Toyota Forklift 7LOP10CW, 7LOP10CF Service Manual SN 931876 - PDF DOWNLOAD

Service Manual en

7LOP10CW, 7LOP10CF Valid from serial number: 931876-

Order number: 232370-040 Issued: 2006-04-10 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:

Issue date

Order number

Changes

2006-04-10

232370-040

Completely new issue.

This manual covers following truck models:

T-code

Model

Serial number

787

7LOP10CW

931876-

788

7LOP10CF

931883-

© TIEE SARL

Service Manual 7LOP10CW, 7LOP10CF

Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

1- Contents ............................................................................................... 1-1 2- Technical data ..................................................................................... 2-1 2.1 Tightening torques ......................................................................... 2-5 2.2 General tightening torques............................................................. 2-6 3- Maintenance ........................................................................................ 3-1 3.1 Safety rules during maintenance work ........................................... 3-1 3.2 Cleaning and washing.................................................................... 3-3 3.2.1 External cleaning ............................................................. 3-3 3.2.2 Cleaning the motor compartment .................................... 3-3 3.2.3 Electric components ........................................................ 3-3 3.3 Safe lifting ...................................................................................... 3-4 3.4 Lifting the truck............................................................................... 3-5 3.5 Maintenance schedule ................................................................... 3-6 3.6 Lubrication schedule .................................................................... 3-11 3.7 Oil and lubricant specifications..................................................... 3-12 4- Tools ..................................................................................................... 4-1 4.1 Super Seal connectors................................................................... 4-1 4.2 AMP connectors............................................................................. 4-2 4.2.1 AMP Connectors, 040 series ........................................... 4-3 4.2.2 AMP connectors CPC ...................................................... 4-4 4.3 Molex connectors........................................................................... 4-5 4.4 Grease guns .................................................................................. 4-6 4.5 Other tools ..................................................................................... 4-7 5- Electric drive motor – 1760 ................................................................. 5-1 5.1 General .......................................................................................... 5-1 5.2 Mechanical design ......................................................................... 5-1 5.3 Disassembly of the motor from the truck ........................................ 5-2 5.4 Assembly of the motor in the truck ................................................. 5-2 5.5 Service and repairs ........................................................................ 5-3 5.5.1 Disassembly of the motor ................................................ 5-3 5.5.2 Disassembly, N side ........................................................ 5-4 5.5.3 Disassembly, D side ........................................................ 5-4 5.5.4 Wearing parts .................................................................. 5-4 5.5.5 Cleaning .......................................................................... 5-5 6- Driving unit/gear – 2550 ...................................................................... 6-1 6.1 Included components..................................................................... 6-2 6.2 Disassembly/Assembly Leakage from top cover............................ 6-3 Assembly is done in reverse. ........................................... 6-3 6.3 Replacing the drive axle jointing ring.............................................. 6-4 6.3.1 Disassembly .................................................................... 6-4 6.3.2 Assembly ......................................................................... 6-5 6.4 Replacing the wheel bolt ................................................................ 6-6 7- Electromagnetic brake – 3370 ............................................................ 7-1 7.1 Included components..................................................................... 7-2 7.2 Disassembly................................................................................... 7-2 7.2.1 Inspection ........................................................................ 7-2 © TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

1

T-code 787, 788

Valid from serial number 931876-

7.3 7.4 7.5

Date 2006-04-10

Order number 232370-040

Assembly ....................................................................................... 7-3 Manual release of the brake........................................................... 7-3 Adjustment ..................................................................................... 7-3 7.5.1 Adjusting the play ............................................................ 7-3

8- Support wheels – 3500 ........................................................................ 8-1 8.1 Main components........................................................................... 8-1 8.1.1 Replacing the wheel ........................................................ 8-2 Disassembly .................................................................... 8-2 Assembly ......................................................................... 8-2 8.1.2 Replacing the wheel bearings ......................................... 8-2 9- Electrical steering system – 4300 ...................................................... 9-1 9.1 General .......................................................................................... 9-1 9.1.1 Electrical steering servo .................................................. 9-2 9.2 Component overview ..................................................................... 9-3 9.3 Adjustment ..................................................................................... 9-5 9.3.1 Reference sensor ............................................................ 9-5 9.3.2 Calibration ....................................................................... 9-5 Parameter 36 ................................................................... 9-5 Parameter 37 ................................................................... 9-5 9.4 Disassembly/assembly of pushbuttons .......................................... 9-6 9.4.1 Replacing the hornbutton/switch ..................................... 9-6 9.4.2 Replacing the lifting/lowering pushbutton ........................ 9-7 9.4.3 Replacing the pushbutton ................................................ 9-7 9.5 Replacing the potentiometer .......................................................... 9-8 9.6 Replacing the inductive brake sensor .......................................... 9-11 9.7 Replacing the viscous damper ..................................................... 9-14 10- Electrical systems – 5000 ............................................................... 10-1 10.1 General ........................................................................................ 10-1 10.1.1 Software/hardware order numbers ................................ 10-1 10.1.2 Nomenclature ................................................................ 10-2 10.2 Electrical equipment overview ..................................................... 10-3 10.2.1 Electric component overview ......................................... 10-5 10.3 Electrical wiring diagram .............................................................. 10-8 10.3.1 Symbol list ..................................................................... 10-8 10.3.2 Overview ........................................................................ 10-9 10.3.3 Detailed wiring diagram ............................................... 10-10 10.4 Functional description ................................................................ 10-19 10.4.1 Description of steering system .................................... 10-24 10.4.2 Spider expansion unit (SEU) ....................................... 10-25 10.4.3 Speed limitation ........................................................... 10-26 10.4.4 Hour meter and battery condition ................................ 10-27 10.4.5 TLS - Truck log system (optional) ................................ 10-28 General ........................................................................ 10-28 Registration ................................................................. 10-28 Logging in/out SD16 .................................................... 10-28 Logging in/out S16 ....................................................... 10-28 Collision sensor ........................................................... 10-29 Settings ........................................................................ 10-29 10.4.6 ID unit (optional) .......................................................... 10-30 General ........................................................................ 10-30 Installation ................................................................... 10-30 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

10.5

10.6

© TIEE SARL

T-code 787, 788

Settings ........................................................................ 10-31 Parameters & adjustments......................................................... 10-33 10.5.1 General ........................................................................ 10-33 10.5.2 Displaying parameters - without the CAN service key . 10-33 10.5.3 Adjusting operator parameters - without the CAN service key ............................................................................... 10-34 10.5.4 Displaying & changing parameters - CAN service key connected 10-34 Changing a parameter ................................................. 10-35 10.5.5 List of operator parameters ......................................... 10-36 10.5.6 Description of operator parameters ............................. 10-37 #1 - Speed, Fork direction ........................................... 10-37 # 2 - Speed, Drive wheel direction ............................... 10-37 # 3 - Acceleration ......................................................... 10-37 # 4 - Neutral braking force ........................................... 10-37 # 5 - Travel speed, cabin > 0.5 m ................................ 10-37 # 6 - Travel speed, walking at side .............................. 10-37 # 7 - Neutral braking, walking at side .......................... 10-37 10.5.7 List of Service parameters ........................................... 10-38 10.5.8 Description of Service parameter ................................ 10-39 # 10 - PIN code ............................................................ 10-39 To enter a new PIN-code: ............................................ 10-40 To remove an existing PIN-code: ................................ 10-40 # 11 - Reverse braking force ....................................... 10-41 # 14 - Creep speed ...................................................... 10-41 #15 - Non-configurable options ................................... 10-41 Setting Non-configurable options ................................ 10-41 #16 - Configurable option #1 ....................................... 10-42 #17 - Configurable option #2 ....................................... 10-42 #19 - Configurable option #4 ....................................... 10-42 # 20 - Hour meter selection ......................................... 10-43 # 21 - Battery size ........................................................ 10-44 # 22 - Machine type ..................................................... 10-45 # 23 - Function selection ............................................. 10-45 # 24 - Special request .................................................. 10-45 # 25 - Service interval .................................................. 10-45 # 28 - Button selection ................................................. 10-45 # 35 - Automatic log-off ............................................... 10-46 # 36 - Steer servo calibration ....................................... 10-46 # 37 - Steering offset ................................................... 10-47 # 39 - Log-in method & operator parameter access .... 10-47 Extended keypad - General ......................................... 10-48 Extended keypad - Programming ................................ 10-48 10.5.9 Configurable “Option” parameters ............................... 10-50 General ........................................................................ 10-50 Parameter #16 to #19 configurable options ................. 10-51 Setting Configurable options ....................................... 10-52 Diagnostic and troubleshooting.................................................. 10-63 10.6.1 General ........................................................................ 10-63 10.6.2 Fault code history ........................................................ 10-64 10.6.3 List of fault codes ......................................................... 10-64 10.6.4 Transistor regulator troubleshooting and error codes .. 10-70 General ........................................................................ 10-70 Transistor regulator errors ........................................... 10-71 Resetting errors ........................................................... 10-72 Safety .......................................................................... 10-72

Service Manual

7LOP10CW, 7LOP10CF

3

T-code 787, 788

Valid from serial number 931876-

10.7

Date 2006-04-10

Order number 232370-040

10.6.5 Built-in Test Function ................................................... 10-73 Digital inputs/outputs test mode .................................. 10-74 10.6.6 Transistor regulator inputs ........................................... 10-74 Transistor regulator outputs ......................................... 10-75 Digital input of logic card [A2] ...................................... 10-75 Digital input/output to expansion unit [A36] ................. 10-76 Digital input/output to expansion unit [A36] (Option) ... 10-76 Extra functions ............................................................. 10-77 10.6.7 Display test mode ........................................................ 10-77 Technical specifications – Curtis 1243 ....................................... 10-78

11- Hydraulic system – 6000 ................................................................. 11-1 11.1 7LOP10CW.................................................................................. 11-1 11.1.1 General .......................................................................... 11-1 11.1.2 Hydraulic drawing and symbol list ................................. 11-2 Symbol list ..................................................................... 11-2 11.1.3 Description ..................................................................... 11-3 Lift .................................................................................. 11-3 Lowering ........................................................................ 11-3 Operating pressure ........................................................ 11-3 Relief valve .................................................................... 11-3 Pressure sensor ............................................................ 11-3 11.2 7LOP10CF ................................................................................... 11-4 11.2.1 General .......................................................................... 11-4 11.2.2 Hydraulic drawing and symbol list ................................. 11-5 Symbol list ..................................................................... 11-6 11.2.3 Description ..................................................................... 11-6 Cabin lifting .................................................................... 11-6 Cabin lowering ............................................................... 11-6 Initial forks ..................................................................... 11-7 Initial forks lowering ....................................................... 11-7 Operating pressure ........................................................ 11-7 Relief valve .................................................................... 11-7 Check valve for the cabin / forks cylinders (3) ............... 11-7 Pressure sensors, B10/B11 ........................................... 11-7 11.3 Adjustments ................................................................................. 11-8 Adjusting the pressure limiting valve ............................. 11-8 12- Main lift chain system – 7120 ......................................................... 12-1 12.1 General ........................................................................................ 12-1 12.2 Checking the chain setting ........................................................... 12-1 12.3 Chain inspection .......................................................................... 12-1 12.3.1 Noise ............................................................................. 12-1 12.3.2 Surface rust ................................................................... 12-1 12.3.3 Rusty links ..................................................................... 12-1 12.3.4 Stiff links ........................................................................ 12-2 12.3.5 Bolt rotation ................................................................... 12-2 12.3.6 Loose bolts .................................................................... 12-2 12.3.7 Outline wear .................................................................. 12-3 12.3.8 Stretching ...................................................................... 12-4 12.3.9 Damage ......................................................................... 12-5 12.3.10 Damaged discs .............................................................. 12-5 12.3.11 Damaged bolts .............................................................. 12-5 12.3.12 Dirty chain ...................................................................... 12-5 12.4 Cleaning....................................................................................... 12-5 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

12.5

T-code 787, 788

Lubrication ................................................................................... 12-6

13- Fork carriage – 7420 ........................................................................ 13-1 13.1 Included components................................................................... 13-1 13.2 Dismounting of the mast carriage................................................. 13-3 13.3 Adjusting the play......................................................................... 13-3 13.4 Roller replacement....................................................................... 13-3 13.5 Dismounting of the initial fork carriage. ........................................ 13-4 14- TruckCom ........................................................................................ 14-1 14.1 General ........................................................................................ 14-1 14.2 Connection................................................................................... 14-1 14.3 Layout .......................................................................................... 14-2 14.3.1 Main program screen ..................................................... 14-2 14.3.2 Nodes ............................................................................ 14-2 14.3.3 Icons .............................................................................. 14-3 14.3.4 Tool buttons and menu bar ............................................ 14-3 14.3.5 Information window ........................................................ 14-4 14.3.6 Status bar ...................................................................... 14-4 14.4 Connection function .................................................................... 14-4 14.5 Disconnection function................................................................. 14-4 14.6 Downloading program function .................................................... 14-5 14.6.1 Normal downloading (truck with key) ............................. 14-5 14.6.2 Normal downloading (truck with keypad) ....................... 14-5 14.6.3 Emergency downloading (truck with keypad) ................ 14-6 14.6.4 Emergency downloading (truck with keypad) ................ 14-6 14.6.5 Downloading in old versions of logic card ..................... 14-6 14.7 Truck report function .................................................................... 14-7 14.8 Parameters function..................................................................... 14-8 14.9 Diagnostics function..................................................................... 14-8 14.9.1 Representation of signal colours ................................... 14-9 14.9.2 “Tiller arm” tab ............................................................... 14-9 14.9.3 “Drive Controller” tab (transistor regulator driving) ..... 14-10 14.9.4 “Pump controller” tab (transistor regulator pump) ....... 14-11 14.9.5 “EPS” (steering servo tab) ........................................... 14-12 14.9.6 SEU tab (Extra I/O module) ......................................... 14-13 14.10 Other menu functions................................................................. 14-13 14.10.1 Save to file ................................................................... 14-13 14.10.2 Download from file ....................................................... 14-13 14.10.3 Reset CAN adapter ..................................................... 14-14 14.10.4 Delete error code log ................................................... 14-14 14.10.5 Reset hour meter ......................................................... 14-14 14.10.6 Read error code log ..................................................... 14-14 14.10.7 Adjust date and time .................................................... 14-14 14.10.8 Adjusting the hour meter on older cards ...................... 14-14 14.10.9 Help ............................................................................. 14-14 About the TruckCom application ................................. 14-14 14.10.10 Exit ............................................................................. 14-14 14.11 Specifications............................................................................. 14-15 14.12 Installation.................................................................................. 14-15 14.12.1 Installation on a PC with Windows® 95/98 .................. 14-15 14.12.2 Installation on a PC with Windows XP/2000 ................ 14-16 Changes in Windows® control panel ........................... 14-19 14.12.3 Installation on a PC with Windows NT ......................... 14-22 © TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

5

T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.12.4 In case of communication problems with CAN ............ 14-22 14.12.5 To uninstall .................................................................. 14-22 15- Destruction instructions ................................................................. 15-1 15.1 General ........................................................................................ 15-1 15.2 Procedure .................................................................................... 15-1 15.3 Abbreviations ............................................................................... 15-2 15.4 Sorting ......................................................................................... 15-2 15.5 Hoods, hatches (0340)................................................................. 15-3 15.6 Hoods, hatches (0340)................................................................. 15-4 15.7 Seat, cushions (0620) .................................................................. 15-5 15.8 Wall/floor covering (0670) ............................................................ 15-6 15.9 Electric motors (1700) .................................................................. 15-7 15.10 Drive assembly/gear (2550) ......................................................... 15-8 15.11 Wheels (3500).............................................................................. 15-9 15.12 Steering arm (4110) ................................................................... 15-10 15.13 General electronic equipment (5100)......................................... 15-11 15.14 Battery cut out connector/contactor (5190) ................................ 15-12 15.15 Expansion unit “SEU”(5730) ...................................................... 15-13 15.16 Hydraulic unit (6100) .................................................................. 15-14 15.17 Hydraulic lines chassis (6230) and main lift cylinders (6610) ..... 15-15 15.18 Frame/chassis (7420) ................................................................ 15-16 15.19 Charger adaptor (9380) ............................................................. 15-17 15.20 Other extra equipment, tuck log device (9420) .......................... 15-18 15.21 Other extra equipment, writing table (9500) ............................... 15-19

6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Technical data Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

2- Technical data Table 1: Technical data Model

7LOP10CW

7LOP10CF

Type

TSL160 A DS60

TSL160 A DS60

Power, kW

2.5

2.5

Intermittence

S2, 60 min

S2, 60 min

Minimum carbon brush length, mm

11

11

Nominal commutator diameter, mm

71

71

Minimal commutator diameter, mm

68

68

Resistance, shunt field winding, Ω at 24°C

0.346

0.346

Resistance, armature winding Ω at 24°C

0.0098

0.0098

Weight, kg

23

23

Type

1EB46-20

1EB46-20

Braking force, Nm

55

55

Power, W

44

44

Resistance, coil, Ω

12

12

Nominal play when applied, mm

0.25-0.38

0.25-0.38

Minimum thickness of brake disc, mm

7.7

7.7

Thickness of new brake disc, mm

9.7

9.7

Drive motor

Brake

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

2- 1

Technical data T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 1: Technical data Model

7LOP10CW

7LOP10CF

Type

2-stage angle gear

2-stage angle gear

Gear ratio

14.20:1

14.20:1

Oil volume, litres

1.75

1.75

Oil type at normal temperature at temperatures < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

Drive wheel, mm

250X105

250X105

Drive wheel load unloaded, with driver, kg

1105

1113

Drive wheel load with rated load, with driver, kg

558

550

Wheel pressure unloaded, kg/cm2

41.4

41.5

Wheel nut tightening torque, Nm

130

130

Support wheels, mm

140x70

140x70

Axle load pressure unloaded, with driver, kg

676

730

Axle load pressure with rated load, with driver, kg

2224

2298

Wheel pressure with rated load, kg/cm2

48

49

Transmission/gear mechanism

Wheels

2- 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Technical data Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 1: Technical data Model

7LOP10CW

7LOP10CF

Power, kW

2.2

2.2

Intermittence

5%

5%

Minimum carbon brush length, mm

12

12

Minimal commutator diameter, mm

4.75

4.75

Pressure at rated load, bar

180

180

Overflow pressure, bar

200

200

Pump flow, litres/minute

5.0

5.0

Tank volume, litre

4.5

4.5

Oil type at normal temperature at temperatures < -15oC

ISO-HM32 ISO-VG32

ISO-HM32 ISO-VG32

Model

Power steering PST 24/10

Power steering PST 24/10

Power, W

240

240

Torque at rated load

0.68 Nm

0.68 Nm

Max. current

60 A

60 A

Resistance,Ω, phase to phase

0.075

0.075

Control circuit, F50, F51

3 A, 7.5 A

3 A, 7.5 A

Drive motor, F1

160 A

160 A

Pump motor, F3

125 A

125 A

Power steering, F52

30 A

30 A

Hydraulic system

Power steering

Fuses

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

2- 3

Technical data T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 1: Technical data Model

7LOP10CW

7LOP10CF

Battery compartment Dimensions (LxWxH), mm

303x790x775

303x790x775

Capacity, Ah

465-620

465-620

Weight, kg

350-530

350-530

Unloaded, km/h

12

12

With rated load, km/h

8

7

Unloaded, km/h

10.5

10.5

With rated load, km/h

6

6

Lift without load, m/s

0.16

0.16

Lift with rated load, m/s

0.12

0.12

Lowerering without load, m/s

0.17

0.17

Lowerering with rated load, m/s

0.18

0.18

Driving unloaded, A

-

-

Driving with rated load, A

-

-

Lifting with no load, A

-

-

Lifting with rated load, A

-

-

Unloaded, short/long chassis, %

13

13

With rated load, short/long chassis, %

6

6

Chassis L2, mm

1594

1690

Wa , mm

1490

1540

Lifting height min/max, mm

80-1100

80-1880

1162

1294

Battery compartment, Batteries

Drive speed, drive wheel direction

Drive speed, fork direction

Lifting/lowering speed

Current consumption

Hill climbing ability

Dimensions

Weight excluding battery 1150 mm forks, kg

2- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Technical data Tightening torques Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

2.1 Tightening torques Table 2: Specific tightening torques

© TIEE SARL

Description

Quantity

Torque Locking method

Reference

Gearbox input shaft locking nut

1

130 Nm

punch mark

See section “6.1 Included components”.

Gearbox output shaft locking nut

1

400 Nm

punch mark

See section “6.1 Included components”.

Gearbox cover screw

6

25 Nm

Loctite 242

See section “6.1 Included components”.

Wheel fixing bolt

5

90 Nm

Loctite 270

See section “6.1 Included components”.

Gearbox mounting screw (M8)

8

27 Nm

Drive motor securing bolt

5

45 Nm

Service Manual

See section “6.2 Disassembly/ Assembly Leakage from top cover”.

Punch mark

7LOP10CW, 7LOP10CF

See section “5.4 Assembly of the motor in the truck”.

2- 5

Technical data General tightening torques T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

2.2 General tightening torques Millimetre threads M3 to M24.

The following applies under ideal conditions, e.g. steel against steel.

Table 3: General tightening torques M3 B

M4 C

B

M5 C

B

M6 C

B

M8

M10

C

B

C

B

C

A

Tightening torque in Newtonmetre Nm

8.8

1.15

1.2

2.8

2.9

5.5

5.7

9.5

9.8

23

24

45

47

12.9

2.0

2.1

4.7

4.9

9.3

9.7

16.3

17.0

38.5

40.0

75.8

79.0

M12 B

M14 C

B

M16 C

B

M20 C

B

M24 C

B

C

A

Tightening torque in Newtonmetre Nm

8.8

77,7

81

123

128

189

197

369.6

385

638.5

665

12.9

130.5

136

208

217

319.7

333

623

649

1075

1120

A = Strength grade B = Galvanised, non-oiled bolts C = Untreated, oiled bolts

NOTE! Experience has shown that if you adjust the torque wrench to the values for untreated bolts, you will get the correct torque value for galvanised bolts.Do not tighten more than the values set out in the table otherwise the bolts can be destroyed.

2- 6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Maintenance Safety rules during maintenance work Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

3- Maintenance To assure maximum safety and minimum downtime, all items in the service programme should be covered. The service intervals are only guidelines and need not be strictly followed. The operator of the truck should adapt these to local requirements, however, it is important that the minimum requirements as stated by Toyota are observed.

The service intervals are based on truck operating hours and can be adapted to most common 8-hour shifts. When calculating the service intervals, the following operating hours have been used: Day time:

08.00-17.00 (20 hours/week)

Double shift:

06.00-14.00, 14.00-22.00 (40 hours/week)

Triple shift:

06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hours/week)

Make sure the truck receives the necessary regular maintenance service according to the maintenance schedule. The truck's safety, efficiency and service life rely on the service and maintenance the truck receives.

For service and repairs, only use spare parts approved by Toyota.

3.1 Safety rules during maintenance work Only technicians who have received the necessary training for service and repairs of this truck type may carry out service and repair work.

• Do not perform any repair work on the truck unless properly trained and possessing the necessary skills to perform such work.

• Keep the service site clean. Oil and water on the floor could make it slippery.

• Never wear loose items and jewellery when working on the truck.

WARNING! Short-circuiting/Burn injuries.

When working on the truck's electrical system, short-circuiting/burn injuries may occur if metal objects come into contact with live electrical connections.

Remove any watches, rings and other metal jewellery.

• Unless otherwise indicated in this service handbook, always disconnect the battery connector prior to performing maintenance work on the truck.

• Prior to opening any covers to the drive unit and the electrical system, be sure to disconnect the power supply to the truck.

• Prior to commencing any work on the hydraulic system of the truck, be sure to slowly depressurize the system.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

3- 1

Maintenance Safety rules during maintenance work T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

• The truck is equiped with a fan for cooling the electronic system.

This fan keeps running as long as the main contactor (K10) is activated. Touching the turning fan can injure fingers, hand.

• Use paper or a thick paper board to inspect possible hydraulic oil leaks. Do NOT use your hand.

• Keep in mind that the transmission oil and hydraulic system oil may be burning hot.

WARNING! Risk of burn injuries.

Hot transmission and hydraulic oil.

Allow the truck to cool down prior to replacing the oil.

• Use only new and clean oil when refilling the hydraulic oil system.

WARNING! Risk of damaging the hydraulic system.

If the oil is contaminated, the hydraulic system components will be damaged.

Always use new and clean oil in the hydraulic system.

• Store and transport replaced oil in accordance with local regulations.

• Do not flush solvents, etc. used for cleaning into drains that are not specifically suited for this. Follow local regulations with regards to destruction of oil, solvents, etc.

• Disconnect the battery prior to performing welding work on the truck.

NOTE! The battery could become damaged.

When using an electric welding system, the welding current could reach the battery.

Be sure to first disconnect the battery.

• Prior to welding or grinding on painted surfaces, be sure to scrape off the paint at least 100 mm around the welding/grinding site using blasting or a paint remover.

CAUTION! Unhealthy gasses.

Paint, which is heated, generates unhealthy gasses.

Remove the paint 100 mm around the working place.

3- 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Maintenance Cleaning and washing Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

3.2 Cleaning and washing Cleaning and washing of the truck is important to assure a high level of reliability.

• Clean and wash the truck once a week.

NOTE! Risk of short-circuiting.

The electrical system can become damaged.

Prior to washing, be sure to disconnect the battery by disconnecting the battery connector.

3.2.1 External cleaning • Remove dirt, chips, etc. from the wheels daily.

• Use a well-known degreasing agent, diluted to a suitable concentration.

• Wash off loose dirt using lukewarm water.

NOTE! Seizure, corrosion.

Mechanical parts could become damaged.

Following washing of the truck, lubricate it according to the lubrication schedule in the Maintenance section.

3.2.2 Cleaning the motor compartment • Prior to washing, cover all electric motors, connectors and valves.

NOTE! Risk of short-circuiting.

The electrical system can become damaged.

Electric components must not be washed with a high-pressure jet.

• Wash the motor compartment with a well-known degreasing agent diluted to a suitable concentration.

• Wash off loose dirt using lukewarm water.

3.2.3 Electric components • Use compressed air to blow clean the electric motors.

• Clean electric panels, logic cards, connectors, valves, etc. with a rag moistened with water and a suitable detergent.

NOTE! Risk of short-circuiting.

Electric components can become damaged.

Avoid breaking the warranty seals on the logic cards.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

3- 3

Maintenance Safe lifting T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

3.3 Safe lifting Perform all lifts on level, slip-proof and firm surfaces. Avoid newly laid asphalt on warm summer days.

• Always apply the parking brake to prevent the truck from moving during lifting. If the brake wheel needs to be lifted, be sure to block the other wheels to make sure the truck will stand still.

• Select a lifting point that will make the lift as light as possible (one corner at a time). If the lifting point on the truck are indicated on the lower part of the chassis, be sure to use this to assure balanced lifting.

• Ensure that the surface where the jack is placed is clean and free from oil.

• Use clean hands and make sure the jack handle is free from grease and oil.

• Use the handle supplied with the jack. Too short a handle will require more strength than necessary. Too long a jack may result in overloading of the jack.

• Secure the truck with trestles, etc.: - As close to the lifted part of the chassis as possible in order to reduce the falling height if the truck should collapse.

- To prevent the truck from rolling.

- Never chock up the jack in order to achieve a higher lifting height.

- Never work under a lifted truck unless it has been securely chocked up.

WARNING! Risk of crushing.

A poorly chocked up truck may fall down.

Never work under a truck unless it has been securely chocked up using trestles or other safe hoisting gear.

3- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Maintenance Lifting the truck Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

3.4 Lifting the truck

• Only lift the truck at the indicated lifting points using suitable lifting equipment.

WARNING! Risk of tipping.

The truck may tip over if it is lifted in the wrong places.

Always lift the truck at the indicated lifting points.

• Lift the truck at its centre of gravity using another fork lift truck.

• Fasten the truck to the forks of the lifting truck.

• Lift it very carefully WARNING! Risk of tipping.

The truck may tip over if it is lifted incorrectly.

Always lift the truck when it has been fastened to the forks of the lifting truck and its centre of gravity between the forks.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

3- 5

Maintenance Maintenance schedule T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

3.5 Maintenance schedule Table 4: Maintenance schedule I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.

M: Measure and adjust if necessary.

Pos. no.

Work to be performed

0000.

Interval in hours - can vary depending on application Interval in days/weeks/months - can vary depending on application Chassis

0000.1

Inspect tension bolts

I

0000.2

Inspect possible damage on the chassis, open the battery cover and use it as an aid

I

0000.3

Inspect all cover locks

I

0000.4

Inspect the finger protectors, load protectors

I

0000.5

Inspect all plates and stickers

I

0450

Frame-mounted components

0450.0

Inspect the mounting bolts of the motor plate

1700.

Motors

1700.1

Inspect any play in the connectors

1700.2

Inspect the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Tighten all mounting bolts

1700.5

Inspect any noise in the bearings

2550.

Drive unit

2550.1

Check for leakage

2550.2

Inspect the oil level

I

2550.3

Inspect any noise

I

2550.4

Inspect the mounting and any play in the guide bearing

I

2550.5

Replace the drive gear oil

2550.6

Lubricate the gear rim

3100

Brake

3100.1

Clean and verify correct functioning of the service brake and parking brake

3100.2

Inspect brake disc wear and verify correct tightening torque (48 Nm)

M

3100.3

Inspect play in the neutral position

M

3- 6

Service Manual

5

20

500

1,000

3,000

1d

1w 6m

12 m

36 m

I I/T1

I/T

T2 I I

I3

L

L4 L

7LOP10CW, 7LOP10CF

C/I

© TIEE SARL

Maintenance Maintenance schedule Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 4: Maintenance schedule I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.

M: Measure and adjust if necessary.

Pos. no.

Work to be performed 5

20

500

1,000

3,000

1d

1w 6m

12 m

36 m

3500.

Interval in hours - can vary depending on application Interval in days/weeks/months - can vary depending on application Wheels

3500.1

Remove strings, dirt, etc.

I

3500.2

Inspect drive wheel and support wheels, wear and there mounting

4110.

Steering unit

4110.1

Inspect any steering response restrictions and jogging

I

4110.2

Inspect any play in steering couplings and the return spring

I

4110.3

Inspect mechanical locking of the steering arm and its centre position

I

4110.4

Inspect the gear of the steering servo-unit

I

4110.5

Inspect correct mounting of the steering linkage on both sides

I

5000.

Electric functions

5000.1

Inspect correct operation of the micro brake switch

I

I

5000.2

Inspect correct operation of the emergency stop switch

I

I

5000.3

Check lifting/lowering the forks / cabin

I

5000.4

Inspect correct operation of the platform switch

I

I

5000.5

Inspect correct operation of the horn

I

I

5000.6

Inspect cable wear

5000.7

Inspect correct operation of operator controls

I

I

5000.8

Inspect the error code log, operating hours and all segments in the display panel

I

I

5000.9

Inspect correct operation of the 0.1 meter switch in the mast

I

I

5000.10

Inspect correct operation of the double 0.5 meter switch in the mast

I

I

5000.11

Inspect correct operation of the end lift switch in mast

I

I

© TIEE SARL

Service Manual

I

I

7LOP10CW, 7LOP10CF

3- 7

Maintenance Maintenance schedule T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 4: Maintenance schedule I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.

M: Measure and adjust if necessary.

Pos. no.

Work to be performed

5110.

Interval in hours - can vary depending on application Interval in days/weeks/months - can vary depending on application Battery

5

20

500

1,000

3,000

1d

1w 6m

12 m

36 m

5110.1

Inspect the electrolyte level: 10-15 mm above the cell plates

M

5110.2

Inspect all battery, truck and charger connections

I

5110.3

Verify that the cell and pole protectors are not damaged

I

5110.4

Inspect the fluid density and temperature

M

5110.5

Suck up excess fluid from the battery pan

C

5110.6

Verify the battery locking device

5400

Power system

5400.1

Clean and inspect the mounting devices

C/T

5400.2

Tighten all cable connectors

T

5400.3

Inspect the K10 and K30 contactor tips

I

5400.4

Inspect contactor mobility

I

5700

Electronic circuit board

5700.1

Check connectors and cables

5700.2

Check all segments on display

6100.

Hydraulic system

6100.1

Check hoses and connections for leakage

I

6100.2

Check hoses for wear and damage

I

6100.3

Check the oil tank for cracks, leakage and damaged mountings

I

6100.4

Check that the oil level is correct

I

I

6100.5

Change the oil and clean the filter

L5

L

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Inspect the mounting

I

3- 8

Service Manual

I

T I

7LOP10CW, 7LOP10CF

© TIEE SARL

Maintenance Maintenance schedule Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 4: Maintenance schedule I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.

M: Measure and adjust if necessary.

Pos. no.

Work to be performed

7100

Interval in hours - can vary depending on application Interval in days/weeks/months - can vary depending on application Lifting mast

7100.1

Check for damage and crack formation

I

7100.2

Check the play of the rollers

I

7100.3

Check the lateral play

I

7100.4

Check for wear on the lifting chains and chain rollers

I

7100.5

Check the adjustment of the lifting chains.

Inspect the chain bolts and the chain mountings.

Retighten the locking nuts and inspect the safety cotter pins on the chain.

I/M

7100.6

Lubricate the lifting chain

L

7420

Fork carriage / Mast carriage

7420.1

Inspect for cracking and other damage

I

7420.2

Inspect any play in bushings and links

I

7420.3

Inspect the guide pins for wear and lubricate (note 6)

5

20

500

1,000

3,000

1d

1w 6m

12 m

36 m

I/L

1 = Retighten all connections the first time after 500 hours, and then every 1,000 hours.

2 = Retighten the mounting bolts after 500 hours to a torque of 45 Nm. 3 = Inspect for leakage during initial oil replacement.

4 = Replace the oil the first time after 500 hours/6 months and then every 3,000 hours/36 months.

5 = Replace the oil and clean the filter the first time after 500 hours/6 months and then every 1,000 hours/12 months.

6 = Repeat every 250 hours if the truck is operated in cold stores or other harsh environments.

Unless otherwise indicated, whenever performing service according to longer service intervals, all service items at shorter intervals should also be carried out. .

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

3- 9

Maintenance Maintenance schedule T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

5000

Order number 232370-040

5000

5000

5700 6600 5000 4110

7000

5400 1700 3100 6100

3500

1700

5110 0000

0450 1700

3- 10

Service Manual

7LOP10CW, 7LOP10CF

2550

© TIEE SARL

Maintenance Lubrication schedule Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

3.6 Lubrication schedule Table 5: Lubrication schedule Pos. no.

Service item

Interval/Operating hours 500 h

1,000 h

3,000 h

O4

I

O

Lubricant

2550

Driving gear

C

2550

Gear rim

6100

Hydraulic system

O5

7100

Lifting chain

S

D

7100

Mast guiding

S

G

7420

Lubricant nipples, guide pins

L

A

L

E

O

B

L = Lubricate I = Inspect O = Oil replacement 4 = Replace the oil the first time before 500 hours and after that every 3,000 hours/36 months.

5 = Replace the oil and clean the filter the first time before 500 hours and after that every 1,000 hours/12 months.

7100

7420

6100

2550

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

3- 11

Maintenance Oil and lubricant specifications T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

3.7 Oil and lubricant specifications Table 6: Oil and lubricant specifications Lubricant

Specification

Application

> - 15°C

< - 15°C

A

Grease

S213366 Q8 Rubens WB

S213366 Q8 Rubens WB

Bearings and bushings

B

Hydraulic oil

ISO-HM32

ISO-VG32

Hydraulic system

C

Transmission oil

Hypoid oil SAE 80W/90

Hypoid oil SAE 75W

Gears

D

Grease

See table below

See table below

Chains

E

Grease

Grafloscon A-G1 (Klüber)

Grafloscon A-G1 (Klüber)

Gear rim

F

Grease

755711-040

755701-040

Swivel wheel

G

Grease

S213366 Q8 Rubens WB

S213366 Q8 Rubens WB

Mast

Pos.

Environmental temperature

Viscosity class

Recommended products*

D

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

D

> - 30°C < + 5°C

VG 68

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA

D

> + 5°C < +45°C

VG 150

Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette

D

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

* Similar products from other manufacturers may be used.

3- 12

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Tools Super Seal connectors Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

4- Tools 4.1 Super Seal connectors 1

3 3 2 Figure

© TIEE SARL

Number

Application

159232

Tools for fitting pins/sleeves

159229

Tools for loosening locks (1)

159230

Tool for fitting secondary locks 1-2 poles (2)

159231

Tool for fitting secondary locks 3-6 poles (2)

159228

Tools for removing pins/sleeves (3)

Service Manual

7LOP10CW, 7LOP10CF

4- 1

Tools AMP connectors T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

4.2 AMP connectors PT = Power Timer (4,8. 5,8. 6,3 mm) JPT = Junior Power Timer (2,8 mm) MPT = Micro Power Timer (1,5 mm)

Figure

2

1

Number

Application

151080 (PT)

Tools for removing pins/sleeves

213296 (JPT)

Tools for removing pins/sleeves

213298 (MPT)

Tools for removing pins/sleeves

1=163787 2=163788

Tools for fitting sleeves

1=213336 (MPT) 2=213337 (MPT)

1=213336 (JPT) 2=213549 (JPT)

2

4- 2

Tools for fitting pins For 0,5-2,5 mm2

1

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Tools AMP connectors Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

4.2.1 AMP Connectors, 040 series

Figure

© TIEE SARL

Service Manual

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

7LOP10CW, 7LOP10CF

4- 3

Tools AMP connectors T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

4.2.2 AMP connectors CPC

Figure

2

2

4- 4

Number

Application

183593

Tool for removing pins/sleeves

1=213336 2=213338

Tools for fitting sleeves

1=213336 2=213338

Tools for fitting pins

1

1

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Tools Molex connectors Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

4.3 Molex connectors 16 9 8 1 Figure

© TIEE SARL

Service Manual

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

7LOP10CW, 7LOP10CF

4- 5

Tools Grease guns T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

4.4 Grease guns Figure

fif

4- 6

Number

Application

24981

A tool with a pointed nozzle used to apply grease. Length 170 mm.

755132

Single-hand grease gun with straight discharge pipe and nozzle.

755142

Two-hand grease gun with angled discharge pipe and nozzle.

755152

Two-hand grease gun with hose and nozzle.

755146

Grease hose 450 mm.

Grease hose 750 mm.

Grease hose 1500 mm.

202154PM

Pointed nozzle for grease guns used to apply grease in recessed nipples.

Fits grease guns with hose and discharge pipe.

Length 125 mm.

755140

Nozzle for neck nipples. Fits grease guns with hose and discharge pipe.

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Tools Other tools Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

4.5 Other tools Figure

Number

Application

179915

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

1=155619-001 2=166161 3=166473

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

Both cables are included when ordering 155619001

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

4- 7

Tools Other tools T-code 787, 788

Valid from serial number 931876-

Figure

4- 8

Service Manual

Date 2006-04-10

Order number 232370-040

Number

Application

08-13022

Driving gear puller

7LOP10CW, 7LOP10CF

© TIEE SARL

Electric drive motor – 1760 General Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

5- Electric drive motor – 1760 5.1 General The drive motor is integrated with the brake and assembled together with the driving gear to form a complete drive unit.

The drive motor uses an independent excitation design. It consists of a field winding and armature winding, which are separately controlled Armature current is transferred in the conventional manner using carbon brushes (8 pcs.) lying against the armature commutator.

The rotational direction of the motor can be reversed by changing the direction of the field current.

5.2 Mechanical design The motor consists of a housing, in which the stator windings are permanently fixed.

In the bearing box at one end, there is a carbon bridge holding four double, spring-loaded carbon brushes, constituting the motor's commutator end. The carbon brushes rest against the rotor commutator and as such are responsible for feeding rotor current to the rotor windings.

One bearing of the rotor is mounted on the bearing plate at the commutator end.

The rotor bearing at the motor drive end is designed to allow mounting of the bearing on a guide, which, together with the bearing, is pressed onto the rotor axle. The rotor axle is centred following final assembly of the guide in the driving gear housing.

All motor windings are accessible via external connections.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

5- 1

Electric drive motor – 1760 Disassembly of the motor from the truck T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

5.3 Disassembly of the motor from the truck •

Switch off the truck and disconnect the battery connector.

•

Remover the motor compartment cover.

•

Disconnect the motor cables (A).

•

Disassemble the brake (B).

•

Unscrew the five screws holding the motor shield against the motor plate (C).

A

B

C •

Lift out the motor and place it on a clean surface. Cover the driving gear opening.

It is now possible to commence with the necessary service and repairs of the motor.

5.4 Assembly of the motor in the truck

5- 2

•

Assembly is done in reverse.

•

Place a new O-ring on the sealing flange (25) on the drive axle.

•

Carefully lower the motor onto the driving gear while making sure the seals and gear wheels are not damaged.

•

Tighten the five screws holding the motor shield in place against the motor plate to a torque of 45 Nm.

•

Connect the motor cables. Verify that the polarity is correct. Connect the brake.

•

Verify brake operation.

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electric drive motor – 1760 Service and repairs Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

5.5 Service and repairs 5.5.1 Disassembly of the motor 1

2

28

N side

16

29

18

15 30 3 31 4 5

32

6

33 34 17

7

8

9 11 10

19

13

20

21

22 12

23 24 25 26

D side

27 14

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

5- 3

Electric drive motor – 1760 Service and repairs T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

5.5.2 Disassembly, N side • Remove the carbon brushes (8).

• Loosen the screws (1), (2).

• Disassemble the bearing plate (3).

• Disassemble the lock rings (4).

• Disassemble the washer (5).

• Disassemble the ball bearing (6).

Assembly is done in reverse.

5.5.3 Disassembly, D side • Disassemble the lock ring (27).

• Disassemble the ball bearing (26).

• Disassemble the seal (25).

• Disassemble the ring (24).

• Disassemble the hub (23).

• Disassemble the expanding sleev (22).

• Disassemble the fan (20). If necessary, use a slide hammer.

• Disassemble the expanding sleev (22).

Assembly is done in reverse.

5.5.4 Wearing parts The following components constitute parts that wear out and need to be replaced whenever necessary.

• Carbon brushes • Bearing • Bearing • Rotor The bearing plate and carbon bridge are supplied as a single unit from the supplier in order to safeguard the truck speed upon replacing these parts.

5- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electric drive motor – 1760 Service and repairs Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

5.5.5 Cleaning To assure proper truck operation, it is important to keep the motor clean. Make sure the motor and motor compartment are free from dust, oil and other contaminants.

If the motor windings and internal compartments are dry, use a vacuum cleaner with a suitable nozzle to clean the motor. Compressed air may be used in combination with a vacuum cleaner, however, in this case, the compressed air should be clean and dry.

If there are deposits on the windings, use a lint-free rag, if necessary moistened with an organic grease solvent and a volatile cleaning agent that do not damage the windings. However, do not use too much cleaning agent as it will penetrate into the motor parts.

Cleaning agent remains must be removed, using a suitable solvent, if grease deposits are left on the surface.

If the motor components are heavily contaminated, it may be necessary to use a solvent that is sprayed onto the parts. It is especially important for the rotor that the cleaning agent is applied in a manner that avoids contaminants from penetrating into the motor section.

One method to clean the rotor is to submerge it in solvent. If the rotor is cleaned in this way, it should always be dried using warm air. While drying the rotor, make sure the work site is well ventilated. Drying should continue until several measurements of the insulation resistance have been made and the measurements are similar and result in passing results.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

5- 5

Electric drive motor – 1760 Service and repairs T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

This page is intentionally left blank

5- 6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Driving unit/gear – 2550 Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

6- Driving unit/gear – 2550

2 1

18

3 4 5 6

15

10

7

16 17 8

9 14

11 12

13

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

6- 1

Driving unit/gear – 2550 Included components T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

6.1 Included components Pos. Name

6- 2

Notes

1

Motor gear wheel

2

Locking nut

3

Primary gear wheel

4

Tapered roller bearing

5

Shim

6

Shim

7

Tapered roller bearing

8

Tapered roller bearing

9

Locking nut

10

Cover

11

Screw

12

Shim

13

Pinion/crown wheel

14

Drive axle

15

Wheel bolt

Tightening torque 90 Nm Lock using Loctite 270

16

Jointing ring

Fill the jointing ring with grease Seal using Loctite 574

17

Tapered roller bearing

Service Manual

Tightening torque 130 Nm Centre punch to lock

Tightening torque 400 Nm Centre punch to lock

Tightening torque 25 Nm Lock using Loctite 242

Gear play 0.09-0.15 mm.

Pretighten the bearing by 2-5/100.

The punched measure in the pinion should be adjusted using shims.

7LOP10CW, 7LOP10CF

© TIEE SARL

Driving unit/gear – 2550 Disassembly/Assembly Leakage from top cover Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

6.2 Disassembly/Assembly Leakage from top cover • Raise the truck and properly secure it using trestles.

• Unscrew the drive wheel.

• Unscrew the M8 bolts securing the gear unit in the gear cover using a 6 mm Allen key. Hold the gear unit to prevent it from falling down.

Assembly is done in reverse.

• Seal the gear unit against the cover using Loctite 547.

• Tighten the M8 bolts to a torque of 27 Nm.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

6- 3

Driving unit/gear – 2550 Replacing the drive axle jointing ring T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

6.3 Replacing the drive axle jointing ring When replacing the drive axle jointing ring, the gear unit can remain installed on the truck.

If the drive axle leaks oil, follow the instructions below.

6.3.1 Disassembly

7 6 5

2 3

4 • Remove the drive wheel from the gear unit.

• Remove the lower gear cover and drain the oil (2).

• Loosen the drive axle nut. Remove the nut and the spacer ring (3).

• Carefully knock out the drive axle using a brass mandrel and hammer (4).

• Pull out the bearing from the drive axle using the bearing removal tool 08-13022 (5).

• Verify that the bearing plates are free from damage. If the plates have been damaged by the bearing puller, then measure the total thickness of the spacing washers and replace them prior to assembly (6).

• Remove the jointing ring from the drive axle (7).

6- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Driving unit/gear – 2550 Replacing the drive axle jointing ring Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

6.3.2 Assembly Assembly of the gear unit after replacement of the drive axle jointing ring is done in reverse.

Pay special attention to the following during assembly: • Fill the jointing ring with grease after setting it on the drive axle.

• Ensure that only undamaged spacing washers of equal total thickness as the original spacers are set on the drive axle.

• Press on the bearing on the drive axle, making sure not to damage the bearing spacing washers.

• During assembly of the drive axle with attached bearing, spacing washers and jointing ring, make sure the placement of the axle wedges coincide with the crown wheel wedges and that the bearing and jointing ring are properly positioned on the axle prior to pressing the axle into the final position.

• Place the spacer ring on the drive axle end and then screw on the axle nut. Be sure to always use a new nut. Tighten the axle nut to a torque of 400 Nm, and lock it with one centre punch in the middle.

Lubricate the drive axle nut prior to setting it on the axle.

• Replace the O-ring before mounting the lower cover. Make sure it is not damaged. Fit the cover and tighten the bolts to a torque of 25 Nm. Lubricate the bolts prior to mounting. Fill with oil according to the oil filling instructions.

Fit the drive wheel and tighten the wheel nut to a torque of 90 Nm. Lubricate the wheel nut prior to mounting.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

6- 5

Driving unit/gear – 2550 Replacing the wheel bolt T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

6.4 Replacing the wheel bolt The wheel bolts on the gear unit are so-called pin bolts. To replace a wheel bolt, proceed as follows:

• Disconnect the battery connector.

• Lift the machine using a lift jack and properly secure it using trestles and wooden blocks.

• Remove the drive wheel.

• Wheel bolts with damaged threads can be removed using the pin bolt tool.

• Broken wheel bolts: • Method 1: Drill a hole in the centre of the bolt and unscrew the bolt using an M14 bolt removal tool.

• Method 2: If the bolt cannot be removed with the bolt removal tool, then drill it out.

- Make one centre punch in the bolt centre. Pay attention to correct centring of the punch.

- Pre-drill a hole through the bolt using a 5 mm drill steel.

Drill out the bolt using an 11.5 mm drill steel.

- Try to remove the bolt remains using pliers, etc. If this is not possible, remove the bolt remains by cleaning the thread with an M14x1.5 thread tap.

• Apply a string of LOCTITE 270 onto the wheel bolt thread.

Fit the new wheel bolt using the pin bolt tool.

Tightening torque 90 Nm. • Fit the drive wheel. Tighten the wheel nuts to a torque of 90 Nm. • Remove the trestle or wooden blocks and lower the truck to the ground.

• Reconnect the battery connector.

6- 6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electromagnetic brake – 3370 Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

7- Electromagnetic brake – 3370 1 2

3 4 5

12 11 10 9

8

7

6

13 A

A

A-A

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

7- 1

Electromagnetic brake – 3370 Included components T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

7.1 Included components Pos.

Name

Notes

1

Magnet housing

2

Screw

3

Pressure plate

4

Sleeve

5

Shims for air gap adjustment

1 pc. = 0.5 mm 5 pcs. = 0.13 mm in each position

6

Friction plate, brake disc

Nom. thickness: 9.7 mm Min. thickness: 7.7 mm

7

O-ring

8

Hub

9

Mounting plate

10

Screw

3 pcs.

11

Spring

8 pcs.

12

Cable with connector

13

Screw for manual release

3 pcs.

Not included M6

7.2 Disassembly • Loosen the screws (10).

• Lift out the brake assembly from the motor axle.

• Place the brake assembly on a clean surface.

• Gradually unscrew the adjusting screws (2) in order to release the spring tension evenly and little by little.

7.2.1 Inspection Inspect all parts for damage and/or wear.

• Be sure to especially examine the brake disc (6) and the wear surface on the pressure plate (3).

• Inspect the springs (11) and spacers (4,5) for damage.

• Inspect the hub splines (8) and the friction plate splines (6) for damage.

• Inspect the magnet plate (1) and pressure plate (3) for swelling/deformations and other damage.

7- 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electromagnetic brake – 3370 Assembly Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

7.3 Assembly • Carefully clean all parts.

• Assembly of the brake assembly is done in reverse of disassembly.

• Pay attention to the following: - The holes in the pressure plate (3) must be centred with the corresponding holes in the magnet housing.

- The correct number of springs is installed.

- The play is correctly set. Adjustment may be required.

NOTE! The friction surfaces must not come into contact with oil or grease since this will seriously impair braking performance.

13 A

A-A

A

7.4 Manual release of the brake The brake can be manually released, e.g. if the brake is broken and the truck needs to be moved to the service area or to facilitate easier centring of the brake disc during assembly. To release the brake, gradually screw in the two screws (13) evenly.

WARNING! Lost braking function.

Braking does not work when the brake has been manually release.

Drive the truck at reduced speed and be very careful.

Do NOT forget to remove the screws after completed work.

7.5 Adjustment 7.5.1 Adjusting the play 9,5 Nm

0,20-0,38 mm

4 5

• Measure the play in three different positions.

• Adjust the play by removing the shims (5).

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

7- 3

Electromagnetic brake – 3370 Adjustment T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

This page is intentionally left blank

7- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Support wheels – 3500 Main components Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

8- Support wheels – 3500 8.1 Main components 18 17 16 15 14 12

13

11

© TIEE SARL

Pos. no.

Description

11

Screw

12

Washer

13

Mounting axle with plate

14

Bush

15

Washer

16

Bearing

17

Wheel

18

Washer

Service Manual

7LOP10CW, 7LOP10CF

8- 1

Support wheels – 3500 Main components T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

8.1.1 Replacing the wheel Disassembly • Loosen the wheel axle screw (pos 11) and punch out the axle.

• Remove the wheel together with the guards and bearings.

Assembly • Place the guards and bearings on the wheel axle prior to assembly.

• Press the mounting axle through brackets and wheel.

• Fit the screw (pos 11) through the mounting plate and tighten it to a torque of 25 Nm. NOTE! Verify that the wheel does not seize. It should rotate by means of hand power.

8.1.2 Replacing the wheel bearings • Disassemble the wheel from the wheel bracket as explained in the previous section.

• Take out the guard and punch out the first bearing set.

• Turn over the wheel and punch out the second bearing set.

• Press new bearings into place.

• Add grease between the two bearing sets.

• Place the guards.

• Mount the wheel as explained in the previous section.

8- 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical steering system – 4300 General Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

9- Electrical steering system – 4300 9.1 General The electrical steering system consists of the steering unit (A) and steering servo (B). A potentiometer in the steering system sends information to the electronic module in the steering servo system. When starting the truck, a drive reference measurement is performed and the drive wheel position is calibrated using the reference sensor (C).

A

B

C

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

9- 1

Electrical steering system – 4300 General T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

9.1.1 Electrical steering servo The electrical steering servo consists of twin potentiometers connected to an electronic module in the motor compartment. The electronic module, which is also referred to as the EPS (Electrical Power Steering), is directly mounted on a Brush-Less Permanently Magnetised servo motor (BLPM). The motor has a power amplifier that consists of 2-stage planetary gearing with a gear wheel mounted on a trailing journal and locked with a nut. The gear wheel is meshed with the gear ring on the driving wheel gear, and as such the drive unit also handles steering of the truck.

The steering system is electric and uses a "Steer-By-Wire" design. This means there is no mechanical contact between the steering unit and the truck's steering wheel.

The electronic module monitors all electrically connected components.

Monitoring is continuous enabling instant detection of possible cable interruptions. Electrical faults detected in potentiometers, cables and the electronic module result in automatic switch-off of the truck's drive mode and application of the electromechanical brake.

An automatic drive reference measurement is performed at each startup after a no-voltage state. During this calibration, the truck cannot be driven. The drive reference mode safety-checks the system and simultaneously calibrates the wheel position.

Steering is progressive, implying slow-down of the travel speed at large steering angle throws. This promotes safe and efficient truck travel. A certain steering response in the steering unit results in an increasingly greater steering response in the steering wheel. The steering unit is limited to a +/- 60 degree steering response which gives the steering wheel +/-100 degree steering response (drive wheel direction) or +/-90 degree steering response (fork direction).

9- 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical steering system – 4300 Component overview Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

9.2 Component overview 3

2

1

1

4

5 6 7

8 9 10

11 10

12

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

9- 3

Electrical steering system – 4300 Component overview T-code 787, 788

9- 4

Valid from serial number 931876-

Pos.

Name

1

Screw

2

Electronic module

3

Seal

4

Motor

5

Drive

6

Washer

7

Nut

8

Screw

9

Guide

10

Nilos ring

11

Pilot bearing

12

Gear rim

Service Manual

Date 2006-04-10

7LOP10CW, 7LOP10CF

Order number 232370-040

© TIEE SARL

Electrical steering system – 4300 Adjustment Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

9.3 Adjustment 9.3.1 Reference sensor After replacement or adjustment of the reference sensor, screw it all the way down until it makes contact with the top of the gear ring. Then screw it upwards two full turns and lock it with the nut. Calibrate the system using parameters 36 and 37.

9.3.2 Calibration Calibration and adjustment of the steering servo is accomplished using parameters 36 and 37.

Parameter 36 Parameter 36 calibrates the potentiometer and must be adjusted when the following components are replaced: • Complete steering servo assembly or parts of the steering servo assembly • Reference sensor • Potentiometer • Following any work on the steering unit.

Detailed instructions as to the function of parameter 36 are presented in C code 5000.

Parameter 37 Parameter 37 adjusts the drive wheel centre position. The wheel can be adjusted 30 degrees to either side. Prior to adjustment of parameter 37, parameter 36 must be adjusted to ascertain the wheel's zero position.

Detailed instructions as to the function of parameter 37 are presented in C code 5000.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

9- 5

Electrical steering system – 4300 Disassembly/assembly of pushbuttons T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

9.4 Disassembly/assembly of pushbuttons • Disassemble the keypad.

• While taking hold of the top cover, remove the screws.

• Disconnect the cable that is connected to the logic card.

• Remove the screws.

• Carefully lift out the lower cover, while holding a finger between the lower cover and the pushbutton in order to keep the pushbutton in place.

Assembly is done in reverse.

NOTE! Static electricity!

Risk of static discharge that can damage the electronic modules.

Before commencing work on the electronic modules, be sure to take the necessary measures.

9.4.1 Replacing the hornbutton/switch • Disassemble the pushbutton as shown in the picture.

• Disconnect the switch connector on the logic card.

• Press out the switch from its holder.

Assembly is done in reverse.

9- 6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical steering system – 4300 Disassembly/assembly of pushbuttons Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

9.4.2 Replacing the lifting/lowering pushbutton • Remove the pushbutton by inserting a flat screwdriver into the slot (A) as shown in the picture below.

A

A

• Unscrew the holder to loosen the arm.

Assembly is done in reverse.

9.4.3 Replacing the pushbutton • Press out the pushbutton laterally with the fingers.

• Insert a screwdriver in the slot as shown in the picture and carefully pry loose the pushbutton.

• Unscrew the pushbutton holder and arm.

Assembly is done in reverse.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

9- 7

Electrical steering system – 4300 Replacing the potentiometer T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

9.5 Replacing the potentiometer • Disassemble the rear cover (A) where the emergency stop switch is situated.

A

• Undo the connection block (B) from the emergency stop switch by depressing the locking device on the connection block.

B

9- 8

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical steering system – 4300 Replacing the potentiometer Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

• Separate the switch at the Ergo arm (C) and pull the entire cable assembly mount straight up.

T-code 787, 788

C

• Disassemble the pivot covers (D, E) and the keypad.

D

© TIEE SARL

Service Manual

E

7LOP10CW, 7LOP10CF

9- 9

Electrical steering system – 4300 Replacing the potentiometer T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

• Disassemble the top cover and cut off the two bundling cords securing the cable.

NOTE! It is important to place new bundling cords at the same places where the old ones were removed.

• Undo the cable clamp and lift the potentiometer and its cabling straight up.

• Assembly is done in reverse. NOTE! It is important that clamps and bundling cords are placed at the same positions as prior to disassembly. After complete assembly, calibrate the steering using parameters 36 and, if necessary, also parameter 37.

9- 10

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical steering system – 4300 Replacing the inductive brake sensor Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

9.6 Replacing the inductive brake sensor • Disassemble the pivot arm covers (A)

A • Disassemble the keypad and the top cover of the steering unit.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

9- 11

Electrical steering system – 4300 Replacing the inductive brake sensor T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

• Cut off the bundling cords and separate the switch (A).

NOTE! It is important to place new bundling cords at the same places where the old ones were removed.

A

9- 12

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical steering system – 4300 Replacing the inductive brake sensor Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

• Loosen the screw that holds the sensor in place and lift it straight up. The sensor has a guide pin on the rear side.

• Reassemble in reverse.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

9- 13

Electrical steering system – 4300 Replacing the viscous damper T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

9.7 Replacing the viscous damper • Disassemble the pivot arm covers (A)

A • Disassemble the cable camp and the pivot arm covers, and loosen the 4 screws (B)

B

9- 14

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical steering system – 4300 Replacing the viscous damper Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

• Loosen the screws that hold the ring in place and gently pry loose the steering head.

The steering head can then be slanted across the motor compartment.

• Remove the screws of the viscous damper and the spacer.

• Assembly is done in reverse.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

9- 15

Electrical steering system – 4300 Replacing the viscous damper T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

This page is intentionally left blank

9- 16

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 General Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

10- Electrical systems – 5000 Software: 231614-001 and later versions.

10.1 General The electrical system of the truck is based on the PowerDrive platform.

• The main power source is a 24 V DC traction battery.

• The travel drive motor is a separate excitation type (SEM) . The travel drive motor is operated by an enclosed transistor regulator relying on pulse width modulation (PWM) technology. The transistor regulator also controls the input and output signals for truck travel and lifting operations.

• The lift unit motor is a conventional DC motor without any external field winding connections. Switch-on of the hydraulic unit's electric motor is achieved using a contactor.

• The truck also features electric power steering. The power steering servo and the motor have been integrated as one unit directly onto the driving gear mounting plate.

• All electric units communicate via a CAN bus with an IC card in the steering unit handle. This card contains a processor and software that controls and monitors truck functions. A set of parameters used to adjust truck functions and characteristics is stored in the card. The card also monitors error conditions that may occur.

10.1.1 Software/hardware order numbers • Press and hold the horn button [S18], enter a valid PIN-code and then press

on the keypad [A17].

• Keep [S18] depressed until displayed.

= the part number is

By scrolling with L1 you can get the following information:

• Software part number

• Hardware part number

• Hardware serial number

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 1

Electrical systems – 5000 General T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

10.1.2 Nomenclature Items shown in square brackets [ ] refer to electric component designations as stated in the electrical wiring diagrams. See “10.2.1 Electric component overview” on page 5. {high} refers to a voltage level that is approximately the same as the supply voltage level. {low} refers to a voltage level of approximately 0 Volt.

10- 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Electrical equipment overview Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

10.2 Electrical equipment overview B10 M3

B11

Y10

Y45

P1

Y69 Y10

Y1 M1 S65 S19

G1 X1

A36

R1 X41 K30

X1 A5 M6 A1 S45

F50 F51 F52

S32 H1 F1 F3

K10

S33

S31:1 S31:2

S32

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 3

Electrical systems – 5000 Electrical equipment overview T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

A17

A6

S18:1

S18:2

A2

A2:S20 A2:S19

A2:S22 A2:S21 L1

S10

R2

S21

10- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Electrical equipment overview Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

10.2.1 Electric component overview The following table shows a summary of the major electric components of this truck.

Table 7: Component designation overview Designation

Function

Description

Associated signal names

Inf .

Energy and main power isolation G1

Main electrical power source

Traction battery 24 V

X1

Battery connection / isolation

Connector

K10

Main contactor

Contactor

A1:OUT MAIN CONTACTOR

Equipment protection F1

Drive motor protection

Fuse 160 A

F3

Pump motor protection

Fuse 125 A

F 50

Operating circuit protection A5, A2

Fuse 3A

F 51

Operating circuit protection A1

Fuse 7,5 A

F 52

Steer servo motor protection

Fuse 30 A

A5:INPUT ENABLE B+

A5:POWER SUPPLY 24VDC

Control and Signal processing A1

Lift, traction and peripherals power control

Transistor regulator

A2

Control of truck functions

Electronic card

1

A5

Steering servo

Electronic card

2

A6

Display of truck functions

Display unit

1

A17

PIN login and data entry

Keypad

1

A36

Expansion unit “SEU”

Logic card

Safety and braking S21

Emergency switch-off

Switch

A1:INP.SUPPLY 24VDC

S10

Activation of mechanical brake

Inductive sensor

A1:OUT.BRAKE A

7

Y1

Mechanical brake

Electromagnetic brake

A1:OUT.BRAKE A

7

H1

Audible warning signal -Horn

Horn

A1:OUT.SIGNAL HORN

S18:1

Horn activation

Switch

A2:INP.HORN1

4

S18:2

Horn activation

Switch

A2:INP.HORN2

4

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 5

Electrical systems – 5000 Electrical equipment overview T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 7: Component designation overview Designation

Function

Description

Associated signal names

Inf .

L1

Speed control and travel direction selector (butterfly)

Hall sensors

S19

Man on platform supervision

Inductive proximity switch

A1:INP.DRIVER ON PLATFORM

7

S31:1

Speed reduction above 500 mm cabin height Speed reduction above 500 mm cabin height

double magnet switch

A1:INP.CABIN > 500mm (A) A1:INP. CABIN > 500mm (B)

7

Truck traction

Motor

R2

Steering angle signal

Potentiometer

A5:INP.IN0 , INP.IN1

S65

Drive wheel in centre reference

Inductive proximity switch

A5:INP.REFERENCE SWITCH

M6

Drive wheel steering

Motor

2

Traction

S31:2 M1

6, 7

Steering

Cabin / Forks lifting A2:S19

Cabin lifting control

Hall sensor

5, 7

A2:S20

Cabin lowering control

Hall sensor

5, 7

A2:S21

Initial forks lifting control hydraulic control

Hall sensor

5, 7

A2:S22

Initial forks lowering control hydraulic control

Hall sensor

5, 7

Y10

Cabin/fork lowering -hydraulic control

Magnetic valve

A1:OUT.LOWER VALVE

Y45

Lift/lower Cabin - hydraulic control

Soft closing magnetic valve

A1:OUT.CABIN LIFT/ LOWER VALVE

Y69

Lift/lower initial forks - hydraulic control

Soft closing magnetic valve

A36:OUT.INITIAL FORKS LIFT LOWER VALVE

S32

Pallet to ground protection or feed protection

singel magnet switch

A1: INP. CABIN/FORKS LOWER THAN < 100mm

3, 7

S33

Cabin in top position

Magnet switch

A1:INP.CABIN IN TOP POSITION

7

S45

Initial forks in top position

Magnet switch

A36:INP. INITIAL FORKS LIFT LIMIT

7

B10

Cabin Load supervision

Pressure sensor

A1:INP.PRESSURE SENSOR CABIN LIFT

7

B11

Initial forks load supervision

Pressure sensor

A36:INP. PRESSURE SENSOR INITIAL FORKS

7

10- 6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Electrical equipment overview Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 7: Component designation overview Designation

Function

Description

Associated signal names

K30

Fork lifting (Pump motor power switching)

Contactor

A1:OUT PUMP CONTACTOR

M3

Hydraulic pressure

Motor

R1

Power supply

PTC-resistor 15 Ohm

S1-6

Options

Switch

X41

CAN communication (external)

Connection point

Inf .

Other

3

Footnotes to the table above: 1. Situated in the tiller unit and communicates via the CAN bus 2. The steering servo controller, servo motor and mechanics are integrated into one single unit.

3. Optional function 4. S18:1 represents the left side button and S18:2 represents the right side button.

5.These inputs signals are processed directly via Hall effect sensors mounted on the A2 card and are handled via the CAN bus.

6. Speed control signals from L1 are processed by Hall element sensors mounted on the A2 card. Sensors A2:S1-9 control speed control signals for driving in fork direction. Sensors A2:S10-18 control speed control signals for driving in drive wheel direction.

7. Signals to/ from these elements can be checked via the Built-in Test function. See “10.6.5 Built-in Test Function” on page 73

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 7

Electrical systems – 5000 Electrical wiring diagram T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

10.3 Electrical wiring diagram 10.3.1 Symbol list Table 8: Symbol list Symbol

A1

E1

M S

Description

Symbol

Description

Truck battery

Horn

Fuse

Emergency stop switch NC

Resistor (PTC)1

Switch, weight pressure operated

DC motor 2(SEM type)3

Sensor, inductive NO

DC motor

Sensor, inductive NC

Contactor

Variable resistor (potentiometer)

Brake coil (normally applied)

Pressure switch NO

Coil for hydraulic magnetic valve

Multi-pin connector

A2

E2

Analogue pressure sensor P

NO = Normally Open NC = Normally closed

1. PTC = Positive Temperature Coefficient (resistance increases as temperature increases) 2. DC = Direct Current 3. SEM = Separately Excited Motor 10- 8

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Electrical wiring diagram Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

10.3.2 Overview 3 24 (+) POWER 24VDC 40 (J2-16) SUPPLY 24VDC (-) POWER 0VDC B10 P

S19

63 65 57

S10

S32

47

S31 S31 S218 74 S217 71 S215 70

S220 S221 73 S222

F3

K10

10

K30

M3 M Y10

38

LOWER VALVE (J2-2)

40

(J2-3) CABIN IN TOP POS. Y1

31

BRAKE; A (J2-5) (J2-13) CABIN<0,1M

F51 K30

45 PUMP CONTACTOR (J2-6) 48 (J2-14) CABIN<0,5M 39 SIGNAL HORN (J2-7) 88 49 (J2-15) CABIN<0,5M CABIN LIFT/LOWER (J2-9) (J2-1/J2-8) CAN H/L 119/120

H1

X1

SERVICE CAN CONNECTOR X41

(27/42) CAN

(33)AUX SW; GO/WALK

G1 AUX CAN CONNECTOR

(20)AUX SW; LIFT FORKS

F50

X29

X1 40 F52

(6)AUX SW; LOWER FORKS

A36

STEER R2 ANGLE SENSOR

20 23 (6) (8/16) (2/10) CAN H/L ENABLE +24V

91/93/92/94 (4/13/5/14) 95 (3) +12V A5 96 (11) REF. 40 (7/15) 0V (12) 0V S65 97

72 (20)AUX SW; LIFT FORKS (6)AUX SW; LOWER FORKS

(X3:3/7) CAN 20 (X3:6) +24VDC 40 (X3:2) 0VDC

OPTION BACKREST BUTTONS 24 (1)+24VDC 40 (29)0VDC

P

85 S45

M M6

A2:S19

Hall A2:S20

(X1:1) HORN 2 (X4:1) HORN 1 163

S21

24

Y45

(34)AUX SW; STOP

B11

21 K10

64

(J2-12) TILLER ARM MAIN CONTACTOR (J2-4) IN DRIVE POSITION

R1

E1

(J2-11) DRIVER ON PLATFORM

71

73

S

5

FIELD (S2)

(34)AUX SW; STOP OPTION SIDE BUTTONS S218

M

2

F1

A1

-

S219 72

E2

M1

+

S216

4

(J2-10) CABIN LIFT

A1 46

A2

FIELD (S1)

24 S33

ARMATURE (M) 6

INITIAL FORKS LIFT/ 89 LOWER (16) (11)INITIAL FORKS (19)INITIAL FORKS LIFT LIMIT

S18:2 S18:1

KEYBOARD A17

A2 (X4:2) (X1:2)

Hall A2:S22

Hall

A2:S1-S9 A2:S10-S18

Hall

DISPLAY A6

A2:S21

(X11)

Y69 INITIAL LIFT

Hall

Hall

(X12)

(X1)

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 9

10- 10

Service Manual

1

30A F52

7,5A F51

2

3

1

S

+

H1

-

K10 A1 A2

4

2

PTC 15~E

R1 2

3

125A F3

160A F1

9 2

1

K30 A1 A2

24V G1 + X1

10

4

A1

2

Y45 1 2

1

Y1

Y10 1 2

M

M3 A2

PUMP MOTOR

4

5

5

E1

A1

S

M

M1

E2

A2

DRIVE MOTOR

6

6

7LOP10CW, 7LOP10CF 88

39

45

31

64

38

5

4

6

3

40

J2-9

J2-7

J2-6

J2-5

J2-4

J2-2

S2

S1

M

+

-

7

OUT. CABIN LIFT/LOWER

OUT. SIGNAL HORN

OUT. PUMP CONTACTOR

OUT. BRAKE; A

OUT. MAIN CONTACTOR

OUT. LOWER VALVE

OUT. FIELD

OUT. FIELD

OUT. ARMATURE

INP. POWER SUPPLY +24V DC

INP. POWER SUPPLY, 0V DC

TRANSISTOR REGULATOR A1

7

8

1 / 9 PROD A 217972

8

F

E

D

C

B

A

Date 2006-04-10

F

24

40

23

21

1

20

X1

3

Valid from serial number 931876-

E

D

Sh. 2

Sh. 2

Sh. 3

Sh. 2

Sh. 2

Sh. 3

3A F50

2

T-code 787, 788

C

B

A

1

Electrical systems – 5000

Electrical wiring diagram Order number 232370-040

10.3.3 Detailed wiring diagram

© TIEE SARL

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

F

1

Sh. 1

Sh. 1 3

Sh. 1 5

Sh. 3

Sh. 1

Sh. 3

1

X20

X80

F

X81

X27

2

3

EMERGENCY SWITCH OFF S21 21 22

EXTERNAL EQUIPMENT

40

24

120

21

119

3

X20

X27

X27

X80

X81

X81

X80

X27

X20

4

4

1

2

S31

4

3

X22

X22 1

B

24

B10

S33

S10

A

P

1 2

5

2

C

5

X22

1

1

S19

S32

X27

2

X81

2

X81

X80

X81

6

X80

X20

X80

6

J2-15

J2-16

24

J2-14

J2-13

J2-12

J2-11

49

48

47

57

65

J2-10

J2-8

120

63

J2-3

J2-1

46

119

7

7

INP. SUPPLY +24V DC

INP. CABIN < 500mm(B)

INP. CABIN < 500mm(A)

INP. CABIN < 100mm

INP. TILLER ARM IN DRIVE POS.

INP. DRIVER ON PLATFORM

8

8

2 / 9 PROD A 217972

INP. PRESSURE SENSOR, CABIN LIFT

CAN LOW

INP. CABIN IN TOP POSITION

CAN HIGH

TRANSISTOR REGULATOR A1

F

E

D

C

B

A

Valid from serial number 931876-

E

D

C

B

A

2

Date 2006-04-10

3

Order number 232370-040

3

1

Electrical systems – 5000 Electrical wiring diagram

T-code 787, 788

10- 11

Service Manual

7LOP10CW, 7LOP10CF

1

Sh. 1 5

Sh. 2 4

Sh. 2 4

20

120

119

23

2

1

3

S65 2

R2, STEER ANGLE SENSOR

4

R2:A

4

R2:B X22

5

X28

X28

X28

X22

X22

X28

X22

5

X81

X81

X81

X81

X80

X80

X80

X80

X21

X21

X21

X21

6

6

15

8

40

23

20

97

6

12

11

3

95

96

14

13

5

94

93

92

4

10

120

91

2

119

16

7

40

23

7

7

INP. ENABLE(B+)

OUT. SUPPLY 0V DC

INP. REFERENCE SWITCH

OUT. SUPPLY +12V DC

OUT. SUPPLY 0V DC

INP. A_IN1

INP. A_IN0

OUT. SUPPLY +5V DC

CAN LOW

CAN HIGH

POWER SUPPLY +24V DC

POWER SUPPLY +24V DC

POWER SUPPLY 0V DC

POWER SUPPLY OV DC

ELECTRONIC ASSY; STEER SERVO A5

M

M6

8

3 / 9 PROD A 217972

8

F

E

D

C

B

A

Date 2006-04-10

F

E

D

C

B

Sh. 1

40

RD BU

Sh. 2 4

3

WH

A

2

Valid from serial number 931876-

3

BU

10- 12 GN

T-code 787, 788

RD

1

Electrical systems – 5000

Electrical wiring diagram Order number 232370-040

© TIEE SARL

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

1

2

1

S45

X20

2

3

X29

X81

X103

X103

X80 X100

4

P

5

Y69 1 2

X29

X29

X103

X103

6

120

119

40

85

89

163

24

42

27

29

19

16

11

1

7

CAN LOW

CAN HIGH

POWER SUPPLY 0VDC

INP. INITIAL FORKS, LIFT LIMIT

4 / 9 PROD A 217972

OUT. INITIAL FORKS, LIFT/LOWER VALVE

INP. PRESSURE SENSOR, INITIAL FORKS

POWER SUPPLY 24VDC

8

D

C

B

A

8

F

X80

ELECTRONIC ASSY; "SPIDER" A36

7

F

X81

6

E

120

119

X29

X27

5

TRUCK WITH INITIAL LIFT

4

Valid from serial number 931876-

E

Sh. 3 5

Sh. 3 5

40

24

3

Date 2006-04-10

D

C

Sh. 3 5

Sh. 2 8

2

Order number 232370-040

B

A

1

Electrical systems – 5000 Electrical wiring diagram

T-code 787, 788

10- 13

10- 14

Service Manual

119

120

3

4

7LOP10CW, 7LOP10CF

1

40

119

120

3

4

24

2

1

2

3

4

X21

X21

X20

X20

4

X80

X80

X80

X80

X81

X81

X81

X81

X28

X28

X27

X27

X22

X22

X22

X22

5

5

6

6

120

119

40

20

CAN LOW

CAN HIGH

INP. OV DC

INP. +24V DC

A2:S20

A2:S19

A2:S22

A2:S21

7

A2:S1-S9 A2:S10-S18

X3:3

X3:7

X3:2

X3:6

8

8

5 / 9 PROD A 217972

FORK LOWER

FORK LIFT

MAN LOWER

MAN LIFT

SPEED REF. VALUE

ELECTRONIC CARD STEERING UNIT A2

7

F

E

D

C

B

A

Date 2006-04-10

F

24

40

2

CAN, AUX CONNECTOR X29

Sh. 1

20

1

3

Valid from serial number 931876-

E

D

120

119

40

20

CAN, SERVICE CONNECTOR X41

Sh. 4

Sh. 4

Sh. 4

Sh. 3

2

T-code 787, 788

C

B

A

1

Electrical systems – 5000

Electrical wiring diagram Order number 232370-040

© TIEE SARL

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

2

3

4

5

6

7

6 / 9 PROD A 217972

8

F

OUT. 0V DC HORN 2 X1 2

D

C

B

A

F

INP. HORN 2 X1 1

OUT. OV DC HORN 1

8

E

S18:2 1 2

X4 2

INP. HORN 1

0V DC

X12 6

X1 6

X4 1

LCLK

ENABLE

X12 5

X12 4

X1 5

X1 4

SCK

SI

X12 2

X1 2

X12 3

+5V DC

X1 3

7

ELECTRONIC CARD STEERING UNIT A2

6

Valid from serial number 931876-

E

1

5

X12 1

S18:1 1 2

4

X1 1

3

Date 2006-04-10

D

C

8 8 8 8

DISPLAY A6

2

Order number 232370-040

B

A

1

Electrical systems – 5000 Electrical wiring diagram

T-code 787, 788

10- 15

10- 16

Service Manual

1

2

I

9

6

3

3

4

4

5

5

7

369#

X11 3

LED_RED X11 9

7LOP10CW, 7LOP10CF 6

X11 10 0V DC

LED_GREEN

-0#

789

456

X11 8

X11 7

X11 6

X11 5

123

2580

X11 2

X11 4

147-

X11 1

7

ELECTRONIC CARD STEERING UNIT A2

6

8

7 / 9 PROD A 217972

8

F

E

D

C

B

A

Date 2006-04-10

F

8

8

0

5

4

O

2

1

3

Valid from serial number 931876-

E

D

KEY BOARD A17

2

T-code 787, 788

C

B

A

1

Electrical systems – 5000

Electrical wiring diagram Order number 232370-040

© TIEE SARL

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF 3

4

5

X102 X81

X102 X81

X102 X81

X102 X81

6

X80 X100

X80 X100

X80 X100

X80 X100

71

73

72

70

34

6

20

33

7

AUX SWITCH; "STOP"

AUX SWITCH; "LOWER FORKS"

AUX SWITCH; "LIFT FORKS"

AUX SWITCH "GO/WALK"

8 / 9 PROD A 217972

8

D

C

B

A

8

F

2

X105

X104

X105

RIGHT; "LOWER" S222 X104 3 4

LEFT; "LOWER" S221 3 4

RIGHT; "LIFT" S220 3 4

LEFT; "LIFT" S219 3 4

RIGHT; "GO/WALK" S216 X104 3 4

X105

ELECTRONIC ASSY; "SPIDER" A36

7

F

X104

71

LEFT; "GO/WALK" S215 3 4

6

E

1

5

OPTION; SIDE BUTTONS

4

Valid from serial number 931876-

E

74

LEFT; "STOP" X105 S217 X105 1 2

3

Date 2006-04-10

D

C

Sh. 4

RIGHT; "STOP" X102 X104 S218 X104 1 2 24

2

Order number 232370-040

B

A

1

Electrical systems – 5000 Electrical wiring diagram

T-code 787, 788

10- 17

10- 18

24

Service Manual 3

4

LEFT; "LOWER" S221 3 4

5

X101 X81

X101 X81

X101 X81

71

73

72

34

6

20

7

AUX SWITCH; "STOP"

AUX SWITCH; "LOWER FORKS"

AUX SWITCH "LIFT FORKS"

9 / 9 PROD A 217972

8

C

B

A

7LOP10CW, 7LOP10CF

8

Date 2006-04-10

F

Valid from serial number 931876-

F

6

X80 X100

X80 X100

X80 X100

ELECTRONIC ASSY; "SPIDER" A36

7

E

75

LEFT; "LIFT" S219 3 4

6

E

2

5

OPTION; BACKREST BUTTONS

4

D

71

RIGHT; "DEADMAN" S101 3 4

3

D

1

Sh. 4

RIGHT; "STOP" X101 S218 1 2

2

T-code 787, 788

C

B

A

1

Electrical systems – 5000

Electrical wiring diagram Order number 232370-040

© TIEE SARL

Electrical systems – 5000 Functional description Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

10.4 Functional description means constantly on

means flashing.

This section gives basic electrical descriptions of the truck’s main functions in tabular form. It describes, in simple terms, what happens when performing any of the truck’s main operations.

• Event - The main stages in performing any of the truck’s main functions are referred to as “Events”. Each event is numbered.

• Prior events - Indicates the event number which must have taken place immediately before in order for current event function correctly.

• Action(s) - A required action from the operator for the event to occur.

• Influencing elements - conditions which must be fulfilled in order for the event to occur. Certain parameter settings may also affect the outcome of the event.

• Resulting conditions - Describes key occurrences which can be checked to confirm operation.

Note that “resulting conditions” show what is expected when no error conditions are present.

Table 9: Functional description Event:

1. Battery connected

Action(s)

Connect the traction battery [X1, G1]

Influencing elements

Main power fuses ok [F1, F3] Operating circuit fuses ok [F50, F51, F52] PTC resistor ok [R1]

Resulting conditions

Curtis status LED blinks once every 5 seconds.[A1]

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 19

Electrical systems – 5000 Functional description T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 9: Functional description Event:

2. Switch on (PIN-code entry)

Prior event(s)

1

Action(s) Enter valid PIN-code and press

Influencing elements

Emergency switch-off closed [S21] Brake switch open [S10]

Resulting conditions

Power lamp and

[A17]

lights. Main display shows hour meter reading for 4 seconds followed by battery condition as a

percentage of full charge and

[A6]

Mechanical brake remains on [Y1, A1:OUT.BRAKE A high]

Event:

3. Tiller unit lowered for driving

Prior event(s)

2

Action(s)

Lower tiller unit handle

Influencing elements

Man-on platform switch [S19]

Resulting conditions

Brake switch closes [S10].

Main contactor ouput goes low [A1:OUT.MAIN CONTACTOR] Main contactor closes [K10]

Event:

4. Traction, forks first

Prior event(s)

3

Action(s)

Move butterfly [L1]in forks drive direction.

Influencing elements

Butterfly Hall sensors [A2:S1-9] Man-on platform switch [S19] Cabin load supervision sensor [B10] Cabin under 0.5 meter S31 [A1:INP.CABIN < 500 mm(A) and INP. CABIN < 500mm(B)].

Steering angle, Parameter settings. See “10.4.3 Speed limitation” on page 26

Resulting conditions

[A1:OUT.BRAKE A] goes low Brake coil [Y1] energises, mechanical brake releases Current fed to traction motor field winding (S2 +ve and S1 -ve) Pulsed current fed to traction motor armature proportional to butterfly deflection When S31 is activated [A1:INP.CABIN > 500 mm(A) and INP. CABIN > 500mm(B)] the truck goes to speed 6 km/h

10- 20

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Functional description Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 9: Functional description Event:

5. Traction, drive wheel first

Prior event(s)

3

Action(s)

Move butterfly [L1]in drive wheel drive direction.

Influencing elements

Butterfly Hall sensors [A2:S10-18] Man-on platform switch [S19] or [B11] initial.

Cabin load supervision sensor [B10], Steering angle, Parameter settings See “10.4.3 Speed limitation” on page 26 Cabin above 500mm S31 [A1:INP.CABIN >500 mm(A) and INP. CABIN > 500mm(B).

Resulting conditions

[A1:OUT.BRAKE A] goes low Brake coil [Y1] energises, mechanical brake releases Current fed to traction motor field winding (S2 -ve and S1 +ve) Pulsed current fed to traction motor armature proportional to butterfly deflection When S31 is activated [A1:INP.CABIN > 500 mm(A) and INP. CABIN > 500mm(B)] the truck goes to speed 6 km/h

Event:

6. Neutral braking

Prior event(s)

4 or 5

Action(s)

Let butterfly [L1] return to neutral position.

Influencing elements

Man-on platform switch [S19] Fork load supervision sensor [B10] or [B11] initial Parameter settings

Resulting conditions

Traction motor [M1] acts as generator and via transistor controller [A1] converts the trucks energy of motion into electrical energy thus reducing the truck’s speed. The excess electrical energy is fed back to the battery helping to recharge it [G1].The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes to a complete stand still

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 21

Electrical systems – 5000 Functional description T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 9: Functional description Event:

7. Reverse braking

Prior event(s)

4 or 5

Action(s)

Move butterfly [L1] so as to reverse the direction of travel

Influencing elements

Man-on platform switch [S19] Fork load supervision sensor [B10] or [B11] initial.

Parameter settings

Resulting conditions

Traction motor [M1] acts as generator and via transistor controller [A1] converts the trucks energy of motion into electrical energy thus reducing the truck’s speed. The excess electrical energy is fed back to the battery helping to recharge it [G1]. The braking effect increases the more the butterfly is deflected The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes to a complete stand still

Event:

8. Mechanical brake operation

Prior event(s)

4 or 5

Action(s)

Move tiller unit handle to upper position

Influencing elements

Brake switch opens [S10]

Resulting conditions

The mechanical brake [Y1, A1:OUT.BRAKE A] activates

Event:

9. Steering

Prior event(s)

2

Action(s)

Steer tiller unit handle to left or right

Influencing elements

Steering angle potentiometer [R2] Steering reference switch [S65, A5:INP.REFERENCE SWITCH] Man on platform switch [S19, A1:INP.DRIVER ON PLATFORM]

Resulting conditions

Steer servo motor positions drive wheel according to tiller handle’s deflection [A5, M6] (See section “10.4.1 Description of steering system”.)

10- 22

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Functional description Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 9: Functional description Event:

10. Cabin lifting

Prior event(s)

2

Action(s)

Press the lift cabin button

Influencing elements

Cabin lift button [A2:S19] Battery status ok (>20% charge left) Lift height limit S33 [A1:INP.CABIN IN TOP POSITION] not activated

Resulting conditions

[A1:OUT.PUMP CONTACTOR] goes low [A1:OUT.CABIN LIFT/LOWER] goes low Cabin hydraulic soft closing valve [Y45] activates.

Pump contactor [K30] activates Pump motor [M3] starts

Event:

11. Cabin lowering

Prior event(s)

2

Action(s)

Press the lower cabin button

Influencing elements

Cabin lower button [A2:S20] Lift height < 0,1 m, S32 [A1:INP. CABIN/FORKS LOWER THAN 100mm] activated

Resulting conditions

[A1:OUT.LOWER VALVE] goes low [A1:OUT.CABIN LIFT/LOWER] goes low Cabin lowering hydraulic valve [Y10] activates.

Cabin hydraulic soft closing valve [Y45] activates.

When S32 [A1: INP. CABIN/FORKS LOWER THAN 100mm] is not activated, pallet to ground protection or footprotection is active.

Event:

12. Initial forks lifting

Prior event(s)

2

Action(s)

Press the lift forks button

Influencing elements

Fork lift button [A2:S21] Battery status ok (>20% charge left) Lift height limit S45[A36:INP.INITIAL FORKS LIFT LIMIT] not activated

Resulting conditions

[A1:OUT.PUMP CONTACTOR] goes low [A36:OUT.INITIAL FORKS SOFT CLOSING VALVE] goes low Forks hydraulic soft closing valve [Y69] activates.

Pump contactor [K30] activates Pump motor [M3] starts

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 23

Electrical systems – 5000 Functional description T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 9: Functional description Event:

13. Initial forks lowering

Prior event(s)

2

Action(s)

Press the lower forks button

Influencing elements

Forks lower button [A2:S22] Lift height < 100mm, S32 [A1:INP. CABIN/FORKS LOWER THAN 100mm] activated (option)

Resulting conditions

[A1:OUT.LOWER VALVE] goes low [A36:OUT.INITIAL FORKS SOFT CLOSING VALVE] goes low Forks lowering hydraulic valve [Y10] activates.

Cabin hydraulic soft closing valve [Y69] activates.

When S32 [A1: INP. CABIN/FORKS LOWER THAN 100mm] is not activated, pallet to ground protection or footprotection is active. (option)

10.4.1 Description of steering system The servo steering system on this truck comprises a synchronous DC motor (M6) with permanently magnetized rotor which is also brushless.

This type of motor is ideal for truck steering applications due to light weight and high torque even from stand still. The motor directly drives the drive wheel gear unit, via an integrated 2 stage planetary gear. The steer motor is controlled by a fully electronic 4-quadrant regulator (A5) which is mounted directly in the servo motor casing. Hall sensors (H) in the servo motor provide timing information for commutation control.

The sensors also provide the steer servo with position information. A double potentiometer (R2) mounted in the tiller unit provides steer angle information from the operator. Every time the traction battery is connected and the truck switched on the steer system performs a reference search for "straight ahead" position. An inductive proximity switch (S65) mounted in the final drive gear mounting plate registers a change in state (either ON to OFF or OFF to ON depending on drive wheel's initial position) and feeds this signal back to the steer servo. From this point on, the steer servo "knows" the position of the drive wheel. Only efter the traction battery is next disconnected, is a new reference search carried out. The steer servo communicates fully via the CAN bus. All steer servo errors codes are transmitted to the truck's control system and displayed on the tiller unit's display.

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10.4.2 Spider expansion unit (SEU) The Spider expansion unit, referred to as the SEU, allows the main control card to handle a greater number of inputs and outputs. The SEU allows up to 8 extra digital inputs and 4 digital outputs which can be addressed and controlled via the CAN bus. The SEU contains firmware but this is only for internal configuration. No truck control logic is present in the SEU. This means a faulty SEU can be exchanged without affecting the truck’s functions in any way.

There are 3 cases covering the usage of SEU: a) The SEU can be fitted if the truck is modified according to a customer special request. In this case, correct operation of the modification is acheived by adjustment of service parameters 16 to 19. b) The SEU is fitted as standard in certain truck models, to allow control of standard features. Such trucks do not require that service parameters 16 to 19 be activated. (Parameters 16 to 19 shall be set to “0”.) c) Trucks fitted with an SEU as standard can also have additional modifications using “configurable options”. These additional modifications are controlled by the setting of service parameters 16 to 19.

Refer to section Parameter #16 to #19 configurable options on page 51 for more detailed information. .

A2 Electronic card TLS

A3 Pump controller

Extra / Customised function(s)

CAN bus

A5 Steer servo

A36 SEU

X41 CAN service connector

A1 Traction controller

Fig. 1 Connection architecture for SEU

Fig. 1 shows how the SEU is used to allow a greater number of functions to be controlled via the CAN bus. The SEU has one 42-pin multipin connector which handles all inputs, outputs, CAN and supply signals. © TIEE SARL

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10.4.3 Speed limitation The truck's maximum travel speed is limited depending on a combination of factors, i.e. direction of travel, load, load lift height, steering angle, the operator's driving position and the platform height. Operator parameter settings also affect maximum speed. See Description of operator parameters on page 37 for more information. The table below summarises the speed limitations and assumes that all relevant operator parameters are set to 100%. Note that the speeds given are nominal.

Table 10: Summary of speed limitations Platform height

Operator position and load (kg)

Steer angle degrees

On platform & 0 kg load

Maximum speed km/h 7LOP10CW

Inf. 7LOP10CF

In drive wheel direction

In forks direction

In drive wheel direction

In forks direction

0

12

10,5

12

10,5

15

10,3

9

10,3

9

25

9,6

8,4

9,6

8,4

60

7,3

6

7,3

6

85

7

6

7

6

On platform and >0 to maximum load

0

12 - 8

10,5 - 6

12 - 7

10,5 - 6

> 0.5 m

On platform

0 to 100

6

6

6

6

2,3

< 0.5 m

By side of truck and 0 to maximum load

0 to 10

6

6

6

6

1

20 to 30

2,5

2,5

2,5

2,5

>30

0

0

0

0

By side of truck and 0 to maximum load

-

0

0

0

0

< 0.5 m

> 0.5 m

1. In this position,

is displayed.

2. In this position,

is displayed.

3. If the operator is not standing on the platform in this position,

is displayed. Neither lifting nor truck travel can be operated in this case.

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10.4.4 Hour meter and battery condition At switch on, the hour meter is displayed and the hour meter symbol lights for 4 seconds. Fig. 2.

Fig. 2

The display will then change to show the battery’s remaining capacity expressed as a percentage of full charge and the battery symbol lights.

Fig. 3.

The truck’s control system stores 5 different elapsed time values in units of hours. The time value normally shown depends on the setting of service parameter #20. (See “ # 20 - Hour meter selection” on page 43). However, any of these time values can be temporarily displayed on the hour meter. To choose which value to display carry out the following procedure:

Fig. 3

• Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold S18 depressed until “H” is displayed, then release S18. Fig. 4

Fig. 4

Hourmeter symbol lights.

The different hourmeter modes are displayed by repeatedly operating speed control L1. The actual time value will be displayed momentarily after the mode is selected.

Table 11: Hour meter modes Description

Display

Key time: Total time truck has been switched on Activity time: Combined time either pump or drive motor has been in operation (Default display mode) Drive motor time: Total time drive motor has been in operation Pump motor time: Total time pump motor has been in operation.

Remaining time to next service (Parameter #25 controls the initial value) See “ # 25 - Service interval” on page 45 for more information.

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10.4.5 TLS - Truck log system (optional) General The truck log system, which is CAN based, is either an integrated system (SD16) or a freestanding supplementary system (S16). A collision sensor can also be connected.

The TLS communicates wirelessly with a base station (RG3) once the truck is within range. The base station then receives information on what the truck has done since they last communicated with one another.

PC

Built-in system

A2 Electronic card

RG3

TLS SD16 CAN bus

CAN bus

Add-on system

Shock sensor

A1 Traction controller

TLS S16

Shock sensor

I/O-unit

Registration To register the truck with the base station, follow the instructions below: • Position the truck close to the base station.

• Press and hold the green button for approx. 5-10 seconds until three LEDs on the base station start flashing at the same time.

The base station can now communicate with the truck whenever it is within range.

Logging in/out SD16 Logging in and out is performed as usual via the keyboard on the handle (or by using an ID unit). The difference is that communication passes through the TLS, which makes all the decisions.

Logging in/out S16 Logging in and out is performed using the keyboard on the TLS. 10- 28

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Collision sensor If there is a collision sensor installed on the CAN bus, it registers when the truck bumps into something. If the impact exceeds a certain level, it is classified as a collision and the truck comes to a halt. It can be reset by entering the PIN code for “resetting the collision sensor” (see table below).

Settings Additional equipment (software and wiring) from Davis Derby is required to change the TLS settings.

Table 12: Settings TLS Function

Description

Default setting

PIN code

PIN code for different driver profiles.

00001 (profile 1) 00002 (profile 2) 00003 (profile 3) 11111 (resetting the collision sensor)

Logoff time

Time in minutes (1-254) that the truck is inactive before it is switched off.

255 (not switched off)

Impact level

Determines how sensitive the truck is to an impact.

5 % (sideways) 5 % (forwards/backwards)

Department

Only applies when ID unit is installed.

14

Type of truck

Only applies when ID unit is installed.

16

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10.4.6 ID unit (optional) General The ID unit is used to start the truck. A smart card or an ID key (see image below) is used instead of a PIN code. It is standard for 2 ID keys to be enclosed with the unit. These have standard settings for use with all types of truck and departments.

Login is performed by pressing the green button and then holding the smart card/ID key close to the ID unit. If the information on the card is confirmed, the truck starts with the correct driver profile and the green LED lights up. If the information on the card is not confirmed, a red LED lights up for 0.7-0.8 seconds. If no information is detected within 5 seconds, the procedure must be repeated.

Logging off is performed by pressing the red button. The red LED then lights up for 0.7-0.8 seconds.

A2 Electronic card

Installation NOTE: During commissioning of the truck (or the ID unit), the ID unit should be programmed with a specific department and truck type. To avoid unauthorised use, rider-controlled trucks and ‘walkie’ trucks, at the very least, must be programmed as different types of truck.

• Connect the service key.

• Set the ID unit to parameter 39. See “10.5.7 List of Service parameters” on page 38. (If values 9-12 are not available, the software must be upgraded with the aid of TruckCom.) • Remove the service key.

• Disconnect the battery contact.

• Replace the keypad with the ID unit. Take care during connection and disconnection.

• Connect the battery contact.

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• Start the truck by pressing the green button and then, within 5 seconds, holding a smart card or ID key close to the scanner on the ID unit. (If the service key is connected, you need only press the green button.) The green LED lights up if login was approved, and the red LED lights up if an invalid smart card/ID key has been used. (Smart cards/ID keys are preprogrammed with a standardised start code.)

• Switch off the truck by pressing the red button. The red LED lights up.

Settings Up to 16 types of truck and 14 departments can be used with the system. A smart card/ID key can be programmed for several departments and types of truck, depending on what the driver is authorised to use.

A smart card/ID key can also be used to program the ID unit if the type of card is changed (see table below). The truck then detects the department and type of truck selected on the smart card/ID key. When the ID unit is programmed, a red LED lights up for 0.7-0.8 seconds.

Table 13: Settings ID unit Truck

Description

Default setting

Department

Up to 14 departments in any combination (1-14)

All

Type of truck

Up to 16 types of truck in any combination (1-16)

All

Smart card/ID key

Description

Default setting

Department

Up to 14 departments in any combination (1-14)

14

Type of truck

Up to 16 types of truck in any combination (1-16)

16

Type of card

Driver card (1) or programming card (3)

1

Driver profile

Profile for different driver parameters (0-9)

0

Driver ID

-

-

A programming unit from Davis Derby (see image below) is required in order to be able to program a smart card/ID key. The unit is connected to a normal PC.

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• Connect the programming unit to the PC’s Com port using the accompanying cable.

• Turn on the PC and open the programming software.

• Connect the programming unit to the mains power.

See separate manual (232629) for more information on programming.

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10.5 Parameters & adjustments 10.5.1 General The truck’s control system stores a number of parameters. These parameters are used to configure the truck for correct operation in the particular application for which it was designed. The parameters are divided into two groups, Operator parameters and Service parameters.

• Operator parameters (1 to 7) - These parameters are used to tailor the driving characteristics of a truck for a specific operator or operation. A maximum of 10 operator parameter sets, so called operator profiles, can be stored in a truck. Operator parameters can be adjusted directly without the requirement for a suitable CAN service key.1 • Service parameters (10 to 40) - These parameters are used to tailor the truck’s performance / operation characteristics and include all other parameters not designated as operator parameters. Service parameters can ONLY be adjusted when a suitable CAN service key is plugged into the truck.2

10.5.2 Displaying parameters - without the CAN service key Proceed as follows to display parameters when a CAN service key is not connected: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN code and then press

on the keypad.

• Hold S18 depressed until “P” is displayed, then release S18. Fig. 5

Fig. 5

Parameters symbol lights.

The different parameters are now displayed by repeatedly operating speed control L1. Operator parameters can be both viewed and changed.1

1.Operator parameters can only be set without a CAN key if parameter #39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Log-in method & operator parameter access on page 47.

2.Service parameters can be viewed without a CAN key being plugged in but they cannot be adjusted. © TIEE SARL

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10.5.3 Adjusting operator parameters without the CAN service key NOTE! Operator parameters can only be set without a CAN key if parameter #39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Log-in method & operator parameter access on page 47.

To change the value of a particular operator parameter carry out the following: • Switch on the truck and log in with the appropriate PIN-code. This is important if the truck has more than one set of Operator parameters active . Any changes made will only be in effect when that particular “operator” is logged in.

• Select the required parameter.

• Press horn button S18.

Parameter symbol flashes.

.

• Set parameter value by repeatedly operating speed control L1 up or down • Press horn button S18 once to confirm the new setting.

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing

on the keypad.

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

For detailed descriptions and effects of these parameters, see the section Description of operator parameters on page 37

10.5.4 Displaying & changing parameters CAN service key connected • Ensure the battery is connected.

• Connect a suitable CAN-service key to X41.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second and then press on the keypad.

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• Hold S18 depressed until “P” is displayed, then release S18. Fig. 6

Parameters symbol lights.

Fig. 6

When pressing the speed control L1 forwards repeatedly, the first operator profile will be displayed. Continue to press L1 in the forward direction and the next operator profile will be displayed (operator no. 2), etc. until the last operator (operator no. 10). See Fig. 7 Once the 10 operator profile have been displayed, the truck service parameters will be displayed as L1 is repeatedly pressed in the forward direction.

Operator parameter no.

Profile no.

Fig. 7

Changing a parameter • Select the required parameter.

• Press horn button S18.

Parameter symbol flashes.

.

• Set the parameter value by repeatedly operating speed control L1 up or down • Press horn button S18 once to confirm the new setting.

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing

on the keypad.

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

The truck’s service parameters can be displayed first by operating speed control L1 in the backward direction. This will cause parameter #40 to be displayed and then parameter #39 etc.1 For detailed descriptions and effects of these parameters see the section List of Service parameters on page 38.

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.

1.Certain parameters numbers displayed are not active in this truck model. © TIEE SARL

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10.5.5 List of operator parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in the sections Displaying parameters - without the CAN service key on page 33 and Changing a parameter on page 35.

See also section Speed limitation on page 26 for information regarding the maximum speeds of the truck.

Table 14: List of Operator parameters Param eter

Name

Unit

Min.

Max.

Step

Std.

Note

01

Speed, Fork direction

%

30

100

5

80

30:lowest Speed 100:highest Speed

02

Speed, Drive wheel direction

%

30

100

5

100

30:lowest Speed 100:highest Speed.

03

Acceleration

%

10

100

5

100

10:lowest acceleration 100:full acceleration

04

Neutral braking effect

%

40

100

5

80

40: lowest reduction force 100: highest reduction force

05

Travel speed, cabin > 0.5 metre

%

0

100

10

100

0: travel distance 100: 6 km/h

06

Speed -Walking at side

%

40

100

5

70

40:lowest Speed 100:highest Speed.

07

Neutral braking effect - Walking at side

%

60

100

5

90

60:reduction force 100:highest reduction force

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10.5.6 Description of operator parameters #1 - Speed, Fork direction Allows for adjustment of the maximum speed of the truck in the fork direction.

# 2 - Speed, Drive wheel direction Allows for adjustment of the maximum speed of the truck in the drive wheel direction.

# 3 - Acceleration The lower the value of the parameter the longer it takes to accelerate the truck to maximum speed.

# 4 - Neutral braking force Defines motor brake force when lever [L1] returns to the neutral position. The lower the value of parameter the longer it takes to reduce speed.

# 5 - Travel speed, cabin > 0.5 m Adjusts the truck's max. speed when the cabin is lifted above 0.5 metre.

The value 0 switches off truck travel. The value 100 allows 6 km/h travel speed with the cabin lifted above 0.5 metre.

# 6 - Travel speed, walking at side Allows for adjustment of the maximum speed of the truck when the operator is not standing on the platform/cabin, i.e. when the operator is walking along side the truck.

# 7 - Neutral braking, walking at side Defines the motor brake force when lever [L1] returns to the neutral position and the operator dismounts the truck and walks by the side of the truck. The lower the value of parameter the longer it takes to reduce speed.

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10.5.7 List of Service parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in the sections Displaying & changing parameters - CAN service key connected on page 34 and Changing a parameter on page 35.

The CAN service key must be connected to the external CAN connector [X41] before adjusting any Service parameters

Table 15: List of Service parameters Parameter

Name

Unit Min.

Max.

Step Std. Note

10

PIN-code

-

0

9999

1

1

PIN code assignment.

NOTE! Not applicable if Parameter #39 has been set to the value 5, 6, 7 or 8.

11

Reversing brake force

%

50

100

5

100

50: lowest reduction force 100: highest reduction force

14

Creep speed

%

-10

10

1

0

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

-10 : lower speed.

10:higher speed

15

Non-configurable options 0 to 9

See “10.5.9 Configurable “Option” parameters” on page 50, Service Manual

16

Configurable option #1

See “10.5.9 Configurable “Option” parameters” on page 50, Service Manual

17

Configurable option #2

18

Configurable option #3

19

Configurable option #4

20

Hour meter selection

-

1

5

1

2

Select which hour meter is normally displayed

21

Battery size

-

1

20

1

10

Selects the battery size

22

Machine type

-

0

1

1

0

Sets the machine type

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Table 15: List of Service parameters Parameter

Name

Unit Min.

Max.

Step Std. Note

23

Function selection

-

0

7

1

0

Enables selection of various functions

24

Special request

-

0

1

1

0

Special request (requires special identification plates)

25

Service interval

h

0

2000

50

500

Setting of service interval timer.

28

Button selector

-

1

3

1

1

Button selection

35

Automatic log-out

min

0

20

1

10

Time interval for automatic log-out 0=4h

36

Calibrate steer servo

-

0

2

1

0

Performs calibration of steer servo

37

Steering offset

-

-300

300

1

0

Fine adjustment of steering (zero) -300:30 deg. left 300:30 deg. right

39

Log-in method & operator parameter access

1

8

1

3

Defines the active log-in method and whether the operator has access to the operator parameter settings.

10.5.8 Description of Service parameter # 10 - PIN code NOTE! The functionality of parameter #10 is ignored if the value of parameter #39 has been set to 5, 6, 7 or 8. PIN code input is facilitated via the extended keypad. For detailed information, see the section Extended keypad - General on page 48.

This parameter stores the active PIN-codes for the truck. The truck can store a maximum of ten operator profiles. The operator profile is activated when the operator logs in with the assigned PIN code. Logging in with a specific PIN code when the truck is started will activate the operator profile to which this PIN code has been assigned. This allows up to ten operators to individually adjust the characteristics of the truck.

On delivery the truck has one default PIN-code stored which is “1“.

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To enter a new PIN-code: • Operate L1 repeatedly in the forward direction to select parameter #10. After one second, the display will show the PIN-code for this operator.

• Repeat the step above until parameter#10 for the next operator is displayed, the display will either show PIN-code for that operator OR “0”(zero).

• Repeat the step above until the PIN-code displayed is “0”(zero).

• Press horn button S18.

Parameter symbol flashes.

.

• Operate L1 to set the desired value of the new PIN-code.1 • Press horn button S18.

Parameters symbol lights (stops flashing).

The new PIN-code has now been entered.

To remove an existing PIN-code: • Operate L1 repeatedly in the forward direction to select parameter #10. After one second, the display will show the PIN-code for this operator.

• Repeat the step above until the PIN-code to be removed is displayed.

• Press horn button S18.

Parameter symbol flashes.

.

• Operate L1 to set the PIN-code value to “0”(zero).

• Press horn button S18.

Parameters symbol lights (stops flashing).

The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in 2. Switch on (PIN-code entry) on page 20.

Parameter #10 cannot be displayed without the CAN service key.

1.Operating L1 lightly will step the value in increments of 1.

Operating L1 fully will step the value in increments of 100 Valid values are 1 to 9999 10- 40

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# 11 - Reverse braking force Determines the amount of motor braking when the speed control L1 is operated opposite the travel direction. The lower the parameter value, the longer time it will take to slow down for a given degree of actuation of L1.

# 14 - Creep speed Defines the speed you will get when you reach the first speed sensor.

#15 - Non-configurable options See Service Manual.

Up to 16 so called sub-parameters are stored and accessed via parameter #15. These options are either switched ON or switched OFF and require no other adjustments. They are therefore called non-configurable options. The number of available options is dependant on the truck type. Consult table Parameter #15 Non-configurable options on page 42 for available options.

Setting Non-configurable options • Ensure the truck is in the parameter mode.

The parameters symbol lights.

• Select parameter #15 using [L1].

The first sub-parameter will be displayed Continued operation of the speed control L1 will display the next subparameter. Note also that only relevant sub-parameters will be displayed.

After 1 second the value of the sub-parameter will be displayed.

• Press horn button S18.

Parameter symbol flashes.

• Set the sub-parameter value by repeatedly operating speed control L1 up or down. See Table 20: for details.

• Press horn button S18 once to confirm the new setting.

The parameters symbol lights. (stops flashing).

• Switch off the truck by pressing © TIEE SARL

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The non-configurable option will now be activated.

• Ensure the option operates correctly before returning the truck for normal use.

P

N/A at present

NOTE! Default setting

1 to 9

Value Function OFF

Option name

Function ON

Sub-parameter No.

Table 16: Parameter #15 Non-configurable options

-

-

-

#16 - Configurable option #1 See “10.5.9 Configurable “Option” parameters” on page 50, Service Manual.

#17 - Configurable option #2 See “10.5.9 Configurable “Option” parameters” on page 50, Service Manual.#18 - Configurable option #3 See “10.5.9 Configurable “Option” parameters” on page 50, Service Manual.

#19 - Configurable option #4 See “10.5.9 Configurable “Option” parameters” on page 50, Service Manual.

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# 20 - Hour meter selection This parameter determines which hour meter mode to display during normal use.

Table 17: Hour meter parameter selection Value

Description

1

Key time: Total time truck has been switched on

2

Activity time: Combined time either pump or drive motor has been in operation (Default display mode)

3

Drive motor time: Total time drive motor has been in operation

4

Pump motor time: Total time pump motor has been in operation

5

Remaining time to next service (Parameter #25 controls the initial value) See # 25 - Service interval on page 45

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Display

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7LOP10CW, 7LOP10CF

10- 43

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

# 21 - Battery size Matches the discharge indication to the characteristics of the battery fitted.

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.

The acid concentration can vary depending on battery brand.

Table 18: Battery size parameter Value

Function

Battery (Ah)

1 2 3 4 5 6 7 8 9 10

↑

11

Less discharged

12

*TBA

13

More discharged

14

↓

*TBA

15

*TBA

16

*TBA

17

*TBA

18

*TBA

19 20 * TBA = To be announced

WARNING! Ensure you have set the parameter correctly.

The battery may otherwise be irreparably damaged.

10- 44

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

# 22 - Machine type This parameter should be set according to the type of truck.

0= 7LOP10CW 1= 7LOP10CF

# 23 - Function selection This parameter activates a number of different travel and lift functions.

0= The truck can be driven with the operator standing next to the truck.

1= The truck CANNOT be driven with the operator standing next to the truck.

2= Activate the “Walkie” button (not used) 3= A combination of mode 1 & 2 4= The pallet stops 100 mm above ground when lowering the forks (“Pallet to ground” function) 5= A combination of modes 1 & 4 6= A combination of modes 2 & 4 7= A combination of modes 1 & 2 & 4

# 24 - Special request The parameters for a special request are entered as follows: 0 = Not activated 1 = Speed restriction. Only 7LOP10CF, special machine plates are required.

# 25 - Service interval This parameter determines the time value in hours to the next service from 0 to 2000 hours in steps of 50 hours. Whenever this value is changed the timer is reset and will start counting activity time up to the set value. On reaching the set value caution code 29 (C29) will be shown on the display.

# 28 - Button selection This parameter determines which button to be used for lifting/lowering.

1 = Lower lift/lower button activated (default) 2 = Upper lift/lower button activated 3 = Both lift/lower buttons are activated.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 45

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

# 35 - Automatic log-off This parameter determines the time interval, in minutes, after which automatic log-off takes place if the truck is not used. The value “0” (zero) results in log-out after 4 hours.

# 36 - Steer servo calibration Value 0 - Parameter always returns to this value after calibration.

Value 1 - Calibrate steer unit (in centre position).

Value 2 - Calibrate steer arm (in end position - not used on this truck).

This parameter is used to perform a calibration of the steer servo. The calibration establishes the steering centre position (straight ahead).

Situations which may require that this calibration be performed are: • The truck deviates from a straight line when steering tiller is in neutral position.

• Occurrences of error codes E121 or E135.

Before performing this calibration, ensure the drive wheel in centre sensor [S65] is functioning and correctly adjusted.

To perform calibration perform following procedure: • Move the steering tiller to the straight ahead position and maintain this position.

• Select parameter #36 and set its value to 1.

• Switch off the truck by pressing • Press

on the keypad.

on the keypad. “PUSH” is displayed

• Maintain steering unit in straight-ahead position and press horn button [S18]. Display now shows “End”.

• Switch off the truck by pressing • Press

10- 46

Service Manual

on the keypad.

on the keypad. Steering calibration is now complete.

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

# 37 - Steering offset This parameter can be used to “trim” the actual steering position of the drive wheel in relation to the position of the steering tiller. It should only be adjusted after having performed a steering calibration (parameter #36).

A situation which may require this parameter to be adjusted, is if the truck tends to drift away from a straight ahead course when driving over longer distances. Many factors can contribute to this. It is therefore advisable to make adjustments to this parameter on a trial and error basis.

Whenever this parameter is adjusted, it is necessary to restart the truck (disconnect and reconnect battery).

# 39 - Log-in method & operator parameter access This parameter determines which function will be used for log-in and whether or not the operator is allowed to adjust the operator parameter settings.

• Value 1 - Key switch installed - Operator parameters accessible (without CAN service key).

• Value 2 - Key switch installed - Operator parameters NOT accessible (without CAN service key).

• Value 3 - Keypad (standard 10 PIN codes) - Operator parameters accessible (without CAN service key). NOTE: This is the default setting.

• Value 4 - Keypad (standard 10 PIN codes) - Operator parameters NOT accessible (without CAN service key).

• Value 5 - Extended keypad (100 PIN codes) - Operator parameters accessible (without CAN service key).

• Value 6 - Extended keypad (100 PIN codes) - Operator parameters NOT accessible (without CAN service key).

• Value 7 - Extended keypad (100 PIN codes) + TLS - Operator parameters accessible (without CAN service key).

• Value 8 - Extended keypad (100 PIN codes) + TLS - Operator parameters NOT accessible (without CAN service key).

• Value 9 - ID unit - Operator parameters accessible (can be changed without CAN service key).

• Value 10 - ID unit - Operator parameters NOT accessible (CAN service key needed).

• Value 11 - ID unit + TLS - Operator parameters accessible (can be changed without CAN service key).

• Value 12 - ID unit + TLS - Operator parameters NOT accessible (CAN service key needed).

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 47

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Extended keypad - General The truck can be programmed with a maximum of 10 operator profiles.

The extended keypad then enables a maximum of 10 PIN codes to be assigned to each operator profile. This makes it possible to handle up to 100 different PIN codes.

NOTE! If the extended keypad is activated, handling of standard PIN codes, that are normally accessible via parameter #10, is ignored.

Extended keypad - Programming A group of PIN codes can be made accessible by defining them as a block. Block no. 0 is activated in the default setting. This means that 3 different operator profiles can be accessed from the very start. Activation of other blocks will make all the PIN codes for that block accessible (see Table 20:). If all 10 blocks have been activated, then 10 PIN codes will be accessible for the operator profile.

The truck software stores the standard PIN code set according to Table 20: NOTE! These PIN codes can be adjusted to any value, however, it is advisable to avoid identical PIN codes in different operator profiles.

10- 48

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Starting programming using the extended keypad: • Connect a suitable CAN-service key to X41.

• Enter code 341671 and depress

on the keypad.

• Select a programming command from Table 19:

Table 19: Programming commands - extended keypad Programming

Function

Notes

Reset to default settings

Blocks 1 - 9 are disabled. The original PIN codes are reset according to Table 20: B = Block no. 0 - 9

Depress “2” + B +

The PIN codes in the block can be used

B = Block no. 0 - 9

Depress “3” + B +

The PIN codes in the block cannot be used Changing current PIN code

B = Block no. 0 - 9 F = Operator profile no. 0 - 9 NNNN = New PIN code

Depress “1” +

Depress “4” + B + F + NNNN +

• Switch off the truck by pressing

on the keypad.

Programming of the extended keypad is now complete.

Parameter #39 must be set to the value 5, 6, 7 or 8 in order for the new PIN codes to take effect.

Perform a test by logging in with one of the new PIN codes. It is important to verify that the correct operator profile is enabled when a specific PIN code is entered, especially if an operator profile has been programmed for a specific application or special goods handling.

Table 20: The table shows the standard PIN codes in the software.

These can be activated for use or changed according to the preferences of the operator.

One or more of these blocks can be activated.

When logging in normally, an operator profile is activated when any of the PIN codes in an activated block is entered.

The truck software will deny log-in if PIN code “0000” is used.

Service technicians are requested to keep notes on activated blocks, PIN code changes and special operator profile settings.

NOTE! If the extended keypad is reset, this does NOT affect the operator profile settings. © TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

10- 49

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 20: Standard PIN code assignment with extended keypad Operator profile

0

1

2

3

4

5

6

7

8

9

Block 0

0000

0001

0002

0003

0000

0000

0000

0000

0000

0000

Block 1

5421

7901

1437

3731

1049

9439

7265

1322

2869

1574

Block 2

1787

4854

2907

9175

5799

1490

3031

7392

5622

5023

Block 3

4659

3174

1026

3815

6703

1179

5152

7514

5668

3215

Block 4

9197

7110

5477

3846

9491

5918

8222

6923

8139

7025

Block 5

2549

6276

9879

9658

1690

4042

5201

9807

4332

9715

Block 6

7474

4142

8620

3754

8432

8788

7430

1948

2595

8527

Block 7

1930

1482

7135

2395

7365

7092

4611

2831

4185

6067

Block 8

2876

4731

1022

5377

3257

7334

9009

7881

8843

7436

Block 9

3242

3162

5878

2828

1910

6907

2136

5730

2957

7691

No.

10.5.9 Configurable “Option” parameters WARNING! The information in this section is not intended as a programming reference and is included solely to allow the reader to gain a thorough understanding of parameter setting/checking.

Do not attempt to make any adjustments to these parameters unless you have sufficient knowledge of the truck’s options/modified functions. This manual only covers the truck’s standard equipment. Specially modified trucks may require that you have access to special service information. Improper adjustment of the option service parameters may compromise safe operation and/or result in a malfunction.

General Parameters #16 to #19 are reserved in the truck’s control system for extra truck options and/or special product modifications. The parameters configure and control the behavior of the Spider expansion unit (SEU) which must be fitted in the truck. See “10.4.2 Spider expansion unit (SEU)” on page 25. This method of implementation allows the standard software program to be used without the need for a specialised software. Normally, these parameters are configured by the manufacturer when the truck is modified or customized. It is advisable to upload the parameter settings from trucks which are modified. In the event the main control card[A2] is changed, the original parameter settings can then be transferred to the new card thus ensuring the special option functions correctly.

10- 50

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a maximum of 4 preprogrammed “base options” to be activated and configured to suit a specific special option or customisation. See table below.

Table 21: Summary of base options Base option no.

Function

Refer to..

1

Pressing an option button controls a digital o/p

table 22 on page 54

2

Activating a digital input will reduce maximum drive speed

table 23 on page 55

3

Specific truck movement(s) activates a digital o/p

table 24 on page 56

4

Activating a digital input causes main contactor to close

table 25 on page 59

5

Activating digital inputs will operate lift /lower

table 26 on page 60

6

Lift height can be restricted by activating a digital input + ability to override by pressing an option button

table 27 on page 62

Parameter #16 to #19 configurable options • Each parameter can be designated to hold a particular base option.

• Each designated option has up to 4 arguments associated with it.

• Each argument holds a value which configures that option.

© TIEE SARL

Service Manual

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10- 51

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

16 - 0 - 1

Date 2006-04-10

Order number 232370-040

Parameter no. (range 16-19) Argument: #0 holds option designator (displayed for 2 s only) Argument value (range 0 - 63) 0= no base option is activated for this parameter 1 to 6 = Base option no. See See separate tables)

OPTION ASSIGNATION

16 - 1- 1

Argument: #1, #2, #3 & #4 hold configurable values for the option Argument value (range depends on argument) Value depends on option and argument selected See separate table OPTION CONFIGURATION

Fig. 8 Configurable option layout

Setting Configurable options To activate a configurable option the base option must first be assigned to one of the parameters #16 to #19. This is achieved by setting argument #0 to the base option number. Once it is assigned, the option’s arguments must be configured. This is achieved by setting a value for arguments #1, #2, #3 and #4.

•

Ensure the truck is in parameter mode.

Parameters symbol lights.

•

Select parameter #16, #17, #18 or #19 using [L1].

Argument #0 will be displayed After 1 second the argument’s value will be displayed. A value of “0” indicates no option is assigned to this parameter, in which case continued operation of the speed control L1 will display the next parameter.

•

Press horn button S18.

Parameter symbol flashes.

10- 52

.

•

Set argument #0 value by repeatedly operating speed control L1 up or down. Refer to base option list Table 21:

•

Press horn button S18 once to confirm the new setting.

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Parameters symbol lights (stops flashing).

•

Select argument #1 by operating speed control L1.

After 1 second the value of argument #1 will be displayed.

•

Press horn button S18.

Parameter symbol flashes..

•

Set argument #1 value by repeatedly operating speed control L1 up or down. Refer to base option list Table 21:

•

Press horn button S18 once to confirm the new setting.

Parameters symbol lights (stops flashing).

Adjust arguments #2, #3 and #4 using the same method as above.

•

Switch off the truck by pressing

on the keypad.

The special option shall now be activated.

•

© TIEE SARL

Ensure the special option operates correctly before returning the truck for normal use.

Service Manual

7LOP10CW, 7LOP10CF

10- 53

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 22: Base option 1 - Option button controls SEU output Argument #0 Initial display

Option designator Values

Meaning

1

Sets relevant parameter to handle base option 1

(value shown after 2s delay)

Argument #1

Initial display (value shown after 2s delay)

Argument #2

Initial display (value shown after 2s delay)

Argument #3

Initial display (value shown after 2s delay)

Argument #4

Initial display (value shown after 2s delay)

10- 54

Selection of SEU unit 1 or 2 Values

Meaning

0

Option is handled by SEU unit 1(A36)

1

Option is handled by SEU unit 2 (second SEU unit)

Selection of SEU digital output Values

Meaning

Pin no.

0

Activate SEU digital o/p 1 (1,6A)

16

1

Activate SEU digital o/p 2 (1,6A)

30

2

Activate SEU digital o/p 3 (1,6A)

1

3

Activate SEU digital o/p 4 (1,6A)

2

Selection of option button Values

Meaning

1

Activated by option button 1

2

Activated by option button 2

3

Activated by option button 3

4

Activated by option button 4

5

Activated by option button 5

6

Activated by option button 6

Type of switching Values

Meaning

0

Activated when button is depressed

1

Option is toggled when button is pressed

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 23: Base option 2 - Reduced drive speed by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

2

Sets relevant option parameter to handle base option 2

(value shown after 2s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

Option is handled by SEU unit 1(A36)

1

Option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s delay)

Argument #2

Selection of SEU digital input

Initial display

Values

Meaning

Pin no.

0

Activate SEU digital i/p 1 (1mA)

5

1

Activate SEU digital i/p 2 (1mA)

19

2

Activate SEU digital i/p 3 (1mA)

33

3

Activate SEU digital i/p 4 (1mA)

6

4

Activate SEU digital i/p 5 (7mA)

20

5

Activate SEU digital i/p 6 (7mA)

34

6

Activate SEU digital i/p 7 (7mA)

7

7

Activate SEU digital i/p 8 (7mA)

21

(value shown after 2s delay)

Argument #3

Speed limitation as a percentage of max. speed

Initial display

Values

Meaning

0-12

Max. speed adjustable from 40-100% formula: =40+5*Arg.3 e.g. 40+5*4=60%

(value shown after 2s delay)

Argument #4

Speed range

Initial display

Values

Meaning

0

Affects only high speed range

1

Affects only low speed range

2

Affects both speed ranges

Service Manual

7LOP10CW, 7LOP10CF

(value shown after 2s delay)

© TIEE SARL

10- 55

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 24: Base option 3 - Truck movement activates SEU O/P

10- 56

Argument #0

Option designator

Initial display (value displayed after 2s)

Values 3

Argument #1

Selection of SEU unit 1 or 2

Initial display (value displayed after 2s)

Values 0 1

Argument #2

Selection of SEU digital output

Initial display (value displayed after 2s)

Values 0 1 2 3

Service Manual

Meaning Sets relevant option parameter to handle base option 3

Meaning Option is handled by SEU unit 1(A36) Option is handled by SEU unit 2 (second SEU unit)

Meaning Pin no.

Activate SEU digital o/p 1 (1,6A) 16 Activate SEU digital o/p 2 (1,6A) 30 Activate SEU digital o/p 3 (1,6A) 1 Activate SEU digital o/p 4 (1,6A) 2 ...table continued on next page

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 24: Base option 3 - Truck movement activates SEU O/P ...continued from previous page

Argument #3

Selection of activating movement

Initial display (value displayed after 2s)

Values

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

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Service Manual

Drive forward X X

Drive backward

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

Any other movement

X X X X

X X

Lower forks

X X

X X

Lift forks

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 X X X X X X X X X X X X X X ...table continued on next page

7LOP10CW, 7LOP10CF

10- 57

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 24: Base option 3 - Truck movement activates SEU O/P ...continued from previous page

10- 58

Argument #4

Output switching mode

Initial display (value displayed after 2s)

Values 0 1 2

Service Manual

Meaning Output continuously on Output switches at 1Hz Output switches at 2Hz

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 25: Base option 4 - Activate main contactor by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

4

Sets relevant option parameter to handle base option 4

(value shown after 2s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

Option is handled by SEU unit 1(A36)

1

Option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s delay)

Argument #2

Selection of SEU digital input

Initial display

Values

Meaning

Pin no.

0

Activated by SEU digital i/p 1 (1mA)

5

1

Activated by SEU digital i/p 2 (1mA)

19

2

Activated by SEU digital i/p 3 (1mA)

33

3

Activated by SEU digital i/p 4 (1mA)

6

4

Activated by SEU digital i/p 5 (7mA)

20

5

Activated by SEU digital i/p 6 (7mA)

34

6

Activated by SEU digital i/p 7 (7mA)

7

7

Activated by SEU digital i/p 8 (7mA)

21

(value shown after 2s delay)

Argument #3

Hold time in minutes

Initial display

Values

Meaning

0-30

Contactor is held on from 0 to 30 minutes after digital i/p is activated

(value shown after 2s delay)

Argument #4

© TIEE SARL

Not used

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10- 59

Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 26: Base option 5 - Activate lift/lower by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

5

Sets relevant option parameter to handle base option 5.

(value shown after 2s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

Option is handled by SEU unit 1(A36)

1

Option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s delay)

Argument #2

Selection of SEU digital inputs

Initial display

Values

Meaning

Pin no.

0

Lift - SEU digital i/p 1 Lower - SEU digital i/p 2 Lower inhibit - SEU digital i/p 3

5 19 33

1

Lift - SEU digital i/p 2 Lower - SEU digital i/p 3 Lower inhibit - SEU digital i/p 4

19 33 6

2

Lift - SEU digital i/p 3 Lower - SEU digital i/p 4 Lower inhibit - SEU digital i/p 5

33 6 20

3

Lift - SEU digital i/p 4 Lower - SEU digital i/p 5 Lower inhibit - SEU digital i/p 6

6 20 34

4

Lift - SEU digital i/p 5 Lower - SEU digital i/p 6 Lower inhibit - SEU digital i/p 7

20 34 7

5

Lift - SEU digital i/p 6 Lower - SEU digital i/p 7 Lower inhibit - SEU digital i/p 8

34 7 21

(value shown after 2s delay)

...table continued on next page

10- 60

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Electrical systems – 5000 Parameters & adjustments Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 26: Base option 5 - Activate lift/lower by SEU i/p ...continued from previous page

Argument #3

Enable/disable lower inhibit

Initial display

Values

Meaning

0

Lower inhibit disabled

1

Lower inhibit enabled

(value shown after 2s delay)

Argument #4

Selection of fork / support arm

Initial display

Values

Meaning

0

Selects fork lift/lower

1

Selects support arm lift/lower

(value shown after 2s delay)

© TIEE SARL

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Electrical systems – 5000 Parameters & adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 27: Base option 6 - Lift height restriction by SEU i/p & override Argument #0

Option designator

Initial display

Values

Meaning

6

Sets relevant option parameter to handle base option 6

(value shown after 2s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

Option is handled by SEU unit 1(A36)

1

Option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s delay)

Argument #2

Selection of SEU digital input for restriction switch

Initial display

Values

Meaning

Pin no.

0

Activate SEU digital i/p 1 (1mA)

5

1

Activate SEU digital i/p 2 (1mA)

19

2

Activate SEU digital i/p 3 (1mA)

33

3

Activate SEU digital i/p 4 (1mA)

6

4

Activate SEU digital i/p 5 (7mA)

20

5

Activate SEU digital i/p 6 (7mA)

34

6

Activate SEU digital i/p 7 (7mA)

7

7

Activate SEU digital i/p 8 (7mA)

21

(value shown after 2s delay)

Argument #3

Selection of option button to override

Initial display

Values

Meaning

1

Activated by option button 1

2

Activated by option button 2

3

Activated by option button 3

4

Activated by option button 4

5

Activated by option button 5

6

Activated by option button 6

(value shown after 2s delay)

Argument #4

10- 62

Not used

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Electrical systems – 5000 Diagnostic and troubleshooting Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

10.6 Diagnostic and troubleshooting 10.6.1 General means constantly on

Fig. 9

means flashing.

The trucks’s electronic control system incorporates built-in fault code display and logging. This capability works as a powerful complement in assessing the cause of eventual truck malfunctions. When a fault code occurs the code number is displayed and the fault condition LED flashes. Fig. 9.

The codes can be broadly divided into two groups: • Caution codes - denoted by prefix “C”. These codes alert the operator to the presence of a caution condition. Caution codes in the range C50 to C99 will limit the truck’s maximum speed to creepspeed. The conditions which cause such codes can usually be easily remedied without further attention. Caution codes C3 to C43 are not stored in the code history log.

• Error codes - denoted by prefix “E”. These codes alert the operator to the presence of a fault condition in the truck. Error codes E100 and higher will stop all truck driving functions until the error code is cleared.

The first time any fault code is displayed it is advisable to check if the condition persists by switching the truck off completely, i.e. disconnect the battery and then switch back on. Check to see if the fault code is again displayed.

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 787, 788

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Order number 232370-040

10.6.2 Fault code history Up to 50 of the most recently occurred fault codes will be stored in a log along with the hour meter reading when the fault occurred. When the fault code log is displayed, it shows the fault codes in chronological order with the newest code first.

Carry out the following to display the fault code log: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold S18 depressed until “E” is displayed, then release S18. Fig. 10

Fig. 10

Fault symbol lights.

The most recently occurred error will be displayed. The display will alternate between the fault code and the hour meter reading when the fault occurred. If the fault code log contains more than one fault code, these can be displayed by repeatedly operating the speed control L1.

10.6.3 List of fault codes NOTE! The text “Restart the truck!” in the following tables always means switching the truck off completely by removing the battery connector [X1], reconnecting and then switching the truck on again.

Table 28: List of error codes Code

Description

Possible cause / Hint or Solution

C3

TLS impact warning

The impact sensor of the TLS system has triggered and all truck modes have been locked. / Reset the TLS unit.

C4

TLS “deactivated” warning

The TLS system is not in the standard travel mode and all truck modes have been locked. / Switch the TLS unit to the standard mode.

C19

Default parameter warning

One or more parameter values may be outside the normal max./min. limits. These parameter values will be reset to the default values. / If this code is displayed, it may become necessary to verify all parameter settings.

C20

Butterfly warning

Problem with butterfly sensor [L1].

The speed control may have been actuated during startup.

Faulty sensor(s) [A2] / Verify operation of the speed control.

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Electrical systems – 5000 Diagnostic and troubleshooting Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 28: List of error codes Code

Description

Possible cause / Hint or Solution

C22

“Walkie” button warning

One of the “Walkie” buttons is depressed during start-up. / Restart the truck!

C26

Steer servo start up error

The steering servo does not respond during initialisation.

[A5] / Inspect the connections to the steering servo. [A5]

C28

Emergency switch warning

Emergency switch activated [S21] No voltage supply to transistor regulator [A1].

Harness problem. / Check emergency switch is not depressed. Check wiring.

C29

Service time warning

Time for next service. / Verify the service parameter. The parameter may not have been reset during the most recent service intervention. / See # 25 - Service interval on page 45 for setting of parameter #25

C31

Pressure sensor warning

Problem with the pressure sensor or the cabling [B10]. / Verify that the voltage is 24 V between cable 24 and 40 on the pressure sensor.

Check voltage between cable 40 and 63 connected to the pressure sensor. The output voltage should be 0.5 Volt (unloaded machine) to 4,5 Volt (max. load)

C32

Pressure sensor varning, initial forks

Problem with the pressure sensor or the cabling [B11]. / Verify that the voltage is 24 V between cable 24 and 40 on the pressure sensor.

Check voltage between cable 40 and 63 connected to the pressure sensor. The output voltage should be 0.5 Volt (unloaded machine) to 4,5 Volt (max. load)

C35

Steer servo - Internal temperature warning

Servo internal temperature has exceeded +68 °C / Steering activity too intensive.See also code E127

C41

Battery undervoltage warning

Battery voltage < 17 volt Battery parameter not correctly adjusted. / See # 21 Battery size on page 44 for setting of parameter #21 Battery due for charging

C42

Battery overvoltage warning

Battery voltage > 33 volt Fully charged battery and energy regeneration during hard reversing braking.

C43

Transistor regulator thermal cutback

Driving may be too intensive Defective transistor regulator [A1]

C50

Platform sensor active > 5 minutes with no truck activity [S19]

Sensor is continuously actuated. The sensor output has short-circuited or faulty sensor. / Inspect sensor operation.

C51

Logical fault in mast sensors

One of the signals from the fork height detection sensors is incorrect. / Verify correct operation of all fork height sensors, [S31], [S32] & [S12]

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 787, 788

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Date 2006-04-10

Order number 232370-040

Table 28: List of error codes Code

Description

Possible cause / Hint or Solution

C52

Wrong trucktype

Wrong trucktype selected / # 22 is probably entered incorrectly / Check # 22.

If #24=1, then #22=1

C80

Steer servo - Home reference error

Reference sensor receives incorrect signal. [S65] Faulty reference sensor [S65] / Inspect the sensor cabling.

C81

Steer servo - Home reference error

Defective home reference sensor [S65] / Low voltage feed to reference sensor. 12 V between cables 95-97 / Inspect the cabling to the reference sensor [S65] Check condition of [F50]

C82

Steer servo- drive current warning

Steer servo drive current is exceeding 80% of maximum.

Steering activity may be too intensive See also code E132

C90

Communication problem with the expansion unit (Expansion unit 1)

Verify the voltage supplied to the unit (A36: POWER SUPPLY 24VDC) and check that the CAN cabling is OK.

C91

Communication problem with the expansion unit (Expansion unit 2)

Verify the voltage supplied to the other expansion unit and check that the CAN cabling is OK.

C92

Programming warning (Expansion unit 1)

Incorrect programming of expansion unit “SEU” 1 [A36].

The truck travels at creep speed. / May have been caused by incorrect allocation of an output during adjustment of the option parameters (16 to 19). Verify all settings of any option parameters...

C93

Programming warning (Expansion unit 2)

Incorrect programming of expansion unit “SEU” 2. The truck travels at creep speed. / May have been caused by incorrect allocation of an output during adjustment of the option parameters (16 to 19). Verify all settings of any option parameters.

E101

Transistor regulator [A1] incompatible with the type of truck

An incorrect transistor regulator type has been installed. / Verify that the correct transistor regulator type has been installed.

E104

Brake switch transistor output in transistor regulator [A1] shorted

Defective transistor regulator [A1] / Check cables and magnetic coil to the brake [Y1]

E106

Digital output fault or field current limit

Attempting to drive more current than specified from outputs.

OR problem regulating field current.

Internal transistor regulator fault. [A1]

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Electrical systems – 5000 Diagnostic and troubleshooting Order number 232370-040

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Valid from serial number 931876-

T-code 787, 788

Table 28: List of error codes Code

Description

Possible cause / Hint or Solution

E107

Main contactor not activated [K10]

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

Contactor control wire not connected.

Incorrect contactor output from the transistor regulator (switched off). / Inspect the main contactor tips. Check control wires to main contactor. Check contactor drive output goes {low}. [A1]

E108

Main contactor tips welded or open circuit in coil.[K10]

Main contactor tips welded.

Contactor drive output in controller faulty (on) / Check main contactor tips Check contactor drive output goes {high}. [A1]

E110

Incorrect rotor current value.

[M1, A1]

Defective transistor regulator [A1].

Can be caused by excessive moisture inside regulator. / Restart the truck.

E113

Unspecified steer servo fault

Control system has detected a fault condition but is unable to ascertain the exact cause. / Restart the truck.

E114

Steer servo phase error [A5, M6]

Loss of motor phase to steer servo motor. / Check internal motor cable connections in steer servo

E115

Steer servo start up error [A5]

Faulty Servo Internal logical fault Incorrect parameter settings. / Restart the truck.

E116

Steer servo checksum error [A5]

Can occur after new software has been loaded into truck. / Restart the truck.

E117

Steer servo communication error

Not used

E118

Command mode error

Not used

E119

Steer servo error during homing operation (Time out)

Home position (steering straight) not achieved within preset time.

Home reference sensor [S65] not adjusted correctly Faulty reference sensor / Check reference sensor gap is adjusted correctly, check wiring to sensor.

E120

Error in steer servo potentiometer

Not used

E121

Steer servo error -steering angle value check

Defective steering signal potentiometer [R2] or cabling / Restart the truck. The sum of the voltages between cables 92-94 and 93-94 =5 V Recalibrate steering. See# 36 - Steer servo calibration on page 46

E122

Steer servo -reference supply out of range

Defective steer servo [A5] / Check voltage between wire nos. 91-94 = 4,5 to 5,5 V.

E123

Steer servo - Hall sensor fault

Intermittent contacts inside steer servo Defective steer servo [A5] / Check internal contacts in steer servo [A5].

E124

Steer servo - overvoltage [A5]

Fully charged battery and energy regeneration during hard reversing braking. / Restart the truck.

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Table 28: List of error codes Code

Description

Possible cause / Hint or Solution

E125

Steer servo - internal short circuit [A5, M6]

Defective steer servo [A5,M6] / Restart the truck

E126

Steer servo - current offset error [A5, M6]

Defective steer servo [A5,M6] / Restart the truck.

E127

Steer servo - temperature too high [A5, M6] (>85º C)

Steering activity too intensive Defective steer servo [A5,M6] / Restart the truck.

E128

Not applicable at present

-

E129

Steer servo - supply undervoltage

Battery charge too low Intermittent connection in servo supply circuit [A5] Steer servo fuse [F52] faulty or blown. / Check condition of Fuse [F52] Charge battery.

E130

Steer servo - analogue steer signal input fault [R2]

Faulty steer angle potentiometer. [R2] Intermittent connection in potentiometer circuit [R2,A5] / Check wiring to potentiometer [R2] Move tiller unit handle in all directions to ensure no wiring problems exist.

E131

Steer servo - analogue steer signal input fault

Faulty steer angle potentiometer. [R2] Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN0] / Check 0,4 to 4.8V between wires 9492, check wiring to potentiometer [R2] Move tiller unit handle in all directions to ensure no wiring problems exist.

E132

Steer servo - current limit reached

Steered portion of drive unit not moving freely./ Check for free movement of drive wheel on floor.

Check steering drive train is free of dirt or other foreign objects. See also code C82.

E133

Steer servo - analogue steer signal input fault

Faulty steer angle potentiometer. [R2] Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires 9493 , check wiring to potentiometer [R2] Move tiller unit handle in all directions to ensure no wiring problems exist.

E134

Steer servo - analogue steer signal input short circuit

Faulty steer angle potentiometer. [R2] or wiring Short circuit between [A5:INP.A_IN1 and INP.A_IN0] / Check wiring to potentiometer. [R2]. Move tiller unit handle in all directions to ensure no wiring problems exist.

E135

Steer servo - offset value error

Requires recalibration / Recalibrate steering (parameter #36) See # 36 - Steer servo calibration on page 46

E136

Steer servo - steer angle potentiometer error

Defective potentiometer [R2] / Ensure potentiometer is fitted correctly.

Recalibrate steering. See # 36 - Steer servo calibration on page 46.

E137

Steer servo - checksum error on received data

Faulty wiring. / Check CAN bus signal cables and connections.[A5, A2] Restart the truck.

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Electrical systems – 5000 Diagnostic and troubleshooting Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Table 28: List of error codes Code

Description

Possible cause / Hint or Solution

E138

Steer servo - data not received

Faulty wiring. / Check CAN bus signal cables and connections.[A5, A2] Restart the truck.

E139

Steer servo - data transmission to servo failed

Faulty wiring. / Check CAN bus signal cables and connections.[A5, A2] Restart the truck.

E140

Checksum error

Faulty internal micro controller [A2], faulty software.

E141

Software problem

Faulty internal micro controller [A2], faulty software / It may be necessary to download new software via the CAN.

E150

Drive communication error

CAN cabling interruption.

Defective transistor regulator [A1].

E151

rive communication transmit error

The transistor regulator [A1] does not respond. Poor connections or defective transistor regulator [A1].

E157

Bus off error

CAN-bus problem, wiring harness or hardware problem.[A2] / Check wiring.

E159

Over-run error

CAN-bus problem, wiring harness or hardware problem.[A2] / Check wiring.

E160

Not applicable for this truck

-

E200

Drive motor field circuit open

Shunt field open [M1], harness broken, transistor regulator defective [A1]. / Check wiring and connections to shunt field [M1].

E201

M minus error

Problem with switch transistor in armature circuit inside transistor regulator [A1].

Defective transistor regulator [A1].

E202

Power amplifier sensor error

Armature current sensor fault in transistor regulator [A1].

Defective transistor regulator [A1].

E214

Power amplifier CAN timeout

Transistor regulator reports unexpected loss of data flow from tiller head [A2].

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

10.6.4 Transistor regulator troubleshooting and error codes

B+

MSTATUS

A1

M

MODEL

VOLTAGE

SERIAL

CURRENT

A2

General

S1

Curtis 1243 is a regulator [A1] 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 S2 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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Electrical systems – 5000 Diagnostic and troubleshooting Order number 232370-040

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Valid from serial number 931876-

T-code 787, 788

Transistor regulator errors The table below depicts the error codes that may be shown by the STATUS LED or read using the hand-held terminal.

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

Table 29: Transistor regulator error code STATUS LED

Hand-held terminal display

Explanation

Possible cause

LED off

-

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator.

LED on

-

Defective regulator

Defective regulator.

1,1

¤¤

CURRENT SHUNT FAULT

Built-in current shunt defective

Armature current sensor fault in motor controller.

1,2

¤ ¤¤

HW FAILSAFE

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head.

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller.

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs.

Problem to regulate field current.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shunt field open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

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

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

1. Battery voltage > 33 volts

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Over-/under-temperature reduction

1. Temp. >85oC or < - 25oC 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions.

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Resetting errors To reset an error turn S17 to off and then on again.

Error

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

Safety The regulator is a high-power component. When working on a battery operated vehicle, necessary precautions should be taken. This includes, but is not limited to, correct training, use of eye protectors, avoiding use of lose-fitting clothes, removal of watches and jewellery, and use of insulated tools only.

WARNING! Risk of short-circuiting.

Remove all watches, jewellery and always use insulated tools only.

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© TIEE SARL

Electrical systems – 5000 Diagnostic and troubleshooting Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

10.6.5 Built-in Test Function The truck’s control system provides a number of useful built-in test functions • Connect CAN-key in X41 and press

[A17].

• Battery status is shown.

• Press Horn S18 repeatedly to choose Built-in Test mode.

NOTE! All truck functions operate as normal in this mode. Care should be taken when operating the truck and reading the display at the same time!

Table 30: Built-in test modes Mode

© TIEE SARL

Flashing symbol

Displayed data

1

Speed reference value sent to Curtis.

2

Digital inputs/outputs can be tested. See Table 31:, Table 32: & Table 33:for more information.

3

Battery voltage (V)

4

Armature current (A)

5

Field current (A)

6

PWM Armature in %

7

Status Curtis

8

Signal from pressure sensor [B10] (Hydraulic pressure in lift circuit) (V)

9

Digital inputs/outputs of expansion unit [A36].

Seetable 34 on page 76

10

Signal from pressure sensor [B11] (Hydraulic pressure in initial lift circuit) (V)

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 787, 788

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Date 2006-04-10

Order number 232370-040

Digital inputs/outputs test mode In the digital inputs/outputs mode, the operation of both inputs and outputs can be checked by checking the individual segments of the main display as given in the following tables.

10.6.6 Transistor regulator inputs o

Table 31: Transistor regulator inputs check Segment

Function Lift height limit [S33], input A1:INP.CABIN IN TOP POSITION Mechanical brake [S10], input A1:INP.TILLER ARM IN DRIVE POSITION Watchdog [Y1], A1:OUT.BRAKE RELEASE (Senses whether Y1 is drawing current correctly - should normally show the inverse of output signal) Man on platform [S19], input A1:INP.DRIVER ON PLATFORM Cabin < 100 mm [S32], input A1:INP.CABIN < 100mm Cabin > 500 mm [S31:1] input A1:INP.CABIN > 500 mm (A) Cabin > 500 mm [S31:2] input A1:INP.CABIN > 500 mm (B)

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Electrical systems – 5000 Diagnostic and troubleshooting Order number 232370-040

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T-code 787, 788

Transistor regulator outputs

Table 32: Transistor regulator outputs check Segment

Function Cabin / Fork lowering [Y10], output A1:OUT.LOWER VALVE Main contactor [K10], output A1:OUT.MAIN CONTACTOR Horn [H1], output A1:OUT.SIGNAL HORN

Mechanical brake [Y1], output A1:OUT.BRAKE A Pump contactor [K30], output A1:OUT.PUMP CONTACTOR Cabin lift / lower valve [Y45], output A1: OUT. CABIN LIFT/LOWER

Digital input of logic card [A2]

Table 33: Digital input of logic card [A2] check Segment

Function Cabin up [A2:S19]

Cabin down [A2:S20]

Initial forks [A2:S21]

Initial forks [A2:S22]

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 787, 788

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Date 2006-04-10

Order number 232370-040

Digital input/output to expansion unit [A36]

Table 34: Digital input/output to expansion unit check Segment

Function Lift height limit Initial forks.

[S45] input A36:INP.INITIAL FORKS LIFT LIMIT Initial forks lift / lower valve [Y69], output A36:OUT.LIFT/LOWER VALVE

Digital input/output to expansion unit [A36] (Option)

Table 35: Digital input/output to expansion unit check (Option) Segment

Function AUX SWITCH; “GO/WALK” [S215] LEFT, [S216] RIGHT AUX SWITCH; “LIFT FORKS” [S219] LEFT, [S220] RIGHT AUX SWITCH; “LOWER FORKS” [S221] LEFT, [S222] RIGHT

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Electrical systems – 5000 Diagnostic and troubleshooting Order number 232370-040

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Valid from serial number 931876-

T-code 787, 788

Extra functions

Table 36: Extra functions check Segment

Function Extra function 6

Extra function 5

Extra function 4

Extra function 3

Extra function 2

Extra function 1

10.6.7 Display test mode The digital display itself can be tested to verify all the segments of the display function correctly.

To select Display test mode carry out the following procedure: • Ensure the battery is connected.

Fig. 11 • Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold S18 depressed until “d” is displayed, then release S18. Fig. 11 Fig. 12

© TIEE SARL

All number segments on the display and symbol lamps should flash sequentially. Fig. 12

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Electrical systems – 5000 Technical specifications – Curtis 1243 T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

10.7 Technical specifications – Curtis 1243 Table 37: Technical specification -Curtis 1243 Item

Traction Lift

Unit

Rated operating voltage

24

24

Volts

Overvoltage limit

33

33

Volts

Undervoltage limit

16

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

500

V AC

Minimum

PWM frequency

16

16

kHz

Max. current of armature winding *

200

300

Amps

For 2 minutes

100

100

Amps

For 1 hour

25

35

Amps

For 2 minutes

20

20

Contactor voltage

24

24

Volts

Same as battery voltage

Contactor current

2

2

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

16.8

Volts

KSI input current

50

50

mA

Logic input voltage

>7.5; High <1; Low

>7.5; High <1; Low

Volts

Logic input current

15

15

mA

Operating temperature

-40 to +50

-40 to +50

°C

Overtemperature, reduction

85

85

°C

Undertemperature, reduction

-25

-25

°C

Max. current of field winding

Explanation

For 1 hour

* During specific test conditions.

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Hydraulic system – 6000 7LOP10CW Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

11- Hydraulic system – 6000 11.1 7LOP10CW 11.1.1 General The hydraulic system consists of a compact hydraulic unit, which includes an electromagnetic valve used to lower the cabin and a pressure limiting valve. Also a valve plate with a (gentle) soft-closing electromagnetic valve, used for cabin lift/lowering is integrated. It also includes a pressure sensor and a cylinder used for fork lifting.

6100

6610

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Hydraulic system – 6000 7LOP10CW T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

11.1.2 Hydraulic drawing and symbol list n

1

4 3

2 5

Symbol list Pos. no.

Description

Function

Notes

1

Lift cylinder

Lifts the cabin

Hose rupture valve

2

Flow regulating valve

10 l / min

3

Pressure limiting valve

max 200 bar

4

Non-return valve

5

Filter

M3

Motor

P

Pump

B10

Pressure sensor

T

Tank

Y10

Valve

Cabin lowering valve

Y45

Valve

Cabin lift/lowering soft closing valve

11- 2

Pump motor

Measures the load

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Analogue signal

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Hydraulic system – 6000 7LOP10CW Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

11.1.3 Description Lift When the pump motor starts, the oil flows through the non-return valve to the lift cylinders.

Lowering When the lowering valve is actuated by the lowering button on the tiller arm, the valve opens to allow the oil in the pressure lines to return to the oil tank. Lowering using the button on the tiller arm gives a constant lower speed.

Operating pressure The operating pressure at rated load is 171 bar.

Relief valve The relief valve opens at 180bar.

Pressure sensor The pressure sensor is used to regulate the drive speed and is influenced by the load and the drive direction. It has an analog operation.

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Hydraulic system – 6000 7LOP10CF T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

11.2 7LOP10CF 11.2.1 General The hydraulic system consists of a compact hydraulic unit, which includes an electromagnetic valve used to lower the cabin or the initial forks and a pressure limiting valve. Also a valve plate with a (gentle) soft-closing electromagnetic valve, used for cabin lift/lowering and initial forks lift/lowering is integrated. It also includes a pressure sensor and a cylinder used forcabin lifting and a pressure sensor and a cylinder used for the initial forks.

6610 6100

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Hydraulic system – 6000 7LOP10CF Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

11.2.2 Hydraulic drawing and symbol list n

2 1

5 4

6

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

3 6

11- 5

Hydraulic system – 6000 7LOP10CF T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

Symbol list Pos. no.

Description

Function

Notes

1

Lift cylinder

Lifts the cabin

Hose rupture valve

2

Lift cylinder

Lifts the initial forks

Hose rupture valve

3

Flow regulating valve

4

Pressure limiting valve

5

Non-return valve

6

Filter

M3

Motor

P

Pump

B10 + B11

Pressure sensor

T

Tank

Y10

Valve

Cabin / Fork lowering valve

Y45

Valve

Gentle-closing electromagnetic valve for the cabin

Y69

Valve

Gentle-closing electromagnetic valve for the initial

Pump motor

Measures the load

Analogue signal

11.2.3 Description Cabin lifting When the cabin lifting control is actuated, the pump contactor closes and the pump motor starts operating. At the same time, the Y45 valve opens and oils flows through the non-return valve and Y45 to the lift cylinder. If the lifting movement is interrupted, Y45 closes gently.

Cabin lowering When the cabin lowering control is actuated, the electromagnetic valves Y10 and Y45 open completely to allow the oil in the pressure lines to flow back into the oil reservoir. If the lowering movement is interrupted, first Y45 closes slowly and then Y10 closes. To ensure Y45 is completely closed before Y10 closes, Y10 receives a retarded holding voltage from the truck's logic card.

The lowering speed cannot be adjusted, and is instead determined by the brake valve for the lowering action in the hydraulic unit valve plate.

11- 6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Hydraulic system – 6000 7LOP10CF Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

Initial forks When the forks lifting control is actuated, the pump contactor closes and the pump motor starts operating. At the same time, the Y69 valve opens and oil flows through Y69 to the lift cylinder.

If the lifting movement is interrupted, Y69 closes gently.

Initial forks lowering When the initial fork lowering control (pushbutton or foot pedal) is actuated, the magnetic valves Y10 and Y69 opens completely to allow the oil in the pressure line to return to the oil reservoir.

If the lowering movement is interrupted, first Y69 closes slowly and then Y10 closes. To ensure Y69 is completely closed before Y10 closes, Y10 receives a retarded holding voltage from the truck's logic card.

Operating pressure The operating pressure at rated load is: 185 bar.

Relief valve Relief valve opening pressure: 200 bar.

Check valve for the cabin / forks cylinders (3) In case of a ruptured hose, the check valve ensures that the lowering speed does not exceed 0.6 m/sec. It is designed as a ball washer and is installed in the hose coupling.

Following dismantling and when later reconnecting the hydraulic hose to the cylinder, make sure the ball washer is in place.

Pressure sensors, B10/B11 The purpose of the pressure sensor is to provide the truck controller with a pulse signal to reduce the speed when carrying loads that exceed 500 kg.

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Service Manual

7LOP10CW, 7LOP10CF

11- 7

Hydraulic system – 6000 Adjustments T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

11.3 Adjustments Adjusting the pressure limiting valve The pressure limiting valve has been correctly set at the factory, however, adjustment may be required if the valve or the entire hydraulic unit is replaced.

The truck must handle lifts between 1000 and 1050 kg.

4 1 2

3

1. Locking nut.

2. Adjusting screw, pressure limitation.

When turned clockwise, the pressure increases.

When turned counterclockwise, the pressure decreases.

3. Pressure limiting valve.

4. Shrinking socket : used to seal the load adjustment setting.

• Remove the schrinking socket.

• Loosen the locking nut (1). Place a load of 1000 kg on the forks and verify that the truck is able to lift this load. If the truck can lift 1000 kg, place an additional 50 kg on the forks. Verify that the truck is able to lift the load.

• If the truck can manage to lift 1100 kg adjust the pressure limiting valve using the adjustment screw (2) by turning it clockwise with a 4 mm Allen key untill it cannot lift the load.

• Mount the locking nut (1) again.

• Place a new schrinking socket (4).

11- 8

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Main lift chain system – 7120 General Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

12- Main lift chain system – 7120 12.1 General Applies to all machines with a mast.

12.2 Checking the chain setting The lift chains must be adjusted at regular periods due to stretching, see below. 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 fork height according to C code 7100, 7420, 7700 and 7800 as applicable.

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

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

The chain should be replaced.

12.3.2 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 chain should be replaced

12.3.3 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 chain should be replaced.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

12- 1

Main lift chain system – 7120 Chain inspection T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

12.3.4 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 chain should be replaced.

12.3.5 Bolt rotation Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when comparing with a new chain.

The chain should be replaced .

12.3.6 Loose bolts If a bolt is loose it will protrude from the side of the chain, which is due to a stiff link or bolt rotation.

The chain should be replaced.

12- 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Main lift chain system – 7120 Chain inspection Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

12.3.7 Outline wear P

H2

H3

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 define as H3 in the figure and denotes the minimum permitted value of the disc height.

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 chapter “Stretching”.

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Service Manual

7LOP10CW, 7LOP10CF

12- 3

Main lift chain system – 7120 Chain inspection T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

12.3.8 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 300-1000 mm of the chain.

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

Table 38: Stretching Type of chain

Nominal disc height H2 ( mm)

Minimum disc height H3 (mm)

Pitch P (mm)

Nominal chain length for 20/30/ 50 discs (mm)

Maximum permitted chain length for 20/ 30/50 discs (mm)

3/4”, 2x3

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 3x4

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 4x6

17.8

16.9

19.05

381/572/953

389/583/972

1”, 4x4

23,6

22,4

25,4

508/762/1270

518/777/1295

1”, 6x6

23,6

22,4

25,4

508/762/1270

518/777/1295

Wear to the bolts 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%.

12- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Main lift chain system – 7120 Cleaning Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

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

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

The chain should be replaced.

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

The chain should be replaced.

12.3.12 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 chapter “Cleaning”.

12.4 Cleaning If a chain is very dirty it is recommended that it is replaced.

Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

12- 5

Main lift chain system – 7120 Lubrication T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

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.

12.5 Lubrication Mineral and synthetic oils can be used to relubricate Rexnord chains.

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

A lift chain should be offloaded 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 stores and corrosive environments.

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

The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below. The following lubricants are recommended:

Table 39: Recommended product Ambient temperature

Viscosity class

Recommended products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5°C

VG 68

> + 5°C < + 45°C

VG 150

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette Klüberoil 4UH 1-220N, Klüber Lubrication

* Equivalent products from another manufacturer may be used.

NOTE! 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 attack.

12- 6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

Fork carriage – 7420 Included components Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

13- Fork carriage – 7420 13.1 Included components TRUCK WITH INITIAL LIFT

11 12 13 14 15 16

17

18 19 20

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Service Manual

7LOP10CW, 7LOP10CF

13- 1

Fork carriage – 7420 Included components T-code 787, 788

13- 2

Valid from serial number 931876-

Date 2006-04-10

Pos.

Name

Notes

11

Screw

12

Fork carriage

13

Bush

14

Screw

15

Locking ring

16

Roller

17

Fork carriage

18

Roller

19

Locking ring

20

Screw

Service Manual

7LOP10CW, 7LOP10CF

Order number 232370-040

© TIEE SARL

Fork carriage – 7420 Dismounting of the mast carriage.

Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

13.2 Dismounting of the mast carriage.

• Dismount security split pin position 11 and both chain bolt nuts postion 12.

• Dismount washer postions 13.

• Remove the complete chain position 14.

• Remove the end plates on top of both mast beams. Take the mastcarriage out of the mast at the upper side by using a crane.

CAUTION! Take care of save load handling.

14

15

16

17

13 12 11

Mounting is done in reverse.

13.3 Adjusting the play • Adjust the play with screw (15).

13.4 Roller replacement • See also earlier drawing.

• Remove the locking ring position (16) and remove the roller (17).

Assembly is done in reverse.

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Service Manual

7LOP10CW, 7LOP10CF

13- 3

Fork carriage – 7420 Dismounting of the initial fork carriage.

T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

13.5 Dismounting of the initial fork carriage.

14 11 13 12

• Dismount the forks.

• Dismount security split pen postions 11 and both chain bold nuts position 12.

• Remove washer position 13.

• Remove chain position 14.

• Take the fork carriage out of the mast at the under side by using a crane.

CAUTION! Take care of safe load handling.

13- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

TruckCom General Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

14- TruckCom User manual for trucks using the “PowerDrive” platform. This manual is valid for version 3.5 of TruckCom p/n 182147-008.

14.1 General TruckCom is a communication program which communicates with trucks equipped with CAN (Controller Area Network) communication.

It enables the following tasks to be performed: • Downloading truck control software.

• Viewing and adjusting operator / truck parameters and hour meters.

Additionally, the truck’s parameter set (including hour meter values) can be saved to file and reloaded later.

• Viewing diagnostic data for various digital inputs/outputs and analogue data including voltages, currents and certain temperatures.

The program is a Windows program running under Windows® 95/98, Windows® XP/2000 and Windows® NT.

14.2 Connection A CAN interface of the CPC-PP type is needed to connect it to the truck, with attendant cable. Connect the interface via the printer port on a PC. Connect the cable between the interface and the truck's CAN terminal.

The CAN interface is supplied with power from the truck electronics and is protected from any high voltages in the truck if a fault should occur.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

14- 1

TruckCom Layout T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.3 Layout 14.3.1 Main program screen Information window

Menu bar

Tool buttons

Nodes Icons

Tool button bar

Fig. 13 Main TruckCom program screen The Main window opens when the program is started. This shows the menu bar, tool buttons, workspace, log window and status window.

14.3.2 Nodes Devices which are connected to and communicate via the CAN interface are called nodes. The nodes detected on the bus are shown in the node window. The current node status and input component/information is shown with different icons.

Fig. 14 A typical node window display 14- 2

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

TruckCom Layout Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

14.3.3 Icons Icon

Description Node OK is shown when contact is made with a node and no errors have been reported.

Node not connected is shown when there is no contact with a node in the network.

Node not OK is shown when an error has been reported by a node. Click on node to obtain more information.

Program version is shown when information is available on which software is installed. Click to obtain more information.

Information is shown when a node has information on, for example, error codes.

Truck report See “14.7 Truck report function” on page 7.

Parameters is shown when a node has information on a parameter.

Diagnostics

Exit

14.3.4 Tool buttons and menu bar The tool button bar allows direct access to the program’s most common functions. The menu bar allows access to all the program functions.

Explanations of each menu bar item are given in the relevant section.

Search for units

Disconnect Download from PC

Truck report

Parameters Diagnostics Information

Exit

Fig. 15 Tool button bar

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Service Manual

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14- 3

TruckCom Connection function T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.3.5 Information window The right section of the main window contains a status window where different messages are shown.To see previous messages, use the scroll arrows in the right margin.

14.3.6 Status bar There is a status bar at the bottom of the main window, which shows variable status when the program is run.

1

2

3

HELPTEXT

REC

MACHINE

4

5

The following are shown from the left: Help text "pop-up" via the mouse cursor, connected/not connected to network, truck type connected, initiation result of CAN interface and the present time.

14.4 Connection function To connect the PC the network, select the Scan units function. This can be done with the menu <Nodes | Scan units> or with the tool button [Scan nodes].

This should also be done when the truck is supplied with voltage and in normal drive mode.The program will now run a check and installation of the CAN interface. A diagnosis will also be carried out to check which units are connected in the system. The result of this diagnosis is shown in the Node window.

14.5 Disconnection function Select the Disconnect function to disconnect from the network. This can be done with the menu <Nodes | Set PC off-Line> or with the tool button [Set PC off-Line].

The CAN interface is then reset and the CAN cable can be disconnected if so required. This enables connection to another truck without having to close the program.

14- 4

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

TruckCom Downloading program function Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

14.6 Downloading program function To download a new program to one of the nodes, select the Download software function. This can be done with the menu <Tools | Download software... > or with the tool button [Download].

Type 123456

14.6.1 Normal downloading (truck with key) Select Open.. to open the file to be downloaded into a node. The file name, file type and version number are shown in the window for file information. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by selecting Start... and by restarting the truck by turning the key off and on twice.

Restart must be made within 20 seconds from when the Start button has been activated.

Close the download window when the download is ready, and then disconnect the PC from the network. A new connection can now be made to verify the new program.

14.6.2 Normal downloading (truck with keypad) Select Open to open the file to be downloaded into a node. The file name, file type and version number are shown in the file information dialogue box. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by depressing and then releasing the red key on the keypad.

The truck must be restarted within 20 seconds from when the Start key has been activated. © TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

14- 5

TruckCom Downloading program function T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

When downloading has been completed, close the download dialogue box and then disconnect the PC from the network. It is now possible to reconnect to verify the new application.

14.6.3 Emergency downloading (truck with keypad) • Disconnect the battery connector.

• Select OK in the dialogue box.

• Keep the red key on the keypad depressed while reconnecting the battery connector.

• Release the red key to commence downloading.

14.6.4 Emergency downloading (truck with keypad) E141 will be shown in the truck’s display when starting, if for any reason there is no program in the electronics card (interrupted downloading).

Communication with the truck via the PC will then be minimised. Use “E141” to download the program in the card.

On some trucks, a counter, which continuously counts up, is displayed.

14.6.5 Downloading in old versions of logic card To download to older versions of electronic cards which do not support restart with key, the button Old card... should be used instead of Start...

Downloading is carried out in the same way, except that restart is done by using the battery lug instead of the key.

NOTE! Once programmed, the logic cards in some trucks can only be upgraded with the same basic firmware. In other words, it is not possible to replace the basic firmware (other machine type).

14- 6

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

TruckCom Truck report function Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

14.7 Truck report function It is possible to generate a report to a file or disk with the truck’s configuration and status. Select menu <Tools | Generate truck report...> or with the tool button Truck report. Save the report in Report.file.

NAME

Example of information generated in the truck report: [GENERAL] REPORT DATE-TIME=2004-01-19 11:11:58 CPC-PP SERIAL No=8002041 MACHINE NUMBER=555555 CUSTOMER=CUSTOMER 1 TECHNICIAN=NONAME COMPANY=Other NOTES=Test report [CAN NODES] MAIN CARD=0 CURTIS DRIVE CONTROLLER=16 [MAIN CARD CONFIGURATION] SOFTWARE=181179-001 HARDWARE=167833-004 SERIAL NO=53676 [DRIVE CONTROLLER CONFIGURATION] SOFTWARE=5 DRIVE CURRENT LIMIT (A)=300 FIELD MAXIMUM (A)=34 SERIAL NO=52857 MFG Date:=26/05/03 HOUR METERS] A IGNITION TIME=81 B TOTAL MOVEMENT=7 C DRIVE MOTOR TIME=7 D PUMP MOTOR TIME=0 S SERVICE TIME=7

[ERROR LOG] 01=104 00007.5 02=104 00007.5 03=104 00007.5 04=104 00007.5 05=104 00007.5 09=104 00005.0

[DRIVER PARAMETERS] 1=100 2=100 3=75 100=0

[TRUCK PARAMETERS] 11=0 12=0 13=0

The contents of certain rows can vary according to truck type.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

14- 7

TruckCom Parameters function T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.8 Parameters function To change the truck parameters, select the Parameter function. This can be done with the menu <Tools | Change parameters > or with the tool button Parameters.

NOTE! The truck must in Normal mode (i.e. not Parameter mode) when connecting TruckCom. Otherwise TruckCom will report “Unable to determine truck brand”

The parameter numbers follow the description in the respective truck Service Manuals, section 5000.

The parameter window shows the information and the current settings for all parameters. The parameters are divided into 4 tabs.

• [Driver] - Driver; driver parameters and PIN code storing • [Truck] - Truck; service parameters • [Time] - Time; time-related service parameters • [Option parameters] - Option parameters. (no. 15 to 19)

.

WARNING! Do not attempt to make any adjustments to the option parameters unless you have sufficient knowledge of the truck’s options/ modified functions. Specially modified trucks may require that you have access to special service information.

Improper adjustment of the option service parameters may result in a malfunction.

14.9 Diagnostics function To access diagnostics, select the Diagnostic function. This can be done with the menu <Tools | Diagnostic...> or with the tool button Diagnostic.

NOTE! If the value “---” is shown in a field, or a “read status LED” is red, the communication has been interrupted for some reason and error data cannot be shown.

NOTE! The tab information displayed in the diagnostics mode depends on the type of truck connected.

14- 8

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

TruckCom Diagnostics function Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

14.9.1 Representation of signal colours The screen dumps shown in the following section have been modified to improve legibility in black and white print.

WHITE GREEN RED

14.9.2 “Tiller arm” tab

Clicking on the tiller arm tab will display a dialogue showing the following: • Speed lever -The status of the speed control and travel direction selector. The status of each individual hall element is displayed.

• Buttons -The status of the control buttons is displayed. “Sxx” refers to the switch designations as given in the circuit diagram.

• Option - Status of option buttons • Battery - The measured battery voltage • R14 - Shows the measured signal voltage from the lift/lower control • R15 - Not used at present.

© TIEE SARL

Service Manual

7LOP10CW, 7LOP10CF

14- 9

TruckCom Diagnostics function T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.9.3 “Drive Controller” tab (transistor regulator driving)

Clicking on the Drive Controller tab will display a dialogue showing the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM - The effective power output supplied to the field circuit as a percentage.

• Armature PWM - The effective power output supplied to the armature circuit as a percentage • Field current - The current flowing in the field circuit in Amperes.

• Armature current - The current flowing in the Armature circuit in Amperes • Raw throttle data - The received speed control signal as a percentage.

• Temperature - The temperature of the output stage of the transistor controller in degrees Celsius • Inp pin 10 - The input voltage from the mode/pressure sensor. “digital O” indicates the digital status of the input.

• Inp pin 11 -The input voltage from the man-on platform sensor. “digital O” indicates the digital status of the input.

14- 10

Service Manual

7LOP10CW, 7LOP10CF

© TIEE SARL

TruckCom Diagnostics function Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

14.9.4 “Pump controller” tab (transistor regulator pump)

If the truck is equipped with a lift/lower transistor regulator, the Pump controller tab displays the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM, Armature PWM, Field current, Armature current, Temperature - See explanation in 14.9.3.

• Raw throttle data - The received lift/lower signal as a percentage.

• Out pin 9 - The output signal to the proportional lowering valve as a percentage.

• Inp pin 10 - The input voltage from the pressure sensor. “digital O” indicates the digital status of the input.

• Inp pin 11 - The input voltage from the pressure sensor. “digital O” indicates the digital status of the input.

© TIEE SARL

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14- 11

TruckCom Diagnostics function T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.9.5 “EPS” (steering servo tab)

Clicking on the “EPS” tab will display a dialogue showing the following: “Status” • “Operational” - Indicates the status of the servo’s control system • “EPS enabled” - Indicates the status of the servo’s power stage output.

• “Reference switch reached” - indicates status of drive wheel in centre reference switch.

• “Reference position found” - indicates whether a successful steering in centre has been performed.

• “EPS in power save mode” - Shows whether the steering servo is in the standby mode (following a certain amount of inactivity).

“Actual values” (Measured values) • “Temperature EPS” - The temperature of the steering servo output stage in degrees Celsius.

• “DC bus voltage” - Supply voltage to steering servo • “Wheel position” - Shows the estimated steering angle of the drive wheel.

• “Voltage analog input 1, pin5”- The measured DC input signal (0) from the steering potentiometer.

• “Voltage analog input 2, pin13”- The measured DC input signal (1) from the steering potentiometer.

• “Current” - The measured current supplied to the steer servo motor in Ampere • “Actual velocity” -The measured rotational speed of the steer servo motor shaft in r.p.m.

14- 12

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© TIEE SARL

TruckCom Other menu functions Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

14.9.6 SEU tab (Extra I/O module)

When the truck is equiped with a Spider Extension Unit (former Extra I/ O module) the SEU tab shows following: • “INP X” - Shows the logical status for the digital inputs.

• “OUT X” - Shows the logical status for the digital outputs.

• “Analog input X” - Shows the voltage level on the analog inputs.

See chapter 5000 for more information about the SEU and how the inputs and outputs are connected.

14.10 Other menu functions 14.10.1 Save to file The truck parameters can be saved in the PC for downloading at a later date.Select <File | Save to file | Parameters>. All parameters in the nodes which are connected to the bus will be scanned in and saved in a file.If only the hour meters are needed, select <File | Save to file | Hour meters>.

14.10.2 Download from file A set of parameters can be downloaded from the PC to the truck. Select <File | Load from file | Parameters >. The parameters in the file will be copied to the nodes connected to the bus. If only the hour meter settings are needed, select <File | Load from file | Hour meters >.

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TruckCom Other menu functions T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.10.3 Reset CAN adapter If problems should occur when resetting the CAN adapter connected to the PC, this can normally be done manually by making sure that the adapter is supplied with voltage and then selecting <Nodes | Reset CPC-PP>.

14.10.4 Delete error code log To delete the truck’s error code log, start the truck in parameter mode and then select <Tools | Erase error log>.

14.10.5 Reset hour meter To reset the truck’s hour meter, start the truck in drive mode and then select <Tools | Reset hour meters >.

14.10.6 Read error code log To show the truck’s error code log, select <Tools | Read error log >.

14.10.7 Adjust date and time To quickly adjust the truck’s data and time, select < Tools | Adjust date & time >. The time given in the PC will now be downloaded into the truck.

NOTE! This does not apply to trucks without a real-time clock.

14.10.8 Adjusting the hour meter on older cards To adjust the hour meter on trucks with older cards, select <Tools | Adjust Hour meters>. The time given in the PC will now be downloaded into the truck.

14.10.9 Help About the TruckCom application To see program information, select <Help | About TruckCom...> or use the tool button [Information].

14.10.10 Exit To exit the program, select <File | Exit > or use the tool button [Exit].

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© TIEE SARL

TruckCom Specifications Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

14.11 Specifications Table 40: CAN interface specification Description

Value

Power consumption

40-120 mA

Supply voltage

11-28 V

Transfer rate

125 kbit/s

Storage temperature

-20-80 °C

Operating temperature

0-60 °C

14.12 Installation NOTE! The program must be installed from the hard disk.

NOTE! The software application in the computer can be damaged, which is why the PC installation should be performed by someone with the required knowledge. Toyota does not accept any responsibility for any errors that occur during the installation.

NOTE! All references to PC operating system actions, menus and commands are based on the English language version of Windows®.

14.12.1 Installation on a PC with Windows® 95/98 If a previous version of the TruckCom application has been installed on the PC, it will be necessary to edit the System.ini file.

Start the Msconfig.exe application by selecting the Start button, selecting Run and then typing msconfig.

• Click on System.ini and open the folder (386Enh).

• Unmark the option at Device=C:\Windows\Cpcppvd.vxd.

• Save the change and close the application.

Now continue with installationThe software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.Then follow the on-screen instructions.

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TruckCom Installation T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.12.2 Installation on a PC with Windows XP/ 2000 To make the application work, it is necessary to enter a value in the Windows® Registry and then make a few alterations in the Windows® Control panel.

Due to the built-in Windows® security, this must be done manually.

The instructions below provide step-by-step guidance to enable these changes and make the interface operate under Windows XP and Windows 2000.The changes can be made either before or after TruckCom is installed.

• Open the Registry Editor. To do this, select the Start button, then Run, type regedit and press Enter.

• Mark the Enum folder which can be found under HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the Registry Editor.

• Select the Edit option, then Find and type PortName to search for the correct folder.

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© TIEE SARL

TruckCom Installation Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

NOTE! The location of the folder differs between different computers (some may be \Enum\Root\.., while others could be \Enum\ACPI\ etc.).

Thus be sure to search for the correct folder.

When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in the PortName data field and that the folder name is Device Parameters.

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TruckCom Installation T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

• Right-click with the mouse in the right box to enter a new value of the DWORD type and with the name

EnableConnectInterruptIoctl.

• Change the value in data field 1 by right-clicking on the name and selecting Modify.

EnableConnectInterruptIoctl

The Device Parameters folder should look like the one in the picture.

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© TIEE SARL

TruckCom Installation Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

The Registry change is now complete. Close the Registry Editor.

Changes in Windows® control panel • Select the Start button.

• Choose Settings, then Control Panel and double-click on System.

• Select Hardware.

• Click on Device Manager and open Ports (Com & LPT).

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TruckCom Installation T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

• Double-click on the LPT port to be changed.

•

• Select the Port Settings tab and select the "Use any Interrupt assigned to the port" option and click OK.

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TruckCom Installation Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.

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TruckCom Installation T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

14.12.3 Installation on a PC with Windows NT The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.

14.12.4 In case of communication problems with CAN Make sure the computer settings for the printer port in the BIOS Setup are as follows: Port address:0378 IRQ:7 Mode:Output only For detailed information on how to change the Setup settings, refer to the User's Guide supplied with the computer.

14.12.5 To uninstall To uninstall TruckCom under Windows®: • Select the Start button, Settings, Control Panel, Add/Remove Programs.

• Then select the TruckCom Program and click Change/Remove.

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Destruction instructions General Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15- Destruction instructions 15.1 General These instructions have been drawn up as part of Toyota's environmental management program. An important motive is, by taking nature into consideration, to economize with resources. In other words, you should try to recycle material as far as possible. This is to minimise the discharge of environmentally-hazardous substances.

The dismantling instructions are designed for an F-code (truck family) and then divided into different C-codes (parts and functions on the truck.) These C-codes are: • 0000 Chassis • 1000 Motors • 2000 Transmission/drive transmission • 3000 Brakes/belt/wheel system • 4000 Steering system • 5000 Electrical system • 6000 Hydraulics/pneumatics • 7000 Working function - lift frame • 8000 Auxiliary/installation equipment • 9000 Accessories/extra equipment The instructions do not tell you the type of material the parts are made of, but refer you to different material containers where the parts should be collected. Some plastics are marked, which means some instructions refer to the marking to determine the collection container to use.

15.2 Procedure When sorting a component part you must know what plastic parts, liquids, environmentally hazardous substances and metals it incorporates.

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15- 1

Destruction instructions Abbreviations T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.3 Abbreviations Abbreviations for Service Manuals and plastic materials are used in the dismantling instructions. The abbreviations used are: ABS = Acrylonitrile-butadiene-styrene PMMA = Plexiglass PP = Polypropylene SM = Service Manual

15.4 Sorting The sorting method for component parts is based on how you can recycle them and whether they must be handled in a special way.

• Plastics must first and foremost be sorted into recyclable and non recyclable plastics. Plastics that can be recycled must be subdivided to differentiate between the different types of plastic. Instructions either indicate in which container the plastic should be placed or there is a reference to the material marking on the plastic component. In those cases where the container is indicated, the type of plastic is shown by an abbreviation.

Sorting is not necessary for non-recyclable plastics. These are placed in the container intended for combustible material.

• Small plastic and rubber items are placed in the container intended for combustible material.

• Iron and steel scrap are sorted separately.

• Composite scrap that is difficult to dismantle and which contains different metals such as steel, aluminium, copper and other materials, for example, plastics, should be sorted separately.

• Oil is collected in the intended container.

• Oil filters are collected in the intended container.

• Parts contaminated by oil, such as hydraulic hoses, should be sorted separately.

• Batteries should be returned to the manufacturer, either directly to the manufacturer or through Toyota.

• Electronic scrap should be sorted from other scrap.

• Cables should be removed and collected separately.

• Small parts, such as screw, bolts, nuts, washers, etc. are not included in the dismantling instructions. These are placed in the container intended for iron and steel scrap.

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Destruction instructions Hoods, hatches (0340) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.5 Hoods, hatches (0340)

4 1 5 2

3

15.5.1 Dismantling • Remove the hood (1).

• Remove the plastic handles (2).

• Remove the hatch (3).

• Remove the hood (4) • Remove the hood (5)

15.5.2 Material handling Hood and hatch should be treated as iron and steel scrap.

The plastic handles and panel should be placed in containers intended for ABS.

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15- 3

Destruction instructions Hoods, hatches (0340) T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.6 Hoods, hatches (0340)

1

15.6.1 Dismantling • Remove the battery panel (1).

15.6.2 Material handling The battery panel should be placed in a container intended for iron and steel scrap.

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Destruction instructions Seat, cushions (0620) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.7 Seat, cushions (0620) 1

15.7.1 Dismantling • Remove the cushion (1).

15.7.2 Material handling The cushion must be placed in a container intended for combustible material.

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15- 5

Destruction instructions Wall/floor covering (0670) T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.8 Wall/floor covering (0670) 3

4

1

2

15.8.1 Dismantling • Remove the carpet (1).

• Remove the the plate (2).

• Remove the finger protection (3) • Remove the bracket (4)

15.8.2 Material handling The carpet (1) must be placed in a container intended for combustible material.

The plate (2) must be placed in a container intended for iron and steel scrap.

The finger protection (3) must be placed in a container intended for PMMA. The bracket (4) must be placed in a container intended for iron and steel scrap.

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Destruction instructions Electric motors (1700) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.9 Electric motors (1700)

2

3

1

15.9.1 Dismantling • Remove the cables.

• Remove the steering motor (1).

• Remove the pump motor including pump (2) (see 6100).

• Remove the drive motor including the electric parking brake from the gearbox (3).

15.9.2 Material handling Cables are to be placed in a container intended for cables.

The motors, pump and electric parking brake should be placed in a container for dangerous waste.

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15- 7

Destruction instructions Drive assembly/gear (2550) T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.10 Drive assembly/gear (2550)

15.10.1 Dismantling • Empty the oil from the gearbox.

• Remove the gearbox from the drive motor (see SM).

• Remove the drive wheel.

15.10.2 Material handling The oil should be treated as dangerous waste.

The gearbox is to be placed in a container intended for iron and steel scrap.

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Destruction instructions Wheels (3500) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.11 Wheels (3500)

15.11.1 Dismantling • Remove the drive wheel and support wheels.

15.11.2 Material handling The vulcanised wheels should be placed in a container for vulcanised wheels.

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15- 9

Destruction instructions Steering arm (4110) T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.12 Steering arm (4110)

1 15.12.1 Dismantling • Remove the steering arm from the hatch (1).

• Remove the cable.

15.12.2 Material handling The steering arm should be placed in a container for dangerous waste.

The cable is to be placed in a container intended for cables.

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Destruction instructions General electronic equipment (5100) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.13 General electronic equipment (5100)

15.13.1 Dismantling • Remove the cables.

• Remove the battery.

15.13.2 Material handling Cables are to be placed in a container intended for cables.

The battery (classified as hazardous waste within the EU) should be returned to the battery manufacturer or the manufacturer's representative (see the rating plate on the battery). The battery can also be handed in to a Toyota representative, who bears responsibility for returning the battery to the manufacturer.

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15- 11

Destruction instructions Battery cut out connector/contactor (5190) T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.14 Battery cut out connector/ contactor (5190)

15.14.1 Dismantling • Remove the electric panel with battery cut out connector/ contactor and transistor panel.

15.14.2 Material handling All parts should be placed in a container for dangerous waste.

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Destruction instructions Expansion unit “SEU”(5730) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.15 Expansion unit “SEU”(5730)

15.15.1 Dismantling • Remove expansion unit “SEU”.

15.15.2 Material handling All parts should be placed in a container intended for electronic scrap.

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15- 13

Destruction instructions Hydraulic unit (6100) T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.16 Hydraulic unit (6100)

2

15.16.1 Dismantling • Empty the oil from the hydraulics.

• Remove oil-filter from tank • Remove the hydraulic cables (see 6230).

• Remove the oil tank (2).

• Remove the hydraulic unit (motor + pump) (see 1710).

15.16.2 Material handling Oil should be treated as dangerous waste.

Oil-filter should be placed in a container for dangerous waste.

Hydraulic cables should be placed in a container for oil-contaminated components.

The tank should be placed in a container for PP. The motor, together with the pump, should be placed in a container for dangerous waste.

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Destruction instructions Hydraulic lines chassis (6230) and main lift cylinders (6610) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.17 Hydraulic lines chassis (6230) and main lift cylinders (6610)

6100 6610

1 2

15.17.1 Dismantling • Remove the cylinder (1).

• Empty the oil from the cylinders • Remove hydraulic hoses (2).

15.17.2 Material handling The oil should be treated as dangerous waste.

Hydraulic hoses should be placed in a container for oil-contaminated components.

Cylinder and hydraulic pipes are to be placed in a contained intended for iron and steel scrap.

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15- 15

Destruction instructions Frame/chassis (7420) T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.18 Frame/chassis (7420) TRUCK WITH INITIAL LIFT

15.18.1 Dismantling • For dismantling, see section 7420.

15.18.2 Material handling The metal pieces should be placed in a container intended for iron and steel scrap.

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Destruction instructions Charger adaptor (9380) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.19 Charger adaptor (9380)

2

1 15.19.1 Dismantling • Charger adaptor (1) comes with the battery.

• Remove the charger adaptor (2).

15.19.2 Material handling The charger adaptor (2) should be placed in a container for electronic scrap.

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15- 17

Destruction instructions Other extra equipment, tuck log device (9420) T-code 787, 788

Valid from serial number 931876-

Date 2006-04-10

Order number 232370-040

15.20 Other extra equipment, tuck log device (9420)

15.20.1 Dismantling • Remove the truck log device.

• Remove wiring harness.

15.20.2 Material handling Truck log device should be treated as dangerous waste.

Wiring harness should be placed in a container intended for cables.

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Destruction instructions Other extra equipment, writing table (9500) Order number 232370-040

Date 2006-04-10

Valid from serial number 931876-

T-code 787, 788

15.21 Other extra equipment, writing table (9500) 1

1

15.21.1 Dismantling • Remove the writing tabel (1).

15.21.2 Material handling The writing table and clamp must be placed in container intended for combustible material.

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©TOYOTA Industrial Equipment Europe SARL Ancenis, France