STILL STED Forklift EK10N Workshop Manual - PDF DOWNLOAD

EK10N

Workshop Manual

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To get the table of sections click here To get the alphabetical index click here

8/0001-4

First Issue: 07/00 Last Revision:

Workshop Manual

EK10N

Id. no. 8 054 220

Foreword Definition of vehicle model names

EK10 NO (Niederhub ohne Zusatzhub = low lift without additional lift)

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

8/0001

EK10 NM (Niederhub mit Zusatzhub = low lift with additional lift)

8/0002

EK10 HO (Hochhub ohne Zusatzhub = high lift without additional lift)

8/0003

EK10 HM (Hochhub mit Zusatzhub = high lift with additional lift)

8/0004

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Sheet no.

I

Foreword Foreword

This workshop manual provides specifications and describes functional characteristics of the standard truck.

5/0002

This provides you with a comprehensive documentation to ensure better understanding of the vehicle technology and so permit correct maintenance and repair work to be carried out.

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The workshop manual is always updated by supplementary sheets.

5/0003

Updating of workshop manuals The industrial truck range is subject to continuous further development. This means that certain components or assemblies are exchanged or modified.

To ensure that the holder of this manual always has the most up to date version of the documentation, it is important to abide by the following updating system.

5/0004

8/0001

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EK10N

Sheet no.

II

Foreword Updating workshop manuals (Contd.)

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1. Exchanging faulty sheets

Page baseline of the existing sheet

If a particular page contains mistakes, for example due to altered setting values, the respective sheet must be exchanged.

A newly inserted sheet can be recognized by the altered left-hand baseline (1). Here, the date of compilation is updated in the line entitled Issue (2). In the line Replaces issue (3) is the compilation date of the sheet to be replaced. The sheet no. remains the same (4).

With every revision the first sheet will be replaced. In (9) you see the first issue and the date of the last revision. This tells you the revision state of the whole book.

sheet.no.

A1

1 2

4

Page baseline of the corrected sheet Workshop sheet-no.

EK10N A1 Manual

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3 Page baseline of the first sheet Workshop EK10N Id. no.

Manual

First issue: 07/00 Last revision:

2. Insertion of supplementary sheets

9

If new, modified or additional components are included in the series truck, it may be necessary to add one or more supplementary sheets.

The additional sheet is recognized by the lefthand and right-hand page baseline (5+6).

In the Issue line on the left-hand side is the compilation date (7). On the right, the supplementary sheet is marked by the sheet no. with continuous index (8).

In addition, the table of contents of the respective assembly must also be exchanged.

Page baseline of the existing sheet

Workshop Manual

Workshop sheet-no.

EK10N A1 Manual

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6

5

Page baseline of the supplementary sheet Workshop sheet-no.

EK10N A 1.1 Manual

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Newly compiled sheets, whether replacements or supplementary sheets, and the new tables of contents are sent by post to all known holders of workshop manuals.

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7

EK10N

8

Sheet no.

III

Foreword Remarks, imprint

No guarantee claims arise as a result of working in accordance with the instructions contained in this manual.

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

This does not affect the guarantee stipulations.

We are continuously involved in the further development of our industrial trucks. Please appreciate that this documentation is subject to alteration and error, and that no claims may be derived from information, illustrations and descriptions contained in the workshop manual .

Publisher STILL WAGNER GMBH & CO KG Trainingszentrum Ernst-Wagner-Weg 1-5 72766 Reutlingen-Mittelstadt

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Sheet no.

IV

Sections

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Sections:

Issue: 07/00 Replaces issue:

A B C

Travel drive Steering system Brake system

D E F M

Slide carriage Lifting device Cylinders Electrical system

N R

Hydraulic system Lubrification plan

Workshop Manual

EK10N

Sheet no.

V

Alphabetical index A

G

Additional lift NM/HM ........................................F7 Additional load carriage ....................................E7 Adjustment of steering controller ....................B10 Adaption, option .............................................M32

Gear ...............................................................A12 Gear oil amount ..............................................A15 Gear oil, classes .............................................A15

B

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Bleeding the lift cylinder ................................N17 Block diagram braking monitor M44 Block diagram electr. system M2 Block diagram of steering system ....................B2 Block diagram of hydraulic system .............N2,N3 Bogie bearing ................................................A17 Brake deceleration ..........................................C9 Brake function ..................................................C3 Brake rotor .......................................................C4 Brake system......................................................C Braking monitor M43 Braking parameters M18 Bubble reservoir ............................................N19

C Carbon brushes, pump motor ..........................N9 Carbon brushes, servo unit ...........................B24 Carbon brushes, travel motor ..........................A6 Changing the battery .....................................M50 Changing the gear oil .....................................A15 Changing the hydraulic oil ..............................N16 Cylinder support................................................F2

D Display unit M48 Direction of rotation .........................................A2 Distributor block NM/HM ................................N18 Drive wheel.....................................................A11 Driver cab, removal .........................................E3 E Electrical steering system.................................B2 Electrical system .............................................M1 Electromagnetic spring brake...........................C2 Electromagnetic spring brake, adjustment ......C6 Electromagnetic spring brake, brake clearance .C6 Electromagnetic spring brake, braking force ...C7 Electromagnetic spring brake, dismantling ......C5 Electromagnetic spring brake, removal ...........C4 Error code, evaluation logic ..........................M42 Evaluation logic..............................................M36 Evaluation logic, displays ..............................M41

H Highpuls ..........................................................M3 Hydraulic pressures .......................................N15 Hydraulic circuit plan .......................................N4 Hydraulic hoses .............................................N20 Hydraulic oil amount.......................................N16 Hydraulic oil, classes ......................................N16 Hydraulic pump unit .......................................N12 Hydraulic system ..............................................N1

I Idling wheel ......................................................D2 Idling wheels, removal .....................................D2 Impressum ............................................Foreword

L Line break protection ........................................F9 Lifting device.......................................................E Lifting function .................................................N6 Lift chain ..........................................................E5 Lowering function .............................................N7 Lubrication plan HO..........................................R4 Lubrication plan HO..........................................R5 Lubrication plan NM .........................................R3 Lubrication plan NO..........................................R2 Lubricants.........................................................R6 M Main lift cylinder HO/HM ..................................F5 Main lift cylinder NO/NM ..................................F3 Maintenance, lift chain......................................E8 Maintenance, travel motor ................................A7 Module 3U51................................................. M32 Maximum pressure valve ...............................N15

O Operating hours counter ...............................M19

P Parameters, setting........................................M18 Potentiometers and LEDs.................................B6 Programming unit PMC ............................M14-30 Pulley................................................................A4 Pump unit, general ...........................................N5 Pump unit, removal ........................................N10

F Flashing error code .........................................M9 Flyer chains ......................................................E8

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Sheet no.

VI

Alphabetical index S Safety test of steering system .............................B4 Sections ................................................................0 Service switch .....................................................B9 Service switch, adjustement ................................B9 Servo unit, installation .......................................B23 Servo unit, removal ...........................................B23 Servo unit, steering system ...............................B21 Setpoint potentiometer 1gear ............................B16 Setpoint potentiometer 5 gear ...........................B18

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Slide carriage ........................................................D Special tool....................................................A4, F9 Speed sensor M44 Steering controler, adjustment ..........................B13 Steering controler, description.............................B5 Support carriage..................................................E2 Support rollers .....................................................E2 Support rollers ....................................................E4

T Table of parameter settings for travel .............. M18 Terminal board ...................................................A3 Travel control, adjustment ...............................M14 Travel control, error display ................................M9 Travel control, flashing code ...........................M10 Travel control, general ........................................M3 Travel control, Id. Nos. .......................................M4 Travel control, input and output signals .............M6 Travel control, safety monitoring.......................M18 Travel control, switchboard ................................M4 Travel control, terminals .....................................M5 Travel drive ...........................................................A Travel motor, general ........................................ A2 Travel motor, installation ....................................A5 Travel motor, Maintenance..................................A7 Travel motor, remove .........................................A4 Travel, parameters ...........................................M18

U Updating the manual ................................Foreword U51 ...................................................................M32

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Sheet no.

VII

Section A

Travel drive

Contents

Sheet no.

Travel motor, general...........................................................................................A 2 Travel motor, terminal board ................................................................................A 3 Travel motor, removal ..........................................................................................A 4 Travel motor, installation ......................................................................................A 5 Replacing the carbon brushes .............................................................................A 6 Travel motor, maintenance ..................................................................................A 7

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Changing the drive wheel ....................................................................................A 11 Gear, removal ......................................................................................................A 12 Gear, installation ..................................................................................................A 14 Changing the gear oil...........................................................................................A 15 Checking the gear oil level...................................................................................A 16 Lubricating the bogie bearing...............................................................................A 17

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Sheet no.

A1

Section A

Travel drive

Drive motor Id. no. W8 408 250

General The drive motor used in this vehicle is a 24V shunt motor.

The armature and field coils are controlled separately by the travel controller.

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The travel movement is initiated as follows: voltage is applied to the armature (A1/A2) and the field (F1/F2) is excited.

As soon as the armature voltage is equal to the battery voltage, the field current is reduced in order to achieve an increase in speed.

The current speed of the drive motor is determined by a current measurement (measuring shunt) in the travel controller.

The drive motor has a temperature monitor (field coil resistor at normal temperature approx. 1.8 Ω).

0/0177

+

-

+

-

A1

A2

F1

F2

If the temperature is >90°C, deceleration is initiated by the Warm Speed parameter. If the temperature rises above 190°C, a traction cut-out is initiated by the Mot Hot parameter.

M

(see chapter M. sheet 19) Clockwise

Note: The field current must not be interrupted during operation, otherwise the speed of the motor increases.

+

-

-

+

A1

A2

F1

F2

M

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Sheet no.

A2

Section A

Travel drive

Travel motor Id. no. W8 408 250 Terminals A1

A2

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Designation at motor A1

Armature winding start

A2

Armature winding end

F1

Field winding

F2

Field winding F1

0/0177

F2

Technical data for travel motor Model designation

GF 114 - F4

Id. no.

W8 408 250

Excitation type

Nebenschluß

Voltage

24 V

Rated output

2000 W

Rated speed

2700 min - 1

Direction of rotation

right / left

Protection / insulation class

JP 00 / 20

Field excitation

6V / 9A

Armature current

104 A

On-period

S 2 = 60 min

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Sheet no.

A3

Section A

Travel drive

Travel motor Id. no. W8 408 250

1

Removing the travel motor

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Note:

Because the brake (2) is mounted on the travel motor, the vehicle is no longer braked once the brake and the travel motor have been removed. For this reason, always secure the vehicle to prevent it rolling away!

-

Pull out the battery plug (1).

-

Remove the 8 Hexagon socket screws.

-

Remove speed sensor (9).

Remark:

The connection point for the connection cable of the spring brake may be in the cable duct (4)!

4

6-02 22

-

Remove the 6 screws (M8x25) (5).

-

Screw the special eyebolt tool M6 (6), into the armature shaft (min. 20 mm).

-

8/0005+6

Pull the rope (7) (special tool: pulley) through the eyebolt (6).

Id.no. W8 420 446

48

6

7

41,5

8

M6x60

Remark: Ensure that the rope is pulled through correctly (8).

6/2004

min. 20 mm 6/2005

-

2

Set the length (holding it tight with your hand is sufficient).

9

3 -

3

Lift the travel motor out with a lever rod.

5

0/0178

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Sheet no.

A4

Section A

Travel drive

Travel motor Id. no. W8 408 250 Removing the travel motor

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Note:

Never work without the correct aids. A considerable amount of force is required to release the seal (1) between the travel motor and the gear.

-

Remove the aids.

-

Lift the travel motor out by hand.

Note:

3 MA = 23 Nm fixed with Loctite

MA = 26 Nm

When the travel motor has been removed, the opening left in the gear (2) must be closed off immediately, in order to prevent oil entering the inside of the gear.

1

Installation To install the travel motor, follow the instructions for removal in reverse order.

It can be installed without the use of any special tools.

Clean the opening in the gear.

2

Note:

Only use screws of the prescribed length, otherwise the four-point bearing may be damaged!

Remark:

Screw in and tighten the 8 screws (3) diagonally in several passes.

6/2006

MA = 140 Nm

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Sheet no.

A5

Section A

Travel drive

Replacing the carbon brushes Id. no. W8 668 356 (1 set) The carbon brushes must be replaced when a residual length of 50% has been reached, which is equivalent to 15mm.

Length of a new carbon brush:

min. 15mm

30mm

An entire set of brushes must be replaced at the same time (4 brushes) (see also A9).

2

1

3

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Removal: -

Pull out the battery plug (see A4).

Remove the cover (4).

Raise the brush spring (1) and hook in.

Pull out the brush on the connection cable (2).

Disconnect the connection cable (3).

Clean the commutator space (by blowing).

Note: You must on no account inhale the carbon dust. Always wear a protective mask.

Insert the new carbon brushes.

Remark:

Ensure that the carbon brushes move easily in the shaft.

Note:

The motor should not be placed under a full load directly after the brushes have been replaced. The carbons run in relatively quickly under a low load.

5/0034.1

3

2

1

0/0179

Checking the brush springs Id. no. W8 408 956 Brush springs which are not adequately pre-tensioned cause the commutator to burn.

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Sheet no.

A6

Section A

Travel drive

Travel motor, maintenance General Maintenance work between major overhauls consists of: - Cleaning - General visual inspection - Replacing damaged parts - Checking the brush mechanisms and commutators - Replacing the carbon brushes (whenever necessary).

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This work should be carried out at least every 500 operating hours or every 3 months.

We recommend entrusting a major overhaul of a motor to a workshop which specialises in work of this kind, since special tools and expertise are required for this work.

Note:

0/0177

The battery plug must always be pulled out before work is started on the motor, in order to prevent short circuits and injury.

Cleaning - Remove the cover and take out the brushes (see sheet no. A6).

- Clean the motor out thoroughly with compressed air (do not inhale the dust, always use a protective mask).

- Clean soiled commutators and brush mechanisms with a clean cloth moistened with petrol (do not use cleaning wool) and dry thoroughly.

Remark:

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

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Sheet no.

A7

Section A

Travel drive

Travel motor, maintenance Continued

Visual inspection, replacing damaged parts: - Check the gear ventilation channels (1) to

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

ensure they are clean. Soiling decreases the air circuilation, which leads to raised temperatures in the motor and can possibly damage it.

1

- Check the field and armature windings for signs of wear (e.g. overheating): darkcoloured, brittle or burned insulators, unsoldered commutators.

Motors which have this kind of overload damage must be replaced without delay.

6/2008

- If oil or grease are found in the motor (usually a paste of oil, oil vapour with dust and carbon dust), the cause must be ascertained and rectified immediately.

The motor must be cleaned thoroughly.

Remark:

Rapid carbon brush or commutator wear is generally found to be caused by oil.

The oil/grease burns in the commutator sparking and leaves behind a sharp-edged oil ash which has an abrasive effect.

The result of this is that the brushes may wear down far more than is permissible even before the next maintenance date is due.

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Sheet no.

A8

Section A

Travel drive

Travel motor, maintenance Continued

Checking the brush mechanism, replacing the carbon brushes: After the brush mechanism has been cleaned, it must be possible to move the brushes easily in their guides when the spring is lifted.

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

If one or more of the brushes stick, they must on no account be treated with emery paper or a similar material.

If this is the case, the entire brush mechanism must be replaced, since it is possible that the brushes have been overheated.

It is also important that the brushes are not broken or worn at their running edges.

Remarks: - Always replace the entire set of brushes, taking the shortest brush as a measure for all of them (see A6).

0/0180

- Only use original replacement carbons (see spare parts list!).

- Do not let the brush springs fall onto the brushes when you are inserting the latter.

- If the brushes have not quite reached the minimum length, they should still be replaced, as their remaining useful life may be shorter than the interval to the next inspection.

- A maximum of 3 brush sets should be replaced one after another. After this, the motor must undergo a major overhaul (by a specialist workshop).

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Sheet no.

A9

Section A

Travel drive

Travel motor, maintenance Continued

Commutator The running surface of the commutator should be uniformly smooth and be grey-black in colour.

The commutator must not be worn down, corrugated or out of round.

If any of the characteristics mentioned above should occur, the commutator must be reworked (major overhaul).

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Never work on it with a file, emery paper or other similar tools.

Bearings The ball-bearings do not need regreasing. The amount of grease they are filled with is sufficient for the maintenance periods between major overhauls.

The bearings must be replaced: - at every major overhaul,

0/0180

- at the latest after a running time of 2000 hours, - if the vehicle running time is very low, after 5 years at the latest.

Always use the bearings in the spare parts list.

Note on risk of overloading when batteries discharged: If the motor speed drops noticeably, work must be stopped immediately and the battery checked without delay. It should be recharged if necessary.

Never use the vehicle with low battery voltage!

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Sheet no.

A 10

Section A

Travel drive

Changing the drive wheel Id. no. W8 393 220 New dimensions: 250 x 100 mm The drive wheel must be replaced when - the running surface is very worn or out of round or cracks appear in it, - the dimater of the typer has decreased by 10 % (smallest permissible tyre diameter: 225 mm).

Removing the drive wheel Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

6/2009

1.

2.

3.

4.

5.

6.

7.

8.

9.

Drive the vehicle up against a wall until the forks touch it, to prevent the vehicle from rolling away (1).

Turn the steering until the wheel nuts are easily accessible.

2 Pull out the battery plug (see A4).

Release the wheel nuts (2) with the vehicle jacked up.

Raise the vehicle in its centre (3) with a hydraulic lifter (5t), Id. no. W8 050 724 to a height of approx. 100 mm.

Use hardwood blocks to support the vehicle safely from below on both sides (4).

Lower the hydraulic lifter and remove it.

100 mm Unscrew the 5 wheel nuts (2).

Remove the drive wheel.

1 6/2010.1

6/2011

Installing the drive wheel Before fitting the drive wheel, clean the wheel seat and check that it is in perfect condition.

1.

2.

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

Tighten the nuts diagonally in several passes with a dynamometric key.

Tightening torque: 140 Nm. 4

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3 Sheet no.

4

A 11

Section A

Travel drive

Gear

Id. no. W8 423 410 Removing the gear Remark:

-

When removing the gear, it is best to leave the drive wheel in place to begin with (drive wheel held in place with 2 nuts tightened by hand).

-

Turn the steering anti-clockwise as far as it goes.

-

Pull out the battery plug (see sheet A4).

-

Remove the travel motor (see sheets A4, A5).

-

Remove the steering chain (see sheet B25).

-

Drain off the gear oil (see sheet A15).

-

Turn the gear so that the wheel side is at the front and pull a rope through the ventilation slots (2).

-

Remove the 6 screws M12 x 40 (1).

-

Raise the vehicle by approx.. 170 mm (!) with a hydraulic lifter, and support the sinking gear with the rope at the same time (lean against the back of the chassis) (see Fig. 2).

-

1

Release the wheel nuts (see A11).

Remark:

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

Once the travel motor has been removed, the vehicle is no longer braked and must be secured to prevent it from rolling away! (see sheet no. A11)

3

6/2006

Bild 1

2

Use hardwood blocks to support the vehicle safely from below on both sides!

Remark:

The centring ring (3) is not attached in any further way. Remove it lay it to one side.

-

Remove the hydraulic lifter.

-

Remove the drive wheel (see sheet A11).

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6-02 32

Sheet no.

A12

Section A

Travel drive

Gear

Id. no. W8 423 410 Removing the gear

Continued

-

Pull the gear forwards under the chassis by tilting it.

Remark:

Cover the gear opening (as a precaution to prevent the gear becoming soiled).

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

6-02 30

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Sheet no.

A 13

Section A

Travel drive

Gear

Id. no. W8 423 410 Installing the gear

Remark:

-

Before installing the gear, check that the gear opening and ventilation slots are clean. The photographs show the installation sequence.

Place the centring ring, gear and drive wheel ready for installation, as shown in the picture.

Ensure the rope is pulled through correctly.

Centring ring with flat side down.

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

6-02 29

-

Push the centring ring under the chassis.

-

Guide the gear into the chassis by tilting it.

-

Push on the centring ring, align the holes and tighten the rope.

-

Push on the drive wheel and tighten it by hand with 2 nuts (see sheet A12, picture 6-02 32).

-

Align the gear with the rope (use foot to support) and set it against back of the chassis.

-

Raise the vehicle with a hydraulic lifter and remove the wooden support block.

-

Lower the vehicle and guide the gear with the rope. Insert front screw M12x40 first.

-

Lower the vehicle further and insert and tighten the other 5 screws.

-

Tighten the remaining drive wheel screws (see sheet no. A11, points 1 and 2).

-

Fill up the gear oil - see sheet no. A15/16.

Remark:

6-02 30

6-02 31

When the gear is installed, check that the gear opening and the ventilation slots are clean.

6-02 33

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Sheet no.

A 14

Section A

Travel drive

Changing the gear oil Id. no. W8 423 410

The first oil change must be carried out after approx.

200 operating hours.

All further oil changes should be made after approx.

2000 operating hours or once a year.

Caution:

The gear oil must be drained off when the vehicle is warm, and can reach a temperature of 80° C. Take care not to burn yourself !

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

Oils with the following viscosity classes are used: Standard oil: SAE 80/90 Ambient temperature: 0°C to 40°C Low temperature oil: Ambient temperature:

SAE 80W to - 26°C

Low temperature oil: Ambient temperature:

SAE 75W to - 40°C

Amount of oil needed for this gear: Remark:

1.5l

The given amount of oil is a guideline only. The correct amount of oil is that required for the level to reach the lower edge of of filling hole (1).

Overfilling must be avoided, otherwise the seals will be damaged and it is possible that the operating temperature may not be maintained.

The maximum permissible operating temperature is 80°C.

1 2

3

Oil change method: 1.

2.

3.

6/2012

Turn the steering anti-clockwise until the oil drainage screw is easily accessible (2).

Position an oil catchment vessel with a volume of at least 2.5l under the oil drainage screw (3) of the gear.

Unscrew the oil filler cap (2) with a hexagon socket screw key (size 6).

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Sheet no.

A 15

Section A

Travel drive

Changing the gear oil Id. no. W8 423 410 Continued 1 4.

Unscrew the oil drainage screw (3) with the hexagon socket screw key (size 6) and drain off the oil.

Caution:

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

5.

6/2012

Oil

Tightening torque for oil filler cap (1) and drainage screw (3) MA= 22Nm.

1 6/2013

Fill with new gear oil up to the lower edge of the filler hole (see remark on sheet no. A 15)

Remark:

7.

Risk of burning!

The oil temperature can reach up to 80°C when the vehicle is in operation.

Clean the magnet on the oil drainage screw (3) and screw it back in with a new sealing ring, Id. no. W8 415 005 (2).

Note:

6.

3

The gear oil can also be filled up or checked through the upper gear opening (travel motor removed, see sheet no A4/ 5).

The oi level is correct, when the spur wheel (5) is immersed in the oil by about 1/3 of its height.

Oil level

5

Screw the oil filler cap (1) W8 003 886 back in.

6/2016

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Sheet no.

A 16

Section A

Travel drive

Checking the oil level Option 1

Oil

1.

Remove the oil filler cap (1).

2.

Make a touch test through the threaded hole of the filler cap. The gear oil level must reach the lower edge of the filler hole. Top the oil up if necessary.

1

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

Option 2

6/2013

1.

Pull out the battery plug (see sheet A4).

2.

Remove the travel motor (see sheet A4).

The brake and connection cables do not have to be disconnected!

2

Oil level

3.

Check the gear oil level through the gear opening (2).

The oillevel is correct, when the spur wheel (3) is immersed in the oil by about 1/3 of its height.

4.

3

Install the travel motor (see sheet A5).

6/2016

Lubricating the bogie bearing The bogie bearing should be lubricated twice a year through the two opposing lubricating nipples (4 and 5). It is particularly important to do this every time the gear has been cleaned (e.g. with steam jets).

4

5

Grease type: all-purpose grease 6/2014

Amount of grease when bearing is dry: 50 g

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EK10N

Sheet no.

A 17

Section B

Steering system

Contents

Sheet no.

Block diagram of electrical steering system..................................................B 2 Block diagram electronic steering controller ................................................B 3 Description of steering controller ..................................................................B 4 Pin assignment for steering controller/steering output stage........................B 7 Main current connections for steering controller/steering output stage ........B 8 Service switch for steering controller/steering output stage .........................B 9 Adjusting steering controller .........................................................................B 10 Setpoint generator with steering button (1 gear) ..........................................B 14 Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Setpoint generator with steering wheel (7 gear) ...........................................B 18 Actual value potentiometer ...........................................................................B 19 Servo unit ....................................................................................................B 21

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EK10N

Sheet no.

B1

Section B

Steering system

Block diagram of electrical steering system ZAG Modul Option 7A10

Option

Wheel position display

Rail switch Option 6/2017 Option EK10N,NM Setpoint

Evaluation logics

Straight on 6/2018

6/2023

2+24V 1+24V

Key-operated switch

2+24V

K1, -3F1,3F5

ABÜ Modul U50

Deadman

Steering error

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

Operating console

Electronic steering controller

-3F1 Safety relay Main contactor -K1

6/0516

Steering motor

ABÜ Modul U50

Enable

-3K1 6/0515

6/2019

Steering error relay

-3K3

right/left

Enable ABÜ Modul U50, K1

Brake

ABÜ Modul U50

Servo unit

Actual value

Travel contr.

1A10

Steering

Actual value potentiometer 6/2020

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0/0181

Travel drive Workshop Manual

EK10N

Sheet no.

B2

Section B

Steering system

Block diagram of electronic steering controller Id.no.: W8 409 271 Actual value 3R10 / 2X2K2

Setpoint 3R11 / 5K

.

X1:1

.

X3.

2K

2K

3R13

.

3

13

red

12

green

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

15 V Act.val. > 2°left Act.val. > 2°right Act.val. ≤ 2°

free 5

X1:2 X1:3 X1:4

5

free X1. 14

X2.

2

1

3

4

X1

4

X3

0,4V 7,5V ± 5V

red

Straight-on steering output

ca.1,2k Ω set

2

1 14,6 V

X1.

.

3U10 3R12

Rail switch 24 V

Act.val. < 10°

free 7 Setpoint < 5°

7,5V ±4,9V

0V

. .

Reference voltage 7,5 V

0V

0V

.

15 V

rot

Setpoint/actual value monitor for cable breakage or short-circuit Setpoint specification straight-on 7,5V.

.

ABÜ Angle for 2 sec. < 2°

Setpoint Error Actual val. rot

&

0V

.

X2:6

Output stage Serviceswitch

Setpoint/ Actual value OK

.

PWM Setpoint offset

Transistor short-circuit monitor

Steering angle

Control logic

Actual value offset

ABÜ X3:4 Deadman switch

X1.3

Setpoint/ actual value OK

Controller OK

&

.

gn

3K1 OK

.

&

Enable Steering still possible for 2 seconds after enable stops!

15V

OK X1 8 Steering control current error --> braking

.

PWM monitor

3K3

7,5V

.

3K1 switched

Delayed enquiry

15V 7,5V 24V

9

3K1 X2:5

ABÜ

. .

Test whether 3K1 open when vehicle switched on 3K1 has closed

M

L

. .

2+24 via K1, 3F1, 3F5 X1.10

Signal sequence: with reference to "R" and "L"

.

X1 4 free

R

≥1 1

2 X4 7 8 Inputs for steering motor signal carbons 1+24V 0V (Option) 24V Power supply via key-operated switch

24V X1 11 Signal carbon output (Option)

Contactor for motor circuit safety

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EK10N

3K1

0V

Output stage OK

Error memory OK

Enable output stage

Power supply OK

. . .

Test 3K1

.

70A current limiter

(PID-controller)

.

. .

24 V

Sheet no.

B3

Section B

Steering system

Description of the steering controller

12 10

11 3

4

X2

2

1

2

3

4

5

6

7

8

9

When the supply voltage 1+ 24 V is applied to X1:1 and 2+24V to X1:10, a safety test is carried out. The error memory checks the opened contact of safety relay 3K1 via connections R, L and +.

If this safety test has a positive result, output X1:9 "Safety relay" is set. The steering motor contactor (3K1) responds and closes its contact. As a result, 24V are applied to connections R, L and + of the steering controller.

Once these conditions are met, and if there are no other errors, output X1:9 remains set.

Enabling: When 24V ( deadman ) are applied to input X1:3 "Enable" and the error memory does not register any errors, output X1:8 "OK" is set.

Relay 3K3, "Steering fault" picks up and the travel enable signal at the travel control system (X1:15, brake switch) is set (steering is ready for operation).

If the enable signal is removed from the steering controller, the steering remains active for approximately 2 seconds longer.

A green LED OK (1) indicates that the steering is enabled.

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S E

F 0

D

1

C

2

B

3

A 6 5

4

4

6

3

2

1

7

1

X3

5

9 8

2 I

rot

S

rot

4

5

X4

8

grün

7

OK

6

3

3

- The "Enable" signal is missing at X1.3 (green LED on) - The signal 2+ 24 V is missing at X1.10 - There is a power supply error (internal 15 V) - The contact for the steering motor contactor is not open before the test - The steering motor is faulty or not connected - Actual value error (red LED, "I", 2) - Setpoint error (red LED, "S",3) - Output stage error - Controller error - Short-circuit error

I

2

The enable signal is removed ( with a delay), (green LED goes off) if:

90°

1

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

13

X1

Safety test when vehicle is switched on:

14

See block diagrams (B2-B4)

1

Remark:

5/0123

EK10N

Sheet no.

B4

Section B

Steering system

13 11

4

5

6

7

8

9

10

If the output "Steering OK"( X1:8) is set to 0, travel is not enabled, so that the vehicle is not used with the steering switched off or faulty.

2

3

4 2

X2

1

1

Manual steering: As soon as a movement is made to the left or right with the steering wheel or knob (setpoint), there is a difference in the controller between the setpoint and actual value. The steering motor (actual value) is now driven to the left or right by the controller until this difference from the setpoint is "zero". The steering current is limited internally to 70A.

°

Driving into the rail guide: The rail switch is actuated, the vehicle comes to a standstill, steering is still possible.

The drive wheel is set to the straight-on position by turning the steering knob to the centre detent.

After a wait of approx. 2 seconds, steering is no longer possible. The "straight-on" output (X3:6) of the steering controller is set.

2-handed operation is now necessary.

When the 2-handed switch is pressed, the travel function is enabled again.

F 0

E D

1

C

2

B

3 7 6

5

4

3

4 2

6

9 8

1

X3

5

A

1 2

OK

3

I

8 4

6

3

5

X4

7

S

2

Rail travel error: If the steered wheel is brought out of the centre position by an external force or because of a loose actual value potentiometer, the vehicle is brought to a standstill because there is a steering error; the red actual value LED (2) on the steering controller lights up. The green LED (1) is no longer illuminated.

1

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

3

Remark:

X1

12

Continued

14

Description of the steering controller

5/0123

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EK10N

Sheet no.

B5

Offset potentiometer actual value

Item 3:

Offset potentiometer setpoint

Item 4:

Service switch

2

Item 2:

3

Offset potentiometer steering angle

LED enable "Steering OK"

Item 6:

LED actual value error meter fault, cable breakage, tact)

Item 7:

LED setpoint error cable breakage,

(potentioweak con-

(potentiometer fault, weak contact)

3

4 2

1 °

2 3 4 F 0

E D

1

C

2

B

3 9 8

7 6

3

4

1

2

X3

5

A

5

4

6

Item 5:

X2

5 OK

6

I

7

8 4 2

6

3

5

X4

7

S

1

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

The service switch can be used to adjust the power of the output stage during adjustment work. See sheet nos. B11,12

1

1

Item 1:

4

5

6

7

8

9

Potentiometers and LEDs

10

11

X1

12

Description of the steering controller

14

Steering system 13

Section B

5/0123

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EK10N

Sheet no.

B6

2

3 3

4 2

X2

1

Power supply Power supply Input Input Output Output Output Output Output Input Output Output Output Test output

°

F 0

E D

Terminal X2

1

C

2

B

3

A

Terminal X3

3

4

1

2

6

4

0 volts Steering straight on

Screening Output

I S

X4

8

Output (Power supply) Input Output (Power supply)

6

4 5 6

Setpoint +15 V (w/o load) ≈14,4 V (mit Last) Setpoint (ca. 1.1 - 10.6 V) Setpoint 0 V (w/o load) ≈ 0.6 V (with load)

4

2 3

5

OK

5

1

X3

2

4

Output (Power supply) Input Output (Power supply) Screening

7

2 3

Actual val. +15 V (w/o load) Actual val. ≈14,6 V (w. load) Actual value 7.5 V ± approx. 4,5 V Actual value 0 V (w/o load) Actual val. ≈0,4 V (with load) 0 volts

7 6

3

1

5

9 8

1

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

9 10 11 12 13 14

1+24 volts 0 volts Enable (error reset) Rail / straight-on (+24 V) Actual value < 10° Actual value < 2° Setpoint > 5° Steering error control current +24 V steering OK Safety relay enable 2 + 24 V Option (signal carbon 24V) Actual value > 2° right Actual value > 2° left 7.5 V reference

1

Terminal X1 1 2 3 4 5 6 7 8

4

5

6

7

Pin assignment

8

9

10

11

X1

12

Description of the steering controller

14

Steering system 13

Section B

5/0123

Terminal X4 not used

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EK10N

Sheet no.

B7

Section B

Steering system

Steering controller Id. no. 409 271

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

Main current connections (1) (2)

+24 volt supply via contactor 3K1 Steering motor field connection (left)

(3) (4)

Steering motor field connection (right) 0 volts

3

1

2

5/0510

4

1

2

+24V

3

L

R

4

0V

5/0505

Issue: 07/00 Replaces issue:

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EK10N

Sheet no.

B8

X1

The switch positions for normal operation and commissioning work are different for different vehicle models. For this reason, it is important to follow the information in the appropriate tables.

6 4

5

2

3

4

1 3

2

X2

1

The service switch is not a continuous switch and can only be switched between positions 0 to F and back again. Forcing the switch over the stop between F and 0 will damage it!

°

1 E

Service switch positions:

F 0

D

1

C

2

B

Current

Normal operation

0

4

max.

Reduction to

8

C

30%

Reduction to

9

D

40%

I

Reduction to

A

E

50%

S

Reduction to

B

F

60%

X3

5

4

6

1-gear

4

5-gear

3

Setpoint potentiom.

7 6

2

Steering button

3 9 8

1

Steering wheel

5

A

8 6 4 2

After commissioning or adjustment work the normal operating position must be set again.

3

5

X4

7

OK

1

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

Note:

7

The service switch (1) can be used to limit the maximum output of the steering controller (the steering speed) by reducing the current.

This service switch must be used during commissioning and adjusting work.

(See table below).

8

9

10

11

Adjusting the service switch

12

Steering controller

14

Steering system

13

Section B

5/0123

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EK10N

Sheet no.

B9

1

2

3

4

5

6

7

- Turn off the vehicle (key-operated switch / emergency-off), jack it up safely (drive wheel free) and secure it to prevent it from rolling away.

8

9

Adjustment

10

11

X1

12

Steering controller

14

Steering system 13

Section B

3

4 2

X2

- Check all the connections at the steering motor and steering controller.

1

- Check all the connections at the potentiometers for actual value and setpoint.

3

- Check the steering mechanism.

1 4

- Turn the trimmers for the setpoint actual value offset (1/2) into the centre position.

For this purpose: Turn the potentiometer clockwise until it reaches a stop (clicking is the stop). Then turn the potentiometer anti-clockwise until it reaches a stop. Count the number of turns. Turn back clockwise for half this number of turns.

If you cannot hear a click, turn the trimmer 20 times in any direction. For the centre position, turn the trimmer 10 turns back in the opposite direction.

F 0

E D

1

C

2

B

3 7 6

5

4

3

4

6

9 8

2

X3

5

A

1

- Service switch (4) - adjustment: Steering button (centre detent): F (limited to 60 %) Steering wheel (no detent): B (limited to 60 %)

°

OK I

8 4

6

3

2

5

X4

7

S

Turn the trimmer for steering angle limitation (3) clockwise until it reaches a stop. This represents the smallest possible steering angle.

1

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

2

5/0123

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EK10N

Sheet no.

B 10

4

°

- Actuate the straight-on input X1.4 (1) with 24 V or actuate the rail switch.

S F 0

E D

1

C

- Switch on the vehicle and actuate the deadman's switch.

2

B 5

4

3

4

6

7 6

2

X3

3 9 8

1

Remark: If the drive wheel turns automatically, the connections at the steering motor, steering controller or the actual value potentiometer are connected the wrong way round. Check this!

5

A

OK

- Turn the steering wheel until the steering is locked. 2-handed operation is required. The steering knob must be in the detent and the steering wheel must be in the electrical / ohmic middle.

I

8 4 2

6

3

5

X4

7

S

1

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

- Check the basic setting of the actual value potentiometer (see sheet no. B19/20)

3

X2

2

- Check the basic setting of the steering wheel setpoint potentiometer (see sheet no. B18).

1

1

- Check the basic setting of the steering button setpoint potentiometer with centre detent (see sheet no. B14, 15, 16).

2

3

4

5

6

7

8

9

1

Adjustment

10

11

Steering controller

12

X1

14

Steering system 13

Section B

5/0123

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EK10N

Sheet no.

B 11

3

4

1

2

X2 2

°

Note: The drive wheel moves during this adjustment work!

S F 0

E D

1

C

2

B 5

4

4

6

7 6

3

X3

3 9 8

2

3

5

A

1

OK

- Check the straight-on position of the drive wheel again. To do this, connect 24 V to the straight-on input (rail switch X1.4) and actuate the steering lock. It may be necessary to make a slight correction with the actual value offset potentiometer (1).

I

3

4 2

5

X4

8

S

6

- Actuate the deadman's switch. The drive wheel must not move. If it does, turn the "Setpoint offset" trimmer (2) until the drive wheel stops moving when the signal is removed from the straighton input.

1

7

- Check that the steering button is in the straight-on position. Setpoint specification 7.5V measured at test point X3:2 (3) against 0V battery.

Release the deadman's switch.

Remove 24 V from the straight-on input.

1

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

If the drive wheel cannot be aligned with the actual value offset potentiometer, the basic setting of the actual value potentiommeter must be checked (see sheets B19,20)

1

- If the drive wheel is not now in the straight-on position, the drive wheel must be aligned with the actual value offset potentiometer (1).

2

3

4

5

6

7

8

9

Adjustment

10

11

X1

12

Electronic steering controller

14

Steering system 13

Section B

5/0123

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EK10N

Sheet no.

B 12

- To test the maximum steering angle, make a steering movement from max. right to max. left and back again.

4 2

1 3 1

X2 2

°

3

1 F 0

E D

1

C

2

B A

3 9 8

7 6

5

4

4 2

6

3 1

X3

Note: It is particularly important to ensure that straight-on travel with simulated rail travel (connect 24 V to straight-on input) is correct.

There should only be a minimal deviation (appr. 0.5 m) from straight-on travel over an extended stretch (approx.

10m) .

If necessary, adjust with the "actual value offset" trimmer (3).

5

- Finally check the entire steering function again and readjust with the trimmers if necessary.

OK I

8 4

6

3

2

5

X4

7

S

1

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

- Actuate the deadman's switch and turn it carefully to move the drive wheel to the maximum steering angle.

This must be 90° to both sides.

- The "Steering angle" trimmer (2) (see sheet B2) can now be used for fine adjustment of the 90° steering angle (turning clockwise gives a smaller steering angle).

This must be carried out with both steering angles (right/left).

2

3

- Move the service switch (1) into the operating position: (see sheet nos. B9)

4

5

6

7

Adjustment

8

9

10

11

X1

13

Electronic steering controller

14

Steering system

12

Section B

5/0123

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EK10N

Sheet no.

B 13

Section B

Steering system

Steering button setpoint generator (centre detent and 1-gear potentiometer) Id. no. W8 346 727

Basic setting Basic setting is necessary when the mechanical connection between the potentiometer (2) and the steering head shaft (1) has been disconnected, e.g. to replace the potentiometer.

4

Note: Pull out the battery plug Remove connector X3 of the setpoint potentiometer from the steering controller.

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

-

1

Remove the operating console (see sheet no.

B20, steps 1 and 2).

3

Move the steering button (4) to the centre detent and adjust the centre position of the setpoint potentiometer (2) as follows.

-

Unscrew the threaded pin (1, AF 1.5) of the coupling, turn the potentiometer shaft (3) (with pointed pliers), until the specified measured values are reached.

Ω

MP Total resistance approx. 5kΩ

1-3

Partial resist. approx. 2.5kΩ

1-2

Partial resist. approx. 2.5kΩ

-

.

Setpoint potentiometer

MP1

Trimmer I

2-3

After tightening the threaded pin connect the Ωmeter and test if the value of the resistance changes symmrtrically approx. 2kΩ from the center to the left and right end.

5

6/0224

2

.

X3.3

Ω

.

MP2

.

MP3 Trimmer II

Ω

.

3.2

3.1

Trimmers I and II must be set symetrically to appr.1,2kΩ Test points Trimmer I appr. 1.2kΩ

X3.3 - MP1

Trimmer II appr. 1.2kΩ

MP3 - X3.1

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EK10N

Sheet no.

B 14

Section B

Steering system

Steering button setpoint generator (Centre detent and 1-gear potentiometer)

Id. no. W8 346 727 Basic setting, live The basic setting described on sheet no. B14 can also be carried out live.

Note: When carrying out work with the system live, ensure that you do not cause a short-circuit with a test prod or screwdriver.

V

.

1

Trimmer I

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

.

Setpoint potentiometer

.

.

3 Trimmer II

2

V

.

V

3.1 V

V 7.5V ±4.8V against 0V

approx.

0.4V

approx. 0.4V

15V internal 15V

0V

Test points Setpoint potentiometer Trimmer I * Trimmer II * Setpoint potentiometer centre position Setpoint potentiometer Left turn Setpoint potentiometer Right turn.

Setpoint lift

Issue: 07/00 Replaces issue:

Resistance appr. 5.0kΩ app. 1.2kΩ app. 1.2kΩ app. 3.7kΩ (app 3.7kΩ)

Voltage

1 3.3 3 3.3 (3.2) 3.3

3 1 3.1 3.2 (3.1) 3.2

3.3

3.2

app. 11,9V

3.3

3.2

app. ±4.8V

Workshop Manual

EK10N

app. 10.6V app. 1.75V app. 1.75V app. 7.1V (app. 7.1V) app. 2.3V

Sheet no.

B 15

Section B

Steering system

Steering button setpoint generator (Centre detent and 1-gear potentiometer) Id. no. W8 346 727

Basic setting, mechanical -

Adjusting retaining force of the centre detent Screw the spring pressure piece (1) in or out and secure with the lock nut (2).

The retaining force is set correctly when a precise centre position is maintained by the spring-loaded ball (3) but no pressure is exerted on the shaft.

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

Remark: To ease the movement, squeeze a little grease into the threaded hole.

3 2 4

1

5 6

- Adjusting the steering resistance The adjusting screw (4) presses with disc springs (5) on a plastic bush (6) which surrounds the steering button shaft. This causes a slight steering resistance which is intended to prevent the steering button moving by itself.

Turning clockwise increases the pressure.

The screw does not have to be secured.

-

6/2025

Checking the maximum deflection The turning movement is limited mechanically by adjustable stops. The stops do not usually need to be adjusted. If, however, the maximum steering angles which can be reached (approx. 270°) at the gear are not adequate, despite adjustment at the steering controller and adjustment of the trimmers in the operating console, it may be necessary to alter the mechanical stops.

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EK10N

Sheet no.

B 16

Section B

Steering system

Setpoint generator with centre detent Id. no. W8 346 727

Removal Note:

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

1.

Pull out the battery plug (see A4).

To pull out the handle (3 and 2), the microcellular rubber (2) must be pulled back until the hole (5) for pushing in a piercer or screwdriver is visible.

2.

Remove the operating console by releasing the 2 fastening screws (1, AF 4) and disconnecting the connectors X2A - C (4).

3.

Pull up the rotary handle (6) and unscrew the 2 hexagon socket screws (7, AF 3).

4.

Pull off the 3 board connectors (8) and remove the 10/98 setpoint generator.

2 7

3

5

1

6/0239

4

Removing the setpoint potentiometer Id. no. W8 002 858 1.

Unsolder the potentiometer connections (9).

For assignment see the relevant wiring diagram for the vehicle.

2.

Release the threaded pin (10, hexagon socket screw AF 1.5) the coupling and the nut (11, AF 12) on the potentiometer (12).

3.

Remove the potentiometer.

6

10

Installation

1

To install the potentiometer, follow the above instructions for removal in reverse order.

12 6/0224

Remark:

The setpoint potentiometer must be set to "Centre" after installation (see sheet nos. B14-15).

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8

EK10N

9

Sheet no.

B 17

Section B

Steering system

Setpoint generator with steering wheel Id. no. W8 406 814

Basic setting

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

Remark:

A steering wheel can be installed as an optional extra (potentiometer with 5 or 7 revolutions).

The table on pages B11,12 for switching the service switch must be observed.

2 1

This setpoint generator covers a range of approx.

2520° from one stop to the other.

No mechanical adjustment is required, since there is no centre detent!

Installation and removal are carried out by the same method as for the setpoint generator with a centre detent (see sheet no. B17).

Steering wheel 160 mm diameter (1) Id. no. W8 414 947 Handle (2) Id. no. W8 411 352 Potentiometer (3)

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8/3120

Id. no. W8 406 814

Workshop Manual

EK10N

Sheet no.

B 18

Section B

Steering system

Actual value potentiometer Id. no. W8 408 634

Basic setting The voltage signal influenced by the actual value potentiometer is sent to steering controller X2:2 as a return signal from the steering angle (see B2,3).

In order to set the actual value potentiometer, the potentiometer must be removed.

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

-

Remark:

-

Note: -

Do not press the deadman switch, otherwise the drive will turn.

Actual value 3R10 / 2X2K2

ge

X1:1

X2:1 +

Workshop Manual

X1:3

X1:4

X2:3 -

X2:2 Actual value

gn X1:2

ws/rt

Steering controller

Connect the test unit to the potentiometer slider (X1:4 poti,wsrt) and battery 0V. Set the potentiometer to 7.5V. Reinstall the potientiometer (take care with the guide, see note above).

Turn the drive wheel until the cheese-head screw (1) is accessible (potentiometer axis must turn too) Screw the potentiometer in place again Check straight on travel and correct with the actual value offset potentiometer (see B11-13).

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3 0/0181

If the screw (1) is removed completely, there is no guide (3) in the flange of the steering motor.

Remove the potentiometer (4).

Turn the drive wheel into the straight-on position.

Switch on the vehicle.

4

1

.

-

2

Set the actual value offset potentiometer to the centre (see B10).

Set the drive wheel so that the cheese-head screw (1) is easily accessible.

Switch off the vehicle.

Unscrew the potentiometer holder (2).

Release the cheese-head screw (1) just enough to allow the potentiometer to be removed when it is pulled gently.

.

-

EK10N

Sheet no.

B 19

Section B

Steering system

Actual value potentiometer Id. no. W8 408 634

Removal -

Set the drive wheel so that the cheese-head screw (1) is easily accessible.

Switch off the vehicle.

Pull connector X1 (7) from the potentiometer.

Unscrew the potentiometer holder (2).

Release the lock nut (5) and unscrew the cheesehead screw (6).

Release the cheese-head screw (1) just enough to allow the potentiometer to be removed when it is pulled gently.

-

If the screw (1) is removed completely, there is no guide (3) in the flange of the steering motor.

2

Remove the potentiometer (4).

1

Installation

4

3 0/0181

To install the actual value potentiometer, follow the instructions for removal in reverse order.

Remark:

After installation, basic setting of the potentiometer must be carried out and the steering must be readjusted.

5 2

1

Actual value 3R10 / 2X2K2

.

ge

X1:1

X2:1 +

.

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

Remark:

0/0183

X1:3

X1:4

X2:3 -

X2:2 Actual value

gn X1:2

ws/rt

6 4

Steering controller

7 0/0184

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EK10N

Sheet no.

B 20

Section B

Steering system

Servo unit Id. no. W8 416 142

General Signal carbon brush

The servo unit consists of: -

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

-

a 24V direct current motor (1) with two separate series field windings (split field motor) and

Temperature monitor

1

a flange-mounted gear (2).

Remark:

The gear is maintenance-free.

2

It is possible to reverse the polarity for clockwise and anti-clockwise rotation.

The servo unit is controlled by the electronic steering controller / steering output stage.

Note:

Adjusting spring

Series-wound motors must never be left without a load for an extended period of time, i.e. they must not be run without gears etc. If they are left in this way, their speed increases independently until they become irrepairably damaged.

5/0048

2+24V A1 M

D2

D1

+

R

L

Steering controller

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EK10N

Sheet no.

B 21

Section B

Steering system

Servo unit Id. no. W8 416 142

Terminal board Designation at the motor A1

Armature winding

D1 / Dr

Field winding right

D2 / Dl

Field winding left

A1

Dl

Dr

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

5/0050

Technical data for servo unit Model designation

R 100/0,15-225/172-81-18 JP20

Excitation type

Series circuit

Voltage

24 V

Current

11 A

Rated output

150 W

Direction of rotation

right/left

Protection / insulation class

JP 20 / F

Gear

18:1

Circuit

diagram

Signal carbon brush

Temperature monitor

5/0049

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Sheet no.

B 22

Section B

Steering system 1

Servo unit Id. no. W8 416 142

Removal 2

- Pull out the battery plug (A4) - Remove the motor connecting cable (1) - Remove the 4 cheese-head screws (2) from the flange (3)

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

- Lift the servo motor (4) with flange (3) up and out - Remove the 4 cheese-head screws (5) from the underside of the flange - Remove the servo motor

6 4

2 7

3

5

Installation To install the servo motor, follow the instructions for removal in reverse order.

Remark:

On installation, ensure that the connecting field (6) is mounted opposite the flat part (7) of the flange (3).

Remark:

After installation, the steering lock and straight-on travel must be reset (see sheet B11-13).

0/0186

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EK10N

Sheet no.

B 23

Section B

Steering system

Servo unit Id. no. W8 416 142

Replacing the carbon brushes 3

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

Detailed information on this subject is provided in the instruction for the travel motor (see sheet A6).

1 2

2 carbon brushes can be built into the servo unit.

Either: 2 x brushes (1): Id. no. W8 013 531 or: 1 x brush for carbon brush monitoring (optional) (2): Id. no. W8 002 999, can be identified by the connection wires and at the terminal board and 1x carbon brush W8 013 531.

4 1x brush (2): Id. no. W8 002 999 Remark:

In vehicles without carbon brush monitoring, two carbon brushes with Id. no. W8 013 531 may be installed.

Length of a new carbon brush: Change when residual length is:

6/2032

22 mm 11 mm

Brush spring (3) Id. no. W8 402 301 A tension spring is used to fix the perforated tensioning belt.

Tension spring (4) Id. no. W8 417 155

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Sheet no.

B 24

Section C

Brake system

Contents Sheet no.

Electromagnetic spring brake General ..................................................................................................................C 2 Function .................................................................................................................C 3 Removal and installation / Checking the rotor / Removing the hub .......................C 4

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

Dismantling ............................................................................................................C 5 Adjusting the brake clearance................................................................................C 6 Adjusting the braking force ....................................................................................C 7 Maintenance ..........................................................................................................C 8 Measuring the brake deceleration..........................................................................C 9

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Sheet no.

C1

Section C

Brake system

Electromagnetic spring brake Id. no. Complete brake: Id. no. Rotor:

W8 423 407 W8 424 837

General

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

The brake used in this vehicle is constructed using the deadman's principle.

It acts as both the service brake and the handbrake.

The spring brake is a closed-circuit brake with two friction surfaces. The braking force, which can be adjusted with a central adjusting device, is generated by spring resistance.

The brake is released electromagnetically.

The brake clearance and the braking force of this brake can be adjusted.

Nameplate

0/0177

Explanation of the nameplate BFK458 - 12 E Brake product group Spring brake Model Size Design adjustable Connection voltage 24V

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Sheet no.

C2

Section C

Brake system

Electromagnetic spring brake 1

Function Fig. 6/0072 shows the brake 1Y44 when it is currentless, i.e., when it is in braking position.

6/0071

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

1. Deadman's switch (1) in the surface not actuated: The compression springs (4) press the armature disc (2) axially against the rotor (3) and this in turn agains the surface A - B.

4

5

2. Deadman's switch actuated: The coil in the magnetic brake is excited with direct current and the magnetic circuit between the armature disc (2) and the magnetic section is closed.

The armature disc (2) moves axially in the direction of the fixed magnetic section, the gap "a" is reduced to "zero" and the rotor (3) can be moved freely.

a B

A

6/0072

3. Steering error when deadman's switch 2 actuated: If there is no steering error, the spring brake is 1F4 excited, as described under "Deadman's K1 switch actuated" and enables the drive.

1K34 If a steering error occurs, relay 3K3 (steering error relay) drops out and switches the excitation of the magnet viatravel control output 1S25 1F11 X1:8, the brake moves into the braking positiDeadman on (see "deadman switch not actuated"). switch 4. Braking error: If the vehicle does not brake correctly (generator braking), internal relay K1 is opened in the braking monitor (ABÜ). The brake goes into braking position (see "deadman switch not actuated").

X3:9

X3:4 X2:3

K1 X3:1

ABÜ

3

only with EK10 high lift

X8:6 U51 X3:6

1Y44 3K3 Steering controller X1:8

Enable X1:15 Travel control

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EK10N

Sheet no.

C3

Section C

Brake system

Electromagnetic spring brake Removal Caution:

Once the brake has been removed, the vehicle is no longer braked, so the vehicle must be secured to prevent it rolling away.

1 X2

1.

Pull out the battery plug (see A4).

2.

Disconnect the lead to the magnet at the connector.

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

Remark:

The connector X29 (1) may be in the cable duct.

3.

Check the polarity and note the connections if necessary.

4.

Release the 3 hexagon socket screws (2) gradually in several passes.

5.

The magnet body (3) can now be lifted off.

6.

Pull off the rotor (4).

6/0074

2 3

Checking the rotor Id. no. W8 410 216 5 Remark:

Thickness of a new rotor: 12 mm Replace when thickness is: 6 mm (when worn symetrically)

4

- Check ease of movement and - that it is firmly seated on the hub (no play) and - Condition of surface (porous, cracked) Remark:

6/0073/.1.2

If the rotor causes noises during travel, check concentricity and bearing clearance of the armature shaft of the travel motor.

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Sheet no.

C4

Section C

Brake system

Electromagnetic spring brake

4

Dismantling 1. Unscrew the 3 adjusting sleeves (1).

2. Remove the 4 compression springs (2).

Remark: The 3 other compression springs, which are not adjustable, are positioned in the outer pocket holes.

3 2

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

3. Remove the 4 pressure elements (3).

4. Unscrew the adjusting ring (4).

Remark:

1

The pressure elements (3) are rounded on one side.

When reassembling, ensure that the rounded side faces the adjusting ring (4).

6/0075

3

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

4

6/0072

6/0076

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Sheet no.

C5

Section C

Brake system

Electromagnetic spring brake

Adjusting the brake clearance General

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

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

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

a B

A 6/0072

Fig. 1

Adjustment process

3

4

2

1. Move the adjusting sleeves (4) up into the magnet section.

2. Use the adjusting screws (5) to set dimension "a" to 0.4 mm.

3. Check dimension "a" at at least 3 points with a feeler gauge (close to the screws (5)).

4. Do up the adjusting sleeves (4) back down and check dimension "a".

Repeat steps 2-4 if necessary.

Remark:

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Every time the lining is replaced a check must be made to ensure the rotor (2) runs freely on the hub (3).

Workshop Manual

0,4 mm 6/

Fig. 2

EK10N

Sheet no.

C6

Section C

Brake system

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

2

1

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

The braking force can be checked with a dynometer (see sheet nos. C9 and C10).

a

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

6/

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

Anti-clockwise rotation of adjusting ring: --> Braking force reduced (distance longer) Clockwise rotation of adjusting ring: --> Braking force increased (distance shorter) Remark:

If this adjusting device no longer allows a reduction in the braking force when this is needed, the outer compression springs (6) can be removed if necessary (see C5 Dismantling the brake).

These outer compression springs are positioned in pocket holes and cannot, therefore, be adjusted.

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Sheet no.

C7

Section C

Brake system

Electromagnetic spring brake

Maintenance

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

The following steps must be carried out or taken into account during maintenance work: -

Adjustment of the brake clearance (see sheet no. C 6).

2

-

Adjustment of the braking force (see sheet no. C7).

1

-

Replace rotor (1) if chipped or unevenly worn.

-

The rotor (1) must be able to run easily up and down on the hub (2).

-

Clean all oil from the brake with compressed air.

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6/

EK10N

Sheet no.

C8

Section C

Brake system

Measuring the brake deceleration General 2

The brake deceleration value is measured with the dynometer (Fig. 1), Id. no. W8 050 605.

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

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

During travel at a steady speed over an even surface, the pendulum always hangs vertically and shows zero on the dial (Fig. 2). On acceleration, the pointer deflects to the right (clockwise) and on braking (deceleration), it moves to the left.

1 5/0115

Fig. 1

Preparations for measurement Moisten the rubber sucker on the underside of the measuring instrument (ideally with glycerin), then use the lever (Fig. 1, no. 1) to fasten the dynometer onto a horizontal surface.

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

Before every deceleration measurement, the measuring case (Fig. 1, no. 2) must be tipped to move the measuring pointer to zero. The dynometer has been set to the correct zero position by tipping the case when the measuring pointer can move almost a full turn to the the left (anti-clockwise) from zero and almost half a turn to the right.

5 3

5/0116

Fig. 2

4

The maximum pointer (Fig. 2, no. 3) must be reset manually, by turning the knob at the centre of the dial (Fig. 2, 4) clockwise, until the pointer is set as closely as possible to zero.

During the braking process, the maximum pointer moves to the maximum deflection point together with the measuring pointer and remains there when the other moves back (Fig. 3).

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Fig. 3

5/0117

Deceleration in %

EK10N

Sheet no.

C9

Section C

Brake system

Continued

Measuring the brake deceleration

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

Evaluating the measurement 1.

Calculate the maximum vehicle speed (V = distance/time).

2.

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

3.

Stop the vehicle by applying the brakes with full force, and read the braking deceleration value "F" off the dynometer (i.e. the maximum pointer reading).

4.

The braking deceleration value required for the calculated speed can be found in the graph below.

Example: Measured speed 7km/h Required braking deceleration 7%

% Deceleration

9 7 4

2

4

6

8

10 11 12

13

km/h 6/0079

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Sheet no.

C 10

Section D

Slide carriage

Contents Sheet no.

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

Replacing the idling wheels ...............................................................................D 2

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EK10N

Sheet no.

D1

Section D

Slide carriage

Replacing the idling wheels Id. no. W8 410 551 (complete) Dimensions when new: Ø 150 x 100

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

The idling wheels must be replaced when -

the surface is deeply pitted or out of round or is cracked,

-

the tyre diameter has decreased by 10% (minimum permissible tyre diameter 135 mm).

Removal 1. Bring the support carriage or cab to a lift height at which the idling rollers are easily accessible.

2. Support the support carriage or cab safely from below to prevent it falling.

1 2

3. Jack up the vehicle and support it safely from below.

3

4. Unscrew the screw (1).

4

5. Pull out the safety pin (2).

8/

6. Push out the bolts (3).

7. Remove the idling wheel (4).

Remark:

To reinstall the wheel, follow the instructions above in reverse order.

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Sheet no.

D2

Section E

Lifting device

Contents Sheet no.

Removing the support carriage and guide rollers on NO, NM*..............................E 2 Removing the cab and guide rollers on HO, HM* ..................................................E 3 Removing the main lift chains on HO, HM*............................................................E 4 Removing the additional lift chains on NM, HM*....................................................E 5

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

Removing the lift bracket and guide rollers on NM, HM* .......................................E 6 Removing the additional lift on NM, HM* ...............................................................E 7 Chain inspection and maintenance........................................................................E 8

* For definition see Foreword, Sheet I.

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Sheet no.

E1

Section E

Lifting device

Removing support carriage on NO, NM 1 1. Remove the operating console (1) (see sheet no. B21).

3

2

2. Pull out the battery plug (see sheet no. A4).

3. Remove the cover (2): release the 4 hexagon socket screws with AF (3), and remove the cover.

9

8

4. Disconnect the cable connections (4 and 5) and pull them through towards the support carriage.

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

Remark:

7 6

On vehicles with an additional lift, the hydraulic hoses must be removed from the additional lift cylinder and both the hoses and the cylinder sealed off with sealing plugs.

8/

5. Remove the circlip (6) with pair of retainer ring pliers. Use a pulley or fork-lift truck to pull the support carriage up and out of the mast profile.

6. To reinstall the support carriage, follow the removal instructions above in reverse order.

Removing the support rollers

4

1. Remove the support carriage (see above, points 1-5) 2. Unscrew the 2 flat-head screws (7), pull off the 2 support rollers and remove the 2 shims (9).

8/

3. To reinstall the support rollers, follow the removal instructions above in reverse order.

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Sheet no.

E2

5

Section E

Lifting device

Removing the cab on HO, HM

1

1. Remove the operating console (1) (see sheet no. B21).

2. Remove the cover (2) (see sheet no. E2) 3. Remove the main lift chains (see sheet E4) Note:

Because both chains have to be taken out in order to remove the cab, the cab must be secured to prevent it falling (use support trestles, pulley, or similar device).

2 7

4. Pull out the battery plug (see sheet no. A4).

6 5

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

5. Disconnect the cable connections (3 and 4) and pull them through towards the cab.

8/

Remark:

On vehicles with an additional lift, the hydraulic hoses must be removed from the additional lift cylinder and both the hoses and the cylinder sealed off with sealing plugs.

6. Use a pulley or fork-lift truck to pull the cab up and out of the mast profile.

7. To reinstall the cab, follow the removal instructions above in reverse order.

Removing the support rollers 3 1. Remove the cab (see above, points 1-6).

2. Unscrew the flat-head screw (5), pull of the support roller (6) and remove the shim (7).

Remark:

4

The complete set of support rollers must always be replaced.

8/

3. To reinstall the support rollers, follow the removal instructions above in reverse order.

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Sheet no.

E3

Section E

Lifting device

Removing the main lift chains on HO/HM

1. Remove the cover (see sheet no. E2, point 2) 2. Raise the cab until the chain tensioning screws are easily accessible.

Note:

Support the cab to prevent it falling (use support trestles, pulley, or similar device)

2

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

3. Release the chain tensioning screw (1) completely.

4. Remove the lock (screws, nuts) from the chain holder support (2).

8/

5. Pull the chain (3) down and out of the chain holder support (2) together with the chain holder (4).

6. Remove the chain (3).

7. To reinsert the chain, follow the removal instructions above in reverse order.

Note:

The chains must be replaced one after the other, since the chain left in the vehicle acts as a safety chain.

3

4 1

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8/

Sheet no.

E4

Section E

Lifting device

Removing the additional lift chain on NM/HM 5

1. Raise the additional lift to approx. 200 mm, and support it safely from below on both sides.

2. Unscrew the cover (1) of the chain guide (2 x hexagon socket screws M10x16).

3. Open the chain tensioner (3) completely (unscrew both nuts (4)).

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

4. Remove the lock (screw, nut) from the chain link holder (7) on the lift bracket.

1

3 4 6

2

2

5. Remove the chain (5) and pull the chain link (6) down and out of the chain link holder (7) on the lift bracket (8).

6. To reinstall the additional lift chain, follow the removal instructions above in reverse order.

8/

8

7 8/0023.1

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Sheet no.

E5

Section E

Lifting device

Removing the lift bracket for additional lift on NM/HM 4

1. Raise the additional lift to approx. 200 mm, and support it safely from below on both sides.

2. Remove the chain from the additional lift (4) (see E5).

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

3. Move the main lift until the lift bracket (5) is free, i.e. is no longer guided in the mast profile. Drive the vehicle away from the lift bracket.

4. To reinstall the lift bracket, follow the removal instructions above in reverse order.

Removing the support rollers

8/

5

1. Unscrew 2 x flat-head screws (1).

Pull off 2 x support rollers (2) and remove 2 x shims (3).

Remark:

3

2 1

The complete set of support rollers must always be replaced.

7 8/0023.1

2. To reinstall the support rollers, follow the removal instructions above in reverse order.

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Sheet no.

E6

Section E

Lifting device

Removing the additional load carriage on NM/HM 1. Remove the chain from the additional lift (see sheet no. E5).

1

2. Remove the lift bracket on the additional lift (see sheet no. E6).

3. Retract the cylinders.

2

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

4. Pull out the battery plug (see sheet no. A4).

5. Remove the cover from the additional lift (1).

Release the 4 screws M6 x 16 (2) and lift the cover up and out of the aditional load carriage (3).

3

8/

6. Disconnect the cable from the two-handed operation switch.

7. Remove the cylinder of the additional lift (5) (see sheet no. F5).

Remark:

Secure the additional lifting device to prevent it falling over

6

or down (pulley or similar device).

8. Unscrew the 4 cheese-head screws M12x70 (6) with AF10 and 2 cheese-head screws M12x30 (7) with AF 10 and remove the additional load carriage.

7 5

8/

4

9. To reinstall the additional load carriage, follow the removal instructions above in reverse order.

8/0023.1

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Sheet no.

E7

Section E

Lifting device

Chain inspection and maintenance

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

Checking the flyer chains The load or control chains must be inspected when they are installed with at least 10% of the rated load. The elongation must not be more than 3% (3 % is approximately equal to one single link). The measurement must be taken in the operating area of the chain. The permissible wear of 3% is equivalent to half a double link for every 17 double links.

This means: if 16.5 used double links are the same length as 17 new ones, the maximum wear limit has been reached. The chain must be replaced (17 double links = 34 single links = 35 chain pins).

1 double link

6/0218

Sample measurement still includes 16 1/2 double links 17 double links of an elongated chain Elongation 1/2 a double link

Chain maintenance All joints, chain holders and chain tensioning screws must be checked to ensure that they are secure. In order to guarantee that the chains run smoothly, they must be lubricated regularly with chain spray.

Remark:

Before treating the chains with chain spray, they must always be cleaned with a spray cleaner or similar product.

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Sheet no.

E8

Section F

Cylinders

Contents Sheet no.

Cylinder support ...................................................................................................F 2 Removing main lift cylinder on NO/NM* ...............................................................F 3 Dismantling main lift cylinder on NO/NM* ............................................................F 4 Removing main lift cylinder on HO/HM* ...............................................................F 5

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

Dismantling main lift cylinder on HO/HM* ............................................................F 6 Removing main lift cylinder on NM/HM*...............................................................F 7 Dismantling main lift cylinder on NM/HM* ............................................................F 8 Line break protection............................................................................................F 9

* For definition see Foreword, sheet I

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EK10N

Sheet no.

F1

Section F

Cylinders

Cylinder support Suitable trestles should be used for dismantling and supporting the cylinder components, so that their surface is not damaged.

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

6/1048

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EK10N

Sheet no.

F2

Section F

Cylinders

Main lift cylinder on NO/NM Removal 1. Remove the support carriage (see E2).

2. Remove the cylinder (1) from its seat (2) on the chassis.

3. Remove the hydraulic hose (3) from the cylinder (1), and seal the cylinder and hydraulic hose with sealing plugs.

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

4. To reinstall the cylinder, follow the removal instructions in reverse order.

2 1

Remark:

On vehicles with an additional lift, the hydraulic hoses (4) must be removed from the additional lift cylinder (5). The hoses and cylinders must be sealed with sealing plugs.

8/0032

1 3

5. After installation, the cylinders and the hydraulic system must be bled (see N17).

Note:

6 8/0033

The line break protection is in the pressure connection of the main lift cylinder (6, see sheet no. F9).

3 1 4 Main lift

6

5 8/0034

Additional lift

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EK10N

Sheet no.

F3

Section F

Cylinders

Main lift cylinder on NO/NM Dismantling 1. Release the lock nut (1) with a hook spanner.

2. Release the cylinder head (2) with a hook spanner and unscrew it.

4

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

3. Pull the piston rod (3) up and out of the cylinder barrel (5).

4. Check the set of seals (4) in the cylinder head (2) and replace if necessary.

Id. no. W8 420 092 Remark:

The entire set of seals (4) must always be replaced.

2 4 3

1

5. To reassemble the cylinder, follow the dismantling instructions in reverse order.

Remark:

a) When ordering the set of seals, always state the Id. no. of the cylinder.

5

b) After assembly, the cylinder and the hydraulic system must be bled (see N17).

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8/0035

EK10N

Sheet no.

F4

Section F

Cylinders

Main lift cylinder on HO/HM

1

Removal 3 1. Remove the cab (1) (see E3).

2. Remove the main lift chains (2) (see E4).

4

3. Remove the trailing cable (3) from the guide rollers.

2

4. Lower the main lift cylinder (6).

5. Take off the (4) by removing the 2 cheese-head screws M10x12 (5).

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

6

5

6. Remove the main lift cylinder (6) from its seat on the chassis.

7. Unscrew the hydraulic hose (7), and seal the cylinder and hose.

8/0036

8. To reinstall the cylinder, follow the removal instructions in reverse order.

6 7

Hinweis:

On vehicles with an additional lift, the hydraulic hoses (9) must be removed from the additional lift cylinder (10). The hoses and cylinders must be sealed with sealing plugs.

8 8/0033

7 6

Caution:

The line break protection (8) is in the pressure connection of the main lift cylinder.

9 Main lift

8

10 8/0034

Additional lift

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EK10N

Sheet no.

F5

Section F

Cylinders

Main lift cylinder on HO/HM Dismantling 5 1. Unscrew the bearing fork (5).

2. Release the lock nut (1) with a hook spanner.

8/0037

3. Release the clinder head (2) with a hook spanner and unscrew it.

4. Pull the piston rod (3) up and out of the cylinder barrel (6).

3

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

4 5. Check the set of seals (4) in the cylinder head (2) and replace if necessary.

Id.No. W8 420 092 Remark:

The entire set of seals (4) must always be replaced.

6. To reassemble the cylinder, follow the dismantling instructions in reverse order.

Remark:

a) When ordering the set of seals, always state the Id. no. of the cylinder.

4 2 1

5

b) After assembly, the cylinder and the hydraulic system must be bled (see N17).

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8/0039

EK10N

Sheet no.

F6

Section F

Cylinders

Additional lift cylinder on NM/ HM Removal 1. Remove the additional lift bracket (1) (see E6).

2. Lower the additional lift cylinder.

3. Take off the retainer clip (3) by removing the 2 cheese-head screws M10x20.

2

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

4. Remove the additional lift cylinder from its seat (5).

5. Unscrew the hydraulic hoses (6) and seal the cylinder and hoses with sealing plugs.

6. To reinstall the cylinder, follow the removal instructions in reverse order.

3 5

4

8/

1

7. After installation, the cylinders and the hydraulic system must be bled (see N17).

8/0023.1

6

8/0034t

Additional lift

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EK10N

Sheet no.

F7

Section F

Cylinders

Additional lift cylinder on NM/ HM Dismantling 5

1. Unscrew the bearing fork (5).

8/0038

2. Release the lock nut (1) with a hook spanner.

3. Release the clinder head (2) with a hook spanner and unscrew it.

4

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

4. Pull the piston rod (3) up and out of the cylinder barrel (6).

5. Check the set of seals (4) in the cylinder head (2) and replace if necessary.

Id.Nr. W8 420 092 Remark:

The entire set of seals must always be replaced.

2 4 3

1

6. To reassemble the cylinder, follow the dismantling instructions in reverse order.

Remark:

a) When ordering the set of seals, always state the Id. no. of the cylinder.

6

b) After assembly, the cylinder and the hydraulic system must be bled (see N17).

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8/0035

EK10N

Sheet no.

F8

Section F

Cylinders

Cylinders Line break protection type LB-3/8 Id. no. see table 2

General

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

The line break protection (1) prevents an uncontrollable sinking movement if the hydraulic lead to the cylinder in question breaks. The line break protection is installed for the hydraulic hose (2) of the lift cylinder.

Type LB is a plate valve. When it is inactive, its valve plate is lifted from the valve seat by a spring and maintains a set flow cross-section.

The forces of flow resistance and dynamic pressure at the valve plate in the flow direction B -->F (operational or triggering direction) are subject to the counteracting force of the spring during normal operation and the valve remains open.

8/0033

1

Symbol simplified

(F

detailed

(B)

F

B 6/0545

If the flow rate increases because a line has broken, the flow forces exceed the force of the spring and the valve closes immediately.

Remark:

A special tool is needed to remove the line break protection.

Id. no. W8 044 065 (3) 1 6/0552

Continued on sheet no. F 10

3

6/0104

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EK10N

Sheet no.

F9

Section F

Cylinders

Cylinders Continued

Line break protection type LB-3/8 Valve for full support of the load

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

The valve plate largely covers the ring-shaped seat. Leakage through the fixing thread does not have any significant effect.

The load remains in the lift position it has just reached. The fault can be rectified either immediately or after the load has been supported from below, depending how high the safety risk is.

The valve is then opened again by feeding hydraulic fluid into the consumer.

Remark:

Issue: 07/00 Replaces issue:

8/0031

The gap width S determines the point at which the valve is triggered.

This is set by the manufacturer and may on no account be altered.

Workshop Manual

EK10N

Sheet no.

F 10

Section M

Electrical system

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

Contents

Sheet no.

Block diagram ...............................................................................................M 2 Highpuls control system ..............................................................................M 3 - General .........................................................................................................M 3 - Complete travel control system. ...................................................................M 4 - Main current circuit - connections. ................................................................M 4 - Input and output signals................................................................................M 5 - Output signals...............................................................................................M 6 - Setpoint generation.......................................................................................M 7 - Safety monitoring..........................................................................................M 11 - Error display..................................................................................................M 12 - Flashing error code.......................................................................................M 13 - Adjustment....................................................................................................M 14 - Adjustment with the Curtis PCM 1307 programming unit .............................M 15 - General data .................................................................................................M 30 Modules .........................................................................................................M 31 - Adaptation option (3U51), Id. no. W8 406 560 .............................................M 31 - Evaluation logic (U51), Id. no. W8 406 561 ..................................................M 35 - LED displays.................................................................................................M 40 - Error code table for electronic evaluation system.........................................M 41 ABÜ (Breaking monitor) ...............................................................................M 42 - Function ........................................................................................................M 42 - Block diagram ...............................................................................................M 43 - Pin assignment .............................................................................................M 44 - Error code .....................................................................................................M 46

Battery discharge indicator "Curtis display unit" .............................................M 47 Changing the battery.......................................................................................M 49

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Sheet no.

M1

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3K3

Workshop Manual

EK10N

Sheet no.

EAZ /BSZ error code

Display

Brake

Speed

Travel motor

1K34

Pump off

BSZ

Key-switch on

Speed sensor

Travel Control 1A10

Mode 1

Travel setpoint

2K1

Hydraulic motor

+24V

K1

K1

+24V

3K1 closed

Setpoint pot.

+24V

+24V

Steering OK

3K3

3K1

Act val. pot

Steering motor

+24V

Steering controller 3A20

Lowering button

Lifting button

Lifting button

Steering safety

Enable

Emergency stop button

Key-switch

+24V

Braking monitor U50

Deadman

Travel direction switch

Enable

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

Section M Electrical system

M2

Section M

Electrical system

Highpulse control General 1

The "Highpulse" pulse control (1) that has been used since 07/00 is a control system that uses the well-proven power MOSFET technology and is micro-processor controlled.

The pulse control allows stepless and low-noise control of the motor torque and motor speed for shunt motors.

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

The travel direction is achieved by reversing the polarity of the field in the motor, so that the travel direction contactors are no longer necessary.

0/0187

The micro-processor has direct control of the following input signals: - Direction sender (travel transducer error) - Overcurrent - Overvoltage and undervoltage - Overtemperature and undertemperature - Welding together of contacts - Hardware error - Start-up protection - Short circuit

2

So that the speed and output of the drive motor can be changed from 0 to 100 %, control of the transistors is changed with pulse width modulation (PWM).

The Highpulse control system has an internal and an external safety monitor. e.g. monitoring: - of error-free program sequence - for cable breakage, etc. (see error list M11) Error diagnosis can be carried out easily with an LED (2) which is fitted in the control section.

Diagnosis information can be read out, and tests and configurations can be carried out and set using parameters and a programming unit.

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EK10N

Sheet no.

M3

Section M

Electrical system

Complete travel control The complete switchboard for the EK10 consists essentially of the following components:

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

No Designation

Component

Id. no.

1

Travel control

1A10

W8 408 890

2

Drive motor contactor

1K34

W8 004 174

3

Main contactor

K1

W8 400 605

4

Pump contactor

2K1

W8 402 864

5

Steering contactor

3K1

W8 004 174

6

Travel fuse

1F4; 160 A

W8 006 406

7

Lifting fuse

2F1; 160 A

W8 006 406

8

Steering fuse

3F1; 35 A

W8 006 418

9

Control current fuse

F2 ; 7.5 A

W8 401 894

10 Steering contr. fuse

3F5 ; 7.5 A

W8 401 892

11 EM brake fuse

1F11,

W8 401 892

3A

12

15 11 10 9 8 5

0/0187

1

13 14

12 Diagnosis LED 13 Buffer capacitor, steering

W8 002 760

14 Braking monitor

W8 408 899

15 Steering OK relay

3K3

W8 014 372

0/0188

2 Remark:

Issue: 07/00 Replaces issue:

6 3

7

4

If a travel control unit (1) is removed and then installed again, heat conducting paste (Id. no. W8 405 113) must be applied on installation, between the heat sink and the switchboard.

Workshop Manual

EK10N

Sheet no.

M4

Section M

Electrical system

Highpulse control Main current section - terminals

4

3

16

9

2

1

8

1

The B+ terminal

S1

is connected indirectly to the positive battery pole and directly with armature A1 of the motor via contactor 1K34.

It is connected internally with the cathodes of the freewheeling diodes and the capacitors.

S2

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The B- terminal is connected to the negative battery pole. It is connected internally with the source of the power MOSFET and the capacitors.

0/0189

B-

M-

B+

The M- terminal is connected to the armature A2 of the motor. It is connected internally with the drain of the power MOSFET, the anodes of the armature diodes and the anodes of the freewheeling diodes.

The S1 / S2- terminal is connected to shunt field F1 and F2 of the motor.

Remark: The travel direction of the vehicle with forwards direction depends on the polarity of S1 and S2.

0/0225

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EK10N

Sheet no.

M5

Section M

Electrical system

Highpulse control Input and output signals

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

The input and output signals take place via the 16-pin connector X1 (1) and the 4-pin connector X3 (3), which is connected directly at the control section housing (2).

Inputs connector X1

16

9

Pin 16:

8

1

2+24 V power supply via key switch and emergency-stop key. This initialises the control system and an internal monitoring circuit starts.

Pin 15: 2 +24 V brake switch input when deadman switch is actuated.

Travel enable.

Pin 14: Input 1 mode (see table 1) Pin 13: Body switch input not occupied Pin 12: Travel direction input, +24 V (forwards) Pin 11: Travel direction input, +24 V (reverse) The power stage of the control system is enabled via inputs 12 and 11.

Pin 9: Input 2 mode (see table 1) Pin 7: 0V power supply for travel transducer Pin 6: Setpoint input, travel transducer Pin 5: + power supply of travel transducer not occupied Pin 2: Input, hour meter start Pin 1: Pressure sensor not occupied Table 1:

1

0/0189

2 4

3

2

1

Operating mode selection

Mode switches 1 and 2 determine the mode.

Mode 1 applies automatically when pins 9+14 are not occupied.

Open = 0 = 0V Closed = 1= 24V

3

Operating mode Mode switch 1

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Mode switch 2

1

Open

Open

2

Closed

Open

3

Open

Closed

4

Closed

Closed

Workshop Manual

EK10N

Sheet no.

M6

Section M

Electrical system

Highpulse control Continued Connector X1 Outputs connector X1 Pin 10: not occupied

Connector X3

Pin 8: Output, auxiliary brake driver Pin 4: Switched negative for main contactor 1K34 enable travel

4

3

2

1

Pin 3: Lift stop

Connector X3 Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin 1: n.c.

Pin 2: 0V/GND Pin 3: data transfer Pin 4: +15V

Belly switch

Forwards

Reverse

Input 1 mode

5kΩ-0 potentiometer

Input 2 mode

Enable

Main contactor coil Key switch Reverse voltage protection diode Control fuse Main contactor Power fuse

- - - - Test lead, belly switch wiring (optional) 0/0190

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EK10N

Sheet no.

M7

Section M

Electrical system

Highpulse control Safety monitoring The Highpulse control has an internal monitoring circuit and a safety monitor for external components.

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

The range of tests includes:

1

- Potentiometer monitoring for cable breakage and short circuit and inadmissible values - Testing of the switching-on sequence - Short-circuit monitoring and overcurrent detection for the switching outputs (main contactor).

- Monitoring for contactor contacts welded together (main contactor).

- Failure monitoring of the switching outputs.

- Overtemperature monitoring Current reduction from Imax at 85°C to 0 at 95°C. - Undertemperature monitor Current reduction to 50% below -25°C. - Undervoltage (16 V) Reduction of the travel current until voltage is no longer below the undervoltage limit (control system switches off below 16 V).

- Short-circuit monitoring, B- to M- (MOSFET) - Overvoltage (45 V) - control system switches off - Short-circuit monitor, drive motor

0/0187

The errors that occur are displayed on the status LED (1) with a flashing code.

All errors are stored in an EEPROM. They can be read out using the service software or on the programming unit.

Errors can generally be reset with the key switch once the error situation has been rectified.

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EK10N

Sheet no.

M8

Section M

Electrical system

Highpulse control Error display When an error is detected, a status LED (1) indicates the type of error with a 2-position flashing code and the error is shown on the display (Spyglass) as an error code (M11).

If no error is detected, the status LED flashes a single pulse about once a second.

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

The LED is in the control section on the nameplate.

0/0187

The code is displayed by means of the flashing LED until the error is reset by switching the control unit off and then on again (enable switch or key switch), on condition that the error has been rectified.

1

Comment: Only one error is ever shown at one time, and this is the last error that has occurred.

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EK10N

Sheet no.

M9

Section M

Electrical system

Travel control Flashing code for errors

Flashing code - example: (hardware error)

The following diagnosis information is generated by the control system. The diagnosis LED in the control section housing shows the diagnosis code by "flashing" and it can be read off the display in the controls compartment hood as an error code (e.g.

CODE 12).

See M48.

1,2 Protocol start

Protocol end

Short pause Pulse1 • Pulse2

long pause

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

The flashing code / the display can be evaluated using the table on sheet M11.

Remark: The last error that has been detected is always displayed.

CODE

12

0/0191

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EK10N

Sheet no.

M 10

Section M

Electrical system

Flashing code for errors LED Pulse1/ pulse2 0.1 1.1 1.2 1.3

Explanation

1.4

1.Incorrect sequence for key switch, enable, direction switch 2.Incorrect SRO type selected 3.Enable or direction switch wiring interrupted 4.Start-up protection delay too short Travel transducer error 1.Cable breakage, setpoint input (X1:6) 2.Short circuit to B+ or B3.Travel transducer faulty 4.Incorrect travel transducer type selected Body switch wiring 1.Body switch cable interrupted faulty 2.Test cable interrupted Start-up protection, 1.Incorrect switching on sequence - key-switch, travel transducer deadman switch, travel transducer triggered 2.Incorrect HPD type selected 3.Travel transducer incorrectly adjusted 4.Start-up protection delay too short Travel transducer 0V 1.Travel transducer 0V wiring interrupted (X1:7) interrupted or short 2.Travel transducer cabling, short circuit circuit 3.Incorrect travel transducer type selected Main contactor/field coil 1.Main contactor coil has short circuit faulty 2.Field winding has short circuit Main contactor error 1.Main contactor contacts welded together Field coil error 1.Field connection interrupted 2.Field winding interrupted Main contactor error 1.Main contactor coil 1K34 interrupted 2.Main contactor coil 1K34 not connected 3.Cabel breakage Battery undervoltage 1.Battery voltage too low 2.Corroded contacts 3.Connection terminals loose Overvoltage 1.Battery voltage too low 2.Operation with charging unit connected Over/undertemperature 1.Temperature <+85°C or >-25°C 2.Vehicle overloaded 3.Control unit mounted incorrectly 4.Extreme ambient conditions Anti Tiedown 1.Incorrect mode input active when key switch on

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

2.1

2.2 2.3

2.4 3.1 3.2 3.3 3.4 4.1 4.2 4.3

4.4

No error Current sensor error Hardware error Internal M- short circuit to BStart-up protection direction switch triggered

Issue: 07/00 Replaces issue:

Possible cause of error

Control unit faulty Control unit faulty Control unit faulty

Workshop Manual

EK10N

Sheet no.

M 11

Section M

Electrical system

Travel control Enable

Input 1 mode

Forward

Reverse

Setpoint generation, fast travel Remark:

In fast travel, the travel control modulates the drive motor to approx. 98% (approx. 9 km/h) with a max. setpoint (0V) (parameter sheet M18)

5kΩ-0 direction sender

Under the following conditions: -

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

-

Deadman switch actuated. Pin 15 enabled.

Pin 14 input 1 mode of the travel control is applied, +24 V. Travel direction is selected (pin 11 or 12).

Switch direction sender through the 4 travel stages (pin 6 and 7).

The following travel speeds result:

0/0190

Fast travel V/max possible

1

Travel speed 1

2

3

Via resistor (1) 5.6 kΩ.

X2:7

R = approx. 5.6 kΩ.

5K6

This represents a setpoint of approx. 3.4 V, measured at X51:10 (0 V) on the component panel, control current to X51:9 (5 K - 0).

4K7

2K7

1U20 X2 6

Travel speed 2 Resistor (1) 5.6 kΩ is parallel to resistor (2) 4.7 kΩ.

RErsatz = approx. 2.55 kΩ, represents a setpoint of approx. 1.5 V.

X51 9

X51 10

X1 6

X1 7

5K-0

Travel control

6/2048.1

Travel speed 3 Resistors (1) 5.6k Ω, (2) 4.7k Ω and (3) 2.7kΩ are connected in parallel.

RErsatz = approx. 1.3kΩ represents a setpoint of approx. 0.8 V.

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0V

EK10N

Sheet no.

M 12

Section M

Electrical system

Travel control Enable

Input 1 mode

Forward

Reverse

Travel speed 4 The resistors are bridged.

R = approx. 0 KΩ, represents a setpoint of approx. 0 V

5kΩ-0 direct. sender

Setpoint generation, slow travel 0/0190

In slow travel, the Highpulse control modulates the drive motor with a max. setpoint (0 V) according to the stored parameters, in this case approx. 36 %.

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

24V from deadman

In slow travel, the system is switched over to deceleration 2.5 km/h (e.g. on automatic braking at end of aisle or lift above 1.2 m) (see parameter sheet M18)

3

1 U51

K3

2

X5 10

Remark: The setpoint at pin 6 (4) remains unchanged.

X1:14 Input 1 mode Travel control 1A10

The switch-over is made by the K3 contact (1), which inactivates Input 1 mode (2) so that operating mode 1 is activated.

X2:7

K3 is on the following components: -U51 adaptation options (3) EK10N or -U51 evaluation logic (3) EK10H

5K6

4K7

2K7

1U20 X2 6 X51 10

X51 9

4 X1 6

5K-0

Travel control

X1 7

0V

6/2048.1

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EK10N

Sheet no.

M 13

Section M

Electrical system

Travel control system Adjusting the travel control system with the Curtis PMC 1307 programming unit Id. no. 4 498 978 The programming unit (1) can be used to carry out the following tasks:

1

2

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

- Programming the parameters for the travel control system - Online-queries about the statuses of the inputs and outputs and the temperature of the travel control system - Display of current errors and of errors which have occurred since the last time the diagnosis history was deleted

5

3

- Copying the control parameters

4

The programming unit is made up of the following components:

7

6

- Display (2) - PROGRAM key (3) for programming the parameters

8 9

- TEST key (4) for online querying of statuses

8/0087

- DIAGNOSTICS key (5) for troubleshooting - SCROLL DISPLAY keys (6) to scroll the display up and down - CHANGE VALUE keys (7) for changing the values - MORE INFO key (8) - Socket (9) for connecting the cable to the control system Issue: 07/00 Replaces issue:

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EK10N

Sheet no.

M 14

Section M

Electrical system 1

Travel control system Adjustment

2

Continued

Switching on 1. Plug the connecting cable (10) into the socket (9) of the programming unit.

2. Plug the second connector on the cable into the socket (11) of the Highpuls control system (12).

3. Switch on the vehicle with the key-operated switch.

The following messages appear on the display (2):

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

a)

5

3

4

For approx. 7 seconds:

7

6

CURTIS PMC 1307 - 2102

9 8 8/0087

b) CONTROLLER NO. 1207 - 1103 MFG DATE SERIAL #

20. Mai 00 XXXXX

SOFTWARE VERS

Remark:

10

07-02

11

12

The data after the texts may vary.

0/0189

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EK10N

Sheet no.

M 15

Section M

Electrical system 2

Travel control system Adjustment Continued

c) PRESS

PROGRAM TEST, OR DIAGNOSTIC

TO SELECT A MENU

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

Remark:

4 3

The display texts under b) and c) are displayed alternately until a selection is made.

Fig 1

Note:

The deadman's switch must not be actuated during the vehicle switchingon procedure or during selection of the menu Special Diagnostic. If it is, the following message appears on the display (2):

8/0087

FAULT CONNECTION PRESS SCROLL DOWN TO CONTINUE

Fig. 2

Setting the parameters Press the "Program" key (3). The LED (4) at the top left of the key lights up.

All the parameters are displayed with values. Four parameters can be seen on the display at any one time (see Fig. 3)

VOLTAGE M1 DRIVE C/L M2 DRIVE C/L M3 DRIVE C/L

-> 2 250 250 250

Fig. 3

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Sheet no.

M 16

Section M

Electrical system

Travel control system Adjustment Continued

Only the parameter which is positioned at the top edge of the display can be altered.

The value can be altered with the "Change Value" keys (1).

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

Remark:

The "MORE INFO" key shows an additional display about the parameter. A bar graph (4), the value entered (5), and the maximum (6) and minimum (7) possible value are displayed (see Fig. 2).

2

9

The LEDs in the top point (2) of the keys indicate whether the value is at the upper or lower limit.

If one of the diodes goes out, the adjusteable limit has been reached, and the value can not be changed any further in the selected direction.

8

1

10

2

Fig. 1

8/0087

5

4

To scroll through the parameter list, press the "SCROLL DISPLAY keys (8). The upwards arrow moves the list up (9) and the downwards arrow moves it down (10).

CREEP SPEED %

6

MIN Note:

Issue: 07/00 Replaces issue:

The values entered here are only examples. The values from the table of settings must be set (see M18 and 19).

Workshop Manual

40

MAX

100

Fig. 2

6

EK10N

Sheet no.

7

M 17

Section M

Electrical system

Travel control Setting the travel control 1243 Mode 1: deceleration 2.5 km/h,

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

Display

Mode 2: maximum speed Mode 1

Explanation

Field coil monitor 0 Field Check 1 Voltage Battery voltage Max. travel current in amps 2 Drive C/L Max. braking current in amps 3 Brake C/L Braking current dependent on the pressure sensor 4 Int Brake C/L Acceleration rate in secs.

5 Accel Rate Deceleration rate in secs.

6 Decel Rate Deceleration rate, setpoint generator 7 Throttle Decel Braking rate in secs. 0% to 100% braking power 8 Brake Rate Braking rate with deadman switch in secs.

9 Int Brake Rate 10 Quick Start Fast start (from neutral to max. setpoint) Field polarity reversal on change of direction 11 Taper Rate Max. speed forwards in % 12 Max F Speed Max. speed reverse in % 13 Max R Speed Creep speed in % of max. speed 14 Creep Speed Direction sender type 15 Throttle Type 16 Thrtl Deadband Neutral zone of the direction sender in % Direction sender maximum in % 17 Throttle Max Direction sender transmission ratio in % 18 Throttle Map Minimum field current in amps 19 Field Min. Maximum field current in amps 20 Field Max. 21 Field Map Start Field current rise, starting point in amps Field current rise in % 22 Field Map Current factor with small setpoints 23 Current Ratio Motor braking with direction sender reduction 24 Restraint Load compensation 25 Load Comp 26 High Pedal Dis. Direction sender start-up protection type Direction switch start-up protection type 27 SRO 28 Sequencing DLY Delay of the start-up protection check Main contactor reacts to enable input 29 Main Cont Intr 30 Main Open Delay Main contactor release delay in sec.

Main contactor monitoring 31 Cont Diag Auxiliary driver output type 32 AUX Type 33 AUX DLY Auxiliary driver cut-out delay in secs.

34 EMR REV En Body switch enable 35 EMR REV C/L Current limitation body switch in amps Issue: 07/00 Replaces issue:

Workshop Manual

EK10N

Mode 2 on 2

250 200

250 200 0

0.1 0.9

0.1 0.9 0.3

1.3

1.3 0.1 10 20

36 36

98 98 15 1 23 90 40 8.2 25 100 50 1

10

10 1.5 2 0 0.0 off 10 on 2 0/3 off 300

Sheet no.

M 18

Section M

Electrical system

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

Setting the travel control 1243 Mode 1: Deceleration 2.5 km/h Mode 2: Maximum speed 36 EMR REV Check Check of the body switch 37 EMR DIR INTR Body switch reset after brake switch 38 EMR TIME LIMIT Body switch time limit 39 Variable Brake Braking current dependent on the direction sender Anti-Tiedown 40 Anti-Tiedown Potentiometer earth error monitor 41 Pot low Fault Battery cell voltage at 100% charge 42 Full Volts Battery cell voltage at 20% charge 43 Empty Volts Battery cell reset voltage at 100% 44 Reset Volts Time constant for battery monitor 45 Capacity Gain Battery charge <20% lift stop 46 BDI Lockout Battrey charge <20% deceleration 47 BDI Disabel 48 ADJ HRS low Operating hours input Operating hours input 49 ADJ HRS mid 00 04 56 = 456 hrs.

Operating hours input 50 ADJ HRS High Operating hours, read in key switch 51 ADJ total Operating hours, read in lifting, lowering, travel 52 ADJ Trac Display, key switch - on, action - off 53 KIS on Hours 54 SRVC HRS x100 Service counter for key switch on (0=not active) 55 Trac HRS x 100 Service counter for lifting, lowering, travel (0=not active) Service counter, reset key switch 56 Service 1243 57 Service Drive Service counter, reset lifting, lowering, travel 58 Total Limit HRS Travel stop on completion service counter key HRS 59 Trac Limit HRS Travel stop on completion service counter LLT HRS Deceleration service counter complete (key) 60 Limit SPD 61 Trac Limit SPD Deceleration service counter complete (LLT) Speed on temperature error >90° 62 Warm Speed 63 Mot WRM x10mΩ Temperature error, deceleration (WarmSpeed) 64 Mot HOT x10mΩ Temperature error, deceleration > 190° Temperature measurement 65 Motor Ω Comp 66 Max Rev Regen max. braking current, deadman brake reverse 67 Max FWD Regen max. braking current, deadman brake forwards 68 Min Rev Regen min. braking current, deadman braking reverse 69 Min FWD Regen min. braking current, deadman braking forwards 70 Max Load Volts Maximum output voltage, pressure sensor 71 Min Load Volts Minimum output voltage, pressure sensor 72 Max Brake Time Time until electromagnetic brake activated Error code display 73 Fault Code

off off off on off on 201 171 210 4.0 on on 0 - 99 0 - 99 0 - 99 off off off 10 5 off off 120 120 25 25 25 72 77 on 210 250 210 250 4.5 4.0 3.0 off

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M 19

Workshop Manual

EK10N

Sheet no.

Section M

Electrical system

Setting the travel control 1243 Battery discharge characteristic curves Setting the parameters Full volts - battery cell voltage with 100% charge Empty volts - battrey cell voltage with 20% charge Reset volts - battrey cell reset voltage to 100% (off-load voltage)

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

Battery type Lead - acid - wet PzS Lead - acid - wet CMS capacity increased Hagen ,PWF,CWF,PzV Sonnenschein dryfit Varta Carat Gel battery Gel batteries in general Data Dryflex Drypower 8WF 800 HL 48

Full volts U/cell 1.97 1.98

Empty volts U/cell 1.78 1.78

Reset Volts U/cell 2.09 2.09

1.99 2.03 2.03 2.03 2.02 1.97

1.82 1.93 1.93 1.93 1.91 1.73

2.09 2.09 2.09 2.09 2.09 2.09

Remark: The values are entered as 3-digit numbers in the control system. e.g.: 199 for 1.99 The values specified in the table are settings for standard loads.

In special cases with heavier loads (high current drain in a short period or in cold store operation), deviations may occur, depending on the application. In cases of this kind, the battery manufacturer must be approached directly.

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EK10N

Sheet no.

M 19.1

Section M

Electrical system

Travel control system Adjustment Continued

4

Special program menu

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

The following tasks can be carried out with the special program: - Resetting to initial settings - Loading control parameters into programming unit - Loading programming unit settings into the control system - Deleting the diagnosis data - Adjusting the display contrast - Language selection - Displaying information about the programming unit - Displaying information about the control system

RESET ALL SETTINGS CONT SETTINGS -> PROG PROG SETTINGS -> CONT CLEAR DIAG HISTORY

3 1

To enter the special program menu, the PROGRAM (1) and MORE INFO (2) keys must be pressed at the same time.

2

The LED (3) on the PROGRAM key lights up.

The first four functions are now visible in the display (4).

Only the function which is in 1st place on the display can be altered.

8/0087

Note: At the moment, only the English language is active !!

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EK10N

Sheet no.

M 20

Section M

Electrical system

Travel control system Adjustment Continued

5

Special program menu To carry out the function, the MORE INFO key (1) must be pressed.

1. Resetting to initial settings

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

Use the SCROLL DISPLAY keys (2) to bring EINST.RUECKSETZEN to the top position on the display (5).

Press MORE INFO (1).

The display in Fig. 1 appears.

RESET ALL SETTINGS CONT SETTINGS -> PROG PROG SETTINGS -> CONT CLEAR DIAG HISTORY

Fig. 1

RESET ALL SETTINGS TO ORIGINAL VALUES? CONFIRM: VALUE UP CANCEL: VALUE DOWN

When VALUE UP (3) is pressed, Fig. 2 appears on the display.

When VALUE DOWN (4) is pressed, Fig. 3 appears on the display.

WORKING ...

Fig. 2

automatically

ALL CONTROLLER SETTINGS RESET TO ORIGINAL VALUES

Fig. 3

3

2

2

OPERATION CANCELED NO ACTION TAKEN

4

1

8/0087

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EK10N

Sheet no.

M 21

Section M

Electrical system

Travel control system Adjustment Continued

Special program menu 2. Loading settings from the control unit into the programming unit.

Use the SCROLL DISPLAY keys (2) to bring CONT SETTINGS -> PROG to the top position on the display.

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

Press MORE INFO (1).

Fig. 1

The display in Fig. 1 apppears.

ALL CONT SETTINGS SAVED IN PROGRAMMER? CONFIRM: VALUE UP CANCEL: VALUE DOWN

When VALUE UP (3) is pressed, Fig. 2 appears on the display.

When VALUE DOWN (4) is pressed, Fig. 3 appears on the display.

WORKING ...

Fig. 2

automatically

ALL CONTROLLER SETTINGS SAVED IN PROGRAMMER

Fig. 3

3

2

2

OPERATION CANCELED NO ACTION TAKEN

4

1

8/0087

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EK10N

Sheet no.

M 22

Section M

Electrical system

Travel control system Adjustment Continued

Special program menu 3. Loading settings from the programming unit into the control system.

Use the SCROLL DISPLAY keys (2) to bring PROG SETTINGS -> CONT to the top position on the display.

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

Press MORE INFO (1).

Fig. 1

The display in Fig. 1 apppears.

ALL CONT SETTINGS SET FROM PROGRAMMER? CONFIRM: VALUE UP CANCEL: VALUE DOWN

When VALUE UP (3) is pressed, Fig. 2 appears on the display.

When VALUE DOWN (4) is pressed, Fig. 3 appears on the display.

WORKING ...

Fig. 2

automatically

ALL CONTROLLER SETTINGS SET FROM PROGRAMMER

Fig. 3

3

2

2

OPERATION CANCELED NO ACTION TAKEN

4

1

8/0087

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EK10N

Sheet no.

M 23

Section M

Electrical system

Travel control system Adjustment

Continued

Special program menu 4. Deleting the diagnosis data Use the SCROLL DISPLAY keys (2) to bring CLEAR DIAG HISTORY to the top position on the display.

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

Press MORE INFO (1).

Fig. 1

The display in Fig. 1 apppears.

CLEAR CONTROLLER DIAGNOSTIC HISTORY? CONFIRM: VALUE UP CANCEL: VALUE DOWN

When VALUE UP (3) is pressed, Fig. 2 appears on the display.

When VALUE DOWN (4) is pressed, Fig. 3 appears on the display.

WORKING ...

Fig. 2

automatically

DIAGNOSTIC HISTORY IN CONTROLLER IS CLEARED

Fig. 3

3

2

2

OPERATION CANCELED NO ACTION TAKEN

4

1

8/0087

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EK10N

Sheet no.

M 24

Section M

Electrical system

Travel control system Adjustment

Continued

Special program menu 5. Adjusting the display contrast

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

Use the SCROLL DISPLAY keys (2) to bring DISPLAY CONTRAST to the top position on the display.

Press MORE INFO (1).

The display in Fig. 1 apppears.

When VALUE UP (3) is pressed (and held down), the display grows darker.

When VALUE DOWN (4) is pressed (and held down), the display grows brighter.

Fig. 1

ADJUST PROGRAMMER DISPLAY CONTRAST DARKER: VALUE UP LIGHTER: VALUE DOWN

3

2

2

4

1

8/0087

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EK10N

Sheet no.

M 25

Section M

Electrical system

Travel control system Adjustment

Continued

Special program menu

2

6. Language selection When the VALUE UP or VALUE DOWN keys are pressed, the preset language is changed to German, English or numeric (Fig. 1).

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

3

2

Note: At the moment, only the English language is active !!

4

1

8/0087

Fig. 1

SELECT LANGUAGE FOR TEXT USING VALUE UP OR VALUE DOWN GERMAN (ENGLISH) (NUMERIC)

7. Displaying information about the programming unit Use the SCROLL DISPLAY keys (2) to bring INFO PROGRAMGR to the top position on the display.

Press MORE INFO (1).

The display in Fig. 2 appears.

Remark:

The data shown here is just for demonstration purposes.

Fig. 2

PROGRAMMGR MFG DATE SOFTWARE VER

1307 - 2102 20 APR 95 00 - 08

8. Displaying information about the control system Use the SCROLL DISPLAY keys (2) to bring INFO CONTROLLER to the top position on the display.

Press MORE INFO (1).

The display in Fig. 3 appears.

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Workshop Manual

Fig. 3

CONTROLLER MFG DATE SOFTWARE VER

EK10N

1243 - 0063 20 APR 00 00 - 01

Sheet no.

M 26

Section M

Electrical system

Travel control system Adjustment

Continued

Menu test (1) 1

In this menu, information about the statuses of the inputs and outputs and the temperature of the control system are shown in real time.

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

The information in the top position can be enlarged by pressing the MORE INFO key (2).

2 8/0087

For example, the following information is presented: (see Fig. 1) Fig. 1

3 Direction sender signal in % of the max. speed 4 Motor field current in amps

3 4 5 6

THROTTLE % FIELD CURRENT ARM CURRENT FIELD PWM %

0 8 180 70

5 Motor armature current in amps 6 Motor field voltage in % For test menu table, see sheet M28

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EK10N

Sheet no.

M 27

Section M

Electrical system

Test menu table

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

Designation Direction sender % Throttle % FIELD CURRENT ARM CURRENT FIELD PWM ARM PWM BDI % LOAD VOLTAGE BATT. VOLTAGE MOT RES X 10 mΩ HEATSINK °C FORWARD INPUT REVERSE INPUT MODE INPUT A MODE INPUT B INTERLOCK EMR REV INPUT MAIN CONT AUX DRIVER SYS MODE

Description Travel transducer signal in % of the max. speed Motor field current Motor armature current Motor field voltage Motor armature voltage Battery voltage Pressure sensor voltage (not on EK10) Battery voltage Temperature dependent resistance value of the field coil Current heat sink temperature Forward switch Reverse switch Input 1 mode active Input 2 mode active Enable switch Body switch Main contactor (1K34) Auxiliary driver (brake output) active Control system operating modes

Display % A A % % % V V 58 °C on/off on/off on/off on/off on/off on/off on/off on/off 0-6

SYS mode display: Meaning of the individual operating modes 0 1 2 3 4 5 6

Neutral, control system is not active Travel, brake released Regenerative brake is active Decrease in the braking current until the end of the braking operation Field polarity is reversed (change of travel direction) Brake is activated (brake is not released) Internal error, travel control is blocked

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EK10N

Sheet no.

M 28

Section M

Electrical system

Travel control system Adjustment Continued

Displaying current errors When the DIAGNOSTIC key (1) is pressed, the current errors are shown on the display (see Table 1).

1

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

Pressing the DIAGNOSTIC (1) and MORE INFO (2) keys simultaneously opens the special diagnostic menu.

Here, a list of errors is displayed which have been identified by the control system since the last deletion (see sheet no. M24).

2 8/0087

Each error is only displayed once.

For the text shown on the display, see Table 1.

Switching off Switch off the vehicle and unplug the connection between the programming unit and the control system.

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EK10N

Sheet no.

M 29

Section M

Electrical system

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

Diagnosis and special diagnosis menu Designation THERMAL CUTBACK SRO HPD M-SHORTED CURRENT SHUNT FAULT FIELD OPEN MAIN CONT WELDED OVERVOLTAGE ANTI-TIEDOWN CONT COIL / FLD SHORT HW FAILSAFE LOW BATTERY VOLTAGE EMR REV WIRING MISSING CONTACTOR FAHRSCH FEHLER 1 THROTTLE FAULT 1 SERVICE CONTROLLER SERVICE DRIVE CONTROLLER DISABLED DRIVER DISABLED MOTOR HOT MOTOR WARM FAHRSCH FEHLER 2 THROTTLE FAULT 2

Issue: 07/00 Replaces issue:

Error Reduction due to overtemperature/undertemperature Start-up protection for direction switch initiated Start-up protection for travel transducer initiated Short-circuit at M- output to BCurrent sensor error Motor field interrupted Main contactor contacts (1K34) welded together Battery voltage too high Mode switch 1 closed when m switching on closed Contact coil / field short circuit Hardware failsafe Battery voltage too low Error found in the body switch check Interruption in the contactor control circuit (1K34) Travel transducer slider error

Motor is too hot > 190°C Motor has reached lowest temperature limit >90°C Travel transducer interruption in cable

Workshop Manual

EK10N

Sheet no.

M 30

Section M

Electrical system

Travel control General data

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

Electrical data 1243 - 43XX Voltage range:

24 V -

36 V

Undervoltage limit:

16.8 V

Overvoltage limit:

45 V

Electrical insulation of the housing:

500 V

Output current: armature

300 A for 2 min.

100 A for 1 hr.

Output current: field

25 A for 2 min.

15 A for 1 hr.

Braking current:

300 A

Switching frequency:

15kHz

Switching outputs:

Maximum coil current 2 A

Ambient temperature:

-40°C to +50°C

Overtemperature reduction:

85°C

Undertemperature reduction:

-25°C

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EK10N

Sheet no.

M 31

Section M

Electrical system

Modules X1

X2

R4 R1 o o

WAGNER

WAGNER

406 560

406 561

EK10NN-Adaption

X3

X4

EK10NH

oo

X5

X6

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

Id. no. W8 406 560 Adaptation option (U51) EK10NO/NM*: • Rail guidance • End-of-aisle safety

R4 R1

X8

X5

Id. no. W8 406 561 Evaluation logic (U51) EK10HO* EK10HM*

* For definition see Foreword, sheet I These modules are vehicle control systems which process internally the input signals, such as switches, operating elements and statuses, and enable them as defined outputs.

Adaptation option (U51) Id. no. W8 406 560 Pin assignment X1 X1

not used

R4 R1 o o

WAGNER

EK10N-Adaption 406 560

X5

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EK10N

X6

Sheet no.

M 32

Section M

Electrical system

Modules Adaptation option (U51), continued Pin assignment X5 X5:1 0V input to K7,2,8,3 (internal) bridged to X1:4 and X1:5 (internally) X5:2 24V input, bridged to X1:2 and K1 (internal)

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

X5:3 24V output, enable signal from X1:8 (internal)

R4 R1 o o

WAGNER

EK10N-Adaption 406 560

X5

X5:4 2+24V input, enable from key-operated switch and emergency-off, bridged internally to X1:7, supply voltage via contacts, relay K2 for lamps "lowerable", "guided", "steerable" X5:5 Output, setpoint generation for travel (3.5V - 0V) (see sheet nos. M8 - M10) X5:6 24V output, "guided" lamp switched via internal relay K2 X5:7 0V input for deceleration (see sheet nos.

M8 - M10) X5:8 Input for deceleration (see sheet nos.

M8 - M10) when 1.2 m switch (high lift) is actuated 1.5 V X5:9 24V input, deceleration to 2,5 km/h via contacts of relays K2, K3 (internal), Option ZAG X5:10 24V output, deceleration to 2.5 km/h, travel control system X1:14, Option ZAG Continued on sheet no. M34

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EK10N

Sheet no.

M 33

Section M

Electrical system

Modules 2

Adaptation option (U51), continued

1 R4 R1 o o

Pin assignment X5, continued

WAGNER

X5:11 24V output, to 3K3 (steering error relay), triggered internally by LR80 (emergency stop, steering error) via K1

EK10N-Adaption 406 560

X5

X5:12 24V input from steering control system X1:8

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

X5:13 24V output, "lenkbar 2" lamp switched via internal relay K2, bridged to X5:14 (internally) X5:14 24V output, see X5:13 "steerable 1" Note: Potentiometers R1 (1) AND R4 (2) are located on the adaptor module.

These trimmers are not active.

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EK10N

Sheet no.

M 34

Section M

Electrical system

Modules Adaptation option (U51), continued (Mechanical automatic steering option) Pin assignment X6 X6:1

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

X6:2

24V input "Lift" to coil K4 via diode with the "lift" button 24V input "Lower" to coil K4 via diode with the "lower" button

X6:3

24V input main lift via 2-handed-operation button only to internal contacts K4 and coil K5

X6:4

24V output via contacts K4 internally, only when K4 has switched and only when additional lift occupied

X6:5

24V input to coil K6, straight-on from steering control system only switched during rail guidance

X6:6

24V input to contacts K7, K5 (internally) from deadman and steering error

X6:7

24V output to contacts K7,5,6 (internally) to travel control system and travel switch, evaluation of steering control system "straight-on", 2-handed operation and steering angle limitation for LR80

X6:8

not occupied

X6:9

not occupied

R4 R1 o o

WAGNER

EK10N-Adaption 406 560

X6

X6:10 0V input (coils K4,5,6)

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EK10N

Sheet no.

M 35

Section M

Electrical system

Modules X2

Evaluation logic (U51)

WAGNER

Id. no. W8 406 561

LED series

EK10H

406 561

1-2 4

LED1

LED2

oo

R4 R1

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

Pin assignment X2 X2:1

1+24V output, supply voltage for right chain limit switch

X2:2

1+24V input via right chain limit switch -2S62. LED1 on when chain OK (if error, no lifting and lowering)

X2:3

1+24V output, power supply for left chain limit switch

X2:4

1+24V input via left chain limit switch -2S63.

LED2 on when chain OK (if error, no lifting and lowering)

Limit switch

X2:5

1+24V output, not connected

X2:6

2+24V input, via 1.2m switch. LED3 lights up if lift not above 1.2 m, deceleration to 2.5 km/h

X2:7

1+24V output, not connected

X2:8

24V input, steering straight-on from the steering control system. LED4 lights up when the straight-on output from the steering control system is active. (see wiring plans EK10HM, sheets 81).

Limit switch 8/0054

2+24V

1S24

LED3

8/0055

1.2 m switch

LED4

Straight-on output

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Sheet no.

8/0056

M 36

Section M

Electrical system

Modules Evaluation logic (U51) , continued X3

Pin assignment X3

WAGNER EK10H

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

X3:1

0V output, supply voltage for additional lift valve 2Y23

X3:2

2+24V output, supply voltage for additional lift valve 2Y23

X3:3

0V output, supply voltage for main lift valve 2Y20

X3:4

2+24V output, supply voltage for main lift valve 2Y20

X3:5

0V output, not connected

X3:6

2+24V output, enable travel (X1:15 travel control)

X3:7

0V output, not connected

X3:8

2+24V output, for pump contactor 2K1

X3:9

0V output, not connected

406 561 oo

R4 R1

X3:10 2+24V output, output for "lowering" valve 2Y21 Remark:

X3:1 to X3:4 are only connected on vehicles with an additional lift

steering error

Brake switch Enable travel

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Sheet no.

8/0057

M 37

Section M

Electrical system

Modules Evaluation logic (U51) , continued X4

Pin assignment X4

WAGNER EK10H

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

X4:1

2+24V input, power supply (barrier switch, 1.2 m switch)

X4:2

1+24V input, power supply (key-operated switch)

X4:3

0V input, power supply

X4:4

0V input, power supply

X4:5

2+24V input, contacts K5, K6 (internal) processor monitoring

X4:6

2+24V output, contacts K5, K6 (internal) processor monitoring

406 561 oo

R4 R1

Barrier switch 2+24V

2+24V 2+24V

1+24V 0V 0V

Processor monitoring 8/0059

Wiring diagram EK10HO, sheet 7

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EK10N

Sheet no.

M 38

Section M

Electrical system

Modules Evaluation logic (U51) , continued

WAGNER EK10H

406 561

Pin assignment X5

oo

R4 R1

X5:1

0V input, supply voltage for relay K3

X5:2

not connected

X5:3

not connected

X5:4

not connected

X5

8/0060

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

X5.1

X5:5

3.5V to 0V output, generation of travel setpoint, not connected.

X5:6

Not connected.

X5:7

0V input, supply voltage for deceleration, not connected.

X5:8

Input, deceleration from direction sender, not connected.

X5:9

2+24V input, via contact K3 (internal), deceleration to 2.5 km/h (LED11), ZAG option.

0V

2+24V

X5:10 24V output, via contact K3 (internal) Deceleration to 2.5 km/h (travel control X1:14 input 1 mode), ZAG option X5:11 not connected 8/0062

X5:12 not connected

Mode Input 1 X1.14

X5:13 not connected X5:14 not connected

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EK10N

Sheet no.

M 39

Section M

Electrical system

Modules Evaluation logic (U51) , continued

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

Pin assignment X8 (8-pin)

WAGNER EK10H 406 561

oo

R4 R1

X8:1

2+24V input, lift cut-out switch and lifting or lifting on load side, LED5

X8:2

2+24V input, lifting switch on load side or 2handed additional lift, on vehicle without additional lift: lift cut-out switch, LED6

X8:3

2+24V input, 2-handed operation switch (only with rail guidance), LED7

X8:4

2+24V input, lowering switch, LED8

X8:5

2+24V input via processor monitoring and battery control (K5,6 internal), LED9

X8:6

2+24V input, steering error relay, deadman, processor monitoring, on vehicles with additional lift: also barrier switch, LED10

X8:7 X8:8

not connected not connected

X8

2+24V

X8:1

2+24V

X8:2

2+24V

X8:3

2+24V

X8:4

2+24V

X8:5

2+24V

X8:6

8/0063

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EK10N

Sheet no.

M 40

Section M

Electrical system

Modules LED displays The LED displays are identical for evaluation logic modules EK10H (Id. no. W8 406 561).

X1

X2

X3

X4

WAGNER EK10H 405 561

oo

R4 R1

X8

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

X5

LED 1 2

green D1

3 4 5 6 7

x

x

x

x

x

X

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Slack chain, right

green D2 Slack chain, left green D3 1.2 m switch green D4 Straight-on output green D5 Lifting green D6 Lift cut-out green D7 2-handed operation, only with rail guidance green D8 Lowering green D9 Battery control green D10 Deadman's switch green D11 Deceleration 2.5Km/h active green D12 No function green D13 RUN-monitor flashes briefly during switching on red D14 LED error code, see table (see sheet no. M42) red D15 LED error code, see table (see sheet no. M42) red D16 RUN-monitor flashes green D17 Enable program, flashes briefly during switching on red D24 5V internal OK LEDs 1,2,3,9,24 light up when the key-switch is on and the main lift is not raised.

The LEDs D18 to 23 do not have a function.

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EK10N

Sheet no.

M 41

Section M

Electrical system

Modules ERROR CODE table for electronic evaluation system EK10H

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

Id. no. W8 406 561

LED D

Constant

Flashing 200 Hz

Flashing 1 Hz

Designation

14 15

1 0

-

-

Relay K6 contact stuck, processor monitor

14 15

0 1

-

-

Relay K5 contact stuck, processor monitor

14 15

1 1

-

-

Relay K6 contact does not close, processor monitor

14 15

-

1 0

-

Relay K5 contact does not close, processor monitor

14 15

-

0 1

-

Main program has not started

14 15

-

1 1

-

Creep speed relay (K3) error

14 15

-

-

1 0

Lifting contactor error

14 15

-

-

0 1

Brake error

14 15

-

-

1 1

Lowering valve error

0 = LED is not triggered 1 = LED is triggered (see headings)

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EK10N

Sheet no.

M 42

Section M

Electrical system

Braking monitor (ABÜ) Function The braking monitor monitors the generator braking of the vehicle. If the generator braking is not powerful enough, the ABÜ opens internal relay K1, which causes the electromagnetic brake to be applied immediately.

Detection of the actual vehicle speed is carried out by the speed sensor. These speed sensor pulses are offset with the braking time to calculate a delay in m/ss.

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

The required delay is stored in the form of software in the ABÜ and is then continuously compared to the actual delay.

If the downwards deviation is too large, relay K1 becomes inoperative and consequently an electromagnetic braking operation initiated.

0/0192

A differentiation is made between 3 types of delay: 1. 0.5 m/ss SU/EK when travel direction signal is removed 2. 1.0 m/ss EK when deadman signal is removed 3. 1.5 m/ss SU when deadman signal is removed K1 opens when: • deadman is (no longer) actuated (X2:3=0V) and the speed is higher than 2.5km/h or the delay is not within the range specified above.

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

• one of the speed sensor channels is faulty.

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0/0193

EK10N

Sheet no.

M 43

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Brake

Workshop Manual

X1:8

X3:1

EK10N

K2

PIC

Sheet no.

Battery discharge curve

X1:3

Pump off

0V OK

X2:9

Switch-on test K1A

K1

Switch-on test K1

X2:8

reverse

Travel direction

X2:7

forw.

24V

X2:6

3K1

1K34

X3:9

3F1

1F4

24V K1

X1:4

1K34

24V

1A10

X1:15 X1:2 Enable

90° phase shift

A1 out

24V

ZAG

K1

K2

Lifting

X3:10

Lowering

2+24V

X3:3 0V

2K1

X3:2

K2

X3:8

U51 evaluation logic only with EK10 high lift

X1:4 X3:6 X3:7 B in K2 X3:7

A2 out

X1:3 A in K1

X2:14 X2:12 X2:13

24V

ABÜ

X1:2 GND

Incremental encoder drive motor

X1:1 RV

BSZ

X3:8

X2:1

Emerg. stop

Key switch

X2:3

3K3 steering error

X3:4

X3:10

Travel control

X1:16

diode

Reverse volt.

&

X2:2

24V

0V Deadman

Enable

24V protection

X2:5

3K1

X1:9

safety

Strg. contr.

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

Section M Electrical system

Block diagram of ABÜ braking monitor (U50)

M 44

Section M

Electrical system

Braking monitor (ABÜ) Pin assignment X1 X1:1 A X1:2 A X1:3 E X1:4 E

12V power supply, speed sensor 0V power supply, speed sensor Signal channel 1; speed sensor Signal channel 2; speed sensor

X2

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

X2:1 X2:2 X2:3 E

2+24V power supply for braking monitor 0V power supply for braking monitor Travel enable for 1A10 and supply voltage via deadman switch X2:4 E Steering controller OK=0V. Is applied as soon as supply voltage is applied at steering controller and there is no internal steering error (only with SU) X2:5 E Steering controller OK=24V applied, as soon as supply voltage is applied at steering controller and there are no internal steering controller errors (only with EK) X2:6 E Steering contactor 3K1 closed, i.e. contact test for steering contactor OK X2:7 E Travel direction DE X2:8 E Travel direction LE X2:9 E Signal from 1A10 to braking monitor to activate lift stop X2:10 E Standstill detection for steering controller. The steering remains active as long as pulses arrive at the steering controller, even if the enable steering signal is removed X2:11 E If this input is connected to 24V, the pulses which are emitted at X2:10 also have a 24V amplitude.

X2:12 A Signal channel 1; speed sensor X2:13 A Signal channel 2; speed sensor X2:14 E Without this 24V signal, the speed sensor pulses cannot be evaluated; FE06 appears.

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0/0193

Sheet no.

M 45

Section M

Electrical system

ABÜ Continued

Pin assignment X3

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

X3:1 A

When X3:9=24V is applied and K1 is closed, 24V should be applied here.

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

Prerequisite is: K1 closed, X3:9=24V, switching-on test K1 positive, 3K1 closed, steering OK signal=0V X3:5 A Inverted output from X2:3 for enable steering=0V X3:6 E Start for the hour meter on lifting X3:7 E Start for the hour meter on lowering X3:8 A Connection via diodes X3:6 and 7 for the hour meter in the travel control X3:9 E Pedal contact of K1, is supplied by steering controller output "steering OK" X1:14 X3:10 A Power supply for the travel control.

24V, if reverse polarity diode in braking monitor is in order.

0/0193

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EK10N

Sheet no.

M 46

Section M

Electrical system

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

If an error has occurred, it is identified on the basis of a longer switching-on pulse.

Example: Error 5 is to be displayed: Error

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

1 2 Pulses

3

4

5

6

7

8

Long pause

Several errors can also be displayed at the same time.

Example: Error 2 and Error 4: Error 1 2 Pulses

Error 3

4

5

6

7

8 Long

pause

1

The following errors can be displayed: Pulse 1: Pulse 2: Pulse 3: Pulse 4: Pulse 5: Pulse 6: Pulse 7: Pulse 8:

Speed too high on braking No voltage at X3:9 (pedal contact relay K1) Relay K1 faulty Output transistor V8 for X3:4 faulty Internal temperature sensor detects overtemperature Sum error (short circuit, voltage missing at X2:14) Speed sensor producing unclear pulses Speed sensor faulty

0/0167

Remark: If there are no errors, the red error LED shows the speed sensor pulses.

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EK10N

Sheet no.

M 47

Section M

Electrical system

Curtis display unit

General

Battery

Operating hours

89%

500.0

The Curtis display unit (1) is purely a display unit.

1

2

LC Display (2) Provides an alphanumeric display (8-digit).

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

- Operating hours (visible 5 seconds after switching on) - Maintenance date

CODE

12

Error rcode

- Battery discharged - Remaining battery capacity (in steps of 1%) - Error code (e.g. CODE 12 alternating with the battery capacity)

0/0191

5

4

3

Control displays - LED 1 (3) - Service symbol - red

6

(Flashes on error message)

- LED 2 (4) - Battery symbol - yellow (on with battery display)

- LED 3 (5) - Hour meter symbol - green (on with hour meter display)

There is an 8 pin connector at the back of the appliance (6).

0/0194

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EK10N

Sheet no.

M 48

Section M

Electrical system

Curtis display unit Pin assignment Operating voltage Pin 5 = B+ (15 V) Pin 8 = B - (0 V)

8

5

4

1

Data input

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

Pin 6 = Data input

Further pin assignment Pin 1 Pin 2 Pin 3 Pin 4 Pin 7

= = = = =

not occupied not occupied not occupied not occupied not occupied

0/0194

Basic data Operating voltage 15 V Operating temperature -10°C to +70°C

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EK10N

Sheet no.

M 49

Section M

Electrical system

Changing the battery Removal The battery must be removed with suitable lifting equipment (e.g. a crane) and with suitable lifting tackle.

1

It is important to note the battery weight for this procedure (information provided on battery nameplate.

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

1

1. Open the battery compartment cover.

2. Pull out the battery plug.

3. Attach the lifting tackle (1) in the eyes at each side.

4. Attach the crane (with suitable carrying capacity) to the lifting tackle.

8/0015

5. Carefully lift the battery up and out.

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EK10N

Sheet no.

M 50

Section N

Hydraulic system

Contents Sheet no.

Block diagram for EK10 NO/HO..............................................................................N 2 Block diagram for EK10 NM/HM .............................................................................N 3 Hydraulic circuit plan ...............................................................................................N 4 Pump unit

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

- General .................................................................................................................N 5 - Lifting function.......................................................................................................N 6 - Lowering function..................................................................................................N 7 - Non-return valve ...................................................................................................N 8 - Replacing the carbon brushes ..............................................................................N 9 - Removal................................................................................................................N 10 - Removing the pump motor....................................................................................N 11 - Hydraulic pump, general .......................................................................................N 12 - Removing the hydraulic pump ..............................................................................N 13 - Dismantling the hydraulic pump............................................................................N 14 - Adjusting the maximum pressure..........................................................................N 15 - Changing the oil ....................................................................................................N 16 Bleeding the system................................................................................................N 17 Distributor block NM/HM .........................................................................................N 18 Bubble reservoir ......................................................................................................N 19 Hydraulic hoses.......................................................................................................N 20

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EK10N

Sheet no.

N1

Section N

Hydraulic system

Block diagram for NO/HO 1

2+24V

* U51 only with HO

Consisting of

Lifting

Battery check

1 Lifting switch

0V

2 Pump contactor

U51 *

2F1

K2 ABÜ

3 Lowering switch

2 6

4 Pump unit 5 Bubble reservoir 6 Lift cylinder for main lift Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

6/0154

3 +24V

7 Hydraulic lead

Remark: The directional valve and the lowering brake valve (throttle) are on the pump block (8).

Lowering

7

8

4

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EK10N

8/0040

Sheet no.

N2

Section N

Hydraulic system

Block diagram for NM/HM Battery check 0V

Consisting of

K2 ABÜ 2+24V

1 Switch for lifting / mast load side 4

2 Switch for lowering / mast load side

3

1

2

2F1

3 Switch for lifting additional lift

U51 only with HM

4 Switch for lifting main lift 5

5 Pump contactor

12

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

6 Pump unit

6/0154

7 Pump block 8 Bubble reservoir 9 2/2 way directional valve, additional lift

11

10

10 2/2 way directional valve, main lift 11 Lift cylinder for main lift

9

13

12 Lift cylinder for additional lift 13 Distributor block

8

8

Remark: The directional valves for lowering and the lowering brake valve are on the pump block (7).

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8/0041

Workshop Manual

EK10N

Sheet no.

7

6

N3

Section N

Hydraulic system

Hydraulic circuit plan

Main lift

1

NO, HO (Fig. 1) NM, HM (Fig. 2)

2

3

Consisting of 1 Lift cylinder

4

2 Line break protection 3 Diaphragm reservoir 4 1-way directional valve

5

1

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

5 Throttle valve

6

6 Pressure-limiting valve

7

7 Electromotor with hydraulic pump

8 9

8 Filter

Fig. 1

9 Tank

8/0042

10 Non-return valve 11 Lift cylinder for additional lift

Additional lift

12 2/2 way directional valve

Main lift

1

1

2 2 3 1

4

5

1 6 7 8 9 Fig. 2

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EK10N

8/0043

Sheet no.

N4

Section N

Hydraulic system

Pump unit Id. no. W8 416 034 (EK10 NO, NM) Id. no. W8 420 362 (EK10 HO, HM)

General 1 The pump unit is made up of the following components: Item Component

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

1

Pump motor 2KW (EK10 NO, NM)

Id. no.

8

7

8 405 460

4 9

AT 8 405 461 1

Pump motor 3 KW (EK10 HO, HM)

8 407 805 AT 8 407 806

2

Hydraulic pump (EK10 NO, NM)

8 416 580

2

Hydraulic pump (EK10 HO, HM)

8 422 489

3

Hydraulic suction filter

8 416 589

4

Directional valve

8 416 574

5

Oil tank

8 416 587

6

Air filter

8 416 588

7

Carbon brushes (EK10 NO, NM)

8 405 466

7

Carbon brushes (EK10 HO, HM)

8 407 808

8

Pressure-limiting valve

8 416 573

9

Lowering brake valve (EK10 NO, NM)

8 416 577

9

Lowering brake valve (EK10 HO, HM)

8 416 576

10

Pressure-limiting valve

8 416 572

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3 10

8/0064

2 5

EK10N

Sheet no.

N5

6

Section N

Hydraulic system

Pump unit

P

Function 4 LIFTING

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

When the pump motor is activated (1), it actuates the external gear pump (2), which immediately sends a stream of oil from the tank via the suction filter (3) and the non-return valve (4) to the pressure connection "P".

A pressure line is connected at pressure connection "P", which is linked to the lift cylinder.

If the pressure at the "P" connection rises, the pressure at the pressure-limiting valve (5) also rises --> the pressure limiting valve opens, and the oil flows back to the tank.

Remark:

On vehicles with an additional lift, the 2/2 way directional valve in the distributor block must also switch (see sheet no. N4).

1

8/0065

.

3

2

5

Excess pressure Operating pressure

Oil pressure from pump

P

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

8/0066

Return flow to tank

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EK10N

Sheet no.

N6

Section N

Hydraulic system

Pump unit

1

Function 2 LOWERING

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

When the load is to be lowered again, the non-return valve (directional valve, 1), which can be released electrically, must be supplied with current by actuating the "lowering" key.

.

8/006

Back flow

The electrically releasable non-return valve now changes its switching position.

So that the load is not lowered too fast, the lowering brake valve (2) is fitted downstream from the directional valve. This only allows a limited amount of oil to flow through during a certain length of time, so that a controlled lowering speed is achieved (11 l/min).

Remark:

On vehicles with an additional lift, the 2/2 way directional valve in the distributor block must also switch (see sheet no. N4).

. ....... .

P

2

.. .. .

8/0066

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EK10N

Sheet no.

N7

Section N

Hydraulic system

Pump unit 1

Electrically releasable non-return valve (2/2 way valve)

2

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

Id. no. W8 416 574

The 2/2 way valve is a bevel-seated valve.

The directional valve illustrated here is a so-called NORMALLY CLOSED valve, i.e. when the coil (1) is not excited, the tapered pin (2) presses onto the slide (3) and closes the control hole in this way (A --> B).

8/0068

3 B

If the coil (1) is now excited, it pulls the tapered pin (2) upwards. The oil pressure which has build up moves the slide (3) up and the oil can flow unhindered through the section A --> B.

A

Coil resistance = 40Ω

1

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8/3122

EK10N

2

Ω

8/0069

Sheet no.

N8

Section N

Hydraulic system

Pump unit Replacing the carbon brushes (EK10 NO, NM)

3

1

2

4

Id. no. 8 405 466 (carbon brushes) Id. no. 8 422 374 (carbon brush spring) The carbon brushes must be replaced when a residual length of 11 mm has been reached, which represents wear of 50 %.

Length of a new carbon brush: 22 mm An entire set of brushes must be replaced at the same time (4 brushes).

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

Removal 1.

Pull out the battery plug.

2.

Unscrew the 2 hexagon bolts (1).

3.

Screw in the hexagon bolt (5 x 30 mm) (2) to help pull off the carbon brush lid (4) until a resistance can be felt.

8/0070

4.

Use a screwdriver to help pull between the motor (3) and the carbon brush lid.

5.

Use the hexagon screw and the screwdriver alternately to pull off the carbon brush lid.

6.

Lift off the carbon brush spring (5) and pull out the carbon brushes.

7.

Release the carbon brush spring (7) slowly.

8.

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

9.

Clean out the commutator space (blow it out free of oil).

5

6

7

8/0071

Note: Do not breathe in carbon dust.

To reinstall, follow the removal instructions in reverse order.

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EK10N

Sheet no.

N9

Section N

Hydraulic system 1

Pump unit

2

Replacing the carbon brushes EK10 HO;HM Id. no. 8 407 808 (carbon brushes) Id. no. 8 400 886 (carbon brush springs) The carbon brushes must be replaced when they have worn down to a length of 50 %.

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

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

Removal 1.

Pull out the battery plug.

2.

Unscrew and remove the cheese-head screw (1).

3.

Remove the locking ring (2).

4.

Remove the paper cover (3).

5.

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

6.

Lift the carbon brush spring (4) and pull out the carbon brushes (5).

7.

Slowly release the carbon brush spring (4).

8.

Clean out the commutator compartment with oil-free compressed air.

0/0226

3

0/0231

4 5

Note: Never inhale carbon dust.

6 To install the new brushes, follow the instructions above in reverse order.

0/0229

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EK10N

Sheet no.

N 9.1

Section N

Hydraulic system

Pump unit

Removal 1. Pull out the battery plug (see sheet no. A4) 2. Remove the electrical cable (1) (key size 13).

5

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

3. Unscrew the hydraulic leads (2) (5U20) and seal them off.

4. Release the 2 screws (3) on the back of the flange-mounted block (4) with key size 17, and lift the pump unit (5) out of the holder in the chassis.

8/0026

5. To reinstall the pump unit, follow the installation instructions in reverse order.

1

2

4

3

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EK10N

8/0041t

Sheet no.

N 10

Section N

Hydraulic system

Pump unit Removing the pump motor EK10 NO, NM

2 1

1.

Pull out the battery plug (see sheet A4).

2.

Unscrew the 2 nuts (item 2).

3.

Detach the connecting cable (1) from the motor (mark the cable).

4.

Take down the motor carefully.

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

Remark:

8/0072

There is an assembly pin (3) in the lower part of the motor housing. Note this when reinstalling the pump motor. The assembly pin is generally on the side of the electrically releasable nonreturn valve.

3 To reinstall the pump motor follow the removal instructions in reverse order, taking care to note the following points: 8/0073

1. See the Remark above.

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

8/0041t

4

8/0074

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EK10N

Sheet no.

N 11

Section N

Hydraulic system

Pump unit Removing the pump motor EK10 HO,HM

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

1 1.

Pull out the battery plug (see sheet A4).

2.

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

3.

Remove the 3 hexagon socket screws (2).

4.

Carefully remove the motor.

2 0/0226

To install the pump motor, follow the instructions above in reverse order, taking into account the following points: 1.

2.

4

The connections must face towards the front.

The motor shaft (3) must be pushed correctly onto the cross coupling (4).

0/0228

8/0041t

3

0/0227

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EK10N

Sheet no.

N11.1

Section N

Hydraulic system

Pump unit Hydraulic pump

General

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

The hydraulic pump is an externally toothed gear pump.

A

A

B

B

C

C

The pump consists mainly of the pair of toothed gears, which is carried in 4 bearing bushes, and the housing with the front and rear cover. The drive shaft, which is sealed with a shaft rotary shaft seal, is inserted through the front cover.

The bearing forces are taken up by sliding bearings. These are designed for high bearing pressures and have good emergency running properties, especially at low speeds.

The delivery chambers are sealed internally in relation to the pressure, which gives optimum efficiency.

Delivery side

At the front end, the movable bearing bushes are pressurised by the operating pressure and pressed against the toothed gears to form a seal.

Intake side

8/0075

The pressurised pressure fields are limited by special seals.

The seal around the edge of the toothed gears is guaranteed with tiny gaps, which adapt when the toothed gears are pushed against the housing by the pressure.

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EK10N

Sheet no.

N 12

Section N

Hydraulic system

Pump unit

Removing the hydraulic pump

1. Pull out the battery plug (see sheet A4).

2. Remove the pump unit (see sheet N11).

3. Remove the pump motor (see sheet no.

N10).

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

4. Unscrew the 4 hexagon bolts (1).

5. Remove the oil container (2).

6. Unscrew the 4 hexagon bolts (3).

7. Remove the hydraulic pump.

Remark: After reassembly, check the oil level (volume of oil approx. 4.5 l)

8/0076

3

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EK10N

2

1

Sheet no.

N 13

Section N

Hydraulic system

Pump unit Dismantling the hydraulic pump Intake side Housing 3 parallel grooves

Drive side cover

Radial grooves

Sealing cover

Grooves for fluid leakage

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

8/0077

Sealing and supporting elements Openings Drive shaft High-pressure seal Toothed gears Radial seal

Delivery side Removal 1. Pull the drive wheel off the shaft.

Housing

2. Release the hexagon socket screw.

3. Lift off the cover over the drive shaft.

Front centre rest Drive gear wheel

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

Mark the driven toothed gear and centre Driven toothed rest. gear

8/0078

5. By pulling on the housing, remove from the housing the shaft with drive gear wheel, driven gear wheel and the front centre rest (use a protective jaw).

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Workshop Manual

EK10N

Sheet no.

N 14

Section N

Hydraulic system

Pump unit Adjustment Pressure release valve 1. Connect the pressure manometer.

2. Unscrew the nut (Item 1).

3. Lift the nominal load with the forks and determine the operating pressure (note the value).

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

Remark:

1

The adjustment value for the maximum pressure is calculated from the operating pressure on lifting with the nominal load plus 10 %.

4. Move the lift to the upper end stop (bridge the lift cut-out) and adjust the maximum pressure with the adjusting screw (Item 2).

Remark:

8/0079

If the vehicle is fitted with an additional lift, this can be used to move the lift to the end stop.

5. Mount the nut (Item 1) with the sealing ring and tighten.

2

For information on the exact maximum pressure values, see the information plate, which is mounted next to the vehicle's factory plate.

Recommended values for adjusting the pressure: EK10NO EK10HM Maximum press.

Op. press. w/o L.

8/0080

ca.150 bar ca. 200 bar ca. 50 bar ca. 75 bar

Op. press. w. L. ca.100 bar ca. 180 bar Curr. cons. w/o L. ca 75A ca. 90A Curr. cons. w. L. Issue: 07/00 Replaces issue:

ca.125A

ca. 170A Workshop Manual

EK10N

Sheet no.

N 15

Section N

Hydraulic system

Pump unit

Changing the hydraulic oil Interval: Type of oil used:

every 12 months HLP46 DIN 51524

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

Oil volume: 4.5 l (EK10 NO, NM, HO, HM)

Procedure

2

1. Follow steps 1 - 5 on sheet no. N11.

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

3. Clean the oil filter (1).

4. Replace the hydraulic suction filter (2) as required.

5. Fill the oil container with hydraulic oil.

6. Mount the oil container.

8/0076

7. Check the hydraulic system for leaks.

1

8. Attach the oil information card 9. Mount the cover.

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EK10N

Sheet no.

N 16

Section N

Hydraulic system

Bleeding the lift cylinders and the hydraulic system The lift cylinders of the hydraulic system should be bled when -

the lift cylinders have been removed and installed again, a hydraulic lead or hose has been replaced, work has been carried out on the hydraulic system.

1 2

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

Procedure 1. Open the bleeder screw (1) (do not remove it).

2. Actuate the switch for lifting the hydraulics and move the cylinder to the end stop.

Remark:

On vehicles with a lift cut-out, the end switch must be bridged so that the pump motor does not cut out.

8/0083

3. As soon as hydraulic oil comes out of the hole (2) without bubbles in it, the bleeder screw (1) can be closed again.

This process must be carried out on all the cylinders.

This entire procedure must be repeated if any of the hydraulic functions are not in order.

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EK10N

Sheet no.

N 17

Section N

Hydraulic system

Distributor block 4

Id. no. W8 421 768 5 The purpose of the distributor block (1) is to switch over the hydraulic oil flow from main lift to additional lift on vehicles with an additional lift (NM or HM).

1

2

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

The distributor block is made up of the following components: 1

2/2 way directional valve (main lift) Id. no. W8 422 029

2

2/2 way directional valve (additional lift) Id. no. W8 422 029

3

3

8/0084

Bubble reservoir Id. no. W8 421 767

3 8/0085

1

2

Technical data: Coil resistance values Test points pin 1 (4) against pin 2 (5) = 24.5Ω

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EK10N

Sheet no.

N 18

Section N

Hydraulic system

Bubble reservoir Id. no. W8 421 767

The bubble reservoir (1) is used to release and compensate pressure peaks in the hydraulic system which arise when the pump motor starts up.

1

The bubble reservoir is maintenance-free.

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

Note: Do not open the bubble reservoir or replace the gas.

8/0086

A faulty bubble reservoir must be disposed of correctly in accordance with the regulations, because of the gas filling.

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EK10N

Sheet no.

N 19

Section N

Hydraulic system

Hydraulic hoses General Hoses and hose assemblies are subject to natural ageing, even during storage and when they are subjected only to the permissible amount of stress. As a result, their storage life and operational life is limited (see UVV regulation ZH1/74).

Hose Inner layer

In order to prevent the quality diminishing prematurely during storage, please note the following :

Insert

Outer layer

Intermediate layer

Wall of hose 8/0081

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

-

Store hoses free of tension and laid out flat Storage temperature +15°C to +25°C Relative humidity 65 % Store in a dust-free area Avoid direct sunlight and UV light Protect from sources of heat

Hose assembly Hose

Nipple

Holder

Union nut

During the period of use, the hoses should be checked for ageing, age, cracks and damage at least once a year, and replaced if necessary.

Hose end

When replacing faulty hoses, it is important to note that:

Connection end

Hose fitting 8/0082

- their natural position and movement should not be obstructed - During operation, they should not be strained by pulling, torsion or blockage caused by external influences.

- Avoid painting over hoses - Do not select a bending radius that is too small Used hoses must not be used again.

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EK10N

Sheet no.

N 20

Section R

Lubrication plan

Contents Sheet no.

Lubrication plan EK10 NO ....................................................................................R 2 Lubrication plan EK10 NM....................................................................................R 3 Lubrication plan EK10 HO ....................................................................................R 4 Lubrication plan EK10 HM....................................................................................R 5

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Lubricants .............................................................................................................R 6

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EK10N

Sheet no.

R1

Section R

Lubrication plan

Lubrication plan EK10 NO 1. Lubricate the bolster bearing with all-purpose grease: every 12 months 2. Lubricate all the moving parts with oil:

2 6

every 3 months 3. Change the hydraulic oil: every 12 months 3

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

4. Change the gear oil: every 12 months

5 5. Grease the idling roller bearing: every 12 months

8/0026

1

4

6. Keep the running surfaces in the mast profiles free of corrosion with a film of grease: every 3 months Remark: for viscosity and oil type, see R6.

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EK10N

Sheet no.

R2

Section R

Lubrication plan

Lubrication plan EK10 NM 1. Grease the bolster bearing with all-purpose grease: every 12 months

2 6

2. Lubricate all the moving parts with oil: every 3 months

3

3. Change the hydraulic oil: every 12 months

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

7 4. Change the gear oil:

8/0027

every 12 months

1

4

5. Chain spray every 3 months

6. Grease the idling roller bearing: every 12 months 6 7. Keep the running surfaces in the mast profiles free of corrosion with a film of grease: every 3 months

5

Remark: for viscosity and oil type, see R6.

8/0002

7

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EK10N

Sheet no.

R3

Section R

Lubrication plan

Lubrication plan EK10 HO 2

6

1. Grease the bolster bearing with all-purpose grease: every 12 months 2. Lubricate all the moving parts with oil: every 3 months

3

3. Change the hydraulic oil: every 12 months 5 1

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

4. Change the gear oil:

8/0029

every 12 months 4 5. Grease the idling roller bearing: every 12 months 7 6. Keep the running surfaces in the mast profiles free of corrosion with a film of grease: every 3 months Remark: for viscosity and oil type, see R6.

8/0003

5

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EK10N

Sheet no.

R4

Section R

Lubrication plan

Lubrication plan EK10 HO

2

1. Grease the bolster bearing with all-purpose grease: every 12 months

2. Lubricate all the moving parts with oil:

3

every 3 months

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

3. Change the hydraulic oil: every 12 months

1

8/0028

4

4. Change the gear oil: every 12 months

5 5. Grease the idling roller bearing: every 12 months

7. Keep the running surfaces in the mast profiles free of corrosion with a film of grease: every 3 months

5

Remark: for viscosity and oil type, see R6.

8/0004

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EK10N

Sheet no.

R5

Section R

Lubrication plan

Lubricants Purpose

Viscosity/ name

DIN

Id. no.

Hydraulic oil

HLP 46 or HVLP 46 HVI 24

51524 /T 2

W8 036 912

51524 / F 3

W8 036 916

51524 / T 3

W8 036 239

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

Hydraulic oil Hydraulic oil (for full-time use in cold store)

HVLP 46 MR 310

Hydraulic oil (for full-time/ part time use in cold store)

HLP 22 Synzh

W8 036 240

Gear oil

SAE 80

W8 036 925

Gear oil (for part-time and full-time use in cold store)

SAE 75W - 90 (Part synth.)

W8 036 929

Chain lubricant

Stabylan 2001

W8 010 100

Chain lubricant (For part-time and full-time use in cold store)

Syntesco

W8 036 220

Lubricants for roller bearings and other lubrication points

Beacon 2

W8 010 107

(for part-time and full-time use in cold store)

Acedo X 2

W8 050 076

Profile spray for lifting device, Ceplattyn 1612 sliding surfaces, toothed racks (also for cold store)

W8 052 125

Brake fluid

W8 034 957

Remark:

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ATE DOT 4

See the oil information card on the vehicle for which lubricants to use (see sheet no. R7).

Workshop Manual

EK10N

Sheet no.

R6