Toyota Forklift 6BWS10 6BWS13 Electric Walkie Adjustable Straddle Stacker Service Guide Manual PDF

Front Cover

Service Guide 6BWS10/13

Electric Walkie Adjustable Straddle Stacker Effective Serial Number 585890 - UP

Warning Read and observe all warnings on this unit before operating it.

Warning DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place.

Part no: 00700-CL3WS-01

Date: September 01, 2003

Table of Contents Table of Contents Parts ordering instructions .......................................................................... 5 Technical Data ............................................................................................... 7 Introduction, Maintenance .......................................................................... 11 Service Program ....................................................................................... 13 Cleaning and Washing .............................................................................. 14 External Cleaning .................................................................................. 14 Motor Compartment Cleaning ............................................................... 15 Electrical Components .......................................................................... 15 Safe Jacking ............................................................................................. 16 Planned Maintenance .................................................................................. 17 Maintenance Schedule ............................................................................. 17 Lubrication Schedule ................................................................................ 22 Oil and Grease Specification ...................................................................... 23 Tools .............................................................................................................. 25 Super Seal Connectors ............................................................................. 25 AMP Connectors ................................................................................... 26 Other Tools ........................................................................................... 27 Support Arm Chassis .................................................................................. 29 General ..................................................................................................... 29 Main Components ..................................................................................... 30 Maintenance ............................................................................................. 30 Support Arm Width Adjustment ................................................................ 31 Support Arm Replacement ....................................................................... 32 Electric Drive Motor ..................................................................................... 35 Component Parts ...................................................................................... 35 Motor Dismantling from Truck ............................................................... 37 Assembling ............................................................................................ 37 Service/Repairs ........................................................................................ 38 Motor Dismantling ................................................................................. 38 Motor Assembling ................................................................................. 39 Cleaning ................................................................................................ 39 Technical Data .......................................................................................... 40 Drive Unit/Gear ............................................................................................. 41 Component Parts ...................................................................................... 42 Technical Data ...................................................................................... 44 Top Cover Leakage .................................................................................. 44 Drive Shaft Sealing Ring Replacement .................................................... 45

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Table of Contents Electromagnetic Brake ................................................................................ 47 Brake Main Components .......................................................................... 47 Maintenance ............................................................................................. 48 Basic Gap Adjustment ........................................................................... 48 Brake Disc Replacement ....................................................................... 49 Steering ......................................................................................................... 51 Component Parts, Steering (Tiller) Arm .................................................... 51 Brake Microswitch Adjustments ................................................................ 52 Steering (Tiller) Arm Handle ..................................................................... 53 Dismantling/Assembling ........................................................................ 55 Electrical Systems ....................................................................................... 57 Electrical Parts .......................................................................................... 57 List of Symbols and Electrical Wiring Diagram ......................................... 59 Electrical Diagram 1(6) .......................................................................... 61 Electrical Diagram 2(6) .......................................................................... 62 Electrical Diagram 3(6) .......................................................................... 63 Electrical Diagram 4(6) .......................................................................... 64 Electrical Diagram 5(6) .......................................................................... 65 Electrical Diagram 6(6) .......................................................................... 66 Functional Description .............................................................................. 67 Starting the Truck .................................................................................. 67 Driving ................................................................................................... 67 Neutral Speed Reduction ...................................................................... 67 Picture 3 ................................................................................................ 67 Neutral Speed Reduction on Slopes ..................................................... 68 Braking .................................................................................................. 68 Forks Lifting ........................................................................................... 68 Forks Lowering ...................................................................................... 68 Horn ...................................................................................................... 68 Hour Meter ................................................................................................ 69 Fault Codes .............................................................................................. 69 Parameters ............................................................................................... 75 Driver Parameters ................................................................................. 76 Service Parameters ............................................................................... 77 Parameter Description .......................................................................... 78 Part Numbers ............................................................................................ 84 Transistor Panel ........................................................................................ 85 General ................................................................................................. 85 Diagnostic and Troubleshooting ............................................................... 86 Error Codes and Troubleshooting ......................................................... 86 Resetting Errors .................................................................................... 87 Technical Specifications – Curtis 1243 ..................................................... 88

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Table of Contents Hydraulic System ......................................................................................... 89 Hydraulic Diagram and Components ........................................................ 89 Main Components ................................................................................. 90 Description ............................................................................................ 90 Main lift chain system .................................................................................. 91 Checking the chain settings ...................................................................... 91 Chain inspection ....................................................................................... 91 Noise ..................................................................................................... 91 Surface rust ........................................................................................... 91 Rusty links ............................................................................................. 91 Stiff links ................................................................................................ 92 Pin rotation ............................................................................................ 92 Loose pins ............................................................................................. 92 Outline wear .......................................................................................... 93 Stretching .............................................................................................. 94 Damage ................................................................................................. 95 Damaged discs ..................................................................................... 95 Damaged pins ....................................................................................... 95 Dirty chain ............................................................................................. 95 Cleaning .................................................................................................... 96 Lubrication ................................................................................................ 96

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Parts ordering instructions How to order When you order parts, supply the part number, quantity, model, chassis serial number, and mast serial number of your machine. The serial number on the figure refers to either the Mast serial number or Chassis serial number (see figure below for location of serial numbers) and not the truck serial number (shown on next page). Supplying this information will assure prompt, efficient handling of your order. The pictorial reference number is not needed and including it can only add confusion.

Mast Serial Number

Chassis Serial Number

Field modifications The regulations imposed by OSHA make it mandatory that alteration of industrial trucks be done only as approved in advance and in writing by the manufacturer. Their regulations apply to counter-weighting, changes in masts when such changes affect capacity and any other safety modifications. It is mandatory that nameplate and instructions be changed accordingly (1910.178 (a)(4)).

Toyota will review such changes requested as we can properly evaluate and rerate as to capacity. A change will be Service Guide

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evaluated upon receipt of a written request which includes truck and mast serial number and a description of all proposed changes.

If the change is approved, authorization will be sent, as will new nameplates or other labeling where appropriate. The new nameplates should be installed over the earlier nameplate.

The modifier should send confirmation of the change to the factory along with pictures of the revised truck.

Explanation, truck serial number

6BWS10-1 0001 Truck number Straddle Stacker Truck

Capacity (2000lb) Model (6BWS)

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Technical Data

Technical Data Model

6BWS10/13 Drive Motor

Type

TSL140S-DS30

Output, hp (kW)

1.6 (1.2)

Duty cycle

S2, 60 min

Minimum carbon brush length, inch (mm)

0.5 (13)

Nominal commutator diameter, inch (mm)

2 (50)

Minimum commutator diameter, inch (mm)

1.85 (47)

Resistance, shunt field winding, Ω at 77° F (25° C)

0.49

Resistance armature winding, Ω at 75° F (24° C)

0.0156

Insulation resistance between the windings and motor casing

>=1 Mohm

Weight, lb (kg)

30 (14) Brakes

Type

BFK457-08

Braking force, ft-lbs (N•m)

8.85 (12)

Output, W

25

Resistance coil, Ω

23

Nominal play in actuated position, inch (mm)

0.078-0.157 (0.2-0.4)

Minimum thickness brake disc, inch (mm)

0.216 (5.5)

Thickness of a new brake disc, inch (mm)

0.275 (7.0)

Transmission/Drive Gear Type

2-stage angle transmission

Gear ratio

19,14:1

Oil volume, gallon (liter)

0.26 (1.0) Hypoid oil SAE 80W/90 SAE 75W

Oil type at normal temperature at temperature < 5° F (-15° C)

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Model

6BWS10/13 Wheels

Drive wheel, inch (mm)

Dia 8.5 x 3 (215 x 70)

Axle pressure without load, lbs (kg)

1521 (690)

Axle pressure at rated load, lbs (kg)

1620 (735)

Tightening torque for wheel bolts, ft-lbs (N•m)

47 (65)

Support arm wheel, inch (mm)

Dia 14 x 3 (100 x 75)

Axle pressure without load, lbs (kg)

2 x 355 (240)

Axle pressure at rated load, lbs (kg)

2 x 1510 (240) Hydraulic System

Output, hp (kW)

2.95 (2.2)

Duty cycle,%

5

Minimum carbon brush length, inch (mm)

0.5 (12)

Minimum commutator thickness/diameter, inch (mm)

0.187 (4.75)

Pressure at rated load, psi (bar)

2800 (193)

Overflow pressure, psi (bar)

3046 (210)

Pump flow, gpm (liter/minute)

1.32 (5.0)

Tank volume, gpm (liter/minute)

1.19 (4.5)

Oil type: at normal temperature at temperature < 5° F (-15° C)

Hydraulic oil ISO-L-HM32 ISO-L-HV32 Fuses

Drive motor circuits, A

125

Pump motor circuits, A

125

Control circuits, A

7.5 Battery Compartment, Batteries

Dimensions LxWxH, inch (mm), 180 Ah 240 Ah 320 Ah

8

7.72 x 25.31 x 17.80 (196 x 643 x 452) 7.72 x 25.31 x 22.52 (196 x 643 x 572) 9.60 x 25.31 x 22.52 (244 x 643 x 572)

Capacity, Ah

180-255

Weight, lbs (kg)

290-600 (131-272) Service Guide

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6BWS10/13 Driving Speed

Without load, 0-750 kg, m/h (km/h)

3.73 (6.0)

With rated load, m/h (km/h)

3.29 (5.3) Lift/Lowering Speed

Lift without load, f/s (m/s)

6.7 (0.19)

Lift with rated load, f/s (m/s)

3.5 (0.10)

Lowering without load, f/s (m/s)

5.3 (0.15)

Lowering with rated load, f/s (m/s)

6.7 (0.19) Power Consumption

Driving without load, A

23

Driving with rated load, A

34

Lift without load, A

54

Lift with rated load, A

148 Incline Climbing Ability

With rated load

8% Turning radius

Turning radius WA, inch (mm)

60 (1519) Weight

Truck without battery, (medium) lbs (kg) With mast 83/128 [2108/3251 mm]

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Introduction, Maintenance Safety Regulations with Maintenance Work Only authorized personnel that have been trained in the service and repair of this type of truck should carry out service and repair work.

• Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so • Keep the area clean where you carry out the service.

Oil or water makes the floor slippery • Do not wear watches, rings, or jewelry when working on the truck • Avoid wearing loose-fitting clothing • Wear personal protection equipment to protect eyes, face, and skin • Use insulated tools WARNING Short-circuiting/Burns.

When working with the truck’s electrical system, short-circuiting/burns can occur if a metal object comes into contact with live electrical connections.

Remove watches, rings or other types of metal jewelry.

• Always disconnect the battery by pulling out the battery isolator when carrying out maintenance work on the truck unless otherwise stated in this Service Manual • Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system • Relieve the system pressure slowly before starting work on the truck’s hydraulic system • Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand

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WARNING Risk of burns.

Hot transmission and hydraulic oil.

Let the truck cool before changing the oil.

Only fill the hydraulic system with new and clean oil • Bear in mind that the oil in the transmission or the hydraulic system can be hot WARNING The hydraulic system can be damaged.

If the oil is contaminated, components can be damaged.

hydraulic

Always use new and clean oil in the hydraulic system.

• Store and dispose of changed oil in accordance with local directives • Do not release solvents and the like, which are used for cleaning/washing, into drains that are not intended for this purpose. Follow the local directives that apply for disposal NOTE!

The battery can be damaged.

When welding using an electric power source, the welding current can enter the battery.

The battery disconnected.

should

therefore

be

• Disconnect the battery when welding on the truck CAUTION Harmful gases.

Paint that is heated gives off harmful gases.

Remove 4.0 inches (100 mm) of paint from the work area.

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• Remove at least 4.0 inches (100 mm) of paint around the welding/grinding area through sand-blasting or the use of a paint stripper when welding or grinding on painted surfaces

1. Service Program All points in the service program should be carried out to attain proper operation and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter. They may be adapted to local conditions, but it is important that the intervals comply with Toyota’s minimum requirements.

The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, such as cold store, dusty or corrosive situations. The following running times have been used when calculating the intervals: - Single shift operation: 20 hr./week - 2-shift operation: 40 hr./week - 3-shift operation: 60 hr./week Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.

Only use Toyota approved spare parts when service and repair work are carried out.

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2. Cleaning and Washing Cleaning and washing of the truck is important to ensure the truck’s reliability.

NOTE!

Risk of short-circuiting.

The electrical system can be damaged Disconnect the battery before washing by pulling out the battery connector.

• Carry out general cleaning and washing weekly

2.1 External Cleaning • Remove rubbish, etc. from the wheels daily • Use a well-known degreasing agent, diluted to a suitable concentration • Rinse off loose grime using tepid water NOTE!

Jamming, corrosion.

Mechanical components can be damaged.

After washing, the truck should be lubricated as set out in the “Maintenance Schedule” on page 17 and “Lubrication Schedule” on page 22.

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2.2 Motor Compartment Cleaning • Cover the electric motors, connections and valves before washing NOTE!

Risk of short-circuiting.

The electrical system can be damaged.

Electrical components must not be cleaned with a high pressure washing unit.

• Clean the motor compartment using a well-known degreasing agent, diluted to a suitable concentration • Rinse off loose grime using tepid water

2.3 Electrical Components WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

• Blow electric motors down using compressed air • Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent NOTE!

Risk of short-circuiting.

Electrical components can be damaged.

Do not break the guarantee seal on the electronic board.

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3. Safe Jacking All lifting must be carried out on a flat, non-slip and firm surface. Avoid new laid asphalt or asphalt on a hot summer’s day.

• Activate the parking brake to prevent the truck from moving during the lift. If the lift applies to the brake wheel, chock the other wheels so that the truck stands still • Select a lifting point so that the lift is as easy as possible (one corner at a time). If the truck has marked lifting points on the under side of the chassis these can be used to obtain a well balanced lift • Ensure that the surface under the jack is clean and free from oil and grease • Ensure that your hands and the jack’s lever are free from oil and grease • Use the lever that belongs to the jack. A lever that is too short requires more force than is necessary. If the lever is too long there is a risk of the jack being overloaded • Support the truck: - as close as possible to the part of the chassis that is to be lifted. This reduces the risk of the truck tipping over - so that the truck cannot roll • Never lift up the jack in order to lift higher • Never work under a lifted truck unless it is well supported WARNING Risk of crushing.

A badly supported truck can fall.

Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

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Planned Maintenance 1. Maintenance Schedule I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

0000.

0000.1 0000.2 0000.3 0000.4 0000.5 0000.6 0380.

0380.1 0380.2 1700.

1700.1 1700.2 1700.3 1700.4 1700.5

Work to carry out Interval in hours - may vary due to application Interval in days/weeks/months - may vary due to application Chassis Check all links and locking pins Check wear on cover/battery locking Check of cracking and damage Check the drive housing’s mounting on the chassis Check finger guard Check signs and stickers Fork Carriage Check for crack formation and damage Check clearance in bushes and links Drive Motor Check clearance in connections Check the carbon brushes in the drive motor Clean the drive motor Re-tighten the attachment bolts Check for abnormal noise in bearing

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20

80

500

1000

3000

1d

1w

1m

6m

12m

36m

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I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

2550 2550.1 2550.2 2550.3 2550.4 2550.5 3100.

3100.1 3100.2 3100.3 3500 3500.1

3500.2

3500.3 3500.4 4110 4110.1 4110.2 4110.3

18

Work to carry out Interval in hours - may vary due to application Interval in days/weeks/months - may vary due to application Drive Gear Check for leakage Check the oil level. Use the screwed in dipstick to measure oil Check for abnormal noise Check the attachment and clearance in steering bearing Change the oil in the drive gear Brake Clean and check functionality Check the brake disc Check the clearance in disengaged position 0.0078-0.02 inch (0.2-0.5 mm) Wheels Remove string and other rubbish Check the drive wheel for wear and the tightening torque on bolts (New wheel: Drive tread thickness = 1.18 inch [30mm]) (Tightening torque = 48 ft-lbs [65 N•m]) Check that the caster wheel turns and rotates freely Check for wear on the caster wheel (New wheel: Drive tread thickness = 0.40 inch [10 mm]) Steering (Tiller) Arm Check the mountings Check the power in the gas damper Check steering

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20

80

500

1000

3000

1d

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1m

6m

12m

36m

I3

I I I I

L4

L C M M

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I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

5000 5000.1 5000.2 5000.3 5000.4 5000.5 5000.6 5110 5110.1 5110.2 5110.3 5110.4 5110.5 5110.6 5400 5400.1 5400.2 5400.3 5400.4 5400.5

Work to carry out Interval in hours - may vary due to application Interval in days/weeks/months - may vary due to application Electrical Functions Check the function of the brake microswitch Check the function of the reverser switch Check the function of the horn Check for wear to cables in the steering (tiller) arm Check the function of the driver’s control Check the error code log and operating times Battery Check the electrolyte level, 0.40-0.60 inch (10-15 mm) over the cell plates Check connections to battery, truck and charger Check that the cell and pole guards are undamaged Check the fluid density and temperature Remove overflow fluid from the battery trough Check the battery locking Power System Cleaning and checking of mounting in chassis Re-tighten cable connections Check the contactor points on K10 and K30 Check the movement of the contactors Check the cable insulation

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500

1000

3000

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6m

12m

36m

I I I

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I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

5700 5700.1 5700.2 6000 6000.1 6000.2 6000.3 6000.4 6100.5 6600 6600.1 6600.2 7100 7100.1 7100.2 7100.3 7100.4 7100.5 7100.6

Work to carry out Interval in hours - may vary due to application Interval in days/weeks/months - may vary due to application Electronic Circuit Board Check connectors and cables Check all segments on display Hydraulic System Check hoses and connections for leakage Check hoses for wear and damage Check the oil tank for cracks, leakage and damaged mountings Check that the oil level is correct Change the oil and clean the filter Lift Cylinder Check for leakage Check the mountings Lifting Mast Check for damage and crack formation Retighten the mast mounting bolts (Tightening torque = 145 ft-lbs [197 N•m]) Check the play of the inner section rollers Check the lateral play of the inner section Check for wear on the lifting chains and chain rollers Check the adjustment of the lifting chains

5

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500

1000

3000

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12m

36m

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L5

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X X

I

X

I

X

1 = The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months.

2 = The attachment bolts are re-tightened after 80 h/ 1 month to 33 ft-lbs (45 N•m).

3 = Check for leakage in conjunction with the first oil change.

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months 5 = The oil is changed and the filter cleaned for the first time after 80 h/1 month, and then every 1000 h/12 months 20

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When points with higher hour intervals are carried out, the points with lower hour intervals should also be carried out unless otherwise specified.

7100

6600 4110

5000 5700

0380

0000

3100 5110

6000 5400

1700

2550 3500

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2 Lubrication Schedule Pos No

Service Point

Interval/Running Hours 500h

1000h

Lubricant

3000h

1

Wheel bearings

L

2

Mast beam

L

F

3

Lifting chains

L

D

4

Hydraulic system

C

5

Steering Bearings

6

Drive gear

O

B

L

G

C

L = Lubrication

A

O C = Check

C O = Oil change

3

2

1 4

5 6

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Oil and Grease Specification Specification

Lubricant A B C D F G

Grease Hydraulic oil Transmission oil Grease Grease Grease

> 5 ° F (- 15°C)

< 5 ° F (- 15°C)

Mystik J6 ISO-L-HM32 SAE 80W/90 SAE 10W/40 Mystik J6 Mystik J6

Mystik J6 ISO-VG32 SAE 75W SAE 10W/40 Mystik J6 Mystik J6

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Application Area Bearings and bushings Hydraulic system Gears Chains and wires Slide under forks Steering bearings

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Tools

Tools 1. Super Seal Connectors 1 3

3 2

Figure

Number

Service Guide

Application

00590-42672-71

Tool for application of pins/ sleeves

00590-42673-71

Tool for release of lock (1)

00590-42674-71

Tool for application of secondary locking 2-pole (2)

00590-42675-71

Tool for application of secondary locking 4-pole (2)

00590-42676-71

Tool for removal of pins/sleeves (3)

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1.1. AMP Connectors

Figure

2

26

Number

Application

00590-42677-71

Tool for removal of pins/sleeves

1=00590-42678-71 2=00590-42679-71

Tool for application of sleeves

1=00590-42680-71 2=00590-42681-71 3=00590-42682-71

Tool for application of pins 1: For 0.2-0.5 mm 2 2: For 0.5-1.0 mm 2 3: For 1.5-2.5 mm 2

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Tools

1.2. Other Tools Figure

Number

Service Guide

Application

00590-42683-71

Service instrument (CAN)

1=00590-42684-71 2=00590-42685-71

Service instrument for program modification

1=00590-42686-71 2=00590-42687-71 3=00590-42688-71

1= Service instrument for Curtis transistor panel 2= Cable for Curtis 1243 and 1207A 3= Cable for Curtis 1207

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Figure

Number 00590-42689-71

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Support Arm Chassis 1. General The truck consists of one unit built up in such a manner that the support arm chassis and the separate mounting points for the mast and lift cylinders are bolted to the drive unit.

The support arms of the straddle chassis are adjustable in width from 35.43 inch to 51.18 inch (900 mm to 1300 mm) to suit different pallet sizes. Normally the support arms are only adjusted prior to a truck being delivered to a customer.

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2 Main Components 4

5

3 6 2

10 1

7 9

8

Pos No

Description

1

Support arm wheel axle

2

Wheel axle locking circlip

3

Support arm wheel

4

Support arm

5

Mounting bracket to drive unit chassis

6

Support arm catch

7

Support arm clamp

8

Support arm locking bolt

9

Lift cylinder mounting bracket

10

Mast mounting bracket

3 Maintenance The fastening of the support arms needs to be checked at the regular 500 hours planned maintenance service. The torque setting of the support arm clamp bolts (7) must be checked with a torque wrench set at 90 ft-lbs (120 N•m).

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4 Support Arm Width Adjustment B

A

B

3 2 1

To adjust the measurement A between the support arms proceed as follows: WARNING The truck can tip over.

Do not jack up both support arms at the same time. The truck is a three wheeler.

Jack up one side at the time and support it while working.

• Jack up the side of the truck.

• Loosen the bolt at the front of the cross beam.

• Loosen the clamp bolts (2).

• Pull out (or push in) the support arm. To get the measurement A, measure B = A/2 - 12.00 inches (305 mm). Make sure that the measurement B is equal on both sides.

Service Guide

2003-08-01

31

F-code

Section

C-code

PS M Support Arm Chassis Version no

T-code

001

354

If the support arm is pulled out too far, the catch (3) will drop into the hole in the arm to stop it from falling out.

• Tighten bolt (1) and lock it with the locking nut.

• Tighten the four clamp bolts (2) with a torque wrench.

Torque value: 90 ft-lbs (120 N•m).

5 Support Arm Replacement When replacing a support arm the job is more extensive than adjusting the arm width.

• Lift out the battery.

• Remove the battery box from the chassis. Two bolts at the bottom of the box.

• Remove the catch from the support arm clamp.

• Jack up the side of the truck where the support arm is to be changed.

2 1

• Loosen the bolt at the front of the cross beam (1).

• Loosen the clamp bolts (2).

• Pull out the support arm.

• Fit the new support arm and adjust the arm width according to “Support Arm Width Adjustment” on page 31.

• Lower the truck to the floor.

32

Service Guide

2003-08-01

F-code

Section

C-code

PS M Support Arm Chassis Version no

T-code

001

354

• After tightened the clamp bolts, fit the catch.

• Remount the battery box.

• Fit the battery.

33

Service Guide

2003-08-01

F-code

Section

C-code

PS M Support Arm Chassis Version no

T-code

001

354

This page is intentionally left blank.

34

Service Guide

2003-08-01

F-code

Section

PS

C-code

M Electric Drive Motor

Version no

T-code

001

354

Electric Drive Motor 1. Component Parts

16 21 14

18

13

19

20

17 10

15

12 11

8

9

7 5

6

4 3 1 2

Service Guide

2003-08-01

35

F-code

Section

C-code

PS M Electric Drive Motor Version no

T-code

001

354

Pos No

36

Description

1 2 3 4 5 6 7

Screw Bearing shield Locking ring Bearing Carbon brush bridge Screw Screw

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

Carbon brush Rotor Key Plug Stator Cable Cable Bearing shield Screw Seal Bearing Washer Locking ring Locking ring

Service Guide

Note M6x25

M5x12 M5x20

M6x25

2003-08-01

F-code

PS

Section

C-code

M Electric Drive Motor

Version no

T-code

001

354

1.1. Motor Dismantling from Truck • Switch off the truck and pull out the battery plug.

• Remove the covers for the motor compartment.

• Release the cables for the motor and steering (tiller) arm.

• Unscrew the four nuts for the attachment of the motor to the drive gear.

• Loosen the cables for the key switch and emergency switch. Pull out all the cables from the cover’s cable duct.

• Loosen the cover over the motor compartment and the steering (tiller) arm’s mounting from the motor.

Remove the cover over the motor compartment together with the steering (tiller) arm.

• Carefully lift the motor straight up, without damaging the sealing surfaces to the drive gear and place the motor on a clean surface.

• Protect the drive gear from impurities by covering over its opening in an appropriate manner, such as with a piece of plastic.

The requisite service and repair of the motor can now be carried out.

1.2. Assembling • Assembling is carried out in the reverse order.

• Carefully lift down the motor in the drive gear to avoid damaging the seals and gear wheels.

• Tighten the nuts on the studs to the prescribed torque 20 ft-lbs (26.6 N•m).

• Fit and adjust the brakes as per the instructions.

Screw tight the cover and steering (tiller) arm, and connect the cables that were previously removed.

Check that the polarity is correct.

• The function of the brakes should be checked before the truck is moved.

Service Guide

2003-08-01

37

F-code

Section

C-code

PS M Electric Drive Motor Version no

T-code

001

354

2. Service/Repairs 2.1. Motor Dismantling • Release the brake disc’s companion flange by first removing the locking ring together with the washer in the end of the rotor shaft. The companion flange can now be lifted off. It may be necessary to unclamp it with an appropriate tool.

• Remove the four plugs that cover the carbon brushes, move the springs on the carbon brushes to one side and pull out the carbon brushes.

• Dismantle the commutator end’s bearing shield (2) together with the carbon brush bridge (5) and carbon brushes (8) by unscrewing the eight screws (1). Now put down the motor with a firm resting point against the edge of the bearing shield, and carefully tap on the rotor shaft’s end with a rubber mallet.

• Dismantle the drive end’s bearing shield (15) together with the rotor (9). Make sure not to damage the motor windings when the rotor is removed from the motor housing.

• After dismantling the motor’s bearing shields and removing the rotor from the motor housing, the gear wheel in the rotor’s drive end is removed. This is done by unscrewing the nuts on the gear wheel and then pulling the gear wheel off with a puller. Note that “Loctite” is used to secure the gear wheel to the rotor shaft.

• Now release the inner locking ring together with the underlying washer. Pull out the rotor shaft from the bearing (18).

• Release the outer locking ring together with its washer, and remove the bearing from the bearing shield.

• Remove the bearing shield’s seal (17) and carefully clean the bearing shield.

• Fit a new seal in the bearing shield.

38

Service Guide

2003-08-01

F-code

PS

Section

C-code

M Electric Drive Motor

Version no

T-code

001

354

2.2. Motor Assembling Assemble the motor in the reverse order.

• Carefully check that the rotor can move freely in the direction of rotation and that the carbon brushes are flush with the commutator.

• Check the motor’s insulation resistance (between respective winding and the motor housing). For a new motor this should lie between 2 - 3 Mohm. When a used motor has been exposed to impurities, an insulation resistance down to approximately 1 Mohm is acceptable.

• Fit a new O-ring in the drive shaft end’s bearing shield and a new seal on the collar of the bearing shield.

2.3. Cleaning An extremely critical factor to ensure correct functioning of the motor is that it is kept as clean as possible. The motor and the motor compartment must be regularly checked for dust, oil, and other impurities.

WARNING When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

A vacuum cleaner with an appropriate nozzle can be used to clean the motor if the motor windings and inner compartment are dry, compressed air can be used in combination with a vacuum cleaner. In which case the compressed air must be clean and dry.

A cloth of non-abrasive material should be used if the windings have a coating. The cloth can also be moistened with a grease-dissolving, organic and volatile detergent that does not damage the windings. Use detergent sparingly to avoid it penetrating into the parts of the motor.

Residual detergent should be removed with an appropriate cleaning solution, if it leaves a greasy surface.

If the parts of the motor are dirty it may be necessary to use a cleaning solution that is sprayed onto the parts. It is important Service Guide

2003-08-01

39

F-code

Section

C-code

PS M Electric Drive Motor Version no

T-code

001

354

that the detergent is applied in a way to prevent dirt from penetrating into the parts of the motor, especially for the rotor.

One method of cleaning the rotor, is to dip it in a cleaning solution. If this is done then the rotor must always be dried with the application of heat. There must be adequate ventilation during the drying process, and the drying should continue until a number of measurements of the insulation resistance provide equivalent and approved results.

3. Technical Data Type Output hp (kW) Intermittence Minimum length of carbon brush, inch (mm) Minimum commutator diameter, inch (mm) Resistance, shunt field winding Ω at 77° F (25° C) Resistance, armature winding, Ω at 75° F (24° C) Insulation resistance between windings and motor housing Weight, lbs (kg)

40

Service Guide

TSL140S-DS30 1.6 (1.2) S2 60 min.

0.5 (13) 1.85 (47) 0.49 0,0156 >= 1Mohm 30 (14)

2003-08-01

F-code

Section

PS

M

Version no

T-code

001

354

C-code

Drive Unit/Gear

Drive Unit/Gear

2 3 4 5

6

01

7 8

24

9 27

25 26

10 11

28 13 12 14 32 29

15

18

16

30

31

19

17 20

23 21

Service Guide

2003-08-01

22

41

F-code

Section

C-code

PS M Drive Unit/Gear Version no

T-code

001

354

1. Component Parts

42

Pos No

Description

Note

01

Drive gear complete

2

Air valve

3

Cover

4

Dip stick

5

Washer

6

Gasket

7

Nut

8

Washer

9

Gear wheel

10

Conical roller bearing

11

Shims

12

Screw

13

Shims

14

Conical roller bearing

15

Pinion/ Crown gear

Cog clearance 0.004-0.006 inch (0.10-0.15 mm) Pretension bearing with 2-5/100 Stamped size on pinion adjusted with shims

16

Nut

Tightening torque 221 ft-lbs (300 N•m) Locked with punch mark

17

Shims

18

Conical roller bearing

19

Shims

20

Screw

Tightening torque 52 ft-lbs (70 N•m) Locked with punch mark

Primary gear

Top cover and gear housing Tightening torque 20 ft-lbs. (26.6 N•m) Lock with Loctite 242

Bottom cover and gear housing Tightening torque 20 ft-lbs (26.6 N•m) Lock with Loctite 242

Service Guide

2003-08-01

Pos No

Description

F-code

Section

PS

M

Version no

T-code

001

354

C-code

Drive Unit/Gear

Note

21

Screw

Bottom cover and gear housing Tightening torque 20 ft-lbs (26.6 N•m) Lock with Loctite 242

22

Cover

23

Gasket

24

Gear wheel

25

Washer

26

Nut

Tightening torque 22 ft-lbs (30 N•m) Locked with punch mark Lock with Loctite 603

27

Screw

Motor and gear housing

28

Nut

Tightening torque 20 ft-lbs (26.6 N•m) Lock with Loctite 242

29

Conical roller bearing

30

Shims

31

Seal

32

Drive shaft

Service Guide

Motor gear

2003-08-01

43

F-code

Section

C-code

PS M Drive Unit/Gear Version no

T-code

001

354

1.1. Technical Data Type of gear

2-step angle gear

Gear ratio

14,20:1

Oil volume, liters

1,75

Oil type

Hypoid oil

Viscosity, normal temperature

SAE 80W90

Viscosity, < 5° F (-15°C)

SAE 75W

2. Top Cover Leakage Dismantling • Lift up and block the truck to ensure that it is stable.

• Unscrew the drive wheel.

• Unscrew the M8 nuts (28), that hold the gear and motor, with a box wrench. Support the gear so that it does not drop.

• Release the M8 bolts (12), that hold the cover (3), with a 0.25 inch (6 mm) hex socket wrench.

• Change the gasket (6).

Assembling • Assembling is carried out in the reverse order • Tighten the four M8 bolts and the four M8 nuts to a torque of 20 ft-lbs (26.6 N•m) Lock with Loctite 242.

• Tighten the drive gear five bolts to a torque of 48 ft-lbs (65 N•m).

44

Service Guide

2003-08-01

F-code

Section

PS

M

Version no

T-code

001

354

C-code

Drive Unit/Gear

3. Drive Shaft Sealing Ring Replacement The drive shaft sealing ring can be changed with the gear mounted in the truck. Follow the instructions below if oil is leaking from the drive shaft.

Dismantling • Unscrew the drive wheel (1).

• Remove the lower cover (22) and drain off the oil.

• Release the drive shaft nut (16). Remove the nut and washer (17).

• Carefully tap out the drive shaft (32) with a brass drift and hammer.

• Pull off the bearing (29) from the drive shaft with tool 08-13022.

• Check that the bearing washers (30) are not damaged. If they have been damaged by the puller tool, measure the total thickness of the shim washers and change them before assembling.

• Remove the sealing ring (31) from the drive shaft.

Assembling Assembling of the gear after changing the drive shaft sealing ring is carried out in the reverse order to dismantling.

Pay special attention to the following during assembling: • Fill the sealing ring with grease after fitting it on the drive shaft.

• Make sure that only undamaged shim washers with the same total thickness as the originals are put on the drive shaft.

• Press the bearing on the drive shaft and make sure not to damage the bearing shim washers.

• When fitting the drive shaft with bearing, shim washers and seal, make sure that the shaft keys correspond with the crown gear keys and that the bearing and seal are correctly positioned in the gear housing before the shaft is pressed in completely.

Service Guide

2003-08-01

45

F-code

Section

C-code

PS M Drive Unit/Gear Version no

T-code

001

354

• Put the distance ring on the drive shaft end, and put on the shaft nut. Always use a new nut. Tighten the shaft nut to a torque of 221 ft-lbs (300 N•m) and lock it with a punch mark in the middle. The drive shaft nut should be lubricated before it is put on the shaft.

• Change the gasket before fitting the bottom cover.

Make sure that it is not damaged. Fit the cover and tighten the bolts to a torque of 20 ft-lbs (26.6 Nm).

The bolts should be lubricated before they are fitted.

Fill up with oil in accordance with the instructions for replenishing the oil.

Fit the drive gear and tighten the bolts to a torque of 50 ft-lbs (65 N•m).

46

Service Guide

2003-08-01

F-code

PS

Section

C-code

M Electromagnetic Brake

Version no

T-code

001

354

Electromagnetic Brake 1. Brake Main Components 10

1 2

9

3

4

8

5 7

6

Pos No 1 2 3 4 5 6 7 8 9 10 Service Guide

Description Magnetic coil Cap screws Electrical wire Pressure plate Adjustment locking nut Pressure springs Flange Mounting bolts Brake disc Hub 2003-08-01

47

F-code

Section

C-code

PS M Electromagnetic Brake Version no

T-code

001

354

2. Maintenance It is recommended according to the planned maintenance schedule, on a regular basis, to check the brake disc for wear. Also check the gap between the magnetic coil housing and the pressure plate.

2.1. Basic Gap Adjustment 5,5 5.5 N•m Nm

0.2 0,2 mm

The nominal gap between the coil housing and the pressure plate, in applied position, shall be 0.008 inch (0.2 mm). The maximum gap before readjustment is necessary is 0.20 inch (0.5 mm).

Loosen the tension of the three adjustment bolts.

48

Service Guide

2003-08-01

F-code

PS

Section

C-code

M Electromagnetic Brake

Version no

T-code

001

354

Turn the lock nuts counterclockwise and tighten the bolts slightly while checking the gap on three points with a 0.008 inch (0.2 mm) feeler gauge. Tighten the lock nuts 4 ft-lbs (5.5 N•m) and recheck the gap with the feeler gauge.

2.2. Brake Disc Replacement The brake disc should be replaced when its total thickness has been reduced to 0.22 inch (5.5 mm).

• Disconnect the electrical wires of the brake.

• Loosen and remove the three mounting bolts and remove the brake coil.

• Replace the brake disc on the hub and make a visual inspection of the wear of the friction plate. Replace the friction plate if the surface is worn uneven.

• Unwind the lock nuts on the coil at least 0.24 inch (6 mm) to make sure there is a gap between the coil and the pressure plate when the coil is refitted.

• Mount the coil on the motor end and carry out adjustment of the gap according to “Basic Gap Adjustment” on page 48.

• Reconnect the electrical wiring.

Service Guide

2003-08-01

49

F-code

Section

C-code

PS M Electromagnetic Brake Version no

T-code

001

354

This page is intentionally left blank.

50

Service Guide

2003-08-01

F-code

Section

PS

M

Version no

T-code

001

354

C-code

Steering

Steering 1. Component Parts, Steering (Tiller) Arm 1 2 3

4

5 6

7

8

9 10

14

12

13

16 18

11

15

17

19 20 21 22 23

Service Guide

2003-08-01

51

F-code

Section

PS Steering

M

Version no

T-code

001

354

C-code

Pos No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Description Screw Washer Handle Screw Washer Cable holder Nut Gas damper Bracket Stop screw Screw Ball joint Screw Distance Bush Damper Axle Cam Distance Screw Distance Distance Switch

Note 4

4 2

4

2 2

S 10

2. Brake Microswitch Adjustments Switch (23) is always adjusted to its lowest position.

• Unscrew the screws (13, 20) that hold the switch and the distance.

• Press down the switch and tighten the screws.

• Check that the switch is actuated by the cam (18) in the arm’s top and bottom position.

52

Service Guide

2003-08-01

F-code

Section

PS

M

Version no

T-code

001

354

C-code

Steering

3. Steering (Tiller) Arm Handle

Pos No 1 2 3 4 5 6 7 Service Guide

Description Screw Cover Handle Electronic circuit board Screw Display card Top cover 2003-08-01

Note Key switch option

53

F-code

Section

PS Steering

M

Version no

T-code

001

354

C-code

Pos No 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

54

Description Push button Signal switch Signal button Display glass Arm Push button Plate Spring Push button Arm Holder Spring Control switch Axle Sliding bearing Control stop Arm Spring holder Spring Spring holder Sliding bearing Control switch Reverser Button Arm Spring Lower cover Screw Screw

Service Guide

Note Option

Lift/Lower

Not used

M4x40 2xM5x45 2xM5x60

2003-08-01

F-code

Section

PS

M

Version no

T-code

001

354

C-code

Steering

3.1. Dismantling/Assembling • Dismantle cover (2), (keyboard option).

• Remove the screws (35), hold top cover (7) firm.

• Disconnect the cable connected to the electronic circuit board (4).

• Remove the screws (34).

• Carefully lift off the lower cover (33), and place a finger between the lower cover (33) and button (30) to hold the button (30) in place.

• Assembling is carried out in the reverse order.

NOTE!

Static electricity!

Risk of static discharge that can damage the electronics.

Make sure to take the necessary precautions before working with the electronics.

3.1.1. Signal Button/Switch (9, 10) Replacement • Dismantle the button as per the diagram.

• Disconnect the connection for the switch on the electronic circuit board (4).

• Press out the switch from its mounting.

• Assembling is carried out in the reverse order.

Service Guide

2003-08-01

55

F-code

Section

PS Steering

M

Version no

T-code

001

354

C-code

3.1.2. Lift/Lowering Button (13) Replacement • Remove the button by placing a screwdriver in the hole (A) as per the diagram below.

A

A

• Unscrew the holder (18) so that the arm (12) comes loose.

• Assembling is carried out in the reverse order.

3.1.3. Push Button (16) Replacement • Press the button by hand sideways.

• Place a screwdriver as per the diagram and carefully pry the button loose.

• Unscrew the button’s holder and arm.

• Assembling is carried out in the reverse order.

56

Service Guide

2003-08-01

F-code

Section

PS

C-code

M Electrical Systems

Version no

T-code

001

354

Electrical Systems 1. Electrical Parts S10

S21 X41

S17 Y1

X1 F50

M3

F51 F1

P2 Y34 Y52 P1 Y41

R1 K10 F3 K30 A1

M1

H1

Service Guide

2003-08-01

57

F-code

Section

C-code

PS M Electrical Systems Version no

T-code

001

354

A6

S18

A2:S19

A2:S20 A2:S17

A2:S1-S9 A2:S10-S18

A17

58

Service Guide

2003-08-01

F-code

PS

Section

C-code

M Electrical Systems

Version no

T-code

001

354

2. List of Symbols and Electrical Wiring Diagram Symbol

Description

A1 A2 A6 A17

Transistor regulator Electronic card Display Keypad

PIN-number login

E1

Light

Flashing

F1 F3 F50 F51 F52

Fuse Fuse Fuse Fuse Fuse

Drive motor circuit Pump motor circuit Operating circuit A5 Operating circuit A1 Optional equipment

G1

Battery

H1

Horn

K10 K30 K101

Contactor Contactor Contactor

Main contactor Pump motor Relay

Speed control

Forward/Rearward

M1 M3

Motor Motor

Drive motor Pump motor

P2

Pressure switch

Pressure switch fork lift

1740 psi (120 bar)

R1

PTC-resistor

Power supply

15 Ohm

A2:S1-S9 A2:S10-S18

Function

Notes

125 A 125 A 7,5 A 7,5 A 10A 24 V

Service Guide

2003-08-01

Flashing light

59

F-code

Section

C-code

PS M Electrical Systems Version no

T-code

001

354

Symbol S10 S17 A2:S17 A2:S19 A2:S20 S18 S21

60

Description

Function

Switch Switch Switch Switch Switch Switch Switch

Travel brake Key Reverser Fork lifting Fork lowering Horn button Master on/off switch

Y1 Y41

Brake Magnetic valve

Fork lowering

X1 X41

Connector Connection point

Battery CAN-communication

Service Guide

Notes Brake lever Option

2003-08-01

125A

Sh. = Sheet or page of Diagram First Number = Previous page wire was found.

Second Number = Next page wire is found

F-code

PS

Service Guide

2003-08-01

Section

M Electrical Systems

Version no T-code

001 354

C-code

2.1. Electrical Diagram 1(6)

61

F-code

Section

C-code

PS M Electrical Systems Version no

T-code

001

354

Sh. = Sheet or page of Diagram First Number = Previous page wire was found.

Second Number = Next page wire is found

2.2. Electrical Diagram 2(6)

62

Service Guide

2003-08-01

F-code

PS

Section

C-code

M Electrical Systems

Version no

T-code

001

354

Sh. = Sheet or page of Diagram First Number = Previous page wire was found.

Second Number = Next page wire is found

2.3. Electrical Diagram 3(6)

Service Guide

2003-08-01

63

F-code

Section

C-code

PS M Electrical Systems Version no

T-code

001

354

Sh. = Sheet or page of Diagram First Number = Previous page wire was found.

Second Number = Next page wire is found

2.4. Electrical Diagram 4(6)

64

Service Guide

2003-08-01

F-code

PS

Section

C-code

M Electrical Systems

Version no

T-code

001

354

Sh. = Sheet or page of Diagram First Number = Previous page wire was found.

Second Number = Next page wire is found

2.5. Electrical Diagram 5(6)

Service Guide

2003-08-01

65

F-code

Section

C-code

PS M Electrical Systems Version no

T-code

001

354

Sh. = Sheet or page of Diagram First Number = Previous page wire was found.

Second Number = Next page wire is found

2.6. Electrical Diagram 6(6)

66

Service Guide

2003-08-01

F-code

Section

PS

C-code

M Electrical Systems

Version no

T-code

001

354

3. Functional Description 3.1. Starting the Truck • Battery connector plugged in.

• S21 closed.

• A17 on.

3.2. Driving

A1 BS1 T1

Ish A2

A A1

T2

K10

B+

3.3. Neutral Speed Reduction • The speed control to neutral position, motor starts to work as generator. Brake energy comes back to battery.

• Y1 will be applied when the truck comes to a stand still even if the tiller is in drive position.

3.4. Picture 3 Energy back to the battery.

The transistors (T2) for the generated brake current are not live.

A1 BS1

Ish

T1

S2

M-

+

Shunt

Ia

• S10 closed.

• The speed control activated in any direction.

MShunt

+

S2

Ia

A2

A A1

T2 K10

Service Guide

2003-08-01

B+

67

F-code

Section

C-code

PS M Electrical Systems Version no

T-code

001

354

3.5. Neutral Speed Reduction on Slopes If the driver releases the speed control on a slope and the truck does not come to a stop within a certain time, the electrical brake will be applied by the system.

3.6. Braking The brake is always applied when the truck is started with the steering (tiller) arm in it is upper or lower position (S10 open).

The brake is released in the same moment as the conditions for driving are fulfilled and the truck starts to move.

Conditions to brake the truck: • S10 open.

3.7. Forks Lifting • A2:S19 activated.

• Battery status OK (if battery capacity >20% left).

3.8. Forks Lowering • A2:S20 activated.

3.9. Horn • S18 activated.

68

Service Guide

2003-08-01

F-code

PS

Section

C-code

M Electrical Systems

Version no

T-code

001

354

4. Hour Meter • Press S18 and turn A17 “on” at the same time.

• Press S18 until you read H= hour meters.

• You have now chosen H=hourmeters the symbol “B” will be highlighted.

• You can now choose type of hourmeter by pressing the speed control.

A= Key time. b= Drive motor time. c= Pump motor time.

A

d= Activity time. s= Time to service.

E

D

C

B

5. Fault Codes • Press S18 and turn A17 “on” at the same time.

• Press S18 until you read E= fault codes.

• By choosing E, the symbol “E” will be highlighted to indicate what is currently shown on display.

• The last 50 fault codes will be stored. The latest fault will be shown first. The display first shows the error code and then which hour the fault occurred.

• The fault codes are divided into two groups C = caution and E = error.

• The C will not be stored. It is only a caution and will be highlighted on display as long as the fault exists.

• If for example you only have one fault registered in memory the second empty place will be shown like this: Fault: E - - - and time: - - - -.

Service Guide

2003-08-01

69

F-code

Section

C-code

PS M Electrical Systems Version no

T-code

001

354

70

Code

C19

Description

Default parameter warning.

Possible fault reason

Parameter area is probably corrupt.

Default values have been down loaded, i.e special parameter settings must be restored.

Code

C20

Description

Butterfly warning

Possible fault reason

Problem with butterfly sensor.

Butterfly may have been activated during start up or faulty sensor.

Code

C28

Description

Emergency switch warning

Possible fault reason

Emergency switch activated No voltage supply to motor controller.

Harness problem.

Code

C29

Description

Service time warning

Possible fault reason

Time to make service Service counter not reset after latest service

Code

C41

Description

Battery undervoltage warning

Possible fault reason

Battery voltage < 17 volts Battery parameter not correctly adjusted Time to charge battery

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354

Code

C42

Description

Battery overvoltage warning

Possible fault reason

Battery voltage > 33 volts Fully charged battery and regenerative braking.

Code

C43

Description

Power amplifier thermal cutback

Possible fault reason

Too intensive driving Defect motor controller

Code

E101

Description

Motor controller does not correspond with the type of truck

Possible fault reason

Check that the right type of motor controller is fitted

Code

E104

Description

Brake switch transistor shorted

Possible fault reason

Defect motor controller Check the cables and magnetic coil to the brake

Code

E106

Description

Digital output or field over current

Possible fault reason

Attempt to drive more current than specified from outputs.

Problem to regulate field current.

Internal controller fault.

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72

Code

E107

Description

Contactor off

Possible fault reason

Problem with main contactor tips or cabling (open circuit).

Contactor control wire not connected.

Contactor drive output in controller faulty (off).

Code

E108

Description

Contactor welded

Possible fault reason

Main contactor tips welded.

Contactor drive output in controller faulty (on).

Code

E110

Description

System error

Possible fault reason

Possible fault in the motor controller. Restart the machine.

Code

E140

Description

Check sum error

Possible fault reason

Internal micro controller (control handle head), software or printed circuit board fault.

Code

E141

Description

Software problem

Possible fault reason

Internal micro controller (control handle head), software or printed circuit board fault.

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354

Code

E150

Description

Drive communication error

Possible fault reason

Broken CAN-cable.

Motor controller broken

Code

E151

Description

Drive communication Tx error

Possible fault reason

Motor controller does not answer, bad connections or faulty motor controller.

Code

E157

Description

Bus off error

Possible fault reason

CAN-bus problem, harness or hardware problem.

Code

E159

Description

Over run error

Possible fault reason

CAN-bus problem, harness or hardware problem.

Code

E160

Description

Error in reverser switch

Possible fault reason

Sensor element faulty

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74

Code

E200

Description

Field open

Possible fault reason

Shuntfield open, harness broken, motor controller defect.

Code

E201

Description

M minus error

Possible fault reason

Problem with switch transistor in armature circuit inside motor controller.

Code

E202

Description

Power amplifier sensor error

Possible fault reason

Armature current sensor fault in motor controller.

Code

E214

Description

Power amplifier CAN-time-out

Possible fault reason

Motor controller reports unexpected loss of data flow from control handle head.

Service Guide

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Section

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Version no

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6. Parameters • Press S18 and turn A17 “on” at the same time.

A

• Press S18 until you read P= parameters.

• You have now chosen P=parameters the symbol “C” on display will be highlighted to indicate what is currently shown on display.

E

D

C

B

• Scroll to the parameter you want to change or look at by pressing the speed control up or down.

• Press S18 once to get access to the parameter.

• Set parameter value by pressing the speed control up or down.

• Press S18 once to confirm change.

• Turn A17 off.

You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid.

NOTE!

Truck handling.

Modifying specific truck parameters will change the driving characteristics of the truck.

Do not change any parameters without the necessary know-how.

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6.1. Driver Parameters Parameter Name

Min Max

Step Std Description

01 02

Parameters can be viewed but cannot be changed Max speed % 40 100 5 100

03

Acceleration

%

10

100

5

70

04

Neutral speed reduction

%

5

100

5

50

05

Log off

1min

0

20

1

0

06 - 09

76

Unit

Max speed 10:low Speed 100:full Speed 10:low acceleration 100:full acceleration Defines motor speed reduction force when lever goes to neutral position.

5: low reduction force 100: full reduction force The time until the truck will be switched off when a key pad is used.

Time is counted from when the latest power consumer is used.

Parameters can be viewed but cannot be changed

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6.2. Service Parameters • Connect CAN-key in X41 • Choose parameter

Parameter

Name

10

PIN code

Unit

Min Max

Step

Std

Description

0

1

0

Possibility to enter up to 10 PIN codes (10 different drivers)

9999

11 - 13 14

Parameters can be viewed but cannot be changed Creep -10 10 1 0 speed

15 - 19 20

Parameters can be viewed but cannot be changed Hour meter 1 5 1 2 selection Battery size 1 20 1 8 Parameters can be viewed but cannot be changed Service 1h 0 2000 50 100 interval Parameters can be viewed but cannot be changed Button 1 3 1 1 option

21 22 - 24 25 26 - 27 28

29 - 38 39

Parameters can be viewed but cannot be changed Access 1 4 1 1 code

Service Guide

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This defines how much output the controller gives when you reach the first speed sensor.

-10: low speed when reaching first speed sensor 10: high speed when reaching first speed sensor Select switch hour meter Battery size selection Possible to set service timer State what button should be used for lifting/ lowering Defines what access level service personnel will have to parameters.

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6.3. Parameter Description 6.3.1. Parameter 1 Parameters can be viewed but cannot be changed 6.3.2. Parameter 2 The maximum speed can be adjusted.

6.3.3. Parameter 3 The lower value of the parameter the longer time it takes to accelerate the truck to top speed.

6.3.4. Parameter 4 Defines motor brake force when the speed control goes to neutral position. The lower value of parameter the longer time to reduce speed.

6.3.5. Parameter 5 The time until the truck will be switched off when a key pad is used. Time is counted from when the latest power consumer is used.

6.3.6. Parameter 6 - 9 Parameters can be viewed but cannot be changed 6.3.7. Parameter 10 10 drivers can have their own PIN-code to obtain access to the truck. Each driver has the possibility to set all the driver parameters individual.

Code 0 is not accepted as a solitary code.

When you wish to start the truck enter your code and press the green button with the number 1.

To turn the truck to off press the red no.0 button.

When you have the CAN-key connected you can turn the truck on by just pressing the green no. 1 button. You turn it to off by pressing the red no. 0 button.

6.3.8. Parameter 11 - 13 Parameters can be viewed but cannot be changed

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6.3.9. Parameter 14 Defines the speed you will get when you reach the first speed sensor.

6.3.10. Parameter 15 - 19 Parameters can be viewed but cannot be changed 6.3.11. Parameter 20 You choose which hour meter you want to display.

1(A) = Key time.

2(b) =Activity time.

3(c) = Drive motor time.

4(d) = Pump motor time.

5(s) = Time to service.

6.3.12. Parameter 21 You must give data about with which battery the truck is equipped.

To adjust the disconnection point of the battery discharge indicator measure according to: • Acid concentration when fully charged battery. To check quality of battery. Shall be between 1,27-1,29.

• When you get lift cut out (80% discharged of battery capacity) you shall have close to 1,14 not less.

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The acid concentration can vary depending of battery brand.

Value

Function

Battery (Ah)

1 2 3 4 5 6 7

140

8

240

9 10 11

Less discharged

12 13

More discharged

14 15 16 17 18 19 20 WARNING Control that you have correct parameter setting.

Otherwise the battery can be destroyed.

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6.3.13. Parameter 22 - 24 Parameters can be viewed but cannot be changed 6.3.14. Parameter 25 With this parameter you can set a time limit to next service from 0 to 2000 hours in step of 50 hours. When it is time for service you will get caution 29 (C29) on the display.

6.3.15. Parameter 26 - 27 Parameters can be viewed but cannot be changed 6.3.16. Parameter 28 Using this parameter you can choose which button should be used for lifting/lowering.

1 = Lower lifting/lowering button activated for fork lift Upper lifting/lowering button activated for support arm lift (Standard) 2 = Lower lifting/lowering button activated for support arm lift Upper lifting/lowering button activated for fork lift 6.3.17. Parameter 29 - 38 Parameters can be viewed but cannot be changed 6.3.18. Parameter 39 This parameter can be adjusted as follows: 1 = Key connected, driver parameters open.

2 = Key connected, driver parameters must be opened with Can-key.

3 = Key pad connected, driver parameters open.

4 = Key pad connected, driver parameters must be opened with CAN-key.

A

6.3.19. Service Display • Connect the CAN key in X41 and start the machine • The battery status is displayed and the symbol “D” is lit continually.

E

D

C

B

• Press S18 to choose display mode.

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See table below.

Flashing symbol

Displayed data

B

Speed reference value sent to Curtis.

C

Digital inputs to Curtis and hallelements. * See explanation below

BC

Battery voltage (V)

D

Armature current (A)

BD

Field current (A)

CD

PWM Armature in%

BCD

Status Curtis

*Displayed by highlighting segments of three of the figures (A).

• The most significant figure active (marked with arrow).

• Power amplifier inputs.

Segment

A

Function

A B

E

D

B

C

C

S31, input A1:15

D

S10, input A1:12

E F

A F

G

E D 82

G B

S10, input A1:5

DP

C DP

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• The second most significant figure active (marked with arrow).

• Power amplifier outputs.

A

Segment

E D

A

B

C

B

A F

G

E

B C DP

D

Function

C

Y41, output A1:2

D

Y1, output A1:3

E

K10, output A1:4

F

H1, output A1:7

G

Y1, output A1:5

DP

K30, output A1:6

• The third most significant figure active (marked with arrow) • Digital input from control sensors.

A

Segment

Function

A E

D

B

C

B C

A F

G

E D

B C DP

Service Guide

D

Forks up

E

Forks down

F

Support arms up

G

Support arms down

DP

Horn

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• The fourth most significant figure active (marked with arrow).

A

E

D

Segment

B

C

Function

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

S113 Turtle function

E

Extra function 2

F

Extra function 1

G DP

7. Part Numbers • Press S18 and turn A17 “on” at the same time.

A

E

84

D

• Press S18 until you Pn= part numbers.

C

B

• You have now chosen Pn= part numbers the symbol “D” on display will be highlighted to indicate what is currently shown on display. In the start the Pn = part number complete unit will be shown.

• By scrolling with the speed control you can get the following information: - SPn= Software part number.

- HPn= Hardware part number.

- HSn= Hardware serial number.

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8. Transistor Panel

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

8.1. General B+

A1

S1

M-

M

A2

S2

Curtis 1243 is a regulator for controlling shunt motors.

Varying the voltage applied through the armature primarily controls the speed. The voltage is varied through use of pulse-width modulation (PWM). This involves varying the “on” time of the MOS-FET transistors regulating the armature current.

Switching of the rotational direction is achieved by switching the polarity on the field winding (S1-S2). The regulator is fitted with a four-quadrant transistor bridge for the field winding and a single-quadrant transistor bridge for the armature winding.

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9. Diagnostic and Troubleshooting 9.1. Error Codes and Troubleshooting

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The table below describes the error codes that may be shown by the STATUS LED or read using the handheld terminal.

STATUS LED

Handheld Terminal Display

LED off

-

LED on 1,1 ¤¤

86

Explanation No voltage or faulty regulator Regulator fault Built-in current shunt bad Power amplifier CAN-time-out

1,2

¤ ¤¤

CURRENT SHUNT FAULT HW FAILSAFE

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short to B-

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Too high current for contactor feeding or shorted field winding Open field winding

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

Service Guide

Possible Cause Burnt fuse, bad contact, not connected, faulty regulator Regulator fault Armature current sensor fault in motor controller.

Motor controller reports unexpected loss of data flow from control handle head Problem with switch transistor in armature circuit inside motor controller.

Attempt to drive more current than specified from outputs.

Problem to regulate field current.

Internal controller fault.

Shuntfield open, harness broken, motor controller problem.

1. Battery voltage <17 volts 2. Corroded battery terminals 3. Loose battery or regulator connections 1. Battery voltage > 33 volts

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Handheld Terminal Display

STATUS LED 4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Explanation Over-/undertemperature reduction

Possible Cause 1. Temp. >185° F (85° C) or < -13° F (-25° C) 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions

9.2. Resetting Errors To reset an error turn A17 off and then on again.

Error

87

Reset when

OVERVOLTAGE

Battery voltage falls below 33 V

THERMAL CUTBACK

The temperature is within allowed range

THROTTLE FAULT 1, 2

Error has been fixed

LOW BATTERY VOLTAGE

When battery voltage exceeds 16 V

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10. Technical Specifications – Curtis 1243 Value

Unit

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

Undervoltage limit

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature winding *

150 100

Amps Amps

for 2 minutes for 1 hour

Max. current of field winding

20 20

Amps Amps

for 2 minutes or 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

2

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

Volts

KSI input current

50

mA

Logic input voltage

>7.5; High <1; Low

Volts

Logic input current

15

mA

-40 to +50 32 to 122

°C °F

Overtemperature, reduction

85 185

°C °F

Undertemperature, reduction

-25 -13

°C °F

Operating temperature

Explanation

* During specific test conditions.

88

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M Hydraulic System

Version no

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001

354

C-code

Hydraulic System 1. Hydraulic Diagram and Components n

1

3

C

2

B

A

D

P

E

F

F

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1.1 Main Components Pos No

Description

Remark

1 2

Lift Cylinders Hydraulic Unit

Fork lift A = Non return valve B = Lowering valve, manual C = Lowering valve, el D = Overflow valve E = Flow control valve F = Filter M = Pump motor P = Pump

1.2 Description 1.2.1 Lift When the pump motor starts, the oil flows through the nonreturn valve to the lift cylinders.

1.2.2 Lowering When the lowering valve is actuated by the lowering lever on the chassis, or the lowering button on the steering (tiller) arm, the valve opens to allow the oil in the pressure lines to return to the oil tank. The lowering speed can be regulated by the movement of the lowering lever on the chassis. Lowering using the button on the steering (tiller) arm gives a constant lower speed.

1.2.3 Operating Pressure The operating pressures at rated load are: • 2800 psi (193 bar) 1.2.4 Relief Valve The relief valve opens at the following pressures: • 3046 psi (210 bar)

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Main lift chain system 1. Checking the chain settings The lift chains must be adjusted at regular periods due to stretching. The chain setting is checked during servicing as set out in the maintenance schedule.

Any adjustment is made with the chain mounting bolts.

Adjust the forks height.

2. Chain inspection The chains are exposed to two types of wear, outline wear and stretching. Wear to the pins and disc holes is caused by sketching. The chains are also affected by the environment they are used in.

2.1. Noise If lubrication has been insufficient there will be metallic friction on the chain and this will result in noise.

The chains should be replaced.

2.2 Surface rust Surface rust is easy to recognize as the chain will be reddish brown. Deep-seated rust has generally started and the chain has impaired strength.

The chains should be replaced.

2.3 Rusty links Fretting corrosion results in a reddish brown powder being visible by the outer discs. It can also appear as if the chain is bleeding when lubricated.

The chains should be replaced.

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2.4 Stiff links If it is not possible to pull out the chain to its normal position this can be because of link rust or seizing.

The chains should be replaced.

2.5 Pin rotation Pin rotation can be a phenomenon of stiff links. It is easy to see when comparing with a new chain.

The chains should be replaced.

2.6 Loose pins If a pin is loose it will protrude from the side of the chain, which is due to a stiff link or pin rotation.

The chains should be replaced.

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2.7 Outline wear 3

+

+

P = Pitch H2 = Nominal disc height.

H3 = Minimum disc height.

A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is defined as H3 in the figure and denotes the minimum permitted value of the disc height.

NOTE!

Maximal permitted outline wear is 5% of the height H2. If a lift chain reaches the maximum level of wear, the chain should be replaced.

The nominal and minimum disc heights for respective lift chains are stated in the table in the section “Stretching”.

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2.8 Stretching The amount of Stretch on a lift chain is measured on the part of the chain that runs over the chain sprocket. The amount of stretch may, at the most, be 2% on the most worn section of the chain. Measurement is suitably made over 12-40 inches [300-1000 mm] of the chain.

The nominal and maximum permitted chain lengths for chains are stated in the table below.

Pitch P

Nominal chain length for 20/30/50 dices

Maximum permitted chain length for 20/30/50 dices

0.66 inch (16.9 mm)

0.75 inch (19.05 mm)

15/22.5/37.5 inch (381/572/953 mm)

15.3/22.9/38.2 inch (389/583/972 mm)

0.7 inch (17.8 mm)

0.66 inch (16.9 mm)

0.75 inch (19.05 mm)

15/22.5/37.5 inch (381/572/953 mm)

15.3/22.9/38.2 inch (389/583/972 mm)

3/4 inch, 4x6

0.7 inch (17.8 mm)

0.66 inch (16.9 mm)

0.75 inch (19.05 mm)

15/22.5/37.5 inch (381/572/953 mm)

15.3/22.9/38.2 inch (389/583/972 mm)

1 inch, 4x4

0.92 inch (23.6 mm)

0.88 inch (22.4 mm)

1.0 inch (25.4 mm)

20/30/50 inch (508/762/1270 mm)

20.3/30.5/50.9 inch (518/777/1295 mm)

1 inch, 6x6

0.92 inch (23.6 mm)

0.88 inch (22.4 mm)

1.0 inch (25.4 mm)

20/30/50 inch (508/762/1270 mm)

20.3/30.5/50.9 inch (518/777/1295 mm)

Type of chain

Nominal disc height H2

Minimum disc height H3

3/4 inch, 2x3

0.7 inch (17.8 mm)

3/4 inch, 3x4

NOTE!

94

Service Guide

Wear to the pins and around the holes on the discs are a reason why the chain stretches. The chain should be replaced if stretching is more than 2%.

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2.9 Damage The chain should be replaced if damaged in any way.

2.10 Damaged discs If a disc has broken on the chain, this can be due to overloading or corrosion.

The chains should be replaced.

2.11 Damaged pins It can be difficult to discover whether a pin has broken. It can appear as pin rotation and/or that the outer disc is loose.

The chains should be replaced.

2.12 Dirty chain If a chain is very dirty it is first and foremost recommended that it is replaced. It can also be dismantled and cleaned as set out in the section “Cleaning”.

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3. Cleaning If a chain is very dirty it is recommended the it be replaced.

Dirty chains should be cleaned before they are lubricated, by cleaning with solvent.

• The chain should be blown dry using compressed air and lubricated directly after cleaning.

NOTE!

Exercise care with degreasing agent as these can contain abrasives.

4. Lubrication Mineral and synthetic oils can be used to re-lubricate lift chains.

NOTE!

Lubricant must not contain substances such as molybdenum disulphide, PTFE or the like.

A lift chain should be off-loaded from the weight of the fork carriage (hanging free) when lubricated.

•

Lubrication intervals: - 500 hours with normal operations - 100 hours when driving in rugged environments such as cold storage and corrosive environments.

The chains are sprayed with lubricant. Note the entire chain must be lubricated (10W40 motor oil), even the fastening bolts. It is especially important that the part of the chain which runs over the chain sprocket is well lubricated.

NOTE!

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Service Guide

Do not use a special rust protective agent to prevent rust on the lift chains. These agents impair the lubrication of the chains.

Regular lubrication is the best method to prevent rust form forming.

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