Toyota Forklift 7SM12F 7SM16D Service Manual SN 551390AT - PDF DOWNLOAD

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60 ) 60 ' Valid from serial number: 551390AT-

Order number: 202187-040 Issued: 2002-05-06 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

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&RQWHQWV &RQWHQWV ............................................................................. 3 7HFKQLFDO GDWD ................................................................ 7 ,QWURGXFWLRQ 0DLQWHQDQFH ..................................... 11 1 2 3

Safety regulations with maintenance work .................. 11 Cleaning and washing ................................................. 13 Safe lifting .................................................................... 14

3UHYHQWLYH PDLQWHQDQFH ......................................... 15 1 2

Maintenance schedule ................................................ 15 Lubrication schedule ................................................... 20

2LO DQG JUHDVH VSHFLILFDWLRQ ................................ 23 7RROV ................................................................................... 25 1

Super Seal connectors ................................................ 25

(OHFWULF GULYH PRWRU ................................................... 29 1 2 3

Component parts ......................................................... 29 Service/Repairs ........................................................... 32 Technical data ............................................................. 34

'ULYH XQLW JHDU .............................................................. 35 1 2 3

Component parts ......................................................... 36 Leakage from top cover ............................................... 38 Changing of the drive shaft’s sealing ring .................... 38

(OHFWUR PDJQHWLF EUDNH ........................................... 41 1 2

Main components of the brake .................................... 41 Maintenance ................................................................ 42

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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6WHHULQJ ............................................................................. 45 1 2 3

Component parts, tiller arm ......................................... 45 Adjustments ................................................................. 46 Tiller arm handle .......................................................... 47

(OHFWULFDO V\VWHPV ...................................................... 53 1 2

Component identification ............................................. 53 List of symbols and electrical wiring diagram 55 3 Functional description .................................................. 62 4 Hour meter ................................................................... 64 5 Fault codes .................................................................. 64 6 Parameters .................................................................. 69 7 Part numbers ............................................................... 78 8 Transistor panel ........................................................... 79 9 Diagnostic and troubleshooting ................................... 80 10 Technical specifications – Curtis 1243 ........................ 82

+\GUDXOLF V\VWHP ........................................................ 83 1

Hydraulic diagram and components ............................ 83

0DLQ OLIW FKDLQ V\VWHP .............................................. 87 2 3 4 5 6

General ........................................................................ 87 Checking the chain setting ........................................... 87 Chain inspection .......................................................... 87 Cleaning ...................................................................... 91 Lubrication ................................................................... 92

&RQWURO FRPSXWHU HTXLSPHQW .............................. 93 1 2 3 4 5

4

General ........................................................................ 93 Connection .................................................................. 93 Layout .......................................................................... 94 Function ....................................................................... 96 Specifications ............................................................ 104

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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%DWWHU\ FKDUJHU ,QEXLOW ....................................... 107 1 2 3 4 5

General ..................................................................... 107 Charging .................................................................... 107 Troubleshooting and service ..................................... 108 Technical data ........................................................... 108 Charging settings ...................................................... 109

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

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60 )

60 '

Type

TSL140S-DS30

TSL140S-DS30

Output, kW

1.2

1.2

Duty cycle

S2, 60 min

S2, 60 min

Minimum carbon brush length, mm

13

13

Nominal commutator diameter, mm

50

50

Minimum commutator diameter, mm

47

47

Resistance, shunt field winding, Ω at 25 C°

0.49

0.49

Resistance armature winding, Ω at 24 °C

0.0156

0.0156

Insulation resistance between the windings and motor casing

>=1 Mohm

>=1 Mohm

Weight, kg

14

14

Type

BFK457-08

BFK457-08

Braking force, Nm

16

16

Output, W

25

25

Resistance coil, Ω

23

23

Nominal play in actuated position, mm

0.2-0.4

0.2-0.4

Minimum thickness brake disc, mm

5.5

5.5

Thickness of a new brake disc, mm

7.0

7.0

Type

2-stage angle transmission

2-stage angle transmission

Gear ratio

19,14:1

19,14:1

Oil volume, litre

1.0

1.0

Oil type at normal temperature at temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

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Service Manual 7SM12F, 7SN16D

Approved by: L-G Andersson

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60 )

60 '

Drive wheel, mm

Dia 215x70

Dia 215x70

Axle pressure without load, kg

345

345

Axle pressure at rated load, kg

345

345

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

Support arm wheel, mm

Dia 80x75

Dia 80x75

Axle pressure without load, kg (Ah)

2 x 270 (240)

2 x 220 (240)

Axle pressure at rated load, kg (Ah)

2 x 1310/1640 (240)

2 x 1195/1515 (240)

Support castor wheels, mm

Dia 125 x 50

Dia 125 x 50

Axle pressure without load (Ah)

2 x 355 (240)

2 x 328 (240)

Axle pressure at rated load, kg

2 x 520/590 (240)

2 x 553/633 (240)

Output, kW

2.2

2.2

Duty cycle,%

5

5

Minimum carbon brush length, mm

12

12

Minimum commutator thickness/diameter, mm

4.75

4.75

Pressure at rated load, bar

191

191

Overflow pressure, bar

220

190

Pump flow, litre/minute

5.0

5.0

Tank volume, litre

4.5

4.5

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

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

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

Drive motor circuits, A

125

125

Pump motor circuits, A

125

125

Control circuits, A

7,5

7,5

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Service Manual 7SM12F, 7SN16D

Approved by: L-G Andersson

7HFKQLFDO GDWD 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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60 )

60 '

Dimensions LxWxH, mm 180 Ah 240 Ah 320 Ah

196 x 643 x 452 196 x 643 x 572 244 x 643 x 572

196 x 643 x 452 196 x 643 x 572 244 x 643 x 572

Capacity, Ah

180 -320

180 -320

Weigh, kg

150 -250

150 -250

Without load, 0 - 750 kg, km/h

6,0

6,0

With rated load, 750 - 1200 kg, km/h With rated load, 1200 - 1600 kg, km/h support arms

5.3 4.4

5.3 4.4

Lift without load, m/s

0.19

0.19

Lift with rated load, m/s

0.10

0.11

Lowering without load, m/s

0.15

0.15

Lowering with rated load, m/s

0.19

0.19

Driving without load, A

23

23

Driving with rated load, A

36

36

Lift without load, A

54

54

Lift with rated load, A

148

148

10 %

10 %

Medium Long

796 848

813 865

Turning radius WA

1685

1786

735

655

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:HLJKW Truck without battery, Medium

Service Manual 7SM12F, 7SN16D

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Service Manual 7SM12F, 7SN16D

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Approved by: L-G Andersson

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,QWURGXFWLRQ 0DLQWHQDQFH 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: - 2-shifts: - 3-shifts:

08.00-17.00 (20 hr./week) 06.00-14.00, 14.00-22.00 (40 hr./week) 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.

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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 :$51,1*

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• 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 Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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• Relieve the system pressure slowly before starting work on the truck’s hydraulic system • Use paper or a rigid sheet of cardboard when checking for oil leakage. 1HYHU use your hand • Bear in mind that the oil in the transmission or the hydraulic system can be hot :$51,1*

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• Only fill the hydraulic system with new and clean oil :$51,1*

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• 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 127(

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• 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 &$87,21

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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&OHDQLQJ DQG ZDVKLQJ Cleaning and washing of the truck is important to ensure the truck’s reliability.

• Carry out general cleaning and washing weekly 127(

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([WHUQDO FOHDQLQJ • 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 127(

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&OHDQLQJ WKH PRWRU FRPSDUWPHQW • Cover the electric motors, connections and valves before washing 127(

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

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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(OHFWULFDO FRPSRQHQWV • 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 127(

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6DIH OLIWLQJ 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 • 1HYHU lift up the jack in order to lift higher • 1HYHU work under a lifted truck unless it is well supported :$51,1*

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14

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

3UHYHQWLYH PDLQWHQDQFH 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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

M: Control measurement, rectify if necessary

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0000.1

Check all links and locking pins

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0000.2

Check wear on cover/battery locking

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0000.3

Check of cracking and damage

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0000.4

Check the drive housing’s mounting on the chassis

0000.5

Check finger guard

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0000.6

Check signs and stickers

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0380.1

Check for crack formation and damage

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0380.2

Check clearance in bushes and links

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1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

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2550.1

Check for leakage

2550.2

Check the oil level. Measured using the screwed in dipstick

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in steering bearing

I

2550.5

Change the oil in the drive gear

T

I/T1

I/T

T2 I I3

Service Manual 7SM12F, 7SM16D

L4

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M: Control measurement, rectify if necessary

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Clean and check functionality

3100.2

Check the brake disc

M

3100.3

Check the clearance in disengaged position 0,2-0,5 mm

M

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3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts (New wheel: Drive tread thickness = 30mm) (Tightening torque = 65Nm)

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3500.3

Check that the castor wheel turns and rotates freely

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3500.4

Check for wear on the castor wheel (New wheel: Drive tread thickness = 10mm)

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4110.1

Check the mountings

4110.2

Check the power in the gas damper

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5000.1

Check the function of the brake microswitch

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5000.2

Check the function of the collision safety switch

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5000.3

Check the function of the horn

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5000.4

Check for wear to cables in the tiller arm

5000.5

Check the function of the driver’s control

I

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5000.6

Check the error code log and operating times

I

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16

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

3UHYHQWLYH PDLQWHQDQFH 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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

M: Control measurement, rectify if necessary

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

M

5110.2

Check connections to battery, truck and charger

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5110.3

Check that the cell and pole guards are undamaged

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5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

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5400.1

Cleaning and checking of mounting in chassis

C/T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

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5400.5

Check the cable insulation

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5700.1

Check connectors and cables

5700.2

Check all segments on display

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6000.1

Check hoses and connections for leakage

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6000.2

Check hoses for wear and damage

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6000.3

Check the oil tank for cracks, leakage and damaged mountings

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6000.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

Service Manual 7SM12F, 7SM16D

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

M: Control measurement, rectify if necessary

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6600.1

Check for leakage

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6600.2

Check the mountings

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7100.1

Check for damage and crack formation

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7100.2

Re-tighten tha mast mounting bolts (Tightening torque =197N m)

T

7100.3

Check the play of the inner section rollers

I

7100.4

Check the lateral play of the inner section

I

7100.5

Check for wear on the lifting chains and chain rollers

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7100.6

Check the adjustment of the lifting chains

I

= The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months. = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm. = Check for leakage in conjunction with the first oil change. = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months = The oil is changed and the filter cleaned for the first time after 80 h/ 1 month, and then every 1000 h/12 months When points with higher hour intervals are carried out the points with lower hour intervals should also be carried out unless otherwise specified above.

18

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

3UHYHQWLYH PDLQWHQDQFH 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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Wheel bearings

2

Mast beam

L

F

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Lifting chains

L

D

4

Hydraulic system

C

5

Steering Bearings

6

Drive gear L = Lubrication

20

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

L

A

O

B

L

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C

O C = Check

Service Manual 7SM12F, 7SM16D

C O = Oil change

Approved by: L-G Andersson

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

21

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22

7 FRGH 702 'DWH 2002-05-06

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

2LO DQG JUHDVH VSHFLILFDWLRQ 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ P3 9HUVLRQ 001

2LO DQG JUHDVH VSHFLILFDWLRQ /XEWLFDQW

6SHFLILFDWLRQ

$SSOLFDWLRQ DUHD

! &

&

A

Grease

26777 (Spray)

26777 (Spray)

Bearings and bushings

B

Hydraulic oil

ISO-L-HM32

ISO-VG32

Hydraulic system

C

Transmission oil

Hypoidolja SAE 80W/90

Hypoidolja SAE 75W

Gears

D

Grease

26778 (Spray)

26778 (Spray)

Chains and wires

F

Grease

055-70111

055-74320

Side shift forks

G

Grease

Staburags NBU 8EP

Staburags NBU 8EP

Steering bearings

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

23

2LO DQG JUHDVH VSHFLILFDWLRQ & FRGH 6HFWLRQ P3 9HUVLRQ 001

24

7 FRGH 702 'DWH 2002-05-06

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

7RROV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ P4 9HUVLRQ 001

7RROV

6XSHU 6HDO FRQQHFWRUV 1

3 3 2 )LJXUH

1XPEHU

$SSOLFDWLRQ

159232

Tool for application of pins/ sleeves

159229

Tool for release of lock (1)

159230

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

159231

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

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

25

7RROV & FRGH 6HFWLRQ P4 9HUVLRQ 001

)LJXUH

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

1XPEHU

$SSOLFDWLRQ

159228

Tool for removal of pins/sleeves (3)

$03 FRQQHFWRUV

)LJXUH

2

26

1XPEHU

$SSOLFDWLRQ

31-151080

Tool for removal of pins/sleeves

1=163787 2=163788

Tool for application of sleeves

1=163789 2=163790 3=163791

Tool for application of pins 1: For 0.2-0.5 mm2 2: For 0.5-1.0 mm2 3: For 1.5-2.5 mm2

1

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

7RROV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ P4 9HUVLRQ 001

2WKHU WRROV )LJXUH

1XPEHU

$SSOLFDWLRQ

179915

Service instrument (CAN)

1=163793 2=163792

Service instrument for program modification

1=155619-001 2=166161 3=166473

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

When ordering 155619-001 both cables are received

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

27

7RROV & FRGH 6HFWLRQ P4 9HUVLRQ 001

)LJXUH

28

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

1XPEHU

$SSOLFDWLRQ

08-13022

Puller, drive gear

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULF GULYH PRWRU 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 1760 9HUVLRQ 001

(OHFWULF GULYH PRWRU

&RPSRQHQW SDUWV 16 21 20 19

14 18

13

17 10

15

12 11

8

9

7 6 5 4 3 1 2

3RV

'HVFULSWLRQ

1RWH

1

Screw

M6x25

2

Bearing shield

3

Locking ring

4

Bearing

5

Carbon brush bridge

6

Screw

M5x12

7

Screw

M5x20

8

Carbon brush

9

Rotor

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

29

(OHFWULF GULYH PRWRU & FRGH 6HFWLRQ 1760 9HUVLRQ 001

7 FRGH 702 'DWH 2002-05-06

3RV

'HVFULSWLRQ

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

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

1RWH

M6x25

'LVPDQWOLQJ RI PRWRU IURP WUXFN • 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.

30

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULF GULYH PRWRU 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 1760 9HUVLRQ 001

$VVHPEOLQJ • 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.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

31

(OHFWULF GULYH PRWRU & FRGH 6HFWLRQ 1760 9HUVLRQ 001

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

6HUYLFH 5HSDLUV

'LVPDQWOLQJ RI PRWRU 16 21 19

14

20

18

13

17 10

15

12 11

8

9

7 6 5 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.

32

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULF GULYH PRWRU 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 1760 9HUVLRQ 001

• 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).

• 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.

$VVHPEOLQJ RI PRWRU 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.

&OHDQLQJ 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.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

33

(OHFWULF GULYH PRWRU & FRGH 6HFWLRQ 1760 9HUVLRQ 001

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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.

34

7HFKQLFDO GDWD

7\SH RI PDFKLQH

60 ) 60 '

Type

TSL140S-DS30

Output (kW)

1,2

Intermittence

S2 60 min.

Minimum length of carbon brush (mm)

11

Minimum commutator diameter (mm)

47

Resistance, shunt field winding Ω at 26 C°

23,31

Resistance, armature winding,Ω at 26C°

0,0156

Insulation resistance between windings and motor housing

>= 1Mohm

Weight (kg)

14

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

'ULYH XQLW JHDU 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 2550 9HUVLRQ 001

'ULYH XQLW JHDU

2 3 4 5

6

01

7 8

24

9 27

25 26

10 11

28

13 12 14 32 29

15

18

16

30

31

19

17 20

23 21

Service Manual 7SM12F, 7SM16D

22

Approved by: L-G Andersson

35

'ULYH XQLW JHDU & FRGH 6HFWLRQ 2550 9HUVLRQ 001

36

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

&RPSRQHQW SDUWV

3RV

'HVFULSWLRQ

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

Service Manual 7SM12F, 7SM16D

1RWH

Tightening torque 70 Nm Locked with punch mark

Primary gear

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

Bottom cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242 Approved by: L-G Andersson

'ULYH XQLW JHDU 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 2550 9HUVLRQ 001

3RV

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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

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

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

Motor gear

7HFKQLFDO GDWD 7\SH RI WUXFN

60 ) 60 '

Type of gear

2-step angle gear

Gear ratio

14,20:1

Oil volume, litres

1,75

Oil type

Hypoid oil

Viscosity, normal temperature

SAE 80W90

Viscosity, <-15°C

SAE 75W

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

37

'ULYH XQLW JHDU & FRGH 6HFWLRQ 2550 9HUVLRQ 001

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

/HDNDJH IURP WRS FRYHU

'LVPDQWOLQJ • 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). $VVHPEOLQJ LV FDUULHG RXW LQ WKH UHYHUVH RUGHU • 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.

&KDQJLQJ RI WKH GULYH VKDIW¶V VHDOLQJ ULQJ

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.

'LVPDQWOLQJ • 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).

38

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

'ULYH XQLW JHDU 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 2550 9HUVLRQ 001

$VVHPEOLQJ 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 XVH 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.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

39

'ULYH XQLW JHDU & FRGH 6HFWLRQ 2550 9HUVLRQ 001

40

7 FRGH 702 'DWH 2002-05-06

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

(OHFWUR PDJQHWLF EUDNH 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 3370 9HUVLRQ 001

(OHFWUR PDJQHWLF EUDNH

0DLQ FRPSRQHQWV RI WKH EUDNH 10

1 2

9

3

4

8

5 7

6

3RV 1R

'HVFULSWLRQ

1

Magnetic coil

2

Cap screws

3

Electrical wire

4

Pressure plate

5

Adjustment locking nut

6

Pressure springs

7

Flange

8

Mounting bolts

9

Brake disc

10

Hub

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

41

(OHFWUR PDJQHWLF EUDNH & FRGH 6HFWLRQ 3370 9HUVLRQ 001

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

0DLQWHQDQFH

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 and the gap between the magnetic coil housing and the pressure plate on a regular basis.

%DVLF $GMXVWPHQW RI JDS 5,5 Nm

0,2

The QRPLQDO JDS between the coil housing and the pressure plate, in applied position, shall be PP. The PD[LPXP JDS before readjustment is necessary is PP. $GMXVWPHQW SURFHGXUH Loosen the tension of the three adjustment bolts .

Turn the lock nuts anti-clockwise and tighten the bolts slightly while checking the gap RQ WKUHH SRLQWV with a 0.2 mm feeler gauge.

Tighten the lock nuts 5,5 Nm and recheck the gap with the feeler gauge.

42

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWUR PDJQHWLF EUDNH 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 3370 9HUVLRQ 001

([FKDQJH RI EUDNH GLVF The brake disc shall be exchanged when its total thickness has been reduced to 5,5 mm.

• Disconnect the electrical wires of the brake.

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

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

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

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

• Reconnect the electrical wiring.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

43

(OHFWUR PDJQHWLF EUDNH & FRGH 6HFWLRQ 3370 9HUVLRQ 001

44

7 FRGH 702 'DWH 2002-05-06

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

6WHHULQJ 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 4000 9HUVLRQ 001

6WHHULQJ

&RPSRQHQW SDUWV WLOOHU DUP 1 2 3

4

5 6

8

7 9

13

11

12

15 17

10

14

16

18 19 20 21 22

3RV

'HVFULSWLRQ

1RWH

1

Screw

4

2

Washer

3

Handle

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

45

6WHHULQJ & FRGH 6HFWLRQ 4000 9HUVLRQ 001

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

3RV

'HVFULSWLRQ

1RWH

4

Screw

4

5

Washer

2

6

Cable holder

7

Gas damper

8

Bracket

9

Stop screw

10

Screw

11

Ball joint

12

Screw

13

Distance

14

Bush

2

15

Damper

2

16

Axle

17

Cam

18

Distance

19

Screw

20

Distance

21

Distance

22

Switch

4

S 10

$GMXVWPHQWV

$GMXVWLQJ RI EUDNH PLFURVZLWFK Switch (22) is always adjusted to its lowest position.

• Unscrew the screws (12, 19) that hold the switch and the distance.

• Press down the switch and tighten the screws.

• Check that the switch is actuated by the cam (17) in the arm’s top and bottom position.

46

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

6WHHULQJ 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 4000 9HUVLRQ 001

7LOOHU DUP KDQGOH 28 29

27 26 24 25

14 23 22 21

16

20

19

15 14 14

30 31 10 9 8

32

35

14

17 18

12 11

13

33 34 5

6

7

4

1

2 3

3RV

'HVFULSWLRQ

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

14

Plate

Service Manual 7SM12F, 7SM16D

1RWH Keyboard option

Option

Lift/Lower

Approved by: L-G Andersson

47

6WHHULQJ & FRGH 6HFWLRQ 4000 9HUVLRQ 001

48

7 FRGH 702 'DWH 2002-05-06

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

3RV

'HVFULSWLRQ

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 7SM12F, 7SM16D

1RWH Not used

Approved by: L-G Andersson

6WHHULQJ 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

& FRGH 6HFWLRQ 4000 9HUVLRQ 001

'LVPDQWOLQJ $VVHPEOLQJ • 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.

127(

6WDWLF HOHFWULFLW\ 5LVN RI VWDWLF GLVFKDUJH WKDW FDQ GDPDJH WKH HOHFWURQLFV 0DNH VXUH WR WDNH WKH QHFHVVDU\ SUHFDXWLRQV EHIRUH ZRUNLQJ ZLWK WKH HOHFWURQLFV

&KDQJH IURP LJQLWLRQ NH\ WR NH\ERDUG • Connect the CAN-key to the truck • Enter parameter mode (P) • Change parameter 39 to value = 3 or 4 • Set the required PIN-code by using parameter 10 • Switch off the truck • Dismantle the cove r(2) on the tiller arm • Fit the keyboard • Remove the ignition key, fit the strap • Fit the cover in the key hole • Start the truck using the chosen PIN-code

&KDQJH IURP NH\ERDUG WR LJQLWLRQ NH\ • Connect the CAN-key to the truck • Enter parameter mode (P) • Change parameter 39 to value = 1 or 2 • Switch off the truck • Remove the keyboard (2) on the tiller arm • Fit the cover • Remove the strap • Remove the cover • Fit the ignition key • Start the truck Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

49

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&KDQJLQJ RI VLJQDO EXWWRQ VZLWFK • 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.

50

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

6WHHULQJ 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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&KDQJLQJ RI OLIW ORZHULQJ EXWWRQ • 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.

&KDQJLQJ RI SXVKEXWWRQ • 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.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

51

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52

7 FRGH 702 'DWH 2002-05-06

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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&RPSRQHQW LGHQWLILFDWLRQ S10

S17 X41

S21

X5 Y1

X1 F50

M3

F51 F1

P2 Y34 Y52 P1 Y41

R1 K10 F3 K30 A1

M1

H1

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

53

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A17

54

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

6\PERO

'HVFULSWLRQ

A1

Transistor regulator

A2

Electronic card

A6

Display

A17

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1RWHV

Keypad

PIN-number login

Option

F1

Fuse

Drive motor circuit

125 A

F3

Fuse

Pump motor circuit

125 A

F 50

Fuse

Operating circuit A5

7,5 A

F 51

Fuse

Operating circuit A1

7,5 A

F 52

Fuse

Optional equipment

Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

A2:S1-S9 A2:S10-S18

Speed control

Forwards/Reverse

M1

Motor

Drive motor

M3

Motor

Pump motor

P1

Pressure switch

Pressure switch support arm lift

70 bar

P2

Pressure switch

Pressure switch fork lift

120 bar

24 V

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

55

(OHFWULFDO V\VWHPV & FRGH 6HFWLRQ 5000 9HUVLRQ 001

56

7 FRGH 702 'DWH 2002-05-06

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)XQFWLRQ

1RWHV

R1

PTC-resistor

Power supply

15 Ohm

S111

Switch

Option

S112

Switch

Option

S113

Switch

Turtle button

S114

Switch

Option

S115

Switch

Option

S116

Switch

Option

S10

Switch

Travel brake

S17

Switch

Key

S18

Switch

Horn button

A2:S17

Switch

Safety reversing

A2:S19

Switch

Fork lifting

A2:S20

Switch

Fork lowering

S21

Switch

Emergency switch off

A2:S21

Switch

Support arm, lifting

A2:S22

Switch

Support arm, lowering

S32

Switch

Lift height limiting, 1.6 m

S33

Switch

Lift height limiting

S42

Switch

Manual fork lowering

S90

Switch

Lift height limiting

Y1

Brake

Y34

Magnetic valve

Forks

Y41

Magnetic valve

Fork lowering

Y52

Magnetic valve

Support arm lifting

X1

Connector

Battery

X41

Connection point

CAN-communication

Service Manual 7SM12F, 7SM16D

Brake lever

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

57

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58

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

59

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60

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

61

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)XQFWLRQDO GHVFULSWLRQ

6WDUWLQJ WKH WUXFN • Battery connector plugged in.

• S21 closed.

• S17 on.

'ULYLQJ

A1 BS1 T1

Ish

Ia

• The speed control activated in any direction.

MShunt

+

• S10 closed .

S2 A2

A A1

T2

K10

B+

1HXWUDO VSHHG UHGXFWLRQ • The speed control to neutral position, motor starts to work as generator. Brake energy comes back to battery.

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

3LFWXUH Energy back to the battery.

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

A1 BS1

T1 Ish

Ia

MShunt

+

S2 A2

A A1

T2 K10

B+

T

62

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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1HXWUDO VSHHG UHGXFWLRQ RQ VORSHV If the driver release the speed control on a slope and the truck doesn’t come to a stop within a certain time the electrical brake will be applied by the system.

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

Conditions to brake the truck: • S10 open.

/LIWLQJ WKH IRUNV • A2:S19 activated.

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

/LIWLQJ WKH VXSSRUW DUPV • A2:S21 activated • Battery status OK (if battery capacity >20% left).

/RZHULQJ WKH IRUNV • A2:S20 activated.

/RZHULQJ WKH VXSSRUW DUPV • A2:S22 activated.

+RUQ • S18 activated.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

63

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+RXU PHWHU

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

• Press S18 until you read H= hour meters.

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

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

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

A

s= Time to service.

E

D

C

B

)DXOW FRGHV

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

• Press S18 until you read E= fault codes.

• By choose E the symbol “E” will be highlighted to indicate what’s currently shown on display.

• The last 50 fault codes will be stored. The latest fault will be shown first. The display first show the error code and then wich hour the fault occured.

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

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

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

64

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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&RGH

&

Description

Default parameter warning.

Possible fault reason

Parameter area is probably corrupt.

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

&RGH

&

Description

Butterfly warning

Possible fault reason

Problem with butterfly sensor.

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

&RGH

&

Description

Emergency switch warning

Possible fault reason

Emergency switch activated No voltage supply to motor controller.

Harness problem.

&RGH

&

Description

Service time warning

Possible fault reason

Time to make service Service counter not reset after latest service

&RGH

&

Description

Battery undervoltage warning

Possible fault reason

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

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

65

(OHFWULFDO V\VWHPV

66

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Description

Battery overvoltage warning

Possible fault reason

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

&RGH

&

Description

Power amplifier thermal cutback

Possible fault reason

Too intensive driving Defect motor controller

&RGH

(

Description

Motor controller does not correspond with the type of truck

Possible fault reason

Check that the right type of motor controller is fitted

&RGH

(

Description

Brake switch transistor shorted

Possible fault reason

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

&RGH

(

Description

Digital output or field over current

Possible fault reason

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault.

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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Description

Contactor off

Possible fault reason

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

Contactor control wire not connected.

Contactor drive output in controller faulty (off).

&RGH

(

Description

Contactor welded

Possible fault reason

Main contactor tips welded.

Contactor drive output in controller faulty (on).

&RGH

(

Description

System error

Possible fault reason

Possible fault in the motor controller. Restart the machine

&RGH

(

Description

Checksum error

Possible fault reason

Internal microcontroller fault (tiller head), faulty software or pcb.

&RGH

(

Description

Software problem

Possible fault reason

Internal microcontroller fault (tiller head),faulty software or pcb.

&RGH

(

Description

Drive communication error

Possible fault reason

Broken CAN-cable.

Motor controller broken

w

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

67

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Description

Drive communication Tx error

Possible fault reason

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

&RGH

(

Description

Bus off error

Possible fault reason

CAN-bus problem, harness or hardware problem.

&RGH

(

Description

Over run error

Possible fault reason

CAN-bus problem, harness or hardware problem.

&RGH

(

Description

Error in safety reversing

Possible fault reason

Critical sensor element faulty

&RGH

(

Description

Field open

Possible fault reason

Shuntfield open, harness broken, motor controller defect.

&RGH

(

Description

M minus error

Possible fault reason

Problem with switch transistor in armature circuit inside motor controller.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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Description

Power amplifier sensor error

Possible fault reason

Armature current sensor fault in motor controller.

&RGH

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Description

Power amplifier CAN-timeout

Possible fault reason

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

3DUDPHWHUV

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

• Press S18 until you read P= parameters.

A

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

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

E

D

C

B

• Press S18 ones to get access to the parameter.

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

• Press S18 ones to confirm change.

• Turn S17 to off.

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

127(

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

69

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70

3DUDPHWHU

1DPH

8QLW

0LQ

0D[

6WHS

6WG

'HVFULSWLRQ

1

Speed, turtle button

%

40

100

5

90

Speed, turtle button 40: low speed 100: full speed

02

Max speed

%

40

100

5

100

Max speed 10:low Speed 100:full Speed

03

Acceleration

10

100

5

70

10:low acceleration 100:full acceleration

04

Neutral speed reduction

5

100

5

50

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

5: low reduction force 100: full reduction force

05

Logg off

0

20

1

0

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

1min

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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6HUYLFH SDUDPHWHUV • Connect CAN-key in X41 • Choose parameter

3DUDPHWHU

1DPH

10

8QLW

0LQ

0D[

6WHS

6WG

'HVFULSWLRQ

PIN code

0

9999

1

0

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

14

Creep speed

-10

10

1

0

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

-10 : low speed when reaching first speed sensor 10: high speed when reaching first speed sensor

20

Hour meter selection

1

5

1

2

Select wich hour meter

21

Battery size

1

20

1

8

Battery size selection

25

Service interval

0

2000

50

100

Possible to set servicetimer

28

Button option

0

2

1

1

State what button button should be used for lifting/ lowering

39

Access code

1

4

1

1

Defines what access level service personnel will have to parameters.

1h

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

71

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3DUDPHWHU GHVFULSWLRQ 3DUDPHWHU The speed when using the tortoise button can be adjusted.

3DUDPHWHU The maximum speed can be adjusted.

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

3DUDPHWHU Defines motor brake force when the speed control goes to neutral position. The lower value of parameter the longer time to reduce speed.

3DUDPHWHU The time until the truck will be switched off when a key pad is used.

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

3DUDPHWHU 10 drivers can have it’s own PIN-code to get access to the truck. Each driver have possibility to set all the driver parameters individual.

Code 0 is not accepted as a solitary code.

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

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

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

3DUDPHWHU Defines the speed you will get when you reach the first speed sensor.

72

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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3DUDPHWHU You choose wich hour meter you want to display.

1(A) = Key time.

2(b) =Activity time.

3(c) = Drive motor time.

4(d = Pump motor time.

5(s) = Time to service.

3DUDPHWHU You must give data about with wich battery the truck is equipped.

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

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

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

73

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The acid concentration can vary depending of battery brand.

9DOXH

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%DWWHU\ $K

1 2 3 4 5 6 7

140

8

240

9

↑

10 11

Less discharged

12 13

More discharged

14

↓

15 16 17 18 19 20 :$51,1*

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3DUDPHWHU With this parameter you can set a time limit to next service from 0 to 2000 hours in step of 50 hours. When it’s time for service you will get caution 29 (C29) on the display.

74

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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3DUDPHWHU Using this parameter you can choose which button should be used for lifting/lowering.

0= Lift/lower buttons not activated 1 = Lower lifting/lowering button activated for fork lift Upper lifting/lowering button activated for support arm lift (Standard) 2 = Lower lifting/lowering button activated for support arm lift Upper lifting/lowering button activated for fork lift

3DUDPHWHU This parameter can be adjusted like: 1=

Key connected, driver parameters open.

2=

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

3=

Key pad connected, driver parameters open.

4=

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

6HUYLFH GLVSOD\ • Connect the CAN key in X41 and start the machine.

A

• The battery status is displayed and the symbol “D” is lit continually.

• Press S18 to choose display mode.

E

D

C

B

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

75

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See table below.

)ODVKLQJ V\PERO

'LVSOD\HG GDWD

B

Speed reference value sent to Curtis.

C

Digital inputs to Curtis and hallelements. * See explanation below

BC

Battery voltage (V)

D

Armature current (A)

BD

Field current (A)

CD

PWM Armature in %

BCD

Status Curtis

*They are displayed by high lighting segments of three of the figures (A).

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

• Power amplifier inputs.

A

T

E

D

C

B

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A

S32, input A1:13. No lifting limit

B C

P2, input A1:15.Pressure switch fork lift

D

S10, input A1:12

E

P1, input A1:10. Pressure switch support arm lift

F

S42, input A1:11. Manual lowering of the forks

G

S10, input A1:5

DP

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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

• Power amplifier outputs.

A

E D

$ )

%

*

(

& '3

'

)XQFWLRQ

A

Y41, output A1:9 Lowering valve

B

B

C

6HJPHQW

C

Y34, output A1:2 Lift/lowering valve, forks

D

Y52, output A1:3. Lift/lowering valve, support arm

E

K10, output A1:4

F

H1, output A1:7

G

Y1 , output A1:5

DP

K30, output A1:6

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

A

6HJPHQW

)XQFWLRQ

A

E

D

B

C

B C

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( '

% & '3

D

Forks up

E

Forks down

F

Support arms up

G

Support arms down

DP

Horn

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

77

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

A

E

D

C

B

6HJPHQW

)XQFWLRQ

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

S113 Turtle function

E

Extra function 2

F

Extra function 1

G DP

3DUW QXPEHUV

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

A

• Press S18 until you Pn= partnumbers.

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

E

D

C

B

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

• HPn= Hardware part number.

• HSn= Hardware serial number.

78

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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STATUS MODEL

VOLTAGE

SERIAL

CURRENT

*HQHUDO B+

A1

S1

M

M-

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

A2

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.

S2

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

79

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STATUS MODEL

VOLTAGE

SERIAL

CURRENT

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

67$786 /('

+DQGKHOG WHU PLQDO GLVSOD\

([SODQDWLRQ

3RVVLEOH FDXVH

LED off

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

Defective regulator

Defective regulator

1,1

¤¤

&855(17 6+817 )$8/7

Built-in current shunt defective

Armature current sensor fault in motor controller.

1,2

¤ ¤¤

+: )$,/6$)(

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

1,3

¤ ¤¤¤

0 6+257('

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller.

3,1

¤¤¤ ¤

&217 &2,/ )/' 6+257

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

),(/' 23(1

Open field winding

Shuntfield open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

/2: %$77(5< 92/7$*(

Low battery voltage

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

4,2

¤¤¤¤ ¤¤

29(592/7$*(

Overvoltage

1. Battery voltage > 33 volts

80

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

(OHFWULFDO V\VWHPV 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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Over-/under-temperature reduction

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

¤¤¤¤ ¤¤¤

5HVHWWLQJ HUURUV To reset an error turn S17 to off and then on again.

(UURU

5HVHW ZKHQ

29(592/7$*(

Battery voltage falls below 33 V

7+(50$/ &87%$&.

The temperature is within allowed range

7+5277/( )$8/7

Error has been fixed

/2: %$77(5< 92/7$*(

When battery voltage exceeds 16 V

6DIHW\ 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. :$51,1*

5LVN RI VKRUW FLUFXLWLQJ 5HPRYH DOO ZDWFKHV MHZHOOHU\ DQG DOZD\V XVH LQVXODWHG WRROV RQO\

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

81

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8QLW

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

Undervoltage limit

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature winding *

150

Amps

for 2 minutes

100

Amps

for 1 hour

20

Amps

for 2 minutes

Max. current of field winding

20

([SODQDWLRQ

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.

82

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

+\GUDXOLF V\VWHP 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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5HPDUN

1

Lift Cylinders

Fork lift

2

Lift Cylinders

Support arm lift

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

83

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3RV 1R

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5HPDUN

3

Hydraulic Unit

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

4

Pressure switches/ lift functions

G = Support arm lift Load >750 kg Speed = 5,3 km/h Load > 1200 kg Speed = 4,4 km/h H = Fork lift Load > 750 kg Speed = 5,3 km/h J = Valve, support arm lift K = Valve, fork lift

'HVFULSWLRQ /LIW When the pump motor starts, the oil flows through the non return valve to the lift cylinders.

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

2SHUDWLQJ SUHVVXUH The operating pressures at rated load are: • 7SM12F: 191 bar • 7SM16D: 191 bar

5HOLHI YDOYH The relief valve opens at the following pressures: • 7SM12F: 220 bar • 7SM16D: 190 bar 84

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

+\GUDXOLF V\VWHP 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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3UHVVXUH VZLWFK The pressure switch is used to regulate the speed and is influenced by the load. It only has an off/on operation.

Load < 750 kg. Speed = 6,0 km/h Load > 750 kg. Speed = 5,3 km/h Load > 1200 kg – support arms. Speed = 4,4 km/h.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

85

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7 FRGH 702 'DWH 2002-05-06

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

0DLQ OLIW FKDLQ V\VWHP 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-12-02

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0DLQ OLIW FKDLQ V\VWHP *HQHUDO Applies to all machines with a mast.

127( 2Q PDFKLQHV ZLWK 7 FRGH )%5( DQG )%5( & WKH FKDLQV VKRXOG EH UHSODFHG HYHU\ \HDUV

&KHFNLQJ WKH FKDLQ VHWWLQJ 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.

&KDLQ LQVSHFWLRQ 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.

1RLVH If lubrication has been insufficient there will be metallic friction on the chain and this will result in noise.

7KH FKDLQ VKRXOG EH UHSODFHG

6XUIDFH UXVW 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.

7KH FKDLQ VKRXOG EH UHSODFHG

5XVW\ OLQNV 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.

7KH FKDLQ VKRXOG EH UHSODFHG Service Manual 7SM 12F/16D

Approved by: S Blom

– 87

0DLQ OLIW FKDLQ V\VWHP & FRGH 6HFWLRQ 7120 9HUVLRQ 001

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9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

6WLII OLQNV If it is not possible to pull out the chain to its normal position this can be because of link rust or seizing.

7KH FKDLQ VKRXOG EH UHSODFHG

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

7KH FKDLQ VKRXOG EH UHSODFHG .

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

7KH FKDLQ VKRXOG EH UHSODFHG

– 88

Service Manual 7SM 12F/16D

Approved by: S Blom

0DLQ OLIW FKDLQ V\VWHP 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-12-02

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2XWOLQH ZHDU 3

+

+

P = Pitch H2 = Nominal disc height.

H3 = Minimum disc height.

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

0D[LPDO SHUPLWWHG RXWOLQH ZHDU LV RI WKH KHLJKW + ,I D OLIW FKDLQ UHDFKHV WKH PD[LPXP OHYHO RI ZHDU WKH FKDLQ VKRXOG EH UHSODFHG

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

Service Manual 7SM 12F/16D

Approved by: S Blom

– 89

0DLQ OLIW FKDLQ V\VWHP & FRGH 6HFWLRQ 7120 9HUVLRQ 001

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6WUHWFKLQJ 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.

7\SH RI FKDLQ

1RPLQDO 0LQLPXP 3LWFK 3 1RPLQDO FKDLQ GLVF KHLJKW GLVF KHLJKW PP OHQJWK IRU + PP + PP GLVFV PP

0D[LPXP SHUPLW WHG FKDLQ OHQJWK IRU GLVFV PP

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

:HDU WR WKH EROWV DQG DURXQG WKH KROHV RQ WKH GLVFV DUH D UHDVRQ ZK\ WKH FKDLQ VWUHWFKHV 7KH FKDLQ VKRXOG EH UHSODFHG LI VWUHWFKLQJ LV PRUH WKDQ

'DPDJH

7KH FKDLQ VKRXOG EH UHSODFHG LI GDPDJHG LQ DQ\ ZD\

– 90

Service Manual 7SM 12F/16D

Approved by: S Blom

0DLQ OLIW FKDLQ V\VWHP 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-12-02

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'DPDJHG GLVFV If a disc has broken on the chain, this can be due to overloading or corrosion.

7KH FKDLQ VKRXOG EH UHSODFHG

'DPDJHG EROWV 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.

7KH FKDLQ VKRXOG EH UHSODFHG

'LUW\ FKDLQ 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”.

&OHDQLQJ 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 127(

([HUFLVH FDUH ZLWK GHJUHDVLQJ DJHQW DV WKHVH FDQ FRQWDLQ DEUDVLYHV

Service Manual 7SM 12F/16D

Approved by: S Blom

– 91

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/XEULFDWLRQ Mineral and synthetic oils can be used to relubricate Rexnord chains.

127(

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

• /XEULFDWLRQ LQWHUYDOV - 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:

$PELHQW WHPSHUDWXUH

9LVFRVLW\ FODVV

5HFRPPHQGHG 3URGXFWV

> - 40°C < - 30°C > - 30°C < + 5°C

VG 15

> + 5°C < + 45°C

VG 150

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-15, Klüber Lubrication 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

VG 68

* Equivalent products from another manufacturer may be used.

127(

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– 92

Service Manual 7SM 12F/16D

Approved by: S Blom

&RQWURO FRPSXWHU HTXLSPHQW 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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&RQWURO FRPSXWHU HTXLSPHQW 8VHU 0DQXDO IRU 7UXFN&RP

*HQHUDO TruckCom is a communication program which communicates with trucks equipped with CAN (Controller Area Network) communication. It enables functions such as downloading programs, adjusting parameters and displaying measuring data etc. to be carried out.

This Manual is valid for program number 182147-xxx.

The program is a Windows program run under Windows® 95/98.

&RQQHFWLRQ A CAN interface of the CPC-PP type is needed to connect it to the truck, with attendant cable. The interface is connected to the printer port on a PC, and the cable is connected between the interface and truck’s CAN connection.

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.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

93

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/D\RXW 0DLQ ZLQGRZ A main window opens when the program is started, consisting of menu bar, tool buttons, workspace, log window and status window.

1RGHV The nodes detected on the bus are shown in the node window.

The current node status and input component/information is show with different icons.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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,FRQV

,FRQ

'HVFULSWLRQ 1RGH 2. is shown when contact is made with a node and no errors have been reported.

1RGH QRW FRQQHFWHG is shown when there is no contact with a node in the network.

1RGH QRW 2. is shown when an error has been reported by a node. Click on node to obtain more information.

3URJUDP YHUVLRQ is shown when information is available on which software is installed. Click to obtain more information. ,QIRUPDWLRQ is shown when a node has information on, for example, error codes.

7UXFN UHSRUW

3DUDPHWHUV is shown when a node has information on a parameter.

'LDJQRVWLFV

([LW

7RRO EXWWRQV Search for units, disconnect from PC, download, truck report, parameters, diagnostics, information and exit.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

95

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,QIRUPDWLRQ ZLQGRZ 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.

6WDWXV EDU There is a status bar at the bottom of the main window, which shows variable status when the program is run.

REC

MACHINE

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.

)XQFWLRQ &RQQHFWLRQ 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.

96

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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'LVFRQQHFWLRQ 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.

The objective is to enable connection to another truck without having to close the program.

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

Type 123456

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

97

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1RUPDO GRZQORDGLQJ 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.

'RZQORDGLQJ LQ ROG YHUVLRQV RI ORJLF FDUG 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.

(PHUJHQF\ GRZQORDGLQJ 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.

7KH 60 VHULHV If there is no program a counter will be shown in the display, which continuously counts up.

127(

7KH ORJLF FDUGV IRU WKH 60 VHULHV FDQ RQO\ EH XSJUDGHG ZLWK WKH VDPH EDVLF SURJUDPV ZKHQ WKH\ KDYH EHHQ SURJUDPPHG ,W LV WKHUHIRU QRW SRVVLEOH WR FKDQJH EDVLF SURJUDPV RWKHU PDFKLQH W\SH

98

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

&RQWURO FRPSXWHU HTXLSPHQW 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

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7UXFN UHSRUW 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=1999-12-09 07:42:14 CPC-PP SERIAL No=8002008 MACHINE NUMBER=392179 CUSTOMER=CUSTOMER 1 TECHNICIAN=NONAME COMPANY=COMPANY 1 NOTES=Test report [CAN NODES] MAIN CARD=125 FORK CARD=-1 TRUCK TRACKER=-1 ACC LIFT CONTROLLER=0 ACC DRIVE CONTROLLER=0 CURTIS LIFT CONTROLLER=-1 [MAIN CARD CONFIGURATION] SOFTWARE=169942-001 HARDWARE=169937-001 SERIAL NO=12112 [HOUR METERS] A IGNITION TIME=1 B TOTAL MOVEMENT=0 C DRIVE MOTOR TIME=0 D PUMP MOTOR TIME=0 S SERVICE TIME=9

[ERROR LOG] 01=55 99-12-09 06:11 02=55 99-12-08 20:54 03=55 99-12-08 14:26 04=231 99-12-08 14:16 05=55 99-12-08 14:11 . . .

50=55 99-12-08 14:40 [DRIVER PARAMETERS] 1=3 2=100 3=100 . . .

100=0 [TRUCK PARAMETERS] 11=100 12=80 13=10

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

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

99

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3DUDPHWHUV 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].

127(

7KH 60 WUXFNV PXVW EH LQ QRUPDO PRGH L H QRW LQ SDUDPHWHU PRGH

This must therefore be done when the truck is in parameter mode. When the truck is in normal drive mode the parameter window is locked and no information can be changed.

Nevertheless, it is possible to unlock the window by restarting the truck in parameter mode and then selecting Unlock... without closing the window first.

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

100

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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7 FRGH 702 'DWH 2002-05-06

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'LDJQRVWLFV To access diagnostics, select the Diagnostic function. This can be done with the menu <Tools | Diagnostic...> or with the tool button [Diagnostic].

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$QDORJXH Several analogue values will be shown on the Analogue side: Inputs, outputs and the drive/lift converter values. The input/ output values are read directly from the in/out directory in the main card and are then shown as voltages and number of revolutions.

127 7+( 60 6(5,(6 “Cmd” is the requested number of revolutions from the main card sent to the drive/lift converters via the CAN bus.

“Actual” is the number of revolutions the drive/lift converters have detected and sent back to the main card.

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson 101

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7HPSHUDWXUH The actual temperatures of the electronic units and motors are shown. The values are shown in degrees Celsius.

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'LJLWDO The digital inputs are read directly from the input directory on the main card. It is assumed that the input is activated if the colour of the LED is green. If the LED is white/transparent the input is not activated.

The digital outputs are read directly from the out-directory on the main card and are shown with red LEDs.

102

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

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2WKHU IXQFWLRQV 6DYH WR ILOH 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 >.

'RZQORDG IURP ILOH 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 >.

5HVHW &$1 DGDSWHU 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 >.

'HOHWH HUURU FRGH ORJ To delete the truck’s error code log, start the truck in parameter mode and then select < Tools | Erase error log >.

5HVHW KRXU PHWHU To reset the truck’s hour meter, start the truck in drive mode and then select < Tools | Reset hour meters >.

5HDG HUURU FRGH ORJ To show the truck’s error code log, select < Tools | Read error log >. $GMXVW GDWH DQG WLPH 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.

127(

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Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson 103

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$GMXVWLQJ WKH KRXU PHWHU RQ ROGHU FDUGV To adjust the hour meter on trucks with older cards, select < Tools | Adjust Hour meters >. The time in the PC will then be downloaded to the truck.

+HOS $ERXW 7UXFN&RP To see program information, select <Help | About TruckCom... > or tool button [About].

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

6SHFLILFDWLRQV &$1 LQWHUIDFH

104

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Power consumption

40-120

mA

Supply voltage

11-28

V

Transfer rate

125

kbit/s

Storage temperature

-20-80

0

C

Operating temperature

0-60

0

C

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson

&RQWURO FRPSXWHU HTXLSPHQW 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

7 FRGH 702 'DWH 2002-05-06

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,QVWDOODWLRQ The program is delivered on disks or over the network, and the installation is started by running A:\SETUP.EXE. Follow the instructions shown on the screen.

Make sure that the computer settings for the printer port in setup (BIOS) are as follows: Port address:

0378

IRQ:

7

Mode:

Output only

For information on how the settings in setup are changed, see the user manual from the computer manufacturer.

7R XQLQVWDOO If you wish to uninstall TruckCom this can be done from Windows < Setup| Control Panel| Add/delete program > .

Service Manual 7SM12F, 7SM16D

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106

7 FRGH 702 'DWH 2002-05-06

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson

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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.

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%

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.

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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.

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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.

Service Manual 7SM12F, 7SM16D

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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.

108

7HFKQLFDO GDWD

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 7SM12F, 7SM16D

Approved by: L-G Andersson

%DWWHU\ FKDUJHU ,QEXLOW 9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

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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

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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

Service Manual 7SM12F, 7SM16D

Approved by: L-G Andersson 109

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110

7 FRGH 702 'DWH 2002-05-06

Service Manual 7SM12F, 7SM16D

9DOLG IURP VHULDO QXPEHU 551390AT2UGHU QXPEHU 202187-040

Approved by: L-G Andersson