Still STED forklift XR-N Workshop Manual - PDF DOWNLOAD

XR-N

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Workshop Manual

7/0457

First issue: Last revision:

07/04 07/01

Workshop Manual

XR-N

Id. no.

8 054 346

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

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

5/0002neu

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Copyright reserved.

The WM is updated on a regular basis.

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

5/0003

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

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Sheet no.

I

Foreword Updating workshop manuals (Continued)

1. Replacing incorrect sheets

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Copyright reserved.

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

The new sheet can be identified by the lefthand side of the page footer (1). The date of issue is updated here in the Issue line (2).

The date of issue of the sheet which needs replacing is specified in the Replaces issue line (3). The sheet no. remains the same (4).

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

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

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

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

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

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

07/04

Workshop Manual

Workshop Manual

Issue: 07/04 Replaces issue:

Sheet no.

A1

1 2

4

Page footer of a corrected sheet Workshop Manual

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Sheet no.

A1

3 Page footer of a cover sheet First issued: Last update:

2. Inserting new sheets

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Page footer of an existing sheet

Workshop Manual

07/04 09/05

Id. No. .....

9

Page footer of an existing sheet Workshop Manual

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5

Sheet no.

A1

6 Page footer of an additional sheet Workshop Manual

Issue: 09/05 Replaces issue:

Sheet no.

A 1.1

7

XR-N

8

Sheet no.

II

Foreword Production number and consecutive identification numbers The production number is used for the identification of industrial trucks. This production number is shown on the vehicle nameplate.

In the production number, the vehicle type is shown in the form of a code, and a consecutive identification number is included. In future, alterations will be introduced starting from a certain number.

When making enquiries, however, please always quote the complete production number.

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As previously, the type number printed above will be used for identification of this workshop manual, in which all vehicle types in the FM group are described, and will continue to be quoted in the footer of every page, e.g.

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Workshop Manual

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Sheet no.

M16

Production number

61 1855 0 52800 Consecutive ID number

XR14-N

Production number

61 1856 0 58300 Consecutive ID number

XR16-N

Production number

61 1857 0 64300 Consecutive ID number

XR20-N

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Sheet no.

III

Foreword

Definition of movement directions

LS

Tilt

Reach LS

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

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DWS

Reach DWS

Lower

LS travel

DWS travel

5/0005

Remark: DWS = Drive wheel side = forwards LS = Load side = backwards With the function TILT the movement directions are turned: DWS = Drive wheel side = Tilt backwards LS = Load side = Tilt forwards

Left and right are as seen when looking in the direction of DWS travel.

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Sheet no.

IV

List of chapters Foreword

List of chapters:

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A B C M N R V

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Workshop Manual

Travel drive Steering Brake Electrical system Hydraulic system Lubrication plan Servicesoftware

XR-N

Sheet no.

0

Assembly A

Travel drive

Contents Sheet Motor, general ................................................................................................A 2 Terminal markings at the motor .....................................................................A 3 Exchanging the carbon brushes.....................................................................A 4 Changing the drive wheel...............................................................................A 5 Removing the travel drive system ..................................................................A 6 Commissioning...............................................................................................A 7

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Oil change, gearbox .......................................................................................A 8

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Sheet no.

A1

Assembly A

Travel drive

Travel motor General information The travel motor used is a 48 V shunt motor.

The armature and field windings are controlled separately by the travel and pump control system.

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The travel movement is initiated when the armature is supplied with voltage and the field excitation is 17A. As soon as the armature voltage is equal to the battery voltage, the field current is reduced, in order to increase the speed.

The actual speed of the travel motor is determined by a current measurement (measuring shunt) in the travel and pump control system.

The travel motor has temperature (140°C) and carbon brush monitors.

For adjustment of the travel motor, see sheet no. M16.

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Sheet no.

A2

Assembly A

Travel drive

Terminal markings at the motor Marking at the motor

Meaning

Main current terminals A1

Start of the rotor winding

A2

End of the rotor winding

F1

Start of the shunt field winding

F2

End of the shunt field winding

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Sensor terminals X15.1

0 V signal, temperature sensor

X15.4

0 V supply, temperature sensor

X15.2

48 V signal, carbon brush monitor

X15.5

Signal for carbon brush monitor

F1

X15

F2 7/0430

A2

A1 7/0431

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Sheet no.

A3

Assembly A

Travel drive

Exchanging the carbon brushes

Min. 15 mm

The carbon brushes must be replaced when they wear of about 50 %.

Always replace the complete set of four carbon brushes.

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Copyright reserved.

Removing the brushes 5/0034

1. Pull out the battery plug.

2. Remove the vehicle covers.

3. Remove the travel motor tensioning belt (1).

4. Lift off the brush spring (2) with a hexagon socket screw key and pull out the carbon at the connecting cable (3).

5. Disconnect the connecting cable (4).

6. Clean out the commutator compartment with compressed air.

Caution: Never breathe in carbon dust.

7. Mount the new carbon brushes.

Remark: After exchanging the brushes, do not run the motor straight away under full load. The carbon brushes run in relatively quickly under minimal loads.

1

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Checking the brush springs Brush springs with insufficient pre-tension lead to burning of the commutator.

2

Ensure that the carbon brushes run easily in the shaft.

4

3 5-03 34

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Sheet no.

A4

Assembly A

Travel drive

Changing the drive wheel (complete) New dimensions: Ø 343 mm/136 mm

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Copyright reserved.

It is necessary to change the drive wheel when: - the running surface is pitted or out of round, - the tyre diameter has reduced by 10%, e.g. 343 mm - 10% = 309 mm.

230 mm Fig. 1 5-01 19

Removing the drive wheel 1. Pull out the battery plug.

2. Jack up the truck by approx. 230 mm (Fig. 1) and secure against rolling away.

Fig. 2 5-01 17

3. Remove the covers.

4. Apply the handbrake.

5. Turn the drive wheel into the position for forwards travel and release the 7 drivewheel nuts (Fig. 2).

6. Position the drive wheel at a 90° angle and remove the nuts (Fig. 3).

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

8. Tip the drive wheel off under the gearbox and pull it out (Fig. 4).

When mounting the new drive wheel, tighten the nuts in diagonal sequence.

5-01 18

Fig. 3

Tightening torque: 140 Nm

5-01 20

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Sheet no.

Fig. 4

A5

Assembly A

Travel drive

Removing the travel drive system

1. Pull out the battery plug.

230 mm

2. Jack up the truck by approx. 230 mm (Fig. 1) and secure it against rolling away.

Fig. 1 5-01 19

3. Remove the covers.

4. Remove the drive wheel.

5. Remove the travel motor.

6. Drain off the gear oil (see sheet no. A8).

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Copyright reserved.

7. Replace the oil drainage screw.

8. Remove the steering chain (see sheet no. B19).

9. Suspend the gearbox on a pulley (Fig. 2) or use a second fork lift truck to support it from below.

10. Remove the 6 cheese-head screws M12x50 (Fig. 3, no. 1).

11. Carefully lower the gearbox on the cable or the second fork lift truck. The wheel bolts should point upwards.

Fig. 2 5-01 31

1

12. Remove the gearbox, pulling it forwards and tilting it upwards (Fig. 4).

Mounting

5/0023.1

Fig. 3

To mount the travel drive system, follow the instructions above in reverse order. Ensure that the emergency steering feature of the steering assembly (mechanical components) moves freely and does not produce any noise.

Fig. 4

2

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1

5-03 02

Sheet no.

A6

Assembly A

Travel drive

Commissioning the gearbox (after exchanging)

1

Oils must be used with the following viscosities: Standard oil: Ambient temperature:

SAE 80 0°C to 40°C

Low-temperature oil:

SAE 75 W-90 partly synthetic to -40°C

Ambient temperature:

5-01 23

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Copyright reserved.

For special requirements, we recommend contacting the manufacturer.

2

Oil quantity: approx. 3.6 l Multiplication: i = 15.93

Ölstand

Remark: The specified oil quantity is a guideline value.

The correct oil quantity is ascertained by filling the tank up to the lower edge of the filling hole (1). At this level, about 1/3 of the the spur wheel is submerged in oil (2).

Overfilling must be avoided. Otherwise oil leaks out of the gearbox breather nipple, the seals can be destroyed or the operating temperature raises extensively.

It is important to avoid overfilling, as otherwise the seals will be damaged and it is possible that the operating temperature will not be maintained. The gearbox breather nipple is to be checked for cleanliners.

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3

Lubrication of the bogie bearing: The bogie bearing should be relubricated once a year using the two lubricating nipples (3), in particular after cleaning the gearbox (using a steam jet).

Grease type: all-purpose grease 5/0038

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Sheet no.

A7

Assembly A

Travel drive

Oil change gearbox The first oil change should take place after around 50-100 operating hours.

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

Between oil changes, the oil level should be checked once a quarter and topped up if necessary.

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Copyright reserved.

Remark:

The gear oil must be drained when at service temperature.

The maximum permissible service temperature is 80°C.

Changing the oil 1. Jack up the vehicle and secure it against rolling away.

2. Set the gearbox to the oil drainage position (see Fig. 1).

3. Place an oil catchment vessel under the oil drainage screw (Fig. 1, no. 1) (capacity at least 4 l).

4. Unscrew the oil filler cap (Fig. 2, no. 2).

5. Remove the oil drainage screw and drain off the oil.

Caution:

1

2

The oil temperature can be as high as 80°C.

6. Replace the oil drainage screw, at the same time replacing the sealing ring.

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

8. Replace the oil filler cap with a sealing ring.

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5-01 12

Fig. 1

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Fig. 2

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Sheet no.

A8

Assembly B

Steering

Contents Sheet no.

General ..........................................................................................................B 2 Structure of the steering system ....................................................................B 3 Functional characteristics of the steering sensor ...........................................B 4 Removing the steering column.......................................................................B 6 Setting the steering sensor ............................................................................B 8 Servo unit, general .........................................................................................B 11

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Copyright reserved.

Exchanging the carbon brushes.....................................................................B 12 Removing the servo unit ................................................................................B 13 Steering transmission, general.......................................................................B 14 Removing the steering transmission ..............................................................B 15 Removing the chain wheels and their bearings .............................................B 16 Chain tensioning ............................................................................................B 18 Exchanging the steering chain .......................................................................B 19 Steering controlle, general .............................................................................B 20 Steering controlle, block diagram...................................................................B 21 Functional characteristics...............................................................................B 22 Safety monitoring ...........................................................................................B 23 Setting ............................................................................................................B 25 Commissioning...............................................................................................B 26 Pin assignment...............................................................................................B 27

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Sheet no.

B1

Assembly B

Steering

General

1 48 V

The electrical steering boost is a device for supporting the steering process in trucks with steering columns.

There is also a mechanical emergency steering system available for the event that the electrical steering boost fails.

2

7/0432

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

Copyright reserved.

The control unit is designed to operate at a voltage of 48 V. The current is limited at max.

30 A (for setting, see sheet no. B25).

The electronic control circuitry and main current circuit are housed in a closed structural unit (1).

The setpoint generator (2) is located on the steering column and is designed as a proximity-type magnetoresistive transducer.

5/0045

The steering lock is 95° to either side.

1

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Sheet no.

B2

Assembly B

Steering

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

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Copyright reserved.

The steering transmission has a chain wheel (3) at the top and is flange-mounted (4) to the frame above the chain wheel.

The chain (5) is tightened at the steering transmission by means of an adjusting screw (6). Transmission of the steering force to the fifth wheel is effected by means of a steering chain (7). Two adjusting screws (8) are used for tensioning here.

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

Caution: Remark:

Do not tighten chains too taut! (see sheet no. B18) If the XR-N is fitted with reversing steering, there is no chain (5). The chain wheels are then replaced by toothed wheels which intermesh directly with one another.

9

1 3 5

4

6

2

10

8

The following elements are also required for the electrical steering system: - A steering column with electrical sensor (9), - A servo unit consisting of the steering servo motor with reducing gear (10), - Electronic control circuitry (see sheet no. B2, no.1).

7

5/0060

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 control system, which works fully electronically, is demand-responsive, and accommodated in an open housing below the valve cover.

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Sheet no.

B3

Assembly B

Steering

Functional characteristics of the steering sensor The steering column is divided into two parts. The upper part with the steering wheel can be twisted using the cardan joint by ± 7° out of centre in opposition to the lower part against two torsion elements made of foam rubber.

To measure the turning angle, which is proportional to the steering force, a differential magnetoresistive sensor (1) and a permanent magnet (2) are used.

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Copyright reserved.

The differential magnetoresistive sensor is mounted on the lower part of the steering column, the magnet on the upper part. When the two parts are turned relative to each other, the magnetic flow changes depending on the angle, so changing the output signal of the differential magnetoresistive sensor.

2

The voltage alteration at the magnetoresistor amounts to approx. ± 1.5 Volt relative to the reference potential for the centre point, depending on the sense of rotation. This voltage alteration is also dependent on the distance of the magnetoresistor from the magnet. For this reason, the distance between the magnetoresistor and magnet should be a maximum of 1 mm.

Remark:

1 mm

1

For reasons of EMC (EMC = electromagnetic compatibility), the supply line to the steering sensor is shielded and is integrated in the vehicle cable harness.The shielding is laid on the housing of the steering controller.

The steering sensor itself has not changed.

Functional characteristics of the magnetoresistor

5/0055

The magnetoresistor is a magnetic field-dependent resistor. The resistors used in the sensor are differential resistors consisting of two series-connected resistors (in one housing) with centre tap. Depending on the position and influence of the magnetic field, the resistance ratio between the two changes, so, with applied voltage (approx.

5 V) at the external terminals (1 and 3), changing the potential at the centre tap (2). This change in potential is fed to the electronic control system as a control signal. +5V ±1,5V 0V von Mpsp

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Sheet no.

B4

Assembly B

Steering

Functional characteristics of the steering sensor (contd.)

Slipring system: As the differential magnetoresistive sensor turns with the steering column, a rotating voltage supply is required.

The current supply and tap-off are carried out using sliding-action contacts (2 x 3 switched in parallel operation) by means of a slipring system.

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Copyright reserved.

These sliding contacts are maintenance-free.

Remark:

The sliding-action contacts should rest against the slipring system under slight pressure.

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Sheet no.

B5

Assembly B

Steering

Removing the steering column 5

As the vehicle can no longer be steered once the steering column has been removed, the vehicle must first be jacked up and secured against rolling away.

Caution:

1.

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Copyright reserved.

2.

3.

4.

5.

6.

Remove the cover (1) in front of the accelerator pedal; to do so, set the pedal adjuster to its lowest position.

Pull out the battery plug.

Release the steering column adjuster with the knob (2) and fold out the steering column completely.

Pull off the knob, washer and sleeve.

Push screw (3) into the housing.

Remove the steering system cover (4) by removing the 3 screws, applying the handbrake and lifting off the cover.

Note: Before removing the cover entirely, disconnect the connector for the key-operated switch.

7.

Remove the steering wheel cover cap (5) with a screwdriver.

8.

Undo the nut (spanner size 27) and remove the circlip.

9.

Pull off the steering wheel. If it is very tight, use a plastic mallet or a puller device.

8 6

7 2

4

3

1 5/0047

10. Remove the curved housing from the steering sensor (6).

11. Remove the metal housing (7).

Continued on sheet no. B7

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Sheet no.

B6

Assembly B

Steering

Contd.

Removing the steering column

Continued from sheet no. B6 12. Disconnect the electrical connector for the steering sensor.

13. Remove the clamping screw of the cardan joint (1).

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Copyright reserved.

14. Hold the steering column steady in one hand and with the other pull the screw (2) right out of the steering wheel clamp.

15. Pull the steering column out of the cardan joint, forcing open the cardan joint with a screwdriver if necessary.

3

16. Tap the steering column out of the bearing (3) with a rubber mallet.

1 2 5/0047

Mounting To mount the steering column, follow the instructions above in reverse order. Check the bearing and sliding surfaces for easy running.

Note:

Observe the setting instructions for the steering sensor (see sheet no. B8).

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Sheet no.

B7

Assembly B

Steering

Setting the steering sensor General: Caution:

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Copyright reserved.

No steering boost may be connected to the battery without a correctly set steering sensor, as otherwise danger is incurred from the steering wheel movement. For this reason, exercise particular caution when setting the steering wheel. Never reach through the steering wheel when carrying out setting work.

The steering sensor is pre-tested, i.e. in normal cases no setting is required. Should setting be necessary for any particular reason, for example after exchanging the steering sensor, repairing the steering column etc., proceed as follows:

1 mm 1

A voltmeter is required (10 V), e.g. Beckmann HD 110 T.

In mounted condition: 1. Pull out the battery plug.

2. Remove both central connections "2" at the slipring.

5/0055

3. Connect the voltmeter, with plus at "1" and minus at "3".

4. Insert the battery plug.

5. Note the measured value (approx. 5 V).

6. Pull out the battery plug.

7. Connect the voltmeter plus pole to "2" and the minus pole to "3". Insert the battery plug.

5/0058

Continued on sheet no. B9

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Sheet no.

B8

Assembly B

Steering

Setting the steering sensor In mounted condition (contd.):

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Copyright reserved.

8. Release the clamping screw (1) at the magnetoresistor holder, and position it approx. 1 mm below the magnet. The magnetoresistor should be located centrally under the magnet, so that 2,47 V (± 0.03 volt) is measured between "2" - "3".

9. Then turn the steering wheel until the clamping sleeve is stopped by the sensor (mechanical end stop, 2).

The voltage between "1" - "2" and "2" "3" must change by approx. 1.5 volts (full modulation).

If the voltage alteration is too small, the distance between the magnetoresistor and the magnet must be reduced.

2

1 mm 1

10. Checking voltage reset: When the steering wheel is released, the voltage must return to the previously set central position. If this does not happen, check all the bearing points in the steering column and test for easy running. If necessary exchange the foam rubber torsion segments.

11. Performance check: Pull out the battery plug, reconnect the two central terminals "2", re-insert the battery plug. It should be possible to turn the steering wheel to the left and right with the same level of force.

5/0055

In the zero position of the steering wheel, the steering motor must be switched off.

No motor current should flow.

If this is not the case, carry out the setting again or calibrate the steering controller (see sheet no. B25).

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Sheet no.

B9

Assembly B

Steering

Setting the steering sensor In an unmounted condition: For this setting work, the sensor must be tensioned with a shaft end in a vice in order to simulate the torsion occurring during steering.

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

Copyright reserved.

Lay a supply voltage of 5 volts using a power supply unit to terminals "1" and "3".

1. Release the clamping screw (1) at the magnetoresistor holder, and position it approx. 1 mm below the magnet. The magnetoresistor should be located centrally under the magnet, so that 2,47 V (± 0.03 volt) is measured between "2" - "3".

2

1 mm 1

2. Now displace the sensor (e.g. with gripper pliers) until the clamping sleeve stops against the sensor (mechanical end stop, 2). The voltage between "1" - "2" and "2" "3" must change by approx. 1.5 volts (full modulation).

If the voltage alteration is too small, the distance between the magnetoresistor and the magnet must be reduced.

3. Checking the voltage reset: When the steering is released, the voltage must return to the previously set central position. If this does not happen, check all the bearing points in the steering sensor and test for easy running. If necessary exchange the foam rubber torsion segments.

5/0055

4. The sensor is now pre-set. It is, however, still essential to carry out a performance check once the steering sensor is mounted.

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Sheet no.

B 10

Assembly B

Steering

Servoeinheit Temperature monitor

General

Signal carbon

The servo unit consists of an electric motor (48 V) (1) and a flange-mounted gear (2).

The ball-bearings are maintenance-free. If the bearings are removed during repair work, they must be replaced. The bearings must be renewed after approx. 25,000 operating hours.

5/0048

The gear is maintenance-free; it has sufficient lubrication for the duration of its operating life.

1

To improve its operation, the motor is fitted with a temperature monitor and a signal carbon for monitoring carbon brush wear.

Signal carbon

2

Temperature monitor

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Copyright reserved.

The servo unit is executed with two separate series field windings (split field motor). Left and right-hand rotation is therefore possible without repoling.

Terminal coding on terminal board

5/0049

A1 = Armature Dr/D1 = Field 1 for right-hand rotation Dl/D2 = Field 2 for left-hand rotation

Side A

Side B

5/0050

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Sheet no.

B 11

Assembly B

Steering

Exchanging the carbon brushes More detailed information on this subject can be found in the travel motor section (see sheet no.

A4).

New length: 22 mm Change at residual length: 11 mm Set of carbon brushes: 2 brushes The signal carbon ican be identified by the black wire.

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Copyright reserved.

Remark:

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Sheet no.

B 12

Assembly B

Steering

Removing the servo unit 1. Jack up the vehicle and secure it against rolling away.

2. Remove the covers.

3. Move the electrial seat adjuster to the top end position.

3

4. Turn the steering so that the chain joint of the steering transmission chain (small chain) is in a suitable position for mounting.

1

5. Isolate the vehicle from the power supply.

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

Copyright reserved.

6. Mark and disconnect the steering motor connections.

7. Relax the tension on the steering transmission chain.

8. Open the chain joint and remove the chain.

2

9. Remove the retaining screw M12x50 from the carrier plate of the steering motor (1).

10. Lift the steering motor with the carrier plate (clear of the tensioning pin) and remove the servo unit. If necessary, use a screwdriver for leverage.

11. Remove the four cheese-head screws M6x12 (2) from the carrier plate and pull the carrier plate off over the chain wheel.

12. Remove the cheese-head screw M8x16 (3) from the chain wheel and then pull off the chain wheel (Id. no. W8 415 972, z = 15).

To mount , follow instructions in reverse order.

5/0051

Ensure the screw tightening torques are correct (see illustration) and tension the chain when the servo unit is fully mounted (see sheet no.

B18). Check that the steering moves freely and does not produce any noise.

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Sheet no.

B 13

Assembly B

Steering

Steering transmission, general

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Copyright reserved.

The steering transmission consists of four chain wheels: 1.

The chain wheel of the servo unit (see sheet no. B13, point 12).

2.

The chain wheel of the steering column (1), z = 15

3.

Large chain wheel (2), z = 38

4.

Chain wheel of the steering chain (3) z = 15

Added to these components are 4 deep-groove ball bearings and their respective assembly fittings.

5/0052

2

Defective or worn bearings and/or chain wheels will detract from optimum steering performance.

1

This can lead to premature wear of the interacting components of the steering transmission.

Pay particular attention to deep-groove ball bearings and chain wheels ("scraping noises").

5 4

3

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Sheet no.

B 14

Assembly B

Steering

Removing the steering transmission 1. Remove the steering column (see sheet no. B6).

3

2. Remove the servo unit (see sheet no.

B13).

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

Copyright reserved.

3. Screw the two chain tensioners of the steering chain right in (1). To do so, release the lock nuts.

4. Remove the two retaining screws (2) of the bearing pedestal and then remove the steering chain (3).

1

5-01 27

5. Remove the bearing pedestal.

Mounting To mount , follow the instructions above in reverse order.

Ensure that the steering chain is correctly tensioned (see sheet no. B18).

Also ensure that the steering transmission is mounted parallel to the side of the chassis.

This is usually the case if the chain is tensioned evenly.

5-01 25

2

Once the steering transmission is mounted, turn the drive wheel by hand to check that no noise is produced.

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Sheet no.

B 15

Assembly B

Steering

Removing the chain wheels and their bearings A. Chain wheel of the steering column with its bearings 1. Remove the steering transmission (see sheet no. B15).

2. Remove the self-locking nut (no. 1, spanner size 24) and pull the shaft (2) out of the bearing pedestal or knock it out with a rubber mallet and drift if necessary.

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

Copyright reserved.

3. Pull the chain wheel (3) off the shaft (taking care of the adjusting spring).

4. Knock the deep-groove ball bearing (4) out of the bearing pedestal using a drift.

Take care of the distance sleeve.

2 6 5/0052

To mount, follow the instructions above in reverse order. Check that the bearings move freely.

Take care not to install the shaft the wrong way round (see illustration to the right). Ensure the tightening torque of the self-locking nut (1) is correct.

3

B. Chain wheel of the steering chain and large chain wheel with their bearings

4

1. Remove the steering transmission (see sheet no. B15).

2. Remove the self-locking nut (no. 5, spanner size 24).

3. Pull off the chain wheel of the steering chain with a puller device.

1 5

4. Remove the adjusting spring and the distance sleeve.

5/0053

5. Knock out the shaft (6) with a rubber mallet and a drift.

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Sheet no.

B 16

Assembly B

Steering

Removing the chain wheels and their bearings Continued from sheet no. B16 6. Knock out the deep-groove ball bearing (7) using a drift and rubber mallet (taking care of the distance sleeve).

7. Remove the distance sleeve from the shaft (6) and knock the large chain wheel (8) off the shaft with a rubber mallet.

2

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

Copyright reserved.

6

Mounting

5/0052

To mount, follow the instructions above in reverse order.

8

Check that the bearings move freely. Ensure the tightening torque of the self-locking nut (5) is correct.

3

4

7

1 5

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5/0053

Sheet no.

B 17

Assembly B

Steering

Chain tensioning The reliability and easy running of the steering are largely dependent on the correct chain tension. Excessive tension necessitates greater manual force and in the long term will serve to damage the steering transmission and chains, while insufficient tension increases response times and also wear of the chains and pinions.

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

Copyright reserved.

Tensioning the steering transmission chain: 1. Remove the covers.

2. Release the retaining screw (1).

3. Using the tensioning screw (2) set the tension of the chain so that the chain gives by one thumb's width when a slight pressure is exerted on the longest part of the chain.

4. Tighten the retaining screw and lock the tensioning nut.

1

5-01 25

2

3

Tensioning the steering chain: 1. Remove the covers.

2. Release the retaining screw (3).

3. Using the two retaining screws (4), tension the chain as described above.

Adjust the tensioning screws evenly, otherwise the tension will be different at the front and back of the chain.

4. Tighten the retaining screws and lock the tensioning nut.

Remark:

5-01 27

The steering chain must always be tensioned first. After tensioning the steering chain, the steering transmission chain must be checked for correct tension.

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4

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Sheet no.

B 18

Assembly B

Steering

Exchanging the steering chain The steering chain must be replaced if the chain can no longer be tensioned with the tensioning device or if the chain is damaged.

1 1. Remove the covers.

2. Turn the drive so that the chain join is easily accessible (see photo to the right).

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

Copyright reserved.

3. Relax the tension on the steering chain completely (see sheet no. B18).

4. Open the chain at the chain joint (1) and remove the chain.

5-01 29

Mounting To fit a new chain, follow the instructions above in reverse order.

Ensure that the steering chain is correctly tensioned (see sheet no. B18).

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Sheet no.

B 19

Assembly B

Steering

Steering controller General Note:

The two potentiometers 2 and 3 (attitude ramp function) do not have a function in this vehicle.

1 23

The following description refers to steering controller The torque requirement from the steering wheel is registered and evaluated by the magnetoresistor, which in turn activates the integrated MOSFET power output stage.

7/0432

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

Copyright reserved.

In combination with the non-linear current/torque characteristic curve, this gives steering performance that guarantees both high stability during fast travel and light steering when stationary.

The numerous monitoring functions ensure the steering system functions safely: - Overvoltage/undervoltage protection - Short-circuit proof power output stage with pulse-by-pulse current limitation - Temperature monitoring of power output stage - Reverse voltage protection - External enable input - Signal output for "steering error" - Steering motor carbon brush monitoring with signal output - Setpoint generator wire breakage monitoring The steering controller can be adjusted to the vehicle with a potentiometer. The maximum motor current is limited to 30 A by fixed resistors.

6/0329

The steering controller is protected by a 30A/125V input fuse (1), Id. no. W8 405 541 (see also block diagram, sheet no. B21).

The electrical connections are made with a J.P.T. connector for the operating voltage and the motor and with a J.P.T. connector for the sensor system.

X2

X1

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Sheet no.

B 20

Assembly B

Steering Block diagram for steering controller

Setpoint generator (magnetoresistor)

+48V

Rmin: 200 Ω

.

Emergency-off impact button

0 volts X1 o 6

o4 o 1

1

3F1 20A

o3

X2 o 7

W8 407 010 2.5V ±1.5V

5V Imax: 25mA

30A

Voltage monitor Undervoltage: 12V Overvoltage: 75V ±5%

. .

5V

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

Copyright reserved.

Amplification P2

Actual Set

X2

o 8

Reverse voltage protection

48V

P3

.

Safety relay

Error monitor

Signal carbon

P.W. modulator

o

o 5

Uon

Dead zone Function generator Current Short-circuit approx. 60A Overvoltage Undervoltage

Current regulator limiter (30A) (pulse-by-pulse) Internal enable

Error

. .

monitor

Temperature 100°C Setpoint generator monitor

Left

Safety relay

Signal carbon

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X1 o 2

o5

"Not ready" to electronic evaluation system (TPS)*

"Carbon o brush wear" to electronic evaluation system (TPS)*

07/04

. .

Current measurement

1

Imax: 200mA

*TPS = Travel and pump control system

M

.. .

..

.

.. .

.

Right

o 6

o 4

stage o 3 Output enable Key-operated switch

.

Workshop Manual

F2 10A 1

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Sheet no.

B 21

Assembly B

Steering

Steering controller Functional characteristics

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

Copyright reserved.

The steering sensor is supplied with stabilized 5 V power by the steering controller. This voltage is short-circuit proof, but must not be greater that 25 mA in continuous operation.

Depending on how far the steering setpoint changes from the non-operation region of 2.47 V, the maximum change being ± 1.5 V, the corresponding power MOSFET of the output stage is activated and activates the minus pole via the outputs "Field L" and "Field R".

The result is that if the setpoint is altered slightly, the transistor timing is slow, and if a greater setpoint alteration is made, the transistor timing is faster. The steering system is demand-responsive.

A1

M B 48V

Dl

X2:5 X2:4 Carbon

X2:6 X2:3

X2:4 X2:1

Field L

Field R

X2:8 X2:5 Armature

Steering controller 30A

0V

X2.2 +48 V via emergencyoff button

release

X1.3

to keyoperated switch

L12/1

L12/2

L12

X1:1

X1:4 X1:4

X1:6 X1:5

X1:1 Vref +

Sensor

5V

2,47 ± 1,5V

0V

not ready

carbon

X1.2

5/0064

If the "signal carbon" signal is activated (48 V at X2.5), the "open collector" output "Carbon" (X1.5) switches to 0 V.

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X1.5

to electronic evaluation system (AWE)

In addition, the output stage is not activated if the safety monitor has responded (see sheet no. B23).

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Vref -

Setpoint steering

Steering motor

X2.6

The output stage is not activated until there are 48 V at the external enable input (X1.3) and the supply voltage is also 48 V (X2.3/ X2.7).

Dr

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Sheet no.

B 22

Assembly B

Steering

Steering controller Safety monitoring 1. Operating voltage The supply voltage is additionally buffered by internal buffer capacitors in the appliance.

If the voltage exceeds 75 V or drops below 12 V, the steering controller cuts out.

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

Copyright reserved.

2. Short-circuit proof output stages In the event that the motor short-circuits, the maximum current is maintained at approx. 30 A by the pulse-by-pulse current limiter, which prevents the transistors being damaged.

If the system is placed at risk by transient high current peaks (higher than 60 A) or the current limiter is defective, a short-circuit monitor switches the steering controller off.

7/0432

1

3. Excess temperature The power output stage is protected against overheating.

The steering controller is switched off when approx. 100 °C is reached at the heat sink of the output stage.

4. Reverse voltage protection If the 48 V supply voltage is connected at the wrong poles (X2.7 = 0V, X2.3 = 48 V), the internal safety relay (1) does not function.

Continued on sheet no. B 24

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Sheet no.

B 23

Assembly B

Steering

Steering controller Safety monitoring Continued 5. External enable input The internal pulse width modulator which generates the timing of the transistors is not enabled until there are 48 V at input X1.3.

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

Copyright reserved.

6. "Steering error" signal output If the safety monitor is actiated under conditions 1, 2, 3 or 8 (see also sheet no.

B23), the safety relay (1) becomes inoperative, the motor is cut off from +48 V and the "open collector" output X1.2 switches off the 0 V signal (Imax. 200 mA).

The pulse width modulator is locked internally.

7/0432

7. Carbon brush monitor

1

If there is a 48 V signal at input X2.5, the "open collector" output X1.5 switches to 0 volts (Imax. 200 mA).

The steering controller is not switched off.

8. Setpoint generator wire breakage monitor If the supply voltage lines to the setpoint generator are broken, the steering controller cuts out and the "Steering error" output switches off the 0 V signal. If the setpoint lead is broken, the "Steering error" output is also switched off.

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Remark: If the fuse 3F1 (power supply to the steering controller at X2.3) or the internal 30A fuse in the steering controller is faulty, the two outputs "Steering error" (X1.2) and "Carbon brush monitor" (X1.5) also switch to a 0 volt signal, which causes error messages FE 40 and FE 41 to be displayed on the console display.

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Sheet no.

B 24

Assembly B

Steering

Steering controller Setting The steering controller is preset in the factory and does not need to be reset with the two potentiometers (1).

If, however, the steering performance is not ideal or the steering motor tends to overheat, a check should be carried out to ensure that the steering sensor is set correctly (see sheet no. B8).

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

Copyright reserved.

Potentiometer P2, "amplification"

1

This potentiometer can be used to vary the ratio between the steering setpoint and the steering motor modulation.

It cannot, however, be used to alter the maximum current limitation of 30 A, since this is defined by fixed resistors.

This potentiometer can only be used to decrease the maximum current, which in turn also decreases the maximum torque.

P2 "amplification" P3 "dead zone"

X2

X1

Potentiometer P3, "dead zone" The dead zone can be set so that the steering system is more sensitive to slight steering movements (during fast travel). The larger the dead zone, the greater the manual force required for slight steering movements.

If a dead zone is selected which is too small, the current may flow even when the steering is not operative. This must be avoided at all costs!

The power steering should be activated at a setpoint change of ± 0.25 V and is preset to this value in the factory!

The potentiometer can be accessed via a hole (2) in the cover.

2

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Sheet no.

B 25

Assembly B

Steering

Steering controller Comissioning

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

Copyright reserved.

For comissioning purposes, the motor field circuit (terminals field R, field L) is not connected.

After switching on the operating voltage, first check the wiring to the magnetoresistor. There should be a voltage of 2.47 V at the centre tap of the magnetoresistor when the steering is in the idle position. If the steering wheel is turned to the mechanical stop, the voltage should change by approx. 1 V or 4 V, depending on the sense of rotation.

Now reconnect the motor field circuit.

You will now notice that the control sense is reversed, since the steering controller now operates against the desired steering movement and a greater manual force is required. The steering may also be unstable.

In this case, the two motor field terminals must be exchanged.

If necessary, the steering controller can then also be calibrated as described on sheet no.

B25.

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Sheet no.

B 26

Assembly B

Steering

Pin assignment

Connector X2 Function

+BAT (48V)

Positive supply voltage terminal

4

Field R

Field terminal of motor for right-hand rotation

5

Carbon_E (48V)

Inlet for signal carbon

6

Field L

Field terminal of motor for left-hand rotation

7

-BAT (0V)

Negative supply voltage terminal

8

Armature

Positive motor terminal

4 6 8

3

3

5

free

7

2

2

free

1

X2

1

4

3 5

2

X1 1

Designation

6

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

Copyright reserved.

X2 pin no.

5/0066

Connector X1 X1 pin no.

1

Designation

Function

Vref+ (5V)

Positive reference voltage for magnetoresistor

2

N_ready

Error output (when error at high)

3

FG

Enable input (48 V = steering motor active)

4

Sensor (2.47V)

Bridge output voltage of the magnetoresistor

5 6

Carbon_A Vref- (0V)

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Carbon output (when signal carbon at low) Negative reference voltage for magnetoresistor

Workshop Manual

XR-N

2

free

free

1

4

Field R

+Bat

3

6

Field L

Carbon

5

8

Armature

-Bat

7

2

N_ready

Vref+

1

4

Sensor

FG

3

6

Vref-

Carbon_A

5

Sheet no.

B 27

Assembly C

Brake

Contents Sheet no.

Functional characteristics...............................................................................C 2 Plan of hydraulic brakes.................................................................................C 3 Setting the brake clearance ...........................................................................C 6 Setting the handbrake ....................................................................................C 7 Setting the brake pedal ..................................................................................C 8 Braking distances...........................................................................................C 10

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

Copyright reserved.

Measuring the brake deceleration..................................................................C 11 Main brake cylinder - General ..............................................................................................C 13 - Special bottom valve ..........................................................................C 14 - Removing ...........................................................................................C 15 Bleeding/filling the brake system....................................................................C 16

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Sheet no.

C1

Assembly C

Brake

Hydraulic/mechanical brake system

1

Functional characteristics

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

Copyright reserved.

This brake system is a positive acting system consisting of a mechanical component, the parking brake (handbrake) and the hydraulic component, the service brake (brake pedal), which applies the travel motor (Fig. 1) and lead wheel brake (Fig. 2).

6

5

2 3

When the brake pedal is actuated, pressure is applied to the wheel brake cylinder (Fig. 1, no. 1) via the main brake cylinder. This then presses the brake shoes (Fig. 1, nos. 2 + 3) against the brake drums (Fig. 1, no. 4) = braking action.

5 4

Fig. 1

When the brake pedal is released, the brake shoes are returned to their home position by tension springs (Fig. 1, no. 5).

5/0067

When the handbrake is used, the brake shoes are actuated by cable (Fig. 1, no. 6) This only acts on the travel motor brake.

At the same time, the 0V signal to the combined travel and lift pulse control is interrupted by a handbrake switch and the travel function is blocked electrically.

6/0283

Fig. 2

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Sheet no.

C2

Assembly C

Brake

Plan of hydraulic brakes

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

Copyright reserved.

Without load wheel brake

6/0284

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Sheet no.

C3

Assembly C

Brake

Plan of hydraulic brakes

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

Copyright reserved.

With load wheel brake

6/0285

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Sheet no.

C4

Assembly C

Brake

Travel motor brake, mounting/removal Note:

1

Since the brake (1) is flangemounted on the travel motor, the vehicle is in an unbraked condition after the brake has been removed.

For this reason, secure the vehicle to prevent it rolling away.

Removal

5/0009

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

Copyright reserved.

1. Release the handbrake.

2. Remove the covers.

2

3. Pull out the battery plug.

4. Remove the 4 cheese-head screws M8x35 (2) and lay the brake to one side, complete with the speed sensor.

3

5/0071

5. Remove the brake hose (4), ensuring that no oil escapes over the brake.

6. Unhook the handbrake cable, relieving the cable tension at the setting device of the handbrake lever if necessary (see sheet no. C7).

7. Remove the brake plate from the housing by releasing the M8 cheese- head screws (3).

4

To mount the travel motor brake, follow the instructions above in reverse order. On completion, carry out a brake performance check and if necessary bleed the brake and check the brake clearance.

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5-01 02

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Sheet no.

C5

Assembly C

Brake

Setting the brake clearance Performance check of brake pedal / Performance check of handbrake.

Note:

Check brake deceleration values once a year and after all adjustments or repairs to the brake system (for setting values, see sheet no. C10).

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

Copyright reserved.

Checking brake lining thickness: There are holes (1) built into the brake plate for visual inspection of the brake linings. If a lining thickness of only approx. 2 mm remains, the brake shoes must be exchanged.

5/0074

Setting the brake: The internally acting shoe brake has a central setting for adjusting play and the envelope circle. The setting process draws a key (2) between the support points of the brake shoes, which alters the envelope circle. This results in optimum utilization of the brake linings and at the same time better leverage for initiation of the braking force on the brake drum. After each readjustment of this brake key, re-centre the brake shoes by braking several times.

2

Setting: Turning the setting hexagon (2) to the right draws the key upwards, i.e. increases the envelope cirvcle and so readjusts the brake lining. Turning to the left reduces the envelope circle, brake clearance 0.3 - 0.5 mm.

5/0075

1

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Sheet no.

C6

Assembly C

Brake

Setting the handbrake Like the brake pedal, the handbrake acts on the drive wheel. The brake cable needed for this purpose is suspended at one end on the hook of the brake shoe and at the other end on the brake lever in the driver's cab. It is at this end that the brake cable must be adjusted.

Before the handbrake can be adjusted, the brake clearance must be set correctly (see sheet no. C6).

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

Copyright reserved.

Setting 1. Remove the covers behind the steering column (see sheet no. B6, points 1-6).

2. Set the bowden cable setting device (1) in such a way that it is only possible to latch the toothing of the handbrake lever onto the 4th tooth by exerting considerable force.

3. Subsequent inspection: Jack up the vehicle securely and accelerate the motor at full speed by bypassing the handbrake switch.

1 5/0076

The motor must now block at the latest when the 3rd tooth latches in.

To determine the exact braking force, a test must be carried out with the vehicle in motion. When you reach maximum speed, brake the vehicle using the handbrake. A brake deceleration value of 15 % must be achieved (see also sheet no.

C10).

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Sheet no.

C7

Assembly C

Brake

Setting the brake pedal The brake pedal must be adjusted when: - the main brake cylinder (Fig. 1, no. 1) has been exchanged, - the piston rod clearance (snifter clearance) (Fig. 1, no. 2) is not correct, - brake pedal components have been exchanged.

4

Since the vehicle is not properly braked during the setting procedure on the brake pedal, the vehicle must be secured against rolling away.

1 5

2

1. Remove the covers.

2. Slightly loosen the nut (figs. 1+2, no. 3) in the mechanical stop for the brake pedal.

Fig. 1

5/0077

3. Push the stop (Fig. 1, no. 4) along the longitudinal slot until the distance between the top edge of the brake pedal and the carrier plate for the accelerator pedal measures approx. 96 mm (see fig. 2).

The measurement must be made with the rubber pedal cover removed.

4. Tighten the nut (figs. 1+2, no. 3).

5. After releasing its nut (Fig. 2, no. 7), turn the threaded rod (Fig. 2, no. 6) until there is a clearance of 1 mm between the piston and piston rod of the main brake cylinder. Lock the nut again.

This "snifter clearance" is not visible, as the protective cap covers the end of the piston rod. However, it is easy to "feel" it by slowly pressing the brake pedal down manually out of the idle position. Once the piston rod has moved by 1 mm, a slight resistance should be felt. This is caused by the piston rod making contact with the piston.

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96 mm

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

Copyright reserved.

Note:

3

5-03 26

Fig. 2

3

XR-N

6

Sheet no.

7

C8

Assembly C

Brake

Continued

Setting the brake pedal

6. Bend the actuator plate (1) of the brake pedal switch by hand so that when the brake pedal is not activated, the switch is activated and when the pedal is tapped lightly the switch is released.

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

Copyright reserved.

This can be heard as a quiet "click" of the switch.

The return force of the pedal is fixed by the tension spring (2).

This setting cannot be altered.

5-03 26

The spring should be replaced as required (Id. no. W8 010 089) and the mechanical components tested regularly for easy running.

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1

Sheet no.

C9

Assembly C

Brake

Braking distances The table of braking distances below is intended purely as an approximate guide. The exact braking force can only be determined by measuring the brake deceleration value with measuring equipment (see sheet no. C11).

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

Copyright reserved.

Speed of travel v in km/h

m/s

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

6

1.67

7

Permissible braking distance in metres with rated load

without rated load

6.0

1.2

0.7

1.94

5.2

1.4

0.9

8

2.22

4.5

1.6

1.0

9

2.50

4.0

1.9

1.1

10

2.78

3.6

2.1

1.3

11

3.06

3.3

2.3

1.4

12

3.33

3.0

2.5

1.5

13

3.61

2.8

2.7

1.7

Remark:

These values apply only for industrial trucks belonging to Group A as per DIN 15161, with a type-related speed of between 5.0 and 13.4 km/h.

This measurement must always be made in the travel direction of the forks.

The braking distance must be measured on a surfaced area which is level and dry.

The lifting device must be drawn in during the braking tests!

Example:

The measurement distance of 10 m is travelled in 6.0 seconds at a travelling speed of 6 km/h. At this speed, a braking distance of 1.2 m with rated load and 0.6 m without a load must be achieved.

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Sheet no.

C 10

Assembly C

Brake

Measuring the brake deceleration General The brake deceleration value is measured with the dynometer (Fig. 1).

2

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

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

Copyright reserved.

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

1 5/0115

Fig. 1

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

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

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

3

5/0116

Fig. 2

4

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

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

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Fig. 3

5/0117

Verzögerung in %

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Sheet no.

C 11

Assembly C

Brake

Continued

Measuring the brake deceleration

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

Copyright reserved.

Evaluating the measurement 1.

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

2.

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

3.

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

4.

The following values are required: Example for v = 10 km/h

With rated load

Without rated load

F = 1.86 x V

F = 1.86 x 1.6 x V

F = 1.86 x 10 km/h

F = 1.86 x 1.6 x 10 km/h

F = 18 %

F = 29.76 %

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Sheet no.

C 12

Assembly C

Brake

Main brake cylinder The main brake cylinder is located under the brake pedal on the floor of the cab and is connected to the brake pedal by a guide mechanism.

The entire braking process is started and controlled by the main brake cylinder, since when the brake pedal is depressed, the main brake cylinder piston (1) pushes the brake fluid in the brake system into the wheel cylinder.

2

The equalizing tank (2) is mounted directly on the main brake cylinder. It must always be filled with sufficient brake fluid, to approx. 15 - 20 mm below the edge of the lid.

3

4

1

F

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

Copyright reserved.

Remark:

Only use original brake fluid! Do not fill with mineral oil! The brake fluid must be changed once a year.

5/0078

The main brake cylinder is fitted with a protective cap (3) to prevent dust and water entering the cylinder. This cap has a vent hole, which lets the air contained in the protective cap escape when the main brake cylinder is actuated.

The protective cap must be mounted in such a way that the vent hole is at the bottom. If the protective cap is mounted so that the vent hole is at the top, water can collect in the cap, from where it can enter the main cylinder when the brake is actuated.

The results of this are: -

Rust formation at the main brake cylinder bore, which causes damage to the secondary sleeve (4) and loss of brake fluid.

-

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

Continued on sheet no. C14

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Sheet no.

C 13

Assembly C

Brake

Continued

Main brake cylinder

If leaks are found at or in the main brake cylinder, or the cylinder is found to be otherwise damaged, the entire main brake cylinder must always be replaced, since special tools and expertise are needed to carry out repairs.

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

Copyright reserved.

Special bottom valve So that excess pressure in the brakes can be relieved entirely when the brakes are released, bringing the pressure to 0, the main brake cylinder is fitted with a special bottom valve (1).

This feature, in combination with the "snifter clearance" of 1 mm, makes it possible to release the brake linings without difficulty (see sheet no. C8, point 5).

Fig. 1

5/0078

1

Unlike the normal bottom valve, the special bottom valve has a throttling port "D" (Fig. 2).

The throttling port has two functions. Firstly, it makes it possible for excess pressure to be relieved entirely, and secondly, it guarantees that on fast operation of the pedal in certain situations, brake fluid can be "pumped" into the pipe system by the main brake cylinder piston; for example, when filling and bleeding the brake system, if there is no filling or bleeding equipment available.

Fig. 2

5/0079

In order to avoid main brake cylinders with a special bottom valve being confused with other main brake cylinders, they must be marked with a metal or adhesive tape labelled "cylinder fitted with a special bottom valve".

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Sheet no.

C 14

Assembly C

Brake

Continued

Main brake cylinder

Removing

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

Copyright reserved.

Caution:

Secure the vehicle against rolling away, since the brake system is not fully operational.

1.

Remove the covers.

2.

Release the lock nut on the fork head (1) and push out the fastening screw.

3.

Release the two fastening screws (2) and tilt the main brake cylinder.

4.

Remove the fork head and the actuator plate (3) of the brake pedal switch.

5.

Remove both the fastening screws (2) and the mechanical stop.

6.

Pull out the main brake cylinder and lay it to one side.

Remark: The main brake cylinder must be set down with the storage tank at the top, otherwise the brake fluid will run out through the vent hole.

7.

Remove the brake hose.

3

5-03 27

2

1

To mount the cylinder, follow the instructions above in reverse order.

After installation, bleed the brake system, set the brake pedal to the correct position and check the brake clearance and the brake deceleration value.

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Sheet no.

C 15

Assembly C

Brake

Bleeding/filling the brake system Caution:

When handling brake fluid, ensure that the aggressive fluid does not come into contact with the eyes, the skin, clothing or parts of the truck. If brake fluid comes into contact with the eyes or skin, rinse immediately with plenty of water and wash with soap.

Never mix brake fluid with mineral oil or dispose of the two together.

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

Copyright reserved.

Filling Brake fluid is hygroscopic, i.e. it takes moisture from the air. We therefore recommend renewing the brake fluid every year.

When filling and bleeding new or repaired brake systems, do not use brake fluid which has overflowed to refill the brake system.

5/0075

1 1.

Fill the storage tank with brake fluid.

2.

Remove the dust protection cap from the bleeding valve (1), pull on a hose which fits on the valve and hang the end of the hose into an open glass vessel positioned at a higher level.

Remark: Only use the bleeding valve at the brake hose, never at the brake plate. Wind a cloth or something similar around the bleeding valve to prevent brake fluid entering the brake.

Open the bleeding valve by a quarter to half turn.

3.

4.

"Pump" the brake pedal until brake fluid runs out of the hose. If necessary, add more brake fluid to the storage tank.

5.

Close the bleeding valve.

6.

Bleed the brake system (see sheet no. C17).

Continued on sheet no. C17

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Sheet no.

C 16

Assembly C

Brake

Continued

Bleeding/filling the brake system

Bleeding If perfect braking performance is only achieved after treading on the brake pedal several times, or if the brake system has been refilled, the brake unit needs bleeding.

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

Copyright reserved.

If an "Ate filling and bleeding device" is available, proceed according to the operating instructions provided by Teves.

If an appliance of this kind is not available, the brake system must be bled by the following method. This process requires two people if the FM is fitted with a load wheel brake: 5/0075

1. Drain the storage tank and fill it with new brake fluid.

1

2. Remove the dust protection cap from the bleeding valve (1), pull on a hose which fits on the valve and hang the end of the hose into an open glass vessel positioned at a higher level.

3. One person presses the brake pedal down as far as it will go and holds it in this position.

Caution:

Ensure that the bleeding hose is fitted firmly. Cover the glass with a cleaning cloth to catch any splashes.

Continued on sheet no. C18

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Sheet no.

C 17

Assembly C

Brake

Continued

Bleeding/filling the brake system

4. A second person opens the bleeding valve (1) by a 1/4 to 1/2 turn.

5. Brake fluid should run out under the pressure of the brake pedal.

6. Close the bleeding valve again immediately.

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

Copyright reserved.

7. Move the brake pedal to its home position.

Repeat this process 4 to 7 times until only bubble-free, clear brake fluid emerges in the glass.

If the oil level in the equalizing tank drops rapidly, top up with new "Ate brake fluid".

5/0075

1

Do not reuse brake fluid which has overflowed.

Remark:

The individual cylinders are bled one after the other. Start with the brake cylinder which is furthest away from the main cylinder. If you notice that there is air in the brake system particularly often, or if the brake cylinders lose brake fluid, the brake cylinder must be exchanged.

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Sheet no.

C 18

Assembly M

Electrical system

Contents

Sheet no.

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

Copyright reserved.

Guide to components .................................................................................................M 3 Traction and pump controller (FPS) - General.............................................................................................................M 5 - Guide to components .......................................................................................M 7 - Main current terminals ......................................................................................M 8 - Control current terminals ..................................................................................M 9 - Block diagram...................................................................................................M 10 - Logic circuit board, general ..............................................................................M 12 - Electronic evaluation system, general ..............................................................M 13 - Travel/hydraulics output stages, general..........................................................M 14 - DC/DC converter, general ................................................................................M 15 - Control of the travel motor ................................................................................M 16 - Operating principle of the main current circuit for travel ...................................M 17 - Operating principle of the main current circuit for generator braking................M 19 - Operating principle of the main current circuit for hydraulics............................M 20 - Safety circuit - General....................................................................................................M 21 - Anti-roll monitor........................................................................................M 22 - Description of errors ................................................................................M 23 - Removing the electronic evaluation system .....................................................M 32 - Removing the DC/DC converter .......................................................................M 34 - Replacing the logic circuit board software........................................................M 35 - Control signals for travel (Vmax) ......................................................................M 36 - Control signals for travel (2.5 km/h)..................................................................M 37 - Control signals for hydraulics ...........................................................................M 38 - Armature current behaviour .............................................................................M 39 - Measuring the armature current.......................................................................M 39

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Sheet no.

M1

Assembly M

Electrical system

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

Copyright reserved.

Contents

Sheet no.

Travel and pump control system - Electronic evaluation system, general ..............................................................M 40 • Steuerung der Hydraulik ...........................................................................M 41 - Block diagram........................................................................................M 42 - Truth table .............................................................................................M 43 - Block diagram, pump setpoint ...............................................................M 44 - Simultaneous movements .....................................................................M 45 - Compulsory reset ..................................................................................M 46 - Shift damper function.............................................................................M 47 • Hydraulic options ......................................................................................M 48 • Control of the console display...................................................................M 49 • Error list ....................................................................................................M 53 • Maintenance intervals...............................................................................M 55 • TEWAK interface software........................................................................M 56 - Closing the TEWAK program ................................................................M 57 - Diagnosis and commissioning - Software, general ...............................M 58 • Menu structure and use.................................................................M 59 - Main menu ................................................................................M 60 - Configuration.............................................................................M 61 - Commissioning .........................................................................M 62 - Parameters ...............................................................................M 69 - Error list.....................................................................................M 71 - Maintenance interval.................................................................M 72 • Replacing the electronic evaluation system software....................M 73 - Serial communication, logic circuit board and electronic evaluation system ....M 75 - Setting the battery discharge characeristic curve.............................................M 77 - Guide to pin assignment...................................................................................M 78 Interface adapter ........................................................................................................M 82

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Sheet no.

M2

Assembly M

Electrical system

Guide to components Key-operated switch Travel direction switch Tilting key Side shift key Potentiometer for main lift Potentiometer for ancillary movements 3A1 Steering controller 1S28 Creep speed rocker switch 4S1 Horn rocker key Q1 Emergency-off switch F1-5F7 See below K1 Main contactor 1A10 Travel/pump control, complete 9M6 Fan (1) 24V 6A10 Operating status display circuit board 1B1 Travel transducer with switch 1B2 Brake pedal switch 1M1 Travel motor 1S27 Battery lock switch 4H1 Horn 2M1 Hydraulics motor

1S3

X55

3M1 1S25X59 7M20

9M5 1S27

4H1 7/0433 7/0434

F1

F2 F3 3F1 4F1 5F1

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

Copyright reserved.

S1 1S1 2S2 2S3 2R2 2R3

Fuses F1 Main current fuse 250 A F2 Switch latch 10 A F3 DC/DC converter input 10 A 3F1 Servomotor 20 A 4F1 Horn 5A 5F7 Reserve 10 A

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Sheet no.

M3

Assembly M

Electrical system

Continued

Components Handbrake switch Servomotor, steering "Shifting" on/off valve (electr. components only) 3S24 Central wheel position switch 2Y29 "Tilting" on/off valve 2Y44 Side shift on/off valve 2S39/38 Proximity switch for shift damper function

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

Copyright reserved.

1S3 3M1 2Y25

7/0436

7/0437

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Sheet no.

M4

Assembly M

Electrical system

Traction and pump controller

(FPS)

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

Copyright reserved.

General The FPS is a combined travel and pump control system. It is used to control a shunt motor (for travel) and a series-wound motor (for hydraulics).

The motors are timed via output stages using a microprocessor-controlled logic circuit board.

An electronic evaluation system evaluates the setpoint (hydraulics) and transmits it further in the system. It also evaluates various different input signals.

The main current circuits are constructed using MOSFET technology and are timed with a frequency of 16 kHz. The voltage is controlled on the principle of pulse width modulation (PWM).

When generator braking of the motor takes place, power flows back to the battery.

Travel against the applied handbrake (for 2 secs.) and anti-roll monitoring are integrated as standard features.

7/0435

Various components are directly connected to the FPS (see block diagram on sheet no.

M11).

The logic board of the FPS is connected to the electronic evaluation system with a ribbon cable. This means that it is possible to exchange (see sheet no. M75) or delete data.

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Sheet no.

M5

Assembly M

Electrical system

Traction and pump controller

The control system uses numerous control current circuits to conduct continuous selfdiagnosis, and switches itself off in the event of a fault being identified.

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

Copyright reserved.

Once the control system has been tested sucessfully, the main contact becomes operative.

After 200 ms the main contactor is supplied with 28 volts, in order to prevent the main contactor coil overheating.

The software can be used together with a notebook and an interface adapter to change the parameters in the control system, in order to adjust the travel and braking performance. System diagnosis can also be carried out.

F2 F3 3F1 4F1 5F1

General, continued

1 2 3 7/0439

There is an interface (1) at the FPS which can be switched over from the electronic evaluation system to the FPS (logic circuit board) by means of an interface switch (2).

Information about the current software version for the electronic evaluation system and the logic circuit board is provided on the cover of the FPS.

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7/0435

XR-N

Sheet no.

M6

Assembly M

Electrical system

Traction and pump controller (FPS)

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

Copyright reserved.

The FPS is made up of the following components: (1) Electronic evaluation system (2) Logic circuit board (3) Travel motor output stage (4) Pump motor output stage (5) DC/DC converter (6) Main contactor (7) Fan (8) Heat sink (9) Control current fuses

1 2 7 8

4

3 7

9 6

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5

1

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Sheet no.

M7

Assembly M

Electrical system 10

Traction and pump controller

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

Copyright reserved.

Main current terminals (1)

+ Batt (A1 travel motor)

(2)

- Batt (travel output stage)

(3)

A2 (clocked minus VMN - travel motor)

(4)

+ Batt (hydraulics output stage)

(5)

P + (pump motor A1)

(6)

- Batt (hydraulics output stage)

(7)

P - (VMN - clocked minus) pump motor D2

(8)

F1 Travel motor field terminal

(9)

F2 Travel motor field terminal

8

9

(10) G + (48V from battery)

7/0435

1

2 3 4 5 6 +

•

G+

7 -

Emergency-off

Main contactor Travel motor A2

M

A1

+ Batt (travel output stage) - Batt (travel output stage)

F2

F1

A2 (VMN travel motor) F1 F2 + Batt (pump motor output stage) - Batt (pump motor output stage)

Pump motor A2

M

A1

P+

D2

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P- (VMN)

XR-N

Sheet no.

M8

Assembly M

Electrical system

Traction and pump controller Control current terminals Connector

Components

X10 (10-pin) evaluation system

Electronic

X11 (6-pin) evaluation system

Electronic

(3)

X5 (Interface) / AWE

Logic circuit board

(4)

X20 (Ribbon cable) / AWE

Logic circuit board

(5)

X100 (Ribbon cable to display)

AWE

(6)

X 4 (18-pin)

Logic circuit board

(7)

E (4-pin internal main contactor control)

Logic circuit board (see sheet M12)

(8)

X2 (14-pin)

Logic circuit board

(9)

X12 (4-pin)

AWE

(10)

X13 (18-pin)

AWE

(11)

X3 (10-pin)

Logic circuit board

(12)

X14 (10-pin)

AWE

(13)

X8 (10-pin)

Switchboard

(14)

CN I (4-pin) internal DC/DC converter (see sheet M15)

(1)

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Copyright reserved.

(2)

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1

(AWE) (AWE)

Workshop Manual

14

7 8

1 2 3

9 11

4 5 6

1 1

7/0435

XR-N

Sheet no.

M9

Assembly M

Electrical system

Block diagram

Steering column

On/off valves

Display

Steering controller Hydraulics setpoints

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

Copyright reserved.

Hydraulics sensor system

FPS

Notebook

Electronic evaluation system

+24 volts

Logic board

• Travel

Power unit +48 volts

setpoint

DC/DC

• Accelerator pedal switch

Heat sink

• Brake pedal switch • Handbrake • Foot-switch • Battery lock • Direction of travel See also M11

Travel motor

Monitoring system: -Carbon brushes -Temperature

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Pump motor

Monitoring system: -Carbon brushes -Temperature

Workshop Manual

XR-N

Sheet no.

M 10

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Valves

Logic circuit board

Fahren 1

Workshop Manual

XR-N Steering

Electronic evaluation system

Sensorik

Schlüsselschalter

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Copyright reserved.

Schlüsselschalter

Sicherungen

Interface to AWE Flachbandkabel

Mikroschalter

Notebook

Assembly M Electrical system

Block diagram

7/0449

Sheet no.

M 11

Assembly M

Electrical system

Traction and pump controller Logic circuit board

Connector E 1

General The logic circuit board is inegrated in the travel and pump control system.

Using the microprocessor mounted on the board, the logic circuit board monitors the switching inputs and the safety circuit and makes logical connections.

5 x2

4

The microprocessor (1) is monitored by a higherlevel processor (2).

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

Copyright reserved.

Various parameter sets are stored in an EPROM (3) and can be adjusted using a notebook.

x3 x4

This makes it possible to optimise the travel and braking performance of the vehicle.

6/0326

The logic circuit board passes information on to the output stages which is based on the digital input signals and the information provided by the electronic evaluation system (pump setpoint, enable pump).

2

3

An interface switch (4) is fitted on the logic circuit board, which can be used to switch over the interface (5) (see also sheet no. M82).

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Sheet no.

M 12

Assembly M

Electrical system

Traction and pump controller General Electronic evaluation system

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

Copyright reserved.

See sheet no. M40

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Sheet no.

M 13

Assembly M

Electrical system

Traction and pump controller General Travel/hydraulics output stages The two output stages for travel (1) and hydraulics (2) are supplied with the necessary information about the control situation via ribbon cables (3 and 4).

The power transistors (MOS-FETs) which are fitted on the output stages are responsible for control of the motors.

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

Copyright reserved.

3

4

1 2 7/0440

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Sheet no.

M 14

Assembly M

Electrical system

Traction and pump controller DC/DC converter General

3

6

2

The DC/DC converter (1) is one of the components integrated in the FPS. The +48 volt battery voltage is reduced here to a +24 volt power supply.

A green LED (6) lights up to indicate that the output voltage is in order.

4

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

Copyright reserved.

Terminals: (2) : 0 volts (3) +24 volts (4): CN I connector (5): S connector

5 - Terminal stud H - Terminal stud T - See illustration below - See illustration below

(7) Fuse: input end 7/0440

For instructions on removing the DC/DC converter, please refer to sheet no. M34

7

1

Technical data Input end: Output end:

+48V/10A +24V/10A, short-circuit proof

10AT

2+48V

Options

F3

Supply for logic circuit board

3+48V

CNI

3

2

Keyoperated switch

Options

4

S

• T (24 volts) H (0 volts) DC/DC converter

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Sheet no.

M 15

Assembly M

Electrical system

Traction and pump controller (FPS) Control of the travel motor

IArmature UArmature IField

At low speeds (potentiometer setpoint < 60%) the field current is equal to the rated current (IF nom = 17A) and the armature voltage changes with the setpoint from 0 volts to 48 volts.

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

Copyright reserved.

If the setpoint is above 60 %, the armature voltage remains constant (48 volts) and the field current is reduced so that the speed is increased, until the set minimum field current is reached (Max.Speed. parameter).

UA =

UA UBatt

Fig. 3 Armature adjustment range

Field weakening area

If, however, the armature current (under load) is slightly increased, the minimum field current is not reached, but the field current remains high in relation to the level of the armature voltage. The torque or efficiency are given priority over the speed.

Similarly, on a slope, an increasingly higher torque is required and the armature current increases. At the same time, the field current increases until double the nominal value is reached. The armature current then almost reaches the maximum current.

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Sheet no.

M 16

IA

t 6/0270

Assembly M

Electrical system

Traction and pump controller (FPS) Operating principle of the main current circuit

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

Copyright reserved.

Travel The 48 V voltage is supplied to the main current circuit via the main contactor K1 and is active as long as the voltage at the capacitor package (1) is higher than 10V. The capacitor package is charged constantly. In the event that a serious fault occurs, the main contactor becomes inoperative.

The main current circuit for travel control consists of an armature control via terminals A2 and A1 for the armature of the travel motor (Fig. 1) and a full bridge (four-quadrant) via terminals F1 and F2 for control of the travel motor field winding (Fig. 2).

Key-operated switch

Main contactor

Charging circuit for capacitor bank

+ 48V +

A1

Q3

16kHz

A A2

1

Measuring shunt

Q2 7/0451

The armature and the field are controlled separately, depending on the travel situation.

The control variables for the armature and the field are: - Travel setpoint - the actual speed and the actual current, which is limited by the measuring shunt (Hall sensor).

48V from F1

When the vehicle moves off, the motor is operated as a series-wound motor, i.e., with normal field excitation (I nom = 17 A) in the breakaway phase, in order to achieve the normal breakaway torque.

4x

•

4x 800Hz F1

•

F2 Q10

•

Q8

4x

Q9

•

Q7

•

• •

4x

•

•

Measuring shunt

0V

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Sheet no.

M 17

Assembly M

Electrical system

Traction and pump controller (FPS) Operating principle of the main current circuit for travel, continued

Key-operated switch

Main contactor

The speed is increased by increasing the armature voltage or the armature current (I max = 273 A) until the armature voltage is equal to the the battery voltage (48 V).

In order to reach the final speed, the field excitation is then weakened.

Charging circuit for capacitor bank

+ 48V +

A1

Q3

16kHz

A A2

1

Measuring shunt

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

Copyright reserved.

Q2

In normal operation, the field and armature controls alternate, depending on the operating situation.

The MOSFET Q3 operates with delayed timing antiparallel to the MOSFET Q2, which generates a clear square signal and reduces the induced voltage.

7/0451

48V from F1

The operating principle is similar for control of the field current (full bridge).

When current flows from F1 to F2, Q10 connects through and Q7 and Q8 switch antiparallel with delayed timing. For a current to flow from F2 to F1, Q8, Q9 and Q10 switch antiparallel with delayed timing.

4x

•

4x 800Hz F1

Q10

Q8

• Fig. 2

•

F2

•

4x

4x

•

•

• Measuring shunt

0V

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Q9

•

Q7

•

Sheet no.

M 18

Assembly M

Electrical system

Traction and pump controller (FPS) Operating principle of the main current circuit for generator braking In generator brake operation, the field is first fully excited. This leads to a voltage increase at the armature of the travel motor during the braking process.

U Motor is greater than U Batt and a current flows from A1 back to the battery via MOSFETs Q2 and the main contactor K1.

Key-operated switch

Main contactor K1

Charging circuit for capacitor bank

+ 48V +

A A2

1

Measuring shunt

The maximum current is limited by the timing of the MOSFETs. Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

A1

Q3

16kHz

Q2

If U Motor is smaller than U Batt, the current flows regulated through MOSFETs Q3.

7/0451

This process continues until the motor comes to a standstill.

48V from F1

4x

- when the travel direction switch is set to neutral

•

4x 800Hz F1

Q10

Q8

4x

- when the travel direction is changed while the accelerator pedal is pressed

• •

- when the foot-switch is released

•

F2

- when the accelerator pedal is released - when the brake pedal is pressed gently

Q9

•

Q7

•

Generator brake operation is initiated:

4x

•

•

• Measuring shunt

- when the vehicle is at a standstill and rolls away during the monitoring phase.

0V

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Sheet no.

M 19

Assembly M

Electrical system

Traction and pump controller (FPS) Operating principle of the main current circuit for hydraulics

Main contactor

Key-operated switch Charging circuit for capacitor bank

For the capacitor bank charging circuit, please refer to sheet no. M17.

The main current circuit for hydraulics control is connected via the MOSFETs Q1 (14 MOSFETs in parallel).

+ 48V +

P+

A

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

Copyright reserved.

The main current circuit controls the current which flows to the hydraulics motor (pulse width modulation), which is connected at the main current terminals P+ and P-.

P-

Q1 7/0452

The maximum current is 500 A, and can be adjusted with parameter settings.

Freewheel diodes D1 (6 diodes parallel) are used to keep the induced voltage low.

Setpoint potentiometer

Control of the motor is proportional to the "pump setpoint" input signal (1).

AWE

The only possible error message is PUMP I = 0 Immer or PUMP STBY I hoch, i.e., there is a problem with the armature current registration.

Error:

Pump I = 0 Immer = main contactor does not become inoperative

Error:

Pump STBY I hoch = main contactor becomes inoperative

Pump setpoint

1 Logic circuit board

Output stage

The actual current flowing is determined by a measuring shunt (2).

M

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Sheet no.

M 20

Assembly M

Electrical system

Traction and pump controller (FPS) Safety circuit General There are two possible error situations: 1. The main contactor becomes inoperative in the event of failure or does not become operative when the vehicle is switched on. This affects operation of the vehicle.

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

Copyright reserved.

2. The main contactor does not become inoperative, but operation of the vehicle is still affected.

The following tables (sheet nos. V22-V24) show whether and as a result of which errors the main contactor becomes inoperative.

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Sheet no.

M 21

Assembly M

Electrical system

Traction and pump controller (FPS) Safety circuit Anti-roll monitor The monitor is activated when:

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

Copyright reserved.

- the handbrake is released, - the pump motor is running, - a lowering movement is initiated, - the generator braking procedure is complete, - the vehicle is started up, - the "travel enable" signal has been sent.

Monitoring is interrupted as soon as the handbrake is applied.

Once the monitor is activated, the speed of the travel motor is monitored for 20 seconds by field excitation.

Current pulses with a duration of 300 ms are sent to the field every 1.48 seconds.

The first pulse at the field is 15% of the nominal value, and all further pulses 30%.

If a movement of the travel motor is determined within the test time (20 secs.), the vehicle is braked by means of generator braking.

The vehicle cannot, however, be brought to an absolute standstill in this way.

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Sheet no.

M 22

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors Battery lock (FE01) see V22 The battery is not locked.

The travel speed is reduced.

The travel setpoint is reduced internally to 20%.

Forw. + Backw. (FE05) see V22

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

Copyright reserved.

Both travel direction signals are sent simultaneously.

Incorrect.start (FE06) see V22 This error message is produced if the signal from the accelerator pedal microswitch is applied for at least 0.5 seconds, but there is no signal from the foot-switch.

Travel is not enabled or is interrupted.

In order to restart, the foot-switch must be pressed first, and then the accelerator pedal.

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Sheet no.

M 23

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors VACC not o.k. (FE07) see V22 As long as the accelerator pedal microswitch is open, the travel setpoint must not deviate from the stored minimum value by more than + 1V.

ACC out of range (FE08) see V22

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

Copyright reserved.

The setpoint must lie between 4V and 9.6V. Remark: If this error is already registered when the vehicle is switched on, the main contactor does not become operative.

EEPROM KO (FE10) see V22 EEPROM check sum error.

Driver shorted (FE11) see V22 When the capacitors charge up (see M32), a check is made to determine whether the driver for the main contactor is open, i.e., whether + 48V is supplied to the negative terminal of the main contactor coil.

Logic Failure (FE11) see V22 Main contactor control not in order.

Contactor driver (FE11) see V22 In order to close the main contactor, a pulse is sent to the driver. A check is made to confirm that the driver has closed, and after 200 ms, control of the main contactor is pulsed with a pulse width modulation (PWM) of 60%.

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Sheet no.

M 24

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors Micro St 6215 KO (FE11) see V22 Microprocessor faulty.

No Field current (FE12) see V22

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

Copyright reserved.

A check is carried out to ascertain whether the microprocessor receives an acknowledgement via the actual field current when a signal is sent to the field.

High Field current (FE 13) see V23 Field current too high, is not monitored during anti-roll monitoring.

The field current is recognised, although no signal has been sent.

Pump I = 0 Ever (FE14) see V23 Monitoring of the pump current.

No current flows, although a signal has been sent to the pump motor.

Pump Stby I High (FE14) see V23 Monitoring to ascertain whether current flows through the pump motor although the output stage is not driving.

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Sheet no.

M 25

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors Capacitor charge (FE15) see V23 +

• Main • contactor +

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

Copyright reserved.

Key-operated switch

R

• C

1 Q2A

•

Travel M motor

• M

VMN

Pump motor

Q1

Q2B

The capacitor bank (1) is loaded when the keyoperated switch is switched on.

If the voltage at V M N (Voltage Motor Negative) does not rise above 5.5 V, the error message is sent.

A check must be carried out with the control system turned off, to ascertain whether there is a short-circuit between positive and negative (via the MOSFETs) or whether the short-circuit is due to the motor connection.

1.

2.

3.

Turn off the vehicle Disconnect the travel motor armature and switch on.

If the short-circuit has disappeared, it was caused by the travel motor.

If the short-circuit is still present, it is due to the hydraulics or travel output stage.

Repeat the procedure with the pump motor to ascertain whether the travel or hydraulics output stage is faulty.

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Sheet no.

M 26

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors VMN not o.k. (FE16) see V23

+

Key-operated switch

• C

M

•

VMN (Voltage-Motor-Negative)

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

Copyright reserved.

This error message is issued if the voltage at the travel motor armature deviates from the applied voltage by > 1V (anti-roll monitor not active).

During anti-roll monitoring, the VMN can deviate from UBatt by max. 3.5V. If the deviation is too great, the error message is issued.

This can indicate either a short-circuit at the VMN or that the vehicle is moving at too high a speed for it to be stopped.

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Sheet no.

M 27

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors V Field not o.k. (FE 17) see V23

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

Copyright reserved.

The voltage at the travel motor field (1) must be about half the voltage at the armature (VMN).

For the error message to be issued, the voltage deviation must be more than 4.4 volts and continue for more than 2 seconds.

The voltage at the field must, however, be more than 4.4 volts.

(Only when anti-roll monitor not active)

+ Key-operated switch

R

•

1

M

C

•

-

VMN

Measuring point microprocessor

•

Stby I High (FE18) see V23 - The armature current of the travel motor is too high when the motor is idling.

- Current flow is detected in the travel motor armature, although no control signal has been sent.

I = 0 Ever (FE18) see V23 - Control signal is sent to the travel motor armature, but the microprocessor does not receive acknowledgement.

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Sheet no.

M 28

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors Contactor closed (FE19) see V23 The capacitors are discharged again briefly after switching on in order to test the condition of the contactor contacts.

Remark:

This error message is issued if there is a fault in the field current circuit.

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

Copyright reserved.

Coil shorted (FE19) see V23 The condition of the flip-flop control of the main contactor is checked for short-circuits.

The flip-flop determines hardware cut-out of the main contactor.

Traction Motor Temp. (FE20) see V24 Travel motor excess temperature from 140° C. The maximum armature current is temporarily reduced by half and after 5 minutes it is set to zero.

The field is maintained at the nominal value.

As soon as the temperature switch closes again, the monitoring process is stopped.

The braking current is maintained.

The cut-out can be reset with the key-operated switch.

Travel is then possible again for 5 minutes.

Traction Brushes (FE 21) see V24 This message is issued when the carbon brushes for the travel motor are worn down.

This has no effect on the system.

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Sheet no.

M 29

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors Th. Protection (FE22) see V24

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

Copyright reserved.

The temperature is too high or too low at the travel output stage.

If the temperature is lower than -10° C, the speed is reduced, i.e., the setpoint is decreased by 60% and the maximum current reduced to 80%.

If the temperature is higher than 77° C, the speed is reduced, i.e., the setpoint is decreased by 60% and the current reduced linear to a further temperature increase from the set value to zero.

I max = 0 at 92° C

Pump. Motor Temp (FE30) see V24 Pump motor excess temperature 160° C. When the temperature switch opens, the full power of the pump motor is maintained for 15 seconds.

After this, there is a cut-out.

This can be reset by switching off the key-operated switch. If the temperature is then still above 160° C, the pump motor can be run again for 15 seconds longer.

Pump Brushes (FE31) see V24 This message is issued as soon as the carbon brushes in the pump motor are worn down.

This has no effect on the system.

Pump Temperature (FE32) see V24 See (FE22) Hydraulics output stage is too high or too low.

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Sheet no.

M 30

Assembly M

Electrical system

Traction and pump controller (FPS) Description of errors

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

Copyright reserved.

State output KO (sok) (FE42) see V24 The control system (logic board) makes available an output which is active when the main contactor is closed. It is deactivated when the main contactor is open.

This output is checked for short circuits every 8 ms.

This output is also referred to as "control started successfully".

The output is sent to the electronic evaluation system via a ribbon cable.

If this information is not available at the electronic evaluation system, the electronic evaluation system blocks the following signals: -

Pump setpoint Pump enable Power outputs to the valves.

Batt out of range (FE43) see V24 Battery voltage outside the window.

This message is issued if the battery voltage is less than 30V.

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Sheet no.

M 31

Assembly M

Electrical system

Traction and pump controller (FPS) Removing the electronic evaluation system Remove the protective panel (see U2 (1))

3.

Pull out the battery plug (1)

4.

Pull out all the connectors (2-5)

5.

Mark the travel motor field terminals (6) and disconnect them.

6.

Mark and disconnect the voltage transformer terminals (7).

7.

Unscrew the 3 screws (8-10).

8.

Remove the cover (11) carefully, taking care to ensure that the interface switch (12) is not damaged.

7

6 1

4

2 12

X12 X2

Remove the cover (see U2 (2))

5 7/0439

X14 X13 X3

2.

8

X11 X100

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Copyright reserved.

1.

3

10

9 11 7/0435

1

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Sheet no.

M 32

Assembly M

Electrical system

Traction and pump controller (FPS) 1

Removing the electronic evaluation system

2

1

Continued

9.

Unscrew the 4 nuts (1) at the electronic evaluation system (2).

3

10. Remove the electronic evaluation system 11. Disconnect the connector X20 (3).

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

Copyright reserved.

To replace the logic circuit board, follow the instructions above in reverse order.

If the electronic evaluation system is replaced, the parameter and configuration settings must be checked (see sheet M58).

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1

Sheet no.

M 33

Assembly M

Electrical system

Traction and pump controller (FPS) Removing the DC/DC converter 1.

Carry out steps 1-8 on sheet no. M32.

2.

Unscrew the 4 screws (1) and remove the DC/DC converter (3).

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

Copyright reserved.

To replace the DC/DC converter, follow the instructions above in reverse order.

7/0440

1

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Sheet no.

M 34

Assembly M

Electrical system

Traction and pump controller (FPS)

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

Copyright reserved.

Replacing the logic circuit board software 1.

Carry out steps 1-8 on sheet no. M32 and steps 9-10 on sheet no. M33.

2.

Pull off the EPROM (1) using suitable tools.

To replace the logic board software, follow the instructions above in reverse order.

1

Fig. 1

6/0326

Remark: Note the installation position of the EPROM (see Fig. 2). The markings (2) must be on the same side.

Remark: For instructions on replacing the electronic evaluation system, see sheet no. M73.

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OOOOOOOO

2

OO 2 O O O O O O6/0005

Fig. 2

XR-N

Sheet no.

M 35

Assembly M

Electrical system

Traction and pump controller (FPS) Control signals for travel (Vmax) Remark: For input wiring, see sheet no. M78-M81

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

Copyright reserved.

Preconditions Signal name

1. Emergency-off not pressed 2. Main current fuse F1 O.K. 3. Fuse F2 4. Fuse F3 5. Power supply for travel output stage 6. Power supply for logic board 7. Power supply for logic board 8. No travel motor excess temp.

9. No travel output stage excess temperature

Connector/PIN

Explanation

X8.1 (see M9) CN I/3 (see M15) BATT + (see M8)

+48V in front of key-operated switch +48V from G+ for DC/DC converter + 48V after main contactor

E1 (see M12)

3+48V after key-operated switch via DC/DC converter CNI/2 (see M15) +24V after DC/DC converter from T-bolt

E2 (see M12) X4.2 (see M9)

0V=no excess temperature (see M35) Error 22 must not appear (see M36)

Truth table Remark: HB= FB= FS= FV= FR= FF= Set=

The signals listed below can all be read off from the tester menu (see sheet no. M65).

Handbrake none 0volts, when applied (ON) Footbrake none 0volts, when pressed (ON) Footbrake 0volts, when pressed (ON) Forw. travel direction 0volts, when selected (ON) Reverse travel direction 0volts, when selected (ON) Travel enable (micro0volts, when pressed (ON) switch for acc. pedal) Setpoint dependent on voltage which is read in

Forw. travel Rever. travel Generator brake

Off

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HB Off Off Off Off Off Off Off Off

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FB Off Off Off Off Off On Off On

FS On On Off On On x On Off

FV On Off On Off (or) x x On On

Workshop Manual

FR Off On Off Off x x Off On

Connector X2.10 Connector X2.12 Connector X3.2 Connector X2.8 Connector X2.6 Connector X2.4

(see M9) (see M9) (see M9) (see M9) (see M9) (see M9)

Connector X2.2

(see M9)

FF Set Parameter On >min On >min On x Release brake On x Release brake Off min Release brake x x Pedal brake On max/min Inversbrake max/min Inversbrake

XR-N

Sheet no.

M 36

Assembly M

Electrical system

Traction and pump controller (FPS) Control signals for travel (2.5 km/h) For preconditions see sheet no. M36 FR1 (X3.4) Deceleration on = selected - no 0-volt signal BV (X3.6) Battery lock on = Battery lock open - no 0-volt signal The signals can be read off from the tester menu (see V18)

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

Copyright reserved.

2.5 km/h

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FR1

BV

On

Off

Off

On

On

On

Workshop Manual

XR-N

Sheet no.

M 37

Assembly M

Electrical system

Traction and pump controller (FPS) Control signals for hydraulics Remark: For input wiring, see sheet no. M78 - M81

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

Copyright reserved.

Preconditions Signal name

Connector/PIN

Explanation

Emergency-off not pressed Main current fuse F1 O.K. Fuse F2 X8.1 (see M9) +48V in front of key-operated switch Fuse F3 CN I/3 (see M15) +48V from G+ for DC/DC converter Power supply for E1 (see M12) 3+48V after key-operated switch via logic board DC/DC converter CNI/2 (see M15) Power supply for E2 (see M12) +24V after DC/DC converter T-bolt logic board Power supply for BATT + (see M8) + 48V after main contactor hydraulics output stage No pump motor excess temp. X4.6 (see M9) 0V=no excess temperature No hydraulics output stage Error FE 32 must not appear excess temperature Input signals in the logic board from the electronic evaluation system

Pump setpoint

see M72

see M72

Enable pump

Electronic evaluation system

Logic board

The pump setpoint and enable pump signals can be read off from the tester menu.

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Sheet no.

M 38

Assembly M

Electrical system

Traction and pump controller (FPS) Armature current behaviour The FPS has a booster function for starting up or changing the travel setpoint. The result is a higher starting torque.

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

Copyright reserved.

When the vehicle is started up, an armature current of approx. 350 A is initially set.

After 10 seconds, this drops to the set parameter value (standard 273 A = parameter value 5).

I approx. 350

Linear reduction proportional to time

approx. 273 A equivalent to parameter 5

approx. 120 A 10 sec.

120 sec.

t

Over a period of another 110 seconds, the armature current decreases linearly to a value of approx. 120 A, i.e., after 2 minutes the current is still approx. 120 A, unless the setpoint for the accelerator pedal changes.

If the armature current falls below the required current (see characteristic curve) during the linear reduction phase for longer than 500 ms, the booster function is restarted. This can also occur if the setpoint is altered.

Measuring the armature current -

Jack up the vehicle securely Apply the handbrake Bridge the switch for the handbrake Press the accelerator pedal It should be possible to read off the set armature current briefly after approx. 10 seconds.

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Sheet no.

M 39

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) General

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

Copyright reserved.

The electronic evaluation system (1) acts as a fix-programmed miniature control unit.

Logical connections and parameter sets for the various different vehicle models are stored in an EPROM. These parameter sets can be modified with a PSION manual programming unit, to optimise the individual hydraulic movements (reach, tilting, fork side shift, additional hydraulics, reach damping function) (see sheet M 6970).

These modified values are stored in an E2PROM.

7/0454

1 The electronic evaluation system derives the control signals for the travel and pump controller, the console display and the hydraulic valves from the digital input signals (keys, limit switches, etc.), the information provided by the travel and pump controller (serial data transmission) and the analogue hand lever settings (main lift and ancillary movements).

The 24 V power supply is provided by the voltage transformer via the logic board.

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Functions Hydraulicfunctions

Display

Diagnostic

Options

XR-N

Sheet no.

M 40

Assembly M

Electrical system

Traction and pump controller (FPS)

1

Electronic evaluation system (AWE) Control of the hydraulic system

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

Copyright reserved.

A mechanically coupled potentiometer (1) on each of the hydraulic directional valves sends an analogue signal to the electronic evaluation system, for the setpoint main lift (SH) and setpoint ancillary movements (SN) (idle position 6 V, approx. 0.5 V - 11.5 V by max. deflection).

5/0099

The voltage level generated in this way serves as the speed setpoint for the hydraulic pump (SP).

On the basis of the selected hydraulic function and the stored parameter, the electronic evaluation system (AWE) sends a speed setpoint to the travel and pump controller, which in turn controls the motor,on condition that the AWE also emits the "enable pump" signal (0V, FP).

Remark: It is very important that the idle position when the valve is not activated is 6 V, as otherwise individual movements may be inaccurate or not function correctly.

The course of the ancillary movements (tilting, reaching, fork side shift and additional hydraulics) is selected with electrical switching valves or selection keys in the "ancillary movements" operating lever (2), which are switched by the power outputs of the electronic evaluation system. These power outputs have a short-circuit, line breakage and excess temperature monitoring facility.

If an error occurs, the electronic evaluation system issues an error code on the console display.

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2

5/0100

SH

12V

SN

0V

X10.1

2

3

12V

AZ AN AQ

..

0V 4

5

6

0V X13.15 9 X10.7

8

Electronic evaluation system X20

X20

X11.1,3

FP

SP

0V

2,4,5, 24V

4 power outputs

X20

X20

Traction and pump controller (FPS) 5/0101

XR-N

Sheet no.

M 41

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Block diagram Main lift potentiometer

Ancill. movem. potentiometer

Ancillary movem. selection

• •

Steering contr. error

Shift damper

AWE

Shift damper

Power outputs Red. setpoint

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

Copyright reserved.

Setpoint generation *TXD RXD

Pump enable (FP)

Pump setpoint (SP)

Valves 0V

Power supply

Hydraulic option

Lowering counter

24V

Settings Konfiguration (Configuration)

Inbetriebnahme (Commissioning)

Logic board

Parameter (Parameters)

Optionen (Options)

Display

Fehlerliste

* The following information is sent from the logic board to the electronic evaluation system as data for the display.

• Logic board software version • Battery charge • Operating hours • Straight-on steering (bogie switch) • Travel direction • Creep speed ON/OFF • Battery lock • Handbrake • Error code

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(Error list)

Wartungsintervall (Maintenance interval)

Notebook

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Sheet no.

M 42

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Continued Control of the hydraulic system The input and output signals of the hydraulic control system are explained in the following table

Output information

Input information

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

Copyright reserved.

Function

SOK SH

Lift Shift forwards Shift backwards Tilt backwards Tilt forwards Side shift, left Side shift, right Lift/shift forwards Lift/shift backwards Lower/shift forwards Lower/shift backwards Lift/tilt backwards Lower/tilt backwards Lower/tilt forwards Addit. hydraulics, left Addit. hydraulics, right

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

> 6.2 V 6V 6V 6V 6V 6V 6V > 6.2 V > 6.2 V < 5.8 V < 5.8 V > 6.2 V < 5.8 V < 5.8 V 6V 6V

SN

AN AQ AZ FP

6V > 6.2 V < 5.8 V > 6.2 V < 5.8 V > 6.2 V < 5.8 V > 6.2 V < 5.8 V > 6.2 V < 5.8 V > 6.2 V > 6.2 V < 5.8 V > 6.2 V > 5.8 V

1 1 1 1 1 -

1 1 -

1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

SP

LS LN LQ ZH

0-10 V 0 parameter val.

0 parameter val.

0 parameter val.

0 parameter val.

0 parameter val.

0 parameter val.

0-10 V 0-10 V 0 parameter val.

0 parameter val.

0-10 V 0 parameter val.

0 parameter val.

0 parameter val.

0 parameter val.

1 1 1 1 1 1 -

1 1 1 1 1 -

1 1 -

1 1

Input information:

Output information:

SOK= Control system OK (see sheet M31) Signal enquiry is possible (see M66) SH = Setpoint, lift SN = Setpoint, ancillary movements AN = Tilt selected (0 volts) AQ = Side shift selected (0 volts) AZ = Addit. hydraulics selected (optional) (0 volts)

FP = Pump enable (0 volts can be read off in the tester menu (see V19) SP = Pump setpoint can be read off in the tester menu (see V19) Remark: It is, however, only possible to read off half the value here (see M73) LS = Power output, shift valve (+24V) LN = Power output, tilt valve (+24V) LQ = Power output, side shift valve (+24V) ZH = Power output, addit. hydraulics (0 volts)

Remark:

The idle position area of the setpoint potentiometers SH and SN is defined with ±0.7 V, i.e., a valid function is recognised from 6.3 V or 5.7 V!

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Sheet no.

M 43

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Block diagram for pump setpoint Ancill. movements potentiometer

Main lift potentiometer

6.0 ±5.5 V

6.0 ±5.5 V

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

Copyright reserved.

Setpoint generation

Conversion to parameters Ancillary movements

Electronic evaluation system

Setpoint, pump for for ancillary movements, dependent on the set parameter 0-6.2V Setpoint, pump for main lift 0-10 volts

Logic circuit board

R1

• R2

0 - 5V 0 - 3.1V Example

•

Logic

Interface

Notebook

*Speed Pump 0-5V 100%

Menu tester *Speed Pump 0-3.1V 20%

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Sheet no.

M 44

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Control of the hydraulic system Simultaneous movements

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

Copyright reserved.

It is possible to carry out the following functions simultaneously: lift/lower lift with forwards/backwards reach, or lift while tilting backwards, and lower while tilting backwards/ forwards.

Max. setpoint = Lift setpoint (10 V) reduced to 50 % during damping phase

When the lift is lifted at the same time as reaching backwards/forwards, the maximum setpoint is that of the lift (limitation of shift speed by 2-way flow regulator valves, see hydraulic system, section N7).

During reach damping, the speed is reduced to 50% and after a slight delay time, the movement continues at the setpoint for the lift.

When the lift is lowered at the same time as reaching forwards/backwards, the maximum setpoint is taken directly from the maximum setpoint for reaching.

If the lift is raised at the same time as tilting backwards, the maximum setpoint = lifting setpoint .

If the lift is lowered at the same time as tilting forwards or backwards, the maximum setpoint = tilting setpoint.

Max. setpoint = Reach setpoint (dependent on paramter)

Max. setpoint = Lift setpoint (10 V)

The maximum tilting speed is also limited by an orifice (see hydraulic system, section N12).

Max. setpoint = Tilt setpoint (dependent on paramter)

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Sheet no.

5/0102

M 45

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE)

1

Control of the hydraulic system Compulsory reset

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

Copyright reserved.

All movements can only be started from home position. When a transition is made from one type of movement to another (e.g. from reaching to tilting), a reset is always required first, which means that the hand lever must always be set to its idle position before the next movement can be started.

5/0103

The reset position is defined between a "bottom" and a "top" value (Reset position 6 V ± 0.7 V.

Reach damping function

6/0026

A ramp is used to cushion the end of each movement, i.e. the output value for the pump setpoint (SP) is reduced proportionally, according to the parameter value entered.

The input information (0 V signals) is provided by inductive proximity switches with a two-wire system (1) which are attached to the slide carriage.

Practical measured values: Switch not activated, SDV/SDH 19.5 V Switch activated, SDV/SDH 6.8 V Function

Reach damping, front Reach damping, rear

Issue: Replaces issue:

SDV SDH

1

-

-

1

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SP

max - red. value

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Sheet no.

M 46

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Hydraulic options A notebook can be used to activate various options in the electronic evaluation system, which extend the hydraulic functions.

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

Copyright reserved.

These options are: 1.Lift cut-out Input information -X13.8(HB1) --> Intermediate lift limit -X13.10 (HB2) --> End lift cut-out -X13.12(EHA) --> Intermediate lift limit release Output information -X20.10(FP) --> Enable pump -X20.9 (SP) --> Pump setpoint An intermediate lift limit can be activated via input HB1. As long as there is a 0V signal at X13.8 the lift is deactivated (setpoint and enable pump).

This cut-out is cancelled with a 0V signal at X13.12 (EHA).

An end lift cut-out can be brought about via input HB2 (X13.10). As long as there is a 0V signal here, the main lift remains switched off. This cut-out cannot be cancelled via input "EHA".

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Sheet no.

M 47

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Control of the hydraulic system Continued

Hydraulic options

2. Shifting and lowering lock

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

Copyright reserved.

If the load carriage is retracted and is lowered below a defined height (0.4 m) (0V signal at X13.2 SSP), the movement is blocked. The load carriage can be lowered further if a transient 0V signal is sent to X13.6 (ESP) by means of the release key.

If the load carriage is extended, it can be lowered without an intermediate stop. This movement is monitored with a 0V signal from the "Shift end position" switch (SEV)" at X13.4.

Input information -X13.2 (SSP) --> -X13.4 (SEV) --> -X13.6(ESP) -->

400 mm lowering lock Shift end position Release of shifting and lowering lock

Output information -X11.6 (LSP) -->

Lowering lock valve

If the load carriage is extended and lowered to below the defined height, the forwards shift function is locked. This locking function can also be cancelled with the release key.

If the fork holder enters the locked area and this is unlocked with the release key, the mast side shift function is deactivated.

3. Additional hydraulics If this option is selected, an additional hydraulic function (e.g. bale carrier) can be controlled with the electronic evaluation system.

Input information

The input signal is a 0V signal at X13.5 (AZ).

Output information

When the operating lever is displaced, output X12.2 (ZH) is activated. This is not a 24 V valve power output, but a 0V switch output. For this reason, a micro-relay must be inserted.

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-X13.5 (AZ)

-X12.2 (ZH)

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-->

-->

Selection of additional hydraulics

Additional hydraulics relay

Sheet no.

M 48

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Control of the console display 1 The following information is provided on the flat LEDs: - Maintenance (1) - Travel direction forwards/backwards (2) - Handbrake applied (3) - Vehicle ON (4) - Creep speed (5) - Heating ON (6), only for cold-store FM

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

Copyright reserved.

The 6-digit, 7-segment display (7) indicates the operating hours and the coded error messages.

Commissioning and diagnosis information is also shown on this display.

3

7

8

O OO O OO O O OO

OOOOOOOO

4 5 6

2

9

5/0110

The 8-digit LED strip (8) shows the battery charge level (see sheet no. M81) In the standard model, the wheel position display (9) only indicates the central wheel position (the two LEDs in the middle light up).

As an optional extra, a semi-circle can be added which represents the position of the wheels (not currently available).

The logic circuit board sends the following signals to the electronic evaluation system to control the display: Serial data transmission from the FPS - Travel direction forwards/backwards (FV/FR) - Handbrake (HB) - Creep speed (SF) - Central wheel position (RM) - Battery capacity - Operating hours (Maintenance is dertermined) - Error messages The signal for "vehicle ON" is evaluated with the applied supply voltage (24 V).

When the vehicle is switched on with the key- operated switch, information about the software version and settings is displayed (see sheet no. M51).

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Sheet no.

M 49

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE)

Continued

Control of the console display

Display

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

Copyright reserved.

The signals received from the AWE are transmitted to the display.

- Maintenance LED - Handbrake LED - Vehicle ON LED - Creep speed LED - Forwards travel LED - Reverse travel LED - Heating ON LED - Battery capacity - Operating hours - Wheel position display - Error messages

5/0112

1

The signals can be tested on the display circuit board as follows: 1. Remove the circuit board from the cover, so that the solder spots of the X900 connector (1) are accessible.

X 900 2 4 6 8

10 12 14 16 18 20 22 24 26

1 3 5 7

9 11 13 15 17 19 21 23 25

2. Measuring the signals at connector X900: Pin 1: 5 V Pin 13: free 2: 5 V 14: free 3: 0 V 15: free 4: 0 V 16: 5 V maintenance 5: Serial data to 17: 5 V handbrake evaluation module (~ 0.6 V DC measurement) 6: 0 V 18: 5 V vehicle ON 7: Start signal for 19: 5 V creep speed loading serial 20: 5 V forwards data (can only be 21: 5 V heating ON measured with oscilloscope) 8: 0 V 22: Reserve LED 9: Timing generator, 23: Reserve LED evaluation module 24: 5 V reverse (~ 0.24 V DC measurement) 10: 0 V 25: 24 V 11: 0 V 26: 24 V 12: 0 V Issue: Replaces issue:

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5/0113

X100

AWE

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Sheet no.

M 50

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Control of the console display 1

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

Copyright reserved.

Software version display • Key-operated switch on - The programmed parameter type number (1) is displayed on the AWE - The code number for the battery discharge characteristic curve (2) and the software version of the electronic evaluation system software version (3) is displayed.

- The software version (4) for the travel and pump control system is then displayed, followed by the current number of operating hours.

Remark:

02 O OO O OO O O OO

OOOOOOOO

5/0110

2

If the data line between the electronic evaluation system and the logic circuit board is interrupted, the display stops at the software version of the electronic evaluation system (3).

2

3

20.3

OOOOOOOO

O OO O OO O O OO 5/0110

4

96011.2 OOOOOOOO

O OO O OO O O OO 5/0110

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Sheet no.

M 51

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Control of the console display 2 Battery charge level

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

Copyright reserved.

The battery charge level is displayed on the 8-digit LED strip (1).

1 OOOOOOOO

O OO O OO O O OO 5/0110

Charge level

Display

100% - 90% 80% 70% 60% 50% 40% 30% 24%

= red, lights up = yellow, lights up = red, flashes

19%

• Lift cut-out, i.e. no setpoint and pump is not enabled.

• The maintenance symbol (2) lights up.

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Sheet no.

M 52

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Error list Errors The electronic evaluation system has various monitoring tasks. When the vehicle is switched on, an error check is carried out. First, possible errors in the electronic evaluation system are checked, and then the messages sent by the travel and pump controller.

2

1 FE 01 OOOOOOOO

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

Copyright reserved.

If errors are identified, they are allocated to a specific error class. Irrespective of how they are classified, they are entered in the event time memory, which can be read and deleted again whenever necessary using the diagnosis interface.

O OO O OO O O OO 5/0110

Errors which occur during operation are treated in the same way.

The error situation is indicated with a specific error number, and the maintenance symbol appears in the 7 segment display on the console (1).

Error class 1: An error is displayed if, for example, an operator tries to drive the vehicle, but travel is only possible in reduced speed because the battery lock is not activated. The error is displayed until it is eliminated. The maintenance symbol flashes (2) when the vehicle is in error mode. The error is not stored.

Error class 2: The error is displayed and remains on the display until the cause has been rectified or the vehicle returns to an error-free condition, e.g. when excess temperature has dropped.

When the error occurs for the first time, the status of the operating hours counter is recorded in the event time memory.

The maintenance symbol (2) flashes when the vehicle is in error mode.

Error class 3: The error is displayed. Every time the vehicle is switched on again, the error is displayed for between 10 and 15 seconds, on condition that the cause has not meanwhile been eliminated, e.g. carbon brushes.

The first time the error occurs, the error is indicated on the display until it is acknowledged with the key-operated switch.

The status of the operating hours counter is recorded in the event time memory. The maintenance symbol flashes until the error is rectified.

Continued on next sheet

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Sheet no.

M 53

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Error list If more than one error occurs at the same time, they are indicated in order of urgency (error classes).

For a more detailed description of the logic circuit board, see sheet no.V22. To delete errors in the electronic evaluation system, see sheet no. M71.

AWE

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

Copyright reserved.

Error messages Batterylock Valves:Shortcut/broken wire No Telegram Telegram error Forw. + Backw.

Incorrectstart VACC not o.k.

VACC out of range EEPROM k.O. Driver shorted Logic failure Contactor driver Micro ST 6215 k.O. No Field current High Field current Pump I=0 Ever Pumpstyb I high Capacitor charge VMN not o.k.

V Field not o.k.

Stby I high I=0 Ever Contactor closed Coil shorted Traction Motor Temp Traction Brushes Th. Protection Pump Motor Temp.

Pump Brushes Pump Temperature Error steering controller Brushes steering motor SOK kO

Issue: Replaces issue:

Logic board

FE

Class

X

01 02 03 04 05 06 07 08 10 11 11 11 11 12 13 14 14 15 16 17 18 18 19 19 20 21

1 2 2 2 2 1 1 2 3 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3

22 30 31 32 40 41 42

2 2 3 2 2 3 2

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

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Sheet no.

M 54

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Maintenance intervals

1

It is possible to define a specific timescale for a maintenance interval (see sheet no. M72).

OOOOOOOO

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

Copyright reserved.

When the interval reaches its end (which is registered by the travel and pump controller from the operating hours), a flag is set which causes the maintenance symbol to light up (1).

O OO O OO O O OO 5/0110

To reset the flag, a new interval must be entered (which is greater than the current number of operating hours) and the key-operated switch must be switched OFF/ON. The interval counter then starts again.

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Sheet no.

M 55

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) TEWAK interface software General

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

Copyright reserved.

In order to be able to change parameters with a Notebook in the electronic evaluation system (AWE), the program TEWAK 95 must be opened.

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Sheet no.

M 56

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) TEWAK interface software Closing the TEWAK program 1. Move the arrow (2) onto the field (3) with the trackball or mouse (1).

3

2

2. Click twice quickly on the field (3) with the key (4).

7/0395

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

Copyright reserved.

3. Press the ALT (6) and F4 (7) keys 4. Press the ENTER key (8).

ESC F1

!

1

F2

F3

F4

F5

F6

F7

F8

F9

F10

3

$ 4

% 5

& 6

/ 7

( 8

) 9

= 0

?

" 2 W

Q

7

A

Strg

E

R

S

D

> <

Y

X

Alt

Fn

° ^

T F

C

Z G

V

U H

B

I

O

J N

K M µ

F11

P

* +

L ; ,

8

F12

# : .

Alt Gr

Bild

_ Einf

Entf Bild

7/0380

7

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4

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1

Sheet no.

M 57

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software

1

2

General The AWE includes software for adjustment and diagnosis purposes which is menu guided and can be activated using the PSION manual programming unit.

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

Copyright reserved.

The menu contains the following points: - Versionsnummer (see block 2, sheet no. M60) - Konfiguration (see sheet no. M61-64) (Configuration) - Inbetriebnahme (see sheet no. M65-68) (Commissioning) - Parameter (see sheet no. M69-70) (Parameters) - Fehlerliste (see sheet no. M71) (Error list) - Wartungsintervall (see sheet no. M72) (Maintenance intervall)

5/0110

When the software is activated, the AWE goes into "STOP mode", so that it is no longer possible to use the vehicle functions.

This is indicated by the maintenance LED (1) and vehicle ON LED (2) on the console display lighting up.

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Sheet no.

M 58

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Menu structure and use

The software installed in the AWE is menu guided and can be activated and used with a notebook.

In order to use the software, the vehicle must be switched on, the interface adapter set to AWE (see sheet no. M82) and the notebook connected with the AWE (the TEWAK software must be installed in the notebook).

The TEWAK software must then be called up in the notebook and started by entering "PP" on the notebook keyboard.

Die Menüführung erlaubt folgende Befehle: - (1)

(shift)

and

W

Continue in a menu level

and

J

Continue to the next menu level down

and

X

Back to the next menu level up

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

Copyright reserved.

(shift)

- (1) (shift)

- (1)

ESC F1

(shift)

- (1)

and

S

!

1

Save changed values

F2

F3

F4

F5

F6

F7

F8

F9

3

$ 4

% 5

& 6

/ 7

( 8

) 9

= 0

" 2 W

Q A

1 -

+

Strg

E

R

S

D

> <

Y

X

Alt

Fn

° ^

Change values / settings

T F

C

Z G

V

U H

B

I K M µ

P L

; ,

: .

Alt Gr

-

Ein

7/0380

The symbols used in the menu flowchart indicate the following: -

Press the appropriate key on the notebook.

-

The menu continues from or goes to this point.

-

Display on the notebook screen

-

Further sequence dependent on conditions

Issue: Replaces issue:

?

O

J N

F10

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Sheet no.

M 59

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE)

Diagnosis and commissioning software Continued

Menu structure and use When "PP" is entered on the notebook, the AWE software registers on the notebook display with the following main menu: WAGNER Service Terminal

Remarks: = shift key (see M59)

Menu continues automatically

(W)eiter ID406860 Vxxx

xxx Current software version displayed

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

Copyright reserved.

+ x or

(W)eiter (J)a Konfiguration

Electronic evaluation system is switched off. Only the symbols for maintenance and the keyoperated switch on the console display continue to be illuminated.

W

+ x + J

1 Contd. on 1 sheet no.

M61

+ W (W)eiter (J)a Inbetriebnahme

+

Issue: Replaces issue:

+ x + J

.

If the power supply fails during programming, the battery plug should be pulled out briefly and the system then reset with the key-operated switch (Reset).

Restart the notebook.

3 Contd. on 3 sheet no.

M69

+x +J

.

4 Contd. on 4 sheet no.

M71

W

(W)eiter (J)a Wart. Intervall

+

2 Contd. on 2 sheet no.

M65

W

(W)eiter (J)a Fehlerliste

+

.

W

(W)eiter (J)a Parameter

+

+ x + J

W

07/04

+ x + J

5 5 Contd. on sheet no.

M72

Workshop Manual

.

Weiter = Continue Ja = Yes Konfiguration = Configuration Inbetriebnahme = Commissioning Parameter = Parameters Fehlersiste = Error list Wartungsintervall = Maintenance interval

End of program Start with 'PP'

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Sheet no.

M 60

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Continued

Menu structure and use Configuration submenu: (see also M62-64) Remarks:

Continued from sheet no.60 1

1

(W)eiter (J)a Typ (type)

+ x

Change the type number with

.

+J +x or + s (S)ich (W)eiter

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

Copyright reserved.

(S)ich Typ: xx = Save = Continue

xx: Display depends which type stored.

+ x Back without

saving the altered value

+ x (W)eiter (J)a Optionen (Options)

+ W

+J

+ x or

(W)eiter (S)ich HUBAB OFF (Lift cut-out)

+ S

nue and save altered value

Continue in

+ W menu without

Selected value not saved (old setting retained)

saving the altered value

+W

(W)eiter (S)ich SS-SPERRE OFF

+ x

+ S Back/ conti-

+W

To change ON/OFF:

(Reach and lowering lock)

+ W S

+ x or

= Shift key (see M59)

+ S Continued on sheet no. M63

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Sheet no.

M 61

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Continued

Table of standard parameter sets

Menu point functions

Parameter

Konfiguration

Reach forw Reach back Tilt forw.

Tilt backw.

Side shift Shift damp fw Shift damp bw Add. hydr.

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

Copyright reserved.

With this menu point, the vehicle can be programmed for specific tasks, and retrofitted elements on the vehicle can be adapted to the software.

This feature is required because there are various different basic versions of the vehicle (load carriage/pump variations) and because the vehicle may already be, or is going to be, fitted with optional extras (e.g. shifting and lowering lock, intermediate lift limit, etc.).

In the "Type" submenu, entering a type number activates a standard set of parameters which is responsible for the different pump speeds.

There are currently 4 different parameter sets (types 0, 1, 2 and 3). The parameter set can be altered within a certain range.

Remark:

When the vehicle is switched on with the key-operated switch, the programmed type no. appears briefly on the display, e.g., ---02 = type no. 2 (see sheet no. M51)

In the "Options" submenu, additional appliance functions can be activated, and if modifications have been made to the vehicle, the AWE is adapted here.

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Parameter Reach forw Reach back Tilt forw.

Tilt backw.

Side shift Shift damp fw Shift damp bw Add. hydr.

Type 0 1 2 3 4,0V 4,4V 4,4V 4,4V 5,0V 5,0V 5,0V 5,0V 4,5V 4,6V 4,5V 4,2V 4,2V 4,5V 5,2V 4,2V 5,0V 4,3V 4,3V 4,0V 68 68 68 68 58 58 58 58 4,0V 3,5V 3,5V 3,5V Type 4 5 6 7 4,8V 4,9V 4,9V 5,4V 5,2V 5,3V 5,3V 5,6V 4,6V 4,5V 3,5V 3,8V 4,7V 4,9V 4,6V 4,0V 4,4V 4,5V 4,5V 4,2V 68 68 68 68 58 58 58 58 4,0V 4,0V 4,0V 4,0V

Reach forw. to Tilt backw can be altered: +/- 1V. Shift damp forw./back can be altered: +/- 20%.

Add. hydr. and side shift can be altered: 0-10V.

Type: 0-3 no application Type: 4 XR-N 14/17 Type: 5 XR-N 20 Type: 6 XR-N with fork tilt Type: 7 XR-N with reduced tilt and side shift

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Sheet no.

M 62

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE)

Diagnosis and commissioning software Continued

Menu structure and use Configuration submenu Continued from sheet no. M61

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

Copyright reserved.

.

+ x or

+ S

(W)eiter (S)ich ZUS_HYDR OFF (Add. Hydraulics)

Remark:

+W

.

+ x or

+ S

= Shift key (see M59)

(W)eiter (S)ich LR_NEU OFF (New steering controller)

* Must be ON

+ W

.

+ x or

+ S

(W)eiter (S)ich WARNLICHT OFF (Warning light)

+W + x or

+ S

(W)eiter (S)ich QUERSCHUB ON (Side shift)

+ W Remark:

Issue: Replaces issue:

If the "Standard-Param!" command is used in the parameter submenu, all option points return to the basic setting, i.e. they are "OFF"!

The only exception here is the "Side shift" option point.

This is "ON" in its basic setting!

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Sheet no.

M 63

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Configuration submenu Continued

Menu point functions

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

Copyright reserved.

Options

Basic setting

1.

Lift cut-out ("HUB AB", see sheet no. M47).

(Lift cut-off)

2.

Schub- und Senksperre (Reach and lowering lock) ("SS-SPERRE", see sheet no.

M48).

3.

Zusatzhydraulik (Add. Hydraulics) ("ZUS.HYDR.", see sheet no. M48).

4.

WARNLICHT (Warning light) For controlling a flashing or all-round light during travel or lowering of the lift.

Because this is a "low-power" output, a flasher relay or a switching relay must be inserted here.

5.

LR_NEU (New steering controller) Adaptation to modified steering controller.

6.

Gabelseitenschub (Fork side shift). This function is available as an optional extra. It is preset to "ON"

OFF

OFF

OFF

OFF

ON or OFF*

ON

* Must be ON

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Sheet no.

M 64

Assembly M

Electrical system

Electronic evaluation system (AWE) Diagnosis and commissioning software

Menu structure and use / Inbetriebnahme submenu: (see also M66-68) 2

Continued from sheet no. M60

(W)eiter (J)a Analog - In (Analogue-In)

+

X

Remarks:

2

.

+ J .+ X

(W)eiter Hfaupthub (Main lift)

+ W + W

(W)eiter Nebenhub (Ancillary lift)

+X

+ W

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

Copyright reserved.

(W)eiter (J)a Digital - E/A

+ X

+ J

(W)eiter DIG-IN: Ø1

+ W

+X

. .

.

.

+ X

(W)eiter DIG-IN: Ø2

= Shift key (see M59)

+ W

+ J

(W)eiter DIG-OUT-BIT: Ø1

+W

(D)aten (Data)

+ X

.

+ W

'E1' appears on the console display. The 7segment display provides information about the input signals: (see also M67)

(W)eiter (J)a Kommunikation (Communication)

+ W

The voltage level of the relevant potentiometer is shown on the console display.

+X

The data from the FPS to the AWE can be read out here (see sheet no. M76)

(W)eiter DIG-OUT-BIT: 10

'A X' appears on the console display, where 'X' can be either 0 or 1.

1 = Output set 0 = Output not set.

Change using '1' '0' 'A2 X' appears on the console display (see above)

(W)eiter = Continue (J)a = Yes

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Sheet no.

M 65

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software 1

Continued

Menu point functions

Inbetriebnahme (Commissioning)

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

Copyright reserved.

The "Commissioning" point in the menu simplifies error detection and makes adjustment work easy to carry out.

'The "Analog-IN" (Analogue-In) submenu can be used to display the voltage levels of the hydraulic potentiometer on the 7 segment display on the console (1). This makes mechanical adjustment very easy (idle position 6 V).

With the "Digital E/A" (Digital I/O) submenu, the switched input/output signals at the AWE can be displayed. They are displayed on the console display in groups of 8.

Display of the switched input signals: The input signals are displayed on the vertical bar LEDs (LED1 to LED8) on the seven-segment display, i.e. when the AWE receives an input signal (0V signal), the corresponding bar LED lights up.

LED 8..................LED 1

OOOOOOOO

The serial connection between the electronic evaluation system and the FPS can be checked in the Communication (data) submenu.

O OO O OO O O OO 5/0110

For division of the groups of 8, see sheet no. M 67.

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Sheet no.

M 66

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Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Continued

Menu point functions, Inbetriebnahme (Commissioning) 8

Input group 1 LED 8 7

6

5

4

3

2

7 6

5 4

3 2

1 Steering motor carbon br. ( KLR) Steering controller error (FLR)

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

Copyright reserved.

Shift damper function, back. (SDH) Shift damper function, forw. (SDH) Reserve input 1 (RES1) Select additional hydraulics (AZ) Heating on (KHA)

Release interm. lift limit (EHA)

Input group 2 LED 8 7

6

5

4

3

2

1 End lift cut-out (HB2) Intermediate lift cut-out (HB1) Release shift/ lowering lock (ESP) Shift end position (SEV) 400mm lowering lock (SSP) Control system OK (SOK) Select tilt Select side shift

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Sheet no.

M 67

1

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Continued

Menu point functions, Inbetriebnahme (Commissioning)

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

Copyright reserved.

Displaying the switched output signals: A notebook can be used to set and reset the AWE outputs. The output statuses are shown on the console on the 7 segment display, e.g., AI 0 means: Output 1 not set, AI 1 means: Output 1 set.

Caution:

This process releases safety-related locks in the AWE, since the outputs are switched directly!

For this reason, the vehicle must be jacked up!

Once work with the diagnosis and commissioning software is completed, the outputs return to the status which is correct according to the signal settings of the vehicle.

Output assignmnt: A1

Shift valve (LS)

A2

Tilt valve (LN)

A3

Side shift valve (LQ)

A4

Lowering valve (LSP)

A5

Enable pump (FP)

A6

Lowering information to FPS (SZ)

A7

Warning light (WL) - low-power

A8

Addit. hydraulics (ZH) - low-power

A9

Reserve X6.3 - low-power

A 10

Reserve X6.6 - low-power

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Sheet no.

M 68

Assembly M

Electrical system

Electronic evaluation system (AWE) Diagnosis and commissioning software

Menu structure and use / Parameter submenu (see also sheet no. M70): 3

Continued from sheet no. M60

(W)eiter (J)a S - vor (Reach forwards)

+W (W)eiter (J)a S - rueck (Reach backwards)

+W

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Copyright reserved.

(W)eiter (J)a N - vor (Tilt forwards)

+W (W)eiter (J)a N - rueck (Tilt backwards)

+W (W)eiter (J)a OS (Side shift)

+W (W)eiter (J)a SDF vor (SDF forwards)

+W (W)eiter (J)a SDF vor (SDF backwards)

+W (W)eiter (J)a Zus_Hydr.

(Add. Hydr)

+W

Remarks:

+ X

+J

(S)ich x.xxV

(W)eiter S - rueck

(S)ich x.xxV

. X

+ 3 X

+J +X 3

+J +X

X

+

X

+J +X +J +X + J + X + J +X

(W)eiter QS

(S)ich x.xxV

(W)eiter (S)ich SDF vor xx

(W)eiter (S)ich SDF rueck xx

+ W or S

+ 3 X

(S)ich x.xxV

+ W or S

3 X

(W)eiter N - rueck

= Shift key (see M59)

If the value is outside the 'window', it cannot be saS ved with the key.

Change using Current value x.xx is displayed in volts (is determined by processor continually).

Change with Premissible alteration ± 1 V from the standard parameter (in steps of 0.1 V).

Current value xx in %.

Permissible alteration ± 20% from the standard parameter.

+W or S

3 X

(S)ich x.xxV

+ W or S

3 X

(W)eiter N - vor

+ W or S

3

+

+

do not save/save

+ W or S

+

+

+ W or S

+ J + X

The "Add_Hydr" parameter is only displayed if it has been set to "ON" under "Option"!

Values in the E2PROM are set to zero! All the option points are then also set to "OFF" again and the mainenance interval set to 500 hours.

(W)eiter (S)ich Zus_Hydr. xx

+ W or S +J

Standard Param.

Continues automatically

+W

Function aktiv

.

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(W)eiter S - vor

back, no chan-

+X 3

(W)eiter (J)a Standard-Param!

3

Continues automatically

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M 69

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Continued

Menu point functions, Inbetriebnahme (Commissioning)

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

Copyright reserved.

Parameter Under this menu point it is possible to alter within certain limits the preset standard parameters that are called by entering the type no. (see sheet no. M62).

In this way, the speed of the following hydraulic functions can be adapted: -

S - vor (reach forward) S - rueck (reach back) N - vor (tilt forward) N - rueck (tilt back) QS (mast side shift) SDF vor (reach forward dampening) SDF rueck (reach back dampening) Zus. hydr. (add hydr. functions)

It is also possible to call the original standard parameter set again with the "Standard parameter" command.

This deletes the contents of the E2PROMS. The parameters for shifting and tilting can be altered within a range of ± 1 V (in steps of 0.1 V).

The parameters for additional hydraulic and fork side shift can be altered within a range of ± 1-10 V.

Parameter

Type 0 1 2 3 Reach forw 4,0V 4,4V 4,4V 4,4V Reach back 5,0V 5,0V 5,0V 5,0V Tilt forw.

4,5V 4,6V 4,5V 4,2V Tilt backw.

4,2V 4,5V 5,2V 4,2V Side shift 5,0V 4,3V 4,3V 4,0V Shift damp fw 68 68 68 68 Shift damp bw 58 58 58 58 Add. hydr.

4,0V 3,5V 3,5V 3,5V Parameter

Type 4 5 6 7 Reach forw 4,8V 4,9V 4,9V 5,4V Reach back 5,2V 5,3V 5,3V 5,6V Tilt forw.

4,6V 4,5V 3,5V 3,8V Tilt backw.

4,7V 4,9V 4,6V 4,0V Side shift 4,4V 4,5V 4,5V 4,2V Shift damp fw 68 68 68 68 Shift damp bw 58 58 58 58 Add. hydr.

4,0V 4,0V 4,0V 4,0V

The parameters for the shift damper function are given as percentages and can be altered within a range of ± 20 % in steps of 1%.

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Sheet no.

M 70

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Menu structure and use Fehlerliste submenu: Fehlerliste (for guide to errors, see M54) When errors and faults of class 2 and 3 occur, the status of the operating hours counter is stored with the error number the first time the fault happens.

This counter status can be read off and deleted as required.

Continued from sheet no. M60 4 Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

4

+ Are there any errors?

(W)eiter Keine Fehler

No

Yes

No 4

(W)eit FE: xx

(S)torno xh

+ X + S

Are there any more errors stored?

+ W Yes List of all further errors (see above for illustration) or, if no more errors in memory:

(W)eiter Keine Fehler (No errors)

X or

W

Remarks: = Shift key (see M59) xx = Error number x = Operating hour during which the error occurred for the first time.

S

= Operating hours reset to zero

(W)eit = Continue (S)torno = Cancel

4

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Sheet no.

M 71

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Menu structure and use

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

Copyright reserved.

Wartungsintervall submenu: Wartungsintervall It is possible to define a set timescale (passed operating hours) for the next maintenance interval.

The interval can be set using this menu.

When the programmed number of operating hours is reached, a marker is set which causes the maintenance symbol to be displayed in the console display.

To reset the marker and consequently the maintenance symbol, an operating hours value must be programmed which is larger than the current number of operating hours. The key-operated switch must also be switched "ON/OFF".

If the maintenance interval is set to zero, the maintenance symbol is illuminated continuously.

Continued from sheet no. M60 5

5

+

(S)ichern (Save) Wartung: xxxxxh (Maintenance)

S or

X

Remarks: = Shift key (see M59) Use

to change value in steps of 50!

Default value for 1st maintenance interval is 500 h.

To save the value, press the S key. If the value saved is zero, the maintenance symbol on the console display is illuminated continuously.

If the "Standard param!" command is used in the parameter submenu, the default value of 500 h is set here.

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Sheet no.

M 72

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Replacing the software The software for the electronic evaluation system is stored in an EPROM (Eraseable Programable Read Only Memory).

1

This means that to replace the software, the EPROM used must also be replaced.

Procedure

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Copyright reserved.

1. Pull out the battery plug.

Remark:

The console display is integrated in the cover. Take care when removing the cover not to damage the control unit for the display.

2. Use the notebook to read off and make a note of the programmed type number, parameters and options.

3. Remove the notebook and disconnect the electrical connections to the AWE. 4. Remove the cover from the FPS (see M32).

5. Carefully lever the EPROM (1) out of the IC base with a suitable tool.

6. Carefully insert the EPROM with the new software in the IC base.

Remark:

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OOOOOOOO O

2

Workshop Manual

OOOOOOOO

2

Always wear antistatic protection when handling the components Take care not to bend any contact vanes on the IC! Observe the markings on the IC and IC base (2). These must both be on the same side.

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Sheet no.

6/0005

M 73

Assembly M

Electrical system

Traction and pump controller (FPS) Electronic evaluation system (AWE) Diagnosis and commissioning software Continued

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

Copyright reserved.

Replacing the software, procedure

7.

Activate the software using the notebook.

8.

Under "Type" in the configuration menu, first save type 0 and then save the relevant type number.

9.

Set the options and parameters as they were before the software exchange, or set them correctly for new vehicle adaptations.

10.

End the program, make the electrical connection for the console display and replace the cover.

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Sheet no.

M 74

Assembly M

Electrical system

Traction and pump controller (FPS) Serial communication between logic circuit board and the electronic evaluation system The AWE polls data from the logic circuit board in a fixed cycle via the RS232 serial interface.

The data is transmitted in ASCII-code format.

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

Copyright reserved.

When ASCII code "D" is transmitted along the TxD lead of the AWE (TxD = Transmit Data), the logic circuit board also sends its data along its TxD lead to the RxD terminal (RxD = Receive Data) of the AWE. If the logic circuit board does not respond to an AWE data enquiry, this is registered and error code FE03 is shown on the console display (e.g. in the event of wire breakage).

In order for the data flow to be displayed, the "Data" submenu must be selected under the menu point Commissioning (see sheet no. M76)

Electronic evaluation system

RxD

TxD

TxD

RxD

Logic circuit board

Explanation of telegram bytes (see sheet no. M76) 5/0111

Travel and pump control system

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Sheet no.

M 75

Assembly M

Electrical system

Traction and pump controller (FPS) Serial communication Continued Meaning of telegram bytes

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

Copyright reserved.

Positions 1-2 3-4 5 - 10 11 12 - 13 14 15 16

Information Error from control sys.

Battery capacity Operating hours Steering angle prefix Steering angle Travel direction Travel status Deceleration

Range of values 01 - 49 or none 90 - 80 - 70 - 60 - 50 - 40 - 30 - 24 - 19 0.0 - 63999.9 represents operating hours. + or none 00 or none V = forwards R = reverse or none D = travel P = handbrake applied or none S = creep speed B = battery open or none

Example of a telegram

20

90

000012 +00 V P S

Error Battery capacity Operating hours Steering angle Travel direction Travel status

The following is displayed: 1 - 2: Error 20 Creep speed 3 - 4: Battery capacity 90 5- 10: Operating hours 1.2 11: Steering angle + 12 -13: Steering angle 00 14: Travel direction forwards 15: Travel status, handbrake applied 16: Deceleration, creep speed active

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Sheet no.

M 76

Assembly M

Electrical system

Traction and pump controller (FPS) Setting the battery discharge characteristic curve

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

Copyright reserved.

Adjustment procedure The ancillary movements lever (1) must be pulled and the ancillary movement selection keys (2) pressed at the same time as the key-operated switch is switched.

The maintenance symbol then flashes and a number appears at the left of the display with a value of between 0 and 7.

Continue pulling the ancillary movements lever and release the selection button. The number can be increased by pressing the right-hand button several times and decreased by pressing the left-hand button.

Once the required characteristic curve has been set, the lever can be released, and the value is stored.

The set value and the word "end" now appears in the display. Before travel is possible, the key-operated switch must be switched off and on again.

Every time the vehicle is started, the set code for the characteristic curve is displayed to the left, next to the current Eprom version for the electronic evaluation system (see sheet no. M51).

1

6/0063

2

The codes stored are: 0 = Wet-cell battery and power increased to 360 Ah 1 = Wet-cell battery and power increased to 480 Ah 2 = Wet-cell battery and power increased to 600 Ah 3 = Wet-cell battery and power increased to 750 Ah 4 = Dry battery to 360 Ah 5 = Dry battery to 480 Ah 6 = Dry battery to 600 Ah 7 = Dry battery to 720 Ah

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Sheet no.

M 77

Assembly M

Electrical system

Traction and pump controller (FPS) Guide to pin assignment Travel 1 (inputs) X2 (logic circuit board)

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

Copyright reserved.

X2.1 X2.2 X2.3 X2.4 X2.5 X2.6 X2.7 X2.8 X2.9 X2.10

Travel potentiometer Setpoint potentiometer Travel potentiometer Accel. pedal microswitch Accel. pedal microswitch Travel direction reverse Travel direction supply Travel direcion forwards Handbrake supply Handbrake

+10V * 0V 0V 0V 0V 0V 0V 0V

I/A I/D

X2.11 Brake pedal microswitch supply X2.12 Brake pedal microswitch X2.13 -----X2.14 ------

0V 0V 0V

I/D

I/D I/D I/D

* Setpoint is approx. 4.8 - 8.7V, depending on the value read in during commissioning).

I/D = Digital input I/A = Analogue input

Travel 2 (inputs) X3 (logic circuit board) X3.1 X3.2 X3.3 X3.4 X3.5 X3.6 X3.7 X3.8 X3.9 X3.10

Foot-switch supply Foot-switch Creep speed supply Creep speed Battery lock supply Battery lock free free free free

0V 0V 0V 0V 0V 0V 0V

I/D I/D I/D I/D

0V I/D

Input wiring on logic circuit board

+24V

• +5V

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Sheet no.

M 78

Assembly M

Electrical system

Traction and pump controller (FPS) Continued

Guide to pin assignment

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

Copyright reserved.

Sensor system X4 (logic circuit board) X4.1 X4.2 X4.3 X4.4 X4.5 X4.6 X4.7 X4.8 X4.9 X4.10 X4.11 X4.12 X4.13 X4.14 X4.15 X4.16 X4.17 X4.18

Travel motor temperature supply Travel motor temperature switch Travel motor carbon brush supply Travel motor carbon brushes Pump motor temperature supply Pump motor temperature switch Pump motor carbon brushes Pump motor carbon brushes

0V 0V 0V 0V 0V 0V 48V 0V

Seat adjustment motor

0V

Output

Central wheel position Central wheel position supply

10V 10V

I/D

0V=ok

I/D

0V=ok

I/D

0V=ok

I/D I/D I/D

I/D = Input Digital

Diagnosis interface X5 X5.1 X5.2 X5.3 X5.4 X5.5 X5.6 X5.7 X5.8 X5.9 X5.10

RXD TXD

FPS or AWE FPS or AWE

GND

FPS or AWE

FPS = Travel and pump control system AWE = Electronic evaluation system

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Sheet no.

M 79

Assembly M

Electrical system

Traction and pump controller (FPS) Continued

Guide to pin assignment X8 Control current fuses (separate connectors)

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

Copyright reserved.

X8.1 X8.2 X8.3 X8.4 X8.5 X8.6 X8.7 X8.8 X8.9 X8.10

F2 for key-operated switch 3F1 for steering controller 3F1 for steering controller 4F1 for horn 5F7 5F7 Key-operated switch Key-operated switch Key-operated switch Key-operated switch

48V /10A 48V / 20A 48V / 20A 48V / 5A (optional) 10A (optional) 10A

X10 Hydraulic lever inputs (electronic evaluation system) X10.1 X10.2 X10.3 X10.4 X10.5 X10.6 X10.7 X10.8 X10.9 X10.10

Main lift potentiometer supply Setpoint input Main lift potentiometer supply Ancillary movement potentiometer supply Setpoint input Ancillary movement potentiometer supply Select tilt --------------------Select side shift Tilt / side shift supply

12V 6 Volt +/- 5,5 0V 2V 6 Volt +/- 5,5 0V 0V 0V 0V 0V

X11 Power valve outputs (24 volts/1.6 A) (electronic evaluation system) X11.1 X11.2 X11.3 X11.4 X11.5 X11.6

Shift value supply Shift power output Tilt valve supply Tilt power output Side shift power output Lowering power output (optional)

0V 24V 0V 24V 24V 24V

X12 Low-power outputs (electronic evaluation system) X12.1

Warning light

X12.2

Additional hydraulics

X12.2

Reserve

X12.2

Reserve

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Sheet no.

M 80

Assembly M

Electrical system

Traction and pump controller (FPS) Continued

Guide to pin assignment

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

Copyright reserved.

X13 Option inputs (electronic evaluation system) X13.1 X13.2 X13.3 X13.4 X13.5 X13.6 X13.7 X13.8 X13.9 X13.10 X13.11 X13.12 X13.13 X13.14 X13.15 X13.16 X13.17 X13.18

0V 400mm Lowering / shift lock 0V Fork end position 0V Lowering / shift lock release 0V Intermediate lift cut-out 0V Lift cut-out 0V Lift cut-out release 0V Cold-store heating 0V Additional hydraulics selection 0V Reserve input

X14 Steering / shift damper function (electronic evaluation system) X14.1 X14.2 X14.3 X14.4 X14.5 X14.6 X14.7 X14.8 X14.9 X14.10

0V Shift damper function, forwards 0V Shift damper function, backwards 0V Steering controller error 0V Steering motor carbon brushes ---

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Sheet no.

M 81

Assembly M

Electrical system

Interface adapter Setting the interface This interface adapter (1) is used to alter parameters in the travel and pump control system (FPS) and AWE using the notebook.

The interface adapter must be selected at the relevant interface with a slide switch (2).

Slide switch position 2 : for travel and pump control (FPS-logic circuit board) and AWE

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

Copyright reserved.

To connect the interface adapter: Input side: Connect notebook.

Output side: Connect to FPS control system with 9-pin ribbon cable (see diagram below) Adjustment: Set the interface switch (4) to AWE or FPS, depending on which parameters you wish to adjust.

Power supply: the interface adapter is connected to the power supply with 2 terminals (3) Red terminal + Black terminal Note:

The ribbon cable (5) may only be connected/disconnected when the power supply is switched off.

The interface switch (4) may only be switched over when the vehicle is switched off.

Interface adapter Notebook

-

4 AWE

5

6/0326

FPS

(logic circuit board)

1 3

+ 24 V

6/0667

2

6/0633

6/0634

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Sheet no.

M 82

Assembly M

Electrical system

Interface adapter Functional elements

1

}

+ 24 V

Interface adapter

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

Copyright reserved.

6

} 10

11 9

4 3 5

6/0633

6/0634

2

1

7

8

1: 2: 3: 4: 5: 6:

Power supply 25-pin notebook connection 10 V power supply O.K. LED lit up - notebook sending data LED lit up - notebook receiving data 17 volt power supply for notebook.

If a different voltage is required, this can be set via an internal potentiometer (max. load 2.5 A) (see M84).

7: Interface connection to MUX-SPS (9-pin) 8: Interface connection to FPS control system (9-pin) and electronic evaluation system 9: Slide selector switch for interface adaptation Position 1: MUX-SPS Position 2: Travel and pump control system 10: Interface connection for SPS digsy 04 11: Control LED on = programming voltage for SPS digsy 04 is switched on.

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Sheet no.

M 83

Assembly M

Electrical system

Interface adapter

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

Copyright reserved.

Adjusting the notebook power supply 1. To open, take the box in your hands as illustrated in fig. 1 and press on the closed element under the ventilation slot with your thumb, pressing the inner catches (5) down and pulling the two housing elements apart at the same time.

2. Connect the notebook at the power supply socket (1).

3. Connect the interface adapter to the voltage converter (2) (see M15).

4. Connect the voltmeter (3) 5. Switch on the notebook and start up the vehicle.

6. Set the required voltage at the trimmer (3).

Remark:

5 7/0455

Notebook

1

The voltage supply required for the notebook is indicated in the documentation provided by the notebook manufacturer.

6/0634

2

+

+24V

DC

DC

DC/DC converter Notebook

3

4

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Sheet no.

M 84

Assembly N

Hydraulic system

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

Copyright reserved.

Contents

Sheet n o.

Functional characteristics of the hydraulic system ..........................................N 2 Block diagram of the hydraulic system............................................................N 3 Manually-operated double directional valve block...........................................N 4 Setting the maximum pressure........................................................................N 6 2-way flow regulator valve...............................................................................N 7 Directly operated directional valves - Shift function 2Y25 .................................................................................N 9 - Tilting and side shift functions 2Y29/44..................................................N 10 Lowering brake valve ......................................................................................N 11 Line break protection.......................................................................................N 12 Pump unit - General ..................................................................................................N 14 - Removing ...............................................................................................N 15 - Pump motor, general..............................................................................N 16 Removing the motor.............................................................................N 17 Replacing the carbon brushes .............................................................N 18 - Hydraulic pump ......................................................................................N 20 Tank display and tank .....................................................................................N 22 Runback filter ..................................................................................................N 23

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Sheet no.

N1

Assembly N

Hydraulic system

Functional characteristics of the hydraulic system When the hydraulics levers (1) are activated or the selector switch (2) for hydraulic ancillary movements is pressed, electrical signals are sent to the electronic evaluation system (AWE).

1

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

Copyright reserved.

This controls the electromagnetic on/off valves accordingly, to initiate the selected hydraulic function.

In addition, the AWE determines the deflection and directional values of the levers from the potentiometers mounted on them.

2 6/0063

This forms the control signals sent to the travel and pump controller, which then controls the stepless speed of the pump unit (see also block diagram on sheet no. N3).

Remark:

The maximum speed of the movements depends on the deflection value (setpoint) and the maximum values programmed in the AWE. These maximum values can be modified using a notebook (see sheet no. M58).

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Sheet no.

N2

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Electrical control by travel and pump control system

Stepless speed control between 0 and max 1/ min

7/0445

Pump unit

Electrical signals to electronic evaluation system

Tank

2-way flow regulator valve

7/0444

Double directional valve block with potentiometer for speed control

6/0060

6/0059

Runback filter

Distributor block

Shift cylinder

7/0441

Distributor block with lowering brake valve (mast)

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

Copyright reserved.

Directional valve block with 4/2-way on/off valves, back-pressure valve and diaphragm for tilting

Tilt cylinder

7/0443

Block diagram of the hydraulic system Side shift cylinder

Electrical control by electronic evaluation system

4/2-way on/off valve for shifting in the chassis

7/0442

with integrated ine break protection

Main lift and special clearance cylinders

Assembly N Hydraulic system

Sheet no.

N3

Assembly N

Hydraulic system

Manually-operated double directional valve block General The DS directional valve block consists of a mounting block (1), an intermediate plate (2), an add-on valve (3) and an end plate (4). It can be accessed by removing the "valve" cover.

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

Copyright reserved.

The mounting block accommodates the connecting threads for the pressure pipe (P, 3/4 inch), the return pipe (R, 1/2 inch) and the working pipe (H, 3/4 inch).

The block can be used to control a single-acting cylinder (N-valve).

A max. pressure relief valve (5) for setting the maximum pressure in the hydraulic system is also integrated in the mounting block (for adjustment instructions see sheet no. N6).

A mini test connection (6) for testing the pressure is integrated in the intermediate plate.

6/0034

The add-on valve (G-valve) is used to control a double-acting cylinder via the two working pipes (A, B, 3/8 inch).

The directional valve block only controls the oil flow direction, i.e. lifting/lowering main lift, tilting forwards/backwards, reaching forwards/backwards or mast side shift to left/right.

6

1

5

2

The speed is dictated by the rotational speed of the pump, which is controlled by the setpoint of the potentiometer on the directional valve.

The entire block is mounted on the chassis with rubber buffers to minimise noise and vibrations.

3

R H P

Remark:

A sealing set is available for the double directional valve block.

Issue: Replaces issue:

07/04

Workshop Manual

4

A

6/0064

B

XR-N

Sheet no.

N4

Assembly N

Hydraulic system

Continued

Manually-operated double directional valve block 1

Designation of the DS directional valve block R H

The designation provides extensive information about the type of directional control block.

It is embossed on the end of the block (Fig. 1, no. 1), DS 34N-2-X50-G-F93/E1-1-200.

P A

Fig. 1

Meaning

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

Copyright reserved.

DS34N =

Basic block with 3/3way valve for lifting/lowering (single-acting cylinder)

2

=

Connecting thread for add-on valves 2 = 3/8 inch; 3 = 1/2 inch

X50

=

Width of intermediate plate = 50 mm

G

=

Flow type for add-on valves (see Fig. 2)

F

=

Activation with weak spring

93

=

With fastening for attaching the potentiometer, without hand lever; 92 = with hand lever

E1

=

Actuator mounting method (see Fig. 3)

1

=

With end plate

200

Remark:

6/0064

B

=

Flow types G B* D

6/0066

* with throttling in return pipe

Actuatormounting method Switch lever deflection wirh

It is especially important to note the designation for the flow type of the directional valve (N, G, D, E) since this influences the performance of the hydraulic device.

The letters are embossed in the directional valve block.

N

Fig. 2

Switching positions

Pressure relief valve setting

E

b

0

all sizes a

a

0

only size 2 u. 3 b

a

0

0

b b

Marking Assembly direction

Connections point

E1

E2

e.g. E1

F1

F2

e.g. F1

to the rear

forward 6/0067

Fig. 3

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Workshop Manual

a

a = presses the slidegate valve piston into the housing b = pulls the slidegate valve piston from the housing

XR-N

Sheet no.

N5

Assembly N

Hydraulic system

Setting the maximum pressure The system pressure for the hydraulic system is set at the maximum pressure valve (1).

This setting can be checked at the test connection point (2).

2

4 3

The maximum pressure valve is set to 200 bar by the manufacturer and does not usually need to be adjusted.

1

Exception: if the pressure is insufficient for special equipment (e.g. add-on appliances), the system pressure should be set at the highest required operating pressure plus 15 bar.

R H

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

Copyright reserved.

The XR-N12 as well as the XR-N 14/17 models with a load carriage which is ≤2.9 m high (1.7 t mast) also require a higher pressure setting than 200 bar (approx. 220 bar or 250 bar).

P A

6/0064

B

Setting 1. Connect the pressure gauge at no. 2 on the diagram.

2. Actuate the lift with a rated load and read off the working pressure.

If this pressure is lower than 200 bar, no setting or adjustment is required at the valve. The pressure then remains set at 200 bar.

3. If a working pressure greater than 200 bar is required, determine the working pressure with the rated load by releasing the lock nut (3) and slowly turning in the adjuster screw (4). The working pressure determined +15 bar is the correct setting for the maximum pressure.

4. Set the maximum pressure with the adjuster screw by moving the lift to the mechanical end stop.

5. Tighten the lock nut (3) again.

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Workshop Manual

XR-N

Sheet no.

N6

Assembly N

Hydraulic system

2-way flow regulator valve This valve is located in a hexagonal cartridge at the add-on valve of the double directional valve block (1).

Its purpose is pressure-independent regulation of the oil quantity in both flow directions.

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

Copyright reserved.

If the hydraulic ancillary movements are made individually, the valve does not enter the regulating position, since the quantity of oil remains lower than the amount required to activate the valve.

1

6/0080

However, if lift and reaching or lift and tilting movements are carried out simulaneously, the valve limits the quantity of oil to the correct litre value (litre value see on the hexagonal cartridge). This creates a "hydraulic resistance" for the oil flow to the ancillary movements, so that the simultaneous functions are carried out at the same time, and the maximum speed of the ancillary movements is not exceeded.

Continued on sheet no. N8 6/0081

6/0083 6/0082

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Workshop Manual

XR-N

Sheet no.

N7

Assembly N

Hydraulic system

Continued

2-way flow-regulator valve

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

Copyright reserved.

Removing 1.

Remove the valve cover.

2.

Lay an absorbent cloth under the valve to catch any escaping oil.

3.

Mark the electrical connectors in this area and disconnect them.Remove the upper hydraulic connection at the add-on valve of the directional valve block (spanner size 17).

5.

Remove the lower hydraulic connection at the hexagonal cartridge (spanner size 17).

6.

Remove the hexagonal cartridge with the 2-way flow regulator valve (spanner size 22).

7.

Clamp the hexagonal cartridge in a vice and unscrew the straight screwed joint (Fig. 1, no. 1).

8.

Unscrew the 2-way flow regulator valve from the hexagonal cartridge with a screwdriver (Fig. 1).

1

Fig. 1

5-04 25

2

Fig. 2

5-04 27

To mount the valve, follow the instructions above in reverse order.

Remark:

When inserting the valve in the hexagonal cartridge, ensure it is screwed in in the right direction!

Turn screwdriver bit in the direction of the outer thread of the hexagonal cartridge (Fig. 2, no. 2).

Only screw in hand-tight.

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Workshop Manual

XR-N

Sheet no.

N8

Assembly N

Hydraulic system

Directly operated directional valves Shift function 2Y25 This 4/2-way valve (1) is located on the chassis floor below the travel transducer and is fastened in place with 2 screws (2).

3

The valve is easy to reach through the mounting opening (3). The mounting opening can be accessed by removing the battery.

6/0034

2

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

Copyright reserved.

Electrical control is carried out by the electronic evaluation system.

1 Technische Daten Voltage (U) Current (I) Coil resistance (R)

24V ca. 1A ca.22 Ohm

Remark: This valve is present in two variants, standard version and coldstorage depot execution.

7/0443

Flow-through diagram 1

4

3

2 6/0088

1 3 2

4 7/0443

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Workshop Manual

XR-N

Sheet no.

N9

Assembly N

Hydraulic system

Directly operated directional valves

5

Tilting and side shift functions 2Y 29 and 2Y44 (optional) This 4/2-way valve (1) is located in the slide carriage and can be accessed by pushing out the mast and removing cover plate (5). The valve block is screwed to the guard plate (3) from below with 2 screws.

5/0103

B3

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

Copyright reserved.

Electrical control is carried out by the electronic evaluation system.

Integrated in this valve block are:

A3

2 7/0442

1

(1) Tilt valve

A1

(2) Side shift valve

B1

2

1

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Workshop Manual

XR-N

Sheet no.

N 10

7/0446

Assembly N

Hydraulic system 3

General

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

Copyright reserved.

With the "fork tilting" option (attachment for fork tilting), an additional load holding valve (1) is used.

It is mounted on the fork holder.

When the forks tilt downwards, the oil flowing out of the tilting cylinders has to pass through the prepressure valve (2) through connection "AV". This does not open until a pressure of 160 bar has been reached.

The oil can flow out via connection "AF".

The opening pressure of 160 bar is set at the adjusting screw (3) in the factory. This ensures that the fork prongs never make an uncontrolled movement, even under the rated load.

Remark: If the fork prongs move upwards on their own, this is caused by an internal control piston in the distributor block that has a leak.

In this case, the entire valve block (1) must be replaced.

1/0203

1 2

1/0204

1/0205

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Workshop Manual

XR-N

Sheet no.

N 10.1

Assembly N

Hydraulic system

Lowering brake valve The lowering brake valve (1) is located in the distributor block on the load carriage.

This is a 2-way flow regulator valve for lowering single-acting cylinders at a constant lowering speed, which is largely independent of the size of the load. The maximum lowering speed must not exceed 60 cm/s and is limited by this valve.

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

Copyright reserved.

Note:

The valve is preset. On no account should any of its settings be altered!

7/0448

2 Used in

Valve type

"S" in mm

XRN14/16 to height of 2700/2900 mm

SB 31C-43

18.2

XRN20 and XRN14/16 from height of 2950 mm

SB 33C-59

18.8

5-cylinder lifting device

SB 27C-40

17.6

1

Symbol

6/0100

6/0099

Reverse direction

Operating direction

Metering notches

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Workshop Manual

XR-N

Shift diaphragm in regulating position

6/0101

Shift diaphragm in free flow-through direction

Sheet no.

N 11

Assembly N

Hydraulic system

Line break protection 1

General The line break protection (1) prevents an uncontrollable, accelerated movement of a loaded hydraulic device (crash) should hydraulic back pressure be lost due to breakage of the pressurized lines or line connection.

6/0102

6/0103

Symbol

The LB type is a disc valve whose valve screw is raised in its idle state by a spring from the valve seat, so maintaining a flowthrough cross-section of adjustable width.

Simplified

•

• v

The force of the flow resistance and the damming effect at the valve screw in the flow direction B --> F (working or release direction) is not as high in normal operation as the counterforce of the spring, and so the valve remains open.

Detailed

If, in an emergency situation, the flow volume increases due to the higher driving force, the flow forces overcome the spring force and the valve shuts instantaneously .

Remark:

(B)

(F)

v

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

Copyright reserved.

It is screwed directly into the hydraulic oil inlet or outlet of the hydraulic device it is to protect (see also plan of hydraulics).

F

o

•

•

B

6/0106

A special tool (2) is needed to remove the line break protection from the lift cylinder.

2

Continued on sheet no. N13

6/0104

Issue: Replaces issue:

07/04

Workshop Manual

XR-N

Sheet no.

N 12

Assembly N

Hydraulic system

Continued

Line break protection Valve for lowering load slowly The valve plate contains a orifice hole (1), through which oil can flow if the valve is triggered, at a rate relative to the size of the load, so that the load is lowered slowly to the floor.

The fault can then be remedied.

6/0102

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

Copyright reserved.

Remark: The gap width determines the response point of the valve. The setting is made by the manufacturer and may not be altered under any circumstances. Specification of the gap width is only provided to help you decide whether the correct line break protection is mounted.

1

6/0105

Different line break protection types are fitted in different types of lifting device (see table).

6/0107

Used in

Hydraulics designation

Valve type

Gap width S in mm

XR-N14/16

S15

LB3C-0,5-52

1,2

up to 2900mm

S16

LB3C-0,5-35

0,7

height and

S17

LB3C-1,0-48

1,1

XR-N12

S18

LB3C-2x1,2-70

1,9

XR-N20 und

S9

LB3C-0,8-40

0,8

14/16

S10

LB4C-1,5-90

1,5

from 2950 mm

S12

LB3C-1,2-63

1,7

heigt

S13

LB3C-0,8-80

2,4

5-Cylinder

S6

LB3C-1,0-37

0,8

mast

S7

LB4C-1,0-78

1,3

Remark:

Issue: Replaces issue:

Valve type LB3C has a 1/2 inch thread Valve type LB4C has a 3/4 inch thread 07/04

Workshop Manual

XR-N

Sheet no.

N 13

Assembly N

Hydraulic system

Pump unit General The pump unit (1) is located under the driver's seat in the front corner.

It can be accessed by removing the front cover.

If you wish to remove the unit, the two cover sheets (2) must also be removed.

6/0109

1

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

Copyright reserved.

The pump unit consists of a self-ventilated 48V series-wound motor (3) (see also sheet no. N16), the speed of which is controlled by the traction and pump controller.

As a result, the quantity of oil delivered by the flange-mounted, external toothed gear pump (4) (see also sheet no. N20) is proportional to the speed of the pump motor.

The rotational speed is transferred from the motor to the pump by a capstan coupling (5).

The coupling between the motor and pump is sealed by an O-ring (6).

The pump unit is fastened to the chassis with 4 rubber bearings (7) to minimise noise.

3

5

7

6 4 Saugseite Druckseite

6/0110

2

Continued on sheet no. N15

Issue: Replaces issue:

07/04

6/0111

Workshop Manual

XR-N

Sheet no.

N 14

Assembly N

Hydraulic system

Continued

Pump unit

Removing 1. Make the pump unit accessible, as described on sheet no. N14.

2. Position the electrical seat adjuster so that the oil filler cap (1) on the tank is easily accessible.

1

3. Push the mast right out.

6/0109

4. Pump the hydraulic oil out of the tank through the oil filler cap with a pump (approx. 25 l oil).

6/0112

3

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

Copyright reserved.

5. Isolate the vehicle from its power supply.

6. Remove the side covers (2) by removing the 3 nuts M8 (3).

Remark: The 3 nuts can be reached from the inside of the chassis. One of them is located below the pump unit.

7. Lay absorbent cloths underneath the pump unit.

2 6/0113.1

5

8. Remove the intake side of the pump, complete with the angled flange socket (4).

9. Through the installation opening on the left (5), remove the delivery side of the pump, complete with angled flange socket (6).

6/0113

10. Mark the electrical connections on the motor and disconnect them.

11. Remove the countersunk screw M8 x 20 (7) from the fan impeller and screw in an eyebolt (9) in its place.

Remark: When replacing the countersunk screw M8 x 20 (7) secure with Loctite no. 242 again!

12. Release the pump unit at the 4 rubber bearings (10).

4

6

6/0110.1

7

MA = 18 Nm

48 48

13. Remove the pump unit vertically upwards, using the "travel motor suspension principle" (see section Z).

41,5 41,5

9

To mount the pump unit, follow the instructions above in reverse order. Ensure that all screws are fastened with the correct tightening torque (see illustration).

M8x25 6/0114 6/0110.2

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Workshop Manual

XR-N

Sheet no.

N 15

Assembly N

Hydraulic system

Continued

Pump unit

Pump motor, general The pump motor (1) is a 48 V self-ventilated series-wound motor.

The motor is equipped with carbon brush monitor and temperature sensor features. The air flows from the bottom to the top of the motor.

The motor speed is controlled by applying different voltages to terminals A1 and D2.

Typical approximate values are as follows:

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

Copyright reserved.

Remark:

Air exit A1

Motor voltage

Setpoint

Main lift, lifting Backwards shift Forwards shift Backwards shift damping Forwards shift damping

45 V 15 V 15 V 3.5 V 5.0 V

10.0 V 6.o V 5.5 V 3.0 V 3.9 V

Forwards tilt Backwards tilt Mast side shift

9.0 V 15.0 V 9.5 V

4.5 V 4.2 V 4.0 V

D2 o

D2

1

M

6/0110.2

Air intake

the values listed below can be read off in the tester menu (see sheet no.

V19.

Function

A1 o

X15 2

6/0115

The temperature sensor and carbon brush monitor signals are transmitted to the combined travel and pump control system via connector X15 (2).

The motor is supported by ball bearings on both sides. The shaft end is sealed at the pump end with a shaft sealing ring.

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Workshop Manual

Pin assignment 1 2 3 4 5 6

XR-N

Temperature sensor Carbon brush + -Temperature sensor Carbon brush --

Sheet no.

N 16

Assembly N

Hydraulic system

Continued

Pump unit

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

Copyright reserved.

Removing the motor 1.

Remove the pump unit (see sheet no. N15).

2.

Remove the hydraulic pump (1) by releasing the 4 screws M10x110 (2).

3.

Remove the tensioning belt (3).

1

4.

Disconnect the electrical connection between the field winding (4) and the brush bridge (5).

2

5.

Release the countersunk screw M8x20 (6) (secured with Loctite no. 242 ) and remove the fan impeller (7).

6.

Remove the two circlips (8).

7.

Release the 4 B-side bearing end-shield screws M6x20 (9) and pull the rotor (10) out of the stator and A-side bearing, complete with B-side end shield (11).

8.

Pull the B-side end shield (11) off the rotor shaft with a puller device.

9.

After the circlip (13) has been removed, the B-side deep-groove ball bearing (12) can be pushed out.

10.

Release the 4 screws M6x20 (14) and remove the A-side end shield (15) from the stator (16).

6/0110

18

17 10

14 16 4 12

Push the A-side deep-groove ball bearing (17) and the shaft sealing ring (18) out of the end shield.

13

To mount the motor, follow the instructions above in reverse order.

3

11.

15

11

8 7 6

9

5

6/0116

When fitting or exchanging the shaft sealing ring (18), ensure that it is inserted in the correct position.

The sealing lip must face towards the pump (see no. 19).

Secure the countersunk screw M8x20 (6) with Loctite no. 242.

19

6/0117

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Workshop Manual

XR-N

Sheet no.

N 17

Assembly N

Hydraulic system

Continued

Pump unit Min. 16 mm

Exchanging the carbon brushes The carbon brushes must be replaced when they reach a minimum length of 16 mm, which is equivalent to wear of about 50 %.

The carbon brush monitor is activated when the carbon brush reaches a length of 15 mm.

Length of a new carbon brush: 32 mm Always replace the complete set of four carbon brushes.

5/0034

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

Copyright reserved.

Removing the brushes 1. Pull out the battery plug.

2. Make the pump unit accessible (see sheet no. N14).

3. Remove the side covers on the left (see sheet no. N15, point 6), so that the installation opening for the carbon brushes can be reached.

4. Remove the pump motor tensioning belt (1).

5. Lift off the brush spring (2) and pull out the carbon at the connecting cable (3).

6. Disconnect the connecting cable (4) 7. Clean out the commutator compartment with compressed air.

Caution:

1

6/0110.2

2

4

3

Never breathe in carbon dust.

8. Mount the new carbon brushes.

Remark:

Issue: Replaces issue:

After exchanging the brushes, do not run the motor straight away under full load. The carbon brushes run in relatively quickly under minimal loads.

07/04

Workshop Manual

6/0118

XR-N

Sheet no.

N 18

Assembly N

Hydraulic system

Continued

Pump unit

Checking the brush springs Brush springs with insufficient pre-tension lead to burning of the commutator.

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

Copyright reserved.

Ensure that the carbon brushes run easily in the shaft.

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07/04

Workshop Manual

XR-N

Sheet no.

N 19

Assembly N

Hydraulic system

Continued

Pump unit Hydraulic pump The pump (1) is an anti-clockwise rotating, externally toothed gear pump. Once the pump unit has been removed from the vehicle (see sheet no. N15), the pump can be removed from the motor by releasing the 4 fastening screws M10x110 (2).

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

Copyright reserved.

3 cylinder mast 1,7t, height ≤2900 FM 14/16

SNP2/11S FR03

11

SNP2/14S FR03

14

SNP2/17S FR03 LFW

17

3 cylinder mast 2,5t, FM20 oder 5 cylinder mast height ≤2480; FM14/16/20 3 cylinder mast 2,5t, height ≥2950 FM14/16

B

B

C

C Delivery side

Delivery output in 3 cm /rev.

Pump type

A

3

Pumps with different delivery outputs are used (cm 3/revolution), depending on the vehicle mast type:

Mast type/Vehicle

A

Intake side

6/0119

1 2

6/0110

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07/04

Workshop Manual

XR-N

Sheet no.

N 20

Assembly N

Hydraulic system

Continued

Pump unit Mounting and commissioning - Before mounting, fill the pump with hydraulic oil.

- Grease the O-ring (1) on the neck of the pump.

- When fitting a new pump, replace the O-ring under the angle flanged socket.

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

Copyright reserved.

- Before installing, clean pipes of dirt, scale, sand and chips. Welded pipes, in particular, must be pickled or rinsed.

- When first commissioning, we recommend slightly releasing the pressure connection to vent the system.

1

- Ensure that the fastening screws are tightened with the correct tightening torque.

6/0110

Remark:

The most frequent cause of premature failure in gear pumps is soiled hydraulic oil. For this reason, particular care must be taken to keep the hydraulic system clean, and the filters must be changed regularly (see sheet no. N23).

If the pump produces noises or the oil forms bubbles: check for leaks between the pump and motor or at the hydraulic connections.

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07/04

Workshop Manual

XR-N

Sheet no.

N 21

Assembly N

Hydraulic system

Tank display Beneath the driver's seat is the tank with an oil sight glass (1). The level of oil in the tank can be read off here once the front cover has been opened.

Use an electric torch when taking the reading.

Check the display without fail: 1. On commissioning, after vehicle assembly 2. During scheduled servicing 3. When the hydraulic system has been opened at any point To take a reading, lower the lifting device completely. Retract the reach carriage completely and tilt the load carriage as far forward as possible.

Remark:

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

Copyright reserved.

1

On commissioning, fill the tank to the centre of the sight glass and carry out all the hydraulic movements with maximum lift, to fill the cylinders and pipes. Then return the hydraulic equipment to its home position, bleed the cylinders and fill the tank to the centre of the sight glass again.

Maximum oil level: Minimum oil level:

Centre of sight glass Bottom edge of sight glass

7/0456

4

3

2

Tank The tank for the hydraulic oil is located under the driver's seat. It is screwed directly onto the chassis (2). The tank holds 25 l (to the centre of the sight glass), which is sufficient for all mast movements.

At the bottom of the tank there is an oil drainage screw (3), which can be reached once the battery has been pulled out.

Oil types used HLP46 HVLP32 HVI32

After draining oil, use a new aluminium sealing ring (4) over this screw.

Remark:

The oil should be changed once a year or every 2000 operating hours.

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07/04

Workshop Manual

XR-N

Sheet no.

N 22

Assembly N

Hydraulic system

Runback filter 4

Application 1.

2.

Filtration of runback oil Filtration of the air entering and leaving the tank

3 2

The filter is mounted on the upper side of the oil tank (6). The filtered oil leaves the tank below the oil level through a hose mounted on the filter bell (1), which prevents bubbles forming in the oil.

5 1

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

Copyright reserved.

On the other side to the hose connection is an air filter (2) made of pressed aluminium fabric. This is used for aeration of the tank.

The filter cartridge used (3) consists of a paper filter (filter mesh gauge 10 µm). This cannot be cleaned.

If the filter is too heavily soiled, the oil can run back into the tank unfiltered through a bypass valve in the lid (4).

Exchanging the filter

7/0456

4

6

1. Switch off the hydraulic system. Pressure on the filter must be relieved on the delivery side.

2. Unscrew the lid (4), first removing the seat (see sheet no. U3).

3. Pull out the filter cartridge (3).

4. Clean the filter bell (5), using a substance such as washing benzene or petroleum.

5. Insert the new filter cartridge.

6. Check the sealing rings and replace if necessary.

7. Oil the lid lightly and screw back on.

Remark:

6/0123

The filter should be changed after 500 operating hours/once a quarter at the latest. The filter element is identical for both types of filter.

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07/04

Workshop Manual

XR-N

Sheet no.

N 23

Assembly N

Hydraulic system

Pump motor specifications

GP 116 - 14/7.9

Motor type

Series-wound motor

Voltage

48 V

Current

230 A

Output

9 KW

Speed

2900 min-1

Protection class

IP00/22

Insulation class

B/F

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

Copyright reserved.

Model

Issue: Replaces issue:

07/04

Workshop Manual

XR-N

Sheet no.

N 24

Assembly R

Lubrication plan

Contents

Sheet no.

Lubrication plan .............................................................................................R 2 Lubricants ......................................................................................................R 3

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

Copyright reserved.

Lubrication card .............................................................................................R 4

Issue: Replaces issue:

07/04

Workshop Manual

XR-N

Sheet no.

R1

Assembly R

Lubrication plan

Lubrication plan 1

Lubricate the steering chains and gears with al-purpose grease every 6 months resp. 1000 hours

2

Lubricate the fith wheel bearing with multipurpose grease every 12 months resp. 2000 hours

3

Lubricate all moving parts with oil every 6 months resp. 1000 hours

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

Copyright reserved.

4

Change the brake fluid every 12 months resp. 2000 hours

5

Change the hydraulic oil every 12 months resp. 2000 hours

6

Change the transmission oil every 12 months resp. 2000 hours

7

Chain spray every 3 months resp. 1000 hours

8

Grease the swivel bearings every 12 months resp. 2000 hours

9

Keep sliding surfaces of the mast sec4 tions free of corrosion with a film of grease 1 every 3 months resp. 1000 hours

9

3

6/0596

7

10

10 In case of mast or fork side shift: Grease sliding surfaces with multipurpose 2 grease every 3 months resp. 1000 hours 11 Grease sliding surface of the battery frame with multi-purpose grease every 3 months resp. 1000 hours

7/0458

6

5

11

8

Remark: To lubricant designation and Viscositaet see sheet no. R3.

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Sheet no.

R2

Assembly R

Lubrication plan

Lubricants Remark: The lubricant types used in the vehicle are marked on the lubrication card on the vehicle (see sheet no. R 4).

Hydraulic oil

HLP 46 or HVLP 32 HVI 32

Hydraulic oil (Cold store)

DIN 51524/T2 DIN 51524/T3

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

Copyright reserved.

Quantity: approx. 25 l Gear oil

SAE 80

Gear oil (Cold store)

SAE 75W - 90 (partly synthetic)

Quantity: approx. 3.6 l

Chain lubricant

Stabylan 2001

Chain lubricant (Cold store)

Syntesco

Lubricants for roller bearings and other lubrication points Beacon 2 Acedo X 2 (Cold store) Profile spray for lifting device, sliding surfaces and toothed racks Ceplattyn 1612 (also for cold store) Brake fluid

ATE SL DOT 4 / DOT 3

Further special lubricants for cold store: For all moving parts Kompranol Spray N74 For screwed joints, Union nuts Rivolta antiwear

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Sheet no.

R3

Assembly R

Lubrication plan

Lubricants 1

Lubrication card

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

Copyright reserved.

The lubricants used in the vehicle are all marked on a card which can be hung on the vehicle. This card is attached close to the filler opening of the oil tank.

The filler opening for hydraulic oil is marked with the symbol shown in Fig. 1.

Whenever the oils are replaced, a cross should be made against the types used (2) and a date entered for the next oil change (3) andbrake-fluid change (4) in accordance with the vehicle lubrication plan.

2

6/0596

Nächster Wechsel Next Change Datum Date

3

HYDRAULIKÖL HYDRAULIC OIL

Decommissioning, disposal In the event that the vehicle described in this manual has to be decommissioned, it is important to ensure that all its components are disposed of in accordance with the applicable regulations. it is particularly important to ensure that the fuels and lubricants used are recycled or disposed of in the correct manner.

GETRIEBEÖL GEARBOX OIL

BREMSFLÜSSIGKEIT BRAKE FLUID

4

ÖL-und LUFTFILTER OIL and AIRFILTER 6/0598

6/0597

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Sheet no.

R4

Assembly V

Servicesoftware

Contents

Sheet no.

General ..........................................................................................................V 2

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

Copyright reserved.

Making a connection......................................................................................V 2 WinPulsE • Menu guide ...........................................................................................V 3 • Starting/stopping connection to the FPS ..............................................V 4 • Reading data out of the FPS (receive from RAM) ................................V 5 • Saving/opening a data set on computer - Saving data with "Menu" (Save as...) ...............................................V 6 - Saving data with "Parameters" (Save as...)......................................V 7 - Opening (Open) a data set (file) .......................................................V 8 - Saving (Save) a data set (file) ..........................................................V 10 • Saving data in the FPS - Sending a data set (File) directly to the FPS (Tx from file)...............V 11 • Changing the parameters (Parameter Change) - Reading parameters out of the FPS and changing them (Receive from RAM) .........................................................................V 12 - Saving parameters in the FPS (Transmit to EEPROM)....................V 13 - Restoring parameters (Restore RAM)..............................................V 13 - List of parameters.............................................................................V 14 • Changing the configuration (Set Configuration) - Changing the configuration...............................................................V 15 - Storing the configuration in the FPS (Transmit to EEPROM)...........V 16 • Reading in the accelerator pedal (Programm VACC)...........................V 17 • Test function (Tester)............................................................................V 18 - Guide to test functions......................................................................V 19 • Reading out the error memory (Alarm Logbook) ..................................V 21 - Table of error codes .........................................................................V 22 • Changing the hour counter (Set Hour Counter)....................................V 25 • Other functions - Closing the program (Exit)................................................................V 26 - Configuring the software (Configuration)..........................................V 26 - Keyboard commands........................................................................V 27

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Assembly V

Servicesoftware

General There are two software products available for diagnosis and setting parameters: - TEWAK95, is needed for the AWE (Fig. 2) - WinPulsE (Fig. 1) The WinPulsE software is needed for the FPS for the following

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

Copyright reserved.

• Changing travel parameters (speeds, acceleration/deceleration) • "Teaching-in" the accelerator pedal • Programming the hour counter • Reading/deleting the error memory • Reading out data and storing as a file • Diagnosis

Fig. 1

1/0081

It can be used to make the following adjustments in the AWE: • Setting the parameters for the individual hydraulic axes (speeds) • Setting the parameters for general vehicle data • Activating/deactivating optional functions • Reading/deleting the error memory • "Teaching-in" the joystick/4-lever system • Reading out data and storing as a file • Software-update of the module • Diagnosis Fig. 2

Making a Connection In order to be able to change parameters in the FPS and/or in the AWE with the Notebook, the Notebook must be connected by the peripheral interface adapter with the vehicle, see chapter M, sheet 82.

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Sheet no.

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Assembly V

Servicesoftware

WinPuls E Menu guide This software is needed for the FPS for the following: • Changing travel parameters (speed, acceleration, deceleration).

• Reading-in accelerator pedal (teaching-in).

• Programming the hour counter.

• Reading / deleting error messages

1/0146

Fig. 1

• Reading data out of the FPS and storing as a file • Sending data from a file to the FPS.

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

Copyright reserved.

• Diagnosis

Main menu File Configuration Connection Function

Open Tx from file Save Save as Exit Com Port Password Start Stop

Parameter Tester Alarm Logbook Program VACC Set Hour Counter

Parameter Change Set Configuration

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Open file Send file to FPS Save file Save file with name Close software

Adjust interface (preselected: com1) Password protected menu

Start connection with FPS Stop connection with FPS

Change travel parameters Diagnosis Read/delete error memory Read in accel. pedal (teach-in) Program hour counter

Change travel parameters Change counting method of hour counter

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V3

Assembly V

Servicesoftware 2

WinPulsE

5

4

1

Starting/stopping connection to FPS • Click on the Start button (1) with the mouse.

OR Start (2) in the "Connection" menu.

• Click on Start

Fig. 1

1/0147

The following information appears on the display (3): Remark:

It is a prerequisite that the computer must be connected to the diagnosis interface (see sheet no. V3).

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

Copyright reserved.

• Connect to: XXXXX.VXXX (current vehicle software version, can vary) • Nominal voltage:

48V

• Nominal Current:

300A

• Hour XXXh (Display of the actual operating hours of the FPS)

Fig. 2

1/0148

6

3

• Alarm: (if fitted, current error as full text) • CONNECTION STATUS: CONNECTED (Status display to indicate that a connection has been made to the FPS or, if not connected: NOT CONNECTED) Breaking the connection • Click on the Stop Stop button (4) with the mouse.

OR • Click on Stop (5) in the "Connection" menu.

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Sheet no.

V4

Assembly V

Servicesoftware 1

WinPulsE Reading data out of the FPS (Receive from RAM)

Before adjustments can be made, the data must be read out of the FPS. • In the menu bar, click on "Function" and then "Parameters" (1).

Fig. 1

1/0149

• In the window that then opens, click on the Receivefrom fromRAM button(2).

Receive • The parameters are read out of the FPS. This takes about 25 secs.

• The parameters are then available (3).

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

Copyright reserved.

• To close the active window, click on the Close Close (4) button.

Remark:

Once the data has been read out of the FPS, the parameters and configuration can be changed. It is also possible to store the complete data set (see sheet no. V6,7).

If there is no User_Comment (5) in the "Parameter change" window, the data is from the FPS. If there is a comment, the data is from a vehicle file that has previously been opened by the computer.

1/0150

Fig. 2

3

2

1/0151

Fig. 3

Fig. 4

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5 Sheet no.

V5

Assembly V

Servicesoftware 1

WinPulsE Saving/opening a data set on the computer Saving the data with "menu" (Save as...)

Before data can be stored, the data must be read out of the FPS (see sheet no. V5).

Fig. 1

1/0153

4

• In the "File" menu, click on "Save as..." (1).

2

• A dialogue window called - Save File - (2) opens.

• In this window, a name must be entered in the "File name" input field (3) (e.g. veh. no. 12345).

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

Copyright reserved.

Remark:

The vehicle number is stamped into the side shift carriage below the right-hand mast bearing.

• In the "Save in" input field (7), another directory can be selected in whch the file is to be stored (e.g. customer directory). The standard setting is the WinPulsE directory.

Fig. 2

3

5

8

1/0154

• The file can be saved in the selected directory with the Save (5) button.

Save • Finally, an additional text can be entered in another dialogue window - Enter a Command - (6). This window must be confirmed with OK OK (7).

• The saving operation can be aborted with the button (8).

Quit Fig. 3

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Sheet no.

1/0155

6

V6

Assembly V

Servicesoftware 1

WinPulsE Saving/opening a data set on the computer Saving the data with "Parameter" (Save as...)

• In the menu bar, click on "Function" and then "Parameter" (1) klicken

Fig. 1

1/0149

• The "Parameter Change" window (2) opens.

Remark:

2

In the event that no data has yet been read out of the FPS, a "Receive from RAM" (3) must be carried out (see sheet no. V5).

Save as... as.... button • Select the Save

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

Copyright reserved.

• The - Save as... - dialogue window (5) opens.

• A name must be entered here in the "File name" input field (6) (e.g. Veh. no. 12345).

Remark:

The vehicle number is stamped into the side shift carriage below the right-hand mast bearing.

Fig. 2

1/0151

3

4

7

• In the "Save in" input field (7), another directory can be selected in whch the file is to be stored (e.g. customer directory). The standard setting is the WinPulsE directory.

5

• The file can be saved in the selected directory with the Save (8) button.

Save • Finally, an additional text can be entered in another dialogue window - Enter a Command - (6). This window must be confirmed with OK OK .

Fig. 3

Quit • The saving operation can be aborted with the Quit button (9).

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Sheet no.

8

9

V7

Assembly V

Servicesoftware 1

WinPulsE Saving/opening a data set on the computer Opening a data set (file) (Open) There are 2 means of opening a file that has previously been saved.

Fig. 1

Option 1:

1/0153

3

5

• In the menu bar, click on "File" and then "Open" (1).

4

2

• The "Open" window (2) opens.

• In the "Search in" input field (3), select the directory in which a vehicle file has been stored, e.g. the customer directory. All the saved files are listed in the selection window (4).

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

Copyright reserved.

Remark:

The standard setting is the WinPulse directory.

• Select the file you want (5). This should appear in the "File name" window (6).

Fig. 2

6

8

7

1/0156

• The file can be read in with the Open Open (7) button. The "Parameter Change" window (8) opens and the parameters are displayed (9).

• There is a User_Comment (10) under the selection window that was entered when the file was saved (see sheet no. V6).

Remark:

A file that is opened in this way cannot be loaded directly into the FPS. It can only be changed!

Fig. 3

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9

Sheet no.

V8

Assembly V

Servicesoftware

WinPulsE

2

1

Saving/opening a data set on the computer Opening a data set (file) (Open) Option 2: Alternatively, the file can be opened from the "Parameter Change" window (1).

• Select the Open Open button (2). The "Open" window (3) appears.

• In the "Search in" input field (4), select the directory in which a vehicle file has been stored, e.g. the customer directory. All the saved files are listed in the selection window (5).

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

Copyright reserved.

Remark:

1/0150

Fig. 1

3

4

6

5

The standard setting is the WinPulse directory.

• Select the file you want (6). This should appear in the "File name" window (7).

Open (7) button. The • The file can be read in with the Open "Parameter Change" window (9) opens and the parameters are displayed (9).

Fig. 2

9

• There is a User_Comment (10) under the selection window that was entered when the file was saved (see sheet no. V6).

Remark:

7

8

1/0156

A file that is opened in this way cannot be loaded directly into the FPS. It can only be changed!

• The current window can be quit by selecting the Close (11) button.

Fig. 3

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11

Sheet no.

V9

Assembly V

Servicesoftware

WinPulsE

1

Saving/opening a data set on the computer Saving a data set (file) (Save) The file that has previously been opened and possibly modified (see sheet nos. V8, 9) can be stored under the same name again.

Fig. 1

1/0153

• In the menu bar, click on "File" and then "Save" (1).

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

Copyright reserved.

• The file that has been opened and possibly changed is overwritten immediately.

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Sheet no.

V 10

Assembly V

Servicesoftware 1

WinPulsE Saving data in the FPS Sending a data set (file) directly to the FPS (Tx from file ) Before data can be transmitted, the connection must be made (see sheet no. V4)

Fig. 1

• In the menu bar, click on "File" and then "Tx from file" (1).

1/0153

5

3

2

4

6

7

9

8

• The "Open" window (2) appears.

• In the "Search in" input field (3), select the directory in which a vehicle file has been stored, e.g. the customer directory. All the saved files are listed in the selection window (4).

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

Copyright reserved.

Remark:

The standard setting is the WinPulse directory.

• Select the file you want (5). This should appear in the "File name" window (6).

Fig. 2

1/0156

• The Open Open button(7) opens the -Tx from file Confirmation - window (8) with "Are you sure?" (safety query) .

No button (9).

• The process can be aborted with the No Yes • The file can be sent directly to the FPS with the Yes button (4).

• When the transmission process is complete, the relevant information window is automatically faded out.

Fig. 3

1/0157

10

• The new parameters can be tested immediately.

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Sheet no.

V 11

Assembly V

Servicesoftware 1

WinPulsE Changing the parameters (Parameter Change)

Reading parameters out of FPS and changing them (Receive from RAM) Before parameters can be changed, a connection must be made (see sheet no. V4). Data must be read out of the FPS (see sheet no. V5) or a vehicle file must be opened (see sheet no. V8).

Fig. 1

1/0149

2

Procedure for "Data from the FPS": • In the menu bar, click on "Function" and then "Parameter" (1).

• The - Parameter Change - window (2) opens.

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

Copyright reserved.

Receive from from RAM button (3); the data is • Select the Receive read out of the FPS (see sheet no. V39).

Remark:

This process is only necessary if no data has yet been read out of the FPS or if no vehicle file has yet been opened.

• In the selection window (4), use the scroll bar (6) to find the parameter you need (5) and then click on it.

Remark:

Fig. 2

7

5

3

1/0150

4

6

9

8

The selected parameter is displayed in the selection window with its name and the value that is currently set (7), and is active for alteration (for a list of parameters, see sheet no. V 48)

• The current value can be changed with the selection fields (8).

OR • By using the + or - keys on the keyboard.

Fig. 3

OR

1/0158

• By double clicking the mouse in the change window (9) - the background to the number then turns blue and entering a value between 0 and 9 (see list of parameters on sheet no. V14) directly in the window.

Remark:

Parameters changed in this way can be tested immediately, since they are written directly into the RAM of the FPS.

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Sheet no.

V 12

Assembly V

Servicesoftware

WinPulsE Changing the parameters (Parameter Change)

Saving parameters in the FPS (Transmit to EEPROM)

If the changed / tested parameters are in order, they must be stored permanently in the FPS (in the EEPROM of the FPS). to EEPROM EEPROM button (1). The • Select the Transmit to data is written into the FPS. This is indicated by a brief "flashing" of the button.

Fig 1

1/0158

1

3

2

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

Copyright reserved.

• Use the Close Close button (2) to close the window and return to the "Start mask".

Restoring parameters (Restore RAM) When the parameters have been changed (see sheet no. V12), the values that were originally read in with the "Receive from RAM" command can be restored. To do so, select the Restore RAM button (3).

Remark:

This function is only possible if no "Transmit to EEPROM" has been carried out in the meantime, i.e. the parameters are not yet stored permanently in the FPS.

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Sheet no.

V 13

Assembly V

Servicesoftware

WinPulsE Changing parameters (Parameter Change) List of parameters Table of the adjustable parameters

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

Copyright reserved.

Parameter

Einheit 1 0.6

2 0.9

3 1.3

Wert 4 1.6

5 1.9

6 2.2

7 2.5

8 2.8

Factory 9 setting 3.1 3

6.3

6.5

7.0

7.4

8.1

8.8

9.7

10.6 11.5

2

Acceler Delay

sec.

0 0.3

Deceler Delay

sec.

6.1

Release Braking

sec.

soft

hard

5

Pedal Braking

sec.

soft

hard

9

Inverse Braking

sec.

soft

hard

7

CutBack Speed

% Vmax

min

max

4

Max Speed Forw.

km/h

min

max

9

Max Speed Back.

km/h

min

max

9

Traction Imax*

A

247

252

257

262

267

273

280

287

300

5

Creep Speed

% PWM

2.3

3.5

4.7

5.9

7.0

8.2

9.4

10.6 11.8 12.9

0

Pump Imax.

A

329

335

342

349

355

364

373

382

8

*Remark:

293

391

400

If the drive motor armature current is to be measured (see sheet no. M39).

Explanation of parameters: Acceler. Delay:

The time needed for the vehicle to reach the required speed.

Deceler. Delay:

Braking when the accelerator position is changed

Release braking:

Generator brake when accelerator pedal /deadman switch is released

Pedal braking:

Generator brake when foot brake pedal is pressed

Inverse braking:

Braking when the travel direction is changed

CutBack speed:

Speed for CutBack travel (adjustable between approx. 1.5 and 3.5 km/h)

Max Speed forw.:

Maximum speed forwards (adjustable between approx. 7.5 and 11 km/h)

Max Speed back.:

Maximum speed reverse (adjustable between approx. 7.5 and 11 km/h)

Traction Imax:

Drive motor armature current

Creep speed:

Minimum speed, slight movement of accelerator pedal

Pump Imax:

Pump motor current

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Sheet no.

V 14

Assembly V

Servicesoftware

WinPulsE Changing the configuration

1

(Set Configuration)

Changing the configuration Before the configuration can be changed, a connection must be made (see sheet no. V4). The data must be read out of the FPS (see sheet no. V5) or a vehicle file must be opened (see sheet no. V8).

Procedure for "Data from the FPS": • In the menu bar, click on "Function" and then "Parameter" (1).

Fig. 1

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

Copyright reserved.

3

2

• The -Parameter- window (2) opens.

• In the -Parameter- window, click on "Set tion" (3). The input window opens (4).

1/0149

Configura-

• Select the Receive from RAM button (5), and the data is read out of the FPS. Remark:

This process is only necessary if no data has yet been read out of the FPS or if no vehicle file has yet been opened.

• In the selection window (6), click on the "Hour Counter" parameter (7).

Remark:

Fig. 2

The selected parameter is displayed in the selection window with its name and the option that is currently set (8), and is active for alteration.

1/0150

8

7

6

9

4

• The arrow key (9) can be used to display the options that can be set (10) and to change them: - Keyon: Hour counter counts when key switch ON - Running:

Hour counter only counts when a motor is driven by the FPS

- Running and Lowering : The hour counter counts when the motors are driven or the main lift lowering function is active

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Sheet no.

1/0159

V 15

Assembly V

Servicesoftware

WinPulsE Changing the configuration

1

(Set Configuration)

Saving the configuration in the FPS (Transmit to EEPROM) Remark:

In order to test the changed configuration or to store it in the FPS, the data must be sent to the FPS. The complete data set is always sent.

• In the -Set Configuration- window (1), click on the Transmit to to EEPROM EEPROM button (2).

Transmit The data is written into the FPS. This is indicated by a brief "flashing" of the button.

Fig. 1

2

3

1/0159

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

Copyright reserved.

Close button (3) to quit the active window.

• Use the Close

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Sheet no.

V 16

Assembly V

Servicesoftware

WinPulsE Reading in the accelerator pedal

1

(Program VACC) Remark:

This process must be carried out every time the accelerator pedal is replaced.

Before the accelerator pedal can be read in (teachingin), the connection must be made (see sheet no. V4).

Procedure: • In the menu bar, click on "Function" and then "Program VACC" (1).

Fig. 1

2

• The -Program VACC- window (2) opens.

The max./min. values (3) that are currently stored are displayed.

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

Copyright reserved.

1/0149

3

• Use the Acquire button (4) to start the teaching-in process. The min./max. values are set to zero.

• Press the accelerator pedal slowly and constantly through to the end stop. The min./max. values are automatically adopted (3).

Fig. 2

• The -Save min/max- window (6) can be opened with Save min/max min/max button (5). the Save

1/0160

4 6

• The values can be stored in the FPS with the Yes command (7).

No • The process can be aborted with the No (8).

command

• Use the Close button (3) to quit the active window.

Fig. 3

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5

Sheet no.

8

9

1/0161

V 17

Assembly V

Servicesoftware

WinPulsE Test function

1

(Tester)

Remark:

Display function for various FPS signals.

No settings can be made in this function.

• In the menu bar, click on "Function" and then "Tester" (1).

• The -Tester- window (2) opens.

The data for the tester is read automatically out of the FPS.

Fig. 1

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

Copyright reserved.

• In the selection window (3), use the scroll bar (4) to find the function you require and click on it with the mouse. The function is automatically displayed in the "Test name" test window (5) with the corresponding "Test value" (6).

Remark:

1/0149

3

4

2

A maximum of 4 functions can be displayed at one time. If you wish to display more functions, one or all the functions must first be deleted.

• Click on the function you want to delete with the mouse. The background to the function turns blue, e.g. "Brake switch" (7).

Signal • Use the Clear Signal selected function.

Fig. 2

1/0162

button (8) to delete the

7

5

6

Clear All all button (9) deletes all the selected test • The Clear points from the display window (10).

Close button (3) to quit the active window.

• Use the Close

Fig. 3

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9

8

Sheet no.

11

1/0163

V 18

Assembly V

Servicesoftware

WinPulsE Test function (Tester)

Guide to test functions

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

Copyright reserved.

Available test points

Displayed value

BATTERY VOLTAGE

Battery voltage value

....V

TR V MOTOR PU TR I Motor PU * FIELD CURRENT

Drive motor - pump motor - voltage (armature) Drive motor - pump motor - current (armature) Drive motor field current

...V ...V ...A ...A ...A

VMN TR CHOPPER TEMP

Timed negative drive motor (armature) Temperature - travel amplifier

...V ...°C

PU CHOPPER TEMP

Temperature - pump amplifier

...°C

ACCELERATOR

Travel potentiometer voltage ( 4.0 - 9.6 V, depending on accelerator pedal) Micro-switch, accelerator pedal (ON / OFF) ON - switch closed Travel direction switch, reverse (ON / OFF) ON - travel direction selected Travel direction switch, forwards (ON / OFF) ON - travel direction selected Switch for electro-magn. brake open / closed ON - brake open (switch closed) Micro-switch, brake pedal OFF - brake pedal not actuated (switch closed) Deadman switch (ON/OFF) ON - Deadman switch actuated Cutback switch OFF - no cutback travel (switch closed) Micro-switch, battery lock OFF - locked (switch closed)

...V ...%

ENABLE SWITCH BACKWARD SWITCH FORWARD SWITCH HANDBRAKE BRAKE SWITCH DEADMAN SWITCH CUTBACK SWITCH BATTERY BLOCK

ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF

*In the display, the currents are exchanged, i.e. if the pump motor is driven, the current is displayed under the drive motor!

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WinPulsE Test function (Tester)

Guide to test functions

Available test points

Displayed value

TR MOTOR TEMP

Temperature monitoring for drive motor (ON / OFF) OFF - Temperature OK (sensor closed) Carbon brush monitoring, drive motor (ON / OFF) OFF - Carbon brushes OK (sensor closed) Temperature monitoring, pump motor (ON / OFF) OFF - Temperature OK (sensor closed) Carbon brush monitoring, pump motor (ON / OFF) OFF - carbon brushes OK (sensor closed) Micro-switch medium setting wheel (0 = straight-on)

BRUSHES TRACTION PUMP MOTOR TEMP BRUSHES PUMP

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

Copyright reserved.

STEER ANGLE SPEED PUMP*

Pump setpoint (from AWE) and pump motor speed 0.00V Perc. = 0%

ENABLE PUMP

Enable pump (from AWE) (ON / OFF) ON - enable signal applied Lowering counter info. (from LAS-module) (ON/OFF) ON - lowering information available

LOWERING SWITCH

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ON/OFF ON/OFF ON/OFF ON/OFF 0 / 255

ON/OFF ON/OFF

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WinPulsE Reading out the error memory

1

(Alarm Logbook) Remark:

This is the display function for errors that have occurred.

No adjustments can be made in this function.

• In the menu bar, click on "Function" and then "Alarm Logbook" (1).

• The Alarm Logbook window (2) opens.

The data for the logbook is automatically read out of the FPS.

Fig. 1

4

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

Copyright reserved.

• The stored FPS errors are shown in plain text in the display window (3).

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3 2 6

7

Alarm Name (4): Error message in plain text (see sheet no. V22).

Repetitions (5): Counter for frequency with which the error has occurred.

Temperature (6): FPS temperature when the error occurred Hour (7): Time (FPS-internal hour counter), at which the error occurred.

• The error memory can be read out again with the Update Update button (8).

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9

• The Clear Clear button (9) first calls up a safety query (10), so that the error memory can subsequently be deleted.

10

• The error memory can be deleted with Yes (11).

• The deletion process can be aborted with No (12).

Close button (13) closes the active window.

• The Close Remark:

A maximum of 5 different errors can be displayed. If a new error occurs, this is put in 1st place and the last error is deleted.

When an error has occurred, it is shown in the display window (14) and on the display in the form of an error code (FE XX).

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WinPulsE

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

Copyright reserved.

Table of error codes

Message/error code

Main contactor Description

Batterie offen (FE01) (Battery lock) see M23

Does not drop out Battery lock not locked

Possible cause •Micro-switch faulty

•Wiring •Logic board, FPS Forw. + Backw. (FE05) Does not drop out The travel direction •Travel direction see M23 signals are both sent switch simultaneously •Wiring •Logic board, FPS Falsche Reihenfolge (FE06) Does not drop out Start sequence not in •Micro-switch error, (Incorrect Start) see M23 order (deadman switch, accelerator pedal accelerator pedal) •Foot switch error •Wiring error •Logic board, FPS Pedalspg. nicht i.O. (FE07) Does not drop out The setpoint of the •Teaching-in not (VACC not ok) see M24 or stays open on travel potentiometer is carried out switching on > 1V than the minimum •Potentiometer programmed value as wrongly adjusted long as the enable •Enable switch does switch is open not close •FPS logic board faulty •Travel potentiometer Bereich Pedalspg. (FE08) Does not drop out Travel setpoint is (ACC out of range) see M24 or stays open on outside the planned faulty switching on range (4-9.6V) •FPS logic board faulty EEPROM KO (FE10) Does not drop out Error in non-volatile •EEPROM error see M24 memory •Micro-processor error •Logic board error Treiber Kurzschluß (FE11) Drops out Error in control of the •Main contactor coil (Driver shorted) see M24 main contactor error •Short-circuit, main contactor driver •Wiring error •Logic board error Logikkarte defekt#1 (FE11) Drops out or stays Error in control of the •Logic board faulty (Logic failure) see M24 open on switching main contactor on Schütztreiber (FE11) Drops out or stays Error in control of the •Main contactor coil Contactor driver) see M24 open on switching main contactor error on •Driver open •Logic board error Mikro ST 6215 KO (FE11) Drops out or stays Micro-processor faulty •Logic board error see M25 open on switching on Kein Feldstrom (FE12) Drops out or stays Field current lower than •Field not connected (No field current) see M25 open on switching required •Logic board error on •Ribbon cable from logic board to travel amplifier faulty •Travel amplifier error

Remark:

Possible action Check/replace Check/replace Replace FPS Check/replace Check/replace Replace FPS Check/replace Check/replace Check Replace FPS

Carry out Check/replace Check/replace Replace FPS Check/replace Replace FPS Replace FPS

Check/replace Replace FPS Check Replace FPS Check/replace

Check/replace Replace FPS Replace FPS Replace FPS

Check motor and wiring ReplaceFPS Replace FPS

Replace FPS

For a detailed description, see sheet nos. M23-M31!

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WinPulsE Table of error codes Message/error code

Main contactor Description

Possible cause

Pumpe I = 0 immer (FE14) (Pump I = 0 ever) see M25

Does not drop out

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

Copyright reserved.

Pumpe stby I hoch (FE14) (Pump stby I high) see M25

Drops out or stays open on switching on Ladung Kondensatoren Drops out or stays (FE15) open on switching (Capacitor charge) see M26 on VMN nicht OK (FE16) Drops out or stays (VMN not OK) see M27 open on switching on V Feld nicht OK (FE17) Drops out or stays (V Field not OK) see M28 open on switching on Stby I hoch (FE18) Drops out or stays (Stby I high) see M28 open on switching on I=0immer (FE18) Drops out or stays (I=0ever) see M28 open on switching on Hauptschütz geschlossen (FE19) (Contactor closed) see M29 Spulenkurzschluß (FE19) (Coil shorted) see M29

Remark:

Drops out or stays open on switching on Drops out or stays open on switching on

•Logic board error •Ribbon cable from logic board to travel amplifier faulty •Test shunt error No current flow, •Hydraulics amplifier although the pump error motor is driven •Logic board error •Pump motor error Current flow in pump •Logic board error motor, although not •Hydraulics amplifier driven error Capacitors do not •Motors faulty charge •Hydraulics/travel amplifiers faulty Voltage at the drive •MOSFET short-circuit motor different from the •Drive motor faulty applied voltage •Logic board error The field voltage is not •Drive motor error half the battery voltage •MOSFETs error •Logic board error Current flow in drive •Travel amplifier motor armature, error although not driven •Logic board error No current flow, •Travel amplifier although the drive motor error is driven •Logic board error •Drive motor error Discharge circuit of the •Main contactor capacitors faulty contacts welded •Logic board error Main contactor •Main contactor short-circuit short-circuit •Main contactor driver •Logic board error

Possible action

Hoher Feldstrom (FE13) Drops out or stays Current flows through (High field current) see M25 open on switching the field, although on not driven

Replace FPS

Replace FPS

Replace FPS Check/replace Replace FPS Replace FPS Check/replace Replace FPS Check/replace Replace FPS Replace FPS Replace FPS

Replace FPS Replace FPS Check/replace Check/replace Replace FPS Check/replace Replace FPS Replace FPS

For a detailed description, see sheet nos. M23-M31!

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WinPulsE Table of error codes Message/error code

Main contactor Description

Possible cause

Fahrmotortemperatur (FE20) Does not drop out Drive motor excess (Traction Motor Temp) see temperature, output is M29 reduced

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

Copyright reserved.

Kohlebürsten Fahrmotor (FE21) (Traction brushes) see M29 Übertemperatur (FE22) (Th.Protection) see M30

Pumpenmotortemperatur (FE30) (Pump Motor Temp) see M30

Does not drop out Carbon brush wear in drive motor, display only Does not drop out Excess/under temperature at travel amplifier, output is reduced Does not drop out Excess temperature at pump motor, pump switches off after 15 seconds

Kohlebürsten Pumpenmotor Does not drop out Carbon brush wear in (FE31) pump motor, display (Pump brushes) see M30 only Pump Temperatur (FE32) (Pump Temperature) see M30

SOK k.o. (FE42) (State output ko) see M31 Batterie k.o. (FE43) (Battery out of range) see M31

Remark:

•Temperature >140°C •Temperature switch faulty •Wire breakage •Logic board error •Carbon brushes worn •Wiring •Temperature > 77°C •Temperature < -10°C •Logic board error •Temperature sensor faulty •Temperature >160°C •Temperature switch faulty •Wire breakage •Logic board error •Carbon brushes worn •Wiring

Does not drop out Excess/under tempera- •Temperature > 77°C ture at hydraulics •Temperature < -10°C amplifier, output is •Logic board error reduced •Temperature sensor faulty Drops out or stays Short-circuit at status •LAS-module error open on switching output •Logic board error on Does not drop out Battery voltage < 30V •Battery voltage too low •Logic board error

Possible action Replace FPS

Replace Check

Replace FPS

Replace FPS

Replace Check

Replace FPS

Replace Replace FPS Charge battery Replace FPS

For a detailed description, see sheet nos. M23-M31!

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WinPulsE Changing the hour counter

1

(Set Hour Counter)

The operating hours that are shown on the display can be modified here. However, the "internal operating hours" of the FPS cannot be changed!

• In the menu bar, click on "Function" and then "Set Hour Counter" (1).

• The -Set Hour Counter- window opens (2).

• The current operating hour is shown on the input window (3).

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• The operating hours can be changed with the selection fields (4).

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

Copyright reserved.

OR • Double click with the mouse in the input window (3).

The background to the displayed value turns blue and the required number of hours can be entered on the keyboard.

• Use the Acquire Acquire button (5) to reset the original value again.

Remark:

A Save operation (6) cannot be carried out prior to this.

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• The value that has been entered can be stored in the FPS with Save (6). The newly set value can be seen on the display immediately.

Close button (7) closes the active window.

• The Close Remark:

No "Transmit to EEPROM" is necessary, since the data is changed directly in the FPS.

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WinPulsE Other functions

2

1

Closing the program (Exit) • In the menu bar, click on "File" and then "Exit" (1).

• The program is closed.

OR • Use the X button (2) in the top right-hand corner of the WinPulsE window.

Fig. 1

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5

Configuring the software (Configuration) Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• In the menu bar, click on "Configuration" (3).

• The computer interface via which the software communicates with the FPS can be set with "Com Port" (4). The standard setting is Comport 1.

• "Password" is not relevant for service work Fig. 2

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WinPulsE Other functions

1

Keyboard commands To enter the menu bar (1) you must press the keys F10 or ALT ALT . The background to the first Shift + F10 Shift menu point (File) turns blue.

Use the <- and -> keys to move between the individual points in the main menu (File, Configuration, etc.).

Use the i key to open the submenu you require. The i and ii keys can now be used to select the required function.

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

Copyright reserved.

The function is started with the ENTER Enter

Fig. 1

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4

3

key.

To change over between Parameter Change and Set Configuration (2): Press the key, until "Parameter Change" is active ( Parameter Change ). Then use the <- and -> keys to switch over between the individual functions.

To enter the selection window (3), the key must be pressed until the background to the first parameter (4) turns blue.

Then press the II and II keys until the required parameter is shown in the selection window (5). The parameter can be set with the + + and -- keys.

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The key can be used to access the function buttons like Transmit, Receive (6) etc.

ENTER The Enter function.

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