the side cover (3).

- Put a suitable trolley (2) beside the battery.

- To install the new battery, position yourself opposite to the side cover and pull the battery towards you into the battery compartment.

EGU 18-20S/08-10.eps

2

- Put the side cover in place.

(Replaces issue:

Issue: 01.2000

)

- Stand on the side opposite the cover and slide the battery (1) onto the trolley (2).

*Option

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Copyright reserved.

EGU 18-20S/08-11.eps

29

Workshop Manual

09

EGU 18/20/20S

Page

Controller

2

General

2

Service hour meter

2

Pin assignment

3

Voltage adjustment

4

Adjustments recommended by the battery manufacturer for standard charging

4

Technical Specifications

5

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

Copyright reserved.

Issue: 01.2000

Contents

(Replaces issue:

)

Lighting equipment and instruments

1

09

Workshop Manual

EGU 18/20/20S

Lighting equipment and instruments Controller

1

General The controller operates according to the principle of continuous comparison of the battery voltage with a series of reference voltages defined internally.

The 36-level reference voltage corresponds to the adjusted discharge voltage curve.

If the mean voltage of the battery dropped below the corresponding reference voltage, within a period of 46 seconds, the controller automatically compares with the next lowest reference voltage. This process continues from voltage level to voltage level.

EGU 18-20S/09-01.eps

A lithium battery (10 years) effects the memorisation of the discharge state of the battery; the counter level is memorised in an EEPROM.

Issue: 01.2000

(Replaces issue:

When the voltage levels decrease, the DEL display (1) jumps from right to left. When the stop threshold is reached (end of discharge voltage), the two left LEDs (red) flash.

On the rear panel of the unit, the discharge characteristic may be adjusted to the utilisation case in presence (see P. 09-04).

2

)

Service hour meter The display (2) is able to indicate up to 99.999.9 hours.

2

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Copyright reserved.

When the tiller is moved to the working position, the meter starts running.

Workshop Manual

09

EGU 18/20/20S

Lighting equipment and instruments Pin assignment (Fig. 1) Service voltages Pin 7 = B+ (24 V) Pin 5 = BStop Function Pin 3/4: stops when end of discharge voltage is reached, at 20% of the residual capacity of the battery.

)

NOTE: Stopping is effected by a thyristor. This is why polarities must be observed on connection (logic positive/negative, (Fig. 3)).

Incorrect polarity may cause irreparable damage to the controller or the switching contact.

Fig. 1

Key switch Pin 2: Powering the LED display

Battery voltage B+

Service Time Counter (Fig. 2) Starting by application (Replaces issue:

Issue: 01.2000

Low voltage with double voltage Key switch

Pin 6: from B+ on (6) or Pin 1: from B- on (1)

Hour meter negative start input Negative start input Battery voltage B-

Fig. 2

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

Copyright reserved.

Positive Logic Terminal:

Negative Logic Terminal:

Fig. 3

3

09

Workshop Manual

EGU 18/20/20S

Lighting equipment and instruments Voltage adjustment End of discharge voltage (volt / element) may be adjusted using the potentiometer (1).

The battery manufacturer’s recommendations for adjustment, must be observed (see table below)!

1

Or

Issue: 01.2000

Connection of a battery to a rest voltage of 2.09 V/ element at least.

1,57 1,63 1,68 1,73 1,78 1,82 1,84 1,86 1,89 1,91 1,93

)

K L M N O P Q R S T U

(Replaces issue:

"Filling up" Voltage at beginning of gas discharge 2.35 V/ element during 6 min at least

Adjustments recommended by the battery manufacturer for standard charging Battery type

Hoppecke

Wet cell

Hagen

Wet cell Maintenance-free: CWF, PWT, PZV Extended capacity: CSM

Sonnenschein

Dryfit gel battery

Voltage rating after discharge (V/Cell) 1,73 1,73 1,82 1,78 1,93

NOTE: In special cases of major charging (major current drain over a short period), the process may start too soon. In such cases, the correct adjustment must be determined through testing.

4

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Battery manufacturer

Workshop Manual

09

EGU 18/20/20S

Lighting equipment and instruments Technical Specifications (also see type plate (1)) Battery discharge indication - 10 LED's: 5 green, 3 yellow, 2 red.

- Lithium accumulator.

- Reset to zero when the beginning of gas discharge voltage is 2.35 V/cell or the residual voltage of 2.09 V/cell is reached.

- Stop by rest contact at self-maintenance.

- Adjustable discharge characteristic.

1

- Optical display, to warn at 25% of residual capacity.

- 3A switching current.

)

Service Time Counter - 6 digit, liquid crystal display.

- Resolution 0.1 hr.

- Memory independent of energy by EEPROM. (Replaces issue:

Issue: 01.2000

- Flashing symbol display.

Basic Characteristics - Service Voltage 24 V and 48 V. - Tolerance +/- 25% of the rated voltage.

- Service Temperature -40°C to +85°C. - Accuracy (max. deviation 2%).

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

Copyright reserved.

- Protection Class (IP65 on front panel).

5

Workshop Manual

10

EGU 18/20/20S

Hydraulic system

Page

Illustration of pump unit

2

Hydraulic functions

3

Lifting

3

Lowering

4

Lowering solenoid valve

5

Removing the pump unit assembly

6

Removing the hydraulic pump

7

Adjusting the maximum pressure

8

Changing the hydraulic oil

9

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

Contents

1

10

Workshop Manual

EGU 18/20/20S

Hydraulic system Illustration of pump unit Item

Component

1

Pump motor (compound-wound) Pump Suction pump Lowering solenoid valve Oil tank Air filter/plug Pressure relief valve

2 3 4 5 6 7

MA = 10Nm

4 MA = 20Nm

Issue: 01.2000

(Replaces issue:

1

MA = 25Nm )

7

MA = 25Nm

MA = 25Nm

3

MA = 10Nm

2 MA = 5Nm

5 MA = 5Nm MA = 22Nm EGU 18-20S/10-05.eps

2

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Copyright reserved.

6

Workshop Manual

10

EGU 18/20/20S

Hydraulic system Hydraulic functions Lifting When the pump motor (1) is operated, it drives the external gear pump (2), which immediately transports the oil from the tank via the intake suction filter (3) and the non-return valve (4) to pressure port "P".

A pressure pipe connected to this port goes to the lift cylinder.

4 6 1

EGU 18-20S/10-06.eps

2

5

Overpressure Operating pressure

(Replaces issue:

...

3

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

Copyright reserved.

Issue: 01.2000

)

When the oil pressure at port "P" increases, or when the lift cylinder has been completely extended, the pressure rises at the pressurerelief valve (5) --> the pressure-relief valve opens, and the oil flows back to the tank (7).

3

10

Workshop Manual

EGU 18/20/20S

Hydraulic system Lowering

1

To lower the load, the lowering solenoid valve (1) must be energised via the "Lower" button.

The solenoid valve changes to the open position.

2

Issue: 01.2000

To ensure that the load does not drop too quickly, the slow lowering valve (2) is mounted downstream of the non-return valve. This permits only a certain amount of oil to flow through in a certain period, so ensuring that a controlled lowering speed is achieved.

(Replaces issue:

EGU 18-20S/10-07.eps

)

...

Return

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4

Workshop Manual

10

EGU 18/20/20S

Hydraulic system Lowering solenoid valve The valve is a bevel seat valve. The illustrated way valve is a so-called NORMALLY CLOSED valve, i.e. when the coil is not excited (1), the plunger (2) presses on the spool (3), so closing the control hole (A --> B).

If the coil (1) is excited, it pulls the plunger (2) up. The applied oil pressure moves the spool (3) up, allowing the oil to flow unhindered from A --> B.

B

)

o

Issue: 01.2000

(Replaces issue:

A

Measure the resistance of the spool between terminals 1 and 2.

Resistance = 40

2

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1

5

Workshop Manual

EGU 18/20/20S/H

10 Hydraulic equipment

Hydraulic functions of EGU-H 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

(Replaces issue: 01.2000)

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

Copyright reserved.

Issue: 12.2000

11.

12.

Pump motor Hydraulic pump Intake filter Valve block Pressure relief valve Main lift solenoid valve Initial lift solenoid valve Tank Check valve Lift lowering solenoid valve (main and initial lift) Main slow-lowering valve lowering Slow-lowering valve

Lift (main and initial) When power is applied to the pump motor (1), the pump immediately sends oil to the solenoid valves (6 or 7) via the check valve (9).

- If the main lift button is pressed, solenoid valve (6) is activated, oil flows to the main lift cylinder through the slow-lowering valve (not pilot controlled).

- If the initial lift button is pressed, solenoid valve (7) is activated and oil flows to the initial lift cylinder.

Lowering (main and initial) Two solenoid valves are operated at the same time. These valves are lowering solenoid valves (main lift 6, or initial lift 7) and the lift lowering solenoid valve (10).

5a

Workshop Manual

EGU 18/20/20S/H

10 Hydraulic equipment

- If the main lowering button is pressed, the solenoid valves (6 and 10) are activated at the same time.

The oil passes through the slow-lowering valve (11).

The slow-lowering valve is controlled by loss of pressure at point A during the activation of the solenoid valves (6 or 10), which allows the oil to flow back to the tank.

- If the initial lowering button is depresses, the solenoid valves (7 and 10) are both activated at the same time, allowing oil to return directly to the tank.

(Replaces issue: 01.2000)

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

Copyright reserved.

Issue: 12.2000

NOTE : In order that the load does not descend too fast, the check valve (12) regulates the oil flow at a given rate, which ensures a controlled lowering speed.

5b

10

Workshop Manual

EGU 18/20/20S

Hydraulic system Removing the pump unit assembly - Lower the forks.

- Remove the battery.

- Remove the cover.

- Disconnect the cable at the pump motor - Remove the hydraulic fitting (1).

- Remove the 2 screws (3).

- Remove the pump unit (2).

Installation is in the reverse order of removal.

Issue: 01.2000

(Replaces issue: )

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Copyright reserved.

6

Workshop Manual

EGU 18/20/20S/H

10 Hydraulic system

Removing the hydraulic pump - Remove the covers.

- Remove the battery.

- Remove the pump unit.

- Remove the 4 hexagonal screws (2).

- Remove the oil tank (3).

- Remove the 4 hexagonal screws (4).

- Remove the hydraulic pump (1).

- Check the oil level after assembly.

Issue: 12.2001

Filling capacity For EGU-18/20/20S : For EGU-H :

0.8 l of hydraulic oil 1.7 l of hydraulic oil

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

Copyright reserved.

(Replaces issue: 01.2000)

The oil level must reach half way up the filler neck (5).

7

10

Workshop Manual

EGU 18/20/20S/H

Hydraulic system Adjusting the maximum pressure - Install the pressure gauge to the port (1).

- Remove the plug (2).

- Pick up the rated load and determine the operating pressure (note the reading).

NOTE: The setting for the maximum pressure is the operating pressure when lifting a rated load plus 10 %.

1

2

EGU 18-20S/10-3.tif

EGU 18-20S/10-04.tif

Specified maximum pressure - EGU18 100 bar - EGU20/20S 130 bar - EGU-H 195 bar

3

- Short lift limiting switch S5 (5) by connecting the cables to terminals 4 (3) and 1 (4).

5

Issue: 12.2001

4

(Replaces issue: 01.2000) I 01 2000

- Raise the forks as far as possible.

- Set the maximum pressure with the setscrew (6).

- Refit the plug (2) with sealing washer.

EGU 18-20S/10-03.tif

8

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6

EGU 18/20/20S/H

Workshop Manual

10 Hydraulic system

Changing the hydraulic oil Change interval: Type of oil: Oil capacity:

every 12 months HLP46 DIN 51524 0.8 l for EGU-18/20/20S 1.7 l for EGU-H

Service - Remove the covers.

- Remove the battery.

- Remove the pump unit.

- Remove the 4 hexagonal screws (1).

- Remove the oil tank (2).

Issue: 12.2001

(Replaces issue: 01.2000)

- Dispose the hydraulic oil properly.

- Clean the oil tank.

- Replace the suction filter (3), if necessary.

- Fill the hydraulic oil into the oil tank.

- Install the oil tank.

- Check for hydraulic oil leaks.

- Check the oil level.

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

Copyright reserved.

- Install the covers.

NOTE : In coldstores, use a grade 32 oil.

9

Workshop Manual

11

EGU 18/20/20S

Issue: 01.2000

Contents

Page

Travel motor

2

Pump motor

2

Travel motor

3

General information

3

Terminal strip

3

Removing the travel motor

4

Installation

5

Replacing the carbon brushes

6

Maintenance

7

Pump motor

9

General

9

Wiring diagram

9

Removing the pump motor

10

Replacing the carbon brushes

11

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

Copyright reserved.

(Replaces issue:

)

Power unit

1

11

Workshop Manual

EGU 18/20/20S

Power unit Travel motor

Type of motor

GF084-G5

Service voltage (V)

24 V

Amperage (A)

61 A

Separate excitation

8.5 V - 11 A

Rated speed (rpm)

2750

Power (kW)

1.2 kW

Service

S2 - 60 min

Protection

IP 20

Insulation

Class F

Brush type

DM4D

Dimensions of the motor brush

10x25x26

Wear limit (mm) min.

12,5

Number of motor brushes

4

Ventilation

TC 00

Commutator diameter

56 mm

Issue: 01.2000

NPO 20099

(Replaces issue:

Designation

)

Pump motor

HB 2000-GC 80031-00

Type of motor

60023-00

Service voltage (V)

24 V C/C

Amperage (A)

185 (200 bar)

Rated speed (rpm)

Idle 5260 Maximum pressure 2150 rpm

Power (kW)

2 kW

Power rating

S3 - 5.5%

Protection

IP 43

Insulation

Class F (155°C)

Brush length (mm)

l = 22 mm

Brush wear limit

11 mm

Number of brushes

4

Ventilation

None

S2 = 2.3 min

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

Copyright reserved.

2

Designation

EGU 18/20/20S

Workshop Manual

11 Power unit

Travel motor General information The pallet truck is provided with a motor with separate excitation.

The reversal of the sense of rotation of the motor is effected by reversing the polarity of the field windings.

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

Travel speed depends on the control unit's duty ratio.

EGU 18-20S/11-01.tif

Terminal strip Designations on terminal strip

Function

A1

Armature

A2

Armature

S1

Field winding

S2

Field winding

1 Forward travel 2 Reverse travel 3 Motor terminals

3

11

Workshop Manual

EGU 18/20/20S

Power unit Removing the travel motor NOTE: When removing the travel motor, the truck is not braked; it must be secured to prevent it from rolling.

1

- Set the truck on maintenance supports.

- Disconnect the battery.

- Remove the cover.

3

EGU 18-20S/11-04.tif

- Mark and disconnect the motor cables (1).

- Mark and disconnect the electromagnetic brake supply lines (2).

2

- Unscrew the cable fasteners (3).

- Move the tiller and cables to the side.

EGU 18-20S/11-03.tif

- Remove the steering stop (4).

Issue: 01.2000

- Remove the electromagnetic brake and armature plate.

(Replaces issue:

- Remove the tiller (see group 06).

- Mark the position of the motor in relation to the turntable. )

- Remove the 3 screws (5), leaving the stops on the motor.

- Remove the motor.

4

5

EGU 18-20S/11-02.tif

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4

Workshop Manual

EGU 18/20/20S

11 Power unit

Installation Travel motor intallation is as per removal, but in reverse order of operations.

The following conditions must, however, be fulfilled before installation.

- Clean the gearbox orifice (2) and the ventilation - slots (1).

- Bring the drive wheel to a straight position.

Issue: 01.2000

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Copyright reserved.

(Replaces issue:

)

- Install the travel motor in the gearbox, in the right position.

5

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EGU 18/20/20S

Power unit Replacing the carbon brushes The brushes must be replaced when a residual length of 50% is reached.

New brushes

Replace at

25 mm

12.5 mm

Only complete sets of carbon brushes (4 units) should be replaced at any one time.

- Fit new brushes.

Torque ...... 5Nm

6

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

Copyright reserved.

Inspection of the brush springs Brush springs with insufficient pre-tension lead to commutator damage. Check that the springs move easily in their housing.

)

NOTE: Do not put a full load on the motor after the replacement of the motor brushes.

The brushes are ground down quite fast with a reduced load.

Issue: 01.2000

ATTENTION: Do not inhale carbon dust.

(Replaces issue:

Disassembly - Remove the battery connector.

- Remove the travel motor cover.

- Lift the brush spring (Item 1) and hold it.

- Remove the brush (Item 2) using the connecting cable.

- Slowly release the brush spring.

- Disconnect the connecting cable by removing the screw (Item 3).

- Clean the commutator area.

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EGU 18/20/20S

11 Power unit

Maintenance The maintenance services between general overhauls consist of: -

Cleaning.

General visual inspection.

Replacement of any defective component.

Inspection of brushes and commutator.

Replacement of brushes (if necessary).

This work must be carried out every 500 hours or every quarter at the latest.

Issue: 01.2000

(Replaces issue:

)

CAUTION: To prevent short-circuits or wounds, the battery must be disconnected before beginning any work on the motor.

Cleaning - Remove the brush cover (1) from the motor and remove the brushes (2).

- Clean the motor using compressed air (do not inhale the dust use a mask).

- Clean the commutator and the brush holder using a petrol-soaked cloth (do not use wool), let dry properly.

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Copyright reserved.

NOTE: Do not lift the brush springs any more than necessary and do not bend them on the side.

Visual inspection, replacing defective components: - Check the cleanliness of the gearbox ventilation channels (3). Dirt reduces the circulation of air and causes heating of the motor which may damage it.

- Check for signs of overloading (overheating) on the field windings and the armature: dark colour, brittle or burned insulation, unsoldered commutators.

Motors with these signs must be replaced immediately.

- If oil or grease is found in the motor (mostly a paste of oil, oil vapour with dust and dirt and carbon deposits), determine the cause at once. Clean the motor thoroughly.

NOTE: Rapid wear of the brushes or the commutator mainly due to oil.

The oil or grease burns in the brush fire and leaves an abrasive residue.

This is why the brushes can be worn down below the limit before the routine maintenance interval.

7

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Power unit Maintenance (continued) Checking the brush holders, replacing the motor brushes After cleaning the brush holders, the motor brushes must move freely in the holders when the spring is lifted.

If one or more brushes stick, they must not be rubbed with emery paper or any other abrasive material.

The complete brush set must be changed to prevent overheating.

The brushes must not be broken or abnormally worn on the friction surface.

Commutator diameter Minimum dimension .............................. 56 mm Do not rework it with a file, emery paper or similar objects.

8

Note on the risk of overloading with discharged batteries: If the RPM level of the motor drops noticeably, stop work immediately and check the battery charge without delay.

Do not drive with undervoltage!

Issue: 01.2000

Otherwise, the commutator must be reworked.

Only fit the bearings specified in the spare parts list.

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Copyright reserved.

The commutator should not be run-in, scoured or untrue.

The bearings must be replaced: - After a maximum operating period of 2,000 service hours.

- No more than every five years.

)

Checking the commutator The commutator's running surface should be evenly smooth and appear grey-black.

The bearings must be inspected: - At each general overhaul.

(Replaces issue:

NOTES: - Always replace the entire set of brushes; the shortest brush determines whether a replacement is required.

- Only fit genuine replacement brushes (refer to spare parts list!).

- Take care not to let the springs drop down while fitting the brushes.

- Change the brushes even if they are not yet down to the minimum length.

The remaining duty period may be less than the time to the next inspection.

- The motor should undergo a general overhaul after 3 sets of brushes have been changed. (specialist workshop)

Checking the bearings The ball bearings do not have to be lubricated.

The grease packing is sufficient for the maintenance period between general overhauls.

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EGU 18/20/20S

Power unit Pump motor

31

30

General 1

The pump group includes the following main components: Component

1

Pump motor

2

Hydraulic unit

3

Oil reservoir

30

Red terminal

31

Blue terminal

2

3

(Replaces issue:

NOTE: Detailled information on the hydraulic unit and the oil reservoir can be found in group 10.

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

Copyright reserved.

Issue: 01.2000

)

Item

EGU 18-20S/11-05.tif

Wiring diagram P 36(+)

30 rouge r ed

M P 37(-)

31 bl bleu ue EGU 18-20S/11-14.eps

9

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EGU 18/20/20S

Power unit Removing the pump motor - Disconnect the battery plug.

- Remove the covers.

- Remove the 2 nuts (1).

- Disconnect the cables (2) at the motor (mark the cable).

1

- Carefully remove the motor.

3 2

EGU 18-20S/11-15.tif

4

- Install the motor shaft correctly on the cross coupling (4).

Issue: 01.2000

NOTE: A locating tab is situated on the bottom of the motor casing. For installation this tab must point to the solenoid valve (3).

(Replaces issue:

Installation is in the reverse order of removal.

Observe the following points:

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

Copyright reserved.

10

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11

EGU 18/20/20S

Power unit Replacing the carbon brushes It is necessary to renew the carbon brushes when they reach a residual length of 11 mm.

This corresponds to a wear of 50 %.

New brushes

Replace at

22 mm

11 mm

The renewal should only be carried out in complete kits of 4 brushes.

2

1

Disassembly - Disconnect the battery plug.

- Remove the covers (see group 01).

EGU 18-20S/11-15.tif

)

- Unscrew the 2 screws (1).

- Remove the cover by tighenting the hex head screws.

(Replaces issue:

Issue: 01.2000

- Remove the small plastic plugs (2) and screw in M5 x 30 mm hex head screws.

5 6

- Lift off the carbon brush springs (5) and pull out the carbon brushes (7).

- Slowly release the carbon brush springs.

7

- Remove the fastening screws (6) on the brush terminal lugs and take out the carbon brushes.

- Clean the armature

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

Copyright reserved.

EGU 18-20S/11-16.tif

CAUTION: Do not inhale any carbon dust.

Installation is in the reverse order of removal.

11

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20

EGU 18/20/20S/H

Page

Removal of the lift cylinder

2

Disassembly of the lift cylinder

3

Removing the EGU-H main lift cylinder

4

Disassembly of the EGU-H main lift cylinder

5

(Replaces issue: 01.2000)

Contents

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

Copyright reserved.

Issue: 12.2001

Mast

1

20

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EGU 18/20/20S

Mast Removal of the lift cylinder - Raise the forks to half height.

- Support the battery compartment securely.

- Support the drive section (1) with a wooden block (35 mm) (2).

- Remove the 2 hexagonal screws (4).

- Pull out the cotter pin (3).

- Lower the lift cylinder (5).

Issue: 01.2000

(Replaces issue:

- Unscrew the hydraulic hose (7) and the fitting (6).

)

- Take out the lift cylinder through the upper opening in the drive section.

2

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

Copyright reserved.

- Carefully tilt the drive section forward in the direction of travel (8) until the drive section is resting on the 35 mm wooden block.

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EGU 18/20/20S

20 Mast

Disassembly of the lift cylinder - Draw out the piston rod (3) until the circlip (5) is on a level with the hydraulic connection (7).

- Lever the circlip into the groove (4) through the hydraulic connection.

- Pull out the piston rod.

Assembly

If this is not the case, the circlip (5) will snap into the groove (6) of the sealing ring (2) so that the piston rod can neither be installed nor removed.

For this reason, bend the circlip, if necessary, in such a way that it has a snug fit.

(Replaces issue:

Issue: 01.2000

)

NOTE: When assembling, the circlip must always be seated tightly in the groove (4).

1 Wiper 2 Sealing ring 3 Piston rod

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

Copyright reserved.

4 Groove 5 Retaining ring 6 Groove 7 Fitting

3

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EGU 18/20/20S/H

Mast Removing the EGU-H main lift cylinder - Remove the fork carriage (see group 22).

- Make sure the cylinder is retracted.

- Remove the battery.

- Place a catch tray under the hydraulic fitting (2) at the cylinder.

- Remove the hydraulic hose (2).

- Unscrew the 2 screws (1) located at the top of the cylinder while holding it vertically.

- Remove the piston by lifting the cylinder body.

Installing the main lift cylinder - Installation is in the reverse order of removal.

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

Copyright reserved.

- Unscrew the screw (3) at the bottom of the cylinder.

NOTE: The screws (1 and 3) are tightened to a torque of 25 Nm. - Refit screw 3 with Loctite 243.

Issue: 12.2000

(Replaces issue: 01.2000)

4

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20

EGU 18/20/20S/H

Mast Disassembly of the EGU-H main lift cylinder - Remove the lock nut (6).

- Remove the guiding ring (7).

5

- Pull the piston out of the cylinder assembly.

4

- Using circlip pliers and a screwdriver, open the circlip (8) (see Fig. 2).

7

1 2

NOTE : If the bushing can not be removed, use sandpaper to deburr the chamfer of the bushing (A).

8

6

- Reassembly is in the reverse order of disassembly.

1-5 10

ATTENTION : When changing the seals, always coat them with a film of hydraulic oil.

When refitting the ring (7), align the draining screw with the lower fastening screw (10).

Seal kit

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Copyright reserved.

(Replaces issue: 01.2000)

A 9

- Lift out the bushing (9).

Issue: 12.2000

1-5

3

5

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

Copyright reserved.

Issue: 12.2001 (Replaces issue: 01.2000)

Workshop Manual

EGU 18/20/20S/H

22

Fork carriage

Contents Page

Removing the fork carriage 2

Guiding roller 3

Adjusting the lift chain 4

1

22

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EGU 18/20/20S/H

Fork carriage Removing the fork carriage - Unscrew the end stop (1).

- Lift the fork carriage to mid-height.

- Suspend the fork carriage with a hoist (see item 2 in picture).

- Unscrew the chain adjuster located between the rollers (increase distance).

- Pull out the pin holding the chain to the adjuster.

- Remove the chain roller.

Installing the fork carriage - Installation is in the reverse order of removal.

NOTE : Refit the end stop (1) with Loctite 243.

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

Copyright reserved.

- Lower the main lift cylinder completely.

Issue: 12.2000

(Replaces issue: 01.2000)

2

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22 Fork carriage

Guide rollers Adjustment Roller diam.

Dimension “A” over to

69.9 70.2 70.5

71.00 71.3

70.0 71.3 -

Dimension “X” 1.1 1.1 1.1

(Replaces issue: 01.2000)

Issue: 12.2000

NOTE : Dimension “A” must be measured at the point where the flange and web meet.

1 : Guide roller 2 : Shim

Lateral play Fork carriage Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

0.3 mm minimum, 1.3 mm maximum NOTE : The guide rollers are installed with the round side (3) facing the mast.

3

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Fork carriage Adjustment of the lift chain Centre chain The lift chain is held by the adjuster (1).

When adjusting the lift chain, make sure that the clearance between the fork carriage and the stop is at least 2 mm.

IMPORTANT : The condition of the lift chains and their elongation (3 % of maximum) must be checked regularly in accordance with safety regulations.

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

Copyright reserved.

Raise the mast as far as possible. In this case the centre of the top rollers on the fork carriage should have a clearance of 10 mm at the top of the mast channel.

Issue: 12.2000

(Replaces issue: 01.2000)

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EGU 18/20/20S

Issue: 01.2000

Contents

Page

General

2

Technical data

3

General

3

General conditions of utilisation

3

Electrical characteristics

3

Mechanical characteristics

3

Discharge curves

4

Other charging characteristics

5

LED indicators

6

Labelling / marking

7

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

Copyright reserved.

(Replaces issue:

)

Built-in charger

1

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EGU 18/20/20S

Built-in charger General The EGU is equipped with an optional built-in charger (1).

The charger is installed on the left-hand side of the truck in the traction compartment as shown in the illustration.

In the standard truck version, it is only intended to charge conventional lead batteries. Chargers for GEL batteries are also available as option.

1

EGU 18-20S/28-01.eps

Issue: 01.2000

(Replaces issue: )

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

Copyright reserved.

2

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28

EGU 18/20/20S/H

Built-in charger Technical data General These specifications characterise a charger developed by IES.

Mechanical characteristics Air input via ventilator with protective grid on top of charger.

The charging curve, entirely controlled by a micro-controller, adapts automatically to batteries of 160 to 300 Ah capacity, even those subjected to heavy-duty use.

Air output at rear.

The charging time depends on the capacity of the battery being charged:

Unit is fastened to baseplate by means of three 6 mm studs.

2.5 m mains lead on front panel.

15 hours for 330 Ah capacity batteries 12 hours for 240 Ah capacity batteries 8 hours for 180 Ah capacity batteries 9 hours for 195 Ah capacity batteries

Issue: 12.2001

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

Copyright reserved.

(Replaces issue: 01.2000)

Energy conversion uses a cycle operating at 80 kHz.

General conditions of utilisation The on-board charger is continuously connected to the battery.

Storage temperature

-10 to +50°C

Operating temperature

0 to +40°C

Relative humidity

90%

Weight

2.2 kg

Volume

1.6 litres

Electrical characteristics Input characteristics Rated input voltage

Mains 230 V +10/-15%

Mains frequency

50 Hz +/-1%

Feeder current (connection to mains)

limited by CNT

Output characteristics Max. output power

720 W +/-3%

Max. output current

30 A +/-2%

Rated battery voltage

24 V

U-range voltage tolerance

1%

3

28

EGU 18/20/20S

Workshop Manual

Built-in charger Discharge Curves Charging start Connecting the charger to the mains triggers the start of charging.

The phase parameter values are independent of mains fluctuations.

The charging operation does not start if the battery voltage is lower than 9 V (for a battery with a rated voltage of 24 V) Charging phases Completion of phases in I1-P-U-I2 as per drawing opposite:

1

3

30A 24V

4 6

7 8

Current Voltage Phase l1 Phase P Phase U

6 Phase l2 (overload) 7 Time 8 Stop

1 10

5

2 0

50

100

1 l2 in A 2 Ah in phase l+P

4

150

200

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

Copyright reserved.

The current amplitude of this phase I2 is determined by the charge injected during the first phases I1 and P. The law giving the current as a result of the charge is shown in the graph opposite:

)

The value of the voltage threshold is 29 V in charger output.

The last phase I2 is made up of one constant current phase whose role is to provide overcharge, required for proper mixing of the electrolyte. At the end of charging, the voltage is limited to 34 V (2.83 V/cell).

Issue: 01.2000

1 2 3 4 5

(Replaces issue:

Phase U maintains the battery voltage constant, the current accepted by the battery in this phase decreases progressively.

5

29V

First phase I1 with constant current (maximum current) is maintained as long as battery voltage is lower than 24 V. The next phase P is a phase where the output power of the charger is maintained constant, the current decreasing slightly while the battery voltage increases. The power value equals the rated power of the charger. This phase is over when the battery voltage reaches the voltage value of the following phase.

2

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EGU 18/20/20S

Built-in charger Technical Data (cont.)

The duration of the final I2 phase is determined so that the charge quantity in this phase represents 17% of the total charge injected in phases I1-P-U beforehand, in order to ensure an overcharge coefficient of 1.15.

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

If topping up is used, charging is stopped by the user before it has ended.

In this case, the ampere-hours injected during phases I1, P and U are stored in the memory.

They will be added to ampere-hours of the I1P-U phases in the next charge operation, to determine the overcharge time. They are cumulated until a charge operation ends with complete overcharge. The overcharge current is determined by the above law, on the basis of the total number of ampere-hours.

Equalizing charge and sulphate removal This charge operation begins automatically after the end of each full charge. It is performed at half the overcharge current. It stops when the battery's voltage stabilizes (variation less than 60 mV/hour).

This type of charge also prevents sulphating and equalizes the twelve 2 V elements that constitute a 24 V battery.

Protections Charge too long Charging stops if the charge duration I1+P is longer than 12 hours. This fault occurs when an element in the battery fails (short circuit).

NOTE: The first charge operation following connection of the charger leads to an overcharge of at least one hour. This characteristic enables sulphate removal from new batteries which may have been stored for several months.

Other charging characteristics Maintenance charging If the charger remains connected to the mains, it restarts a charge cycle every 48 hours after the end of the previous charge operation, to compensate for self-discharge.

Partial recharge The CHARIS HF is built to adapt automatically to battery discharge situations and can therefore be used for any type of partial charging (topping up).

The overcharge calculation takes into account any partial charges. The circulation is always sufficient, without pointless water consumption, thus avoiding prematurely wearing out the batteries (often due to excessive overcharge) and reducing maintenance.

5

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Built-in charger Mains micro-cut protection In the event of a mains power cut, all the current charge parameters are stored in the memory for 13 minutes. As soon as the main supply is re-established, charging resumes at the point (I,U) where the power cut occurred, while memorizing the number of ampere-hours already injected.

If the power cut lasts longer than 13 minutes, a complete charge cycle is initialized.

Temperature safety system The charger is cooled by fan, so the air inlets and outlets must not be obstructed.

The fan starts running as soon as the mains power is connected. It stops when the mains supply is disconnected.

The charger stops if the micro-controller detects a temperature measurement fault.

The yellow LED indicates the current charge status: - it is on during phases I1 and P. - it flashes quickly in phase U. - it flashes slowly in the final overcharge phase.

- it comes on periodically between the end of overcharging and the end of the equalization phase.

- it goes off after charging.

Fault indication In the event of a charge duration fault (abnormal duration of I1+P phase), the green light flashes.

1

2

Issue: 01.2000

Electrical safety Galvanic insulation: 1500 V RMS Protection against battery polarity inversion: two 25 A automobile-type fuses on output.

(Replaces issue:

The charger delivers reduced power if the ambient temperature is outside the temperature range for use, in order to protect itself.

Normal operation The green LED indicates that a mains supply is present.

LED indicators )

The CHARIS 24V 30A STD battery charger is delivered with two LED indicators (diameter 5 mm) mounted on the ends of two cables.

6

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

Copyright reserved.

EGU 18-20S/28-05.eps

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EGU 18/20/20S

28 Built-in charger

Labelling / marking The adhesive label is affixed to the front of the charger.

It contains the following information: - Manufacturer's name: I.E.S. Intelligent Electronic Systems - Type of charger: CHARIS HF 24V-30A STL - Manufacturing Index No: 9 - Nominal input characteristics: 230V 8,5A 50Hz

)

- Nominal output characteristics: 24V 30A - Battery capacity: 160Ah - 300Ah

(Replaces issue:

- Product no.: (serial number) - Serial no.: (as per type)

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

Copyright reserved.

Issue: 01.2000

- Protection index: IP20 (CEI 529)

7

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EGU 18/20/20S

Diagnostics

Page

Programmer Operation

2

Operating Modes: PROGRAM, TEST, DIAGNOSTICS, SPECIAL PROGRAM, SPECIAL DIAGNOSTICS

4

Controller cloning

6

Peace-of-mind programming

6

Programmer Self Test

7

Parameter list of Curtis controller 1243

8

Test Menu

10

Special Program Menu

10

Diagnostics and Special Diagnostics "Menu"

11

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

Contents

1

31

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EGU 18/20/20S

Diagnostics Programmer Operation The universal 1307 Curtis PMC handheld programmer (optional) can be used to program, test, and diagnose Curtis PMC programmable controllers. The programmer is powered by the host controller, via the modular connector located on the front of the controller.

When it is first plugged into the controller, the programmer displays the controller’s model number, date of manufacture, and software revision code. Following this initial display, the programmer displays a prompt for further instructlons.

1 A 4-line LCD display is presented in this window.

1

2 Choose the Program, Test, or Diagnostics Mode with one of these three keys.

6

5 Scroll the 4-line display (up and down) with this two keys.

6 The LED in the corner of the key lights up to identify the mode of operation.

2 5

Issue: 01.2000

4 Get more information about selected items with this key. Also, use this key in combination with other keys to put the programmer in Special modes.

(Replaces issue:

3 Change the selected item's value (up or down) with this two keys.

3 )

4

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Copyright reserved.

2

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31

EGU 18/20/20S

Diagnostics The programmer is operated via an 8-key keypad. Three keys select operating modes (Program, Test, Diagnostics), two scroll the display up and down, and two change the values of selected parameters. The eighth key, the MORE INFO key, is used to display further information about selected items within any of the three standard modes. In addition, when pressed together with the PROGRAM or the DIAGNOSTICS key, the MORE INFO key selects the Special Program mode or the Special Diagnostics mode.

To scroll up and down within a menu, use the two SCROLL DISPLAY arrow keys. The SCROLL DISPLAY arrow keys can be pressed repeatedly or be held down. When a key is held down, the scrolling speed increases the longer the key is held.

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

The display window presents a 4-line LCD display. The display is visible even in bright sunlight. You can adjust the display contrast in the Special Program mode.

When one of the menu keys is pressed, the LED at the corner of the key lights up, identifying the mode of programmer operation.

For example, if the TEST key is pressed, the LED at the corner of the key indicates that the programmer is now in the Test mode, and the Test Menu is displayed.

Four lines of a menu are displayed at a time.

The item at the top of the display window is the selected item. To select an item, scroll within the menu until the desired item is positioned at the top of the display window.

The selected item is always the top line. (In the Program mode, the selected item is highlighted by a flashing arrow.) To modify a parameter or obtain more information about it, it must be scrolled to the top position in the display window.

A small scroll bar at the left of the display window provides a rough indication of the position of the four displayed items within the entire menu. That is, when the bar is at the top of the window, the top of the menu is displayed. As you scroll through the menu, the bar moves downward. When the bar is at the very bottom of the window, you have reached the end of the menu. This sample display is from the Program Menu:

1 Menu cursor 2 Selected parameter

3

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Diagnostics The two CHANGE VALUE arrow keys are used to increase or decrease the value of a selected menu item. Like the SCROLL DISPLAY arrow keys, the CHANGE VALUE arrow keys can be pressed repeatedly or be held down. The longer a key is held, the faster the parameter changes. This allows rapid changing of any parameter.

An LED on each CHANGE VALUE arrow key indicates whether the key is active and whether change is permissible. When the value of a parameter is being increased, the LED on the „up“ CHANGE VALUE key is on until you reach the maximum value for that parameter. When the LED goes off, you cannot increase the value.

4

Selected parameter Display Minimum value Stored value Maximum value Units

Issue: 01.2000

1 2 3 4 5 6

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

Copyright reserved.

"More information" is available in all of the programmer operating modes. After using the MORE INFO key to display additional information about the selected item, press the MORE INFO key again to return to the original list.

The LED's on these keys indicate whether there is still room for change. That is, when the upper limit of a parameter’s range is reached, the LED on the "up" key no longer lights up, indicating that the present value cannot be increased; when the lower limit is reached, the LED on the "down" key no longer lights up.

The MORE INFO key, when used in the Program mode, displays a bar graph along with the minimum and maximum values possible for the selected parameter.

Parameters can be changed either from the main Program Menu or after the MORE INFO key has been pressed and the additional information is being displayed (see example below).

)

- to display more information about the selected item, - to access the Special Program and Special Diagnostics modes (when used together with the PROGRAM and DIAGNOSTICS keys), and - to initiate certain commands (such as the Self Test).

In the Program mode, accessed by pressing the PROGRAM key, all the adjustable parameters and features of the controller are displayed (four at a time), along with their present settings. The setting of the selected item-the item at the top of the display, with the flashing arrow-can be changed, using the two CHANGE VALUE keys.

(Replaces issue:

The MORE INFO key has three functions:

Operating Modes: PROGRAM, TEST, DIAGNOSTICS, SPECIAL PROGRAM, SPECIAL DIAGNOSTICS

Workshop Manual

EGU 18/20/20S

31 Diagnostics

The Program Menu is presented at the end of this section.

NOTE: Some items may not be available on all 1243 models.

Issue: 01.2000

(Replaces issue:

)

In the test mode, accessed by pressing the TEST key, real-time information is displayed about the status of the inputs, outputs, and controller temperature.

For example, when the status of the forward switch is displayed, it should read "On/Off/On/ Off/On/Off" as the switch is repeatedly turned on and off. In the Test mode, the item of interest does not need to be the top item on the list; it only needs to be among the four items visible in the window. The Test mode is useful for checking out the operation of the controller during initial installation, and also for troubleshooting should problems occur.

The MORE INFO key, when used in the Test mode, causes additional information to be displayed about the selected item (top line in the window).

The Test Menu is presented at the end of this section.

The Special Program mode allows you to perform a variety of tasks, most of which are self-explanatory. Through the Special Program Menu, you can revert to earlier settings, save controller settings into the programmer memory, load the controller settings from the programmer into a controller, clear the controller’s diagnostic history, adjust the contrast of the programmer’s LCD display, select the language to be displayed by the programmer, and display basic information (model number, etc.) about the controller and the programmer.

To access the Special Program mode, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the PROGRAM key. The LED on the PROGRAM key will light, just as when the programmer is in Program mode. To distinguish between the Program and Special Program modes, look at the menu items in the display.

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Copyright reserved.

NOTE: Some items may not be available on all 1243 models.

In the Diagnostics mode, accessed by pressing the DIAGNOSTICS key, currently active faults detected by the controller are displayed.

The MORE INFO key, when used in the Diagnostics mode, causes additional information to be displayed about the selected item.

A list of the abbreviations used in the Diagnostics display is included at the end of this section.

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Diagnostics Controller cloning NOTE: Two of the special Program menu items"Save Controller Settings in Programmer" and "Load Programmer Settings into Controller"-allow you to "clone" controllers. To do this, simply program one controller to the desired settings, save these settings in the programmer, and then load them into other similar (same model number) controllers, thus creating a family of controllers with identical settings.

Each fault is listed in the diagnostic history file only once, regardless of the number of times it occurred.

To access Special Diagnostics, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the DIAGNOSTICS key. The LED on the DIAGNOSTICS key will light, just as when the programmer is in Diagnostics mode.

6

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

Copyright reserved.

NOTE: The maximum and minimum temperatures recorded by the controller are included in the Test Menu.

)

In the Special Diagnostics mode, the controller’s diagnostic history file is displayed.

This file includes a list of all faults observed and recorded by the controller since the history was last cleared.

Each time the programmer is connected to the controller, it acquires all the controller’s parameters and stores them in its temporary memory. You can revert back to these original settings at any time during a programming session via the Special Program Menu. Select "Reset All Settings" by scrolling it to the top of the display window, press the MORE INFO key, and follow the instructions displayed. Any inadvertent changing of parameters can be "undone" using this procedure-even if you can’t remember what the previous settings were-as long as the programmer has not been unplugged and power has not been removed from the controller.

Issue: 01.2000

The Special Program Menu is presented at the end of this section.

Peace-of-mind programming

(Replaces issue:

The MORE INFO key is used initially to access the Special Program mode, and once you are within the Special Program mode, it is used to perform the desired tasks. To adjust the contrast in the display window, for example, select "Contrast Adjustment" by scrolling until this item is at the top of the screen, and then press MORE INFO to find out how to make the adjustment.

The MORE INFO key, when used within the Special Diagnostics mode, causes additional information to be displayed about the selected item.

To clear the diagnostic history file, put the programmer into the Special Program mode, select "Clear Diagnostic History", and press the MORE INFO key for instructions. Clearing the diagnostic history file also resets the maximum/ minimum temperatures in the Test Menu.

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31 Diagnostics

Programmer Self Test As part of the Self Test, you can also test the keys by pressing each one and observing whether its corner LED lights up. To exit the Self Test, unplug the programmer or turn off the controller, and then repower it without holding the MORE INFO key.

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

You can test the programmer by displaying two special test screens.

Press the MORE INFO key while the programmer is powering up. During the Self Test, you can toggle between the two test screens by pressing the SCROLL DISPLAY keys. The first screen turns on every LCD element, and the second screen displays all the characters used in the various menus.

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Diagnostics Parameter List of Curtis Controller 1243 For the EGU 20-N only mode 1 is used.

Listed below are the parameters and their ranges which can be modified by service staff.

BRAKE C/L: ACCEL RATE: DECEL RATE: BRAKING RATE: MAX SPEED:

from 130 to 200 from 0.5 to 3 total range (0.1 to 10) from 0.1 to 3 total range

Nominal battery voltage, in volts

2

M1 DRIVE C/L

Mode 1 drive current limit, in amps

200

M2 DRIVE C/L

Mode 2 drive current limit, in amps

200

M3 DRIVE C/L

Mode 3 drive current limit, in amps

200

M4 DRIVE C/L

Mode 4 drive current limit, in amps

200

M1 BRAKE C/L

Mode 1 braking current limit, in amps

200

M2 BRAKE C/L

Mode 2 braking current limit, in amps

200

M3 BRAKE C/L

Mode 3 braking current limit, in amps

200

M4 BRAKE C/L

Mode 4 braking current limit, in amps

200

M1 ACCEL RATE

Mode 1 acceleration rate, in seconds

2.5

M2 ACCEL RATE

Mode 2 acceleration rate, in seconds

1

M3 ACCEL RATE

Mode 3 acceleration rate, in seconds

1

M4 ACCEL RATE

Mode 4 acceleration rate, in seconds

1

M1 DECEL RATE

Mode 1 deceleration rate, in seconds

5

M2 DECEL RATE

Mode 2 deceleration rate, in seconds

5

M3 DECEL RATE

Mode 3 deceleration rate, in seconds

5

M4 DECEL RATE

Mode 4 deceleration rate, in seconds

5

THROTTLE DECEL

Transition period from driving to braking

0.5

M1 BRAKING RATE

Mode 1 braking rate, in seconds

3

M2 BRAKING RATE

Mode 2 braking rate, in seconds

1

M3 BRAKING RATE

Mode 3 braking rate, in seconds

1

M4 BRAKING RATE

Mode 4 braking rate, in seconds

1

QUICK START

Quick-start throttle factor in seconds

0

TAPER RATE

Rate of field polarity change during direction reversal: 1 to 20

10

M1 MAX SPEED

Mode 1 maximum speed, as % PWM output

100

M2 MAX SPEED

Mode 2 maximum speed, as % PWM output

100

M3 MAX SPEED

Mode 3 maximum speed, as % PWM output

100

M4 MAX SPEED

Mode 4 maximum speed, as % PWM output

100

CREEP SPEED

Creep speed, start ramp in seconds

0

Issue: 12.2001

VOLTAGE

8

Value

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

Copyright reserved.

Desription

(Replaces issue: 01.2000)

Display

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EGU 18/20/20S/H

Issue: 12.2001

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

Copyright reserved.

(Replaces issue: 01.2000)

Diagnostics Display

Description

Value

THROTTLE TYPE

Throttle type

1

THROTTLE DEADBAND

Throttle neutral deadband, as % of 5 kOhm pot

7

THROTTLE MAX

Throttle input req'd for 100% PWM, as % of 5 kOhm pot

100

THROTTLE MAP

Throttle map, as %

20

FIELD MIN

Minimum field current, in amps

8

FIELD MAX

Maximum field current, in amps

25

FIELD MAP START

Armature current at wich field map takes effect, in amps

75

FIELD MAP

Field current map setting, as % between field map start and 100% armature current

50

CURRENT RATIO

Current ratio: factor of 1, 2, 4 or 8

4

RESTRAINT

Ramp restraint: Field Min setting to 40 amps

10

LOAD COMPEN

Load compensation: 0 to 25 % PWM output

3

HPD

High pedal disable (HPD) type

2

SRO

Static return to off (SRO) type

0

SEQUENCING DLY

Sequencing delay, in %

1

MAIN CONT INTER

Main contactor uses interlock input

ON

MAIN OPEN DLY

Main contactor open delay

10

CONT DIAG

Contactor diagnostics

ON

AUX TYPE

Auxiliary driver type

1

EMR REV C/L

Emergency reverse current limit, in amps

200

AUX DLY

Auxiliary driver open delay, in seconds

0.2

EMR REV CHECK

Emergency reverse wiring check

ON

EMR DIR INTR

Emerg. reverse direction interlock

ON

VARIABLE BRAKE

Variable braking

ON

ANTI DIEDOWN

Anti-tiedown

OFF

POT LOW FAULT

Pot Low fault

ON

FAULT CODE

Fault code outputs 1 and 2

ON

Activation of 2 driving modes TERMINAL 14

TERMINAL 9

MODE 1

0V

0V

MODE 2

+ 24 V

0V

NOTE : The models EGU-18/20/20S/H all have the same parameters.

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Diagnostics Test Menu NOTE: Certain information is not accessible to all controllers.

Motor field current, in amps

ARM CURRENT

Motor armature current, in amps

FIELD PWM

Motor field applied duty cycle, as %

ARM PWM

Motor armature applied duty cycle, as %

BATT VOLTAGE

Battery voltage across the capacitors

HEATSINK TEMP

Heatsink temperature, in °C

FORWARD INPUT

Forward switch: on/off

REVERSE INPUT

Reverse switch: on/off

MODE INPUT A

Mode Select 1 switch: on/off

MODE INPUT B

Mode Select 2 switch: on/off

INTERLOCK

Interlock switch: on/off

EMR REV INPUT

Emergency reverse switc: on/off

MAIN CONT

Main contactor: on/off

AUX DRIVER

Auxiliary driver: on/off

Issue: 01.2000

Throttle reading, as % of full throttle

FIELD CURRENT

(Replaces issue:

THROTTLE %

)

Special Program Menu Revert to original settings

CONT SETTINGS => PROG

Save controller settings in programmer

PROG SETTINGS => CONT

Load programmer settings in controller

CLEAR DIAG HISTORY

Clear diagnostic history memory

CONTRAST ADJUSTMENT

Adjust display contrast

LANGUAGE SELECTION

Select displayed language

PROGRAMMER INFO

Display programmer information

CONTROLLER INFO

Display controller information

10

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

Copyright reserved.

RESET ALL SETTINGS

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31 Diagnostics

Diagnostics and Special Diagnostics "Menu" No known faults

ANTI-TIEDOWN

Mode Select 1 switch closed at startup

CONT COIL/FLD SHORT

Contactor driver overcurrent or field winding short

CURRENT SHUNT FAULT

Current sensor error

ENR REV WIRING

Emerg. reverse wiring check failed

FIELD OPEN

Motor field winding open

HPD

High pedal disable (HPD) activated

HW FAILSAFE

Hardware failsafe activated

LOW BATTERY VOLTAGE

Battery voltage too low

M-SHORTED

M- shorted to B-

MAIN CONT WELDED

Welded main contactor

MISSING CONTACTOR

Missing contactor

OVERVOLTAGE

Battery voltage too high

SRO

Static return to off (SRO) activated

THERMAL CUTBACK

Cutback, due to over/under temp

THROTTLE FAULT 1

Throttle wiper input fault

THROTTLE FAULT 2

Throttle low input fault

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

NO KNOWN FAULTS

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Page

Special tools for AMP connectors

2

Special tools for Molex connectors

3

Programmer

3

Tools for group 02

4

Maintenance supports

5

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

Copyright reserved.

Issue: 01.2000

Contents

(Replaces issue:

)

Special tools

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Special tools Special tools for the AMP connector The following special tools are required for the black AMP connectors (1) and sockets (2): NOTE: In order to press out the pins or sockets, open the flaps (7).

Item 1: Socket housing, 14 pins ld. No. 8 403 734

ld. No. 8 403 726 ld. No. 8 403 729

Item 3: Press-out tool

ld. No. 1 675 079

Item 6: Press-out tool

ld. No. 0 148 478

2

Issue: 01.2000

ld. No. 8 403 863 ld. No. 8 403 864

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

Copyright reserved.

Item 5: Single Contact 0.5 - 1.0 mm2: 1.5 - 2.5 mm2:

)

Item 4: Connector housing, 14 pins ld. No. 8 403 739

(Replaces issue:

Item 2: Single Contact 0.5 - 1.0 mm2: 1.5 - 2.5 mm2:

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EGU 18/20/20S

Special tools Special tool for the Molex connector The following press-out tool is used for the white Molex connectors on the "Curtis CombiController 803" discharge indicator (option) and the Wagner Highpuls Control: Item 1: Connector housing, 8 pins ld. No. 8 403 826 Connector housing,16 pins ld. No. 8 403 828 ld. No. 8 403 829 ld. No. 8 403 830

Item 3: Press-out tool

ld. No. 1 675 073

Issue: 01.2000

Programmer Item 4: Programmer

Curtis ld. No. 5 456 444

4

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Copyright reserved.

(Replaces issue:

)

Item 2: Single Contact 0.2 - 0.75 mm2: 0.75 - 1.5 mm2:

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Special tools Adapter cable PC (with windows 3.1) -> controller ld. No. 4 498 906 Adapter cable PC (with windows 95) -> controller ld. No. 4 498 916

Cable for connection to controller 1207 ld. No. 5 456 483

)

Tool for group 02 Plugs for removal of hydraulic unit ld. No. 4 498 851

Issue: 01.2000

ld. No. 5 456 433

(Replaces issue:

Cable for connection to controller 1207 and 1243

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

Copyright reserved.

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EGU 18/20/20S

Special tools

Maintenance supports The following material is required to make the maintenance supports: Flat bar steel 12 x 30 290 mm 1 item Flat bar steel 6 x 30 20 mm 1 item Hex head screw M12 x 40 1 item Star handle nut, cast (Norelem) M12 1 Nut 2 Hex head screw

30

Issue: 01.2000

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

Copyright reserved.

(Replaces issue:

)

12

1

12,5

2

290

223 6 20

102

5