Still STED forklift TSR30 CSR 12,5 16 20 Workshop Manual - PDF DOWNLOAD

Workshop Manual

TSR30 CSR 12,5/16/20

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30000

30001

First issue: Last revision:

08/03 07/01

WorkshopManual

TSR/CSR

Id. no.

01

888 054 329

Workshop Manual

TSR30 CSR 12,5/16/20

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

Copyright reserved.

This Workshop Manual can be used for the truck types

TSR:

2t

Nominal Load Capacity

24V Battery Voltage TSR:

3t

Nominal Load Capacity

48V Battery Voltage CSR12,5/16/20:

1,25/1,6/2,0t Nominal Load Capacity 24V Battery Voltage

First issue: Last revision:

08/03

WorkshopManual

TSR/CSR

Id. no.

8 054 329

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

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.

50002

The workshop manual is always updated by supplementary sheets.

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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.

50003

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.

50004

00255

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Sheet no.

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Foreword Updating workshop manuals

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Exchanging faulty sheets 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.

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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.

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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N° id. -------

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5 Page baseline of the supplementary sheet Workshop Manual

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Sheet no.

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2

Vorwort Foreword Remarks, imprint No guarantee claims arise as a result of working in accordance with the instructions contained in this manual.

This does not affect the guarantee stipulations.

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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.

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Sections 1

Vehicle data

2

Travel motor

3

Drive wheel

4

Gear

5

Brake

6

Steering

7

BDI/HM

8

Circuit board

9

Travel control

10

Accelerator pedal

11

Hydraulic TSR

12

Hydraulic CSR

13

Lifting device

14

Mast CSR

99

Maintenance

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Table of Contents Section

Contents Sheet Foreword........................................................................................1 Updating of workshop manuals .............................................1 Exchanging faulty sheets ......................................................2 Insertion of supplementary sheets ........................................2 Remarks, imprint............................................................................3 Sections .........................................................................................4 Contents.........................................................................................5

1

Vehicle data Identification..............................................................................1-01 Signs on the vehicle..................................................................1-02

2

Travel motor General .....................................................................................2-01 Technical Data ..........................................................................2-02 Terminals ..................................................................................2-02 Removing the drive motor.........................................................2-03 Replacing the carbon brushes ..................................................2-04 Maintenance .............................................................................2-05 General ............................................................................2-05 Cleaning ...........................................................................2-05 Visual inspection, replacing damaged parts.....................2-06 Checking the brush unit, replacing the carbon brushes...........................................2-07 Commutator .....................................................................2-08 Bearings ...........................................................................2-08

3

Drive wheel Replacing..................................................................................3-01 Removal....................................................................................3-01

4

Gear Removing..................................................................................4-01 Lubricating the bogie bearing ...................................................4-02 Changing the gear oil................................................................4-02 Oil change.................................................................................4-03 Oil change procedure.......................................................4-03

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Table of Contents

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Section

Contents

Sheet

5

Brake Function ....................................................................................5-01 Service brake (brake pedal)......................................................5-01 Parking brake (handbrake) .......................................................5-01 Guide to components................................................................5-02 Installing/removing the drive motor brake.................................5-03 Removal ...........................................................................5-03 Installation ........................................................................5-03 Adjusting the brake clearance ..................................................5-04 Checking the brake lining thickness.................................5-04 Adjusting the brakes.........................................................5-04 Adjusting the handbrake ...........................................................5-05 Checking the setting.........................................................5-05 Adjusting the brake pedal .........................................................5-06 Measuring the brake deceleration ............................................5-07 General ............................................................................5-07 Preparations for measurement.........................................5-07 Measuring the brake deceleration ............................................5-08 Evaluating the measurement ...........................................5-08 Main brake cylinder...................................................................5-09 Bleeding / filling the brake system ............................................5-10 Filling the brake system ...................................................5-10 Bleeding the brake system...............................................5-10

6

Steering General .....................................................................................6-01 Structure of the steering system ...............................................6-02 Steering sensor.........................................................................6-03 General ............................................................................6-03 Slipring system.................................................................6-04 Adjusting the steering sensor ...................................................6-05 General ............................................................................6-05 Adjustment when installed ...............................................6-05 Adjustment when not installed .........................................6-07 Servo unit..................................................................................6-08 General ............................................................................6-08 Terminal markings on terminal board ...............................6-08 Exchanging the carbon brushes.......................................6-09 Specifications ...................................................................6-09 Steering controler .....................................................................6-10 General ............................................................................6-10 Function ...........................................................................6-10 Safety monitoring .............................................................6-11 Adjusting the current limitation .........................................6-12

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Table of Contents

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Section

Contents

Sheet

7

BDI/HM Curtis Combi-Controller 803 .....................................................7-01 General ............................................................................7-01 Pin assignment.................................................................7-02 Setting the final discharge voltage ...................................7-03 Technical data ..................................................................7-04 Accumeter EL-AC5 (up to 6/93)...............................................7-05 Battery discharge indicator...............................................7-05 Hour meter .......................................................................7-06 Accumeter EL-AC5 (from 7/93) ................................................7-07 General ............................................................................7-07 Installation ........................................................................7-07 Electrical connection ........................................................7-08 Specifications ...................................................................7-09 Adjusting accumeter EL-AC......................................................7-10

8

Circuit board Circuit board A1with adapter card A8 .......................................8-01 Components.....................................................................8-01 Fuses ........................................................................................8-02 Testing the fuses ..............................................................8-03 Components .............................................................................8-04 Rating plate ......................................................................8-04 Contactor clearance .........................................................8-04 Contact pressure..............................................................8-04

9

Travel control General .....................................................................................9-01 Functional characteristics.................................................9-01 Cycle ratio and current profile ..........................................9-01 Setpoint value current, frequency characteristic.......................9-02 Primary current circuit...............................................................9-03 Ignition process ................................................................9-03 Thyristors ..................................................................................9-04 Function ...........................................................................9-04 Thyristors ..................................................................................9-05 Installation ........................................................................9-05 Installation instructions.....................................................9-05 Thyristor power block................................................................9-06 General ............................................................................9-06 Diodes.......................................................................................9-07 Functional characteristics.................................................9-07 Layout, installation ...........................................................9-07

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Contents

Sheet

Travel control Diodes.......................................................................................9-08 Testing the diodes ............................................................9-08 Diode power block ....................................................................9-09 General ............................................................................9-09 Testing..............................................................................9-09 Terminal............................................................................9-09 Functional Characteristics................................................9-10 Testing the primary current ......................................................9-11 Test procedure .................................................................9-12 Current actual value sensor n35...............................................9-13 Functional characteristics.................................................9-13 Control circuit board u200.........................................................9-14 Functional characteristics.................................................9-14 Checking the safety circuit ...............................................9-14 Removing .........................................................................9-15 Settings ............................................................................9-15 Speed restriction GB (from 12/90) ...........................9-15 Ramp-up time HZ ....................................................9-15 Reversing current RS ..............................................9-16 Drive current FS.......................................................9-16 Drive reduction 2,5kph .....................................................9-17 Adjustment of drive current ..............................................9-18 Current setting .........................................................9-18 Adapter card A8 ........................................................................9-20 General ............................................................................9-20 Settings ............................................................................9-21 Default factory settings.....................................................9-21 LED display ......................................................................9-22 Measured signals .............................................................9-23 Block circuit diagram ........................................................9-24 Wiring diagram .........................................................................9-25 Circuit board A1 with adapter card A8..............................9-25

10

Accelerator pedal General ...................................................................................10-01 Functional characteristics of the magnetoresistor..........10-01

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Table of Contents

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Section

Contents

Sheet

11

Hydraulics Block diagram .........................................................................11-01 Hydraulic circuit diagram.........................................................11-01 Pump assembly ......................................................................11-02 General...........................................................................11-02 Function LIFTING...........................................................11-03 Function LOWERING .....................................................11-04 Electrically pilot controlled non-return valve ...................11-05 Replacing the carbon brushes........................................11-06 Removal / Installation .....................................................11-06 Removal .........................................................................11-07 Installation ......................................................................11-07 Removing the pump motor .............................................11-08 Hydraulic pump ..............................................................11-09 General ..................................................................11-09 Removing the hydraulic pump........................................11-10 Setting the maximum pressure.......................................11-12 Recommended values for pressure adjustment: ...11-12 Hydraulic oil change .......................................................11-13 Bleeding the lifting cylinder and hydraulic system of air .........11-14 Procedure.......................................................................11-14

12

Hydraulic system Diagram of the hydraulic system ............................................12-01 Pump unit................................................................................12-02 Removal .........................................................................12-02 Carbon brushes..............................................................12-02 Directional slide valve block....................................................12-02 Adjusting the maximum pressure valve .........................12-03

13

Lifting device Function of the angled lever ...................................................13-01 Adjustment..............................................................................13-01 Drawbar adjuster............................................................13-01 End stops at bottom .......................................................13-01 End stops at top .............................................................13-02 Lift stop...........................................................................13-02 Angled lever - pressure rods ..........................................13-03 Lifting cylinder, low lift .............................................................13-04 Guide to parts.................................................................13-04 Adjusting the tension springs .........................................13-04

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Table of Contents

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Section

Contents

Sheet

14

Mast Basic lift ..................................................................................14-01 General ..........................................................................14-01 Setting the height when lowered ....................................14-01 General ...................................................................................14-02 Load carriage, concealed cylinder version.....................14-02 Load carriage, exposed cylinder version........................14-02 Function ..................................................................................14-03 Removing the telscopic load carriage.....................................14-04 Mounting ........................................................................14-04 Removing the lift cylinder .......................................................14-05 Support rollers - outer mast ....................................................14-06 Lift bracket ..............................................................................14-07 General ..........................................................................14-07 Removing ......................................................................14-07 Lift bracket ..............................................................................14-08 Setting the adjusting screws .........................................14-08 Chains.....................................................................................14-09 General ..........................................................................14-09 Setting the control chains .......................................................14-10 Setting the clearance lift chain ................................................14-11 Chain setting at the triplex load carriage ................................14-12 Testing with/without rated load .......................................14-12

99

Maintenance General ...................................................................................99-01 Safety instructions ..................................................................99-02 Handling fuels and lubricants .........................................99-02 Brake ......................................................................................99-03 Testing the function of the service brake........................99-03 Testing the function of the parking brake .......................99-03 Testing the function of the reversing brake ....................99-03 Wear limit for the brake lining.........................................99-03 Battery ....................................................................................99-04 Checking the electrolyte level ........................................99-04 Checking the electrolyte density ....................................99-04 Cleaning the battery .......................................................99-04 Battery lock ....................................................................99-05 Battery charger...............................................................99-05 Operating elements ................................................................99-06 Ease of movement .........................................................99-06 Steering ..................................................................................99-07 Ease of movement .........................................................99-07 Cut-out in the event of error ...........................................99-07 Steering chain ................................................................99-07 Reverse steering ............................................................99-07

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99

Contents

Sheet

Maintenance Lifting chains...........................................................................99-08 General ..........................................................................99-08 Checking the lifting chains for damage ..........................99-09 Checking the lifting chains for damage ..........................99-12 Checking the chain elongation .......................................99-13 Replacing the lifting chains ............................................99-14 Lubricating the lifting chains ...................................................99-15 Cleaning the chains ................................................................99-16 Hydraulic tank .........................................................................99-17 Volume ...........................................................................99-17 Seals ..............................................................................99-17 Soiled oil.........................................................................99-17 Wheels....................................................................................99-18 Wear...............................................................................99-18 Wheel bearings ..............................................................99-18 Load wheels ...................................................................99-18 Motor.......................................................................................99-19 Carbon brushes..............................................................99-19 Checking the brush springs............................................99-19 Other maintenance work ................................................99-19 Gear........................................................................................99-20 Changing the gear oil .....................................................99-20 Noises ............................................................................99-20 Leaks..............................................................................99-20 Mast ........................................................................................99-21 Mast rollers.....................................................................99-21 Guide rollers of the fork holder.......................................99-21 Windscreen ....................................................................99-21 Lifting cylinder ................................................................99-21 Guides, surfaces ............................................................99-21 Forks ..............................................................................99-21 Chain adjustment ...........................................................99-21 Pump assembly ......................................................................99-22 Carbon brushes..............................................................99-22 Oil level ..........................................................................99-22 Noises ............................................................................99-22 Soiling ............................................................................99-22 Lubrication plan ......................................................................99-23 Lubricants.......................................................................99-23 Disposal .........................................................................99-23 Lubrication plan..............................................................99-24

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Chapter 1

Vehicle data

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Identification

30000

TSR

30001

CSR 12,5/16/20

• Load bearing capacity

2000/ 3000kg

1250/ 1600/ 2000kg

• Tavel motor

2,8/ 4,2kW

2,8kW

• Maximum speed

12km/h

8km/h

• Dimensions L/W/H ca.

2330-4700/ 980/ 1550mm

2230/ 980/ 2350mm

• Weight with battery

1450-2100kg

1700-2200kg

• Battery voltage

24/ 48V

24V

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Chapter 1

Vehicle data

Signs on the vehicle

5

1 Nameplate (beside driver seat) 2 UVV check 3 Maximum pressure hydraulic 4 Towing points 5 Vehicle no. on chassis 6 Carrying load diagram

30000

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

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6

30002

1

10309

3

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1 – 02

Chapter 2

Travel motor

General Series-wound motors are used in the travel drive unit.

The armature and field winding are connected in series, so ensuring greater torque particularly in the lower speed ranges.

Remark:

Series-wound motors must never be operated for long periods without load, i.e. without being in gear. Otherwise, they automatically increase their speed to the point of self-destruction .

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The motor speed is controlled by the stroke ratio of the main thyristor, which is timed by the control circuit board of the pulse control system.

The sense of rotation of the motor is controlled by the flow direction of the current through the field winding.

The direction of flow is determined by the travel direction contactors.

30003

In 24V appliances, the motor is self-ventilating.

Ventilation is effected by a fan impeller wheel mounted on the armature shaft.

48 V motors are additionally separately ventilated by an external radial fan in the area of the commutator.

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Chapter 2

Travel motor

Technical Data Manufacturer Model Motor version Voltage Current Output Speed Protection class Insulation class

(V) (A) (kW) (min -1)

JULI JULI GF 116-14/1.9/2.8 Series-wound 24 48 145 108 2,8 4,2 1700 2000 IP 21 IP21 B B/F

Terminals

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Designation Armature coil Field coil

new A1/A2 D1/D2

old A/B E/F

The rotary direction of the motor (1) depends on the direction in which the current (2) flows through the field coil.

The current direction is determined by the travel direction contactors.

10279

A2

A1

D2

D1

•

•

•

•

1

A2

•

A1

D2

D1

•

•

•

1

2

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Chapter 2

Travel motor

Removing the drive motor Note:

Because the brake (1) is flangemounted on the drive motor, the vehicle is no longer braked once the motor has been removed.

The vehicle must be secured before work commences, to prevent it rolling away.

1

Removal

2

• Pull out the battery plug.

• Jack up the vehicle and secure it to prevent it from roling away.

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• Mark the motor connecting cable and disconnect it.

30003

• Release the 4 hexagon socket screws M8x30 (4) and remove them completely.

6

• Lift the drum brake up and out and set it down to one side.

4

• Remove the 6 hexagon socket screws M8x30 (5).

2

• Lift and remove the motor (2) together with the flange (6).

5

• The pinion stays on the shaft end of the motor.

• Cover the gear opening to protect the inside from dirt.

Remark:

When you install the motor again, you must ensure that the bearing bridge is in the correct position when the wheel is in the straight-on position. When it is in the right position, an optimal cooling effect is achieved.

10280

Bearing bridge

End shield

Ventilation shafts

Wheel in straight-on position 10281

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Chapter 2

Travel motor

Replacing the carbon brushes The carbon brushes must be replaced when they reach a residual length of 16mm resp. 20mm. At this length, they are worn down by 50 %.

Length of a new carbon brush: 32mm (24V) 40mm (48V) The entire set of brushes must always be replaced (4 brushes).

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Removal: • • • • • •

Pull out the battery plug.

Remove the tensioning belt of the drive motor.

Raise the brush spring (1).

Pull out the carbon at the connecting cable (2).

Disconnect the connecting cable.

Clean out the commutator compartment (blow it out).

Caution:

60163

1

Never inhale carbon dust!

• Mount the new carbon brushes.

Remark: After replacing the carbon brushes, do not run the motor straight away at full power. The carbon brushes run in relatively quickly under low loads (see drive motor maintenance).

Checking the brush springs Brush springs with insufficient pre-tension cause the commutator to burn.

Ensure that the carbon brushes move easily in the shaft.

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Chapter 2

Travel motor

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

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

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

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Note:

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

Cleaning • Remove the sealing tape and take out the brushes.

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

10288

• Clean soiled commutators and brush unit using a clean cloth (not cleaning wool) moistened with benzine and dry well.

Remark:

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

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Chapter 2

Travel motor

Maintenance

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Visual inspection, replacing damaged parts • Straighten or replace dented sealing tapes.

• Check fan impellers for damage. Damaged fans (imbalance, reduced output) must be replaced.

• Clean the gear ventilation channels (1). To do so, remove the drive motor and clean the channels with a vacuum cleaner (do not blow them out with compressed air). Soiling impairs the air circulation, which leads to increased temperatures in the motor and possibly to irreparable damage.

• Check field and armature coils for signs of over-loading (overheating): dark coloration, brittle or burned insulation, unsoldered commutators.

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

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

Remark:

1

50039

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

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

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

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Chapter 2

Travel motor

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

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

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

It is also important that the carbon brushes are not broken or chipped at the running edges.

Remarks: • Always replace the entire brush set, basing your assessment on the shortest brush.

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

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

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

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

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Chapter 2

Travel motor

Maintenance Commutator The running surface of the commutator should be even and smooth with a grey-black appearance. The commutator must not be worn, scored or out of round.

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

Never attempt to achieve the neccesary finish using a file, emergy paper or similar.

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Bearings The ball bearings do not need to be re-lubricated.

The volume of grease in the bearings is sufficient for the maintenance period between major overhauls.

The bearings must be replaced: • without fail during every major overhaul, • after they have been in use for 2000 operating hours, at the latest • if the vehicle is only used with short operating times, then after 5 years at the latest.

Only use the bearings specified in the spare parts list.

Note on risk of overloading when batteries are run down: If the speed of the motors drops noticeably, work must be stopped immediately. Check the battery without delay, then recharge it if necessary.

Never drive the vehicle if the voltage is too low!

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Chapter 3

Drive wheel

Replacing Dimensions of new wheel:

300 x 130mm

The drive wheel must be replaced when: • The running surface is badly cracked or out of round, or its diameter is very different from that of the other drive wheel.

• The tyre diameter has reduced by 10 %, e.g. 300mm - 10 % = 270mm.

Removal • Pull out the battery plug.

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• Apply the handbrake.

• Jack up the vehicle securely and secure it to prevent it from rolling away.

• Turn the drive wheel (1) until the wheel nuts (2) are accessible.

10285

• Release the wheel nuts.

2

• Remove the drive wheel.

1

• When mounting the new drive wheel, tighten the wheel nuts diagonally in several passes.

Tightening torque: 140Nm.

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Chapter 4

Gear

Removing 2

• Pull out the battery plug.

• Turn the drive wheel to the side.

1

• Releae the drive motor with the brake (6 hexagon socket screws (2) M8x30).

• Raise the drive motor and lay a flat metal plate approx. 20mm thick underneath it.

• Cover the gear opening (to prevent soiling of the gear and oil).

10284

• Release the tension on the steering chain and open the chain joint at the chain holder.

The chain can now be removed.

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• Remove the 6 screws M12x60 (1).

Remark:

Suspend the gear from a rope or underlay it with wood to prevent it tilting back or to one side.

• Move a fork-lift truck or lifting gear into the correct position for raising the vehicle.

10285

• Support the device safely from below.

• Have a lifting truck at the ready for removing the drive unit.

• Lift out the drive unit.

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Chapter 4

Gear

Lubricating the bogie bearing

1

2

The bogie bearing should be lubricated twice a year through the two lubricating nipples (2), in particular when the gear has been cleaned with a steam jet.

Grease type:

multi-purpose grease

Changing the gear oil

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

Copyright reserved.

The following viscosity classes are used: Standard oil: Ambient temperature:

SAE 80/90 0°C to 40°C

Low-temperature oil: Ambient temperature:

SAE 80 W to -26°C

Low-temperature oil: Ambient temperature:

SAE 75 W to -40°C

10287

For use of the vehicle in special conditions, please contact the manufacturer without fail.

Oil volume:

approx. 2.0 l

Remark: The oil volume specified here is intended for guidance only. The correct amount of oil has been poured in when the oil level reaches the bottom edge of the filler hole (1).

Please avoid overfilling, otherwise the seals will be damaged and it is possible that the operating temperature may not be maintained under certain circumstances.

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Chapter 4

Gear

Oil change

2

The oil should be changed for the first time after approx. 1000 operating hours.

All subsequent gear oil changes should be made at intervals of 2000 operating hours or once a year.

Remark: The gear oil must be drained off when it is at operating temperature. The maximum permissible operating temperature is 80°C.

Oil change procedure • Set an oil catchment vessel under the oil drainage screw (1) (it should have a capacity of at least 3.5l).

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

Copyright reserved.

• Unscrew the oil filler cap (2).

• Unscrew the oil drainage screw and drain off the oil.

Caution: Risk of scalding: The oil temperature may be as high as 80°C!

1

10287

• Replace the oil drainage screw, inserting a new sealing ring at the same time.

• Fill the gear with new gear oil up to the bottom edge of the threaded hole for the oil filler cap.

• Insert the oil filler cap, using a new sealing ring.

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Chapter 5

Brake

Function Thishydraulic/mechanical brake system is a pressure application system (positive acting), and consists of a mechanical component, which is the parking brake (handbrake) and the hydraulic component, which is the service brake (brake pedal).

Service brake (brake pedal)

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

Copyright reserved.

When the brake pedal is depressed, pressure is applied to the wheel brake cylinder (2) by the main brake cylinder, so that the wheel brake cylinder presses the brake shoes (8 + 9) against the brake drum (17) .

When the brake pedal is released, the brake shoes are moved back into the home position by tension springs (11 + 13).

10289

Parking brake (handbrake)

17

When the handbrake is used, the brake shoes are actuated by a cable pull (18). At the same time, the minus conductor for the travel direction contactors K2 and K3 are interrupted via a handbrake switch.

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Chapter 5

Brake

Guide to components in the hydraulic/mechanical brake system

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

Copyright reserved.

1 Handbrake lever 2 Handbrake switch 3 Bowden cable 4 Brake unit at the drive motor 5 Brake pedal lever 6 Main brake cylinder 7 Return spring 8 Hydraulic lead 9 Compensation tank

9 8

1

6 5

7

2

4

3 10217

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Chapter 5

Brake

Installing/removing the drive motor brake Note:

1

5

4

Once the brake has been removed, the vehicle is no longer braked. For this reason: • Pull out the battery plug.

• Jack up the vehicle and secure it to prevent it from rolling away.

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

Copyright reserved.

Removal • Remove the brake hose (1) from the brake cylinder, making sure that no oil runs out over the brake and motor.

• Remove the brake housing (2) by releasing the 4 hexagon socket screws (3) from the drive motor.

• For easy removal of the cable pull, relieve the tension on it at the adjusting device of the handbrake lever.

• Separate the baseplate (4) from the housing by releasing the 7 hexagon socket screws (5) M8x16.

10291

2

3

Installation • Attach the baseplate to the housing.

• Secure the cable pull for the handbrake.

• Set the brake on the motor and screw the housing to the motor flange.

• Attach the brake hose.

• Bleed the brake and reset the handbrake.

• Check that the brake functions correctly.

• Brake pedal function check • Handbrake function check.

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Chapter 5

Brake

Adjusting the brake clearance Note:

The brake deceleration values must be checked in accordance with the guidelines (see brake deceleration) once a year and after all adjustments/ repairs made to the brake system.

Checking the brake lining thickness There are holes (1) integrated in the brake plate which are designed for visual inspection of the brake linings. If there is only a residual thickness of approx. 2mm visible, the brake shoes must be replaced.

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

Copyright reserved.

Adjusting the brakes The inner shoe brake has a central adjustment feature for the clearance and enveloping circle. In this adjusting process, a wedge (2) is drawn between the contact points of the brake shoes, which causes the enveloping circle to change. As a result, ideal utilisation of the brake linings is achieved, while at the same time, the leverage for transfer of the brake force to the brake drum is improved. After every new adjustment of this brake wedge, the brake shoes must be re-centred by braking several times.

10292

2

Turning the adjusting wedge (2) to the right pulls the wedge upward, in other words expands the enveloping circle and results in re-adjustment of the brake linings. Turning the wedge to the left makes the enveloping circle smaller. Brake clearance setting 0.3-0.5mm.

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5 – 04

Chapter 5

Brake

Adjusting the handbrake Like the brake pedal, the handbrake acts on the drive wheel. The brake cable required for this function is attached to the hook of the brake shoe at one end and to the brake lever at the other end, in the driver's cab; adjustments to the brake cable are made at this end.

• Set the brake clearance correctly (0.3-0.5mm).

• Set the brake cable adjuster (1) so that the teeth of the handbrake lever can only be notched into the 4th tooth by applying considerable force.

Checking the setting • Jack up the vehicle securely.

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Copyright reserved.

• Bridge the handbrake switch.

• Accelerate the motor to maximum speed.

• Apply the handbrake.

The motor should block when the 3rd tooth engages, at the latest.

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Sheet no.

5 – 05

Chapter 5

Brake

Adjusting the brake pedal The brake pedal must be adjusted when: 1. The return force of the brake pedal needs to be altered, 2. The main brake cylinder has been changed, 3. The piston rod clearance is not correct.

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

Copyright reserved.

Remark: •

•

7

ca.35mm

Procedure: • Release the nuts (1 to 6).

• Screw in the threaded rod so that it is flush with the inside of the fork head (9) and lock it with the nut (5).

• Turn the nut (3) until there is a distance of approx. 35mm between the lower edge of the pedal plate (7) and the footplate.

Then lock with the nut (4).

The brake pedal must not come into contact with the upper fork head (6).

Now screw in the nut (2) until the required pedal return force is set. Lock with the nut (1).

An adequate pedal return force is achieved when a dimension of approx. 60 mm from the spring (10) is set.

After releasing the nut (6), turn the upper threaded rod so that there is a clearance of 1 mm between the piston and piston rod of the main brake cylinder.

10295

1

This "snifter clearance" can be felt by pressing the brake pedal slowly downwards out of its home position. When the piston rod has moved a distance of 1mm, it should be possible to feel a slight resistance, which is caused by the piston rod and the piston coming into contact with each other.

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4

5

6

9

10

Sheet no.

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Chapter 5

Brake

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

6

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

2

During travel at a steady speed over an even surface, the pendulum always hangs vertically and shows zero on the dial (4). On acceleration, the pointer deflects to the right (clockwise) and on braking (deceleration), it moves to the left.

1

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

Copyright reserved.

Preparations for measurement 50115

Moisten the rubber sucker on the underside of the dynometer then use the lever (1) to fasten it 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 (2) must be tipped to move the measuring pointer (5) to zero.

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

The maximum pointer (3) is moved round to the measuring pointer from the right by turning the knob (6).

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

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50116

Sheet no.

5 – 07

Chapter 5

Brake

Measuring the brake deceleration Evaluating the measurement 1. Calculate the maximum vehicle speed (speed = distance/time).

2. Accelerate the vehicle to vmax in the direction of the forks.

3. Stop the vehicle by applying the brakes with full force, and read the braking deceleration value "F" off the dynometer (position of max. pointer).

4. The following values are needed: Example for v = 12km/h F = 1,86 x v

F = 1,86 x 12km/h Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

F = 22,32%

Remark: Since measurement of the brake deceleration value is heavily dependent on the ground conditions, measurement of the deceleration value should only be carried out on a hard-surface, non-slip floor that is level and dry.

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Chapter 5

Brake

Main brake cylinder

1

2

The main brake cylinder is located under the edal for the foot brake in the underfloor compartment, and is connected to the brake pedal by a turning mechanism.

The cylinder is connected to the compensation tank (3) by the plastic connection piece (1) and a hose.

The compensation tank must always be filled with brake fluid up to about 15 - 20 mm below the edge of the lid.

10296

3

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

Copyright reserved.

Remark: Only use original brake fluid! Do not add any mineral oil!

The main brake cylinder has a protective cap (2) which prevents dust and water penetrating into the cylinder. The protective cap is fitted with an air hole so that the air contained in the protective cap can escape when the main brake cylinder is actuated.

The protective cap must be mounted so that the air hole is at the bottom. If the protective cap is installed so that the air hole is at the top, water may collect in the protective cap which can penetrate into the main cylinder when the brake is applied.

The consequences of this are: • Formation of rust at the main brake cylinder hole, which can cause damage to the secondary ring and result in loss of brake fluid.

• The main brake cylinder piston can freeze solid at minus temperatures.

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Chapter 5

Brake

Bleeding / filling the brake system

1

Caution: When handling brake fluid, ensure that the aggressive fluid does not come into contact with the eyes, skin, clothing or parts of the fork-lift truck. If you get brake fluid in your eyes or on your skin, rinse out immediately with lots of clear water or off the skin with soap.

Never mix brake fluid with mineral oil or dispose of it together with mineral oil!

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

Copyright reserved.

Filling the brake system Brake fluid is hygroscopic, i.e. it absorbs moisture from the air. For this reason, we recommend replacing the brake fluid at least once a year. When filling and bleeding air out of new brake systems or after maintenance, any brake fluid which has overflowed must not be used for filling the system.

10291

Bleeding the brake system If good braking results are not achieved until the pedal has been pressed several times, the brake system must be bled of air. If you have an "Ate filling and bleeding device" available, follow the instructions for use provided by Teves, the manufacturer. If a device of this kind is not available, the brake system must be bled as follows. Two people are needed for this work: • Empty the storage tank and fill it with new brake fluid.

• Remove the dust cap from the bleeder valve (1), push on a well-fitting hose and hang the other end of the hose in an open glass container that is positioned higher than the first end.

Note:

Only use the bleeder valve at the brake hose and not the one at the brake plate!

Bind a cloth or something similar round the bleeder valve so that brake fluid does not get into the brake!

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Chapter 5

Brake

Bleeding / filling the brake system • One person presses the brake pedal down as far as it goes and holds it in this position.

Caution:

1

Ensure that the bleeder hose cannot slip out of place. Cover the glass with a cleaning cloth to catch any splashes.

• The second person opens the bleeder valve (1) by a quarter or a half turn.

• Brake fluid should emerge due to the pressure exerted by the brake pedal.

• Close the bleeder valve again immediately.

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

Copyright reserved.

• Slowly move the brake pedal back into its home position.

Repeat this process between 4 and 7 times until only bubble-free, clear brake fluid emerges into the glass container.

If the oil level in the compensation container drops significantly during this process, the system must be topped up with new "Ate brake fluid".

10291

Do not reuse brake fluid that has come out of the system.

Remark: If it is often found that there is air in the brake system or if the brake cylinders loose brake fluid, the sealing rings must be replaced or the affected brake cylinder replaced.

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Chapter 6

Steering

General 1 The electrical steering aid is a device designed to assist the steering of fork-lift trucks with a steering column.

For the event that the electrical steering aid fails, there is also a mechanical emergency steering system!

2

The control electronics and the main current circuit are combined in one closed unit (1), which is referred to as the steering controller.

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

Copyright reserved.

The setpoint generator (2) is located on the steering column. It is a non-contact differential magnetoresistive sensor.

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Chapter 6

Steering

Structure of the steering system

7

8

1

The lower end of the inclinable steering column with steering wheel is connected to the steering transmission (2) by a cardan joint (1).

The steering transmission has a chain wheel at the top and is flange-mounted to the frame above the chain wheel.

Transmission of the steering force to the fifth wheel is effected by means of a steering chain (3). Two adjusting screws (4) are used to for tensioning here.

The bearing pedestal of the steering transmission must be displaced to tension the chain. After tensioning, tighten the fastening screws.

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

Copyright reserved.

Caution:

30012

2

4

3

5

6

Do not tighten chains too taut!

The following elements are also required for the electrical steering system: • A steering column with magnetoresistor • A servo unit consisting of the steering servo motor with reducing gear (5), • Electronic control circuitry (6).

The steering servo motor is flange mounted on the steering transmission by a retainer and is connected by a chain to the shaft of the steering transmission.

The chain (7) is tightened at the steering motor by means of an adjusting screw (8).

The control system, which works fully electronically, is accommodated in a closed black plastic housing.

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Chapter 6

Steering

Steering sensor General For measurement of the setpoint, which is proportional to the steering force, the system uses a differential magnetoresistive sensor (1), which is influenced by a permanent magnet (2)

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

Copyright reserved.

The steering column is divided into 2 sections. The upper section with the steering wheel can be turned against the lower section with the cardan joint by ±7° out of the centre position against two torsion elements made of foam rubber.

The differential magnetoresistive sensor can be seen as a resistor that is dependent on a magnetic field. It is fitted on the lower section of the steering column, and the magnet on the upper section. When the two sections are turned in opposite directions, the magnetic field changes in dependence on the angle of the magnetic field, which also causes the output signal to change.

2 1mm 1

When not actuated, the centre point voltage of the differential magnetoresistive sensor is half the supply voltage and is the reference potential for the steering controller.

The change in voltage in comparison to the reference potential is approx. ±2.5V, depending on the turning direction and force.

50055

This change in voltage is also dependent on the distance between the magnetoresistor and the magnet. For this reason, the distance between the magnetoresistor and the magnet should be 1mm at the most.

50056

0V

10V

Centre point voltage ±2,5V

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Chapter 6

Steering

Steering sensor Slipring system Because the differential magnetoresistive sensor turns with the steering column, a power supply is required that also turns.

The power is supplied by means of a slipring system with 3 sliprings, each of which has two sliding-action contacts connected in parallel.

These sliding-action contacts are maintenance-free.

They should be applied to the slipring system with a slight pressure.

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

Copyright reserved.

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Chapter 6

Steering

Adjusting the steering sensor General Note:

This steering aid must not be connected to the battery until the steering sensor has been set, otherwise there is a risk that the steering wheel may turn suddenly, making it a potential source of injury. For the same reason, you must exercise extreme caution when adjusting the steering wheel.

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

Copyright reserved.

Do not reach through the steering wheel during the adjusting process.

The steering sensor is checked in advance, i.e. it is not usually necessary to adjust it. However, if it is necessary to make an adjustment for some reason, e.g. after the steering sensor has been replaced or the steering column has been repaired, etc. you should proceed as follows: A voltmeter is needed for this work.

1

Adjustment when installed 1. Pull out the battery plug.

2. Disconnect both the central terminals "2" on the slipring system (1).

3. Connect the voltmeter (voltage measurement).

Connect positive to "3" and negative to "1".

50055

4. Plug in the battery plug.

5. Check the supply voltage.

6. Pull out the battery plug.

7. Connect the voltmeter positive to "2", negative to "1". Plug in the battery plug.

50056

0V

10V

Centre point voltage ±2,5V

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Chapter 6

Steering

Adjusting the steering sensor Adjustment when installed 8. Release the clamping screw (1) on the magnetoresistor holder, then position the latter at a distance of approx. 1 mm centrally under the magnet, so that 5V (± 0.05V) is measured between terminals "2" and "3". Tighten the clamping screw again.

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

Copyright reserved.

9. Now turn the steering wheel until the clamping sleeve (2) in the sensor hits the mechanical end stop. The voltage between "1" and "2" and "2" and "3" should change by approx. 2.5V (full turn).

If the change in voltage is too low, the distance between the magnetoresistor and the magnet must be reduced.

3

2

10. Checking the voltage reset When the steering wheel is released, the voltage should return to the centre position which was set previously. If this is not the case, all the bearing points in the steering column must be checked to ensure that they move easily, and if necessary the foam rubber torsion segments (3) replaced.

1mm

11. Function check: Pull out the battery plug and reconnect the two central terminals "2", then plug in the battery plug. It should be possible to turn the steering wheel to the left and right with the same amount of force.

When the steering wheel is not turned, the steering motor should be switched off. There is no motor current flowing.

If this is not the case, the adjustment must be made again or the steering controller calibrated.

1 50055

50058

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Chapter 6

Steering

Adjusting the steering sensor Adjustment when not installed In order to carry out this adjusting work, the sensor must be clamped into a vice at one shaft end, so that the torsion that usually occurs during steering can be simulated.

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

Copyright reserved.

Connect a supply voltage of 10V to terminals "1" and "3" from a power unit.

1. Release the clamping screw (1) on the magnetoresistor holder, then position the latter at a distance of approx. 1 mm centrally under the magnet, so that 5V (± 0.05V) is measured between terminals "2" and "3".

Tighten the clamping screw again.

2. Now turn the sensor (e.g. with a pair of gripping pliers), until the clamping sleeve in the sensor hits the mechanical end stop (2). The voltage between 1 "1" and "2" and "2" and "3" should change by approx. 2.5V (full turn).

If the change in voltage is too low, the distance between the magnetoresistor and the magnet must be reduced.

3. Checking the voltage reset When the turning element is released, the voltage should return to the centre position which was set previously. If this is not the case, all the bearing points in the steering column must be checked to ensure that they move easily, and if necessary the foam rubber torsion segments replaced.

2

1mm

50055

4. The sensor is now pre-set. However, it is still essential to carry out a function check once the sensor is installed.

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Chapter 6

Steering

Servo unit General The servo unit consists of an electric motor (1) and a flange-mounted gear (2).

The motor is designed with two separate series-wound motors (split field motors). For this reason, it can be run in a clockwise or anti-clockwise direction without reversing the polarity.

2

• The ball bearings are maintenance-free.

1

500049

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

Copyright reserved.

• The bearings must be replaced after 25,000 operating hours.

• If the ball bearings are pulled off during repair work, they must be replaced.

• The gear is greased adequately for its entire operating life and is therefore maintenance-free.

Terminal markings on terminal board A1 = Armature Dr/D1 = Field 1 for right-hand rotation Dl/D2 = Field 2 for left-hand rotation

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Chapter 6

Steering

Servo Unit Exchanging the carbon brushes For detailed information (see drive motor/ maintenance).

New length:

22mm

Change at residual length:

11mm

Brush spring tension:

4.5cN

Set of carbon brushes:

2 brushes

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

Copyright reserved.

Specifications Manufacturer Type Motor type Voltage (V) Current (A) Output (kW) Speed (min -1) Protection class Insulation class

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Schabmüller R100/0,4-184/149-81-18 R100/0,4-185/131-81-18 Series wound motor (Split field motor) 24 48 25 12.6 0.4 0.4 2950 2815 IP 20 IP 20 F F

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Chapter 6

Steering

Steering controler General The control electronics, the main current circuit and the safety circuit are all integrated in the control unit and cannot be replaced individually.

The system is protected in the negative lead with 2 fuses (1) parallel with 20A. Supply voltage

24V

48V

Maximum current

25A

17A

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

Copyright reserved.

Function 1

The steering controller supplies the steering sensor with stabilised 10V. When the upper and lower steering columns are not turned in opposite directions to each other, the motor is currentless. When a turn is made, the motor is controlled via the amplifier in accordance with the setpoint deviation (switching frequency 100Hz).

10300

10301

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Chapter 6

Steering

Steering controler Safety monitoring The following are monitored: • Function of amplifier transistor • Motor lead, for short-circuiting • Function of steering motor • Sensor signal (setpoint must be within range of ±3V)

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

Copyright reserved.

• Electronics in control unit • Adjustable current limitation This also includes the super fast-action fuses, which are made to burn out in the event that errors caused by switching functions occur in the electronics.

Remark:

If an error occurs, the system can only be made ready for operation again by switching it off.

Note:

Always pull out the battery plug when the motor current circuit needs to be interrupted, otherwise the super fast-action fuses may burn out.

Always use the specified type of fuse when making replacements.

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Chapter 6

Steering

Steering controler Adjusting the current limitation The control unit is set in the factory. It is only necessary to make adjustments if the system does not function correctly or if it has been replaced. a) Steering to end stop, right/left b) Steering wheel released

I =25A (24V) I =17A (48V) I = 0A

10302

A

)

• Clip the current measuring instrument to lead A; if you do not have a clip-on current measuring instrument, see the section on measurement with shunt.

)

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

Copyright reserved.

Current measurement with clip-on measuring instrument:

•

• Turn the steering as far as it goes and read off the value.

• If necessary, adjust at potentiometer (1), only at 48V unit.

10303

1

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Chapter 7

BDI/HM

Curtis Combi-Controller 803 General The Curtis Combi-Controller 803 works on the principle of continuously comparing the battery voltage with an internally set reference voltage series.

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

Copyright reserved.

This 36 stage reference voltage is the same as the course of the discharge voltage that has been set.

If the mean value of the battery voltage drops below the reference voltage within a space of 46 seconds, the Combi-Controller 803 automatically makes a comparison with the next reference voltage down.

This process is repeated from one voltage stage to the next.

As the voltage stages decrease, the LED display moves from the right to the left. When the cut-off wave (final discharge voltage) is reached, the two LEDs on the left flash (in red).

The discharge characteristic curve can be set on the back of the appliance, to suit the relevant operating conditions.

The battery charging status is stored with a lithium battery (10 years), and the counter status is stored in an EEPROM.

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Chapter 7

BDI/HM

Curtis Combi-Controller 803 Pin assignment Operating voltage Pin 7 = B+ (24V) Pin 8 = B+ (48V) Pin 5 = BCut-off function Pin 3/4

10307

Cut-off when the final discharge voltage is reached, at 20% of the residual battery capacity.

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Copyright reserved.

Remark:

B+ 48V B+ 24V

The cut-off is executed by a thyristor.

Key switch Cut off

For this reason, it is absolutely essential to ensure that the polarity is correct when making the connection! (positive/negative - for logic, see diagram to the right).

positive start input hour counter negative start input Battery voltage B10306

If the polarity is incorrect, the Curtis Combi-Controller 803 and the switching contact can be irreparably damaged.

Positive / negative logic connection

+

Key switch Pin 2

Switching on the LED display

Hour counter Pin 6 Pin 1

Start by applying from B+ to (6) or from B- to (1)

3

+

3

+

4

-

4

-

-

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Chapter 7

BDI/HM

Curtis Combi-Controller 803 Setting the final discharge voltage The final discharge voltage (volt/cell) can be set with the potentiometer (1).

The setting recommendations made by the battery manufacturer should be taken into account here (see table below).

10307

Reset to "full"

1

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

Copyright reserved.

Voltage at begin of gassing 2.35V/cell for at least 6 mins. or Connect a battery with an off-load voltage of at least 2.09 V/cell.

K L M N O P Q R S T U

1.57 1.63 1.68 1.73 1.78 1.82 1.84 1.86 1.89 1.91 1.93

Battery manufacturers' recommended settings for standard load Lead/acid wet-cell battery PzS Lead/acid wet-cell batteries increased capacity CMS Hagen PWF.CWF.PzV Sonnenschein dryfit Varta Carat (Gel)-Batterie Deta Dryflex (Gel) battery, general

Remark:

1,73V/C 1,78V/C 1,82V/C 1,93V/C, 60% discharge 1,93V/C 1,91V/C, 70% discharge 1,93V/C

In some cases where the load is very high (high power extraction in a short time), it is possible that the cut-off process can take place too early. In cases of this kind, the correct setting must be determined by testing.

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Chapter 7

BDI/HM

Curtis Combi-Controller 803 Technical data Battery discharge indicator: • • • • • • •

10 LEDs; 5 green, 3 yellow, 2 red Lithium storage battery Reset when gassing voltage of 2.35 V/cell or offload voltage of 2.09 V/cell is reached Cut-off by a locking NC contact Discharge characteristic curve, adjustable Visual warning at 25% remaining capacity Switching current 3A

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

Copyright reserved.

Hour counter: • • • •

10308

LC display, 6-figure Resolution 0.1 hrs Flashing symbol when counting Power-independent memory with EEPROM

Typenschild

Basic data: • • • • • •

Operating voltage 24V and 48V Tolerance ±25% of the rated voltage Operating temperature -40°C to + 85°C Compact connector with lock Accuracy - max. deviation 2% Protection class IP65 at front.

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Chapter 7

BDI/HM

Accumeter EL-AC5 (up to 6/93) This instrument is equipped with a 7-digit hour meter additionally to the battery discharge display.

Battery discharge indicator

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

Copyright reserved.

A yellow LED chain indicates the discharge status of the battery. WIth progressing discharge, the LEDs are extinguished one by one. When the exhaustive discharge level is reached (appr. 80% discharge), the red LED "Charge battery" begins to light up (all other LEDs are extinguished).

This cut-out limit can be adjusted using a potentiometer underneath the device to the respective operating conditions. However, attention must be paid to adhere to the battery manufacturers' specification regarding cut-out voltage (final discharge voltage in volts/cell).

Remark:

30013

When exchanging an accumeter, check the potential setting!

At the same time, a relay is switched which switches off the lift hydraulics (via contacts 2 and 3). This relay signal has a latching function, i.e. the switching function remains set also with rising battery voltage.

The self-latching function can be released by briefly interrupting the supply voltage. This release possibility is only given when a higher voltage than the cut-out voltage has been set after cut-out, e.g. as a result of battery charging.

Remark:

Due to the digital storage of the discharge status, it is necessary for the accumeter to be connected direct with terminals 8 and 4 to the battery supply, i.e. without disconnection at the keyoperated or any other switch.

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Chapter 7

BDI/HM

Accumeter EL-AC5 (up to 6/93) Hour meter The hour meter consists of a quartz oscillator and a downstream electronic temporary storage.

As long as positive battery voltage is applied at the counter inputs (terminals 5, 6 or 7) (by actuating the key-operated switch), even the shortest operating periods are read in. After every expired period of 36s (00.01h), the temporary storage transmits the information to the electromechanical counter which at the same time exercises a display function.

Specfications:

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

Copyright reserved.

Battery voltage: Switch contact:

Cut-out point:

30015

48V 1 changeover contact, 120W switching capacity Imax.=5A Umax.=100V 1.88V - 2.0V adjustable

Diodes

Electrical connection using flat connector 6.3 x 0.8mm.

Remark:

30016

When mounting the combination display in a plastic cover, it is possible that the instruments will be damaged by static charging. To avoid this, an equalizing conductor of 0.75 dia. must be laid from the metal housing of the instrument to the chassis.

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Chapter 7

BDI/HM

Accumeter EL-AC5 (from 7/93) General This combination display has been installed in the truck since 7/93.

The functional characteristics of the new EL-AC5 correspond to those of the previous model.

1

The new mode has the advantage that it can be installed using any material type (plastic or metal) without the risk of damage due to static charging.

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

Copyright reserved.

It is simple to exchange the "old" version for the "new" one as the installation dimensions are the same.

The only change is in the electrical terminals, which are slightly altered due to technical design modification. The basic terminals such as voltage supply and the tripping contact of the hydraulic system have remained the same.

1

2

Installation By turning the screws accessible from the front (1), the device is clamped using the two lugs (2) into the retaining borehole.

Attention must be paid that the screws are not excessively tightened (max. tightening torque 30Ncm).

30017

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Chapter 7

BDI/HM

Accumeter EL-AC5 (from 7/93) Electrical connection Voltage supply Pin 8 Pin 4

+Battery -Battery

30018

Hour meter

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

Copyright reserved.

Pin 5 Pin 6

Positive counting input Negative counting input

The hour meter starts when +battery is switched against pin 5 (e.g. key-operated switch). For this, pin 6 must be directly connected to -battery. The counter also starts when +battery is connected directly to pin 5 and pin 6 is switched against -battery.

Tripping contact

9

Pin 2 Pin 3 Voltage supply, LED chain Pin 9

8

6

5

4

3

2

+Battery

+Battery

If direct voltage is applied to pin 9 (jumper pin 8 and pin 9), the display is continuously alight.

Should the display only light up under certain circumstances, e.g. when the key-operated switch is ON, then pin 9 is switched via the respective contact.

This does not impair the measured result.

8

Remark:

2

+

9 5

For connection, always use insulated push-on receptacles.

3

M

6 4

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h

Chapter 7

BDI/HM

Accumeter EL-AC5 (from 7/93) Specifications Battery voltage:

48V

Switching contact:

1 NO contact, 90W switching capacity Imax = 3A Umax = 125V

Tripping point:

1.88V - 2.0V adjustable

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

Copyright reserved.

Remark:

Before commissioning, check whether all inductors, in particular coils, are connected to a free-wheeling diode.

High-energy spurious pulses can lead to an incorrect indication.

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Chapter 7

BDI/HM

Adjusting accumeter EL-AC The basic setting of the accumeter must be selected according to the battery type.

A differentiation is made between wet-cell batteries, increased-capacity wet-cell batteries (CSM batteries) and batteries with fixed electrolyte (dry and gel batteries).

2 1

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

Copyright reserved.

Batteries of the same type manufactured by different companies are essentially the same as far as voltage is concerned.

The figures specified are for battery discharge with a medium current for 5-hours. The basic settings must be altered when the discharge current is changed from a medium current used for 5 hours or when extreme temperatures have an effect on the possible battery discharge.

Important The basic setting must be adjusted on location to suit the operating conditions.

In case of doubt, the battery manufacturer should be asked for the correct value for their battery.

30019

Factory setting "G" (marked by white spot on the potentiometer) 30058

Identification letter

Adjustments can be made with the potentiometer on the underside of the accumeter (1). The white spot marks the set value. To make the adjustment, the markings on the potentiometer must be compared with the scale printed on the nameplate (2). If there is any doubt, the adjustment is displayed when the potentiometer is briefly turned to the right/ left as far as it will go.

Breaking voltage S

2,06 1,99 1,98

J

1,97 1,96 1,95

G

1,94 1,93 1,92

D

1,91 1,90 1,89

A

1,88

Breaking voltage = battery terminal voltage immediately after load switch-off.

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Chapter 7

BDI/HM

Adjusting accumeter EL-AC

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

Copyright reserved.

The table below shows the various different basic settings for different battery types.

When the vehicle is used in cold storage areas there may be variations, depending on the operating conditions.

In cases of this kind, please contact the battery manufacturer.

Battery type

Basic setting

Lead acid wet-cell battery (PZS) Lead acid wet-cell battery Capacity-increased (CSM) Sonnenschein Dryfit Varta Carat (gel battery) Deta Dryflex Gel batteries in general

G I

Remark:

K K K K

Identification letter I is between G and J. Identification letter K is between J and M.

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Chapter 8

Circuit board

Circuit board A1with adapter card A8

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

Copyright reserved.

Components 1 Series resistor control board u200 (only with 48V) 2 Control circuit board u200 3 Capacitor K22 4 Charge converter m23 5 Main thyristor n20 (1v1) 6 Current actual value sensor n35 7 Fuses 8 Air-core conductor m22 9 Transcharge and gate turn-off thyristor n36, n22 10 Field free-wheeling diode n24 (Diode powerblock only with 48V) 11 Armature free-w. diode n25 (1v5) 12 Adapter card A8 13 Fuses F5, F6 14 Main contactor K50 15 Pump contactor K1 16 Travel direction contactor forwards K2 17 Travel direction contactor reverse K3

1

u200

2

3 K22 4

5 n2

m 23

n3

6

7 n36

n22

9 8 A 8 F5

14 K50

11

F6

13

10 n24

n25

12

15 K1

16 K2

17 K3

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Chapter 8

Circuit board

Fuses Remark: If a fuse has to be exchanged, discon-nect the system by pulling out the mains plug. For fuse ratings, see below.

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

Copyright reserved.

F1:

Control current key operated switch 15A / 80V, blue F2: Control c. travel directioncontactor 5A / 80V, light brown F3: Control current pump contactor and main contactor 5A / 80V, light brown F4: Control current hooter 5A / 80V, light brown F15: Steering (2 fuses) 15A / 80V, blue F16: External fan 5A / 80V, light brown F20: Discharge display / batt. controller 5A / 80V, light brown F6: Main current, drive motor 200A / 24V, 125A / 48V F5: Main current, pump motor 200/250A (2/3kW) / 24V, 125A / 48V

F1

F2

F3

F4

1

F15

F16 F20

u200

2

3 K22 4

5 n2

m 23

n3

6

7 n36

n22

9 8 A 8 F5

14 K50

11

F6

13

10 n24

n25

12

15 K1

16 K2

17 K3

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Chapter 8

Circuit board

Fuses Testing the fuses

5A

However, should you be uncertain as to the condition of a fuse, remove it and carry out a test with the continuity tester or an ohmmeter.

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

Copyright reserved.

Continuity or 1-10Ω means: Fuse in order.

No continuity or resistance in the megaΩ-range means: Fuse defective.

32 V

1

The control current fuses (2) must also be taken out of their retainers for testing purposes. As the control current fuses are held in clamps, check the contact surface and if necessary restore the metallic polish.

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Chapter 8

Circuit board

Components Rating plate The rating plate for the contactors is located in the form of an adhesive label on the coil. If contactors have be replaced completely, pay attention to the rated voltage.

Contactor clearance

oder 48 V

If correctly assembled, there must be a distance of between 1.8 and 3.2mm between the contact bridge and the support arm when the contactor is energized.

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

Copyright reserved.

Contact pressure

30062

Contact pressure of the contactor when fully actuated: Setpoint 11-14N per contact, relative to centre contact.

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Chapter 9

Travel control

General The pulse control is a device for low-loss, infinite adjustment of battery-run industrial trucks.

Functional characteristics A thyristor (HT) is connected in the main circuit of the drive motor. If the thyristor receives an ignition pulse from the control board, it is energized and the motor circuit is closed. The motor starts running.

+

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Copyright reserved.

The main thyristor is then turned off. This interrupts the circuit again and switches off the motor.

The current make/break operation happens at an extremely fast rate which does not allow the current to ever die down completely. The motor output is influenced by altering the make/break time of the main thyristor.

Travel direction contactor

M

PCB

Cycle ratio and current profile The ratio of make to break time is called the cycle ratio. A short cycle ratio results in short make times and long break times.

The ascertained current profile curve indicates the motor output.

Make/break profile in the main thyristor 1 Current profile in the motor t (s)

0 Low motor output

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30064

Sheet no.

9 – 01

Chapter 9

Travel control

Setpoint value current, frequency characteristic With increasing setpoint value, the cycle ratio is altered from approximately zero to approximately one.

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

Copyright reserved.

Cycle ratio

ap. 0.97

ap. 0.03

4

5

6

7

8

9

30065

U (Volt) Set value at drive switch

With increasing setpoint value, the pulse frequency is varied in accordance with the graphs below.

250 Frequency (Hz)

0

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8

9

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30066

U (Volt) Set value at drive switch

Sheet no.

9 – 02

Chapter 9

Travel control

Primary current circuit Ignition process

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

Copyright reserved.

1. At the beginning of the ignition process, the capacitor K22 must be charged.

This happens as a result of ignition of the gate turn-off thyristor n22.

Current path: M5, m22, K22, n22, m23 2. The main thyristor n20 can now be ignited - the motor starts up.

At the same time, the transload thyristor n20 must be ignited, to permit the + charge of the K22 to flow to the other side. This transcharge process is supported by the charge transformer m23 (induction, transformer principle).

The capacitor is now charged with the correct polarity (+ at anode n22).

Transcharge path: K22, m22, n20, n36, m23.

3. Turn-off of the main thyristor is effected by triggering the gate turn-off thyristor n22.

The parallel connection of the main thyristor and the capacitor is now closed - the capacitor charge can now flow to the main thyristor, permitting turnoff.

In addition, the motor current is now redirected via the now briefly discharged capacitor K22. (No current flows for a short time via main thyristor).

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Chapter 9

Travel control

Thyristors Function Symbol

Thyristors are semi-conductor components, and have two stable operating statuses: a high-resistance and low-resistance status. They possess the characteristics of switches. Switchover from highresistance to low-resistance status can be controlled by a gate.

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

Copyright reserved.

A

A = Anode K = Cathode G = Gate (Steueranschluß)

K G

Main thyristor

n 36

Transchange thyristor

Gate turn-off thyristor

Mode of operation A thyristor polarized in the triggered direction pulls out on the arrival of a sufficiently large and longlasting control pulse to the low-resistance (conductive) status.

30068

Triggered direction of a thyristor IAK M

In the low-resistance status, the gate becomes ineffective.

The normal thyristor cannot be switched back to the high-resistance (disabled) status with the aid of the gate. It remains in the low-resistance status until the current IAK has dropped below a certain minimum value. This minimum current value is called the holding current IH. Remark:

The thyristor can be tested when it is installed (see Travel control/ Testing the primary current).

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Chapter 9

Travel control

Thyristors Installation Disc-type thyristors are used as main thyristors and gate turn-off thyristors.

The drawing shows the three most commonly used variants. a) Ceramic housing (BBC) b) Ceramic/metal housing (AEG) c) Plastic housing (AEG)

a)

b)

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

Copyright reserved.

The installation instructions apply to all types, as only when an even level of pressure is applied through the tension cap is reliable function achieved under full load.

Installation instructions • The contact surfaces of the cooling arrangement must be level in the areas where components meet, as well as free of foreign bodies or dust.

• Contact surfaces must be painted with heat transfer paste.

• Observe the installation direction. See the switch symbol on the cell (anode to heat sink).

• The screws must be tightened alternately.

• Tighten screws until the tension cap makes contact with the heat sink.

Flexible link, cup spring and tension cap are riveted together and provided with each thyristor.

• The transcharge thyristor n36 must be handtightened (4Nm). The thread must be painted with heat transfer paste.

c)

Remark: All heat sinks are insulated by a common hostafan foil and screwed onto the base plate. Under the gate turn-off thyristor cooling plate is an additional hostafan foil.

To improve heat conduction, the heat sink and the cooling plate must be coated with a thin layer of heat transfer paste before installation.

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Chapter 9

Travel control

Thyristor power block General The thyristor power block is used on the control panel A1 with adapter card A8, and incorporates the gate turn-off and transcharge thyristor (n22 and n36).

3

The thyristor can be tested when it is installed (see Travel control/ Testing the primary current).

AK

K

A

2

1

Ω

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

Copyright reserved.

Remark: No conducting connection should exist between the individual terminal and the cooling surface (resistance measurement, 3).

30070

Terminals AK - K:

Transcharge thyristor n36

AK - A:

Turn-off thyristor n22

1:

Gate transcharge thyristor

2:

Gate turn-off thyristor AK

K

A 2

1

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Chapter 9

Travel control

Diodes Functional characteristics When the vehicle rolls without the driver activating the drive lever (e.g. braking, reversing, coasting), the motor is no longer driven by the vehicle control system, but by the kinetic energy of the vehicle.

n24 n25

The drive motor now works as a generator which is generating an inductive voltage.

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

Copyright reserved.

This inductive voltage is opposed to the applied current, and so leads to uncontrolled deceleration of the vehicle.

30071

n25 and n25 short circuit the induction voltage. This prevents the induction voltage from generating any further deceleration moment, and the motor coasts to rest freely.

The "field free-wheeling diode" n24 additionally supports the reversing operation.

Layout, installation The two power diodes n24 and n25 are identical in design.

They must both be installed with a rated tightening torque of 15Nm. In addition, paint the thread with heat transfer paste.

n36

n25

Remark: When installing a power diode on the heat sink, ensure that the contact surfaces of the diode are coated with heat transfer paste.

n24

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30072

9 – 07

Chapter 9

Travel control

Diodes Testing the diodes • Pull out the battery plug • Disconnect the diode on one side

A

• Set "Diode test" res."resistance meassuring" at the mulimeter.

• Connect the diode anode to the V/Ω-terminal socket and the cathode to the COM-terminal socket K

• The multimeter must indicate "continuity" (0.5..0.7V res. kΩ ..MΩ) • Change the terminals on the diode Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• The multimeter must indicate no "continuity" Remark: A insulation test is only required for highcapacity diodes such as for example n24 and n25. Small diodes, such as suppressor circuits, can only be tested using the "continuity" test function, as otherwise the test voltage can bring about flashover of the diode in the nonconducting direction.

COM

V, Ω

Multimeter

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Chapter 9

Travel control

Diode power block General

The diode power block is used in the control panel A1 with adapter card A8. However, here only in the 48V version. For the field free-wheeling diode n24, two diodes are switched in series. This brings about a more gentle reversing action.

Testing

The performance check can be carried out using a corresponding method as for the screw-type thyristors.

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

Copyright reserved.

Remark:

No conducting connection should exist between the individual terminals and the cooling surface (resistance measurement, 2).

1K6

24

1K8

23

M11

14 13

D1 D2

1K6

13

1K8

24

14 A1

M11

23

n25

M

(nur 48V)

n24

A2

n35

1 2 3

1

Terminal AK - K:

Diode 1

AK - A:

Diode 2

A - K:

Series connection of diode 1 and 2

AK

K

Ω

A

30073

AK

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Sheet no.

A

9 – 09

Chapter 9

Travel control

Capacitors 1

Functional Characteristics The capacitor (1) has the capability of storing electrical energy.

It consists of a roll of special paper and a dielectric fluid. Both are mounted in an aluminium beaker with a plastic lid from which the terminals project. This metal paper capacitor is not polarized, i.e. it can also be charged with reverse polarity.

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

Copyright reserved.

When fluid escapes from the beaker or an internal short circuit occurs, the capacitor is defective.

The capacitor has two terminals. The voltage at the capacitor is around +UBatt in a charged state. When discharged, the voltage is 0.

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Chapter 9

Travel control

Testing the primary current The test described below is used to check all components of the pulse control system and the wiring in the primary current circuit. If the statuses described in the test procedure are achieved, it may be assumed that the primary current circuit is in order.

1

The following conditions must be complied with

v

• The vehicle must be jacked up securely and underlaid • Load wheel free, parking brake not applied.

• Travel direction contactor mechanically activated (load contacts closed).

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Copyright reserved.

• Control board removed.

• Voltage +UBatt measured parallel to the main thyristor (1) between anode and cathode.

30010

Test procedure

2

• Connect voltmeter parallel to the discharged transcharge capacitor (ensure correct polarity), if necessary discharge with "soft" resistor (1).

• Connect the positive terminal socket of the thyristor test unit (2) with +UBatt.

Remark: Do not short the capacitor for discharging.

This can destroy the capacitor!

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Chapter 9

Travel control

Testing the primary current Test procedure 1. Connect the gate lead of the thyristor test unit to the gate terminal of the turn-off thyristor and trigger.

UK must rise from 0V to appr. +UBatt.

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

Copyright reserved.

2. Connect the gate lead of the thyristor test unit to the gate terminal of the main thyristor and trigger. The motor should now run at full speed.

3. Connect the gate lead of the thyristor test unit to the gate terminal of the transcharge thyristor (3) and trigger.

UK remains approximately at the same value, but changes its polarity, i.e. a minus sign appears in front of the value 4. Disconnect the firing lead from the transcharge thyristor, connect it to the gate turn-off thyristor (4), and trigger.

UK must now change polarity again; the motor decelerates because the main thyristor has been "turned off".

30010

2

1 3

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01 9 – 12

Chapter 9

Travel control

Current actual value sensor n35 In order to set limitation of the motor current, this must first be measured.

This is carried out using a magnetoresistor which is located in the primary current circuit of the drive motor (1).

1

Functional characteristics The current running in the current rail generates a magnetic field and so influences the magnetoresistor.

The magnetoresistor is supplied from the circuit board with 10V (stabilized voltage) via terminals 1 and 3.

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

Copyright reserved.

If no current flows, a voltage of around 5V is applied at the central terminal 2.

As soon as current flows, the mean voltage at terminal 2 changes its value to around 0.4V per 100A.

30010

In this way, a voltage proportional to the increase in current is made available at the circuit board, which permits a restriction of modulation at maximum current intensity.

Remark: Every current sensor is precisely adjusted, measured and sealed.

No alterations may be made at the current sensor.

1

2

3

10 A

17 A

8A

Control circuit board u200

+10V

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Chapter 9

Travel control

Control circuit board u200 Functional characteristics The control circuit board accommodates all functions for regulation of the drive pulse control system.

up to 11/90

The travel setpoint value for the circuit board is delivered directly from the drive sensor (u25). The actual value comes from the current actual value sensor n35.

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

Copyright reserved.

This creates the following logical switching processes in the circuit board:

30075

• Contactor switching.

• Control of the power circuit (thyristor) • Control of the motor current • Restriction of current input

from 12/90

At the same time, a monitoring function is carried out which suppresses uncontrolled vehicle movements by preventing system modulation.

Remark: The new control circuit board has been in use since 11/90.

When used in older models, a jumper must be laid between the contacts B6 and B15.

30076

Checking the safety circuit Disconnect the gate conductor of the transcharge thyristor (1). When starting up, the vehicle first jerks forward, then the travel direction contactors release, and the vehicle comes to a stop. This means that the safety circuit is working correctly.

1 1

30011

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Sheet no.

9 – 14

Chapter 9

Travel control

Control circuit board u200

up to 11/90

Removing HZ RS FS

• Take out the battery plug.

no function

• Pull out the cover by releasing two sheet metal screws from the board housing at the side.

• Pull ou the control circuit board with the supplementary handle at the lateral edge of the circuit board.

o

Remark: Do not pull at the components on the front of the board!

o

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

Copyright reserved.

Settings Speed restriction GB (from 12/90) The truck is set for a maximum speed. If necessary, it is possble to reduce the set maximum using this potentiometer. When reducing the speed by more than 30%, the tractive force and climb capability of the truck will be reduced correspondingly.

Potentiometer setting in the furthest left-hand position = maximum speed (This setting is not possible in the previous version of the control board).

from 12/90

GB HZ RS FS

Ramp-up time HZ If the accelerator pedal is applied suddenly, the time delay until full modulation is appr. 1.5s.

Potentiometer setting in the furthest left position = shortest ramp-up time.

= =

Lower setting value Higher setting value

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Sheet no.

9 – 15

Chapter 9

Travel control

Control circuit board u200

up to 11/90

Reversing current RS If the travel direction switch is switched over while the accelerator is pressed, the truck is electrically braked and accelerated in the opposite direction.

This process must be set in such a way that the drive wheel does not block and a "gentle" acceleration is carried out.

Potentiometer setting at the furthest right-hand poistion (full reversing current).

HZ RS FS

no function

o

Drive current FS By correct setting of the drive current, the optimum power output of the vehicle is achieved without the possibility of overloading occurring in the drive system.

o

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

Copyright reserved.

Maximum values for drive current: 24V truck: 48V truck:

280A 220A from 12/90

Remark: As these are maximum values, they must not be exceeded. Before precise setting of the drive current, it is necessary to set the reversing current! (see travel control/ Measurement and adjustment of drive current)

GB HZ RS FS

= =

Lower setting value Higher setting value

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Sheet no.

9 – 16

Chapter 9

Travel control

Control circuit board u200 up to 11/90

Drive reduction 2,5kph

1

It is possible to fit the truck with an optional drive reduction 2.5kph.

For this function, a switch and a resistor R = 2,7kΩ must be connected at terminals 13A and 14A of the control circuit board (see travel control/ terminals u200).

In addition, a jumper must be inserted on the control circuit board.

Component side

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

Copyright reserved.

For the control circuit board up to 11/90, it is necessary to bypass a 5.6kΩ / 0,35W resistor (1).

In the case of the control circuit board from 12/90, a jumper (2) must be inserted from terminal 14A to the upper solder point of the speed restriction potentiometer GB. B

from 12/90 FS

RS HZ GB

Wire jumper on the solder side

2

A 18

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14

Sheet no.

1

9 – 17

Chapter 9

Travel control

Control circuit board u200 Adjustment of drive current Recommended measurement device Digital multimeter and clip-on ammeter.

Measurement range adjustment Digital multimeter: Clip-on ammeter: Display value:

2A

2V DC 600A Current in Amps

2B D1

Current setting

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

Copyright reserved.

Caution

D2

Jack up the truck securely (drive wheel without floor contact).

• Key-operated switch on.

• Apply handbrake.

• Bypass the manual brake switch (driver's seat switch) mechanically or electrically.

• Select a direction of travel.

• Clip the ammeter onto cable B (A2) of the drive motor and • Adjust the clip-on ammeter.

• Turn the drive current potentiometer as far as possible to the left.

• Apply the accelerator (manually) on full.

• Turn the drive current potentiometer clockwise until the prescribed drive current is reached. This setting must be carried out quickly!

1B 1A A1

M A2

B

B

n35

n20 30078

Remark: Manufacturing tolerances and differing battery statuses necessitate slightly deviating settings from one vehicle to the next to ensure that driving speed and climbing capacity reach the values in the data sheet.

If the max drive current values are not sufficient, please consult the technical office.

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Sheet no.

9 – 18

Chapter 9

Travel control

Control circuit board, terminals u200 A 1

3

4

5

Clock signal Anode HT

7

8

9 X20

10

11

12

n35

Actual value

Setpoint

5V

14

15

16 6

13

17

18

5

7

FR *

2,7 kΩ

Cathode Free-w. diode n25 3 2

13

X20

8

13 A: 10V 14 A: 0V -> vmax

1

u25

X20

6

Cathode Brake diode n24

LT Anode n22

470Ω 5W onlyi 48V

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

Copyright reserved.

2

10V -> v=0

0,4V / 100A

1 10V

3 2

10V 4,5 - 8V

1

HT n20 foot switch

LT n22 UT n36

Hand brake Trevel direction

*FR = Drive reduction K3

K2

UT Cathode n36

bwd

fwd

Insert this jumper when using the new board (SMD technology) in older truck models!

B

Component side

1

2

3

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6

7

8

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9

10

11

12

TSR/CSR

13

14

15

Sheet no.

16

17

18

9 – 19

Chapter 9

Travel control

Adapter card A8 General

The adapter card A8 fulfils a variety of functions:

• Current control for the main and pump contactors, i.e. initially 100% current, after 1s only 60%.

This increases the service life of the contactors.

This function permits omission of the "Voltage reduction circuit boards" which were previously plugged onto the contactors.

• Dropout delay for the pump contactor (connectable via DIP switch).

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

Copyright reserved.

• Selection of contactor voltage 24 / 48V (via DIP switch).

Remark:

Alongside these basic functions, the adapter card fulfils other control functions. However, these are only used in trucks with PLC control.

30059

X21

30079

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Sheet no.

9 – 20

Chapter 9

Travel control

Adapter card A8 Settings

By means of 8 DIP switches (1), the card must be adapted to the respective fork lift truck.

Default factory settings 24V: 48V:

all DIP switches to ON DIP switches 1-6 to OFF DIP switches 7-8 to ON

DIP switch Switch setting / Meaning

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

Copyright reserved.

OFF

ON

1

X

(DIP 1 - 5 only

2

X

relevant with

3

X

PLC control)

4

X

5

X

6

Minimum ON time pump OFF

Minimum ON time pump ON

7

Pump contactor 24V

Pump contactor 48V

8

Main contactor 24V

Main contactor 48V

30080

The LED chain (2) indicates the correct function of the adapter card A8.

1

3

2

Remark: The 4 potentiometers (3) are not of any significance in vehicles without PCL controls.

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Chapter 9

Travel control

Adapter card A8 LED display

The LED display is a useful aid in troubleshooting.

Meaning of the LED's V23

Main contactor power supply OK (internal signal on board) V24 Output stage main contactor set V32 Control signal for pump contactor available V33 Power supply for pump contactor OK (internal signal on board) V34 Output stage pump contactor set V25-31 only relevant with PLC controls

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

Copyright reserved.

If the following signal statuses are created certain of the LEDs must light up: 1) Emergency OFF switch depressed and keyoperated switch activated: --> V33 lights up continuously.

2) Only key-operated switch activated, emergency OFF switch released: --> V23, V24, V33 light continuously.

3) Conditions as 2) and one of the switches at the directional valve block activated (lift function): --> V23, V24, V33 light continuously --> V34 lights as long as the hydraulic pump is running/pump contactor is picked up.

--> V32 lights up when one of the microswitches at the directional valve block is actuated.

30080

V 23 24

If the signal statuses are not as described here, there is either a defect on the card or a fault in the system.

V 25 26 27 28 29 30 31 32 33 34

rote LED grüne LED

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Chapter 9

Travel control

Adapter card A8 Measured signals Pin 1 / X23.4 (X20.4): Switched minus pole of the microswitches at the directional valve block for pump contactor control.

Pin 2 / X21.6: Voltage supply Plus (24V / 48V)

F3

Pin 4 / X21.1: Controlled minus for pump contactor, voltage reduction 24V --> appr. 15V 48V --> appr. 30V

Pin 6 / X23.12 (X20.12): Switched minus for main contactor control via emergency OFF switch Pin 7 / X21.2: Controlled minus for main contactor, voltage reduction as at PIN 4

A1 A2

X21 2

6

7

11 1

Diodes V23, V24 and V33 light up despite missing voltage supply at X21.6 (e.g. due to wire breakage).

It is possible to drive but not to operate the hydraulic system.

1

A8

Pin 11 / X21.6: Voltage supply Plus (24V / 48V) Remark:

K1

A2

Pin 5 / X21.3: Direct minus for pump contactor control Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

K50

A1

X23 4 (X20)

6

2

4

5

12

X21 3

X26 1

2

(X35) X25:2 (L16) X24:N

3

0V(N)

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Chapter 9

Travel control

Adapter card A8 Block circuit diagram

A

RS

A8/9 24V/48V Minus: main contactor control via emerg. OFF Direct minus: Pump contactor control

A8/11

A8/12

Powerpack

A8/6 A8/5

AØ A8/13

Drive reduction control

A8/10

Drive reduction potent.

12 V

DIP switches

A8/3

A8/15 1 2 3 4 5

A8/8

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

Copyright reserved.

V25 V26 V27 V28 V29 V30 V31

Main contactor control 24V/48V

A8/7

V24

DIP8

Minus output, main contactor

&

Current supply main contactor OK

V23

Shorting safeguard

Pump contactor control 24V/48V

A8/4

V34

DIP7

Minus output pump contactor

&

Direct plus pump contactor

A8/2

A8/1 Control input Minus pump contactor via microswitch on the directional valve block

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Current supply, pump contactor OK Shorting safeguard

V33

V32

•

•

DIP6

TSR/CSR

Minimum ON time

Sheet no.

9 – 24

Issue: Replaces issue:

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n20

n35

M1

K2

K2

m23

F6

K50

1A

1B

2B

2A

1B 1A

n25

2A

2B

1B

1A

n36

n22 m23

K22

m22

K3

K3

2B 2A

n24

K1

F5

K1

F2

X20

X20

F1

u200

X20

K2

X20

K3

X35

F20

X20

470 Ω

L16

F15

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

Copyright reserved.

F4

F16

X20

Sheet no.

L16

X35

K50

F3 K1

Chapter 9 Travel control

Wiring diagram Circuit board A1 with adapter card A8

9 – 25

Chapter 10

Accelerator pedal

General The accelerator pedal with electronic sensor is a closed unit and operates on a contact-free and therefore wear-free basis.

The lower part of the plastic pedal accommodates a permanent magnet, the exterior of which is moved past the closed sensor.

Depending on the position of the manget, a control signal (appr. 4-8V) is given off to the control circuit board via the sensor. Adjustment is not possible.

30082

Magnet with colour coding positioned towards the outside.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Functional characteristics of the magnetoresistor The resistor can be seen as a magnetic field-dependent resistor.

3 2 1

The magnetoresistors used in the sensor and current transformer are differential resistors.

They consist of two series-connected resistors in one housing with central tapping.

Depending on the position and influence of the magnetic field, the resistance ratio of the two resistors in relation to each other changes and so, when voltage is applied (appr. 10V) at the outside terminals (1 and 3), also the potential at the central tap (2).

1

2

3

The alteration in potential of the central tap is transmitted to the control circuit board as a control signal.

15 A 18 A

9A

control circuit board

+ 10V

Measured values:

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1 against 1 against

3 2

1 against

2

TSR/CSR

Sheet no.

=10 V =ca. 4V (0-position) =4-8 V (actuated)

10 – 01

Chapter 11

Hydraulics

Block diagram 1

With following components: 1 Lifting button (via relay)

+24V

2

Lift

2 Pump contactor 3 Lowering button (via relay)

5

4 Pump assembly

60154

5 Lifting cylinder

3

6 Hydraulic lead valve

+24V

Lower

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

Copyright reserved.

7 Flow control valve 6

Remark: The directional control valve and the lowering brake valve (throttle) are on the pump block.

7

8

4

Hydraulic circuit diagram With following components:

00263

1 9

1 Lifting cylinder 2 2/2-way valve 3 Throttle valve 4 Pressure relief valve 5 Electric motor with hydraulic pump

2

6 Filter 7 Tank 8 Non-return valve (load-holding valve)

3

8

4 5 6 7

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00264

Sheet no.

11 – 01

Chapter 11

Hydraulics

Pump assembly 1

General The pump assembly is made up of the following components: Item/Component 1 Pump motor (compound)

8

7

2 Hydraulic pump

4

3 Hydraulic suction filter 9

4 Lowering valve (pilot controlled non return valve 5 Tank (1.5 litres)

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

Copyright reserved.

6

3

6 Air filter 7 Carbon brushes

10

8 Pressure relief valve 9 Lowering brake valve 10 Non-return valve (load holding valve)

80064

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11 – 02

Chapter 11

Hydraulics

Pump assembly Function LIFTING

P

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

4

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

1

If the pressure generated exceeds the pressure set at the pressure relief valve, the pressure relief valve opens and the oil flows back into the tank.

80065

3

2

5

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

Copyright reserved.

Working pressure

Oil pressure from pump

P

4

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

80066

Return flow to tank

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11 – 03

Chapter 11

Hydraulics

Pump assembly Function LOWERING

1

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

2

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

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

80067

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

Copyright reserved.

Return flow

. . . . . . . .

P

.

2 . . . . .

80066

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11 – 04

Chapter 11

Hydraulics

Pump assembly Electrically pilot controlled non-return valve (2/2-way-valve) The 2/2-way valve is a bevel-seated valve.

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

1

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

2

Coil resistance = 160Ω Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

80068

3 B

83122

A

1

2

Ω

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Sheet no.

11 – 05

Chapter 11

Hydraulics

Pump assembly Replacing the carbon brushes

3

2

1

4

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

Length of a new carbon brush: 22mm

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

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

Copyright reserved.

Removal / Installation 1. Pull out the battery plug.

2. Unscrew the 2 hexagon screws (1).

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

4. Continue pulling the carbon brush lid off the motor (3) with a screw-driver.

5. Pull off the puller screw and the carbon brush lid alternately, using the screw-driver for the latter.

6. Raise the carbon brush spring (5) and pull out the carbon brush.

7. Slowly release the carbon brush spring (7).

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

9. Clean out the commutator compartment (blow it out with oil-free air).

80070

5

6

7

Caution: Never inhale carbon dust!

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

80071

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Sheet no.

11 – 06

Chapter 11

Hydraulics

Pump assembly Removal 1. Pull out the battery plug

1

2. Remove the electric cable (1) (spanner size 13).

3. Unscrew the hydraulic leads (2) and seal off.

4. Release the 2 screws (3) spanner size 17 at the back of the valve block (4) and lift the pump assembly (5) out of the holder in the chassis.

2 4

Installation 5 3

80041

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

Copyright reserved.

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

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Sheet no.

11 – 07

Chapter 11

Hydraulics

Pump assembly Removing the pump motor 1. Pull out the battery plug 2. Unscrew the 2 nuts (2).

2

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

1

4. Carefully lift down the motor.

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

Copyright reserved.

Remark: There is a mounting pin (3) in the lower part of the motor housing. Take note of this when reinstalling. The mounting pin is generally on the side of the electrically pilot controlled non-return valve.

80072

To install, follow the instructions above in reverse order, taking care to comply with the following points: 1. See the remark above.

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

3

80073

8/

4

80074

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Sheet no.

11 – 08

Chapter 11

Hydraulics

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

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

Copyright reserved.

The pump consists essentially of a pair of gear wheels, which is mounted in 4 bearing bushes, and a housing with a lid at the front and back. A drive shaft sealed with a 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.

A

A

B

B

C

C

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

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

Pressure side

80075

Suction side

The pressure fields which are applied, are limited by special seals.

The seal around the edge of the gear wheels is guaranteed with tiny gaps, that adjust when the gear wheels are pressed against the housing as pressure is applied.

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Sheet no.

11 – 09

Chapter 11

Hydraulics

Pump assembly Removing the hydraulic pump 1. Pull out the battery plug 2. Remove the pump assembly 3. Remove the pump motor 4. Unscrew the 4 hexagon screws (1).

5. Remove the tank (2).

6. Unscrew the 4 hexagon screws (3).

7. Remove the hydraulic pump.

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

Copyright reserved.

Remark: After re-assembling again, check the oil level (oil volume approx. 1.5 litres).

80076

3

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2

Sheet no.

1

11 – 10

Chapter 11

Hydraulics

Pump assembly Suction side End cover Housing 3 parallel Drive-end cover

grooves Grooves for

Radial grooves

leaking fluid

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

Copyright reserved.

80077

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

Pressure

Dismantling 1. Pull the drive wheel off the shaft.

2. Release the hexagon socket screws.

Housing

3. Raise the cover over the drive shaft.

Front rest

gearwheel

4. On a piercing press, push the shaft together with the ball bearing out of the bearing cap. Mark the driven gearwheel and rest.

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

Drive

Driven gearwheel 80078

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Sheet no.

11 – 11

Chapter 11

Hydraulics

Pump assembly Setting the maximum pressure at the pressure relief valve 1. Connect a pressure manometer.

2. Unscrew the nut (1).

3. Pick up a nominal load on the forks and measure the working pressure (make a note of the measurement).

1

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

Copyright reserved.

Remark: The adjusting value for the maximum pressure is calculated from the working pressure during lifting with a nominal load plus 10 %.

4. Move as far as the end stop (bridge lift cut-off) and set the maximum pressure at the adjusting screw (2).

5. Mount the nut (1) with sealing ring and tighten.

Information about the exact maximum pressure values can be found on the information plate, which is located next to the vehicle's factory nameplate.

80079

Recommended values for pressure adjustment: Maximum pressure approx.180 bar Working pressure with load approx.160 bar 2

80080

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Sheet no.

11 – 12

Chapter 11

Hydraulics

Pump assembly Hydraulic oil change Frequency: Oil type: Oil volume:

every 12 months HLP46 DIN 51524 1.5 litres

Procedure 1. Remove the tank.

2. Remove the hydraulic oil in accordance with the regulations.

3. Clean the tank (1).

2

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

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

Copyright reserved.

5. Fill the tank with hydraulic oil.

6. Mount the tank.

7. Check the hydraulic system for leaks.

80076

1

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Sheet no.

11 – 13

Chapter 11

Hydraulics

Bleeding the lifting cylinder and hydraulic system of air All air must be bled from the system when • a lifting cylinder has been removed and replaced, • a hydraulic lead or hose has been replaced, • work has been carried out on the hydraulic system.

2 1

Procedure 1. Open the bleeder screw (1) (do not remove it completely).

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

Copyright reserved.

2. Select the function for lifting the hydraulics and extend the cylinder right to the end stop.

Remark: On vehicles with a lift cut-off, the limit switch must be overbridged, so that the pump motor does not switch off.

3. As soon as bubble-free hydraulic oil emerges from the hole (2), the bleeder screw (1) can be closed again.

00256

If the hydraulic functions do not work as they should, this process must be repeated.

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Sheet no.

11 – 14

Chapter 12

Hydraulic system

Diagram of the hydraulic system 1 Tank 2 Filter 3 Electric motor with hydraulic pump 4 Pressure relief valve 5 Directional slide valve, main lift 6 Directional slide valve, basic lift 7 Lowering brake valve 8 Line break protection 9 Free lift cylinder 10 Main lift cylinder 11 Basic lift cylinder 12 Runback

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

Copyright reserved.

On vehicles without a basic lift/free lift, the relevant components are not included.

10

10 9

5

6

4 7

8

11

3

11

30005

12 2 1 Issue: Replaces issue:

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Sheet no.

12 – 01

Chapter 12

Hydraulic system

Pump unit Removal • Pull out the battery plug.

• Disconnect the electrical leads.

• Drain off the hydraulic oil.

To do so, set a container underneath (with a volume of at least 18 litres).

Open the drainage screw (1) in the tank. Let the oil drain out, then close the drainage screw again and tighten it.

• Disconnect the hydraulic leads.

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

Copyright reserved.

• Remove the pump unit.

To install the pump unit again, follow the instructions above in reverse order.

Then bleed all air out of the hydraulic system.

Carbon brushes The carbon brushes must be replaced when they have worn down to a length of 15 mm, which means they have worn down by 50%.

1

30003

Directional slide valve block Directional slide valves allow the main and basic lift to be raised and lowered sensitively. On lifting, a switching lug (2) also actuates a switching contact (3), which switches on the contactor for the hydraulic pump.

The pressure relief valve (4) is mounted on the directional slide valve block.

After work has been carried out on the directional slide valves, all air must be bled out of the hydraulic system (please see Hydraulic system / Bleeding the lifting cylinders).

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12 – 02

Chapter 12

Hydraulic system

Directional slide valve block Adjusting the maximum pressure valve The value that should be set for maximum pressure limitation is calculated from the working pressure during lifting with the nominal load plus 10%.

3 2

1. Lift the nominal load (please see the carrying capacity plate).

2. Connect pressure manometer to pressure connection (1).

30082

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Copyright reserved.

3. Actuate hydraulics and read off the working pressure.

For example: 150bar working pressure + 10% (15 bar) 165 bar maximum pressure

1

4. Release the seal lock (2) quite a long way, so that the vulcanised seal is not damaged in the thread.

5. With the load (forks), move right to the end stop.

6. Use the adjusting screw (3) to set the maximum value of 165 bar (see example above).

Turning to the right increases the pressure Turning to the left decreases the pressure 7. Tighten the seal lock.

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Chapter 13

Lifting device

Function of the angled lever When pressure is applied to the lifting cylinder, the load holder is pushed upwards. As a result of this upward movement, the angled lever (1) makes a rotating movement, since its centre axis is mounted so that it revolves on the load holder. The long end of the angled lever (2) is fixed securely to the chassis at a constant height. Consequently, the rotating movement of the angled lever is converted into a pulling or pushing movement, depending on the design, which moves the load wheel forks up.

3

1

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

Copyright reserved.

Drawbar adjuster (depends on vehicle type, 3) Simultaneous actuation of both drawbars is set here.

Screw lifting eyebolt into load holder, attach to crane and pull slowly upwards.

Both fork ends must be raised at the same time, otherwise readjust the drawbar adjuster of the relevant fork.

00257

2

End stops at bottom The height that the forks are lowered to is set here.

Lower the forks as far as possible and then screw in the adjusting screws (4) until a distance of 85mm (floor to top of fork) is set at each fork.

Both adjusting screws must reach the stops on the chassis at the same time.

1

00258

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Chapter 13

Lifting device

Adjustment End stops at top (depends on vehicle type, 1) The height that the forks are lifted to is set here.

Move the load holder with the nominal load to the maximum lifting height and now turn this adjusting screw until a distance of 200mm (floor to top of forks) is set at the forks.

The angled lever must reached both adjusting levers at the same time.

00261

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Copyright reserved.

1

00262

Lift stop (depends on vehicle type, 2) The maximum lifting height is set here.

Raise the load holder with nominal load to 200mm (distance from floor to top to forks). Set the position holder for the lift stop so that the top edge of the fork is set to the correct measurement when the hydraulic pump switches off.

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Chapter 13

Lifting device

Adjustment Angled lever - pressure rods (depends on vehicle type) The length of the pressure rods cannot be adjusted. If adjustment is necessary, spacer plates can be added at the fastening of the angled lever hinge point (1).

30006

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Copyright reserved.

1

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Sheet no.

01 13 – 03

Chapter 13

Lifting device

Lifting cylinder, low lift Guide to parts 1 2, 3 4 5 6 7 8 9

Stopper Cheese-head screw for securing Groove nut Washer Adjusting screw Conical socket Spherical washer Round element

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Copyright reserved.

Adjusting the tension springs Adjusting dimension: x = 7 - 8mm -> affects the lowering speed (only adjustable when item 10 is released).

If the springs are disconnected or faulty, the fork can no longer be lowered without a load.

Gabelvorbau

Remark: When installing, ensure that the cylinder itself is centred, otherwise the cylinder will leak!

10

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Chapter 14

Mast

Basic lift ( Depending on the truck type)

General Using the basic lift attachment, it is possible to raise the wheel arms to allow the truck to drive more easily over poor or uneven surfaces, and in particular to negotiate the top and bottom of ramps.

The lift movement is effected via the basic lift cylinder • hoisting lever - pressure rod - roller fork.

Setting the height when lowered 2

1. Raise the basic lift cylinder).

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Copyright reserved.

2. Release the 2 lock nuts and unscrew the 2 hexagon socket screws upwards.

1

3

3. Lower the basic lift.

4. Measure the height when lowered (upper edge of the forks to floor 85 mm).

5. Adjust the 2 hexagonal socket screws until you reach the correct height when lowered.

6. Tighten the lock nut.

Remark: After completion of setting work, the two forks must be at the same height (check using a spirit level).

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Chapter 14

Mast

General

Fig. 3

Load carriages are available in a variety of configurations which differ as follows:

1

Load carriage, concealed cylinder version • Single load carriage (E1250 - 1600 kg), One internal cylinder (not illustrated). Only the lift bracket travels upwards.

Fig. 3

• Telescopic dual load carriage(Te + Do 1250 / 1600 / 2000kg),with pallet clearance (1, Fig. 1),one internal cylinder.

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• Triplex load carriage (TR 1600 + 2000kg), Three mast profiles, one internal cylinder (Fig. 2).

Load carriage, exposed cylinder version • Telescopic load carriage (Te 1250 + 1600kg), two external cylinders (Fig. 3).

30085

• Dual load carriage, with clearance lift (Do 1250 + 1600kg), two ext ernal and one internal cylinder (similar to Fig. 3).

Fig. 3

• Triplex load carriage (similar to Fig. 3), three mast profiles, two external cylinders and one internal clearance cylinder.

Standard: Telescopic load carriage (Te 1250kg and 1600 kg) with clearance lift.

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Chapter 14

Mast

Function Functional characteristics of the telescopic/triplex load carriage, exposed cylinder version The telescopic load carriage is composed of two mast elements: the outer and the inner mast.

Telescopic load carriage without clearance

The telescopic cylinder (6) is supported on the outer mast (1) and raises the inner mast (2). The load chain (8) thus raises the fork holder at double velocity.

8

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Copyright reserved.

If, due to space conditions, a small overall truck height but a high lifting height is required, the triplex load carriage with clearance lift is used.

2 6

30088

1

The triplex load carriage has 3 mast elements plus telescopic cylinders. The cylinders (6) are located between the outer mast (1) and the middle mast (2).

Triplex load carriage without clearance lift cylinder

If pressure is applied to the cylinder (6), the middle mast (2) is raised. At the central mast is the deflection roller for the control chain (5), and the end of which the inner mast is suspended. The other end of the load chain (4) is fixed to the lower part of the middle mast (2).

4

The triplex load carriage with clearance lift cylinder (7) carries out two independent movements. First the fork carrier is raised to the end of the inner mast by the load chain and the clearance cylinder, and the the load carriage is extended.

5

3 2 6

30089

1

Triplex load carriage with clearance lift cylinder 5 4

3 7

2 6

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1

14 – 03

Chapter 14

Mast

Removing the telscopic load carriage (complete with lift bracket)

1. Pull out the battery plug.

2. Safeguard the truck against rolling.

3. Release the hydraulic connections.

A

B

1

4. Fix the inner mast to a suitable hoisting device with approved belts or cables (A).

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Copyright reserved.

5. Raise the inner mast appr. 1000mm using the hoisting device.

6. Safeguard the inner mast against dropping by providing a secure underlay see example with wood underlay in the drawing).

2

5

7. Back out the hexagonal screws , taking care to note the number of shims there are on each side.

8. Lower the inner mast.

9. Now attach the hoisting cables or belts around both mast sections (inner mast 1 and outer mast and raise until slightly under tension.

10. Also attach the lift bracket (tips of the forks) to the hoisting device in order to prevent tilting forward following the weight shift when the load carriage is lifted out.

6 4 7 30091

3

11. Sowly lift the load carriage out of the chassis using the hoisting device.

Mounting Remount in reverse order.

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Chapter 14

Mast

Removing the lift cylinder (telescopic load carriage) 1. Secure the vehicle against rolling.

1

2. Raise the load carriage appr. 100 mm.

3. Pull out the battery plug.

4

4. Underlay the load carriage with a block of wood in such a way that the inner mast is prevented from sinking again (see example (4)).

3

5. Remove the circlip and washer (1).

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

Copyright reserved.

6. Push back the piston rod through the upper cylinder retainer into the cylinder using a suitable tool, at the same time actuating the directional valve block (lowering).

7. Release the connecting union at the foot of the cylinder (2).

Remark: When the load carriage is raised, the cylinder must be safeguarded against falling over by suspending at a hoisting device.

8. Unscrew the cylinder retainer (3).

9. It is now possible to raise and lift out the cylinder.

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Chapter 14

Mast

Support rollers - outer mast To adapt the lateral guide, spacer washers (2) can be pushed on.

(3 different outside diameters).

The support rollers are used for vertical guidance of the mast.

1

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Copyright reserved.

Apart from a light surface application of lubricant (corrosion protection), the support rollers are maintenance-free.

2

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Chapter 14

Mast

Lift bracket General The lift bracket runs in the inner mast. 4 guide rollers (1) are required for guidance.

The guide rollers are not adjustable. They should be provided with a light film of grease during maintenance work (corrosion protection).

4

2

Remark: If a lift bracket is fitted with brass adjusting screws, these must be set or adjusted .

30096

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

Copyright reserved.

The running surfaces of the brass screws must be greased as part of routine maintenance.

Removing 1. Move the lift bracket upwards (appr. 100mm).

2. Suspend the lift bracket safely at a hoisting device.

3 30097

3. Back out screw (2) (run-out safegard).

4. Release the chain tension using the chain tensioner.

5. Unscrew the 2 hexagonal socket screws (3).

1

30095

6. Remove the 2 chain holders (4) from below.

7. Using the hoisting device, raise the lift bracket and remove.

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Chapter 14

Mast

Lift bracket Setting the adjusting screws Different lift brackets are fitted to the various truck types depending on the load carriage construction.

1

2

The lift bracket indicated in the illustration has an adjusting screw setting facility on both sides.

In order not to impair trouble-free lift operation, ensure correct setting of these adjusting screws.

1. Release the lock nut (1).

2. Screw in the adjusting screw (2) until you feel a slight resistance.

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

Copyright reserved.

3. Tighten the lock nut.

4. Carry out a lift process to check the function of the lift bracket.

30099

If the lift bracket tilts during lifting, the setting process must be repeated.

2

1

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Chapter 14

Mast

Chains General Chains increase in length with time. Once a determined tolerance is exceeded, the chain must be exchanged. In order to keep wear to a minimum, carry out the following work once every 6 months: 1. Regular cleaning with compressed air (in special cases using a steam jet without cleaning additives) followed by spraying the chain using a chain spray.

30101

2. Check correct setting (tension) of the chains.

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Copyright reserved.

3. Avoid one-sided strain due to incorrect chain tension or a mechanical fault.

The control chains are tensioned using the two chain tensioners (1).

1 30102

The chain tensioner (2) for the clearance lift is located directly behind the clearance lift cylinder.

Two types of chains are used • 3/4inch chains (19.05mm) Control chain • 1inch chains (25.4mm) clearance lift chains

30104

1" / 3/4" 30103

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Chapter 14

Mast

Setting the control chains (Telescopic load carriage with clearance) Remark: If the truck is fitted with a basic lift facility, this must be adjusted first.

30101

Fig. 1

1. Tension the chain slightly using the chain tensioner (1).

2. Raise the load carriage slowly to maximum lift height.

2

1

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

Copyright reserved.

3. Tension the chains until the screw (2) is at least 2mm away from the run-out safeguard (2).

4. Once a distance of 2mm is guaranteed, the rollers (4) should be positioned so that no more than 40 % of their diameter (dia. appr. 76mm) is projecting beyond the inner mast when the lift bracket is raised (see Fig. 3). If necessary, adjust the chain setting.

5. Check the height when lowered (max. 86mm).

The height of the forks when lowered is measured from the floor to the upper edge of the forks.

30106

4

30107

Fig. 2

2 30108

4

4 1600kg

1250kg

Fig. 3 30109

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Sheet no.

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Chapter 14

Mast

Setting the clearance lift chain (1250kg, 1600kg) If the chain is correctly tensioned, the distance from the upper edge of the forks to the floor should be 85mm.

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

Copyright reserved.

Continue to adjust the chain tensioner (1) until the distance of 85mm is guaranteed.

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Chapter 14

Mast

Chain setting at the triplex load carriage 1. Remove the cross member (1).

2. Remove the cylinder guard (2).

3. Using the feeler gauge (3), it should be possible to measure 3mm.

If not, replace the Vulkolan or rubber buffers (4) or underlay using suitable shims until it is possible to measure the specified dimension of 3mm (3).

4 1

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Copyright reserved.

4. Tension the control chains slightly. The chains should still give when pushed evenly with your hand.

Testing with/without rated load (against end stop) 2

Remark: The hydraulic oil should be at operating temperature.

5

30112

Without rated load The chain setting is in order when both telescopic masts come to a complete stop when fully extended and the piston (4) rises briefly under spring force from the hoist support (5) and then comes to a standstill.

With rated load Ensure without fail that the piston rod (4) does not rise off the hoist support (5).

1. Tighten the lock nut.

2. Replace the cross member and cylinder guard.

3 30113

4

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Chapter 99

Maintenance

General Maintenance work must be carried out when the period specified in the maintenance instructions comes to an end or is exceeded.

Before and during all maintenance work, appropriate measures must be taken to ensure that work is carried out safety.

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Copyright reserved.

Before carrying out work on the hydraulic system, ensure that the pressure has been released from the system by lowering the load bearing device to the floor.

Before carrying out work on the drive system, ensure that the vehicle is securely jacked up and supported from below in order to prevent it rolling away or starting up when not intended.

In operating conditions where there is more dust in the atmosphere or the floors and aisles are heavily soiled, the maintenance intervals must be shortened.

The same applies for conditions with severe temperature fluctuations or continuous extreme temperatures.

Remark:

After all maintenance work, a test of the vehicle functions and condition must be carried out!

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Chapter 99

Maintenance

Safety instructions Handling fuels and lubricants

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Copyright reserved.

The following fuels and lubricants are used in the vehicle: • Gear oil • Hydraulic oil • Battery acid.

There are comprehensive safety specifications prescribed for the use and handling of these substances. The most important points are: For gear oil and hydraulic oil • Avoid contact with the skin. It is particularly important not to let oil that escapes under pressure come into contact with the skin.

• Do not breathe in oil mist.

• Oils are a potential hazard for water. For this reason, always transport and collect oil in containers that conform with regulations.

• Do not spill oil if possible. If spillage does occur, bind the spilt oil with suitable materials.

• Dispose of waste that contains oil in accordance with environmental regulations.

For battery acid • Battery acid is poisonous, so never breathe in its vapours.

• Battery acid is caustic, so avoid contact with the skin without fail.

• Always rinse off any battery acid that is spilt or splashes onto the skin with copious amount of clear water.

• When handling battery acid, use safety clothing like protective gloves and clothing and a face mask. In the event that acid still comes into contact with the skin, wash it off immediately with copious amounts of cold water and call a doctor.

• An explosive mixture of gases can be produced during battery charging which may still be present once the charging process is complete. For this reason, ensure that the charging bay is well ventilated.

• Smoking and naked flames are prohibited within a range of 2m around the charged battery.

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Chapter 99

Maintenance

Brake Note:

The brake deceleration values should be checked once a year and after all adjustments/repairs to the brake system, it should be checked to ensure that it complies with the regulations (see Brake/ Brake deceleration).

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

Copyright reserved.

Testing the function of the service brake To brake during travel, the foot brake must be applied, otherwise the vehicle will coast onwards.

When it has come to a standstill, the parking brake should be applied.

In order to achieve sufficient brake deceleration values, the brake clearance (2) and the brake pedal must be set correctly (see Brake/ Adjustment).

Testing the function of the parking brake

10292

1 2

• Jack up the vehicle securely.

• Bridge the handbrake switch.

• Accelerate the motor to maximum speed.

• Apply the handbrake: the motor should be blocked at the latest when the 3rd tooth engages.

Testing the function of the reversing brake If the travel switch is moved into the opposite direction during travel, the vehicle should be braked electrically without delay. No negative feed - braking is only achieved with plugging.

Wear limit for the brake lining The brake lining (1) must be replaced when it has worn down to a thickness of 2mm (see Brake/ Brake lining).

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Chapter 99

Maintenance

Battery Checking the electrolyte level The electrolyte level (battery fluid) must reach the baffle (plastic grid under the stopper) but not rise above it.

Always check the electrolyte level in several cells, since it can differ greatly.

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

Copyright reserved.

Checking the electrolyte density The electrolyte density is an indication of the degree to which the battery is charged, i.e. the greater the density, the higher the battery capacity. The electrolyte density is measured with an aerometer (1).

The electrolyte density must be tested after the battery has been charged. The electrolyte density should be between 1.22 and 1.27kg/l after the battery is charged. A lower reading is not acceptable. It may be necessary to top up the acid.

30022

1

Cleaning the battery The battery must be kept dry and clean. Any battery acid that runs out into the battery tray must be removed with a suction device (2).

Any verdisgris that has formed on the terminals should be removed.

Clean any oil smears, dust or other soiling off the surface of the battery with a clean, dry cloth.

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Chapter 99

Maintenance

Battery Battery lock The battery lock mechanism must not be bent.

The sealing lips and rubber pads that hold the battery in its end position should be undamaged.

The battery should be held securely in its end position, even during fast travel around bends.

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

Copyright reserved.

Battery charger The output voltage of the battery charger must match the battery voltage.

The current of the battery charger must match the capacity.

The insulation on the battery connecting cable must not have any bare patches. The charger should switch on automatically when it is connected with the battery. The charger must be set up in a place where good through-ventilation is guaranteed.

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Chapter 99

Maintenance

Operating elements Ease of movement The operating elements include: • Emergency-stop switch • Key switch • Steering wheel • Travel switch • Lifting button • Lowering button • Horn button

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

Copyright reserved.

• Deadman switch All the operating elements must move smoothly and return automatically to their neutral position.

Switches must click firmly into position. Covers or cladding must not scrape against the operating elements.

Check all operating elements to ensure that they function correctly.

Replace damaged elements.

The symbols on the operating elements must be clearly legible.

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Chapter 99

Maintenance

Steering Ease of movement It should be possible to turn the steering wheel with a moderate amount of force.

On vehicles with electrical power assisted steering (1), the function of the steering controller and steering sensor must be checked (please see Steering).

Note:

During work on the steering controller or steering sensor the steering wheel can turn. If this is a problem, dismantle the chain to the steering motor.

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

Copyright reserved.

1

30012

Cut-out in the event of error If there is an internal or external error in the steering controller, the vehicle can be steered in emergencies with the mechanical steering column.

Steering chain The steering chain and pinion must be lubricated.

Reverse steering If the vehicle is fitted with reverse steering, the appropriate information sign (2) must be mounted on the vehicle.

2 30027

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Chapter 99

Maintenance

Lifting chains

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Copyright reserved.

General The lifting chains used for the main lift are multi-link chains, also known as flyer chains. Flyer chains are dimensioned in inches.

Chains tend to elongate during the course of time as a result of wear on the chain link pins. When the specified tolerance of 2% is exceeded, the chain must be replaced (see Lifting chains/ Checking the chain elongation).

In order to keep wear to a minimum, please always ensure that: • The chains are cleaned regularly and then sprayed with a special chain spray.

• The chains are checked regularly to ensure they are correctly adjusted (tension).

• Any imbalance due to incorrect chain tension or faulty mechanical elements is avoided.

Note:

Chains are safety components. They must therefore be checked with particular care.

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Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage The lifting chains on the main lift must be checked for the following signs of damage: • Surface rust

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

Copyright reserved.

20132

• Rust in the joints

20133

• Stiff links

20134

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Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage • Twisted link pins

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Copyright reserved.

20135

• Loose link pins

20136

• Unacceptable external wear

20137

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Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage • Damage

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Copyright reserved.

20138

• Broken link plates

20139

• Broken link pins

20140

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Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage • Soiling

20141

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

Copyright reserved.

• Wear in the link plate holes

20142

• Wear on a link pin

If any of these signs of damage are found, the chain must be replaced immediately, since damage of this kind can cause the chain to break before the wear limit for permissible chain elongation is actually reached (see maintenance/ Replacing the lifting chains).

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Sheet no.

99 – 12

Chapter 99

Maintenance

Lifting chains Checking the chain elongation Main lift

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Copyright reserved.

Caution:

Even if the wear limit of 2% has not yet been reached, we recommend that all chains (load chains and control chains) on the main lift should be replaced every 5000 operating hours, for safety reasons. This is because negative effects on the chains are very difficult to ascertain, due to ageing and material fatigue!

Elongation of the load chains on the main lift must be tested while installed with at least 10% of the rated load. It must not be elongated by more than 2%. The chain must be cleaned before the measurement is taken. The measurement must be carried out in the working area of the chain. The max. permissible chain elongation of 2% is 5mm over 10 single links of a 1" chain (please see table below).

If a length of 259mm is exceeded over 10 single links of a 1" main lift chain, the wear limit has been reached. The chain must be replaced.

General table of measurements for inch gauge chains Chain pitch 1/2" (12.70mm) 5/8" (15.88mm) 3/4" (19.05mm) 1" (25.40mm) Chains with different pitches can be calculated from this information

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Chapter 99

Maintenance

Lifting chains Replacing the lifting chains Note:

Always use original spare parts when replacing lifting chains!

When the lifting chains are replaced, the connecting bolts (1) between the chain anchor (2) and chain (3) must also be replaced.

The lifting chains for the main lift must always be replaced at the same time.

This is the only way to guarantee an even distribution of weight over both chains.

10230

3

2

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Copyright reserved.

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Chapter 99

Maintenance

Lubricating the lifting chains How often lubrication is required depends on what the vehicle is used for and on the conditions in which it is used. With normal use in single-shift operation, the chains must be re-lubricated every 6 month or every 1000 operating hours.

In tougher and/or multi-shift operation, and in situations where heavy soiling occurs or in humid conditions, lubrication must be carried out more often.

The intervals must be shortened as appropriate for the situation, e.g. if the vehicle is used in two-shift operation, the intervals should be halved.

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Copyright reserved.

Note:

If the outside of the chain is so soiled that penetration of the lubricating oil cannot be guaranteed, the chain must be cleaned before lubrication (see Cleaning the chains).

"Stabylan 2001" lubricant (Id. no. W8 010 100) should be used for lubricating the lifting chains.

Remark:

If the vehicle is used in a cold store environment (-30°C), the lubrication intervals should be reduced to half the length, and in multi-shift cold store operation, intervals should be shortened to 1/4 or 1/6 of the standard length, according to the amount of use.

"Syntesco" lubricant should be used for lubricating the lifting chains of vehicles used in cold store conditions (Id. no. W8 036 220).

Remark:

Dirt should not adhere to the outside of the chains.

The chains are correctly lubricated if your finger is covered with a film of oil when you touch the chain and if the lubricant does not drip off the chain.

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Sheet no.

99 – 15

Chapter 99

Maintenance

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Copyright reserved.

Cleaning the chains If chains are covered with a layer of grease on the outside or if they are heavily soiled, new lubricant cannot penetrate through the layer of grease or dirt into the chain. This causes wear and allows corrosion to occur, which subsequently makes the chain links stiffen.

For this reason, it is essential to clean soiled chains before they are lubricated.

Chains should only be cleaned with paraffin derivates like diesel fuel, petroleum, cleaning naphtha, etc.

Cleaning with steam jets in combination with cold solvent cleaners or any kind of agents containing caustic or acidic substances is strictly prohibited. This kind of treatment can cause direct damage to the chains.

If cleaning the chains with steam jet equipment is absolutely unavoidable, you should proceed as follows: • Cleaning Only use steam jet equipment without adding any cleaning agents.

• Blowing out Immediately after a chain has been cleaned, all the water left on its surface and in the chain links should be removed with a compressed air blower.

The chain should be moved several times during this process.

• Spraying The chain should then be sprayed immediately with one of the preserving and lubricating agents recommended by us. The chain should also be moved often enough during this process to ensure that the preserving and lubricating agent does actually penetrate into the chain links.

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Sheet no.

99 – 16

Chapter 99

Maintenance

Hydraulic tank Volume The hydraulic tank volume is as follows for the different vehicles ca. 1.5l (low lift) or 18l (hight lift).

Seals The tank and pump assembly are connected to each other with a screw-fit connection.

For additional protection around the joint, a hose clamp is fitted that must be checked for leaks.

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Copyright reserved.

Filter

30029

The paper air filter (2) lets air flow into or out of the tank.

Hydraulic oil that has leaked out of the oil tank gums up gradually in the filter and blocks it off. When this happens, the filter must be replaced.

1

Soiled oil The hydraulic oil can become soiled by different materials: • Condensation water • Rubber that rubs off the hydraulic hoses • Metal splinters off the valve block • Other dirt For this reason, the hydraulic oil must be replaced to schedule, or at the latest when the colour of the oil has turned darker than honey yellow.

30030

2

Please displose of used oil correctly.

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Sheet no.

99 – 17

Chapter 99

Maintenance

Wheels Wear The drive wheel must be replaced when the diameter has worn down to 270mm.

It must also be replaced when: • The running surface is very pitted • The running surface is out of round • The running surface is cracked The tightening torque for the wheel bolts is 140Nm. 30031

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Copyright reserved.

Wheel bearings When replacing the drive wheel, always check the wheel bearing.

To do so, jack up the vehicle, and chock it up securely, then take hold of the drive wheel with both hands and jiggle it. You should be able to feel that it is fitted firmly without any play.

1

Load wheels Load wheels must be replaced when the diameter has worn down to 65mm.

They must also be replaced when: • The running surface is very pitted • The running surface is out of round • The running surface is cracked.

When the load wheels are replaced, the lubricating nipples (1) in the load wheel axles must be lubricated.

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Sheet no.

99 – 18

Chapter 99

Maintenance

Motor Carbon brushes The carbon brushes must be replaced when they have worn down to the following length: Drive motor: 16mm (24V), 20mm (48V) Pump motor: 11mm (2kW), 15mm (3kW) Steering motor: 11mm The entire brush set (4 brushes) must always be replaced (see Drive motor/ carbon brushes).

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Copyright reserved.

Remark:

The motor should not be placed under a full load immediately after the carbon brushes have been replaced. The carbon brushes run in relatively quickly under a minimum load.

30039

Checking the brush springs Brush springs that are not adequately pre-tensioned can cause the commutator to burn. Ensure that the carbon brushes move easily in the shaft.

Other maintenance work As well as replacing the carbon brushes, motor maintenance includes the following points: • Cleaning (see Travel motor/ Maintenance).

• Visual inspection (see Travel drive/Maintenance) • Replacing damaged parts (see Travel motor/ Maintenance).

• Checking the brush assembly and commutator (see Travel motor/ Maintenance).

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Sheet no.

99 – 19

Chapter 99

Maintenance

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

The maximum permissible operating temperature is 80C°.

Use new seals on the oil drainage screw. Tightening torque: 22Nm. The filling volume is about 2 litres (see Gaer/ Oil change).

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Copyright reserved.

Noises Noises are a sign of excessive wear or an internal fault. The problem may be that there is not enough oil in the gear or the wrong type, but it is more commonly due to mechanical action (driving over floor joints or rails).

Leaks Check the gear for leaks at the inlet and outlet screws, the screw holes, at the shaft outlet and the back cover.

If necessary, replace the seal or shaft ring.

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Sheet no.

99 – 20

Chapter 99

Maintenance

Mast Mast rollers The mast rollers (2) must not be worn out or cracked.

Mast rollers with lubricating nipples must be lubricated with all-purpose grease.

Guide rollers of the fork holder The guide rollers (1) must not be worn out or cracked.

Guide rollers with lubricating nipples must be lubricated with all-purpose grease.

1

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Copyright reserved.

Windscreen The windscreen is on the one hand designed to protect the driver from drops of chain grease and draughts, and on the other hand to guarantee him a clear view of the forks. For this reason, the windscreen must be kept clean at all times.

30040

2

Lifting cylinder The lifting cylinder must be inspected for leaks. If necessary, replace the set of seals.

Guides, surfaces

30041

The surfaces of the mast profiles that the guide and mast rollers run up and down continuously, must be cleaned regularly and then greased again, in order to keep wear to a minimum.

Forks The welded seams of the forks on the fork holder must be inspected for cracks.

Chain adjustment The chain tension must be adjusted with the main lift fully lowered. Tighten both chain tensioners (4) until a slight tension can be felt.

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3

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Sheet no.

99 – 21

Chapter 99

Maintenance

Pump assembly Carbon brushes The carbon brushes must be replaced when they have worn down to 11mm (2kW) or 15mm (3kW).

Never replace single carbon brushes - always replace the entire set.

Oil level The oil level cannot be measured until all the cylinders have been retracted. The oil level should be between the minimum and maximum mark.

20412

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Copyright reserved.

Noises Screeching,whining or scraping noises caused by faulty bearings, if the oil level is too low or scuffing toothed gears in the pump must be rectified by replacing the worn parts.

Soiling A mixture of abrasive dust from the carbon brushes and a fine oil vapour makes a very good electrically conductive connection. If this connection forms between the chassis and the positive or negative battery pole, this is referred to as a short to ground. It can cause various different faults. For this reason, clean all surface dust off the motors every time maintenance work is carried out.

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Sheet no.

99 – 22

Chapter 99

Maintenance

Lubrication plan Lubricants The following lubricants should be used: Hydraulic oil HLP DIN 51524/T2 Id. no. 8 036 912 The refill opening for the hydraulic oil is marked with a symbol (1).

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

Copyright reserved.

Gear oil SAE 80 Id. no. 8 036 925

30035

All-purpose grease ESSO Beacon 2 Id. no. 8 010 107

1

Chain lubricant Stabylan 2001 Id. no. 8 010 100

Disposal If the vehicle described here has to be taken out of service, it is important to ensure that all the components are disposed of in accordance with the regulations (relevant components are marked with the symbol (2) shown here).

In particular the fuels used in the vehicle must be either recycled or disposed of in the correct manner.

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2

Sheet no.

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Chapter 99

Maintenance

Lubrication plan Grease the toothed gears in the steering chains with all-purpose grease (1): Every 6 months.

Grease bolster bearings with all-purpose grease (2): Every 12 months.

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Copyright reserved.

Lubricate the load wheel axle with all-purpose grease (3): Every 12 months.

30042

4

5

2

1

Lubricate all moving parts with oil: Every 6 months.

Change the hydraulic oil (4): Every 12 months.

Change the gear oil (5): Every 12 months.

Lubricate all the guide rollers in the battery compartment with oil (6).

Every 6 months.

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3

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Sheet no.

99 – 24