Toyota Forklift 7PM18 7PM20 7PML20 7PLL24 Service Guide Manual SN 723964 - PDF DOWNLOAD

Service Guide en

7PM18, 7PM20, 7PML20, 7PLL24 Valid from serial number: 723984-

Order number: 225842-040 Issued: 2005-05-26 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Issue date

Resp.

Changes

2005-05-26

ITS

Completely new issue

This manual covers following truck models:

T-code

Model

Serial number

660

7PM18

723984-

661

7PM20

723984-

662

7PML20

723984-

497

7PLL24

723984-

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20, 7PLL24

Approved by: L- G Andersson

Table of contents Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662, 497 Date 2005-05-26

1- Table of contents Technical data – M4 7PM18, 7PM20, 7PML20

2-1

Technical data – M4 7PLL24

3-1

Preventive maintenance – P2 7PM18, 7PM20, 7PML20

4-1

Maintenance schedule.................................. 1 Lubrication schedule..................................... 6

Preventive maintenance – P2 7PLL24

5-1

Maintenance schedule.................................. 1 Lubrication chart ........................................... 6

Oil and grease specifica tion – P3 7PM18, 7PM20, 7PML20

6-1

Oil and grease specification – P3 7PLL24

7-1

Tools – P4 7PM18, 7PM20, 7PML20, 7PLL24

8-1

Super Seal connectors ................................. 1 AMP connectors ........................................... 2 8.2.1 AMP Connectors, 040 series .............................. 3

Molex connectors ......................................... 3 Other tools .................................................... 4 © TIEE SARL Service Guide 7PM18, 7PM20, 7PML20, 7PLL24Approved by: L- G Andersson

1- 1

Table of contents T-code 660, 661, 662, 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Electrical System – 5000 7PM18, 7PM20, 7PML20

9-1

Electrical components................................... 1 Symbol List and Wiring Diagram................... 3 Operating description................................... 15 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8

Starting truck ..................................................... 15 Driving speed £ 6 km/h ..................................... 15 Braking in neutral mode .................................... 15 Braking in neutral mode on a slope .................. 15 Braking .............................................................. 16 Lifting the forks ................................................. 16 Lowering the forks ............................................ 16 Horn .................................................................. 16

Hour meter................................................... 16 Error codes .................................................. 17 Parameters .................................................. 30 9.6.1 Operator parameters ........................................ 30 9.6.2 Parameter description ....................................... 31 Parameter 1 ...................................................... 31 Parameter 2 ...................................................... 31 Parameter 3 ...................................................... 31 Parameter 4 ...................................................... 31 Parameter 5 ...................................................... 31 9.6.3 Service parameters ........................................... 32 9.6.4 Parameter description ....................................... 33 Parameter 10 .................................................... 33 Parameter 14 .................................................... 33 Parameter 15 - Non-configurable option ........... 33 Parameter 16 - Configurable option #1 ............. 34 Parameter 17 - Configurable option #2 ............. 34 Parameter 18 - Configurable option #3 ............. 34 Parameter 19 - Configurable option #4 ............. 34 Option parameters ............................................ 34 General ............................................................. 34 Parameter #15 Non-configurable options ......... 34 Changing non-configurable options .................. 35 Parameter #16 to 19 configurable optional functions ........................................................... 36 Changing configurable optional functions ......... 37 Parameter 20 .................................................... 41 1- 2

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20, 7PLL24Approved by: L- G Andersson

Table of contents Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662, 497 Date 2005-05-26

Parameter 21 .................................................... 41 Recommendation on parameter setting for freely ventilated batteries ........................................... 42 Instructions for verifying parameter setting ....... 43 Recommendation on parameter setting for valve-controlled batteries (VRLA) ..................... 44 Instructions for verifying parameter setting ....... 45 Parameter 22 .................................................... 45 Parameter 25 .................................................... 45 Parameter 28 .................................................... 45 Parameter 39 .................................................... 46 Login method and driver parameter access ..... 46 Expanded keypad - General ............................. 46 Expanded keypad - Programming .................... 46 Service indication ............................................. 48

Part number................................................. 51 Transistor panel........................................... 51 9.8.1 General ............................................................. 51

Troubleshooting........................................... 52 9.9.1 Error codes and troubleshooting ...................... 52 9.9.2 Reset error ....................................................... 53 9.9.3 Safety ............................................................... 53

Technical specifications – Curtis 1243......... 54

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20, 7PLL24Approved by: L- G Andersson

1- 3

Table of contents T-code 660, 661, 662, 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Electrical systems – 5000 7PLL24

10-1

Electrical parts .............................................. 1 Symbol list and electrical diagram................. 3 10.2.6 Electrical wiring diagram Servo (Option) .......... 10

Functional description.................................. 11 10.3.1 Starting the truck .............................................. 11 10.3.2 Driving without using platform and gates, speed £ 6 km/h ................................................. 11 10.3.3 Driving from platform without using gates, speed £ 6 km/h ................................................. 11 10.3.4 Driving from platform and using gates, speed Š 8 km/h ................................................. 11 10.3.5 Neutral speed reduction ................................... 11 10.3.6 Neutral speed reduction on slopes ................... 12 10.3.7 Braking ............................................................. 12 10.3.8 Lifting the forks ................................................. 12 10.3.9 Lowering the forks ............................................ 12 10.3.10 Horn ................................................................ 12

Hour meter................................................... 13 Error codes .................................................. 13 Parameters .................................................. 26 10.6.1 Driver parameters ............................................. 26 10.6.2 Parameter description ...................................... 27 Parameter 1 ...................................................... 27 Parameter 2 ...................................................... 27 Parameter 3 ...................................................... 27 Parameter 4 ...................................................... 27 Parameter 5 ...................................................... 27 10.6.3 Service parameters .......................................... 28 10.6.4 Parameter description ...................................... 29 Parameter 10 .................................................... 29 Parameter 14 .................................................... 29 Parameter 15 - Non-configurable option ........... 29 Parameter 16 - Configurable option #1 ............. 30 Parameter 17 - Configurable option #2 ............. 30 Parameter 18 - Configurable option #3 ............. 30 Parameter 19 - Configurable option #4 ............. 30 Option parameters ............................................ 30 General ............................................................. 30 1- 4

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20, 7PLL24Approved by: L- G Andersson

Table of contents Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662, 497 Date 2005-05-26

Parameter #15 Non-configurable options ......... 30 Changing non-configurable options .................. 31 Parameter #16 to 19 configurable optional functions ........................................................... 32 Changing configurable optional functions ........ 33 Parameter 20 .................................................... 37 Parameter 21 .................................................... 37 Recommendation on parameter setting for freely ventilated batteries ........................................... 38 Instructions for verifying parameter setting ....... 39 Recommendation on parameter setting for valve-controlled batteries (VRLA) ..................... 40 Instructions for verifying parameter setting ....... 41 Parameter 22 .................................................... 41 Parameter 25 .................................................... 41 Parameter 28 .................................................... 41 Parameter 39 .................................................... 42 Login method and driver parameter access ..... 42 Expanded keypad - General ............................. 42 Expanded keypad - Programming .................... 42 Service indication ............................................. 44

Part numbers ............................................... 47 Transistor panel........................................... 47 10.8.1 General ............................................................ 47

Diagnostic and troubleshooting ................... 48 10.9.1 Error codes and troubleshooting ...................... 48 10.9.2 Resetting errors ................................................ 49 10.9.3 Safety ............................................................... 49

Technical specifications – Curtis 1243......... 50

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20, 7PLL24Approved by: L- G Andersson

1- 5

Table of contents T-code 660, 661, 662, 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Hydraulic/Pneumatik – 6000 7PM18, 7PM20, 7PML20

11-1

General ......................................................... 1 Hydraulic chart and list of symbols................ 1 11.2.1 List of Symbols ................................................... 1

Adjustments 7PM18...................................... 2 11.3.1 Adjusting the pressure limit valve ....................... 2 11.3.2 Tools ................................................................... 3

Adjustments 7PM20...................................... 4 11.4.1 Adjusting the pressure limit valve ....................... 4

Hydraulic chart and list of symbols................ 5 11.5.1 List of Symbols ................................................... 5

Adjusting the pressure limit valve.................. 6

Hydraulic, pneumatic – 6000 7PLL24

12-1

General ......................................................... 1 12.1.1 Hydraulic diagram .............................................. 1 12.1.2 Symbol list .......................................................... 2

Adjustments .................................................. 3 12.2.1 Adjustment of the pressure limit valve ................ 3

Cleaning the filter .......................................... 4

1- 6

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20, 7PLL24Approved by: L- G Andersson

Technical data – M4 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

2- Technical data – M4 7PM18, 7PM20, 7PML20 Model

7PM18

7PM20, 7PML20-6

7PML20-8

Type

TSL140S-DS20

TSL140S-DS30

TSL140SDS40

Output, kW

1.0

1.2

1,7

Duty cycle

S2, 60 min

S2,60 min

S2,60 min

Minimum carbon brush length, mm

13

13

13

Nominal commutator diameter, mm

47

47

60

Minimum commutator diameter, mm

47

47

60

Resistance, shunt field winding, Ω at 25 C°

0,55

0,55

0,4498

Resistance armature winding, Ω at 24 °C

0.0156

0,0156

0,0161

Insulation resistance between the windings and motor casing

>=1 Mohm

>= 1Mohm

>= 1Mohm

Weight, kg

14

14

17

Type

BFK457-08

BFK457-08

BFK458-12

Braking force, Nm

16

16

32

Output, W

25

25

40

Resistance coil, Ω

23

23

14.4

Nominal play in actuated position, mm

0.2-0.4

0.2-0.4

0.3-0.5

Minimum thickness brake disc, mm

5.5

5.5

8.8

Thickness of a new brake disc, mm

7.0

7.0

10.0

Type

2-stage angle transmission

2-stage angle transmission

2-stage angle transmission

Gear ratio

19,14:1

19,14:1

16,29:1

Oil volume, litre

1.0

1.0

1.0

Oil type at normal temperature at temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

Drive motor

Broms

Transmission/drive gear

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

2- 1

Technical data – M4 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Model

Valid from serial number 723984Order number 225842-040

7PM18

7PM20, 7PML20-6

7PML20-8

Drive wheel, mm

Dia 215x70

Dia 215x70

Dia 215x70

Axle pressure without load, kg

200

374

374

Axle pressure at rated load, kg

650

565

565

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

65 Nm

Fork wheel, mm

Dia 85x75

Dia 85x75

Dia 85x75

Axle pressure without load, kg

2x40 (240)

2x65 (240)

2x65 (240)

Axle pressure at rated load, kg

2x710 (240)

2x790 (240)

2x790 (240)

Support castors, mm

Dia 125x40

Dia 125x40

Dia 125x40

Axle pressure without load

2X70 (240)

2X75 (240)

2x75 (240)

Axle pressure at rated load, kg

2x80 (240)

2x210 (240)

2x210 (240)

Output, kW

1.2

2.2

2.2

Duty cycle,%

10

10

10

Minimum carbon brush length, mm

7.5

12

12

Minimum commutator thickness/diameter, mm

4.75

4.7

4.7

Pressure at rated load, bar

110

150

150

Overflow pressure, bar

130

170

170

Pump flow, litre/minute

4.7

4.6

4,6

Tank volume, litre

0,5

1,0

1,0

Oil type: at normal temperature at temperature < -15oC

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

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

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

Drive motor circuits, A

125

125

125

Pump motor circuits, A

125

125

125

Control circuits, A

7,5

7,5

7,5

Wheels

Hydraulic system

Fuses

2- 2

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Technical data – M4 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

Model

T-code 660, 661, 662 Date 2005-05-26

7PM18

7PM20, 7PML20-6

7PML20-8

Dimensions LxWxH, mm

193x642x450

193x642x450510

193x642x450510

Capacity, Ah

160-320

240-320

240-320

Weigh, kg

165-250

210-250

210-250

Without load, km/t Without load, m/s

6,0 1.7

6,0 1.7

8,0 2.22

With rated load, km/t With rated load, m/s

6,0 1,7

6,0 1,7

7.2 2.0

Lift without load, s

2.2

1.7

1.7

Lift with rated load, s

3.4

2.3

2.3

Lowering without load, s

2.6

1.4

1.4

Lowering with rated load, s

3.1

1.5

1.75

Driving without load, A

38

28

46

Driving with rated load, A

45

46

65

Lift without load, A

39

49

49

Lift with rated load, A

80

52

52

8%

9%

9%

Short Medium Lång

519 565 613

519(7PM20) 660 1008

660 1008

Turning radius WA

1466

1960

1960

Lift height

205

205

205

295

420

440

Battery compartment, Batteries

Driving speed

Lift/lowering speed

Power consumption

Incline climbing ability With rated load

Measurement, L2

Weight Truck without battery, Medium

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

2- 3

Technical data – M4 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

This page is intentionally left blank

2- 4

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Technical data – M4 7PLL24 Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

3- Technical data – M4 7PLL24 Model

7PLL24

Drive motor Type

TSL160 A DS60

Output, kW

2.5

Duty cycle

S2, 60 min

Minimum carbon brush length, mm

11

Nominal commutator diameter, mm

71

Minimum commutator diameter, mm

68

Resistance, shunt field winding, Ω at 24 C°

0.346

Resistance armature winding, Ω at 24 °C

0.0098

Insulation resistance between the windings and motor casing

>= 1 Mohm

Weight, kg

23

Brakes Type

1EB46-11

Braking force, Nm

48

Output, W

44

Resistance coil, Ω

12

Nominal play in actuated position, mm

0.25-0.38

Minimum thickness brake disc, mm

7.7

Thickness of a new brake disc, mm

9.7

Transmission/drive gear

© TIEE SARL

Type

2-stage angle transmission

Gear ratio

14.20:1

Oil volume, litre

1.75

Oil type at normal temperature at temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Service Guide 7PLL24

Approved by: L- G Andersson

3- 1

Technical data – M4 7PLL24 T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Model

7PLL24

Wheels Drive wheel, mm Drive wheel for servo, mm

250x75 250x105

Axle pressure without load, kg

460

Axle pressure at rated load, kg

770

Wheel pressure at rated load, kg/cm2

30

Tightening torque wheel bolts, Nm

130

Fork wheel, Bogie, mm

80x74

Axle pressure without load, kg

175-320

Axle pressure at rated load, kg

1800-2300

Wheel pressure at rated load, kg/cm2

47-55

Swivel wheel, mm

150x50

Axle pressure without load

175-605

Axle pressure at rated load, kg

120-790

Wheel pressure at rated load, kg/cm2

12-37

Hydraulic system

3- 2

Output, kW

2.0

Duty cycle

10%

Minimum carbon brush length, mm

8

Minimum commutator diameter, mm

45

Minimum commutator diameter, mm

43

Pressure at rated load, bar

130

Overflow pressure, bar

145

Pump flow, cc/r

2.5

Tank volume, litre

1.2

Oil type: at normal temperature at temperature < -15oC

ISO-L-HM32 ISO-L-HV32

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Technical data – M4 7PLL24 Valid from serial number 723984Order number 225842-040

Model

T-code 497 Date 2005-05-26

7PLL24

Servo steering, Motor (Option) Type

MET 3B 24 V

Output, W

160

Torque constant

0.6 Nm/A

Max current

55 A

Speed, rpm

2550

Minimum carbon brush length, mm

-

Minimum commutator diameter, mm

-

Resistance,Ω,armature

0.27

Fuses Control circuits, F50, F51

7.5 A

Drive motor

125 A

Pump motor

160 A

Servo steering (Option)

20 A

Battery compartment, Batteries Battery compartment Dimensions LxWxH, mm Short Long

212x790x775 296x790x775

Capacity, Ah

292-600

Weight, kg

240-500

Driving speed Without load, km/h Without load, m/s

12 3.33 + 5%

With rated load, km/h With rated load, m/s

9,5 2.63 + 5%

Lift/lowering speed

© TIEE SARL

Lift to top with load, s

2.0

Lowering without load, s

2.3

Service Guide 7PLL24

Approved by: L- G Andersson

3- 3

Technical data – M4 7PLL24 T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Model

7PLL24

Power consumption Driving without load, A

82

Driving with rated load, A

92

Lift without load, A

49

Lift with rated load, A

116

Incline climbing ability Without load

15%, 8.5°

With rated load

8%, 4.5°

Measurement L2 Short Long

730 mm 814 mm

Wa with 1170 mm forks and lift fork

-

Wa with 1170 mm forks and lift fork, fixed side gates

-

Wa with 1170 mm forks and lift fork, fixed back rest

-

Lift height

225 mm

Weight

3- 4

Truck without battery, Max

600 kg

Fixed gates

- kg

Fixed back rest

- kg

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Technical data – M4 7PLL24 T-code 497 Date 2005-05-26

85

185

959

1050

1451

Valid from serial number 723984Order number 225842-040

422

L2

800-2350

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

450-685

790

180

Wa

3- 5

Technical data – M4 7PLL24 T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

This page is intentionally left blank

3- 6

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Preventive maintenance – P2 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

4- Preventive maintenance – P2 7PM18, 7PM20, 7PML20 4.1 Maintenance schedule I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

1d

1w

1m

6m

12m

36m

0000

Interval in days/weeks/months Chassis

0000.1

Check all links and locking pins

l

0000.2

Check wear on cover/battery locking

l

0000.3

Check of cracking and damage

l

0000.4

Check the cover locks

I

0000.5

Check finger guard

I

0000.6

Check signs and stickers

I

0000.7

Press grease into grease nipples

0380

Fork carriage

0380.1

Check for crack formation and damage

l

0380.2

Check clearance in bushes and links

I

0380.3

Press grease into grease nipples (Option)

0380.4

Check the lift limit switch

0560

Platform and mountings

0560.1

Check for any cracks or damage

l

0560.2

Check gas damper and cup springs

l

1700.

Drive motor

1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

I/L6

I/L6 l

I/T1

I/T

T2 l

Approved by: L- G Andersson

4- 1

Preventive maintenance – P2 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out

2550

Interval in hours Interval in days/weeks/months Drive gear

2550.1

Check for leakage

2550.2

Check the oil level

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in steering bearing

I

2550.5

Change the oil in the drive gear

3100.

Brake

3100.1

Clean

3100.2

Check for wear on the brake disc

M

3100.3

Check the clearance in disengaged position

M

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts

I/T

3500.3

Check that the support wheel turns and rotates freely

I

3500.4

Check for wear on the support wheel

I

4110

Tiller arm

4110.1

Check the mountings

4110.2

Check the power in the gas damper

5000

Electrical functions

5000.1

Check the operation of the brake microswitch in the upper and lower brake positions.

Lubricate the switch head.

I

5000.2

Check the function of the collision safety switch

I

5000.3

Check the function of the gate switches

I

I

5000.4

Check the function of platform switch

I

I

5000.5

Check the function of the horn

I

I

5000.6

Check for wear on cabling

5000.7

Check the function of the driver’s control

I

I

5000.8

Check the error code log and operating times

I

I

4- 2

5 1d

20 1w

80 1m

500 6m

1000 12m

3000 36m I

I3

L

L4 C

I

I I I/L

I

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Preventive maintenance – P2 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

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

M: Control measurement, rectify if necessary

Pos. No. 5110

Work to carry out Interval in hours Interval in days/weeks/months Battery

5 1d

20 1w

80 1m

500 6m

1000 12m

I

I

5110.1

Check the electrolyte level, 10-15 mm over the cell plates

M

5110.2

Check connections to battery, truck and charger

I

5110.3

Check that the cell and pole guards are undamaged

I

5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

5400

Power system

5400.1

Cleaning and checking of mounting in chassis

C/T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

5700

Electronic circuit board

5700.1

Check connectors and cables

5700.2

Check all segments on the display

6100

Hydraulic system

6100.1

Check hoses and connections for wear

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

6100.5

Change the oil and clean the filter

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

T1

3000 36m

C/T

I I

I L5

Approved by: L- G Andersson

L

4- 3

Preventive maintenance – P2 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

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

M: Control measurement, rectify if necessary

Pos. No. 6680

Work to carry out Interval in hours Interval in days/weeks/months Power Trak

6680.1

Check if there is any damage or cracks on the PowerTrak spring

6680.2

Grease in the contact pressure spring’s guides

5 1d

20 1w

80 1m

500 6m

1000 12m

3000 36m

I C/L

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

2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm. 3 = Check for leakage in conjunction with the first oil change.

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

6 = If the truck goes into a refrigerated environment or other harsh environment, the point is addressed at more frequent intervals.

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

4- 4

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Preventive maintenance – P2 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

5000

T-code 660, 661, 662 Date 2005-05-26

5000

6680 4110 5110 5700

5000

6600 5400 3100 1700 0380

6100

0560

0000

2550 5000 3500

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

4- 5

Preventive maintenance – P2 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

4.2 Lubrication schedule Pos. No.

Service point

Interval/Operating hours 80 h

500

1000 h

0380

Lubricating nipples (Option)

2550

Drive gear

O4

C

6100

Hydraulic system

O5

O

L = Lubrication

3000 h

L

Type of lubricant E

C = Check

O

C B

O = Oil change

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

6100 0000 2550

0380

4- 6

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Preventive maintenance – P2 7PLL24 Maintenance schedule Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

5- Preventive maintenance – P2 7PLL24 5.1 Maintenance schedule I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate M: Measure, correct if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

0000.

Chassis

0000.1

Check all links and spiral pins

I

0000.2

Check for damage to the platform.

I

0000.3

Check the cover locks

I

0000.4

Check the finger guard

I

0000.5

Check signs and stickers

I

0000.6

Push in grease in the grease nipples

0380

Fork carriage

0380.1

Check for crack formation and damage

I

0380.2

Check the play in bushings and links

I

0380.3

Push in grease in the grease nipples

0380.4

Check the lift limit switch

1700.

Motors

1700.1

Check for loose connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Tighten the mounting bolts

1700.5

Check for abnormal noise in the bearings

I

1700.6

Check the steering motor carbon brushes (Option)

M

© TIEE SARL

Service Guide 7PLL24

I/L6

I/L6

I/L I

I/T1

I/T

T2

Approved by: L- G Andersson

5- 1

Preventive maintenance – P2 7PLL24 Maintenance schedule T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate M: Measure, correct if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

2550.

Drive assembly

2550.1

Check for leakage

2550.2

Check oil level

I

2550.3

Check for abnormal noise

I

2550.4

Check mountings and play in the steering bearings

I

2550.5

Change the oil in the drive transmission

2550.6

Lubricate the gear ring (Servo, Option)

3100

Brakes

3100.1

Clean

3100.2

Check for wear to the brake discs

M

3100.3

Check for play in released position

M

3500.

Wheels

3500.1

Remove string and other detritus

3500.2

Check for wear on the drive wheel

I

3500.3

Check that the swivel wheels rotate and swing freely

I

3500.4

Check for wear to the swivel wheels

I

4110.

Tiller arm

4110.1

Check for play on steering joints

I

4110.2

Check the steering force

I

4110.3

Check the gas cartridge's force

4110.4

Check the adjustment of the steering chain, lubricate

5- 2

© TIEE SARL Service Guide 7PLL24

I

I3

L

L4 L C

I

I L/M

Approved by: L- G Andersson

Preventive maintenance – P2 7PLL24 Maintenance schedule Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate M: Measure, correct if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

5000.

Electrical functions

5000.1

Check the operation of the brake microswitch in the upper and lower brake positions. Lubricate the switch head

I

5000.2

Check the function of the safety switch against collision

I

5000.3

Check the operation of the gate switch

I

I

5000.4

Check the operation of the platform switch

I

I

5000.5

Check the horn

I

I

5000.6

Check for wear to the cables

5000.7

Check the operation of the driver's controls

I

I

5000.8

Check the error code log and operatingtimes

I

I

5110.

Battery

5110.1

Check electrolyte levels, 10-15 mm above the cell plates

M

5110.2

Check connections on the battery, truck and charger

I

5110.3

Check that the cell and pole guards are undamaged

I

5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery lock

5400

Power system

5400.1

Clean and check the mountings

C/T1

5400.2

Tighten the cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the contactor movement

I

© TIEE SARL

Service Guide 7PLL24

I/L

I

I

Approved by: L- G Andersson

C/T

5- 3

Preventive maintenance – P2 7PLL24 Maintenance schedule T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate M: Measure, correct if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

5700

Electronic card

5700.1

Clean the electrical panel

5700.2

Check the connectors and cables

5700.3

Check all segments on the display

6100.

Hydraulic system

6100.1

Check for leakage from hoses and couplings

I

6100.2

Check for wear to the hoses

I

6100.3

Check the tank

I

6100.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

6600.

Lift cylinders

6600.1

Check for leakage

I

6600.2

Check the mountings

I

6680

PowerTrak

6680.1

Check for any damage, cracks on the PowerTrak springs

6680.2

Grease the ground pressure spring's guides

C I

TI

I

I L

L5

I C/L

1= Connections are tightened for the first time after 80 hours and then every 1000 hrs/ 12 months.

2= Mounting bolts are tightened after 80 hrs/1 month to 45 Nm. 3= Check for leakage in connection with the first oil change.

4= The oil is changed for the first time after 80 hrs/1 month and then every 3000 hrs/36 months.

5= The oil is changed and the filter cleaned for the first time after 80 hrs/1 month and then every 1000 hrs/12 months.

6 = If the truck goes into a refrigerated environment or other harsh environment, the point is addressed at more frequent intervals.

When points with higher time intervals are addressed, the points with shorter time intervals should also be addressed unless otherwise stated above.

5- 4

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Preventive maintenance – P2 7PLL24 Maintenance schedule Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

5000 5000

5700 4110

4110 6680

5000

5000

5110 6600 0380

5400 3100

2550

1700 3500 0000

0000 6100 3500 5000

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

5- 5

Preventive maintenance – P2 7PLL24 Lubrication chart T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

5.2 Lubrication chart Pos. no.

Service point

Interval/Operating hours

Lubrication type 80 hrs 1000 hrs 3000 hrs

0380

Grease nipples (Option)

2550

Drive transmission

2550

Gear ring

L

E

4110

Steering chain

L

D

6100

Hydraulic system

O

B

6680

PowerTrak, ground pressure spring

L

F

L O4

O5

L= Lubricate

I

I = Inspection

F O

C

O = Oil change

4= The oil is changed for the first time after 80 hrs/1 month and then every 3000 hrs/36 months.

5= The oil is changed and the filter cleaned for the first time after 80 hrs/ 1 month and then every 1000 hrs/12 months.

0000 6680

0380

4110

0380

2550

6100

5- 6

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Oil and grease specifica tion – P3 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

6- Oil and grease specifica tion – P3 7PM18, 7PM20, 7PML20 Pos.

Type of lubricant

Specification

Application

> -15° C

< -15o C

A

Grease

TOYOTA 26777 (Spray)

TOYOTA 26777 (Spray)

Bearings and bushes

B

Hydraulic oil

ISO-L-HM32

ISO-L-VG 32

Hydraulic system

C

Transmission oil

Hypoid oil SAE 80W/90

Hypoid oil SAE 75W

Gears

D

Grease

Staburags NBU 8EP

Staburags NBU 8EP

Guide bearing

E

Grease

TOYOTA 73942XX5 TOTAL N3942

TOYOTA 73942XX5 TOTAL N3942

Lubricating nipples, Contact pressure spring

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

6- 1

Oil and grease specifica tion – P3 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

This page is intentionally left blank

6- 2

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Oil and grease specification – P3 7PLL24 Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

7- Oil and grease specification – P3 7PLL24 Pos.

Lubrication type

Specification >-15°C

<-15°C

A

Grease

TOYOTA 26777 (Spray)

TOYOTA 26777 (Spray)

Bearings and bushings

B

Hydraulic oil

ISO-L-HM32

ISO-VG32

Hydraulic system

C

Transmission oil

Hypoid oil SAE 80W/90

Hypoid oil SAE 75W

Gears

D

Grease

TOYOTA 26778 (Spray)

TOYOTA 26778 (Spray)

Chains

E

Grease

Grafloscon A-G1 (Klüber)

Grafloscon A-G1 (Klüber)

Gear ring

F

Grease

TOYOTA 73942XX5 TOTAL N3942

TOYOTA 73942XX5 TOTAL N3942

Grease nipples, Ground pressure spring

© TIEE SARL

Service Guide 7PLL24

Use

Approved by: L- G Andersson

7- 1

Oil and grease specification – P3 7PLL24 T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

This page is intentionally left blank

7- 2

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Tools – P4 7PM18, 7PM20, 7PML20, 7PLL24 Super Seal connectors Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662, 497 Date 2005-05-26

8- Tools – P4 7PM18, 7PM20, 7PML20, 7PLL24 8.1 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 Guide 7PM18, 7PM20, 7PML20, 7PLL24

Approved by: L- G Andersson

8- 1

Tools – P4 7PM18, 7PM20, 7PML20, 7PLL24 AMP connectors T-code 660, 661, 662, 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

8.2 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 8- 2

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

1

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20, 7PLL24Approved by: L- G Andersson

Tools – P4 7PM18, 7PM20, 7PML20, 7PLL24 Molex connectors Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662, 497 Date 2005-05-26

8.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

8.3 Molex connectors 16 9 8 1 Figure

© TIEE SARL

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

Service Guide 7PM18, 7PM20, 7PML20, 7PLL24

Approved by: L- G Andersson

8- 3

Tools – P4 7PM18, 7PM20, 7PML20, 7PLL24 Other tools T-code 660, 661, 662, 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

8.4 Other tools Figure

8- 4

Number

Application

179915

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

08-13022

Driving gear puller

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20, 7PLL24Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9- Electrical System – 5000 7PM18, 7PM20, 7PML20 9.1 Electrical components S17

S10

S31

S21

X41 X5 X1

Y1

F50 M3

F51 F1

Y41

R1 K10 F3

M1

K30 A1 H1

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 1

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

A17

9- 2

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.2 Symbol List and Wiring Diagram Symbol

Description

A1

Transistor regulator

A2

Electronic card

A6

Display

Display of truck functions

A17

Keypad

Login with PIN code

Option

F1

Fuse

Drive motor circuits

130 A

F3

Fuse

Pump motor circuits

130 A

F 50

Fuse

Working circuit A5

7.5 A

F 51

Fuse

Working circuit A1

7.5 A

F 52

Fuse

Optional equipment

Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

A2:S1-S9 A2:S10-S18

Speed controls

Forward/backward

M1

Motor

Drive motor

M3

Motor

Pump motor

P1

Pressure sensor

Load monitoring

Digital (Applies to 7PML20-8)

R1

PTC resistance

Power supply

15 Ohm

S111

Switch

Option

S112

Switch

Option

© TIEE SARL

Function

Comments

24 V

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 3

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

9- 4

Valid from serial number 723984Order number 225842-040

Symbol

Description

Function

S113

Switch

Option

S114

Switch

Option

S115

Switch

Option

S116

Switch

Option

S10

Inductive switch

Mechanical activation of the brake

S17

Switch

Key

S18

Switch

Button for horn

S19

Switch

Man on the platform

A2:S17

Switch

Emergency reversing

S21

Switch

Emergency switch

S31

Switch

Lift height limiter

A2:S19

Switch

Fork lift (Standard)

A2:S20

Switch

/Fork lowering (Standard)

A2:S21

Switch

Fork lift (Alternative, see parameter 28)

A2:S20

Switch

/Fork lowering (Alternative, see parameter 28)

S53

Switch

Gates

(Applies to 7PML20-8)

S59

Switch

Platform in folded position

(Applies to 7PML20-8)

Y1

Electromechanical brake

Mechanical brake

Y41

Solenoid valve

Fork lowering

X1

Coupling

Battery

X9

Connection point

CAN communication (Extra I/O)

X41

Connection point

CAN communication (External)

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Comments

Brake handle

(Applies to 7PML20-8)

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.2.1 Wiring diagram 1(5) 7PM18/20, 7PML20-6

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 5

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.2.2 Wiring diagram 2(5) 7PM18/20, 7PML20-6

9- 6

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.2.3 Wiring diagram 3(5) 7PM18/20, 7PML20-6

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 7

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.2.4 Wiring diagram 4(5) 7PM18/20, 7PML20-6

9- 8

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.2.5 Wiring diagram 5(5) 7PM18/20, 7PML20-6

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 9

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.2.6 Wiring diagram 1(5) 7PML20-8

9- 10

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.2.7 Wiring diagram 2(5) 7PML20-8

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 11

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.2.8 Wiring diagram 3(5) 7PML20-8

9- 12

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.2.9 Wiring diagram 4(5) 7PML20-8

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 13

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.2.10 Wiring diagram 5(5) 7PML20-8

9- 14

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.3 Operating description 9.3.1 Starting truck To enable the truck to be started, the battery plug must be connected, the emergency switch (S21) closed and the start key (S17) in the ON position.

9.3.2 Driving speed ≤ 6 km/h When driving at a speed of 6 km/h - the switch for driving brake (S10) must be closed, and the - Speed controls must be activated in any direction.

A1 BS1 T1

Ish A2

A A1

T2

K10

B+

• when the speed controls are in neutral mode, the engine functions as a generator. The braking energy is fed back to the battery.

• The brake (Y1) is engaged when the truck stops completely even if the tiller arm is in drive position.

• Energy is fed back to the battery (see diagram below).

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

A1 BS1

Ish + Ia

T1

S2

MShunt

Ia

9.3.3 Braking in neutral mode

MShunt

+

S2

A2

A A1

T2 K10

B+

9.3.4 Braking in neutral mode on a slope If the driver releases the speed control on a slope and the truck does not stop within a certain space of time, the electrical brake is automatically engaged.

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 15

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.3.5 Braking The brake is always engaged when the truck is started with the tiller arm in the top or bottom position (S10 open). The brake is released once all the requirements for driving have been fulfilled, and the truck begins to move.

Requirements for the truck to be able to brake: • S10 open.

9.3.6 Lifting the forks • S34 • S31 closed.

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

9.3.7 Lowering the forks • S41 activated.

9.3.8 Horn • S18 activated.

9.4 Hour meter • Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until H = hour meter is displayed.

• You have now selected H = hour meter. The “B” symbol lights up.

• You can now select type of hour meter by pressing the speed control.

1A = Key time 2b = Movement time

A

3c = Drive motor time 4d =Pump motor time 5s = Time remaining until service

E

9- 16

D

C

B

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.5 Error codes • Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until E = error codes is displayed.

• When E is selected, the “E” symbol will light up as an indication of what is shown in the display.

• The 50 most recent error codes are stored. The latest error is displayed first. The display shows the error code first, followed by the time when the error occurred.

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

• C codes are not stored. They are only cautions and remain lit in the display as long as the fault remains.

• If there is only one error registered in the memory, the other empty entry lines appear as follows: Error: E - - - and time: - - - - .

© TIEE SARL

Code

C3

Description

TLS: Shock sensors registered values outside the limits

Possible error cause

A shock sensor has reported values that exceed the truck’s tolerance values.

Driving may be too hard Check that the shock sensor’s limit values are correctly set.

Check that the shock sensor is correctly positioned./The brake engages and stops the truck.

The TLS reset command activates the truck

Code

C4

Description

TLS: Use of the truck has been blocked

Possible error cause

Truck use can be “blocked” by a TLS command. / The truck cannot be used until a new TLS command cancels the blocking of the truck

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9- 17

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

9- 18

Valid from serial number 723984Order number 225842-040

Code

C19

Description

Parameter caution. Displayed for 5 seconds.

Possible error cause

The parameters have probably been changed.

When changing/updating the program the parameters have automatically been changed to default values (only applies to old program versions).

In later program versions the parameters are only changed if they are outside the values permitted by the new program.

Action

1. This means that the special parameters must be reset manually.

Code

C20

Description

Speed control caution.

Possible error cause

Problem with the speed control sensors.

The toggle switch may have been activated when starting or there may be a fault on one of the sensors on the electronic card. (tiller arm head)

Action

1. Restart with the speed control in neutral position.

2. Replace the electronic card.

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

Code

C28

Description

Emergency switch caution

Possible error cause

The emergency switch has been activated.

No current to the travel regulator, input. A1/16.

Action

1. Check fuse F51.

2. Check the emergency switch.

3. Check the cables from the battery and the battery contacts.

4. If PTC resistor R1 is very hot, remove the battery contact and allow the resistor to cool.

Restart.

© TIEE SARL

Code

C29

Description

Service warning

Possible error cause

Time for service.

The service counter has not been reset since the last service.

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9- 19

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

7PML20-6, 7PML20-8

9- 20

Code

C31

Description

Pressure switch warning.

Possible error cause

A problem with the pressure switch. Check that the voltage is approximately 24 V between cables 24 and 40 connected to the pressure sensor.

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

Code

C41

Description

Warning of low battery voltage

Possible error cause

Battery voltage < 17 volt.

The battery parameters are not correctly set.

Time to charge up the battery.

Action

1. Check parameter 21, battery size and type.

2. Check the battery contact and the pole connections on the battery 3. Check the key switch, S17, poor contact causes unpermitted voltage drop.

The electrical system measures the voltage inside the travel regulator.

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

© TIEE SARL

T-code 660, 661, 662 Date 2005-05-26

Code

C42

Description

Warning of high battery voltage

Possible error cause

Battery voltage > 33 volt.

Energy return feed to battery during motor braking with a fully-charged battery.

Action

1. The fault disappears after a few lifts, once the battery has been run down slightly.

2. Check the cabling, the battery contact and the contact points on main contactor K10.

Code

C43

Description

The travel regulator shuts off due to excess or subnormal temperature.

Possible error cause

Too intensive operation or ambient temperature too cold.

Error in the travel regulator.

Temperature levels below -25oC or above +85oC reduce running speed.

Action

1. Check that the M12 fan is functioning.

(Applies to P 24) 2. Check that the travel regulator is installed with good contact with the chassis.

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 21

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

9- 22

Valid from serial number 723984Order number 225842-040

Code

C90 (Option)

Description

Extra I/0 (0) CAN communication error

Possible error cause

Data from extra I/0 box /(0) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C91 (Option)

Description

Extra I/0 (1) CAN communication error

Possible error cause

Data from extra I/0 box /(1) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C92 (Option)

Description

Configuration error Extra I/0 (0)

Possible error cause

Incorrect setting of options in the extra I/0 box (0) Check the outputs’ allocation on the I/0 expansion box (0)

Code

C93 (Option)

Description

Configuration error Extra I/0 (1)

Possible error cause

Incorrect setting of options in the extra I/0 box (1) Check the outputs’ allocation on the I/0 expansion box (1)

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

© TIEE SARL

T-code 660, 661, 662 Date 2005-05-26

Code

E101

Description

Travel regulator does not correspond with the type of truck

Possible error cause

Incorrect travel regulator or electronic card has been installed. The truck has a built-in control function that checks to ensure the wrong combination of travel regulator and electronic card has not been installed.

Action

Check travel regulator and electronic card.

Code

E104

Description

Switch-transistor to brake is short-circuited

Possible error cause

Error in the travel regulator, output. A1/3.

Incorrect value on parameter 22

Action

Check cabling and contacts. Measure Ohms on the magnet coil (Y1) for the brake.

Value 13-15 ohm.

Check parameter 22

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 23

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9- 24

Valid from serial number 723984Order number 225842-040

Code

E106

Description

Digital outputs short-circuited or exceeding field current limit.

Possible error cause

Problem regulating the field current.

Internal monitoring error.

Action

1. Check the output for main contactor K10 (A1/ 4), check cabling and contacts and measure ohms for the coil. Value 25-30 ohm. Check the output for the brake coil K10 (A1/3), check cabling and contacts and measure ohms for the coil. Value 13-15 ohm.

2. Check the output for horn (A1/7), check cabling and contacts.

3. Check the drive motor’s shunt winding and cabling and contacts. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

© TIEE SARL

T-code 660, 661, 662 Date 2005-05-26

Code

E107

Description

Contactor K10 does not close.

Possible error cause

Problem with main contactor points or coil.

Contactor’s operating cabling off/not connected.

Interruption in the travel regulator’s output, A1/4.

Action

1. Check if the contactor is activated.

2. If the contactor is working, check the contact points and accompanying cabling.

3. If the contactor is not working, check the coil and accompanying cabling. Measure Ohms for the coil. Value 25-30 ohm.

4. Check the travel regulator’s output, A1/4.

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 25

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

9- 26

Valid from serial number 723984Order number 225842-040

Code

E108

Description

Contactor K10 does not open.

Possible error cause

Main contactor points welded.

Short circuit in the travel regulator’s output A1/4.

Action

1. Check that the contactor’s contact points are not welded together.

2. Check that the R1 resistor is not shortcircuited.

3. If the contact points are OK, but the contactor engaged, check cable 64 and the travel regulator’s output A1/4.

Code

E110

Description

System error.

Possible error cause

Temporary error/error in the travel regulator.

Action

1. Restart the machine.

2. Replace travel regulator.

Code

E140

Description

Error in control total.

Possible error cause

Fault on the internal micro-monitoring (tiller arm head), incorrect software or circuit board.

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

Code

E141

Description

Software problem.

Possible error cause

Fault on the internal monitoring (tiller arm head), incorrect software or circuit board.

Action

1. Restart the machine.

2. Download the program again.

3. Replace the electronic card

Code

E150

Description

Fault in the data communication.

Possible error cause

Break on the CAN cable.

Action

1. Check the 119 and 120 cables and their contacts.

2. Replace travel regulator.

Code

E151

Description

Tx error in data communication.

Possible error cause

Travel regulator not responding.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

Code

E157

Description

Bus shut off.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

w

© TIEE SARL

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9- 28

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Code

E159

Description

Transgression error.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

Code

E160

Description

Error in safety reversing function

Possible error cause

Error in important sensor part.

Action

1. Replace the electronic card

Code

E200

Description

Open field.

Possible error cause

Shunt field’s circuit open.

Action

1. Check the field winding connections E1 and E2. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

2. Check cables 4 and 5 and outputs S1 and S2 3. Replace travel regulator

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

© TIEE SARL

T-code 660, 661, 662 Date 2005-05-26

Code

E201

Description

M minus error.

Possible error cause

Problem with switch transistor in the armature circuit inside the travel regulator.

Action

1. Check cable and connections between A1/M on the travel regulator and connection A2 on drive motor.

2. Replace travel regulator.

Code

E202

Description

Fault on sensor in travel regulator

Possible error cause

Fault on armature current sensor in travel regulator

Action

Replace travel regulator

Code

E214

Description

CAN timeout in power amplifier.

Possible error cause

The motor monitor is reporting an unexpected data loss from the electronic card in the tiller arm head.

Action

1. Check cables 119 and 120 between electronic card and travel regulator.

2. Replace electronic card 3. Replace travel regulator.

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 29

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.6 Parameters A

E

D

C

B

• Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until P = parameters is displayed.

• You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

• Press L1 up or down and scroll to the parameter you want to change or view.

• Press S18 once to access the parameter.

• Press L1 up or down to specify the parameter value.

• Press S18 once to confirm the change.

• Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine.

NOTE: Truck handling When you change specific truck parameters, the truck’s driving characteristics are also changed.

Do not change any parameters unless you really know what you are doing.

9.6.1 Operator parameters Parameter

Description

Unit Min.

Max.

Step Std.

Description

01

Speed, Turtle button

%

40

100

5

100

Speed, Turtle button 10: slow speed 100: maximum speed.

02

Max. speed

%

40

100

5

100

Max. speed 10: slow speed 100: maximum speed

03

Acceleration

10

100

5

50

10: slow acceleration 100: maximum acceleration

04

Braking in neutral mode

5

100

5

50

Specifies motor braking once the lever is put into neutral.

5: weak braking power 100: maximum breaking power

05

Logout

0

20

1

20

The time it takes for the truck to switch off when the keypad is used. The time counts down from the moment the last powerconsuming unit is used.

Value = 0 gives 4 hours.

In steps of 1

9- 30

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

1min

Approved by: L- G Andersson

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9.6.2 Parameter description Parameter 1 The speed of use of the turtle button can be adjusted.

Parameter 2 The maximum speed can be adjusted.

Parameter 3 The lower the parameter value, the longer it takes for the truck to achieve maximum speed.

Parameter 4 Specifies the motor braking power when the lever (L1) is put into neutral. The lower the parameter value, the longer the braking time.

Parameter 5 The time it takes for the truck to switch off when the keypad is used.

The time counts down from the moment the last power-consuming unit is used.

Value = 0 gives 4 hours.

© TIEE SARL

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Valid from serial number 723984Order number 225842-040

9.6.3 Service parameters • • • •

A

E

D

C

B

• • • • •

Connect the CAN key to X41.

Press and hold S18 while turning S17 to “ON” position.

Press and hold S18 until P = parameters is displayed.

You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

Press L1 up or down and scroll to the parameter you want to change or view.

Press S18 once to access the parameter.

Press L1 up or down to specify the parameter value.

Press S18 once to confirm the change.

Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine.

NOTE: Truck handling When you change specific truck parameters, the truck’s driving characteristics are also changed.

Do not change any parameters unless you really know what you are doing.

Parameter

Description

10

Unit

Min.

Max.

Step

Std.

Description

PIN-code

0

9999

1

1

Facility for specifying up to 10 PIN codes (10 different drivers).

14

Crawling speed

-10

10

1

0

The amount of power the monitor should emit when you reach the first speed sensor can be specified here.

-10: low speed for the first speed sensor.

10: high speed for the first speed sensor

15

Non-configurable option 0 to 9

See “Option parameters” on page 34, Servicemanual

16

Configurable option #1

See “Option parameters” on page 34, Servicemanual

17

Configurable option #2

18

Configurable option #3

19

Configurable option #4

9- 32

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Parameter

Description

20

Unit

T-code 660, 661, 662 Date 2005-05-26

Min.

Max.

Step

Std.

Description

Hour meter option

1

5

1

2

Select hour meter.

21

Battery size

1

20

1

5

Selection of battery size.

22

Inductive sensor

0

1

1

1

0: Mechanical switch 1: Inductive sensor

25

Service interval

0

2000

50

100

Option for setting service timer

28

Lift button selection

1

3

1

1

Button selection

39

Password

1

12

1

1

States which level of authorization the driver has for the parameters.

Odd values specify open driver parameters, even values specify that driver parameters must be opened using the CAN key

1h

9.6.4 Parameter description Parameter 10 NOTE! The functionality of parameter #10 is set aside if the value of parameter #39 is set to 5,6,7 or 8. The PIN codes are managed using the socalled expanded keypad. See section Expanded keypad - General on page 46 for more detailed information.

Ten drivers can have their own PIN code to gain access to the truck.

Each driver can set all driver parameters individually.

On delivery the PIN code is set to 1 and this only applies for driver no. 1.

Code 0 is not accepted as a solitary code.

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

When you want to switch off the truck, press the red button numbered 0.

When the CAN key is connected, you can start the truck by simply pressing the green button numbered 1. Switch off by pressing the red button numbered 0.

Parameter 14 Specifies the speed you will have when you reach the first speed sensor.

Parameter 15 - Non-configurable option See “Option parameters” on page 34, Servicemanual

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

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Valid from serial number 723984Order number 225842-040

Parameter 16 - Configurable option #1 See “Option parameters” on page 34, Servicemanual

Parameter 17 - Configurable option #2 See “Option parameters” on page 34, Servicemanual

Parameter 18 - Configurable option #3 See “Option parameters” on page 34, Servicemanual

Parameter 19 - Configurable option #4 See “Option parameters” on page 34, Servicemanual

Option parameters WARNING !

Do not try to change these parameter unless you have specific knowledge of the truck options or truck modifications. This service manual only covers the truck’s standard equipment. Specially modified trucks may require you to have access to particular service information. Incorrect adjustment of option parameters may result in incorrect function.

General Parameters #15 to #19 have been reserved in the truck control system for extra options and/or specific product modifications. These parameters are normally configured by the manufacturer on modification or customisation of the truck. It is recommended that the parameter settings be loaded up from the truck when carrying out any modification. If, for example, the main electronic card [A2] must be replaced, the original parameter settings can then be simply transferred to the new card, which ensures that all the special options function correctly.

Parameter #15 Non-configurable options Up to 16 so-called sub-parameters are stored under parameter #15.

Their status is either ON or OFF and they do not require any other adjustments. They are therefore called non-configurable options.

9- 34

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T-code 660, 661, 662 Date 2005-05-26

Changing non-configurable options • Ensure the truck is in parameter mode.

The parameter symbol is lit.

• Select parameter #15 using [L1].

The first set-up of sub-parameters is displayed The next set-up of sub-parameters is displayed if you continue to activate the speed control L1. Ensure that only the relevant sub-parameters are displayed.

The value of the sub-parameters is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

.

• Enter the sub-parameter value by repeatedly operating the speed control L1 in either direction. See Table 1: for more information.

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

The parameter symbol is lit (i.e. stops flashing).

• Switch off the truck by pressing

© TIEE SARL

on the keypad.

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The non-configurable option is now activated.

• Check that the function works correctly before the truck is put back in operation.

P

Sub-parameter no.

Function name

Function ON

Function OFF

Basic setting

Table 1: Parameter #15 Non-configurable option Value

Note!

1

"Turtle" function

1

0

0

2 to 9

For future use

-

-

-

Parameter #16 to 19 configurable optional functions Parameter no. #16, #17, #18 & #19 can be adjusted to activate up to a maximum of 4 pre-programmed functions and configure these to suit optional equipment or customisation of the truck. See “Table 2:List of configurable optional functions” on page 38. These are thus called the configurable optional functions.

• Each parameter can be programmed to cover a specific optional function.

• Each optional function can have up to 4 independent variables associated with it.

• Each independent variable has a value you can change to configure the function.

9- 36

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

Parameter no. (range 16-19) Independent variable: #0 is the option designation

16 - 0 - 1

Independent variable value (range 0-63) 0= no option has been activated for this parameter 1 to 63 = Pre-programmed option number. See separate table.)

SETTING THE OPTIONAL FUNCTION

Independent variable: #1, #2, #3 & #4 contain the optional function valu

16 - 1- 1

Independent variable value (the range depends on the function referred The value depends on the option and independent variable selected.

See separate table CONFIGURING THE OPTIONAL FUNCTION

Fig. 1

Summary – option parameter

Changing configurable optional functions In order to activate a configurable optional function, it must first be assigned a parameter from #16 to #19. This is done by changing independent variable #0 to the pre-programmed option number. Once this has been done, the independent variable for the option must be configured. This is done by changing the values for independent variables #1, #2, #3 and #4.

• Ensure the truck is in parameter mode.

The parameter symbol is lit.

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

Independent variable #0 is displayed The independent variable value is displayed after 1 second. The value “0” means that an optional function has not been assigned to this parameter, and the speed control L1 in this case displays the next parameter if you continue to activate it.

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction. See Table 2: © TIEE SARL

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Valid from serial number 723984Order number 225842-040

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

The parameter symbol is lit (i.e. stops flashing).

• Select independent variable #1 by activating the speed control L1.

Independent variable value #1 is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #1 by repeatedly operating the speed control L1 in either direction. See the list of optional functions in Table 2: • Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

Adjust independent variables #2, #3 and #4 in the same way as above.

• Switch off the truck by pressing

on the keypad.

The optional function is now activated.

• Check that the optional function works correctly before the truck is put back in operation.

Table 2: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 1: The option button controls the spider output 0:Spider 0 1:Spider 1

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

1-6:option button 1-6

Type of function: 0:instantaneous 1:butterfly switch

Independent variable #0 = 2:Reduced running speed controlled by the spider’s digital input 0:Spider 0 1:Spider 1

9- 38

0-7:Digital input 1-8

0-12:reduced speed 40-100% (i.e. 40+5*arg3 e.g.

4: 40+5*4=60%)

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

0:high-speed range 1:low-speed range 2: both ranges

Approved by: L- G Andersson

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Table 2: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 3:Activate the spider output for specific movements 0:Spider 0 1:Spider 1

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

Select movements.

See Table 3:

Initial position: 0: shines constantly 1: flashes 1 Hz 2: flashes 2 Hz

Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input 0:Spider 0 1:Spider 1

0-7:Digital input 1-8

0-30:Holding time 030 minutes

Not used

Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs 0:Spider 0 1:Spider 1

0: Lift, digital input 1 Lowering, digital input 2 Blocking of lowering, input 3 1: Lift, digital input 2 Lowering, digital input 3 Blocking of lowering, input 4 2: Lift, digital input 3 Lowering, digital input 4 Blocking of lowering, input 5 3: Lift, digital input 4 Lowering, digital input 5 Blocking of lowering, input 6 4: Lift, digital input 5 Lowering, digital input 6 Blocking of lowering, input 7 5: Lift, digital input 6 Lowering, digital input 7 Blocking of lowering, input 8

0: Blocking of lowering disconnected 1: Blocking of lowering connected

0: Fork lift/lowering 1: Support arm lift/ lowering

Independent variable #0 = 6:Lift height limitation with by-pass 0:Spider 0 1:Spider 1

© TIEE SARL

0-7: Limit switch for digital input 1-8

1-6: By-pass, option switch 1-6

Not used

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9- 39

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Table 3: Option 3 – Choice of movement

9- 40

Selected movement

Independent variable #3

-

0

Driving forward

1

Driving backward

2

Driving forward or backward

3

Fork lift

4

Fork lift or driving forward

5

Fork lift or driving backward

6

Fork lift or driving forward or driving backward

7

Fork lowering

8

Fork lowering or driving forward

9

Fork lowering or driving backward

10

Fork lowering or driving forward or driving backward

11

Fork lift or fork lowering

12

Fork lift or fork lowering or driving forward

13

Fork lift or fork lowering or driving backward

14

Fork lift or fork lowering or driving forward or driving backward

15

All other movements (AOM)

16

Driving forward or AOM

17

Driving backward or AOM

18

Driving forward or driving backward or AOM

19

Fork lift or AOM

20

Fork lift or driving forward or AOM

21

Fork lift or driving backward or AOM

22

Fork lift or driving forward or driving backward or AOM

23

Fork lowering or AOM

24

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

Table 3: Option 3 – Choice of movement Selected movement

Independent variable #3

Fork lowering or driving forward or AOM

25

Fork lowering or driving backward or AOM

26

Fork lowering or driving forward or driving backward or AOM

27

Fork lift or fork lowering or AOM

28

Fork lift or fork lowering or driving forward or AOM

29

Fork lift or fork lowering or driving backward or AOM

30

Fork lift or fork lowering or driving forward or driving backward or AOM

31

Parameter 20 You decide yourself what the hour meter will show.

1A = Key time 2b = Movement time 3c = Drive motor time 4d =Pump motor time 5s = Time for service

Parameter 21 You must specify the type of battery the truck is equipped with.

In order to set the meter for the battery’s level of discharge, the following should be taken into account: • Acid concentration when the battery is fully charged, to check the grade of the battery. Must be between 1.27-1.29.

• When the lifting capacity is disconnected (the battery is 80 % discharged), the value must be close to, but not below, 1.14.

The acid concentration can vary depending on the battery make.

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 41

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Recommendation on parameter setting for freely ventilated batteries Parameter 21

Battery size 7PM18, 7PM20, 7PML20-6

Battery size 7PML20-8

1 Less discharge

2 3 4 5

260Ah - 320Ah Standard value

6

190Ah - 250Ah

7

120Ah - 180Ah

260Ah - 320Ah Standard value

8

190Ah - 250Ah

9

120Ah - 180Ah

10 11 Greater discharge

12 13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

9- 42

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Remove the battery from the truck and allow to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the acid weight of the battery at room temperature. If the acid weight is less than 1.15 g/cm3, the parameter value must be reduced. If the value significantly exceeds 1.15 g/cm3, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 43

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Recommendation on parameter setting for valve-controlled batteries (VRLA) Parameter 21

Battery size 7PM18, 7PM20, 7PML20-6

Battery size 7PML20-8

1 Less discharge

2

260Ah - 320Ah

3

190Ah - 250Ah

4

120Ah - 180Ah

260Ah - 320Ah

5

190Ah - 250Ah

6

120Ah - 180Ah

7 8 9 10 11 12 Greater discharge

13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

9- 44

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Disconnect the battery from the truck and allow the battery to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the battery voltage at room temperature. If the voltage is less than Uend, see the table below, the parameter value must be reduced. If the value significantly exceeds Uend, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

Battery type

Battery voltage at rest, Uend

Hawker Evolution

24,24 V

Parameter 22 You must specify the type of brake switch the truck is equipped with.

Mechanical switch = 0 Inductive sensor= 1

Parameter 25 Using this parameter you can specify a limit for when the next service is to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for a service, warning 29 (C29) is shown in the display.

Parameter 28 Using this parameter you can select which button is to be used for lift/lower.

1 = Bottom lift/lower button activated (default) 2 = Top lift/lower button activated 3 = Both lift/lower buttons are activated

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 45

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Parameter 39 Login method and driver parameter access This parameter determines which function is to be used for login and whether the operator can adjust the driver parameter settings.

• Value 1 – Key switch fitted – Driver parameters accessible (without CAN service key).

• Value 2 – Key switch fitted – Driver parameters NOT accessible (without CAN service key).

• Value 3 – Keypad (Standard 10 PIN code)- Driver parameters accessible (without CAN service key) NB! this is the original setting.

• Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT accessible (without CAN service key).

• Value 5 – Expanded keypad (100 PIN code)- Driver parameters accessible (without CAN service key) • Value 6 – Expanded keypad (100 PIN code)- Driver parameters NOT accessible (without CAN service key) • Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parameters accessible (without CAN service key) • Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parameters NOT accessible (without CAN service key)

Expanded keypad - General The truck can contain a maximum of 10 individual driver profiles. The expanded keypad function thus allows you to assign a maximum of 10 PIN codes for each of the driver profiles. This allows you to manage a maximum of 100 unique PIN codes.

If the expanded keypad function is activated, the standard management of PIN codes normally accessible via parameter #10 is set aside.

Expanded keypad - Programming A number of PIN codes can be made accessible by activating the socalled block. Block no. 0 is activated as standard. This means that 3 different driver profiles are available from the start. Activation of other blocks means that all PIN codes for the block are accessible (See Table 5:). If all 10 blocks are activated, there will be 10 PIN codes available for the driver profile.

The truck program stores a standard list of PIN codes as per Table 5: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles.

9- 46

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

To start programming the expanded keypad: • Connect an appropriate CAN service key to X41 • Enter code 341671 and press

on the keypad.

• Select the programming command from Table 4:

Table 4: Programming command - expanded keypad Progamming

Function

Notes

Reset to factory settings

Block 1 - 9 is deactivated.

Original PIN codes reset as per Table 5:

PIN codes in the block can be used

B= Block no. 0 - 9

PIN codes in the block cannot be used

B= Block no. 0 - 9

Programming a new PIN code

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

Press “1” +

Press “2” + B + Press “3” + B + Press “4” + B + F + NNNN +

• Switch off the truck by pressing

on the keypad.

The expanded keypad programming is now complete Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN codes to be valid.

Carry out a practical test by logging in using some of the new PIN codes. It is important to establish that the correct driver profile has been activated when a certain PIN code has been entered, especially if a specific driver profile has been set for a specific application/goods handling.

Table 5: shows the PIN codes available as standard in the program.

These can be activated for use or changed according to the driver’s wishes.

One or more of these blocks can be activated.

A driver profile is activated, on normal login, by all PIN codes whose block no. is activated.

The truck program does not approve login using the PIN code “0000”.

Service personnel should keep notes on activated blocks, changed PIN codes and specially-set driver profiles.

NOTE! Resetting the expanded keypad does NOT affect the driver profile settings. © TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 47

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Table 5: Standard PIN code assignment with the expanded keypad Driver 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.

_

Service indication A

• Connect CAN key to X41 and start the truck • Battery status is shown and symbol “D” is lit • Press S18 to go to display mode.

See the table below.

E

D

C

B

Flashing symbol

Data

B

A speed reference value has been sent to Curtis

C

Digital inputs to Curtis and hall sensors. * See explanation below

BC

Battery voltage (V)

D

Armature voltage (A)

BD

Field current (A)

CD

PWM (pulse width modulation) armature in percentage

BCD

Status of Curtis

*These are displayed by segments of three of the figures being marked (A).

9- 48

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

• The figure with the highest value is active (marked with an arrow).

• Power amplifier, inputs.

A

T

Segment

Function

A

E

D

B

C A

F

G

S31, input A1:15

D

S10, input A1:12

F

C DP

D

C

E

B

E

B

G

S10, input A1:5

DP

• The figure with the second highest value is active (marked with an arrow).

A

• Power amplifier, inputs

Segment

Function

A

E

D

B

C

A F

G

E D

© TIEE SARL

B C DP

B C

Y41, output A1:2

D

Y1, output A1:3

E

K10, output A1:4

F

H1, output A1:7

G

Y1, output A1:5

DP

K30, output A1:6

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 49

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

• The figure with the third highest value is active (marked with an arrow).

A

• Digital input from control sensors.

Segment

Function

A

E

D

B

C

B C

A F

B

G

E

C DP

D

D

Forks up

E

Forks down

F

Support arm up

G

Support arm down

DP

Horn

• The figure with the fourth highest value is active (marked with an arrow).

A

E

D

C

B

Segment

Function

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

Extra function 3

E

Extra function 2

F

Extra function 1

G DP

9- 50

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.7 Part number A

• Press and hold S18 while turning S17 to “ON” position.

• Press S18 until Pn = part number is displayed.

E

D

C

• You have now selected Pn = part number and the symbol ”D” is lit as an indication of what is now shown in the display. Initially, Pn = number is displayed for the component’s entire unit.

B

• By scrolling with L1, you can get the following information: • SPn = Part number for software.

• HPn = Part number for hardware.

• HSn = Serial number for hardware.

9.8 Transistor panel

STATUS

B+

A1

M-

M

A2

MODEL

VOLTAGE

SERIAL

CURRENT

9.8.1 General Curtis 1243 is a regulator that controls shunt motors. What primarily controls the speed is the variation in the voltage in the rotor. The voltage is varied by means of pulse width modulation (PWM). This also includes variation in "on" time for the MOS transistors that regulate the rotor current.

The rotation direction is changed by changing the polarity in the field winding (S1-S2). The regulator is equipped with a transistor-fitted fourquadrant bridge for the field winding and a single-quadrant bridge for the rotor winding.

S1

© TIEE SARL

S2

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 51

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.9 Troubleshooting 9.9.1 Error codes and troubleshooting

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The table below describes the error codes that can be displayed with the status light or read on the hand unit.

STATUS LED

Text on hand unit

Explanation

Possible cause

LED off

-

No voltage or error in the regulator.

Defective fuse, poor contact, not connected, error in the regulator.

LED on

-

Error in the regulator.

Error in the regulator.

1,1

¤¤

CURRENT SHUNT FAULT

Error in the built-in current shunt.

Error in the rotor current sensor in the motor monitor.

1,2

¤ ¤¤

HW FAILSAFE

CAN timeout in power amplifier.

The motor monitor is reporting an unexpected data loss from the tiller arm head.

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short circuited to B-.

Problem with switch transistor in the rotor circuit inside the motor monitor.

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Voltage too high for contactor feed or short-circuited field winding.

Attempt to extract more current than the output device can manage.

Problem regulating the field current.

Internal monitoring error.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding.

Shunt field open, defective cable, defective motor monitor.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage.

1. Battery voltage < 17 volt.

2. Battery poles affected by corrosion.

3. Loose battery or regulator connections.

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Voltage too high.

1. Battery voltage > 33 volt.

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Too high/too low temperature reduction.

1. Temp. > 85oC or < -25oC 2. The truck is overloaded.

3. Incorrectly installed transistor regulator.

4. Operation under extreme conditions.

9- 52

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical System – 5000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

9.9.2 Reset error When you want to clear an error, first turn S17 to the “OFF” position and then “ON” again.

Error

Reset when

OVERVOLTAGE

The battery voltage is below 33 V.

THERMAL CUTBACK

The temperature is within the permitted interval.

THROTTLE FAULT 1, 2

The fault has been dealt with.

LOW BATTERY VOLTAGE

When the battery voltage exceeds 16 V.

9.9.3 Safety The regulator is a heavy current component. When it is used on a battery-powered vehicle, all necessary safety measures must be taken.

This means, among other things, that the driver must have suitable training, use goggles, avoid loose clothing, take off watches and jewellery and only use insulated tools. It may also be necessary to take other measures.

WARNING !

Risk of short circuiting Remove watches, jewellery and always use insulated tools only.

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20 Approved by: L- G Andersson

9- 53

Electrical System – 5000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

9.10 Technical specifications – Curtis 1243 Value

Unit

Operating voltage

24

Volt

Top voltage limit

33

Volt

Bottom voltage limit

16

Volt

Minimum operating voltage

Electrical insulation against cold chassis

500

V AC

Minimum

PWM frequency

16

kHz

Maximum current in rotor winding*

150

Ampere

for 2 minutes

100

Ampere

for 1 hour

20

Ampere

for 2 minutes

Maximum current in field winding

20

Explanation

for 1 hour

Contactor voltage

24

Volt

The same as for the battery

Contactor current

2

Ampere

Max (valid limit for 2.5 ampere)

KSI input voltage, min.

16,8

Volt

KSI input current

50

mA

Logical voltage value in

> 7.5; High < 1; Low

Volt

Logical input current value

15

mA

Operating temperature

-40 to +50

°C

Upper temperature limit, reduction

85

°C

Lower temperature limit, reduction

-25

°C

* Under special test conditions.

9- 54

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Electrical parts Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10- Electrical systems – 5000 7PLL24 10.1 Electrical parts

S10 S17

S53

S21

Y1 M1

X1

A1 F50 M3 F51 X41 R1 F1

Y41

K10 F3 K30 P1

H1 M6

S19

S59

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 1

Electrical systems – 5000 7PLL24 Electrical parts T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

A7

10- 2

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Symbol list and electrical diagram Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.2 Symbol list and electrical diagram Symbol

Description

Function

Notes

A1

Transistor regulator

A5

Electronic card

A6

Display

A7

Keypad

PIN-number login

Option

F1

Fuse

Drive motor circuit

175 A

F3

Fuse

Pump motor circuit

130 A

F 50

Fuse

Operating circuit A5

7,5A

F 51

Fuse

Operating circuit A1

7,5 A

F 52

Fuse

Optional equipment

Option

F64

Fuse

Steering motor

20 A Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

M1

Motor

Drive motor

M3

Motor

Pump motor

M6

Motor

Steering motor

option

M12

Motor

Fan

Not cold store

P1

Potentiometer

Load sensor

R1

PTC-resistor

Power supply

© TIEE SARL

24 V

Service Guide 7PLL24

15 Ohm

Approved by: L- G Andersson

10- 3

Electrical systems – 5000 7PLL24 Symbol list and electrical diagram T-code 497 Date 2005-05-26

10- 4

Valid from serial number 723984Order number 225842-040

Symbol

Description

Function

S1

Switch

Option

S2

Switch

Option

S3

Switch

Option

S4

Switch

Option

S5

Switch

Option

S6

Switch

Option

S10

Switch

Travel brake

S17

Switch

Key

S18

Switch

Horn button

S19

Switch

Man on platform

S20

Switch

Switch for safety reversing

S21

Switch

Emergency switch off

S31

Switch

Lift height limiter

S34

Switch

Fork lifting

S41

Switch

Fork lowering

S53

Switch

Gates

S59

Switch

Platform in upper position

Y1

Brake

Y41

Magnetic valve

Fork lowering

X1

Connector

Battery

X41

Connection point

CAN communication

© TIEE SARL Service Guide 7PLL24

Notes

Brake lever

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Symbol list and electrical diagram Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.2.1 Electrical wiring diagram 1(5)

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 5

Electrical systems – 5000 7PLL24 Symbol list and electrical diagram T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

10.2.2 Electrical wiring diagram 2(5)

10- 6

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Symbol list and electrical diagram Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.2.3 Electrical wiring diagram 3(5)

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 7

Electrical systems – 5000 7PLL24 Symbol list and electrical diagram T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

10.2.4 Electrical wiring diagram 4(5)

10- 8

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Symbol list and electrical diagram Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.2.5 Electrical wiring diagram 5(5)

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 9

Electrical systems – 5000 7PLL24 Symbol list and electrical diagram T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

10.2.6 Electrical wiring diagram Servo (Option)

10- 10

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Functional description Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.3 Functional description 10.3.1 Starting the truck • Battery connector plugged in.

• S21 closed.

• S17 on.

10.3.2 Driving without using platform and gates, speed ≤ 6 km/h

A1 BS1

• S59 open.

T1

Ish

S2

• S10 closed.

MA2

Shunt

+ Ia

• L1 activated in any direction.

A A1

T2

B+

K10

10.3.3 Driving from platform without using gates,speed ≤ 6 km/h • S 19 closed.

• S10 closed.

• L1 activated in any direction.

10.3.4 Driving from platform and using gates, speed ≥ 8 km/h • S 19 closed.

• S 53 closed.

• S10 closed.

• L1 activated in any direction.

10.3.5 Neutral speed reduction

A1 BS1

Ish

Ia

• Load sensor P1 determines speed reduction force.

MShunt

+

T1

S2 A2

A A1

T2 K10

• L1 to neutral position, motor starts to work as generator. Brake energy comes back to battery.

B+

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

• Energy back to the battery, see picture.

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

T

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 11

Electrical systems – 5000 7PLL24 Functional description T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

10.3.6 Neutral speed reduction on slopes If the driver release the speed leaver (L1) on a slope and the truck doesn’t come to a stop within a certain time the electrical brake will be applied.

10.3.7 Braking The brake is always applied when the truck is started with the tiller arm in it’s upper or lower position (S10 open). The brake is released in the same moment as the conditions for driving are fulfilled and the truck starts to move.

Conditions to brake the truck: • S10 open or S19 open.

10.3.8 Lifting the forks • S34 activated.

• S31 closed.

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

10.3.9 Lowering the forks • S41activated.

10.3.10 Horn • S18 activated.

10- 12

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Electrical systems – 5000 7PLL24 Hour meter Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.4 Hour meter • Press S18 and turn S17 to on at the same time.

• Press S18 until you read the H= hour meters.

A

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

• You can now choose type of hourmeter by pressing L1.

E

D

C

B

1(A)= Key time.

2(b)= Drive motor time.

3(c)= Pump motor time.

4(d)= Activity time.

5(s)= Time left to make service.

10.5 Error codes • Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until E = error codes is displayed.

• When E is selected, the “E” symbol will light up as an indication of what is shown in the display.

• The 50 most recent error codes are stored. The latest error is displayed first. The display shows the error code first, followed by the time when the error occurred.

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

• C codes are not stored. They are only cautions and remain lit in the display as long as the fault remains.

• If there is only one error registered in the memory, the other empty entry lines appear as follows: Error: E - - - and time: - - - - .

© TIEE SARL

Code

C3

Description

TLS: Shock sensors registered values outside the limits

Possible error cause

A shock sensor has reported values that exceed the truck’s tolerance values.

Driving may be too hard Check that the shock sensor’s limit values are correctly set.

Check that the shock sensor is correctly positioned./The brake engages and stops the truck.

The TLS reset command activates the truck

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Electrical systems – 5000 7PLL24 Error codes T-code 497 Date 2005-05-26

10- 14

Valid from serial number 723984Order number 225842-040

Code

C4

Description

TLS: Use of the truck has been blocked

Possible error cause

Truck use can be “blocked” by a TLS command. / The truck cannot be used until a new TLS command cancels the blocking of the truck

Code

C19

Description

Parameter caution. Displayed for 5 seconds.

Possible error cause

The parameters have probably been changed.

When changing/updating the program the parameters have automatically been changed to default values (only applies to old program versions).

In later program versions the parameters are only changed if they are outside the values permitted by the new program.

Action

1. This means that the special parameters must be reset manually.

Code

C20

Description

Speed control caution.

Possible error cause

Problem with the speed control sensors.

The toggle switch may have been activated when starting or there may be a fault on one of the sensors on the electronic card. (tiller arm head)

Action

1. Restart with the speed control in neutral position.

2. Replace the electronic card.

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Electrical systems – 5000 7PLL24 Error codes Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

Code

C28

Description

Emergency switch caution

Possible error cause

The emergency switch has been activated.

No current to the travel regulator, input. A1/16.

Action

1. Check fuse F51.

2. Check the emergency switch.

3. Check the cables from the battery and the battery contacts.

4. If PTC resistor R1 is very hot, remove the battery contact and allow the resistor to cool.

Restart.

© TIEE SARL

Code

C29

Description

Service warning

Possible error cause

Time for service.

The service counter has not been reset since the last service.

Code

C31

Description

Pressure switch warning.

Possible error cause

A problem with the pressure switch. Check that the voltage is approximately 24 V between cables 24 and 40 connected to the pressure sensor.

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

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Electrical systems – 5000 7PLL24 Error codes T-code 497 Date 2005-05-26

10- 16

Valid from serial number 723984Order number 225842-040

Code

C41

Description

Warning of low battery voltage

Possible error cause

Battery voltage < 17 volt.

The battery parameters are not correctly set.

Time to charge up the battery.

Action

1. Check parameter 21, battery size and type.

2. Check the battery contact and the pole connections on the battery 3. Check the key switch, S17, poor contact causes unpermitted voltage drop.

The electrical system measures the voltage inside the travel regulator.

© TIEE SARL Service Guide 7PLL24

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Electrical systems – 5000 7PLL24 Error codes Valid from serial number 723984Order number 225842-040

© TIEE SARL

T-code 497 Date 2005-05-26

Code

C42

Description

Warning of high battery voltage

Possible error cause

Battery voltage > 33 volt.

Energy return feed to battery during motor braking with a fully-charged battery.

Action

1. The fault disappears after a few lifts, once the battery has been run down slightly.

2. Check the cabling, the battery contact and the contact points on main contactor K10.

Code

C43

Description

The travel regulator shuts off due to excess or subnormal temperature.

Possible error cause

Too intensive operation or ambient temperature too cold.

Error in the travel regulator.

Temperature levels below -25oC or above +85oC reduce running speed.

Action

1. Check that the M12 fan is functioning.

(Applies to P 24) 2. Check that the travel regulator is installed with good contact with the chassis.

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Electrical systems – 5000 7PLL24 Error codes T-code 497 Date 2005-05-26

10- 18

Valid from serial number 723984Order number 225842-040

Code

C90 (Option)

Description

Extra I/0 (0) CAN communication error

Possible error cause

Data from extra I/0 box /(0) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C91 (Option)

Description

Extra I/0 (1) CAN communication error

Possible error cause

Data from extra I/0 box /(1) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C92 (Option)

Description

Configuration error Extra I/0 (0)

Possible error cause

Incorrect setting of options in the extra I/0 box (0) Check the outputs’ allocation on the I/0 expansion box (0)

Code

C93 (Option)

Description

Configuration error Extra I/0 (1)

Possible error cause

Incorrect setting of options in the extra I/0 box (1) Check the outputs’ allocation on the I/0 expansion box (1)

© TIEE SARL Service Guide 7PLL24

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Electrical systems – 5000 7PLL24 Error codes Valid from serial number 723984Order number 225842-040

© TIEE SARL

T-code 497 Date 2005-05-26

Code

E101

Description

Travel regulator does not correspond with the type of truck

Possible error cause

Incorrect travel regulator or electronic card has been installed. The truck has a built-in control function that checks to ensure the wrong combination of travel regulator and electronic card has not been installed.

Action

Check travel regulator and electronic card.

Code

E104

Description

Switch-transistor to brake is short-circuited

Possible error cause

Error in the travel regulator, output. A1/3.

Incorrect value on parameter 22

Action

Check cabling and contacts. Measure Ohms on the magnet coil (Y1) for the brake. Value 13-15 ohm.

Check parameter 22

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Electrical systems – 5000 7PLL24 Error codes T-code 497 Date 2005-05-26

10- 20

Valid from serial number 723984Order number 225842-040

Code

E106

Description

Digital outputs short-circuited or exceeding field current limit.

Possible error cause

Problem regulating the field current.

Internal monitoring error.

Action

1.

© TIEE SARL Service Guide 7PLL24

Check the output for main contactor K10 (A1/4), check cabling and contacts and measure ohms for the coil. Value 25-30 ohm. Check the output for the brake coil K10 (A1/3), check cabling and contacts and measure ohms for the coil. Value 13-15 ohm.

2. Check the output for horn (A1/7), check cabling and contacts.

3. Check the drive motor’s shunt winding and cabling and contacts. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

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Electrical systems – 5000 7PLL24 Error codes Valid from serial number 723984Order number 225842-040

© TIEE SARL

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Code

E107

Description

Contactor K10 does not close.

Possible error cause

Problem with main contactor points or coil.

Contactor’s operating cabling off/not connected.

Interruption in the travel regulator’s output, A1/4.

Action

1. Check if the contactor is activated.

2. If the contactor is working, check the contact points and accompanying cabling.

3. If the contactor is not working, check the coil and accompanying cabling. Measure Ohms for the coil. Value 25-30 ohm.

4. Check the travel regulator’s output, A1/4.

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10- 21

Electrical systems – 5000 7PLL24 Error codes T-code 497 Date 2005-05-26

10- 22

Valid from serial number 723984Order number 225842-040

Code

E108

Description

Contactor K10 does not open.

Possible error cause

Main contactor points welded.

Short circuit in the travel regulator’s output A1/4.

Action

1. Check that the contactor’s contact points are not welded together.

2. Check that the R1 resistor is not shortcircuited.

3. If the contact points are OK, but the contactor engaged, check cable 64 and the travel regulator’s output A1/4.

Code

E110

Description

System error.

Possible error cause

Temporary error/error in the travel regulator.

Action

1. Restart the machine.

2. Replace travel regulator.

Code

E140

Description

Error in control total.

Possible error cause

Fault on the internal micro-monitoring (tiller arm head), incorrect software or circuit board.

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Electrical systems – 5000 7PLL24 Error codes Valid from serial number 723984Order number 225842-040

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Code

E141

Description

Software problem.

Possible error cause

Fault on the internal monitoring (tiller arm head), incorrect software or circuit board.

Action

1. Restart the machine.

2. Download the program again.

3. Replace the electronic card

Code

E150

Description

Fault in the data communication.

Possible error cause

Break on the CAN cable.

Action

1. Check the 119 and 120 cables and their contacts.

2. Replace travel regulator.

Code

E151

Description

Tx error in data communication.

Possible error cause

Travel regulator not responding.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

Code

E157

Description

Bus shut off.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

w

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10- 23

Electrical systems – 5000 7PLL24 Error codes T-code 497 Date 2005-05-26

10- 24

Valid from serial number 723984Order number 225842-040

Code

E159

Description

Transgression error.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

Code

E160

Description

Error in safety reversing function

Possible error cause

Error in important sensor part.

Action

1. Replace the electronic card

Code

E200

Description

Open field.

Possible error cause

Shunt field’s circuit open.

Action

1. Check the field winding connections E1 and E2.

Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

2. Check cables 4 and 5 and outputs S1 and S2 3. Replace travel regulator

© TIEE SARL Service Guide 7PLL24

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Electrical systems – 5000 7PLL24 Error codes Valid from serial number 723984Order number 225842-040

© TIEE SARL

T-code 497 Date 2005-05-26

Code

E201

Description

M minus error.

Possible error cause

Problem with switch transistor in the armature circuit inside the travel regulator.

Action

1. Check cable and connections between A1/M on the travel regulator and connection A2 on drive motor.

2. Replace travel regulator.

Code

E202

Description

Fault on sensor in travel regulator

Possible error cause

Fault on armature current sensor in travel regulator

Action

Replace travel regulator

Code

E214

Description

CAN timeout in power amplifier.

Possible error cause

The motor monitor is reporting an unexpected data loss from the electronic card in the tiller arm head.

Action

1. Check cables 119 and 120 between electronic card and travel regulator.

2. Replace electronic card 3. Replace travel regulator.

Service Guide 7PLL24

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10- 25

Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

10.6 Parameters A

E

D

C

B

• Press S18 and turn S17 to on at the same time.

• Press S18 until you read P= parameters.

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

• Scroll to the parameter you want to change or look at by pressing the L1 up or down.

• Press S18 ones to get access to the parameter.

• Set parameter value by pressing L1 up or down.

• Press S18 ones to confirm change.

• Turn S17 to off.

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

NOTE !

Truck handling.

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

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

10.6.1 Driver parameters Parameter

Name

Unit

Min

Max

Step

Std

Description

1

Speed, low Speed

%

10

100

5

100

10:low Speed 100:highest Speed

02

Speed, high speed

%

10

100

5

100

10:low Speed 100:highest Speed.

03

Acceleration

10

100

5

75

10:low acceleration 100:full acceleration

04

Neutral speed reduction

5

100

5

80

Defines motor speed reduction force when lever goes to neutral position.

5: low reduction force 100: full reduction force

05

Logout

0

20

1

20

The time it takes for the truck to switch off when the keypad is used. The time counts down from the moment the last power-consuming unit is used.

Value = 0 gives 4 hours.

In steps of 1

10- 26

1min

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Electrical systems – 5000 7PLL24 Parameters Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.6.2 Parameter description Parameter 1 Possibility to adjust the speed in the low speed range (when the safety gates are not used).

Parameter 2 Possibility to adjust the speed in the high speed range (when the safety gates are used).

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

Parameter 4 Defines motor brake force when lever (L1) goes to neutral position.The lower value of parameter the longer time to reduce speed.

Parameter 5 The time until the truck will be switched off when a key pad is used.

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

Value = 0 gives 4 hours.

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10- 27

Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

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10.6.3 Service parameters • • • •

A

E

D

C

B

• • • • •

Connect CAN-key in X41 Press S18 and turn S17 to on at the same time.

Press S18 until you read P= parameters.

You have now choosen P=parameters the symbol “C” on display will be highlighted to indicate what’s currently shown on display.

Scroll to the parameter you want to change or look at by pressing the L1 up or down.

Press S18 ones to get access to the parameter.

Set parameter value by pressing L1 up or down.

Press S18 ones to confirm change.

Turn S17 to off.

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

NOTE !

Truck handling.

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

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

Parameter

Description

10

Unit

Min.

Max.

Step

Std.

Description

PIN-code

0

9999

1

1

Facility for specifying up to 10 PIN codes (10 different drivers).

14

Crawling speed

-10

10

1

0

The amount of power the monitor should emit when you reach the first speed sensor can be specified here.

-10: low speed for the first speed sensor.

10: high speed for the first speed sensor

15

Non-configurable option 0 to 9

See “Option parameters” on page 30, Servicemanual

16

Configurable option #1

See “Option parameters” on page 30, Servicemanual

17

Configurable option #2

18

Configurable option #3

19

Configurable option #4

10- 28

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Parameter

Description

20

Unit

T-code 497 Date 2005-05-26

Min.

Max.

Step

Std.

Description

Hour meter option

1

5

1

2

Select hour meter.

21

Battery size

1

20

1

5

Selection of battery size.

22

Inductive sensor

0

1

1

1

0: Mechanical switch 1: Inductive sensor

25

Service interval

0

2000

50

100

Option for setting service timer

28

Lift button selection

1

3

1

1

Button selection

39

Password

1

12

1

1

States which level of authorization the driver has for the parameters.

Odd values specify open driver parameters, even values specify that driver parameters must be opened using the CAN key

1h

10.6.4 Parameter description Parameter 10 NOTE! The functionality of parameter #10 is set aside if the value of parameter #39 is set to 5,6,7 or 8. The PIN codes are managed using the socalled expanded keypad. See section Expanded keypad - General on page 42 for more detailed information.

Ten drivers can have their own PIN code to gain access to the truck.

Each driver can set all driver parameters individually.

On delivery the PIN code is set to 1 and this only applies for driver no. 1.

Code 0 is not accepted as a solitary code.

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

When you want to switch off the truck, press the red button numbered 0.

When the CAN key is connected, you can start the truck by simply pressing the green button numbered 1. Switch off by pressing the red button numbered 0.

Parameter 14 Specifies the speed you will have when you reach the first speed sensor.

Parameter 15 - Non-configurable option See “Option parameters” on page 30, Servicemanual © TIEE SARL

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Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

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Parameter 16 - Configurable option #1 See “Option parameters” on page 30, Servicemanual

Parameter 17 - Configurable option #2 See “Option parameters” on page 30, Servicemanual

Parameter 18 - Configurable option #3 See “Option parameters” on page 30, Servicemanual

Parameter 19 - Configurable option #4 See “Option parameters” on page 30, Servicemanual

Option parameters WARNING !

Do not try to change these parameter unless you have specific knowledge of the truck options or truck modifications. This service manual only covers the truck’s standard equipment. Specially modified trucks may require you to have access to particular service information. Incorrect adjustment of option parameters may result in incorrect function.

General Parameters #15 to #19 have been reserved in the truck control system for extra options and/or specific product modifications. These parameters are normally configured by the manufacturer on modification or customisation of the truck. It is recommended that the parameter settings be loaded up from the truck when carrying out any modification. If, for example, the main logic card [A2] must be replaced, the original parameter settings can then be simply transferred to the new card, which ensures that all the special options function correctly.

Parameter #15 Non-configurable options Up to 16 so-called sub-parameters are stored under parameter #15.

Their status is either ON or OFF and they do not require any other adjustments. They are therefore called non-configurable options.

10- 30

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Changing non-configurable options • Ensure the truck is in parameter mode.

The parameter symbol is lit.

• Select parameter #15 using [L1].

The first set-up of sub-parameters is displayed The next set-up of sub-parameters is displayed if you continue to activate the speed control L1. Ensure that only the relevant sub-parameters are displayed.

The value of the sub-parameters is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

.

• Enter the sub-parameter value by repeatedly operating the speed control L1 in either direction. See Table 6: for more information.

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

The parameter symbol is lit (i.e. stops flashing).

• Switch off the truck by pressing

© TIEE SARL

Service Guide 7PLL24

on the keypad.

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Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

The non-configurable option is now activated.

• Check that the function works correctly before the truck is put back in operation.

P

Sub-parameter no.

Function name

Function ON

Function OFF

Basic setting

Table 6: Parameter #15 Non-configurable option Value

Note!

1

"Turtle" function

1

0

0

2 to 9

For future use

-

-

-

Parameter #16 to 19 configurable optional functions Parameter no. #16, #17, #18 & #19 can be adjusted to activate up to a maximum of 4 pre-programmed functions and configure these to suit optional equipment or customisation of the truck. See “Table 7:List of configurable optional functions” on page 34. These are thus called the configurable optional functions.

• Each parameter can be programmed to cover a specific optional function.

• Each optional function can have up to 4 independent variables associated with it.

• Each independent variable has a value you can change to configure the function.

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Parameter no. (range 16-19) Independent variable: #0 is the option designation

16 - 0 - 1

Independent variable value (range 0-63) 0= no option has been activated for this parameter 1 to 63 = Pre-programmed option number. See separate table.)

SETTING THE OPTIONAL FUNCTION

Independent variable: #1, #2, #3 & #4 contain the optional function valu

16 - 1- 1

Independent variable value (the range depends on the function referred The value depends on the option and independent variable selected.

See separate table CONFIGURING THE OPTIONAL FUNCTION

Fig. 2

Summary – option parameter

Changing configurable optional functions In order to activate a configurable optional function, it must first be assigned a parameter from #16 to #19. This is done by changing independent variable #0 to the pre-programmed option number. Once this has been done, the independent variable for the option must be configured. This is done by changing the values for independent variables #1, #2, #3 and #4.

• Ensure the truck is in parameter mode.

The parameter symbol is lit.

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

Independent variable #0 is displayed The independent variable value is displayed after 1 second. The value “0” means that an optional function has not been assigned to this parameter, and the speed control L1 in this case displays the next parameter if you continue to activate it.

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction. See Table 7: © TIEE SARL

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Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

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

The parameter symbol is lit (i.e. stops flashing).

• Select independent variable #1 by activating the speed control L1.

Independent variable value #1 is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #1 by repeatedly operating the speed control L1 in either direction. See the list of optional functions in Table 7: • Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

Adjust independent variables #2, #3 and #4 in the same way as above.

• Switch off the truck by pressing

on the keypad.

The optional function is now activated.

• Check that the optional function works correctly before the truck is put back in operation.

Table 7: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 1: The option button controls the spider output 0:Spider 0 1:Spider 1

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

1-6:option button 1-6

Type of function: 0:instantaneous 1:butterfly switch

Independent variable #0 = 2:Reduced running speed controlled by the spider’s digital input 0:Spider 0 1:Spider 1

10- 34

0-7:Digital input 1-8

© TIEE SARL Service Guide 7PLL24

0-12:reduced speed 40-100% (i.e. 40+5*arg3 e.g.

4: 40+5*4=60%)

0:high-speed range 1:low-speed range 2: both ranges

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Parameters Valid from serial number 723984Order number 225842-040

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Table 7: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 3:Activate the spider output for specific movements 0:Spider 0 1:Spider 1

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

Select movements.

See Table 8:

Initial position: 0: shines constantly 1: flashes 1 Hz 2: flashes 2 Hz

Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input 0:Spider 0 1:Spider 1

0-7:Digital input 1-8

0-30:Holding time 030 minutes

Not used

Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs 0:Spider 0 1:Spider 1

0: Lift, digital input 1 Lowering, digital input 2 Blocking of lowering, input 3 1: Lift, digital input 2 Lowering, digital input 3 Blocking of lowering, input 4 2: Lift, digital input 3 Lowering, digital input 4 Blocking of lowering, input 5 3: Lift, digital input 4 Lowering, digital input 5 Blocking of lowering, input 6 4: Lift, digital input 5 Lowering, digital input 6 Blocking of lowering, input 7 5: Lift, digital input 6 Lowering, digital input 7 Blocking of lowering, input 8

0: Blocking of lowering disconnected 1: Blocking of lowering connected

0: Fork lift/lowering 1: Support arm lift/lowering

Independent variable #0 = 6:Lift height limitation with by-pass 0:Spider 0 1:Spider 1

© TIEE SARL

0-7: Limit switch for digital input 1-8

Service Guide 7PLL24

1-6: By-pass, option switch 1-6

Not used

Approved by: L- G Andersson

10- 35

Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Table 8: Option 3 – Choice of movement

10- 36

Selected movement

Independent variable #3

-

0

Driving forward

1

Driving backward

2

Driving forward or backward

3

Fork lift

4

Fork lift or driving forward

5

Fork lift or driving backward

6

Fork lift or driving forward or driving backward

7

Fork lowering

8

Fork lowering or driving forward

9

Fork lowering or driving backward

10

Fork lowering or driving forward or driving backward

11

Fork lift or fork lowering

12

Fork lift or fork lowering or driving forward

13

Fork lift or fork lowering or driving backward

14

Fork lift or fork lowering or driving forward or driving backward

15

All other movements (AOM)

16

Driving forward or AOM

17

Driving backward or AOM

18

Driving forward or driving backward or AOM

19

Fork lift or AOM

20

Fork lift or driving forward or AOM

21

Fork lift or driving backward or AOM

22

Fork lift or driving forward or driving backward or AOM

23

Fork lowering or AOM

24

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Parameters Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

Table 8: Option 3 – Choice of movement Selected movement

Independent variable #3

Fork lowering or driving forward or AOM

25

Fork lowering or driving backward or AOM

26

Fork lowering or driving forward or driving backward or AOM

27

Fork lift or fork lowering or AOM

28

Fork lift or fork lowering or driving forward or AOM

29

Fork lift or fork lowering or driving backward or AOM

30

Fork lift or fork lowering or driving forward or driving backward or AOM

31

Parameter 20 You decide yourself what the hour meter will show.

1A = Key time 2b = Movement time 3c = Drive motor time 4d =Pump motor time 5s = Time for service

Parameter 21 You must specify the type of battery the truck is equipped with.

In order to set the meter for the battery’s level of discharge, the following should be taken into account: • Acid concentration when the battery is fully charged, to check the grade of the battery. Must be between 1.27-1.29.

• When the lifting capacity is disconnected (the battery is 80 % discharged), the value must be close to, but not below, 1.14.

The acid concentration can vary depending on the battery make.

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 37

Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Recommendation on parameter setting for freely ventilated batteries Parameter 21

Battery size 7PLL24 1

Less discharge

2 3 4 5 6 7

Greater discharge

8

570Ah - 640Ah Standard value

9

510Ah - 560Ah

10

430Ah - 500Ah

11

370Ah - 420Ah

12

300Ah - 360Ah

13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

10- 38

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Parameters Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Remove the battery from the truck and allow to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the acid weight of the battery at room temperature. If the acid weight is less than 1.15 g/cm3, the parameter value must be reduced. If the value significantly exceeds 1.15 g/cm3, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 39

Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Recommendation on parameter setting for valve-controlled batteries (VRLA) Parameter 21

Battery size 7PLM20-8 1

Less discharge

2 3 4 5

570Ah - 640Ah

6

510Ah - 560Ah

7

430Ah - 500Ah

8

370Ah - 420Ah

9

300Ah - 360Ah

10 11 12 Greater discharge

13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

10- 40

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Parameters Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Disconnect the battery from the truck and allow the battery to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the battery voltage at room temperature. If the voltage is less than Uend, see the table below, the parameter value must be reduced. If the value significantly exceeds Uend, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

Battery type

Battery voltage at rest, Uend

Hawker Evolution

24,24 V

Parameter 22 You must specify the type of brake switch the truck is equipped with.

Mechanical switch = 0 Inductive sensor= 1

Parameter 25 Using this parameter you can specify a limit for when the next service is to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for a service, warning 29 (C29) is shown in the display.

Parameter 28 Using this parameter you can select which button is to be used for lift/ lower.

1 = Bottom lift/lower button activated (default) 2 = Top lift/lower button activated 3 = Both lift/lower buttons are activated

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 41

Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Parameter 39 Login method and driver parameter access This parameter determines which function is to be used for login and whether the operator can adjust the driver parameter settings.

• Value 1 – Key switch fitted – Driver parameters accessible (without CAN service key).

• Value 2 – Key switch fitted – Driver parameters NOT accessible (without CAN service key).

• Value 3 – Keypad (Standard 10 PIN code)- Driver parameters accessible (without CAN service key) NB! this is the original setting.

• Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT accessible (without CAN service key).

• Value 5 – Expanded keypad (100 PIN code)- Driver parameters accessible (without CAN service key) • Value 6 – Expanded keypad (100 PIN code)- Driver parameters NOT accessible (without CAN service key) • Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parameters accessible (without CAN service key) • Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parameters NOT accessible (without CAN service key)

Expanded keypad - General The truck can contain a maximum of 10 individual driver profiles. The expanded keypad function thus allows you to assign a maximum of 10 PIN codes for each of the driver profiles. This allows you to manage a maximum of 100 unique PIN codes.

If the expanded keypad function is activated, the standard management of PIN codes normally accessible via parameter #10 is set aside.

Expanded keypad - Programming A number of PIN codes can be made accessible by activating the socalled block. Block no. 0 is activated as standard. This means that 3 different driver profiles are available from the start. Activation of other blocks means that all PIN codes for the block are accessible (See Table 10:). If all 10 blocks are activated, there will be 10 PIN codes available for the driver profile.

The truck program stores a standard list of PIN codes as per Table 10: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles.

10- 42

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Parameters Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

To start programming the expanded keypad: • Connect an appropriate CAN service key to X41 • Enter code 341671 and press

on the keypad.

• Select the programming command from Table 9:

Table 9: Programming command - expanded keypad Progamming

Function

Notes

Reset to factory settings

Block 1 - 9 is deactivated.

Original PIN codes reset as per Table 10: B= Block no. 0 - 9

Press “2” + B +

PIN codes in the block can be used PIN codes in the block cannot be used

B= Block no. 0 - 9

Press “3” + B +

Programming a new PIN code

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

Press “1” +

Press “4” + B + F + NNNN +

• Switch off the truck by pressing

on the keypad.

The expanded keypad programming is now complete Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN codes to be valid.

Carry out a practical test by logging in using some of the new PIN codes. It is important to establish that the correct driver profile has been activated when a certain PIN code has been entered, especially if a specific driver profile has been set for a specific application/goods handling.

Table 10: shows the PIN codes available as standard in the program.

These can be activated for use or changed according to the driver’s wishes.

One or more of these blocks can be activated.

A driver profile is activated, on normal login, by all PIN codes whose block no. is activated.

The truck program does not approve login using the PIN code “0000”.

Service personnel should keep notes on activated blocks, changed PIN codes and specially-set driver profiles.

NOTE! Resetting the expanded keypad does NOT affect the driver profile settings. © TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 43

Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

Table 10: Standard PIN code assignment with the expanded keypad Driver 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.

_

Service indication A

• Connect CAN key to X41 and start the truck • Battery status is shown and symbol “D” is lit • Press S18 to go to display mode.

See the table below.

E

D

C

B

Flashing symbol

Data

B

A speed reference value has been sent to Curtis

C

Digital inputs to Curtis and hall sensors. * See explanation below

BC

Battery voltage (V)

D

Armature voltage (A)

BD

Field current (A)

CD

PWM (pulse width modulation) armature in percentage

BCD

Status of Curtis

*These are displayed by segments of three of the figures being marked (A).

10- 44

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Parameters Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

• The figure with the highest value is active (marked with an arrow).

• Power amplifier, inputs.

A

T

Segment

Function

A

E

D

B

C A

F

G

S31, input A1:15

D

S10, input A1:12

F

C DP

D

C

E

B

E

B

G

S10, input A1:5

DP

• The figure with the second highest value is active (marked with an arrow).

A

• Power amplifier, inputs

Segment

Function

A

E

D

B

C

A F

G

E D

© TIEE SARL

B C DP

B C

Y41, output A1:2

D

Y1, output A1:3

E

K10, output A1:4

F

H1, output A1:7

G

Y1, output A1:5

DP

K30, output A1:6

Service Guide 7PLL24

Approved by: L- G Andersson

10- 45

Electrical systems – 5000 7PLL24 Parameters T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

• The figure with the third highest value is active (marked with an arrow).

A

• Digital input from control sensors.

Segment

Function

A

E

D

B

C

B C

A F

B

G

E

C DP

D

D

Forks up

E

Forks down

F

Support arm up

G

Support arm down

DP

Horn

• The figure with the fourth highest value is active (marked with an arrow).

A

E

D

C

B

Segment

Function

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

Extra function 3

E

Extra function 2

F

Extra function 1

G DP

10- 46

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Part numbers Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.7 Part numbers A

• Press S18 and turn S17 to on at the same time.

• Press S18 until you read Pn= partnumbers.

E

D

C

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

B

• By scrolling with the L1 you can get the following information: • SPn= Software part number.

• HPn= Hardware part number.

• HSn= Hardware serial number.

10.8 Transistor panel

STATUS

B+

A1

M

MODEL

VOLTAGE

SERIAL

CURRENT

M-

10.8.1 General

A2

Curtis 1243 is a regulator for controlling shunt motors. Varying the voltage applied through the armature primarily controls the speed. The voltage is varied through use of pulse-width modulation (PWM). This involves varying the “on” time of the MOS-FET transistors regulating the armature current.

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

S1

© TIEE SARL

S2

Service Guide 7PLL24

Approved by: L- G Andersson

10- 47

Electrical systems – 5000 7PLL24 Diagnostic and troubleshooting T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

10.9 Diagnostic and troubleshooting 10.9.1 Error codes and troubleshooting

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

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

STATUS LED

Handheld 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 currrent.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shuntfield 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

10- 48

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Electrical systems – 5000 7PLL24 Diagnostic and troubleshooting Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

10.9.2 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

10.9.3 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.

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

10- 49

Electrical systems – 5000 7PLL24 Technical specifications – Curtis 1243 T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

10.10 Technical specifications – Curtis 1243 Value

Unit

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

Undervoltage limit

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature winding *

300

Amps

for 2 minutes

100

Amps

for 1 hour

35

Amps

for 2 minutes

Max. current of field winding

20

Explanation

for 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

2

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

Volts

KSI input current

50

mA

Logic input voltage

>7.5; High <1; Low

Volts

Logic input current

15

mA

Operating temperature

-40 to +50

°C

Overtemperature, reduction

85

°C

Undertemperature, reduction

-25

°C

* During specific test conditions.

10- 50

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Hydraulic/Pneumatik – 6000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

11- Hydraulic/Pneumatik – 6000 7PM18, 7PM20, 7PML20 11.1 General To avoid functional problems with the lowering valve (Y41), such as unintentional lowering of forks, the valve must be cleaned and the function checked before replacing the valve.

11.2 Hydraulic chart and list of symbols 7PM18, 7PM20 n

1

A Y41

4

2 3

M3

P

5 T

11.2.1 List of Symbols Pos No

Description

Function

1

Lift cylinder

Lifting the forks

2

Preasure relief valve

3

Flow control valve

4

Non-return valve

5

Filter

M3

Motor

P

Pump

T

Tank

Y41

Valve

© TIEE SARL

Remarks

Pump motor 1,2 litre (B20 0,5 litre) Lowering valve for the forks

Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson11- 1

Hydraulic/Pneumatik – 6000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

11.3 Adjustments 7PM18 11.3.1 Adjusting the pressure limit valve The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 1850-1900 kg.

1 2 3

1. Locking nut. Use special tool, see drawing in chapter “Tools”.

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

3. Pressure limit valve. Use special tool, see drawing in chapter “Tools”.

• Loosen the locking nut (1) using a special tool (see drawing 3.2).

Place a load of 1800 kg on the forks and check that the truck can lift it.

• If the truck lifts 1800 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

• If the truck lifts 1900 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.

11- 2

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Hydraulic/Pneumatik – 6000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

11.3.2 Tools • Use a 22 mm standard socket and turn it down to the values shown below in drawing A, when you wish to loosen or tighten the pressure limit valve.

• Use a 10 mm standard socket and turn it down to the values shown below in drawing B, when you wish to loosen or tighten the locking nuts.

A

26,5

© TIEE SARL

Service Guide 7PM18, 7PM20, 7PML20

8

12

B

13,5

Approved by: L- G Andersson11- 3

Hydraulic/Pneumatik – 6000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

11.4 Adjustments 7PM20 11.4.1 Adjusting the pressure limit valve The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 2050-2100 kg.

1. Locking nut.

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

• Loosen the locking nut (1) using a 13 mm spanner.

• Place a load of 2000 kg on the forks and check that the truck can lift it.

• If the truck lifts 2000 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

• If the truck lifts 2100 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.

11- 4

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Hydraulic/Pneumatik – 6000 7PM18, 7PM20, 7PML20 Valid from serial number 723984Order number 225842-040

T-code 660, 661, 662 Date 2005-05-26

11.5 Hydraulic chart and list of symbols 7PML20-6, 7PML20-8 n

2

1

A Y41

5

3 4

M3

P

6 T

11.5.1 List of Symbols Pos No

Description

Function

Remarks

1

Lift cylinders

Lifting the forks

2 pieces

2

Powertrakcylinder

Increase the pulling quality when loaded

3

Preasure relief valve

4

Flow control valve

5

Non-return valve

6

Filter

M3

Motor

P

Pump

T

Tank

Y41

Valve

© TIEE SARL

Pump motor

1.2 litre Lowering valve for the forks

Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson11- 5

Hydraulic/Pneumatik – 6000 7PM18, 7PM20, 7PML20 T-code 660, 661, 662 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

11.6 Adjusting the pressure limit valve The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 2050-2100 kg.

1. Locking nut.

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

• Loosen the locking nut (1) using a 13 mm spanner.

• Place a load of 2000 kg on the forks and check that the truck can lift it.

• If the truck lifts 2000 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

• If the truck lifts 2100 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.

11- 6

© TIEE SARL Service Guide 7PM18, 7PM20, 7PML20

Approved by: L- G Andersson

Hydraulic, pneumatic – 6000 7PLL24 General Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

12- Hydraulic, pneumatic – 6000 7PLL24 12.1 General To avoid functional problems with the lowering valve (Y41), such as unintentional lowering of forks, the valve must be cleaned and the function checked before replacing the valve.

12.1.1 Hydraulic diagram

1 2

3

Y41 7

6

4 P

M3 5

5 T

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

12- 1

Hydraulic, pneumatic – 6000 7PLL24 General T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

12.1.2 Symbol list Sym bol

Description

Function

Notes

1

Lift cylinders

Fork lift

2

PowerTrak cylinder

Increases the pulling capacity with a loaded machine

3

Pressure sensor

Input signal to transistor panel that a flow limit change is to be made

4

Flow valve

5

Filter

6

Pressure relief valve

7

Non-return valve

M3

Motor

P

Pump

2.5 ccpr

T

Tank

1.2 litre

Y41

Valve

One filter on the pump's suction side and one on the return

Pump motor

Lowering valve for forks

M3

5 P

T

5 6

4

3 Y41

12- 2

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Hydraulic, pneumatic – 6000 7PLL24 Adjustments Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

12.2 Adjustments 12.2.1 Adjustment of the pressure limit valve The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or complete hydraulic unit is replaced.

The truck should be able to lift a load of between 2250-2300 kg.

Pos.

Description

1

Cover nut

2

Adjuster screw, pressure limit

Notes Adjustment clockwise results in increased pressure Adjustment anticlockwise results in reduced pressure

• Unscrew the cover nut (1) with a spanner, 13 mm.

• Place a load, 2200 kg, on the forks and check that the machine lifts this.

• If the machine can lift 2200 kg, place a further 100 kg on the forks.

Check whether machine can lift the load.

• If the machine can lift 2300 kg, adjust the pressure limit valve by screwing the adjuster screw (2) anticlockwise using a 4 mm allen key until the machine cannot lift the load.

© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

12- 3

Hydraulic, pneumatic – 6000 7PLL24 Cleaning the filter T-code 497 Date 2005-05-26

Valid from serial number 723984Order number 225842-040

12.3 Cleaning the filter

1

3 4

2

5 • Dismantle the hydraulic unit from the machine.

• Empty the oil from the tank.

• Loosen and remove the hose clip (1).

• Loosen and remove the two tank holders (2).

• Loosen the suction filter (5) and the return filter (3).

• Clean the filter in an environment friendly cleaning agent.

Assemble in the reverse order.

12- 4

© TIEE SARL Service Guide 7PLL24

Approved by: L- G Andersson

Hydraulic, pneumatic – 6000 7PLL24 Cleaning the filter Valid from serial number 723984Order number 225842-040

T-code 497 Date 2005-05-26

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© TIEE SARL

Service Guide 7PLL24

Approved by: L- G Andersson

12- 5

©TOYOTA Industrial Equipment Europe SARL Ancenis, France