Toyota Forklift 7SM08F Master Service Manual 904519 - PDF DOWNLOAD

Service Manual en

7SM08F Valid from serial number: 904519-

Order number: 229735-040 Issued: 2005-11-04 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:

Issue date

Order number

Changes

2005-11-04

229735-040

Completely new issue.

This manual covers following truck models:

T-code

Model

Serial number

781

7SM08F

904519-

© TIEE SARL

Service Manual

7SM08F

Approved by: L-G A

Contents Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

1- Contents 1- Contents ............................................................................................... 1-1 2- Technical data ..................................................................................... 2-1 2.1 General tightening torques............................................................. 2-4 3- Maintenance ........................................................................................ 3-1 3.1 Safety regulations with maintenance work ..................................... 3-1 3.2 Cleaning and washing.................................................................... 3-2 3.2.1 External cleaning ............................................................. 3-3 3.2.2 Cleaning the motor compartment .................................... 3-3 3.2.3 Electrical components ..................................................... 3-3 3.3 Safe lifting ...................................................................................... 3-4 3.4 Maintenance Schedule .................................................................. 3-5 3.5 Lubrication chart .......................................................................... 3-10 4- Oil and grease specification ............................................................... 4-1 5- Tools ..................................................................................................... 5-1 5.1 Super Seal connectors................................................................... 5-1 5.2 AMP connectors............................................................................. 5-2 5.2.1 AMP Connectors, 040 series ........................................... 5-3 5.3 Molex connectors........................................................................... 5-3 5.4 Grease guns .................................................................................. 5-4 5.5 Other tools ..................................................................................... 5-5 6- Chassis - 0000 ..................................................................................... 6-1 6.1 Support arms ................................................................................. 6-1 6.1.1 Main Components ........................................................... 6-1 6.1.2 Maintenance .................................................................... 6-2 7- Electric drive motor – 1000 ................................................................. 7-1 7.1 Component parts ........................................................................... 7-1 7.2 Service/Repairs.............................................................................. 7-3 7.2.1 Dismantling of motor from truck ....................................... 7-3 7.2.2 Assembling ...................................................................... 7-3 7.2.3 Dismantling of motor ........................................................ 7-4 7.2.4 Assembling of motor ........................................................ 7-5 7.2.5 Cleaning .......................................................................... 7-5 8- Drive unit/gear – 2000 ......................................................................... 8-1 8.1 Component parts ........................................................................... 8-1 8.2 Leakage from top cover ................................................................. 8-3 8.2.1 Dismantling ...................................................................... 8-3 8.2.2 Assembling is carried out in the reverse order ................ 8-3 8.3 Changing of the drive shaft’s sealing ring....................................... 8-4 8.3.1 Dismantling ...................................................................... 8-4 8.3.2 Assembling ...................................................................... 8-4 9- Brake system – 3000 ........................................................................... 9-1 9.1 Main components........................................................................... 9-1 © TIEE SARL

Service Manual

7SM08F

1- 1

Contents T-code 781

Valid from serial number 9045199.2

Date 2005-11-04

Order number 229735-040

Maintenance .................................................................................. 9-2 9.2.1 Exchange of brake disc ................................................... 9-2

10- Steering – 4000 ................................................................................ 10-1 10.1 Component parts, tiller arm.......................................................... 10-1 10.2 Tiller arm handle .......................................................................... 10-3 10.2.1 Dismantling/Assembling ................................................ 10-5 11- Electrical systems – 5000 ............................................................... 11-1 11.1 General ........................................................................................ 11-1 11.2 Software/hardware part numbers................................................ 11-2 11.3 Nomenclature .............................................................................. 11-2 11.4 Electrical equipment overview ..................................................... 11-3 11.5 Electrical component list .............................................................. 11-5 11.6 Electrical circuit overview ............................................................. 11-8 11.7 Symbol list.................................................................................... 11-9 11.8 Electrical wiring diagram ............................................................ 11-10 11.9 Functional description ................................................................ 11-15 11.9.1 Theory of operation ..................................................... 11-15 11.9.2 Transistor regulator ..................................................... 11-21 11.9.3 Spider expansion unit (SEU) (option) .......................... 11-21 11.9.4 Speed limitation ........................................................... 11-24 11.9.5 Hour meter and battery condition ................................ 11-25 11.10 Diagnostic and troubleshooting.................................................. 11-27 11.10.1 General ........................................................................ 11-27 11.10.2 Error code history ........................................................ 11-27 11.10.3 List of error codes ........................................................ 11-28 11.10.4 Transistor regulator errors ........................................... 11-31 11.10.5 Built-in Test Function ................................................... 11-33 11.11 Parameters ................................................................................ 11-37 11.11.1 General ........................................................................ 11-37 11.11.2 Viewing parameters - without the CAN service key ..... 11-37 11.11.3 Adjusting operator parameters - without the CAN service key .......................................................... 11-38 11.11.4 Viewing & changing parameters - CAN service key connected .................................................................... 11-39 11.11.5 Summary of driver parameters .................................... 11-41 11.11.6 Description of driver parameters ................................. 11-42 11.11.7 Summary of service parameters .................................. 11-43 11.11.8 Description of service parameters ............................... 11-44 11.11.9 Configurable “Option” Parameters ............................... 11-52 11.12 Technical specifications – Curtis 1243 ....................................... 11-66 12- Hydraulic system - 6000 ................................................................. 12-1 12.1 General ........................................................................................ 12-1 12.2 Hydraulics diagram and components........................................... 12-2 12.3 Description ................................................................................... 12-4 12.4 Adjustments ................................................................................. 12-5 13- Lift mast – 7000 ............................................................................... 13-1

1- 2

Service Manual

7SM08F

© TIEE SARL

Contents Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

13.1

13.2 13.3

T-code 781

Main mast .................................................................................... 13-1 13.1.1 Components .................................................................. 13-1 13.1.2 Maintenance .................................................................. 13-2 13.1.3 Cylinder ......................................................................... 13-3 Fork carriage................................................................................ 13-4 13.2.1 Maintenance .................................................................. 13-4 Main lift chain system................................................................... 13-5 13.3.1 Checking the chain setting ............................................ 13-5 13.3.2 Chain inspection ............................................................ 13-5 13.3.3 Cleaning ........................................................................ 13-8 13.3.4 Lubrication ..................................................................... 13-9

14- Peripherals – 8000 ........................................................................... 14-1 14.1 Battery charger (Inbuilt)................................................................ 14-1 14.1.1 General .......................................................................... 14-1 14.1.2 Charging ........................................................................ 14-1 14.1.3 Troubleshooting and service ......................................... 14-2 14.1.4 Technical data ............................................................... 14-2 14.1.5 Charging settings ........................................................... 14-3 15- TruckCom ........................................................................................ 15-1 15.1 General ........................................................................................ 15-1 15.2 Connection................................................................................... 15-1 15.3 Layout .......................................................................................... 15-2 15.3.1 Main program screen ..................................................... 15-2 15.3.2 Nodes ............................................................................ 15-2 15.3.3 Icons .............................................................................. 15-3 15.3.4 Tool buttons and menu bar ............................................ 15-3 15.3.5 Information window ........................................................ 15-4 15.3.6 Status bar ...................................................................... 15-4 15.4 Connection function .................................................................... 15-4 15.5 Disconnection function................................................................. 15-4 15.6 Downloading program function .................................................... 15-5 15.6.1 Normal downloading (truck with key) ............................. 15-5 15.6.2 Normal downloading (truck with keypad) ....................... 15-5 15.6.3 Emergency downloading (truck with keypad) ................ 15-6 15.6.4 Emergency downloading (truck with keypad) ................ 15-6 15.6.5 Downloading in old versions of logic card ..................... 15-6 15.7 Truck report function .................................................................... 15-7 15.8 Parameters function..................................................................... 15-8 15.9 Diagnostics function..................................................................... 15-8 15.9.1 Representation of signal colours ................................... 15-9 15.9.2 “Tiller arm” tab ............................................................... 15-9 15.9.3 “Drive Controller” tab (transistor regulator driving) ......................................... 15-10 15.9.4 “Pump controller” tab (transistor regulator pump) .......................................... 15-11 15.9.5 “EPS” (steering servo tab) ........................................... 15-12 15.9.6 SEU tab (Extra I/O module) ......................................... 15-13

© TIEE SARL

Service Manual

7SM08F

1- 3

Contents T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

15.10 Other menu functions................................................................. 15-13 15.10.1 Save to file ................................................................... 15-13 15.10.2 Download from file ....................................................... 15-13 15.10.3 Reset CAN adapter ..................................................... 15-14 15.10.4 Delete error code log ................................................... 15-14 15.10.5 Reset hour meter ......................................................... 15-14 15.10.6 Read error code log ..................................................... 15-14 15.10.7 Adjust date and time .................................................... 15-14 15.10.8 Adjusting the hour meter on older cards ...................... 15-14 15.10.9 Help ............................................................................. 15-14 15.10.10 Exit ............................................................................. 15-14 15.11 Specifications............................................................................. 15-15 15.12 Installation.................................................................................. 15-15 15.12.1 Installation on a PC with Windows 95/98 .................... 15-15 15.12.2 Installation on a PC with Windows XP/2000 ................ 15-16 15.12.3 Installation on a PC with Windows NT ......................... 15-21 15.12.4 In case of communication problems with CAN ............ 15-21 15.12.5 To uninstall .................................................................. 15-21 16- Destruction instructions ................................................................. 16-1 16.1 General ........................................................................................ 16-1 16.2 Procedure .................................................................................... 16-1 16.3 Abbreviations ............................................................................... 16-2 16.4 Sorting ......................................................................................... 16-2 16.5 Chassis (0300)............................................................................. 16-3 16.6 Hoods, hatches (0340)................................................................. 16-4 16.7 Electric Pump Motor (1710) ........................................................ 16-5 16.8 Electric Drive Motor (1760) ......................................................... 16-5 16.9 Drive assembly/gear (2550) ......................................................... 16-6 16.10 Wheels (3500).............................................................................. 16-7 16.11 Steering handle (4110) ................................................................ 16-8 16.12 Tiller arm (4110)........................................................................... 16-9 16.13 General electrical equipment (5100) .......................................... 16-10 16.14 Sensor (5800) ............................................................................ 16-11 16.15 Hydraulic unit (6100) .................................................................. 16-12 16.16 Hydraulic cables/lift cylinder (6230/6610) .................................. 16-13 16.17 Main mast and fork carriage (7100) ........................................... 16-13

1- 4

Service Manual

7SM08F

© TIEE SARL

Technical data Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

2- Technical data Model

7SM08F

Drive motor Type

TSL140S-DS30

Output

1,2 kW

Duty cycle

S2, 60 min

Minimum carbon brush length

13 mm

Nominal commutator diameter

50 mm

Minimum commutator diameter

47 mm

Resistance, shunt field winding

0,55 Ω at 25 C°

Resistance, armature winding

0,0156 Ω at 24 C°

Insulation resistance between windings and motor casing

>=1 Mohm

Weight

14 kg

Brakes Type

BFK457-08

Brake power

12 Nm

Output

25 W

Resistance, coil

23 Ω

Nominal play in actuated position

0,2-0,4 mm

Minimum thickness brake disc

5,5 mm

Thickness of new brake disc

7,0 mm

Transmission/drive gear

© TIEE SARL

Type

2-stage angle transmission

Gear ratio

19,14:1

Oil volume

1,0 litre

Oil type Normal temperature < -15 oC

Hypoid oil SAE 80W/90 SAE 75W

Service Manual

7SM08F

2- 1

Technical data T-code 781

Valid from serial number 904519-

Date 2005-11-04

Model

Order number 229735-040

7SM08F

Wheels Drive wheel

Ø215x70 mm

Axle pressure without load

245 kg

Axle pressure at rated load

376 kg

Axle pressure with 1600 kg on support arms

467 kg

Tightening torque for wheel bolts

65 Nm

Support arm wheels

Ø85 mm

Axle pressure without load

162 kg

Axle pressure at rated load

820 kg

Axle pressure with 1600 kg on support arms

1500 kg

Support arm wheels

Ø125x40 mm

Axle pressure without load

2x156 kg

Axle pressure at rated load

2x166 kg

Axle pressure with 1600 kg on support arms

2x175 kg

Hydraulic system Output

2.2 kW

Duty cycle

4,5 %

Minimum carbon brush length

12,5 mm

Minimum commutator thickness/diameter

4,7 mm

Pressure at rated load

180 bar

Overflow pressure

200 bar

Pump flow (with rated load)

4,9 l/min

Tank volume

3,5 l

Oil type Normal temperature < -15oC

ISO-L-HM32 ISO-L-HV32

Fuses Drive motor circuits

125 A

Pump motor circuits

160 A

Control circuits

7,5 A

Battery compartment, Batteries

2- 2

Dimensions LxWxH 160 Ah 210 Ah 230 Ah

211x295x450 mm 211x295x590 mm 211x295x590 mm

Capacity

160/210/230 Ah

Weight max/min

2x76/2x106 kg

Service Manual

7SM08F

© TIEE SARL

Technical data Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Model

7SM08F

Driving speeds Without load, 0-750 kg

6,0 km/h (1.6 m/s)

With rated load

6,0 km/h (1.6 m/s)

Lift/lowering speed Lifting without load

0,19 m/s

Lifting with rated load

0,13 m/s

Lowering without load

0,13 m/s

Lowering with rated load

0,17 m/s

Power consumption (truck at room temperature) Driving without load

33 A

Driving with rated load

36 A

Lifting without load

43 A

Lifting with rated load

100 A

Hill-climbing ability With rated load

9%

Measurement L2

642 mm

Turning radius WA

1460 mm

Lifting height, support arms raised/lowered

600/780 mm 1580/1700 mm

Weight Truck without battery, Medium

© TIEE SARL

Service Manual

7SM08F

500 kg

2- 3

Technical data General tightening torques T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

2.1 General tightening torques Millimetre thread M3 to M24.

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

Table 1: General tightening torques [Nm] M3

M4

M6

M8

M10

B

C

B

C

B

C

B

C

B

C

B

C

1,15

1,2

2,8

2,9

5,5

5,7

9,5

9,8

23

24

45

47

12,9 2,0

2,1

4,7

4,9

9,3

9,7

16,3

17,0

38,5

40,0

75,8

79,0

A 8,8

M12 A

M5

8,8

M14

M16

M20

M24

B

C

B

C

B

C

B

C

B

C

77,7

81

123

128

189

197

369,6

385

638,5

665

649

1075

1120

12,9 130,5 136 208 217 319,7 333 623 A=Strength class B = Galvanised, non-oiled bolts C = Untreated, oiled bolts NOTE:

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

2- 4

Service Manual

7SM08F

© TIEE SARL

Maintenance Safety regulations with maintenance work Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

3- Maintenance All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter. The operator may adapt them to local conditions, but it is important that the intervals comply with TOYOTA’s minimum requirements.

The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations. The following running times have been used when calculating the intervals: Day time:

08.00-17.00 (20 hr./week)

2-shifts:

06.00-14.00, 14.00-22.00 (40 hr./week)

3-shifts:

06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)

Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.

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

3.1 Safety regulations with maintenance work Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work.

• Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so • Keep the area where you carry out the service clean. Oil or water makes the floor slippery • Never wear loose objects or jewellery when working on the truck WARNING! Short-circuiting/Burns.

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

Remove watches, rings or other types of metal jewellery.

• Always disconnect the battery by pulling out the battery isolator when carrying out maintenance work on the truck unless otherwise stated in this Service Manual • Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system • Relieve the system pressure slowly before starting work on the truck’s hydraulic system © TIEE SARL

Service Manual

7SM08F

3- 1

Maintenance Cleaning and washing T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

• Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand • Bear in mind that the oil in the transmission or the hydraulic system can be hot WARNING! Risk of burns.

Hot transmission and hydraulic oil.

Let the truck cool before changing the oil.

• Only fill the hydraulic system with new and clean oil WARNING! The hydraulic system can be damaged.

If the oil is contaminated hydraulic components can be damaged.

Always use new and clean oil in the hydraulic system.

• Store and dispose of changed oil in accordance with local directives • Do not release solvents and the like, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local directives that apply for disposal • Disconnect the battery when welding on the truck NOTE! The battery can be damaged.

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

The battery should therefore be disconnected.

• Remove at least 100 mm of paint around the welding/grinding area through sand-blasting or the use of a paint stripper when welding or grinding on painted surfaces CAUTION! Harmful gases.

Paint that is heated gives off harmful gases.

Remove 100 mm of paint from the work area.

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

• Carry out general cleaning and washing weekly NOTE! Risk of short-circuiting.

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

3- 2

Service Manual

7SM08F

© TIEE SARL

Maintenance Cleaning and washing Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

Mechanical components can be damaged.

After washing, the truck should be lubricated as set out in the chapter Maintenance and lubrication chart.

3.2.2 Cleaning the motor compartment • Cover the electric motors, connections and valves before washing NOTE! Risk of short-circuiting.

The electrical system can be damaged.

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

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

3.2.3 Electrical components • Blow electric motors down using compressed air • Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent NOTE! Risk of short-circuiting.

Electrical components can be damaged.

Do not break the guarantee seal on the electronic board.

© TIEE SARL

Service Manual

7SM08F

3- 3

Maintenance Safe lifting T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

• Activate the parking brake to prevent the truck from moving during the lift. If the lift applies to the brake wheel, chock the other wheels so that the truck stands still • Select a lifting point so that the lift is as easy as possible (one corner at a time). If the truck has marked lifting points on the under side of the chassis these can be used to obtain a well balanced lift • Ensure that the surface under the jack is clean and free from oil and grease • Ensure that your hands and the jack’s lever are free from oil and grease • Use the lever that belongs to the jack. A lever that is too short requires more force than is necessary. If the lever is too long there is a risk of the jack being overloaded • Support the truck: - as close as possible to the part of the chassis that is to be lifted.

This reduces the risk of the truck tipping over - so that the truck cannot roll • Never lift up the jack in order to lift higher • Never work under a lifted truck unless it is well supported WARNING! Risk of crushing.

A badly supported truck can fall.

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

3- 4

Service Manual

7SM08F

© TIEE SARL

Maintenance Maintenance Schedule Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

3.4 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

0000

Chassis

0000.1

Check all links (4 links) and spiral pins

0000.2

Check for wear on the cover/battery lock

0000.3

Interval in hours – can vary depending on the application

5

20

500

1000

3000

I

I

I

I

I

Check for cracks and damage

I

I

I

0000.4

Check the finger guard

I

I

I

0000.5

Check the signs and decals

I

I

I

0000.6

Check the lift limit switch

I

I

I/L1

I/L

I/L

I/T2

I/T

I/T

0000.2 0000.6 0000.4

0000.1

0350

Support arms

0350.1

Inject grease into the grease nipples (2x4 nipples, with a bogie another 4 nipples)

1700

Drive motor

1700.1

Check for play in the connections

1700.2

Check the carbon brushes (4 brushes) in the drive motor

M

M

1700.3

Clean the drive motor

C

C

1700.4

Check the mounting bolts (4 bolts)

I

I

1700.5

Check for abnormal noise in the bearings

I

I

I

1700.2

1700.3

© TIEE SARL

Service Manual

1700.4

7SM08F

3- 5

Maintenance Maintenance Schedule T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

Pos. No.

Work to carry out

2550

Drive transmission

2550.1

Check for leakage

2550.2

Interval in hours – can vary depending on the application

5

20

500

1000

3000

I

I

I

Measure the oil level with the dipstick pushed in

I

I

2550.3

Check for abnormal noise

I

I

2550.4

Check the mountings and play in the steering bearings

I

I

2550.5

Change the oil in the drive transmission

3100.

Brakes

3100.1

Clean and check the functioning

3100.2

Check the brake discs

3500

Wheels

3500.1

Remove string and other debris

3500.2

L

L3 C

C

I

I

I

I

I

Check the drive wheels for wear and check the tightening torque of the bolts (New wheel: Tread depth = 30 mm) (Tightening torque = 65 Nm)

I/T

I/T

I/T

3500.3

Check that the swivel wheels swing and rotate freely

I

I

I

3500.4

Check for wear to the swivel wheels (New wheel: Tread depth = 10 mm)

I

I

I

4110

Tiller arm

4110.1

Check the mountings

I

I

I

4110.2

Check the power of the gas damper (ensure that the handle goes back)

I

I

I

5000

Electrical functions

5000.1

Check the function of the brake switch

I

I

I

I

I

5000.2

Check the function of the safety switch that prevents collisions

I

I

I

I

I

5000.3

Check the emergency brake

I

I

I

I

I

5000.4

Check the horn function

I

I

I

I

I

5000.5

Check for wear to the cables in the tiller arm

I

I

I

5000.6

Check the operation of the driver's controls

I

I

I

5000.7

Check the error code log and operating times

I

I

I

3- 6

Service Manual

C

I

7SM08F

I

I

I

© TIEE SARL

Maintenance Maintenance Schedule Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

Pos. No.

Work to carry out

5110

Battery

5110.1

Interval in hours – can vary depending on the application

5

20

500

1000

3000

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

M

M

M

M

5110.2

Check the connections to the battery, truck and charger

I

I

I

I

5110.3

Check that the cell and terminal guards are undamaged

I

I

I

I

5110.4

Check the fluid density and temperature

M

M

M

M

5110.5

Remove excess fluid from the battery tray

C

C

C

C

5400

Power system

5400.1

Clean and check the chassis mountings

C/T2

C/T

C/T

5400.2

Tighten the cable connections

T

T

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the contactors' movement

I

5400.5

Check the cable insulation

I

I

5400.1

5400.2

5700

Electronic card

5700.1

Check the contacts and cables

T

T

5700.2

Check all the segments on the display

I

I

6000

Hydraulic system

6000.1

Check the hoses and connections for leaks, wear and damage

I

I

I

6000.2

Check the oil tank for cracks, leaks and damage to the mountings

I

I

I

6000.3

Check that the oil level is correct

I

I

I

6000.4

Change the oil and clean the filter

L4

L

L

6600

Lift cylinders

6600.1

Check for leakage

I

I

I

6600.2

Check the mountings

I

I

I

© TIEE SARL

Service Manual

I

7SM08F

3- 7

Maintenance Maintenance Schedule T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

Pos. No.

Work to carry out

7100

Mast

7100.1

Interval in hours – can vary depending on the application

5

20

500

1000

3000

Check for cracks and damage

I

I

I

7100.2

Carry out a visual inspection of the bolt joint between the mast and the chassis.

I

I

I

7100.3

Check for wear on the lift chains and sprockets. Ensure that the lift chain is well lubricated to prevent corrosion damage.

I/L

I/L

I/L

7100.4

Check the adjustment of the lift chain

I

I

I

7100.5

Check the cylinder cover on the mast

I

I

I

7420

Fork carriage

7420.1

Check for cracks and damage

I

I

I

7420.2

Check for play between the mast beam and the fork carriage rollers

I

I

7420.3

Check for wear in the steering pivots and grease them

I/L

I/L

I/L

1 = If the truck is being used in a very cold environment or another type of harsh environment, the checks must be carried out at shorter intervals.

2 = The connections must be checked and tightened for the first time after 500 h / 6 months, and then every 1000 h / 12 months.

3 = The oil must be changed for the first time after 500 h / 6 months, and then every 3000 h / 36 months.

4 = The oil must be changed and the filter cleaned for the first time after 500 h / 6 months, and then every 1000 h / 12 months.

When the checks with longer time intervals are carried out, the checks with shorter time intervals must also be carried out, unless stated otherwise above.

Approximate time required • Oil change in the drive axle: 40 min.

• Oil change in the hydraulic system: 40 min.

• Service interval 500 h (without oil change in the drive axle and hydraulic system): 40 min.

• Service interval 1000 h (without oil change in the drive axle and hydraulic system): 48 min.

• Service interval 3000 h: (without oil change in the drive axle and hydraulic system): 53 min.

3- 8

Service Manual

7SM08F

© TIEE SARL

Maintenance Maintenance Schedule Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

6000

0350

5000 5700 7100 6600

5400

3100

5110

1700 3500 2550

7420 0000

© TIEE SARL

Service Manual

7SM08F

3- 9

Maintenance Lubrication chart T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

3.5 Lubrication chart Pos. no.

Service check

Interval/Operating hours 500 h

1000 h

Lubrication type

3000 h

1

Wheel bearings

L

A

2

Mast beam

L

F

3

Lift chain

L

D

4

Hydraulic system

I

5

Steering bearing

6

Drive transmission

I

7

Grease nipples (see separate section about support arms)

L

O

B

L

G O

C H

L = LubricateI = InspectO = Oil change

4

1

2&3

5 7 6

3- 10

Service Manual

7SM08F

© TIEE SARL

Oil and grease specification Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

4- Oil and grease specification Table 2: Oil and grease specification Lubrication type

Specification

Use

> -15 °C

< -15 °C

A

Grease

223690 Q8 Rembrandt EP2

223690 Q8 Rembrandt EP2

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

See table below

See table below

Chains

F

Grease

29586 Gleitmo 805

29586 Gleitmo 805

Inside of beam ribs

223690 Q8 Rembrandt EP2

223690 Q8 Rembrandt EP2

Inside of beam flanges

G

Grease

Staburags NBU 8EP

Staburags NBU 8EP

Steering bearing

H

Grease

213366 Q8 Rubens WB

213366 Q8 Rubens WB

Grease nipples

Ambient temperature

Viscosity class

Recommended products (Similar products from another manufacturer may be used)

> -40°C < -30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> -30°C < +5°C

VG 68

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

> +5°C < +45°C

VG 150

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

> +45°C < +80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

© TIEE SARL

Service Manual

7SM08F

4- 1

Oil and grease specification T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

This page is intentionally left blank

4- 2

Service Manual

7SM08F

© TIEE SARL

Tools Super Seal connectors Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

5- Tools 5.1 Super Seal connectors 1 3

3 2

Figure

© TIEE SARL

Number

Application

159232

Tools for fitting pins/sleeves

159229

Tools for loosening locks (1)

159230

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

159231

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

159228

Tools for removing pins/sleeves (3)

Service Manual

7SM08F

5- 1

Tools AMP connectors T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

5.2 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

5- 2

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

1

Service Manual

7SM08F

© TIEE SARL

Tools Molex connectors Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

5.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

5.3 Molex connectors 16 9 8 1 Figure

© TIEE SARL

Service Manual

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

7SM08F

5- 3

Tools Grease guns T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

5.4 Grease guns Figur

fif

5- 4

Nummer

Användning

24981

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

755132

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

755142

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

755152

Two-hand grease gun with hose and nozzle.

755146

Grease hose 450 mm.

Grease hose 750 mm.

Grease hose 1500 mm.

202154PM

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

Fits grease guns with hose and discharge pipe.

Length 125 mm.

755140

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

Service Manual

7SM08F

© TIEE SARL

Tools Other tools Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

5.5 Other tools Figure

© TIEE SARL

Service Manual

Number

Application

179915

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

08-13022

Driving gear puller

7SM08F

5- 5

Tools Other tools T-code 781

Valid from serial number 904519-

Figure

-1 -2

Date 2005-11-04

Order number 229735-040

Number

Application

Compl=V1015191 1=V10-15191-1 2=V10-15191-2 3=V10-15191-3 4=V10-15191-4

Oil cleaning 1=Filter for cleaning 2=Filter for removing water 3=Pipe 4=Pipe

-3 -4

5- 6

Service Manual

7SM08F

© TIEE SARL

Chassis - 0000 Support arms Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

6- Chassis - 0000 6.1 Support arms 6.1.1 Main Components 11

12

13 14 15 16 17

18

23

L

22

19

25 24 20

21 26

27

28

© TIEE SARL

32 29

30

Position

Name

11

Pivot pipe

12

Bushing

13

Grease nipple

14

Axle

15

Mounting

Service Manual

7SM08F

6- 1

Chassis - 0000 Support arms T-code 781

Valid from serial number 904519-

Date 2005-11-04

Position

Name

16

Screw

17

Grease nipple

18

Bushing

19

Screw

20

Axle

21

Grease nipple

22

Push rod (complete)

23

Push rod

24

Bushing

25

Grease nipple

26

Spiral pin

27

Axle

28

Grease nipple

29

Axle

30

Spiral pin

32

Wheel fork (complete)

Order number 229735-040

6.1.2 Maintenance The support arms should be greased regularly according to the maintenance schedule.

Table 3: Lubricating the nipples Position Placement 1

6- 2

Picture

Behind the support arms

Service Manual

7SM08F

© TIEE SARL

Chassis - 0000 Support arms Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 3: Lubricating the nipples Position Placement

© TIEE SARL

2

Above the swivel wheels

3

Behind/above the support arm wheels

4

Behind/above the support arm wheels, on the outside

5

On the outside of the bogie, if there is one.

Service Manual

7SM08F

Picture

6- 3

Chassis - 0000 Support arms T-code 781

Valid from serial number 904519-

6- 4

Service Manual

7SM08F

Date 2005-11-04

Order number 229735-040

© TIEE SARL

Electric drive motor – 1000 Component parts Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

7- Electric drive motor – 1000 7.1 Component parts 16 21 14

18

13

19

20

17 10

15

12 11

8

9

7 5

6

4 3 1 2

© TIEE SARL

Pos

Description

Note

1

Screw

M6x25

2

Bearing shield

3

Locking ring

4

Bearing

5

Carbon brush bridge

6

Screw

Service Manual

7SM08F

M5x12 7- 1

Electric drive motor – 1000 Component parts T-code 781

7- 2

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Pos

Description

Note

7

Screw

M5x20

8

Carbon brush

9

Rotor

10

Key

11

Plug

12

Stator

13

Cable

14

Cable

15

Bearing shield

16

Screw

17

Seal

18

Bearing

19

Washer

20

Locking ring

21

Locking ring

Service Manual

7SM08F

M6x25

© TIEE SARL

Electric drive motor – 1000 Service/Repairs Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

7.2 Service/Repairs 7.2.1 Dismantling of motor from truck • Switch off the truck and pull out the battery plug.

• Remove the covers for the motor compartment.

• Release the cables for the motor and tiller arm.

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

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

• Loosen the cover over the motor compartment and the tiller arm’s mounting from the motor. Remove the cover over the motor compartment together with the tiller arm.

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

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

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

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

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

• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm. • Fit and adjust the brakes as per the instructions. Screw tight the cover and tiller arm, and connect the cables that were previously removed. Check that the polarity is correct.

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

© TIEE SARL

Service Manual

7SM08F

7- 3

Electric drive motor – 1000 Service/Repairs T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

7.2.3 Dismantling of motor 16 21 14

18

13

19

20

17 10

15

12 11

8

9

7 5

6

4 3 1 2

• Release the brake disc’s companion flange by first removing the locking ring together with the washer in the end of the rotor shaft.

The companion flange can now be lifted off. It may be necessary to unclamp it with an appropriate tool.

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

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

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

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

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

7- 4

Service Manual

7SM08F

© TIEE SARL

Electric drive motor – 1000 Service/Repairs Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

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

• Fit a new seal in the bearing shield.

7.2.4 Assembling of motor Assemble the motor in the reverse order.

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

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

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

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

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

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

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

If the parts of the motor are heavily fouled it may be necessary to use a solvent that is sprayed onto the parts. It is important that the detergent is applied in a way to prevent dirt from penetrating into the parts of the motor, especially for the rotor.

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

© TIEE SARL

Service Manual

7SM08F

7- 5

Electric drive motor – 1000 Service/Repairs T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

This page is intentionally left blank

7- 6

Service Manual

7SM08F

© TIEE SARL

Drive unit/gear – 2000 Component parts Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

8- Drive unit/gear – 2000 8.1 Component parts

2 3 4 5

6

01

7 8

24

9 27

25 26

10 11

28 13 12 14 32 29

15

18

16

19

17 20

23 21

© TIEE SARL

30

31

Service Manual

7SM08F

22

8- 1

Drive unit/gear – 2000 Component parts T-code 781

8- 2

Valid from serial number 904519-

Date 2005-11-04

Pos Description

Note

Order number 229735-040

01

Drive gear complete

2

Air valve

3

Cover

4

Dip stick

5

Washer

6

Gasket

7

Nut

8

Washer

9

Gear wheel

10

Conical roller bearing

11

Shims

12

Screw

13

Shims

14

Conical roller bearing

15

Pinion/ Crown gear

Cog clearance 0.09-0.15 mm Pretension bearing with 2-5/100 Stamped size on pinion adjusted with shims

16

Nut

Tightening torque 300 Nm Locked with punch mark

17

Shims

18

Conical roller bearing

19

Shims

20

Screw

Bottom cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

21

Screw

Bottom cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

22

Cover

23

Gasket

24

Gear wheel

25

Washer

26

Nut

Service Manual

Tightening torque 70 Nm Locked with punch mark Primary gear

Top cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

Motor gear Tightening torque 30 Nm Locked with punch mark Lock with Loctite 603

7SM08F

© TIEE SARL

Drive unit/gear – 2000 Leakage from top cover Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Pos Description

Note

27

Screw

Motor and gear housing

28

Nut

Tightening torque 26.6 Nm Lock with Loctite 242

29

Conical roller bearing

30

Shims

31

Seal

32

Drive shaft

8.2 Leakage from top cover 8.2.1 Dismantling • Lift up the truck, and block up to ensure that it is stable.

• Unscrew the drive wheel.

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

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

• Change the gasket (6).

8.2.2 Assembling is carried out in the reverse order • Tighten the four M8 bolts and the four M8 nuts to a torque of 26.6 Nm Lock with Loctite 242.

• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.

© TIEE SARL

Service Manual

7SM08F

8- 3

Drive unit/gear – 2000 Changing of the drive shaft’s sealing ring T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

8.3 Changing of the drive shaft’s sealing ring The drive shaft’s sealing ring can be changed with the gear mounted in the truck.

Follow the instructions below if oil is leaking from the drive shaft.

8.3.1 Dismantling • Unscrew the drive wheel 1).

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

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

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

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

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

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

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

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

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

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

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

• Put the distance ring on the drive shaft end, and put on the shaft nut.

Always use a new nut. Tighten the shaft nut to a torque of 300 Nm and lock it with a punch mark in the middle. The drive shaft nut should be lubricated before it is put on the shaft.

• Change the gasket before fitting the bottom cover. Make sure that it is not damaged. Fit the cover and tighten the bolts to a torque of 26.6 Nm. The bolts should be lubricated before they are fitted. Fill up with oil in accordance with the instructions for replenishing the oil.

Fit the drive gear and tighten the bolts to a torque of 65 Nm.

8- 4

Service Manual

7SM08F

© TIEE SARL

Brake system – 3000 Main components Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

9- Brake system – 3000 9.1 Main components 9

1 2

8

3

4

7

5

© TIEE SARL

Pos No

Description

1

Magnetic coil

2

Cap screws

3

Electrical wire

4

Pressure plate

5

Pressure springs

6

Flange

7

Mounting bolts

8

Brake disc

9

Hub

Service Manual

7SM08F

6

9- 1

Brake system – 3000 Maintenance T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

9.2 Maintenance Basically the brake is maintenance free in normal work environments.

However it is recommended according to the preventive maintenance schedule to check the brake disc for wear.

9.2.1 Exchange of brake disc The brake disc shall be exchanged when its total thickness has been reduced to 5,5 mm.

• Disconnect the electrical wires of the brake.

• Undo and remove the three fastening bolts.

• Loosen the brake disc from the hub and check for wear and tear. Replace the brake disc if the surface is unevenly worn.

• Reassemble the brake.

• Reconnect the electrical wiring.

9- 2

Service Manual

7SM08F

© TIEE SARL

Steering – 4000 Component parts, tiller arm Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

10- Steering – 4000 10.1 Component parts, tiller arm 1 2

3

4

5 6 7

8

L

9 25 10 11 24

22

12 13

23 22

16

20 16 19 18 17

14

21

26 27

15

© TIEE SARL

Service Manual

7SM08F

10- 1

Steering – 4000 Component parts, tiller arm T-code 781

10- 2

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Pos.

Name

Notes

1

Screw

4 items

2

Plate

3

Handle

4

Screw

2 items

5

Screw

2 items

6

Plate

7

Cable bushing

8

Profile

9

Mounting

10

Spiral pin

11

Screw

12

Screw

13

Washer

14

Holder

15

Spiral pin

16

Bushing

17

Spacer

18

Ridge

19

Spacer

20

Mounting

21

Axle

22

Rubber buffer

23

Bushing

24

OK

25

Gas damper

26

Inductive sensor

27

Screw

Service Manual

7SM08F

L = 60 mm

4 items

2 items

2 items

2 items

© TIEE SARL

Steering – 4000 Tiller arm handle Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

10.2 Tiller arm handle 28 29

27 26 24 25

14 23 22

17 18

21 20

16

19

15 14 14

30 31 10 9 8

32

35

14

12 11

13

33 34 5

6

7

4

1

2 3

© TIEE SARL

Pos

Description

1

Screw

2

Cover

3

Handle

4

Electronic circuit board

5

Screw

6

Display card

7

Top cover

8

Pushbutton

9

Signal switch

10

Signal button

11

Display glass

12

Arm

13

Pushbutton

Service Manual

Note Keyboard option

7SM08F

Option

Lift/Lower 10- 3

Steering – 4000 Tiller arm handle T-code 781

10- 4

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Pos

Description

14

Plate

15

Spring

16

Pushbutton

17

Arm

18

Holder

19

Spring

20

Control switch

21

Axle

22

Sliding bearing

23

Control stop

24

Arm

25

Spring holder

26

Spring

27

Spring holder

28

Sliding bearing

29

Control switch

30

Button for safe reversing

31

Arm

32

Spring

33

Lower cover

34

Screw

M4x40

35

Screw

2xM5x45 - 2xM5x60

Service Manual

7SM08F

Note

Not used

© TIEE SARL

Steering – 4000 Tiller arm handle Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

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

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

• Remove the screws (34).

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

Assembling is carried out in the reverse order.

NOTE! Static electricity!

Risk of static discharge that can damage the electronics.

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

Changing of signal button/switch (9, 10) • Dismantle the button as per the diagram.

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

• Press out the switch from its mounting.

Assembling is carried out in the reverse order.

© TIEE SARL

Service Manual

7SM08F

10- 5

Steering – 4000 Tiller arm handle T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Changing of lift/lowering button (13) • Remove the button by placing a screwdriver in the hole (A) as per the diagram below.

A

A

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

Assembling is carried out in the reverse order.

Changing of pushbutton (16) • Press the button by hand sideways.

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

• Unscrew the button’s holder and arm.

Assembling is carried out in the reverse order.

10- 6

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 General Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11- Electrical systems – 5000 11.1 General The electrical system of the truck is based on the PowerDrive platform.

• The main power source comprises 2 series connected 12V DC traction batteries.

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

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

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

© TIEE SARL

Service Manual

7SM08F

11- 1

Electrical systems – 5000 Software/hardware part numbers T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

11.2 Software/hardware part numbers To select part number display mode carry out the following procedure: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

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

on the keypad.

• Hold S18 depressed until “Pn” is displayed (Fig. 1), then release S18.

Fig. 1

The display will now show the part numbers for the control program, the hardware part number and hardware serial number.

The part numbers are displayed by repeatedly operating speed control L1. The display will first show the starting portion of the number, then the ending portion.

Table 4: Part numbers Display

Meaning Software (Control program) part number

Control card’s [A2] hardware part number

Hardware serial number

11.3 Nomenclature Items shown in square brackets [ ] refer to electric component designations as stated in the electrical wiring diagrams. See section “11.5 Electrical component list” . {high} refers to a voltage level that is approximately the same as the supply voltage level. {low} refers to a voltage level of approximately 0 Volt. s/c = short circuit o/c = open circuit i/p = input o/p = output

11- 2

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Electrical equipment overview Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.4 Electrical equipment overview A2:S22 A2:S21 A2:S1-9

A2:S10-18

A2

9

1 10 18

A2:S17 A2:S20 A2:S19 A6 S113 S112 S111

S116 S115 S114

S18:1

S18:2 A2:S20 A2:S19

L1

L1

A2:S22 A2:S21

A2:S17

A17

Fig. 2

© TIEE SARL

Service Manual

7SM08F

11- 3

Electrical systems – 5000 Electrical equipment overview T-code 781

Valid from serial number 904519-

F51 F50

S31

X41

Date 2005-11-04

Order number 229735-040

X1 G1 S10

F1 R1

A1

K10 F3 K30

Y1 M1

H1

M3 A36

G2

S21

Y34

Y52

Y41 Fig. 3 11- 4

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Electrical component list Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.5 Electrical component list The following table shows a summary of the major electrical components of this truck.

Table 5: Electrical component list

G1, G2

Main electrical power source

Traction battery 12 V 2 series connected

Fig. 4

Fig. 3

X1

Battery connection / isolation

Connector

Fig. 4

Fig. 3

K10

Main contactor

Contactor

Fig. 4

Fig. 3

R1

Temporary supply

PTC-resistor 15 Ohm

Fig. 4

Fig. 3

Designation

Picture ref.

Component type

Diagram ref.

Function

Inf.

Energy and main power isolation

7

Equipment protection F1

Drive motor protection

Fuse 130 A

Fig. 4

Fig. 3

F3

Pump motor protection

Fuse 130 A

Fig. 4

Fig. 3

F 50

Operating circuit protection, A2

Fuse 7,5 A

Fig. 4

Fig. 3

F 51

Operating circuit protection, A1

Fuse 7,5 A

Fig. 4

Fig. 3

Control and Signal processing A1

Traction and peripherals power control

Transistor regulator

Fig. 4, Fig. 5

Fig. 3

A2

Control of truck functions

Electronic card

Fig. 6, Fig. 7, Fig. 8

Fig. 2

A6

Display of truck functions

Display unit

Fig. 7

Fig. 2

A17

PIN log in and data entry

Keypad

Fig. 8

Fig. 2

© TIEE SARL

Service Manual

7SM08F

11- 5

Electrical systems – 5000 Electrical component list T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 5: Electrical component list Inf.

A2:S17

Emergency reverse

Hall sensor

Fig. 6

Fig. 2

5

S10

Tiller arm in drive position (Mechanical brake activation)

Inductive proximity switch

Fig. 4

Fig. 3

7, 10

S18:1

Horn activation - lefthand

Switch

Fig. 7

Fig. 2

7

S18:2

Horn activation - righthand

Switch

Fig. 7

Fig. 2

7

S21

Emergency switch-off

Switch

Fig. 5

Fig. 3

Y1

Mechanical brake

Electromechanical brake

Fig. 4

Fig. 3

7

H1

Audible warning signal - Horn

Horn

Fig. 4

Fig. 3

7

L1

Speed control and travel direction selector (butterfly)

Hall sensor

Fig. 2

6, 7

S113

“Turtle” function

Switch

Fig. 7

M1

Truck traction

Motor

Fig. 4

Fig. 3

Designation

Picture ref.

Component type

Diagram ref.

Function

Braking, Safety & Supervision

Traction

3

Forks lift A2:S19

Fork lift control

Hall sensor

Fig. 6

Fig. 2

7

A2:S20

Fork lower control

Hall sensor

Fig. 6

Fig. 2

K30

Pump motor activation

Contactor

Fig. 4

Fig. 3

Y34

Fork lift cylinder selection-hydraulic control

Magnetic valve

Fig. 5

Fig. 3

7

Y41

Lower -hydraulic control

Magnetic valve

Fig. 4

Fig. 3

7

M3

Hydraulic pressure

Motor

Fig. 4

Fig. 3

Support arm lift A2:S21

Support arm lift control

Hall sensor

Fig. 6

Fig. 2

5,7

A2:S22

Support arm lower control

Hall sensor

Fig. 6

Fig. 2

5,7

S31

Support arms at top supervision

Inductive proximity switch

Fig. 5

Fig. 3

7,-9

Y52

Support arm lift cylinder selectionhydraulic control

Magnetic valve

Fig. 5

Fig. 3

7

11- 6

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Electrical component list Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Component type

Picture ref.

X41

CAN communication (external)

Connection point

Fig. 6

Fig. 3

X9

CAN communication (SEU)

Connection point

Fig. 6

-

A36

“Spider” expansion unit (SEU)

Logic card

-

Fig. 3

2,3

S113

Option button 1

Switch

-

Fig. 2

3

S112

Option button 2

Switch

-

Fig. 2

3

S111

Option button 3

Switch

-

Fig. 2

3

S114

Option button 4

Switch

-

Fig. 2

3

S115

Option button 5

Switch

-

Fig. 2

3

S116

Option button 6

Switch

-

Fig. 2

3

Designation

Function

Diagram ref.

Table 5: Electrical component list Inf.

Other

Footnotes to the table above: 2. See section “11.9.3 Spider expansion unit (SEU) (option)” .

3. Optional function.

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

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

7. Signals to/ from these elements can be checked via the Built-in Test function. See “11.10.5Built-in Test Function” on page 33.

9. Output is {low} when sensor is activated.

10. Output is {high} when sensor is activated.

© TIEE SARL

Service Manual

7SM08F

11- 7

Electrical systems – 5000 Electrical circuit overview T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

11.6 Electrical circuit overview X41

A6

X9

A17 6

10

KEYBOARD SIGNALS

CAN

DISPLAY SIGNALS

A2

S18:1 INP. HORN 1

ONLY KEYPAD INP. 24V

OUT. HORN 1

INP. 0V

INP. HORN 2

S18:2 F50

S17

OUT. HORN 2 K10

EXT. EQ.

R1

SPEED & DIRECTION

TURTLE

FORKS lift / lower

EMERGENCY REVERSE

TURTLE

Hall

Hall

X1

S113 (OPTION)

SUPP.ARMS lift / lower

Hall

Hall

+ -

G1

F51

F1

F3 K30

+ -

G2

M3 A1

S21

M

A2

X1

M1 INP. POWER 24V

OUT. ARMATURE

INP. 0V INP. 24V

OUT. FIELD

A1

A1

E1

M S

A2

E2

OUT. FIELD Y34

S31

OUT. FORK VALVE INP. SUPPORT ARM NOT IN TOP

Y52 OUT. SUPPORT ARM VALVE

S10

Y1 INP. TILLER ARM IN DRIVE POSITION

OUT. BRAKE RELEASE K10

OUT. MAIN CONTACTOR K30 OUT. PUMP CONTACTOR Y41

CAN

H1

OUT. LOWER VALVE OUT. SIGNAL HORN

11- 8

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Symbol list Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.7 Symbol list Table 6: Symbol list Symbol

A1

E1

M S

fif

Description

Symbol

Description

Truck battery

Horn

Fuse

Emergency stop switch NC

Resistor (PTC)1

Brake coil (normally applied)

DC motor2 (SEM type)3

Sensor, inductive NO

DC motor

Contactor

Coil for hydraulic magnetic valve

Multi-pin connector

Switch, key operated NO

Brake solenoid, normally applied

A2

E2

NO = Normally Open NC = Normally closed 1. PTC = Positive Temperature Coefficient (resistance increases as temperature increases) 2. DC = Direct Current 3. SEM = Separately Excited Motor

© TIEE SARL

Service Manual

7SM08F

11- 9

11- 10

Service Manual

Sh. 2

Sh. 3

Sh. 2

Sh. 3

24

40

21

20

7,5A

F51

7,5A

F50

1

1

7SM08F

IN

+

9

2

K30 A1 A2

1

G2 12V + X1

10

A1

Y41 1 2

M

M3 A2

PUMP MOTOR

X10

X10

X10

1

Y1

S10

2 1

2

X10

X10

E1

A1

S

M

M1

E2

A2

DRIVE MOTOR

39

38

45

7

9

6

12

4

64

57

5

S1

5

31

S2

4

M

+

3

6

-

40

1 / 5 217222

OUT. SIGNAL HORN

OUT. LOWER VALVE

OUT. PUMP CONTACTOR

PROD A

INP. TILLER ARM IN DRIVE POS.

OUT. MAIN CONTCTOR

OUT. BRAKE RELEASE

OUT. FIELD

OUT. FIELD

OUT ARMATURE

INP. POWER SUPPLY +24V DC

INP. POWER SUPPLY 0V DC

Date 2005-11-04

-

130A

F3

130A

F1

EXTERNAL EQUIPMENT

2

G1 12V + -

Valid from serial number 904519-

H1

K10 A1 A2

2

PTC 15ohm

R1

X1

T-code 781

3

TRANSISTOR REGULATOR A1

Electrical systems – 5000

Electrical wiring diagram Order number 229735-040

11.8 Electrical wiring diagram

Fig. 4 Sheet 1 of 5

© TIEE SARL

© TIEE SARL

Service Manual

7SM08F

Sh. 3

S31

120

53

120

Y52

58

49

119

Y34

2

119

1

8

1

3

2

13

16

2 /5

CAN LOW

CAN HIGH

217222

OUT. SUPPORT ARM VALVE

OUT. FORK VALVE

PROD A

INP. SUPPORT ARM NOT AT TOP

INP. SUPPLY +24V DC

Valid from serial number 904519-

Sh. 3

40

24

24

Date 2005-11-04

Sh. 3

Sh. 1

21

TRANSISTOR REGULATOR A1

Order number 229735-040

3

Sh. 1

EMERGENCY SWITCH OFF S21 1 2

Electrical systems – 5000 Electrical wiring diagram

T-code 781

Fig. 5 Sheet 2 of 5

11- 11

11- 12

Sh. 2

Service Manual

7SM08F

X41 3 4

120 CAN CONNECTION

40

119

120

2

3

4

40 119

2

20

20

X9 1

1

CAN, SERVICE CONNECTOR

40

40

120

119

20

S17

X5

X5

X5

X5

X5

X5

X5

X5 40

120

119

22

3 /5

217222

Date 2005-11-04

PROD A

FORK LOWER

FORK LIFT

SUPPORT ARM LOWER

SUPPORT ARM LIFT

SPEED REF. VALUE

BELLY BUTTON

Valid from serial number 904519-

A2:S20

A2:S19

A2:S22

A2:S21

A2:S10-S18

A2:S17

INP. OV DC

CAN LOW

CAN HIGH

INP. +24V DC

A2:S1-S9

X3 6

X3 7

X3 3

X3 2

ELECTRONIC CARD TILLER ARM A2

T-code 781

Sh. 1

Sh. 2

Sh. 2

Sh. 1

KEY

ONLY KEYPAD

Electrical systems – 5000

Electrical wiring diagram Order number 229735-040

Fig. 6 Sheet 3 of 5

© TIEE SARL

© TIEE SARL

OPTION

S18:1 2 1

Service Manual

7SM08F S113 2

X2:1/3

TURTLE

TURTLE

4 / 5

217222

OUT. 0V DC HORN 2

X1 2

X2:1/2

INP. HORN 2

X1 1

PROD A

Valid from serial number 904519-

1

S18:2 2 1

OUT. OV DC HORN 1

0V DC

X12 6

X1 6

X4 2

LCLK

X12 5

X1 5

INP. HORN 1

ENABLE

X12 4

X1 4

Date 2005-11-04

X4 1

SCK

X12 3

SI

X12 2

X1 2

X1 3

+5V DC

X12 1

X1 1

ELECTRONIC CARD A2

Order number 229735-040

A6

DISPLAY

DISPLAY A6

Electrical systems – 5000 Electrical wiring diagram

T-code 781

Fig. 7 Sheet 4 of 5

11- 13

Electrical systems – 5000 Electrical wiring diagram Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

456

789

-0#

LED_GREEN

LED_RED

0V DC

X11 5

X11 6

X11 7

X11 8

X11 9

X11 10

5 / 5

123

369# X11 3

X11 4

2580 X11 2

1 2 3 4 5 6 7 8 9 0 I

147A2

X11 1

ELECTRONIC CARD KEY BOARD

A17

217222

PROD A

T-code 781

11- 14

Fig. 8 Sheet 5 of 5 Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Functional description Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.9 Functional description means constantly on

means flashing

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

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

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

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

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

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

Note that “resulting conditions” show what is expected when no error conditions are present. Items shown in square brackets [ ] refer to electrical component designations as stated in the electrical wiring diagrams.

Unless otherwise stated, high ≈ 24 V and low ≈ 0 V.

© TIEE SARL

Service Manual

7SM08F

11- 15

Electrical systems – 5000 Functional description T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 7: Theory of operation Event:

1. Battery connected

Action(s)

Connect the traction battery [X1, G1].

Influencing elements

Main power fuses ok [F1, F3] .

Operating circuit fuses ok [F50, F51].

PTC resistor ok [R1] (15 Ohm at room temperature)

Resulting conditions

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

Event:

2. Switch on (PIN-code entry)

Prior event(s)

1

Action(s) Enter valid PIN-code and press

Influencing elements Resulting conditions

[A17].

Emergency switch-off closed [S21] [A1:INP.SUPPLY+24VDC] {high}.

Tiller in drive position sensor not activated [S10] [A1:INP.TILLER ARM IN DRIVE POS] {low}.

Power lamp and

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

percentage of full charge and

[A6].

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

Event:

3. Tiller unit lowered for driving

Prior event(s)

2

Action(s)

Lower tiller unit handle.

Influencing elements

Tiller in drive position sensor [S10].

Resulting conditions

Tiller in drive position sensor activates [S10] [A1:INP.TILLER ARM IN DRIVE POS] {low}.

Main contactor output goes {low} [A1:OUT.MAIN CONTACTOR].

Main contactor closes [K10].

11- 16

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Functional description Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 7: Theory of operation Event:

4. Traction, forks first

Prior event(s)

3

Action(s)

Move butterfly [L1] in forks direction.

Influencing elements

Butterfly Hall sensors [A2:S10-18].

Parameter #2 & #3 settings affect traction performance

Resulting conditions

[A1:OUT.BRAKE A] goes {low}.

Brake coil [Y1] energises, mechanical brake releases.

Current fed to traction motor field winding (S2 +ve and S1 -ve).

Pulsed current fed to traction motor armature proportional to butterfly deflection.

Event:

5. Traction, drive wheel first

Prior event(s)

3

Action(s)

Move butterfly [L1] in drive wheel drive direction.

Influencing elements

Butterfly Hall sensors [A2:S1-9].

Parameter #2 & #3 settings affect traction performance.

Resulting conditions

[A1:OUT.BRAKE A] goes {low}.

Brake coil [Y1] energises, mechanical brake releases.

Current fed to traction motor field winding (S2 -ve and S1 +ve).

Pulsed current fed to traction motor armature proportional to butterfly deflection.

Event:

6. Neutral braking

Prior event(s)

4 or 5

Action(s)

Let butterfly [L1] return to neutral position.

Influencing elements

[L1].

Parameter #4 setting.

Resulting conditions

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

© TIEE SARL

Service Manual

7SM08F

11- 17

Electrical systems – 5000 Functional description T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 7: Theory of operation Event:

7. Reverse braking

Prior event(s)

4 or 5

Action(s)

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

Influencing elements

[L1].

Resulting conditions

Traction motor [M1] acts as generator and via transistor controller [A1] converts the trucks energy of motion into electrical energy, thus reducing the truck’s speed. The excess electrical energy is fed back to the battery [G1] helping to recharge it. The braking effect increases the more the butterfly is deflected.

The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes to a complete stand still.

Event:

8. Mechanical brake operation

Prior event(s)

4 or 5

Action(s)

Move tiller unit handle to upper or lower position.

Influencing elements

Tiller in drive position sensor [S10].

Resulting conditions

Tiller in drive position sensor [S10] de-activates, [A1:INP.TILLER ARM IN DRIVE POS] {low}.

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

Event:

9. Emergency reverse function

Prior event(s)

5

Action(s)

Whilst travelling in drive wheel direction, the emergency reverse button [A2:S17] becomes depressed.

Influencing elements

Emergency reverse [A2:S17].

Resulting conditions

Hall switch [A2:S17] is directly activated. The [A2] card interprets this signal as a command to the transistor regulator [A1] to drive the traction motor at a reduced speed in the forks direction as long as [A2:S17] is depressed.

The normal drive command signal received from [L1] is blocked until [L1] is released and returns to neutral position.

11- 18

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Functional description Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 7: Theory of operation Event:

10. Forks lifting

Prior event(s)

2

Action(s)

Press the lift forks button [A2:S19].

Influencing elements

Main contactor [K10].

Fuse [F3].

Fork lift button [A2:S19].

Battery status ok (battery discharge indicator > 0 or battery charge > 20 %).

Resulting conditions

[A1:OUT.PUMP CONTACTOR] goes {low}.

Pump contactor [K30] activates, pump motor [M3] starts.

[A1:OUT.FORK VALVE] goes {low}.

Fork lift selection valve [Y34] activates.

Event:

11. Forks lowering

Prior event(s)

2 or 10

Action(s)

Press the lower forks button [A2:S20].

Influencing elements

Main contactor [K10].

Forks lower button [A2:S20].

Resulting conditions

[A1:OUT.LOWER VALVE] goes {low}, lowering hydraulic valve [Y41] activates.

[A1:OUT.FORK VALVE] goes {low}, fork lift selection valve [Y34] activates.

Event:

12. Support arms lifting

Prior event(s)

2

Action(s)

Press support arms lift button [A2:S21].

Influencing elements

Main contactor [K10].

Fuse [F3].

Support arm lift button [A2:S21].

Battery status ok (battery discharge indicator > 0 or battery charge > 20 %).

Support arms at top sensor S31[A1:INP.SUPP.ARM NOT AT TOP] not activated {high}.

Resulting conditions

[A1:OUT.PUMP CONTACTOR] goes {low}.

Pump contactor [K30] activates, pump motor [M3] starts.

[A1:OUT.SUPP.ARM VALVE] goes {low}, Support arm selection valve [Y52] activates.

© TIEE SARL

Service Manual

7SM08F

11- 19

Electrical systems – 5000 Functional description T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 7: Theory of operation Event:

13. Support arms lowering

Prior event(s)

2 or 12

Action(s)

Press support arms lower button [A2:S22].

Influencing elements

Main contactor [K10].

Support arms lower button [A2:S22].

Resulting conditions

[A1:OUT.LOWER VALVE] goes {low}, lowering hydraulic valve [Y41] activates.

[A1:OUT.SUPP.ARM VALVE] goes {low}, support arm selection valve [Y52] activates.

Event:

14. Click-2-creep (option)

Prior event(s)

2

Action(s)

“Double-operate” [L1] to activate function.

Operate [L1] with tiller arm in upright position to drive truck at creep speed (2.5 km/h).

Influencing elements

Main contactor [K10].

Setting of parameter #15:0.

Resulting conditions

[A1:OUT.BRAKE A] goes {low}.

Brake coil [Y1] energises, mechanical brake releases.

Current fed to traction motor field winding (S2 +ve and S1 -ve).

Pulsed current fed to traction motor armature proportional to butterfly deflection. “SLO” displayed (flashing).

Event:

15. Turtle (option)

Prior event(s)

3

Action(s)

Press [S113] to activate function.

Move butterfly [L1] in either direction.

Influencing elements

Option button 1 [S113].

Setting of parameter #1 & #15:1.

Resulting conditions

[A1:OUT.BRAKE A] goes {low}.

Brake coil [Y1] energises, mechanical brake releases.

Current fed to traction motor field winding (S2 +ve and S1 -ve).

Pulsed current fed to traction motor armature proportional to butterfly deflection. Maximum speed limited by parameter #1. “SLO” displayed (constantly on).

11- 20

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Functional description Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.9.2 Transistor regulator

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

Curtis 1243 is a regulator [A1] for controlling separately excited motors (SEM). 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.

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

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

Service Manual

7SM08F

11- 21

Electrical systems – 5000 Functional description T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Refer to section Configurable “Option” Parameters on page 52 for more detailed information.

A2 Electronic card TLS Extra / Customised function(s)

CAN bus

A36 SEU

X41

CAN service connector

A1 Traction controller Fig. 9 Connection architecture for SEU Fig. 9 shows how the SEU is used to allow a greater number of functions to be controlled via the CAN bus. The SEU has one 42-pin multipin connector which handles all inputs, outputs, CAN and supply signals.

11- 22

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Functional description Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 8: SEU 42-p connector Pin

Connection

Pin

Connection

Pin

Connection

14

AGND

28

AGND

42

CAN_L

13

+5V EXT

27

CAN_H

41

AGND

12

ANALOG IN 4 (5V)

26

ANALOG IN 5 (30V)

40

ANALOG IN 6 (30V)

11

ANALOG IN 1 (5V)

25

ANALOG IN 2 (30V)

39

ANALOG IN 3 (30V)

10

RS-232 +12V

24

RS-232 TxD

38

9

RS-232 GND

23

RS-232 RxD

37

8

22

36

7

DIGITAL IN 7 (H)1

21

DIGITAL IN 8 (H)

35

6

DIGITAL IN 4 (L)2

20

DIGITAL IN 5 (H)

34

DIGITAL IN 6 (H)

5

DIGITAL IN 1 (L)

19

DIGITAL IN 2 (L)

33

DIGITAL IN 3 (L)

18

BOX ADDRESS 1

32

BOX ADDRESS 2

4 3

DIGITAL OUT 4 (PWM OUT 2)

17

GND

31

GND

2

DIGITAL OUT 3 (PWM OUT 1)

16

DIGITAL OUT 1

30

DIGITAL OUT 2

1

B+ (+24V)

15

GND

29

GND (0V)

1.H = high-current (7 mA) 2.L = low-current (1 mA)

© TIEE SARL

Service Manual

7SM08F

11- 23

Electrical systems – 5000 Functional description T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

11.9.4 Speed limitation The truck’s maximum speed is limited by driver / service parameter settings and the presence of certain error codes. See “11.11.5Summary of driver parameters” on page 41 for more information. The table below summarises the speed limitations and assumes that all relevant driver parameters are set to 100%. When a combination of limiting factors are present the lowest speed will be active NOTE! The speeds given are nominal.

Table 9: Summary of speed limitations Error code

Turtle Click-2-creep Maximum speed km/h

Inf.

None

OFF

OFF

6

1

None

OFF

ON

2,5

2

None

ON

OFF

6

3

C50-C99

-

-

2,5

E101-E214

-

-

0

1.The maximum speed is adjustable by parameter #2

2.

flashes on the display.

3.The maximum speed is adjustable by parameter #1 and is shown continuously on the display.

11- 24

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Functional description Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.9.5 Hour meter and battery condition At switch on, the hour meter is displayed and the hour meter symbol lights for 4 seconds (Fig. 10).

Fig. 10

Fig. 11

The display will then change to show the battery’s remaining capacity expressed as a percentage of full charge and the battery symbol lights (Fig. 11).

The truck’s control system stores 5 different elapsed time values in units of hours. The time value normally shown depends on the setting of service parameter #20. (See “# 20 - Hour meter selection” on page 47). However, any of these time values can be temporarily displayed on the hour meter. To choose which value to display carry out the following procedure: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

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

on the keypad.

• Hold S18 depressed until “H” is displayed, then release S18 (Fig. 12).

Fig. 12

© TIEE SARL

Hour meter symbol lights.

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

Service Manual

7SM08F

11- 25

Electrical systems – 5000 Functional description T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 10: Hour meter modes Description

Display

Key time: Total time truck has been switched on.

Activity time: Combined time either pump or drive motor has been in operation.

(Default display mode.)

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

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

Remaining time to next service: (Parameter #25 controls the initial value). See “#25 - Service interval” on page 48 for more information.

11- 26

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.10 Diagnostic and troubleshooting means constantly on

means flashing

11.10.1 General

Fig. 13

The trucks’s electronic control system incorporates built-in fault code display and logging. This capability works as a powerful complement in assessing the cause of eventual truck malfunctions. When a fault code occurs the code number is displayed and the fault condition LED flashes (Fig. 13).

The codes can be broadly divided into two groups: • Caution codes - denoted by prefix “C”. These codes alert the operator to the presence of a caution condition. Caution codes in the range C50 to C99 will limit the truck’s maximum speed to creepspeed. The conditions which cause such codes can usually be easily remedied without further attention. Caution codes C19 to C43 are not stored in the code history log.

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

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

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

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

• Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid on the keypad.

PIN-code and then press • Hold S18 depressed until “E” is displayed (Fig. 14), then release S18.

Fig. 14 © TIEE SARL

Fault symbol lights.

Service Manual

7SM08F

11- 27

Electrical systems – 5000 Diagnostic and troubleshooting T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

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

Table 11: List of error codes Code Description

Possible cause / Hint or Solution

C3

TLS impact warning

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

C4

TLS “deactivated” warning

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

C19

Default parameter warning

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

C20

Butterfly warning

Problem with speed control & travel direction selector [L1].

The speed control may have been actuated during start-up.

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

C28

Emergency switch warning

Emergency switch [S21] activated.

No voltage supply to transistor regulator [A1].

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

C29

Service time warning

Time for next service. / Verify the service parameter. The parameter may not have been reset during the most recent service intervention. / See parameter #25 - Service interval on page 48 for setting of parameter.

C31

Pressure sensor warning

Not applicable on this truck type.

C41

Battery undervoltage warning

Battery voltage < 17 volt - battery due for charging.

Battery parameter may not be correctly adjusted. / See # 21 - Battery size on page 47 for setting of parameter #21.

Burnt fuse [A1]. / Change [A1].

C42

Battery overvoltage warning

Battery voltage > 33 volt.

Can occur with a fully charged battery and hard reverse braking.

C43

Transistor regulator thermal cutback

Driving may be too intensive.

Defective transistor regulator [A1].

11- 28

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 11: List of error codes Code Description

Possible cause / Hint or Solution

C90

Communication problem with the SEU unit no.1 (A36)

The A2 card is not receiving expected data from the SEU unit 1. / Verify the voltage supplied to the SEU unit (A36: POWER SUPPLY 24VDC) and check that the CAN cabling is OK. This error can also occur if an option parameter has been accidentally activated but no option (with an SEU) is fitted./ Ensure all option parameters (16 to 19) are set to inactive.

C91

Communication problem with the SEU unit no.2

The A2 card is not receiving expected data from the SEU unit 2./Verify the voltage supplied to the SEU unit 2 (POWER SUPPLY 24VDC) and check that the CAN cabling is OK. This error can also occur if an option parameter has been accidentally activated but no option (with a second SEU) is fitted. / Ensure all option parameters (16 to 19) are set to inactive.

C92

Programming warning (SEU unit no.1)

Incorrect programming of SEU unit 1 [A36]. The truck travels at creep speed. / May have been caused by incorrect allocation of an output during adjustment of the option parameters (16 to 19). Verify all settings of any option parameters.

C93

Programming warning (SEU unit no.2)

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

E101

Transistor regulator [A1] incompatible with the type of truck

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

E104

Brake switch transistor output in transistor regulator [A1] shorted

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

E106

Digital output fault or field current limit

Attempting to drive more current than specified from outputs.

OR problem regulating field current.

Internal transistor regulator [A1] fault.

E107

Main contactor not activated [K10]

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

Contactor control wire not connected.

Incorrect contactor output from the transistor regulator (switched off). / Inspect the main contactor tips [K10].

Check control wires to main contactor. Check contactor drive output goes {low} [A1].

E108

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

Main contactor tips welded.

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

© TIEE SARL

Service Manual

7SM08F

11- 29

Electrical systems – 5000 Diagnostic and troubleshooting T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 11: List of error codes Code Description

Possible cause / Hint or Solution

E110

Incorrect rotor current value [M1, A1]

Defective transistor regulator [A1].

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

E140

Checksum error

Faulty internal main control card [A2], faulty software / Download correct software to card and check operation of truck again.

Change the main control card [A2]

E141

Software problem

Faulty internal main control card [A2], faulty software / Download correct software to card and check operation of truck again.

Change the main control card [A2].

E150

[A1] to [A2] communication error

CAN wiring interruption. / Check CAN wiring.

Defective transistor regulator [A1].

E151

[A2] to [A1] communication error

CAN wiring interruption. / Check CAN wiring.

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

E157

Bus off error

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

E159

Over-run error

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

E160

Hall sensor error

Problem with emergency reverse Hall sensor [A2:S17]. / Check switch mechanism.

Supply fault on main control card[A2]. / Change main control card [A2].

E180

TLS error

Not applicable on this truck.

E200

Drive motor field circuit open

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

E201

M minus error

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

Defective transistor regulator [A1].

E202

Power amplifier sensor error

Armature current sensor fault in transistor regulator [A1].

Defective transistor regulator [A1].

E214

Power amplifier CAN timeout

Transistor regulator reports unexpected loss of data flow from main control card [A2]. / Check CAN wiring.

11- 30

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.10.4 Transistor regulator errors All errors generated by or within the transistor regulator [A1] are communicated to the main control card [A2]. The fault conditions are then displayed as error or caution codes according to the List of error codes on page 28. However, there is a status LED on the transistor regulator which displays the current status of the regulator.

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

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

Table 12: Transistor regulator error code STATUS LED

Curtis 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 current.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding.

Shunt field open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage.

1. Battery voltage < 17 volts.

2. Corroded battery terminals.

3. Loose battery or regulator connections.

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage.

1. Battery voltage > 33 volts.

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Over-/under-temperature reduction.

1. Temp. > 85 oC or < -25 oC. 2. Truck overloaded.

3. Wrong installation of transistor regulator.

4. Operation under extreme conditions.

© TIEE SARL

Service Manual

7SM08F

11- 31

Electrical systems – 5000 Diagnostic and troubleshooting T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

Error

Reset when

OVERVOLTAGE

Battery voltage falls below 33 V.

THERMAL CUTBACK

The temperature is within allowed range.

THROTTLE FAULT 1, 2

Error has been fixed.

LOW BATTERY VOLTAGE

When battery voltage exceeds 16 V.

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

WARNING! Risk of short-circuiting.

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

11- 32

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

[A17].

• Battery status is shown.

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

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

Table 13: Built-in test modes Mode

Flashing symbol

Displayed data

1

Speed reference value sent to Curtis.

2

Digital inputs/outputs can be tested. See “Digital inputs/outputs test mode” on page 34.

3

Battery voltage (V).

4

Armature current (A).

5

Field current (A).

6

PWM Armature in %.

7

Status Curtis.

© TIEE SARL

Service Manual

7SM08F

11- 33

Electrical systems – 5000 Diagnostic and troubleshooting T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

Inputs check

Table 14: Inputs check Element

11- 34

Segment

Function

[S31]

Segment on when support arms not at top.

[S10]

Segment on when tiller arm is in drive position.

[A2:S19]

Segment on when forks lift button is depressed.

[A2:S20]

Segment on when forks lower button is depressed.

[A2:S21]

Segment on when support arms lift button is depressed.

[A2:S22]

Segment on when support arm lower button is depressed.

[S18]

Segment on when signal horn button(s) pressed.

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Outputs check

Table 15: Outputs check Element

© TIEE SARL

Segment

Function

[Y1]

Segment on when Brake solenoid output activated.

Complement [Y1]

Segment on when Brake solenoid NOT activated.

[K10]

Segment on main contactor output is activated.

[K30]

Segment on when pump contactor output is activated.

[Y34]

Segment on when fork cylinder selection valve output is activated.

[Y52]

Segment on when support arm selection valve output is activated.

[Y41]

Segment on when lower valve output is activated.

Service Manual

7SM08F

11- 35

Electrical systems – 5000 Diagnostic and troubleshooting T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Option buttons check

Table 16: Option buttons check Element

Segment

Function

[S116]

Segment on when option button 6 is pressed.

[S115]

Segment on when option button 5 is pressed.

[S114]

Segment on when option button 4 is pressed.

[S111]

Segment on when option button 3 is pressed.

[S112]

Segment on when option button 2 is pressed.

[S113]

Segment on when option button 1 is pressed.

Display test mode The digital display [A6] itself can be tested to verify all the segments of the display function correctly.

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

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press Fig. 15

on the keypad.

• Hold S18 depressed until “d” is displayed (Fig. 15), then release S18.

All number segments on the display and symbol lamps should flash sequentially (Fig. 16).

Fig. 16 11- 36

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.11 Parameters 11.11.1 General The truck’s control system stores a number of parameters. These parameters are used to configure the truck for correct operation in the particular application for which it was designed. The parameters are divided into two groups, Driver parameters and Service parameters.

• Driver parameters (2 to 7) - These parameters are used to tailor the driving characteristics of a truck for a specific driver or operation. Up to 10 sets of driver parameters can be stored. Driver parameters can be adjusted directly without the requirement for a suitable CAN service key.1 • Service parameters (10 to 39) - These parameters are used to tailor the truck’s performance / operation characteristics and include all other parameters not designated as driver parameters. Service parameters can ONLY be adjusted when a suitable CAN service key is plugged into the truck.2

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

• Ensure the truck is switched off. Press

on the keypad.

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

on the keypad.

• Hold S18 depressed until “P” is displayed (Fig. 17), then release S18.

Fig. 17

Parameters symbol lights.

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

1.Driver parameters can only be set without a CAN key if parameter #39 is set to value 1,3,5,7,9 & 11. See “#39 - Log-in method & operator parameter access” on page 48.

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

Service Manual

7SM08F

11- 37

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

11.11.3 Adjusting operator parameters without the CAN service key NOTE! Operator parameters can only be set without a CAN key if parameter #39 is set to value 1, 3, 5, 7, 9 or 11. See #39 - Log-in method & operator parameter access on page 48.

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

• Select the required parameter.

• Press Horn button S18.

Parameter symbol flashes.

• Set parameter value by repeatedly operating speed control L1 up or down.

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

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing

on the keypad.

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

For detailed descriptions and effects of these parameters, see the section Description of driver parameters on page 42.

11- 38

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.11.4 Viewing & changing parameters CAN service key connected • Ensure the battery is connected.

• Connect a suitable CAN-service key to X41.

• Ensure the truck is switched off. Press

on the keypad.

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

• Hold S18 depressed until “P” is displayed (Fig. 18), then release S18.

Fig. 18 Parameters symbol lights.

When pressing the speed control L1 forwards repeatedly, the first operator profile will be displayed. Continue to press L1 in the forward direction and the next operator profile will be displayed (operator no. 2), etc. until the last operator (operator no. 10). See Fig. 19.

Operator parameter no.

Profile no.

Fig. 19

Once the 10 operator profile have been displayed, the truck service parameters will be displayed as L1 is repeatedly pressed in the forward direction.

© TIEE SARL

Service Manual

7SM08F

11- 39

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Changing a parameter • Select the required parameter.

• Press Horn button S18.

Parameter symbol flashes.

• Set the parameter value by repeatedly operating speed control L1 up or down.

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

Parameters symbol lights (stops flashing).

• Switch off the truck by pressing

on the keypad.

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

The truck’s service parameters can be displayed first by operating speed control L1 in the backward direction. This will cause parameter #40 to be displayed and then parameter #39 etc.1 For detailed descriptions and effects of these parameters see the section Summary of service parameters on page 43.

NOTE! Truck handling.

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

Do not change any parameters without the necessary know how.

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

11- 40

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.11.5 Summary of driver parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in sections “11.11.3Adjusting operator parameters - without the CAN service key” on page 38 and “11.11.4Viewing & changing parameters - CAN service key connected” on page 39.

See also section “11.9.4Speed limitation” on page 24 for information regarding the maximum speeds of the truck.

01

Name

Unit

Min. Max. Step

Maximum speed, Turtle mode

%

40

Note Standard

Parameter #

Table 17: Summary of driver parameters

100

5

60 S 40:

100:

S = maximum speed 02

Maximum speed

%

40

100

5

100 S 40:

100:

S = maximum speed 03

Acceleration

%

5

100

5

70 A 10:

100:

A = maximum acceleration 04

Neutral braking force

%

5

100

5

50 F 5:

100:

F = maximum braking force 05

Automatic log-off

minute

0

20

1

20 T 1:

20:

T = log-out time

© TIEE SARL

Service Manual

7SM08F

11- 41

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

11.11.6 Description of driver parameters #1 - Maximum speed in Turtle mode Parameter #1 allows for adjustment of the maximum speed of the truck when Turtle mode is in operation.

Turtle mode allows the operator to temporarily reduce the maximum speed of the truck by pressing option button 1. Pressing the button alternately toggles the function on and off. For Turtle to operate, it must first be activated by setting a non-configurable option #15. See section “ #15 - Non-configurable options” for information about how to activate Turtle mode.

#2 - Maximum speed Allows adjustment of the maximum speed of the truck.

#3 - Maximum acceleration Allows adjustment of the truck’s maximum acceleration. The lower the value of the parameter the longer it takes to accelerate the truck to the demanded speed control lever position [L1].

#4 - Neutral braking force Allows adjustment of the neutral braking force applied when speed control lever [L1] returns to the neutral position. The lower the value of the parameter the longer it takes to bring the truck to a standstill.

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

11- 42

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

11.11.7 Summary of service parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in sections “11.11.4Viewing & changing parameters - CAN service key connected” on page 39.

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

Table 18: Summary of service parameters Min.

Max. Step

Note

10

PIN-code

-

0

9999

1

1

14

Creep speed

%

-10

+10

1

-5

Standard

Unit

Parameter #

Name

PIN code assignment.

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

S -10:

+10:

S= Speed at first sensor 15

Non-configurable options 0 to 9

See “#15 - Non-configurable options” on page 45.

16

Configurable option #1

17

Configurable option #2

18

Configurable option #3

19

Configurable option #4

These parameters provide correct operation of trucks which have been modified with an approved special request modification. If no such modifications are present on the truck, these parameters shall all be set to “0” See “11.11.9Configurable “Option” Parameters” on page 52.

20

Hour meter selection

-

1

5

1

2

Select which hour meter is normally displayed.

21

Battery size

-

1

20

1

5

Battery size selection.

22

[S10] type

-

0

0

0

0

N/A for this truck type.

25

Service interval

h

0

2000

50

0

Setting of service intervaltimer.

28

Fork switch selection

-

0

2

1

1

Sets which buttons control fork lifting.

39

Log-in method & parameter access

-

1

12

1

3

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

© TIEE SARL

Service Manual

7SM08F

11- 43

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

11.11.8 Description of service parameters # 10 - PIN code NOTE: The functionality of parameter #10 is ignored if the value of parameter #39 has been set to 5, 6, 7 or 8. PIN code input is facilitated via the extended keypad. For detailed information, see the section Extended keypad - General on page 49.

The parameter stores the truck’s active PIN-codes. The truck can store up to ten PIN-codes. Each PIN-code has a set of parameters associated with it, called driver Parameters. Entering a particular PIN-code at start-up will make the selected PIN-code’s driver parameters active.

This allows up to ten operators to individually adjust the characteristics of the truck.

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

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

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

• Repeat the step above until the PIN-code displayed is “0” (zero) • Press Horn button S18

Parameter symbol flashes.

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

Parameters symbol lights (stops flashing).

The new PIN-code has now been entered.

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

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

Operating L1 fully will step the value in increments of 100.

Valid values are 1 to 9999.

11- 44

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

• Press Horn button S18.

Parameter symbol flashes.

.

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

• Press Horn button S18.

Parameters symbol lights (stops flashing).

The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in Table 7, “Theory of operation,” on page 16 (Event 2 -Switch on (PIN code entry).

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

# 14 - Creep speed This parameter allows adjustment of the initial speed when the first Hall sensor is activated in the speed control [L1].

#15 - Non-configurable options Up to 10 so called sub-parameters are stored and accessed via parameter #15. These options are either switched ON or switched OFF and require no other adjustments. They are therefore called non-configurable options. The number of available options is dependant on the truck type. Consult table Parameter #15 Non-configurable options on page 46 for available options.

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

The parameters symbol lights.

• Select parameter #15 using [L1].

The first sub-parameter will be displayed.

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

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

• Press horn button S18.

© TIEE SARL

Service Manual

7SM08F

11- 45

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Parameter symbol flashes.

• Set the sub-parameter value by repeatedly operating speed control L1 up or down. See Table 24: for details.

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

The parameters symbol lights (stops flashing).

• Switch off the truck by pressing

on the keypad.

The non-configurable option will now be activated.

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

P

Sub-parameter No.

Option name

Function ON

Function OFF

Default setting

Table 19: Parameter #15 Non-configurable options Value

NOTE!

0

Click-2-creep

1

0

1

1

Turtle

1

0

0

#16 - Configurable option #1 See “11.11.9Configurable “Option” Parameters” on page 52.

#17 - Configurable option #2 See “11.11.9Configurable “Option” Parameters” on page 52.

#18 - Configurable option #3 See “11.11.9Configurable “Option” Parameters” on page 52.

#19 - Configurable option #4 See “11.11.9Configurable “Option” Parameters” on page 52.

11- 46

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

Table 20: Hour meter parameter selection Value

Description

Display

1

Key time: Total time truck has been switched on.

2

Activity time: Combined time either pump or drive motor has been in operation.

(Default display mode.)

3

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

4

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

5

Remaining time to next service.

(Parameter #25 controls the initial value.)

See “#25 - Service interval” on page 48 for more information.

# 21 - Battery size This parameter matches the discharge indication to the characteristics of the battery fitted.

Instructions for verifying parameter setting • Fully charge 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 battery acid’s specific density at room temperature. If the specific density 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 by a maximum one step.

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

The acid’s specific density can vary depending on battery brand.

© TIEE SARL

Service Manual

7SM08F

11- 47

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 21: Battery size parameter Value

Function

3

¦

4

Less discharged

5

Battery (Ah)

230 Ah (Standard)

6 7

More discharged

8

ý

WARNING! Ensure you have set the parameter correctly.

The battery may otherwise be irreparably damaged.

#22 - [S10] Type This parameter is only used for other older truck models which use a mechanical [S10] switch. It is always set to 0 in this truck type.

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

#28 - Forks lift button selection This parameter determines which buttons are used for forks lift function.

• Value 0 - No buttons active.

• Value 1 - A2:S19 & 20 operate forks / A2:S21 & 22 operate support arms (default).

• Value 2 - A2:S21 & 22 operate forks / A2:S19 & 20 operate support arms.

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

11- 48

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 22: Parameter #39 settings Method

Operator can change driver parameters

CAN key required to change driver parameters

Value Key switch fitted

1

2

Keypad fitted (standard 10 PIN codes)

3

4

Extended keypad (100 PIN codes)

5

6

Keypad + TLS

7

8

Smartcard

9

10

Smartcard + TLS

11

12

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

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

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

Extended keypad - Programming A group of PIN codes can be made accessible by defining them as a block. Block no. 0 is activated in the default setting. This means that 3 different operator profiles can be accessed from the very start. Activation of other blocks will make all the PIN codes for that block accessible (see Table 24:). If all 10 blocks have been activated, then 10 PIN codes will be accessible for the operator profile.

The truck firmware stores a standard PIN code set as depicted in Table 24:.

These PIN codes can be adjusted to any value, however, it is advisable to avoid identical PIN codes in different operator profiles.

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

• Enter code 341671 and depress

on the keypad.

• Select a programming command from Table 23:

© TIEE SARL

Service Manual

7SM08F

11- 49

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 23: Programming commands - extended keypad Function

Command

Note

Depress “1” +

Blocks 1 - 9 are disabled.

The original PIN codes are reset according to Table 24:

Reset to default settings

Enable PIN codes in block “B” Disable PIN codes in block “B”

B = Block no. 0 - 9 Depress “2” + B + B = Block no. 0 - 9 Depress “3” + B +

Modify a PIN code to NNNN Depress “4” + B + F + NNNN +

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

• Switch off the truck by pressing

on the keypad.

Programming of the extended keypad is now complete.

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

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

Table 24: shows the standard PIN codes in the firmware. These can be activated for use or changed according to the preferences of the operator.

One or more of these blocks can be activated.

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

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

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

NOTE: If the extended keypad is reset, this does NOT affect the operator profile settings.

11- 50

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 24: Standard Pin-code assignment with extended keypad Driver Profile no

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

© TIEE SARL

Service Manual

7SM08F

11- 51

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

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

General Parameters #16 to #19 are reserved in the truck’s control system for extra truck options and/or special product modifications. The parameters configure and control the behaviour of the Spider expansion unit (SEU) which must be fitted in the truck. See “11.9.3Spider expansion unit (SEU) (option)” on page 21. This method of implementation allows the standard software program to be used without the need for a specialised software. Normally, these parameters are configured by the manufacturer when the truck is modified or customized. It is advisable to up-load the parameter settings from trucks which are modified. In the event the main control card [A2] is changed, the original parameter settings can then be transferred to the new card thus ensuring the special option functions correctly.

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

Table 25: Summary of base options Base Function option

Refer to...

1

Pressing an option button controls a digital o/p.

Table 26 on page 55

2

Activating a digital input will reduce maximum drive speed.

Table 27 on page 56

3

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

Table 28 on page 57

4

Activating a digital input causes main contactor to close.

Table 29 on page 60

5

Activating digital inputs will operate lift /lower.

Table 30 on page 61

6

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

Table 31 on page 63

11

Automatic control of fork lifting/lowering.

Table 32 on page 64

11- 52

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Convention for configurable options • Each parameter can be designated to hold a particular base option.

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

• Each argument holds a value which configures that option.

16 - 0 - 1

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

OPTION ASSIGNATION

16 - 1- 1

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

Fig. 20 Configurable option laySetting Configurable options To activate a configurable option the base option must first be assigned to one of the parameters #16 to #19. This is achieved by setting argument #0 to the base option number. Once it is assigned, the option’s arguments must be configured. This is achieved by setting a value for arguments #1, #2, #3 and #4.

• Ensure the truck is in parameter mode.

Parameters symbol lights.

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

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

• Press Horn button S18.

© TIEE SARL

Service Manual

7SM08F

11- 53

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Parameter symbol flashes.

• Set argument #0 value by repeatedly operating speed control L1 up or down. Refer to base option list Table 25:.

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

Parameters symbol lights (stops flashing).

• Select argument #1 by operating speed control L1.

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

• Press Horn button S18.

Parameter symbol flashes.

• Set argument #1 value by repeatedly operating speed control L1 up or down. Refer to base option list Table 25:.

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

Parameters symbol lights (stops flashing).

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

• Switch off the truck by pressing

on the keypad.

The special option shall now be activated.

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

11- 54

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Detailed option parameter tables

Table 26: Base option 1 - Option button controls SEU output Argument #0

Option designator Values

Meaning

Initial display (value shown after 2 s delay)

1

Sets relevant parameter to handle base option 1

Argument #1

Selection of SEU unit 1 or 2

Initial display (value shown after 2 s delay)

Argument #2

Initial display (value shown after 2 s delay)

Argument #3

Initial display (value shown after 2 s delay)

Argument #4 Initial display (value shown after 2 s delay)

© TIEE SARL

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

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

Selection of SEU digital output Values

Meaning

Pin no.

0

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

16

1

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

30

2

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

3

3

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

4

Selection of option button Values

Meaning

1

activated by option button 1

2

activated by option button 2

3

activated by option button 3

4

activated by option button 4

5

activated by option button 5

6

activated by option button 6

Type of switching Values

Meaning

0

activated when button is depressed

1

option is toggled when button is pressed

Service Manual

7SM08F

11- 55

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 27: Base option 2 - Reduced drive speed by SEU i/p Argument #0 Initial

Option designator display

Values

Meaning

2

Sets relevant option parameter to handle base option 2

(value shown after 2 s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

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

(value shown after 2 s delay)

Argument #2

Selection of SEU digital input

Initial display

Values

Meaning

Pin no.

0

activate SEU digital i/p 1 (1mA)

5

1

activate SEU digital i/p 2 (1mA)

19

2

activate SEU digital i/p 3 (1mA)

33

3

activate SEU digital i/p 4 (1mA)

6

4

activate SEU digital i/p 5 (7mA)

20

5

activate SEU digital i/p 6 (7mA)

34

6

activate SEU digital i/p 7 (7mA)

7

7

activate SEU digital i/p 8 (7mA)

21

(value shown after 2 s delay)

Argument #3

Speed limitation as a percentage of max. speed

Initial display

Values

Meaning

0-12

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

(value shown after 2 s delay)

Argument #4

Speed range

Initial display

Values

Meaning

0

Affects only high speed range

1

Affects only low speed range

2

Affects both speed ranges

(value shown after 2 s delay)

11- 56

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 28: Base option 3 - Truck movement activates SEU o/p Argument #0

Option designator

Initial display (value displayed after 2 s)

Values

Meaning

3

Sets relevant option parameter to handle base option 3

Argument #1

Selection of SEU unit 1 or 2

Initial display (value displayed after 2 s)

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

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

Argument #2

Selection of SEU digital output

Initial display (value displayed after 2 s)

Values

Meaning

Pin no.

0

activate SEU digital o/p 1 (1.6 A)

16

1

activate SEU digital o/p 2 (1.6 A)

30

2

activate SEU digital o/p 3 (1.6 A)

2

3

activate SEU digital o/p 4 (1.6 A)

3

...table continued on next page

© TIEE SARL

Service Manual

7SM08F

11- 57

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 28: Base option 3 - Truck movement activates SEU o/p ...continued from previous page

Argument #3

Selection of activating movement

Initial display (value displayed

Values

Drive forward

after 2 s)

1

X

2 3

Drive backward

X

X

X X

X X

X

X

X

8 9

X X

10 11

X

X X

X

X

X

12 13

X

X

X

X

X

X

X

X

X

X

X

14 15

X

16 17

X X

18 19

X

X X

X

X

X

20 21

X

X

X

X

X

X

X

X

X

X

X

22 23

X

24 25

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

26 27

X

28 29

X

30 31

Any other movement

X

6 7

Lower forks

X

4 5

Lift forks

X

...table continued on next page

11- 58

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 28: Base option 3 - Truck movement activates SEU o/p ...continued from previous page

Argument #4

Output switching mode

Initial display (value displayed after 2 s)

Values

Meaning

0

Output continuously on

1

Output switches at 1 Hz

2

Output switches at 2 Hz

© TIEE SARL

Service Manual

7SM08F

11- 59

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 29: Base option 4 - Activate main contactor by SEU i/p Argument #0 Initial

Option designator display

Values

Meaning

4

Sets relevant option parameter to handle base option 4

(value shown after 2 s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

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

(value shown after 2 s delay)

Argument #2

Selection of SEU digital input

Initial display

Values

Meaning

Pin no.

0

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

5

1

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

19

2

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

33

3

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

6

4

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

20

5

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

34

6

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

7

7

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

21

(value shown after 2 s delay)

Argument #3

Hold time in minutes

Initial display

Values

Meaning

0-30

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

(value shown after 2 s delay)

Argument #4

11- 60

Not used

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 30: Base option 5 - Activate lift/lower by SEU i/p Argument #0 Initial

(value delay)

Option designator display

shown

after

Values

Meaning

5

Sets relevant option parameter to handle base option 5

2s

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1 (A36)

1

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

(value shown after 2 s delay)

Argument #2

Selection of SEU digital inputs

Initial display

Values

Meaning

Pin no.

0

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

5 19 33

1

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

19 33 6

2

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

33 6 20

3

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

6 20 34

4

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

20 34 7

5

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

34 7 21

(value shown after 2 s delay)

...table continued on next page

© TIEE SARL

Service Manual

7SM08F

11- 61

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 30: Base option 5 - Activate lift/lower by SEU i/p ...continued from previous page

Argument #3

Enable / Disable lower inhibit

Initial display

Values

Meaning

0

Lower inhibit disabled

1

Lower inhibit enabled

(value shown after 2 s delay)

Argument #4

Selection of fork / support arm

Initial display

Values

Meaning

0

Selects fork lift / Lower

1

Selects support arm lift / lower

(value shown after 2 s delay)

11- 62

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 31: Base option 6 - Lift height restriction by SEU i/p & override Argument #0 Initial

Option designator display

Values

Meaning

6

Sets relevant option parameter to handle base option 6

(value shown after 2 s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

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

(value shown after 2 s delay)

Argument #2

Selection of SEU digital input for restriction switch

Initial display

Values

Meaning

Pin no.

0

activate SEU digital i/p 1 (1 mA)

5

1

activate SEU digital i/p 2 (1 mA)

19

2

activate SEU digital i/p 3 (1 mA)

33

3

activate SEU digital i/p 4 (1 mA)

6

4

activate SEU digital i/p 5 (7 mA)

20

5

activate SEU digital i/p 6 (7 mA)

34

6

activate SEU digital i/p 7 (7 mA)

7

7

activate SEU digital i/p 8 (7 mA)

21

(value shown after 2 s delay)

Argument #3

Selection of option button to override

Initial display

Values

Meaning

1

activated by option button 1

2

activated by option button 2

3

activated by option button 3

4

activated by option button 4

5

activated by option button 5

6

activated by option button 6

(value shown after 2 s delay)

Argument #4

© TIEE SARL

Not used

Service Manual

7SM08F

11- 63

Electrical systems – 5000 Parameters T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Table 32: Base option 11 - Automatic lift/lower function Argument #0

Option designator

Initial display

Values

Meaning

11

Sets relevant option parameter to handle base option 11

(value shown after 2 s delay) Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

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

(value shown after 2 s delay)

Argument #2

Selection of option buttons

Initial display

Values

Meaning

0

No option buttons used

1

Option button 1 & 2 used (left side of handle)

2

Option button 2 & 3 used (left side of handle)

3

Option button 3 & 4 used (one on each side of handle)

4

Option button 4 & 5 used (right side of handle)

5

Option button 5 & 6 used (right side of handle)

6

Option button 1, 6, 2 & 5 used (Duplicate switches on both sides of handle)

7

Option button 2, 5, 3 & 4 used (Duplicate switches on both sides of handle)

(value shown after 2 s delay)

...table continued on next page

11- 64

Service Manual

7SM08F

© TIEE SARL

Electrical systems – 5000 Parameters Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

Table 32: Base option 11 - Automatic lift/lower function ...continued from previous page Argument #3

Selection of input & output signals

Initial display

Values

Meaning

Pin no.

0

Photocell -SEU digital i/p 1 (1 mA) Lower limit -SEU digital i/p 2 (1 mA) upper limit -SEU digital i/p 3 (1 mA) External lift button -SEU digital i/p 4 (1 mA) External lower button -SEU digital i/p 5 (7 mA) Auto lamp o/p - SEU digital o/p 1 (1,6 A)

5 19 33 6 20 16

1

Photocell -SEU digital i/p 2 (1 mA) Lower limit -SEU digital i/p 3 (1 mA) upper limit -SEU digital i/p 4 (1 mA) External lift button -SEU digital i/p 5 (1 mA) External lower button -SEU digital i/p 6 (7 mA) Auto lamp o/p - SEU digital o/p 2 (1,6 A)

19 33 6 20 34 30

2

Photocell -SEU digital i/p 3 (1 mA) Lower limit -SEU digital i/p 4 (1 mA) upper limit -SEU digital i/p 5 (1 mA) External lift button -SEU digital i/p 6 (1 mA) External lower button -SEU digital i/p 7 (7 mA) Auto lamp o/p - SEU digital o/p 3 (1,6 A)

33 6 20 34 7 2

3

Photocell -SEU digital i/p 4 (1 mA) Lower limit -SEU digital i/p 5 (1 mA) upper limit -SEU digital i/p 6 (1 mA) External lift button -SEU digital i/p 7 (1 mA) External lower button -SEU digital i/p 8 (7 mA) Auto lamp o/p - SEU digital o/p 4 (1,6 A)

6 20 34 7 21 3

(value shown after 2 s delay)

Argument #4

Activation of external lift & lower buttons

Initial display

Values

Meaning

0

Disabled

1

Enabled

(value shown after 2 s delay)

© TIEE SARL

Service Manual

7SM08F

11- 65

Electrical systems – 5000 Technical specifications – Curtis 1243 T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

11.12 Technical specifications – Curtis 1243 Table 33: Technical specification - Curtis 1243 Item

Traction

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 *

200

Amps

for 2 minutes

100

Amps

for 1 hour

25

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.

11- 66

Service Manual

7SM08F

© TIEE SARL

Hydraulic system - 6000 General Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

12- Hydraulic system - 6000 12.1 General

The hydraulic system is composed of a compact hydraulic unit, including a solenoid valve for lowering the forks and a pressure limit valve.

There is also a valve for the lift cylinder of the support arms and one for the lift cylinder of the forks.

© TIEE SARL

Service Manual

7SM08F

12- 1

Hydraulic system - 6000 Hydraulics diagram and components T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

12.2 Hydraulics diagram and components

1

2

3

Y52

Y34

4 Y41 6

P

M3 7

12- 2

Service Manual

5

7SM08F

8

© TIEE SARL

Hydraulic system - 6000 Hydraulics diagram and components Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

8 M3

4 P

1

Y34 5 Y52

7 6 Y41 2

3

Table 34: Main Components

© TIEE SARL

Pos.

Name

1

Lift cylinder, support arm

2

Lift cylinder, forks

3

Hose breakage valve

4

Non-return valve

5

Flow regulation valve

6

Pressure limit valve

7

Intake filter

8

Return filter

M3

Pump motor

P

Pump

Y34

Valve for fork lift

Y41

Lowering valve

Y52

Valve for support arm lift

Service Manual

7SM08F

12- 3

Hydraulic system - 6000 Description T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

12.3 Description Lift The system has two electric valves, one for fork lifting (Y34) and one for support arm lifting (Y52). By opening the valve for the fork lift (Y34) and at the same time running the pump motor (M3), the forks' lifting motion takes place. When the load is in the lifted position, it is held in place by the closed valve (Y34).

The speed of the fork lift depends on the weight of the load. A hose rupture valve is located at the lift cylinder to prevent the load from falling uncontrollably in the event of a hose rupturing.

To lift the support arms, the valve for the support arm lift (Y52) is opened at the same time that the pump motor (M3) is run. The support arms are kept in the lifted position by the closed valve (Y52).

Lowering To lower the forks, both the valve for fork lifting (Y34) and the electric lowering valve (Y41) must be opened. To lower the support arms, both the valve for support arm lifting (Y34) and the lowering valve (Y41) must be opened.

The flow control valve regulates the maximum lowering speed and the non-return valve prevents leakage through the pump. A pressure limit valve (overflow valve) prevents overload and at the same time protects the pump motor from overpressure.

Operating pressure Operating pressure at rated load is 180 bar.

Pressure limit valve The pressure limit valve opens at 200 bar.

12- 4

Service Manual

7SM08F

© TIEE SARL

Hydraulic system - 6000 Adjustments Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

12.4 Adjustments 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.

2

The truck should be able to lift a load of between 850 and 900 kg on the forks and between 1650 and 1700 kg on the support arms.

1 1. Lock nut.

2. Adjuster screw, pressure limit When the screw is turned clockwise pressure increases.

When the screw is turned counter clockwise pressure decreases.

• Loosen the lock nut (1).

• Place a load of 800 kg on the forks and check that the truck can lift it with the fork lift.

• If the truck cannot lift 800 kg the pressure limit valve is adjusted by turning the adjuster screw (2) clockwise until the truck is able to lift the load.

• If the truck can lift 800 kg, place a further 100 kg on the forks. Check that the truck cannot lift the load with the fork lift.

• If the truck can lift 900 kg the pressure limit valve is adjusted by turning the adjuster screw (2) counter clockwise until the truck is unable to lift the load.

© TIEE SARL

Service Manual

7SM08F

12- 5

Hydraulic system - 6000 Adjustments T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

This page is intentionally left blank

12- 6

Service Manual

7SM08F

© TIEE SARL

Lift mast – 7000 Main mast Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

13- Lift mast – 7000 13.1 Main mast 13.1.1 Components 3

7

4 5

6 1

8 2

© TIEE SARL

Pos.

Name

1

Cover

2

Main lift cylinder

3

Plate (cylinder cover)

4

Lift chain

5

Roller

6

Mounting bolt

7

Plate (chain guide)

8

Mounting bolts

Service Manual

7SM08F

13- 1

Lift mast – 7000 Main mast T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

13.1.2 Maintenance Mounting The maintenance schedule states that only a visual inspection of the mast mounting bolts (8) must be carried out and that they must not be tightened when they are checked. If the mast has to be replaced or if the bolts have become loose, new bolts and washers must be used.

The tightening torque must be 150+/-15 Nm. Fig. 21 Bolt joints

Lubrication Lubricating the beam 1

2

13- 2

The inner sides of the beam flanges must be lubricated with TOYOTA part no. 223690 (Q8 Rembrandt EP2).

1

2

The inner sides of the beam rib must be lubricated with TOYOTA part no.

29586 (Gleitmo 805).

Service Manual

7SM08F

© TIEE SARL

Lift mast – 7000 Main mast Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

13.1.3 Cylinder Disassembly • Remove the mast cover.

• Lift the fork carriage so that the lift chain slackens.

• Unscrew the chain guide (Fig. 22).

• Remove the chain sprocket (Fig. 22).

Fig. 22 Removing the chain sprocket • Undo the bolts on the cylinder mounting (Fig. 23).

• Lift the fork carriage up past the cylinder.

• Lift out the cylinder and unscrew the hose (Fig. 23).

Fig. 23 Removing the cylinder NOTE: If the hose is difficult to reach, remove one of the truck’s batteries and loosen the other end of the hose.

Assembly Assembly takes place in the reverse order.

© TIEE SARL

Service Manual

7SM08F

13- 3

Lift mast – 7000 Fork carriage T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

13.2 Fork carriage 13.2.1 Maintenance

1

• Check that the fork carriage’s play is not too great.

• Shim as illustrated (1) if necessary.

13- 4

Service Manual

7SM08F

© TIEE SARL

Lift mast – 7000 Main lift chain system Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

13.3 Main lift chain system 13.3.1 Checking the chain setting The lift chains must be adjusted at regular periods due to stretching, see below. The chain setting is checked during servicing as set out in the maintenance schedule.

Any adjustment is made with the chain mounting bolts.

Adjust the fork height according to C code 7100, 7420, 7700 and 7800 as applicable.

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

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

The chain should be replaced.

Surface rust Surface rust is easy to recognize as the chain will be reddish brown.

Deep-seated rust has generally started and the chain has impaired strength.

The chain should be replaced

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

The chain should be replaced.

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

The chain should be replaced. © TIEE SARL

Service Manual

7SM08F

13- 5

Lift mast – 7000 Main lift chain system T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

The chain should be replaced

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

The chain should be replaced

Outline wear P

H2

H3

P = Pitch H2 = Nominal disc height.

H3 = Minimum disc height.

A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is define as H3 13- 6

Service Manual

7SM08F

© TIEE SARL

Lift mast – 7000 Main lift chain system Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

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

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

Stretching The amount of stretch on a lift chain is measured on the part of the chain that runs over the chain sprocket. The amount of stretch may, at the most, be 2% on the most worn section of the chain.

Measurement is suitably made over 300-1000 mm of the chain.

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

Type of chain

Nominal disc height H2 ( mm)

Minimum disc height H3 (mm)

Pitch P (mm)

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

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

3/4”, 2x3

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 3x4

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 4x6

17.8

16.9

19.05

381/572/953

389/583/972

1”, 4x4

23,6

22,4

25,4

508/762/1270

518/777/1295

1”, 6x6

23,6

22,4

25,4

508/762/1270

518/777/1295

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

© TIEE SARL

Service Manual

7SM08F

13- 7

Lift mast – 7000 Main lift chain system T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

Damage

The chain should be replaced if damaged in any way.

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

The chain should be replaced.

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

The chain should be replaced.

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

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

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

The chain should be blown dry using compressed air and lubricated directly after cleaning NOTE! Exercise care with degreasing agent as these can contain abrasives.

13- 8

Service Manual

7SM08F

© TIEE SARL

Lift mast – 7000 Main lift chain system Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

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

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

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

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

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

Ambient temperature

Viscosity class

Recommended Products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5°C

VG 68

> + 5°C < + 45°C

VG 150

>+ 45°C <+ 80°C

VG 220

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

* Equivalent products from another manufacturer may be used.

NOTE! Do not use a special rust protective agent to prevent rust on the lift chains.

These agents impair the lubrication of the chains. Regular lubrication is the best method to prevent rust attack.

© TIEE SARL

Service Manual

7SM08F

13- 9

Lift mast – 7000 Main lift chain system T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

This page is intentionally left blank

13- 10

Service Manual

7SM08F

© TIEE SARL

Peripherals – 8000 Battery charger (Inbuilt) Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

14- Peripherals – 8000 14.1 Battery charger (Inbuilt) 14.1.1 General SMCI is a battery charger intended for valve-regulated or freely ventilated lead acid batteries. It is adapted for batteries from about 100 Ah up to 320 Ah.

A

B

The charger which uses advanced switch techniques is connected to a normal (grounded 230 V single phase) socket (B) and the built-in micro controller then controls charging following the pre-set charging curve.

During charging the charging process is displayed with a status indicator on the standby housing (A).

The micro controller also controls charging with respect to charging time and temperature in the charger so that charging can be limited, e.g. if a fault occurs in some cell in the battery or when there is insufficient cooling of the charger.

SMCI 300 is delivered pre-set for 24 v and with software intended for charging valve-regulated or freely ventilated lead acid batteries.

The size and type of the battery are selected using the switch on the side of the fan(C) which is accessible via a slotted head screwdriver.

C

14.1.2 Charging Connect the charger to the mains. When charging starts after a few seconds, the orange status indicator on the standby housing(A) lights up. Yhis indicator remains lit until the battery is fully charged and the indicator turns to green.

Charging time varies depending on the type of battery and the degree of discharge. Normally the charger is started after working hours and the battery is fully charged the next morning. A highly discharged freely ventilated battery of 320 Ah may need up to 14 hours re-charging time, a VR battery even longer.

Some time after charging (depending on, for example, type of battery) SMCI 300 switches to maitenance charging. The green indicator remains lit to show that the battery is fully cgarged.

When charging is completed, the mains plug is placed in the standby housing.

© TIEE SARL

Service Manual

7SM08F

14- 1

Peripherals – 8000 Battery charger (Inbuilt) T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

14.1.3 Troubleshooting and service First check whether the charger indicates an error. A red, blinking indicator means that the charger cannot detect that any battery is connected.Check the cables, pole terminals and other connections to the batteries. Measure battery voltage. If the charger still doesn´t work, send it to your supplier for repair.

14.1.4 Technical data

14- 2

Size

250x115x67 mm

Weight

1,6 kg

Ambient temperature

-25°C till +40°C

Mains voltage

90-255 V AC 45-400 Hz (Reduced charging current for mains voltage below 200 V

Rated voltage

24 V DC

Rated current

30 A

Max output

750 W

Efficiency

> 86%

Battery type

Freely ventilated lead batteries (with water refilling). Valve regulated (VR) lead batteries.

Protection

IP 20

General

Temperature regulated cooling fan, protected against faulty polarisation

Service Manual

7SM08F

© TIEE SARL

Peripherals – 8000 Battery charger (Inbuilt) Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

14.1.5 Charging settings Freely ventilated batteries Switch

Batterysize

Output current

I2 current

Max current maintenance

0

No charging (red LED is lit)

-

-

-

1

100-119 Ah

30 A

5,5 A

0,5 A

2

120-144 Ah

30 A

6,6 A

0,6 A

3

145-174 Ah

30 A

8A

0,8 A

4

175-209 Ah

30 A

9,6 A

1,0 A

5

210-249 Ah

30 A

11,5 A

1,2 A

6

250-299 Ah

30 A

13,7 A

1,4 A

7

300-350 Ah

30 A

16,2 A

1,6 A

Valve regulated batteries Switch

Batterysize

Output current

I2 current

Max current maintenance

8

No charging (red LED is lit)

-

-

-

9

300-350 Ah

30 A

3,9 A

1,6 A

A

250-299 Ah

30 A

3,3 A

1,4 A

B

210-249 Ah

30 A

2,75 A

1,2 A

C

175-209 Ah

30 A

2,3 A

1,0 A

D

145-174 Ah

25 AA

1,9 A

0,8 A

E

120-144 Ah

21 A

1,58 A

0,6 A

F

100-119 Ah

17 A

1,32 A

0,5 A

© TIEE SARL

Service Manual

7SM08F

14- 3

Peripherals – 8000 Battery charger (Inbuilt) T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

This page is intentionally left blank

14- 4

Service Manual

7SM08F

© TIEE SARL

TruckCom General Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

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

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

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

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

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

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

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

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

© TIEE SARL

Service Manual

7SM08F

15- 1

TruckCom Layout T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

15.3 Layout 15.3.1 Main program screen Information window

Menu bar

Tool buttons

Nodes Icons

Tool button bar

Fig. 24 Main TruckCom program screen The Main window opens when the program is started. This shows the menu bar, tool buttons, workspace, log window and status window.

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

Fig. 25 A typical node window display 15- 2

Service Manual

7SM08F

© TIEE SARL

TruckCom Layout Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

15.3.3 Icons Icon

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

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

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

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

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

Truck report GB“15.7Truck report function” on page 7 Parameters is shown when a node has information on a parameter.

Diagnostics

Exit

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

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

Search for units

Disconnect Download from PC

Truck report

Parameters Diagnostics Information

Exit

Fig. 26 Tool button bar

© TIEE SARL

Service Manual

7SM08F

15- 3

TruckCom Connection function T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

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

1

2

3

HELPTEXT

REC

MACHINE

4

5

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

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

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

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

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

15- 4

Service Manual

7SM08F

© TIEE SARL

TruckCom Downloading program function Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

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

Type 123456

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

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

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

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

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

Service Manual

7SM08F

15- 5

TruckCom Downloading program function T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

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

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

• Select OK in the dialogue box.

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

• Release the red key to commence downloading.

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

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

On some trucks, a counter, which continuously counts up, is displayed.

NOTE! Once programmed, the logic cards in some trucks can only be upgraded with the same basic firmware. In other words, it is not possible to replace the basic firmware (other machine type).

15.6.5 Downloading in old versions of logic card To download to older versions of electronic cards which do not support restart with key, the button Old card... should be used instead of Start...

Downloading is carried out in the same way, except that restart is done by using the battery lug instead of the key.

15- 6

Service Manual

7SM08F

© TIEE SARL

TruckCom Truck report function Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

15.7 Truck report function It is possible to generate a report to a file or disk with the truck’s configuration and status. Select menu <Tools | Generate truck report...> or with the tool button Truck report. Save the report in Report.file.

NAME

Example of information generated in the truck report: [GENERAL] REPORT DATE-TIME=2004-01-19 11:11:58 CPC-PP SERIAL No=8002041 MACHINE NUMBER=555555 CUSTOMER=CUSTOMER 1 TECHNICIAN=NONAME COMPANY=Other NOTES=Test report [CAN NODES] MAIN CARD=0 CURTIS DRIVE CONTROLLER=16 [MAIN CARD CONFIGURATION] SOFTWARE=181179-001 HARDWARE=167833-004 SERIAL NO=53676 [DRIVE CONTROLLER CONFIGURATION] SOFTWARE=5 DRIVE CURRENT LIMIT (A)=300 FIELD MAXIMUM (A)=34 SERIAL NO=52857 MFG Date:=26/05/03 HOUR METERS] A IGNITION TIME=81 B TOTAL MOVEMENT=7 C DRIVE MOTOR TIME=7 D PUMP MOTOR TIME=0 S SERVICE TIME=7

[ERROR LOG] 01=104 00007.5 02=104 00007.5 03=104 00007.5 04=104 00007.5 05=104 00007.5 09=104 00005.0

[DRIVER PARAMETERS] 1=100 2=100 3=75 100=0

[TRUCK PARAMETERS] 11=0 12=0 13=0

The contents of certain rows can vary according to truck type.

© TIEE SARL

Service Manual

7SM08F

15- 7

TruckCom Parameters function T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

15.8 Parameters function To change the truck parameters, select the Parameter function. This can be done with the menu <Tools | Change parameters > or with the tool button Parameters.

NOTE! The truck must in Normal mode (i.e. not Parameter mode) when connecting TruckCom. Otherwise TruckCom will report “Unable to determine truck brand”

The parameter numbers follow the description in the respective truck Service Manuals, section 5000.

The parameter window shows the information and the current settings for all parameters. The parameters are divided into 4 tabs.

• [Driver] - Driver; driver parameters and PIN code storing • [Truck] - Truck; service parameters • [Time] - Time; time-related service parameters • [Option parameters] - Option parameters. (no. 15 to 19) WARNING! Do not attempt to make any adjustments to the option parameters unless you have sufficient knowledge of the truck’s options/ modified functions. Specially modified trucks may require that you have access to special service information.

Improper adjustment of the option service parameters may result in a malfunction.

15.9 Diagnostics function To access diagnostics, select the Diagnostic function. This can be done with the menu <Tools | Diagnostic...> or with the tool button Diagnostic.

NOTE! If the value “---” is shown in a field, or a “read status LED” is red, the communication has been interrupted for some reason and error data cannot be shown.

NOTE! The tab information displayed in the diagnostics mode depends on the type of truck connected.

15- 8

Service Manual

7SM08F

© TIEE SARL

TruckCom Diagnostics function Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

15.9.1 Representation of signal colours The screen dumps shown in the following section have been modified to improve legibility in black & white print.

WHITE GREEN RED

15.9.2 “Tiller arm” tab

Clicking on the tiller arm tab will display a dialogue showing the following: • Speed lever -The status of the speed control and travel direction selector. The status of each individual hall element is displayed.

• Buttons -The status of the control buttons is displayed. “Sxx” refers to the switch designations as given in the circuit diagram.

• Option - Status of option buttons • Battery - The measured battery voltage • R14 - Shows the measured signal voltage from the lift/lower control • R15 - Not used at present

© TIEE SARL

Service Manual

7SM08F

15- 9

TruckCom Diagnostics function T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

15.9.3 “Drive Controller” tab (transistor regulator driving)

Clicking on the Drive Controller tab will display a dialogue showing the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM - The effective power output supplied to the field circuit as a percentage.

• Armature PWM - The effective power output supplied to the armature circuit as a percentage • Field current - The current flowing in the field circuit in Amperes.

• Armature current - The current flowing in the Armature circuit in Amperes • Raw throttle data - The received speed control signal as a percentage.

• Temperature - The temperature of the output stage of the transistor controller in degrees Celsius • Inp pin 10 - The input voltage from the mode/pressure sensor. “digital O” indicates the digital status of the input.

• Inp pin 11 -The input voltage from the man-on platform sensor. “digital O” indicates the digital status of the input.

15- 10

Service Manual

7SM08F

© TIEE SARL

TruckCom Diagnostics function Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

15.9.4 “Pump controller” tab (transistor regulator pump)

If the truck is equipped with a lift/lower transistor regulator, the Pump controller tab displays the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM, Armature PWM, Field current, Armature current, Temperature - See explanation in 15.9.3 • Raw throttle data - The received lift/lower signal as a percentage.

• Out pin9 - The output signal to the proportional lowering valve as a percentage.

• Inp pin 10 - The input voltage from the pressure sensor. “digital O” indicates the digital status of the input.

• Inp pin 11 - The input voltage from the pressure sensor. “digital O” indicates the digital status of the input.

© TIEE SARL

Service Manual

7SM08F

15- 11

TruckCom Diagnostics function T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

15.9.5 “EPS” (steering servo tab)

Clicking on the “EPS” tab will display a dialogue showing the following: “Status” • “Operational” - Indicates the status of the servo’s control system • “EPS enabled” - Indicates the status of the servo’s power stage output.

• “Reference switch reached” - indicates status of drive wheel in centre reference switch.

• “Reference position found” - indicates whether a successful steering in centre has been performed.

• “EPS in power save mode” - Shows whether the steering servo is in the standby mode (following a certain amount of inactivity).

“Actual values” (Measured values) • “Temperature EPS” - The temperature of the steering servo output stage in degrees Celsius.

• “DC bus voltage” - Supply voltage to steering servo • “Wheel position” - Shows the estimated steering angle of the drive wheel.

• “Voltage analog input 1, pin5”- The measured DC input signal (0) from the steering potentiometer.

• “Voltage analog input 2, pin13”- The measured DC input signal (1) from the steering potentiometer.

• “Current” - The measured current supplied to the steer servo motor in Ampere • “Actual velocity” -The measured rotational speed of the steer servo motor shaft in r.p.m.

15- 12

Service Manual

7SM08F

© TIEE SARL

TruckCom Other menu functions Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

15.9.6 SEU tab (Extra I/O module)

When the truck is equiped with a Spider Extension Unit (former Extra I/ O module) the SEU tab shows following: • “INP X” - Shows the logical status for the digital inputs.

• “OUT X” - Shows the logical status for the digital outputs.

• “Analog input X” - Shows the voltage level on the analog inputs.

See chapter 5000 for more information about the SEU and how the inputs and outputs are connected.

15.10 Other menu functions 15.10.1 Save to file The truck parameters can be saved in the PC for downloading at a later date.Select <File | Save to file | Parameters>. All parameters in the nodes which are connected to the bus will be scanned in and saved in a file.If only the hour meters are needed, select <File | Save to file | Hour meters>.

15.10.2 Download from file A set of parameters can be downloaded from the PC to the truck. Select <File | Load from file | Parameters >. The parameters in the file will be copied to the nodes connected to the bus. If only the hour meter settings are needed, select <File | Load from file | Hour meters >.

© TIEE SARL

Service Manual

7SM08F

15- 13

TruckCom Other menu functions T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

15.10.3 Reset CAN adapter If problems should occur when resetting the CAN adapter connected to the PC, this can normally be done manually by making sure that the adapter is supplied with voltage and then selecting <Nodes | Reset CPC-PP>.

15.10.4 Delete error code log To delete the truck’s error code log, start the truck in parameter mode and then select <Tools | Erase error log>.

15.10.5 Reset hour meter To reset the truck’s hour meter, start the truck in drive mode and then select <Tools | Reset hour meters >.

15.10.6 Read error code log To show the truck’s error code log, select <Tools | Read error log >.

15.10.7 Adjust date and time To quickly adjust the truck’s data and time, select < Tools | Adjust date & time >. The time given in the PC will now be downloaded into the truck.

NOTE! This does not apply to trucks without a real-time clock.

15.10.8 Adjusting the hour meter on older cards To adjust the hour meter on trucks with older cards, select <Tools | Adjust Hour meters>. The time given in the PC will now be downloaded into the truck.

15.10.9 Help About the TruckCom application To see program information, select <Help | About TruckCom...> or use the tool button [Information].

15.10.10 Exit To exit the program, select <File | Exit > or use the tool button [Exit].

15- 14

Service Manual

7SM08F

© TIEE SARL

TruckCom Specifications Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

15.11 Specifications Table 35: CAN interface specification Description

Value

Power consumption

40-120 mA

Supply voltage

11-28 V

Transfer rate

125 kbit/s

Storage temperature

-20-80 °C

Operating temperature

0-60 °C

15.12 Installation NOTE! The program must be installed from the hard disk.

NOTE! The software application in the computer can be damaged, which is why the PC installation should be performed by someone with the required knowledge. TOYOTA does not accept any responsibility for any errors that occur during the installation.

NOTE! All references to PC operating system actions, menus and commands are based on the English language version of Windows.

15.12.1 Installation on a PC with Windows 95/ 98 If a previous version of the TruckCom application has been installed on the PC, it will be necessary to edit the System.ini file.

Start the Msconfig.exe application by selecting the Start button, selecting Run and then typing msconfig.

• Click on System.ini and open the folder (386Enh).

• Unmark the option at Device=C:\Windows\Cpcppvd.vxd.

• Save the change and close the application.

Now continue with installationThe software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.Then follow the on-screen instructions.

© TIEE SARL

Service Manual

7SM08F

15- 15

TruckCom Installation T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

15.12.2 Installation on a PC with Windows XP/ 2000 To make the application work, it is necessary to enter a value in the Windows Registry and then make a few alterations in the Windows® Control panel.

Due to the built-in Windows security, this must be done manually.

The instructions below provide step-by-step guidance to enable these changes and make the interface operate under Windows XP and Windows 2000.The changes can be made either before or after TruckCom is installed.

• Open the Registry Editor. To do this, select the Start button, then Run, type regedit and hit Enter.

• Mark the Enum folder which can be found under HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the Registry Editor.

• Select the Edit option, then Find and type PortName to search for the correct folder.

15- 16

Service Manual

7SM08F

© TIEE SARL

TruckCom Installation Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

NOTE! The location of the folder differs between different computers (some may be \Enum\Root\.., while others could be \Enum\ACPI\ etc.).

Thus be sure to search for the correct folder.

When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in the PortName data field and that the folder name is Device Parameters.

• Right-click with the mouse in the right box to enter a new value of the DWORD type and with the name

EnableConnectInterruptIoctl.

© TIEE SARL

Service Manual

7SM08F

15- 17

TruckCom Installation T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

• Change the value in data field 1 by right-clicking on the name and selecting Modify.

EnableConnectInterruptIoctl

The Device Parameters folder should look like the one in the picture.

The Registry change is now complete. Close the Registry Editor.

Changes in Windows Control Panel • Select the Start button.

• Choose Settings, then Control Panel and double-click on System.

• Select Hardware.

• Click on Device Manager and open Ports (Com & LPT).

15- 18

Service Manual

7SM08F

© TIEE SARL

TruckCom Installation Order number 229735-040

© TIEE SARL

Date 2005-11-04

Valid from serial number 904519-

Service Manual

7SM08F

T-code 781

15- 19

TruckCom Installation T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

• Double-click on the LPT port to be changed, and select the Port Settings tab.

• Check the "Use any Interrupt assigned to the port" option and click on OK.

The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.

15- 20

Service Manual

7SM08F

© TIEE SARL

TruckCom Installation Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

15.12.3 Installation on a PC with Windows NT The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.

15.12.4 In case of communication problems with CAN Make sure the computer settings for the printer port in the BIOS Setup are as follows: Port address:0378 IRQ:7 Mode:Output only For detailed information on how to change the Setup settings, refer to the User's Guide supplied with the computer.

15.12.5 To uninstall To uninstall TruckCom under Windows: • Select the Start button, Settings, Control Panel, Add/Remove Programs.

• Then select the TruckCom Program and click Change/Remove.

© TIEE SARL

Service Manual

7SM08F

15- 21

TruckCom Installation T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

This page is intentionally left blank

15- 22

Service Manual

7SM08F

© TIEE SARL

Destruction instructions General Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

16- Destruction instructions 16.1 General These instructions have been drawn up as part of the truck manufacturer’s environmental management program. An important motive is, by taking nature into consideration, to economise with resources. In other words, you should try to recycle all material as far as possible. This is to minimise the discharge of environmentally-hazardous substances.

The dismantling instructions are divided into different C-codes (parts and functions on the truck.) These C-codes are: • 0000 Chassis • 1000 Motors • 2000 Transmission/drive transmission • 3000 Brakes/belt/wheel system • 4000 Steering system • 5000 Electrical system • 6000 Hydraulics/pneumatics • 7000 Working function - lift mast • 8000 Auxiliary/installation equipment • 9000 Accessories/extra equipment The instructions do not tell you the type of material the parts are made of, but refer you to different material containers where the parts should be collected. Some plastics are marked, which means some instructions refer to the marking to determine the collection container to use.

16.2 Procedure When sorting a component part you must know what plastic parts, liquids, environmentally-hazardous substances and metals it incorporates.

© TIEE SARL

Service Manual

7SM08F

16- 1

Destruction instructions Abbreviations T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

16.3 Abbreviations Abbreviations for Service Manuals and plastic materials are used in the dismantling instructions. The abbreviations used are: ABS = Acrylonitrile-butadiene-styrene PA= Polyamide PMMA = Plexiglass PP = Polypropylene SM = Service Manual

16.4 Sorting The sorting method for component parts is based on how they can be recycled and whether they must be handled in a special way.

• Plastics must first and foremost be sorted into recyclable and non recyclable plastics. Plastics that can be recycled must be subdivided to differentiate between the different types of plastic. Instructions either indicate in which container the plastic should be placed or there is a reference to the material marking on the plastic component. In those cases where the container is indicated, the type of plastic is shown by an abbreviation. Sorting is not necessary for non-recyclable plastics. These are placed in containers intended for combustible material.

• Small plastic and rubber items are placed in the container intended for combustible material.

• Iron and steel scrap are sorted separately.

• Composite scrap that is difficult to dismantle and which contains different metals such as steel, aluminium, copper and other materials, for example, plastics, should be sorted separately.

• Oil is collected in the intended container.

• Oil filters are collected in the intended container.

• Parts contaminated by oil, such as hydraulic hoses, should be sorted separately.

• Batteries should be returned to the manufacturer (manufacturer of the battery or the truck).

• Electronic scrap should be sorted from other scrap.

• Cables should be removed and collected separately.

• Small parts, such as screws, bolts, nuts, washers, etc. are not included in the dismantling instructions. These are placed in containers intended for iron and steel scrap.

16- 2

Service Manual

7SM08F

© TIEE SARL

Destruction instructions Chassis (0300) Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

16.5 Chassis (0300)

Disassembly • Remove the chassis from the truck.

Material handling All parts are to be treated as iron and steel scrap.

© TIEE SARL

Service Manual

7SM08F

16- 3

Destruction instructions Hoods, hatches (0340) T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

16.6 Hoods, hatches (0340)

5

4

6

1

3

2

Disassembly • Remove the hoods (1, 2, 3, 4 and 5).

• Remove the plastic handle (6).

Material handling Hoods should be treated as iron and steel scrap.

The plastic handle and panel should be placed in containers intended for ABS.

16- 4

Service Manual

7SM08F

© TIEE SARL

Destruction instructions Electric Pump Motor (1710) Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

16.7 Electric Pump Motor (1710) Disassembly • Remove the hydraulic unit.

• Remove hydraulic cables.

• Remove the pump motor including the pump.

Material handling Oil should be treated as dangerous waste.

Hydraulic cables should be placed in a container for oil-contaminated components.

The motor, together with the pump, should be placed in a container for dangerous waste.

16.8 Electric Drive Motor (1760)

Disassembly • Remove the cables.

• Remove the drive motor including the electric parking brake from the gearbox.

Material handling Cables are to be placed in a container intended for cables. The motor and electric parking brake should be placed in a container for dangerous waste.

© TIEE SARL

Service Manual

7SM08F

16- 5

Destruction instructions Drive assembly/gear (2550) T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

16.9 Drive assembly/gear (2550)

Disassembly • Empty the oil from the gearbox.

• Remove the gearbox from the drive motor.

• Remove the drive wheel.

Material handling The oil should be treated as dangerous waste.

The gearbox is to be placed in a container intended for iron and steel scrap.

16- 6

Service Manual

7SM08F

© TIEE SARL

Destruction instructions Wheels (3500) Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

16.10 Wheels (3500)

1 3 2

Disassembly • Remove the drive wheel (1), castor wheel (2) and fork wheel (3).

Material handling The vulcanised wheels should be placed in a container for vulcanised wheels.

© TIEE SARL

Service Manual

7SM08F

16- 7

Destruction instructions Steering handle (4110) T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

16.11 Steering handle (4110) 2 1 3

4

Disassembly • Remove the display (1).

• Remove the electronics card (2).

• Remove the potentiometer (3).

• Remove the keyboard (4).

• Remove the cable.

Material handling The display, electronic card, potentiometer and keyboard should be placed in a container intended for electronic scrap.

The cable is to be placed in a container intended for cables.

16- 8

Service Manual

7SM08F

© TIEE SARL

Destruction instructions Tiller arm (4110) Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

16.12 Tiller arm (4110)

1

2

Disassembly • Remove the gas dashpot (1) and cut it in half.

• Remove the switch (2).

Material handling Metal parts and gas dashpots should be placed in a container for metal.

The switch is to be placed in a container intended for electronic scrap.

© TIEE SARL

Service Manual

7SM08F

16- 9

Destruction instructions General electrical equipment (5100) T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

16.13 General electrical equipment (5100)

7.5 A 7.5 A

Disassembly • Remove the cables.

• Remove the battery.

• Remove the electronic devices.

Material handling Cables are to be placed in a container intended for cables.

The battery (classified as hazardous waste within the EU) should be returned to the battery manufacturer or the manufacturer's representative (see the rating plate on the battery). The battery can also be handed in to a representative of the truck manufacturer, who bears responsibility for returning it to the battery manufacturer.

The electronic units should be placed in a container intended for electronic scrap.

16- 10

Service Manual

7SM08F

© TIEE SARL

Destruction instructions Sensor (5800) Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

16.14 Sensor (5800)

1

2

Disassembly • Remove the height sensor (1).

• Remove the safety sensor (load sensor and height reference sensor) (2).

Material handling The sensors should be placed in a container intended for electronic scrap.

© TIEE SARL

Service Manual

7SM08F

16- 11

Destruction instructions Hydraulic unit (6100) T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

16.15 Hydraulic unit (6100)

Disassembly • • • • •

Empty the oil from the hydraulics.

Remove hydraulic cables.

Remove the oil tank.

Empty the oil from the tank.

Remove the hydraulic unit (motor + pump) (see 1710).

Material handling Oil should be treated as dangerous waste.

Hydraulic cables should be placed in a container for oil-contaminated components.

The tank should be placed in a container for PP. The motor, together with the pump, should be placed in a container for dangerous waste.

16- 12

Service Manual

7SM08F

© TIEE SARL

Destruction instructions Hydraulic cables/lift cylinder (6230/6610) Order number 229735-040

Date 2005-11-04

Valid from serial number 904519-

T-code 781

16.16 Hydraulic cables/lift cylinder (6230/6610)

Disassembly • Remove the cylinders.

• Empty the oil from the cylinders.

• Cut the cylinders in half.

• Remove hydraulic cables.

• Remove the hydraulic hoses.

Material handling The oil should be treated as dangerous waste.

The cylinder and hydraulic pipes are to be placed in a container intended for iron and steel scrap.

Hydraulic hoses should be placed in a container for oil-contaminated components.

16.17 Main mast and fork carriage (7100) Disassembly • For dismantling of main masts, see separate chapter on masts.

• Remove plastic components from the main mast.

Material handling The mast and fork carriage should be treated as iron and steel scrap.

Plastic components are to be placed in the container intended for combustible material. © TIEE SARL

Service Manual

7SM08F

16- 13

Destruction instructions Main mast and fork carriage (7100) T-code 781

Valid from serial number 904519-

Date 2005-11-04

Order number 229735-040

This page is intentionally left blank

16- 14

Service Manual

7SM08F

© TIEE SARL

©TOYOTA Industrial Equipment Europe SARL Ancenis, France