Toyota Forklift Easymover PP13 Service Manual 555494AA - PDF DOWNLOAD

Service Manual GB

Easymover PP13 Valid from serial number: 555494AA-

Order number: 208588-040 Issued: 2002-06-04 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Contents Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section M4 Version 001

Contents Technical data ................................................................ 5 Introduction Maintenance ....................................... 9 1 Safety regulations with maintenance work ......... 9 2 Cleaning and washing ........................................... 11 3 Safe lifting ................................................................. 12

Maintenance, Lubrication schedule ................ 13 1 Maintenance schedule .......................................... 13 2 Lubrication schedule .............................................. 17

Oil and grease specification ................................ 19 Drive unit/drive gear ................................................. 21 1 Component parts .................................................... 21 2. Service and repairs ................................................ 24 3 Technical data ......................................................... 27

Electrical systems ...................................................... 29 1 Electrical parts ......................................................... 29 2 List of symbols ......................................................... 31 3 Functional description ........................................... 35 4 Error codes .............................................................. 36 5 Parameters .............................................................. 39 6 Test ............................................................................ 41 7 Technical specifications – SEM-X ...................... 43 Service Manual Easymover PP13

Approved by: L-G Andersson

3

C-code/Section M4 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

In-built battery charger ............................................ 45 1 General ..................................................................... 45 2 Charging ................................................................... 45 3 Trouble shooting ..................................................... 45 4 Technical data ......................................................... 46

Transistor panel ........................................................... 47 1 General ..................................................................... 47 2 Connections ............................................................. 48

Hydraulic system ........................................................ 51 1 Hydraulic chart and list of symbols ..................... 51 2 Adjustments PP13 .................................................. 52

4

Service Manual Easymover PP13

Approved by: L-G Andersson

Technical data Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section M4 Version 001

Technical data Model

PP13

Drive motor Type

TSL115-16

Output, kW

0.5

Duty cycle

S2, 60 min

Minimum carbon brush length, mm

14.5

Nominal commutator diameter, mm

43

Minimum commutator diameter, mm

40

Resistance, shunt field winding, Ω at 25 C°

23.31

Resistance armature winding, Ω at 24 °C

0.0156

Insulation resistance between the windings and motor casing

>=1 Mohm

Weight, kg

25

Brake Type

891.270.0

Braking force, Nm

9

Output, W

28

Resistance coil, Ω

20,8

Minimum thickness brake disc, mm

6,75

Thickness of a new brake disc, mm

6,90

Transmission/drive gear Type

2-stage drive gear

Gear ratio

24,8:1

Volume of grease, kg

0,3

Type of grease

SHELL RETINAX G

Service Manual Easymover PP13

Approved by: L-G Andersson

5

Technical data C-code/Section M4 Version 001

T-code 675 Date 2002-06-04

Model

Valid from serial number 555494AAOrder number 208588-040

PP13

Wheels Drive wheel, mm

Dia 250x60

Axle pressure without load, kg

175

Axle pressure at rated load, kg

570

Tightening torque for wheel bolts, Nm

20 Nm

Fork wheel, mm

Dia 85x75

Axle pressure without load, kg

2x18

Axle pressure at rated load, kg

2x496

Support castors, mm

Dia 100x40

Axle pressure without load

2X30)

Axle pressure at rated load, kg

2x24

Hydraulic system Output, kW

1.2

Duty cycle,%

10

Minimum carbon brush length, mm

7.5

Minimum commutator thickness/diameter, mm

4.75

Pressure at rated load, bar

110

Overflow pressure, bar

130

Pump flow, litre/minute

4.7

Tank volume, litre

1.0

Oil type

Hydraulic oil

Normal temperature

ISO-L-HM32

Fuses Drive motor circuits, A (Common with the pump)

50

Pump motor circuits, A (Common with the drive motor)

50

Control circuits, A

5

Battery charger, A

10

6

Service Manual Easymover PP13

Approved by: L-G Andersson

Technical data Valid from serial number 555494AAOrder number 208588-040

Model

T-code 675 Date 2002-06-04

C-code/Section M4 Version 001

PP13

Battery compartment, Batteries Dimensions LxWxH, mm

278 x 175 x 190

Capacity, Ah

50

Weigh, kg

2X18

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

5.4 1.5

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

4.0 1,1

Lift/lowering speed Lift without load, s

1.7

Lift with rated load, s

3.0

Lowering without load, s

3.0

Lowering with rated load, s

3.0

Power consumption Driving without load, A

13

Driving with rated load, A

?

Lift without load, A

?

Lift with rated load, A

?

Incline climbing ability With rated load %

5

Without load%

10

Measurement, L2

420

Turning radius WA, mm

1410

Lift height, mm

205

Weight Truck without battery, Medium

200

Service Manual Easymover PP13

Approved by: L-G Andersson

7

Technical data C-code/Section M4 Version 001

8

T-code 675 Date 2002-06-04

Service Manual Easymover PP13

Valid from serial number 555494AAOrder number 208588-040

Approved by: L-G Andersson

Introduction Maintenance Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section P1 Version 001

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

The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations. The following running times have been used when calculating the intervals: - Day time: 08.00-17.00 (20 hr./week) - 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week) - 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week) Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.

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

1

Safety regulations with maintenance work

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

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

• Keep the area where you carry out the service clean. Oil or water makes the floor slippery.

• Never wear loose objects or jewellery when working on the truck.

WARNING! Short-circuiting/Burns.

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

Remove watches, rings or other types of metal jewellery.

• Always disconnect the battery by pulling out the battery isolator when carrying out maintenance work on the truck unless otherwise stated in this Service Manual.

• Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system.

Service Manual Easymover PP13

Approved by: L-G Andersson

9

Introduction Maintenance C-code/Section P1 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

• Relieve the system pressure slowly before starting work on the truck’s hydraulic system.

• Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand.

• Bear in mind that the oil in the transmission or the hydraulic system can be hot.

WARNING! Risk of burns.

Hot transmission and hydraulic oil.

Let the truck cool before changing the oil.

• Only fill the hydraulic system with new and clean oil.

WARNING! The hydraulic system can be damaged.

If the oil is contaminated hydraulic components can be damaged.

Always use new and clean oil in the hydraulic system.

• Store and dispose of changed oil in accordance with local directives.

• Do not release solvents and the like, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local directives that apply for disposal.

• Disconnect the battery when welding on the truck.

NOTE! The battery can be damaged.

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

The battery should therefore be disconnected.

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

CAUTION! Harmful gases.

Paint that is heated gives off harmful gases.

Remove 100 mm of paint from the work area.

10

Service Manual Easymover PP13

Approved by: L-G Andersson

Introduction Maintenance Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section P1 Version 001

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

• Carry out general cleaning and washing weekly.

NOTE! Risk of short-circuiting.

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

2.1 External cleaning • Remove rubbish, etc. from the wheels daily.

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

• Rinse off loose grime using tepid water.

NOTE! Jamming, corrosion.

Mechanical components can be damaged.

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

2.2 Cleaning the motor compartment • Cover the electric motors, connections and valves before washing.

NOTE! Risk of short-circuiting.

The electrical system can be damaged.

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

• Clean the motor compartment using a well-known degreasing agent, diluted to a suitable concentration.

• Rinse off loose grime using tepid water.

Service Manual Easymover PP13

Approved by: L-G Andersson

11

Introduction Maintenance C-code/Section P1 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

2.3 Electrical components • Blow electric motors down using compressed air.

• Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent.

NOTE! Risk of short-circuiting.

Electrical components can be damaged.

Do not break the guarantee seal on the electronic board.

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

• Activate the parking brake to prevent the truck from moving during the lift. If the lift applies to the brake wheel, chock the other wheels so that the truck stands still.

• Select a lifting point so that the lift is as easy as possible (one corner at a time). If the truck has marked lifting points on the under side of the chassis these can be used to obtain a well balanced lift.

• Ensure that the surface under the jack is clean and free from oil and grease.

• Ensure that your hands and the jack’s lever are free from oil and grease.

• Use the lever that belongs to the jack. A lever that is too short requires more force than is necessary. If the lever is too long there is a risk of the jack being overloaded.

• Support the truck: - as close as possible to the part of the chassis that is to be lifted.

This reduces the risk of the truck tipping over.

- so that the truck cannot roll.

• Never lift up the jack in order to lift higher.

• Never work under a lifted truck unless it is well supported.

WARNING! Risk of crushing.

A badly supported truck can fall.

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

12

Service Manual Easymover PP13

Approved by: L-G Andersson

Maintenance, Lubrication schedule Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section P2 Version 001

Maintenance, Lubrication schedule 1

Maintenance schedule

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

Pos. no.

Work to carry out

0000.

Chassis

0000.1

Check all links and locking pins

I

0000.2

Check wear on battery locking

I

0000.3

Check of cracking and damage

I

0000.4

Check signs and stickers

I

0000.5

Check the mounting, lock and function of the covers

I

0380

Fork carriage

0380.1

Check for crack formation and damage

I

0380.2

Check clearance in bushes and links

I

0380.3

Press grease into grease nipples

I/L

0380.4

Check the lift limit switch

I

1700.

Drive motor

1700.1

Check clearance in connections

I/T1

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

T2

1700.5

Check for abnormal noise in bearing

I

2550.

Drive gear

2550.1

Check for leakage

2550.2

Check for abnormal noise

I

2550.3

Check the attachment and clearance in steering bearing

I

2550.4

Change the grease in the drive gear

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

1d

1w

12 m

36 m

I4

Service Manual Easymover PP13

L

Approved by: L-G Andersson

13

Maintenance, Lubrication schedule C-code/Section P2 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

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

Pos. no.

Work to carry out

3100

Brake

3100.1

Clean

C

3100.2

Check for wear on the brake disc

M

3100.3

Check the function of the brake

M

3500.

Wheels

3500.1

Remove string and other rubbish

3500.2

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

I/T3

3500.3

Check that the support wheel turns and rotates freely

I

3500.4

Check for wear on the support wheel

I

4110.

Tiller arm

4110.1

Check the mountings

I

4110.2

Check the power in the gas damper

I

4110.3

Check the touching protection

I

5000.

Electrical functions

5000.1

Check the function of the brake microswitch

I

5000.2

Check the function of the collision safety switch

I

5000.3

Check the function of the horn

I

5000.4

Check for wear on cabling

5000.5

Check the function of the driver’s control

I

I

5000.6

Check the emergency switch off

I

I

5000.7

Check the charging plug and start block

I

I

5110.

Battery

5110.1

Check connections to battery, truck and charger

I

5110.2

Check that the cell and pole guards are undamaged

I

5110.3

Check the battery locking

14

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

Service Manual Easymover PP13

1d

1w

12 m

36 m

I

I

I I

I

Approved by: L-G Andersson

Maintenance, Lubrication schedule Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section P2 Version 001

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

Pos. no.

Work to carry out

5400

Power system

5400.1

Cleaning and checking of mounting in chassis

C/T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

5700

Electronic circuit board

5700.1

Check connectors and cables

6100.

Hydraulic system

6100.1

Check hoses and connections for wear

I

6100.2

Check hoses for wear and damage

I

6100.3

Check the oil tank for cracks, leakage and damaged mountings

I

6100.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

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

1d

1w

12 m

36 m

T1

I

I L5

1 = The connections are re-tightened every 12 months.

2 = Retighten securing bolts to 45 Nm every 12 months.

3 = The drive gear is replaced when its diameter is < 235 mm. Drive wheel bolts are retightened every 12 months to 20 Nm. 4 = Check for leakage when changing the grease for the first time.

5 = The oil is changed and the filter cleaned for the first time after 12 months, and then every 24 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.

Service Manual Easymover PP13

Approved by: L-G Andersson

15

Maintenance, Lubrication schedule C-code/Section P2 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

5000 5000 4110

5000

0380

0000

3500

5700

6600

5400

3100 2550 1700

16

Service Manual Easymover PP13

Approved by: L-G Andersson

Maintenance, Lubrication schedule Valid from serial number 555494AAOrder number 208588-040

2 Pos no

T-code 675 Date 2002-06-04

C-code/Section P2 Version 001

Lubrication schedule

Service point

Interval/Running hours 12 m

0380

Lubricating nipples

L

2550

Drive gear

C

6100

Hydraulic system

O5

L = Lubrication

C = Check

Lubricant

36 m D G4

C B

O = Oil change

F=Grease

4= The grease is changed every 36 months.

5= The oil is changed and the filter cleaned for the first time after 12 months, and then every 24 months.

Service Manual Easymover PP13

Approved by: L-G Andersson

17

Maintenance, Lubrication schedule C-code/Section P2 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

0380

6100

2550

18

Service Manual Easymover PP13

Approved by: L-G Andersson

Oil and grease specification Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section P3 Version 001

Oil and grease specification Pos.

Type of lubricant

Specification

Application

>0°C A

Grease

TOYOTA 26777 (Spray)

Bearings and bushes

B

Hydraulic oil

ISO-L-HM32

Hydraulic system

C

Grease

SHELL RETINAX G

Gears

D

Grease

TOYOTA 73942XX5 TOTAL N3942

Lubricating nipples

0380

6100

2550

Service Manual Easymover PP13

Approved by: L-G Andersson

19

Oil and grease specification C-code/Section P3 Version 001

20

T-code 675 Date 2002-06-04

Service Manual Easymover PP13

Valid from serial number 555494AAOrder number 208588-040

Approved by: L-G Andersson

Drive unit/drive gear Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 2550 Version 001

Drive unit/drive gear Complete

1 1

2

4 5 6

3

Component parts 7

8

9

10

11

12

13

14

39 4

32

5

33

34 35 4 36

37

15

16 17 18

19 20 21 22 23 24

25

25 28

26

27

29

30

31

38

Pos

Benämning

Anm.

1

Screw

7 st

2

Washer

7 st

3

Cap

4

Locking ring

5

Ball bearing

6

Key

7

Axle

8

Venting nipple

9

Gear housing

10

Screw

11

Sealing ring

12

Gear ring

13

O-ring

14

Ball bearing

15

Locking ring

16

Drive track

17

Screw

18

Locking ring

Service Manual Easymover PP13

8 st

8 pcs. Tightened to 20Nm

Approved by: L-G Andersson

21

Drive unit/drive gear C-code/Section 2550 Version 001

22

T-code 675 Date 2002-06-04

Pos

Benämning

19

Magnetic coil

20

Key

21

Rotor

22

Carbon brush

23

Locking ring

24

Ball bearing

25

Driver

26

Screw

27

Connector

28

Guide pin

29

Locking ring

30

Stropping

31

Brake complete

32

Gear wheel

33

Locking ring

34

Gear wheel

35

Sealing ring

36

Locking ring

37

Washer

38

Ball bearing

39

Sealing ring

Service Manual Easymover PP13

Valid from serial number 555494AAOrder number 208588-040

Anm.

4 st

Approved by: L-G Andersson

Drive unit/drive gear Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 2550 Version 001

1.1 Dismantling the motor from the truck • Shutdown the truck, pull out the plug from the start block.

• Remove the hoods from the battery compartment.

• Loosen the battery connections.

• Lift out the batteries.

• Loosen the two screws holding the instrument panel.

• Place the instrument panel in the truck.

• Seal the oil-filling plug.

• Loosen the connections on the tiller arm.

• Dismantle the cover plate and the two nuts on the tiller arm.

• Lift off the tiller arm.

• Place the truck on its side.

• Loosen the four bolts on the motor’s chassis mounting.

• Carefully lift out the motor and place on a clean surface.

Essential service and repair work can now be carried out on the motor.

1.2 Assembling Assembly takes place in the reverse order.

Service Manual Easymover PP13

Approved by: L-G Andersson

23

Drive unit/drive gear C-code/Section 2550 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

2. Service and repairs 2.1 Inspection/replacement of the carbon brushes • Shut down the truck, pull out the plug from the start block.

• Remove the hoods from the battery compartment.

• Loosen the battery connections.

• Lift out the batteries.

• Loosen the two screws holding the instrument panel.

• Place the instrument panel in the truck.

• Seal the oil-filling plug.

• Refit the instrument panel.

• Place the truck on its side.

• Dismantle the covers from the carbon brushes.

• Loosen the cable connections are push back the carbon brush springs.

• Pull out the carbon brushes and inspect/measure the wear. (See table) • Assembly takes place in the reverse order.

2.2 Replacing the drive gear • Shut down the truck, pull out the plug from the start block.

• Remove the hoods from the battery compartment.

• Loosen the battery connections.

• Lift out the batteries.

• Loosen the two screws holding the instrument panel.

• Place the instrument panel in the truck.

• Seal the oil-filling plug.

• Refit the instrument panel.

• Place the truck on its side.

• Loosen the cable connections on the motor.

• Loosen the 8 bolts holding the drive gear.

• Carefully lift off the gear, avoid damaging the seals.

• NOTE! The securing bolts should always be replaced when replacing the drive gear.

• Assembly takes place in the reverse order.

24

Service Manual Easymover PP13

Approved by: L-G Andersson

Drive unit/drive gear Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 2550 Version 001

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

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

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

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

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

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

Service Manual Easymover PP13

Approved by: L-G Andersson

25

Drive unit/drive gear C-code/Section 2550 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

2.4 Brakes, Maintenance In general the brakes require no maintenance when used in a normal working environment. However, according to the chart for preventive maintenance it is recommended that the brake discs are regularly inspected with regard to wear.

2.5 Replacing the brake disc The brake disc should be replaced when its overall thickness has decreased to 5.5 mm.

• Disconnect the electrical cables routed to the brake.

• Loosen and remove the two securing bolts.

• Loosen the brake disc from the hub and check the wear. Replace the brake disc if the surface shows signs of uneven wear.

• Assemble the brake again.

• Connect the electrical cables.

26

Service Manual Easymover PP13

Approved by: L-G Andersson

Drive unit/drive gear Valid from serial number 555494AAOrder number 208588-040

3

T-code 675 Date 2002-06-04

C-code/Section 2550 Version 001

Technical data

Truck type

PP13

Drive motor Type

TSL115-16

Output, kW

0.5

Duty cycle

S2, 60 min

Minimum carbon brush length, mm

14.5

Nominal commutator diameter, mm

43

Minimum commutator diameter, mm

40

Resistance, shunt field winding, Ω at 25°C

23.31

Resistance armature winding, Ω at 24 °C

0.0156

Insulation resistance between the windings and motor casing

>=1 Mohm

Weight, kg

25

Brake Type

891.270.0

Braking force, Nm

9

Output, W

28

Resistance coil, Ω

20,8

Minimum thickness brake disc, mm

6,75

Thickness of a new brake disc, mm

6,90

Transmission/drive gear Type

2-stage drive gear

Gear ratio

24,8:1

Volume of grease, kg

0,3

Type of grease

SHELL RETINAX G

Wheels Tightening torque for wheel bolts, Nm

Service Manual Easymover PP13

20 Nm

Approved by: L-G Andersson

27

Drive unit/drive gear C-code/Section 2550 Version 001

28

T-code 675 Date 2002-06-04

Service Manual Easymover PP13

Valid from serial number 555494AAOrder number 208588-040

Approved by: L-G Andersson

Electrical systems Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 5000 Version 001

Electrical systems 1

Electrical parts

Service Manual Easymover PP13

Approved by: L-G Andersson

29

Electrical systems C-code/Section 5000 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040 S41

S18 S34

S15

S16 S20

30

Service Manual Easymover PP13

Approved by: L-G Andersson

Electrical systems Valid from serial number 555494AAOrder number 208588-040

2

T-code 675 Date 2002-06-04

C-code/Section 5000 Version 001

List of symbols

Symbol

Description

Function

Notes

A1

Transistor regulator

A30

Integrated charger

F1

Fuse

Drive motor circuit

50 A

F 50

Fuse

Operating circuit A5

5A

F 51

Fuse

Battery charger

10 A

G1

Battery

24 V

G2

Battery

12 V

H1

Horn

H81

LED

Battery indicator

K10

Contactor

Main contactor

K30

Contactor

Pump motor

M1

Motor

Drive motor

M3

Motor

Pump motor

S10

Switch

Travel brake

S15

Switch

Driving, fork direction

S16

Switch

Driving, drive wheel direction

S17

Switch

Key

S18

Switch

Horn button

S20

Switch

Safety reversing

S21

Switch

Emergency switch off

S31

Switch

Lift height limiter

S34

Switch

Fork lifting

S41

Switch

Fork lowering

S170

Switch

Start block

S171

Switch

Y1

Brake

Y41

Magnetic valve

230 V

Brake lever

Fork lowering

Service Manual Easymover PP13

Approved by: L-G Andersson

31

Electrical systems C-code/Section 5000 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

2.1 Electrical diagram 1 (3)

32

Service Manual Easymover PP13

Approved by: L-G Andersson

Electrical systems Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 5000 Version 001

2.2 Electrical diagram 2 (3)

Service Manual Easymover PP13

Approved by: L-G Andersson

33

Electrical systems C-code/Section 5000 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

2.3 Electrical diagram 3 (3)

34

Service Manual Easymover PP13

Approved by: L-G Andersson

Electrical systems Valid from serial number 555494AAOrder number 208588-040

3

T-code 675 Date 2002-06-04

C-code/Section 5000 Version 001

Functional description

3.1 Starting the truck • Start block S170 should be engaged.

• S21 closed.

• S17 closed.

3.2 Driving • S10 closed.

• L1 activated in any direction.

• S15 closed. Driving in the direction of the drive wheel.

• S16 closed. Driving in the direction of the forks.

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

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

3.4 Braking 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.

3.5 Lifting the forks • S34 activated.

• S31 closed.

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

• Simultaneous driving gives reduced speed.

Service Manual Easymover PP13

Approved by: L-G Andersson

35

Electrical systems C-code/Section 5000 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

3.6 Lowering the forks • S41 closed.

3.7 Horn • S18 closed.

4

Error codes

4.1 Diagnosis and trouble shooting The Status LED is dimmed under normal operating conditions without faults. If the regulator discovers a fault, a single digit code flashes until the fault is rectified, see the table below.

When a hand terminal is used in diagnostic mode for trouble shooting, information regarding the diagnosis can be read off on the terminal’s display, see the table below.

LED-code Hand terminal Long + short LCD-display

Description

1

¤

Watch-dog

Electronic card and/or software failure

1

¤

EEPROM KO

EEPROM or Logic problem

1+1 ¤¤

EB DRIVER SHORT

1+1 ¤¤

EB DRIVER KO

1+2 ¤ ¤¤

CONTACTOR DRIVER

1+2 ¤ ¤¤

DRIVER SHORTED

1+2 ¤ ¤¤

CONTACTOR CLOSED

36

Possible cause

Faulty contactor driver

The contactor coil is either shortcircuit, open circuit or not connected Contactor coil driver short-circuit Defective contactor wiring Electronic card failure

Faulty main contactor points

Main contactor power points are fused Field circuit problem Problem detected by the safety micro processor

Service Manual Easymover PP13

Approved by: L-G Andersson

Electrical systems Valid from serial number 555494AAOrder number 208588-040

LED-code Hand terminal Long + short LCD-display

T-code 675 Date 2002-06-04

C-code/Section 5000 Version 001

Description

Possible cause

1+2 ¤ ¤¤

CONTACTOR OPEN

1+3 ¤ ¤¤¤

POWER FAILURE #1

2+1 ¤¤ ¤

CAPACITOR CHARGE

Power Block problem

Capacitors are not charged within 500 ms after Key switch is closed

2+1 ¤¤ ¤

VMN NOT OK

Chopper problem

Incorrect motor connection Short circuit, motor windings to chassis Power unit defect

2+1 ¤¤ ¤

VFIELD NOT OK

Field Voltage problem

Motor´s field winding short-circuit or interruption Field winding incorrectly connected to the electronic card Electronic card failure in the section relative to the field

2+2 ¤¤ ¤¤

NO FIELD CUR

2+2 ¤¤ ¤¤

FW HIGH FIELD CURR.

2+2 ¤¤ ¤¤

BW HIGH FIELD CURR.

2+3 ¤¤ ¤¤¤

STBY I HIGH

High armature standby current

Defective current sensor Electronic card failure Power unit failure

2+3 ¤¤ ¤¤¤

I=0 EVER

No armature current

Defective current sensor Defective armature or carbon brushes Electronic card failure Power unit failure

2+3 ¤¤ ¤¤¤

CURR. PROTECTION

3+1 ¤¤¤ ¤

TH. PROTECTION

Defective field wiring Defective field current sensor Field power unit failure

Temperature outside Defective temperature sensor range >70°C or <10°C Bad temperature sensor connection Defective electronic card

Service Manual Easymover PP13

Approved by: L-G Andersson

37

Electrical systems C-code/Section 5000 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

LED-code Hand terminal Long + short LCD-display

Description

Possible cause

3+3 ¤¤¤ ¤¤¤

Potentiometer wiper

The track of the potentiometer has become open The potentiometer is not wired correctly The potentiometer itself is defective The values set in PROGRAM VACC routine have not remained or made correctly

3+5 ¤¤¤ ¤¤¤¤¤ INCORRECT START

Starting sequence for travel not correct

ENABLE micro switch fused or faulty Operator starting sequence error Wiring error

3+6 ¤¤¤ ¤¤¤¤¤¤

FORW+BACK

Multiple direction orders

Wiring error Direction switch fused or faulty Operator starting sequence error

3+7 ¤¤¤ ¤¤¤¤¤¤¤

BELLY SW ERROR

3+8 ¤¤¤ ¤¤¤¤¤¤¤¤

CHECK UP NEEDED

Service warning

It is time for service.

The service counter has not been reset following the previous service visit.

Low battery voltage

Battery voltage less than 50% of nominal value

32

38

VACC NOT OK

¤.............¤ BATTERY LOW

Service Manual Easymover PP13

Approved by: L-G Andersson

Electrical systems Valid from serial number 555494AAOrder number 208588-040

5

T-code 675 Date 2002-06-04

C-code/Section 5000 Version 001

Parameters

The following parameters can be changed.

NOTE !

Truck handling.

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

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

5.1 Parameters Parameter

Min

Max

Std

Description

ACC. DELAY

0

9

6

Determines the acceleration ramp

MAX SP BACK

0

9

7

Maximum speed, fork direction, adjustment

MAX SP FORW

0

9

7

Maximum speed, steer wheel direction, adjustment

INVERSION BRAKING

0

9

9

Determines the deceleration ramp when the direction switch is inverted during driving

RELEASE BRAKING

0

9

5

Determines the deceleration ramp when the travel request is released

DECELER DELAY

0

9

5

Determines the deceleration ramp according to the speed controller position

OFF

Resets the hour meter of the service counter.

CHECK UP DONE CHECK UP TYPE

0

3

0

Allows setting of the service counter

CHECK UP HOURS

0

9

2

Indicates the time when the next service visit is required

ACC.DELAY The higher the parameter value, the longer it takes for the truck to reach the maximum speed.

MAX SPEED BACK The maximum speed in the fork direction can be adjusted as a percentage of maximum speed.

0 = 100 % 9 = 62 %

Service Manual Easymover PP13

Approved by: L-G Andersson

39

Electrical systems C-code/Section 5000 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

MAX SPEED FORW The maximum speed in the drive wheel direction can be adjusted as a percentage of maximum speed.

0 = 100 % 9 = 62 %

INVERSION BRAKING Determines the retardation when the accelerator control is shifted to the opposite direction while driving.

0 = Softer retardation 9 = Harder retardation

RELEASE BRAKING Determines motor braking efficiency when the accelerator control is released to the neutral position.

0 = Softer retardation 9 = Harder retardation

DECELER DELAY Determines retardation in relation to the position of the accelerator control. Changing this parameter results in limited change.

CHECK UP DONE ON/OFF parameter. Resets the hour meter of the service counter.

Automatically set to OFF when the hour meter is reset.

CHECK UP TYPE It is possible to programme the Next Service function: 0 = No service warning 1 = Service warning after the set number of hours in the parameter CHECK UP HOURS. 2 = Service warning after the set number of hours in the parameter CHECK UP HOURS. Speed reduction when the time has been exceeded by 10 hours.

3 = Service warning after the set number of hours in the parameter CHECK UP HOURS. Speed reduction when the time has been exceeded by 10 hours. Blocking of all functions when the time has been exceeded by 20 hours.

The service warning results in an alarm on the transistor panel: 3 + 8 CHECK UP NEEDED Quick blinking of the BDI battery indicator.

CHECK UP HOURS Determines "After number of hours" when the service warning is displayed. The parameter can be set from 0 to 9. Each step increments the time by 50 hours.

0 = 200 hours 9 = 650 hours.

40

Service Manual Easymover PP13

Approved by: L-G Andersson

Electrical systems Valid from serial number 555494AAOrder number 208588-040

6

T-code 675 Date 2002-06-04

C-code/Section 5000 Version 001

Test CONSOLE V1.01

CONNECTED TO: SEM -X

SEM-X 24v

75A

V..

V..

00000

ENTER *

MAIN MENU * PARAMETER CHANGE

ENTER

OUT

ROLL *

MAIN MENU STEER TABLE

*

ENTER

*

ENTER

*

ENTER

*

ENTER

*

ENTER

*

ENTER

NOT AVAILABLE

ROLL *

MAIN MENU PROGRAM VACC ROLL

*

MAIN MENU ALARMS ROLL

*

MAIN MENU RESTOR PARAM. ROLL

*

MAIN MENU SAVE PARAM. ROLL

* OUT

MAIN MENU TESTER ROLL

Service Manual Easymover PP13

Approved by: L-G Andersson

41

Electrical systems C-code/Section 5000 Version 001

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

6.1 Test functions Display

Function

BATTERY VOLTAGE

Level of the battery voltage measured at the input to the key switch

BATTERY CHARGE The voltage appearing across the drive motor as measured between B+ and VMN

42

SAFTEY REVERSING

The level of the digital input from the switch for safety reversing (pin A5): ON/+VB = active input, B SW closed OFF/GND = non active input, B SW open

DIGITAL INPUT

Level of digital input, micro switch S31 for lift limiting: ON/GND = active input OFF/+VB = non active input

H&S

For future use.

BACKWARD SWITCH

The level of the fork direction digital input MI (pinA7): ON/+VB = active input, switch closed OFF/GND = non active input, switch open

FORWARD SWITCH

The level of the steer wheel direction digital input MA (pin A6): ON/+VB = active input, switch closed OFF/GND = non active input, switch open

TILLER SWITCH

The level of the tiller arm micro switch digital input (pinA5): ON/+VB = active input, switch closed OFF/GND = non active input, switch open

ACCELERATOR

The voltage of the accelerator potentiometer wiper (CPOT) Left hand of the display indicates voltage level and the right hand the value in percent

TEMPERATURE

The temperature measured on the aluminium heat sink holding the MOSFET devices

FIELD CURRENT

Drive motor field current

MOTOR CURRENT

Drive motor armature current

VMN

The voltage appearing across the drive motor as measured between B- and VMN

Service Manual Easymover PP13

Approved by: L-G Andersson

Electrical systems Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 5000 Version 001

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

WARNING! Risk of short-circuiting.

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

7 Technical specifications – SEM-X Value

Unit

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

28.8 V continuously

Undervoltage limit

16,8

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature winding *

75

Amps

for 2 minutes

40

Amps

for 1 hour

12

Amps

for 2 minutes

Max. current of field winding

6,6

Description

for 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

3

Amps

Max

KSI input voltage, Min.

16.8

Volts

Logic input voltage

>9,4; High <9,2; Low

Volts

Operating temperature

-30 to +40

°C

Overtemperature, reduction

70

°C

Undertemperature, reduction to 80%

-10

°C

Maximum temperature limit

90

Service Manual Easymover PP13

Reduced in proportion to the rise in temperature

Approved by: L-G Andersson

43

Electrical systems C-code/Section 5000 Version 001

44

T-code 675 Date 2002-06-04

Service Manual Easymover PP13

Valid from serial number 555494AAOrder number 208588-040

Approved by: L-G Andersson

In-built battery charger Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 5170 Version 001

In-built battery charger 1

General

The LEAB CHAMP charger is optimised for valve regulated lead batteries. The charger is protected against dust and water jets (IP65).

The charger is connected to a normal earthed 230 V single-phase wall socket. The charging process is automatic.

2 A

B

Charging

Connect the charger (A) to the mains supply. If a discharged battery is connected, the charger will start with the main charge (yellow LED (B) and 28,8 V). When the battery is fully charged, maintenance charging starts (yellow and green LED (B) and 27.6 V). This continues until the charger switches off. If a fully charged battery is connected to the charger or if the charger does not find a connected battery the maintenance charge is started (yellow and green LED 27.6 V). The charger starts with the main charge (yellow LED and 28,8 V) after a power failure if a discharged battery is connected.

The truck’s mains lead can be connected to the mains supply whenever the truck is not in use to ensure the batteries are always fully charged.

The charging process is gentle and consequently does not shorten the life of the battery. It is also beneficial if the truck can be recharged over night or for 12 hours at least once a week.

3

Trouble shooting

• Check the mains supply to the charger.

• Check the fuse on the charger’s battery cable.

• Check whether the charger is overheated.

• If the charger still does not work, replace the charger.

Service Manual Easymover PP13

Approved by: L-G Andersson

45

In-built battery charger C-code/Section 5170 Version 001

4

46

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

Technical data

Dimensions

195x100x46 mm

Weight

1.6 kg

Ambient temperature

-25°C to +50°C

Mains supply

230 V

Rated voltage

24 V DC

Rated current

7A

Degree of efficiency

>85 %

Battery types

Valve regulated lead battery (gelade)

Protection class

IP 65

Miscellaneous

The charger switches off automatically when there is risk of overheating It restarts automatically when the temperature drops

Service Manual Easymover PP13

Approved by: L-G Andersson

Transistor panel Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 5460 Version 001

Transistor panel

1 B F1 1 A F2

ALARM B+

B-

VMN

A 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

5

6

7

8

B 1

B+

A1

M

2

3

4

M-

1

General

A2

ZAPI SEM-X is a regulator that controls the shunt motors. In the first case, it controls the speed by varying the rotor voltage. The voltage is varied using Pulse Width Modulation (PWM). This also includes varying the "ON" time of the MOS transistors used to regulate rotor current.

Shifting of the rotational direction is achieved by reversing the polarity in the field winding (F1-F2). The regulator features a transistorised fourquadrant bridge and a single-quadrant bridge for the rotor winding.

F1

F2

Service Manual Easymover PP13

Approved by: L-G Andersson

47

Transistor panel C-code/Section 5460 Version 001

2

48

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

Connections

Connection

Function

Description

A1

CPOT

Accelerator´s potentiometer wiper input

A2

NLIFT

Lift and lower electrovalve coil negative.

It´s a B- crossing the auxiliary switch installed on the main contactor.

A3

PPOT

Provides a voltage supply from the transistor panel to the accelerator´s potentiometer, protected against short to B+ and B-

A4

TILLER

Tiller microswitch input, active high(B+)

A5

BELLY

Safety reversing input, used for quick inversion, active high (B+).

3K3 to B+ when released.

A6

FW

Forward direction switch input, active high (B+)

A7

REV

Reverse direction switch input, active high (B+)

A8

H&S

For future use

A9

NPOT

Output potentiometer (-)

A10

PLIFT

Lift contactor coil positive

A11

NEB

Electric brake driver output, 1.5A continuous, protected against shortcircuit

A12

NLED

Output to drive a BDI, 100mA max.

A13

PEVD

Down electrovalve coil positive

A14

NMC

Line contactor driver output, 1.0A continuous, protected against shortcircuit.

A15

PMC

Line contactor coil positive supply, 1.0A continuous.

A16

KEY

Controller supply, must be connected to B+ through a cable and a 5A fuse.

B1

--

Connection for hand terminal

B2

NCLRXD

-”-

B3

PCLTXD

-”-

B4

NCLTXD

-”-

B5

GND

-”-

B6

+12

-”-

B7

--

-”-

Service Manual Easymover PP13

Approved by: L-G Andersson

Transistor panel Valid from serial number 555494AAOrder number 208588-040

Connection

Function

Description

B8

--

Connection for hand terminal

T-code 675 Date 2002-06-04

+B

Positive Supply from Battery

-B

Negative Supply from Battery

VMN

Negative Supply (via controller) to Motor

F1, F2

Connections to Drive Motor Field Winding

Service Manual Easymover PP13

C-code/Section 5460 Version 001

Approved by: L-G Andersson

49

Transistor panel C-code/Section 5460 Version 001

50

T-code 675 Date 2002-06-04

Service Manual Easymover PP13

Valid from serial number 555494AAOrder number 208588-040

Approved by: L-G Andersson

Hydraulic system Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 6000 Version 001

Hydraulic system 1

Hydraulic chart and list of symbols 1

A Y41

4

2 3

M3

P

5 T

1.1 List of Symbols Pos No

Description

Function

1

Lift cylinder

Lifting the forks

2

Preasure relief valve

3

Flow control valve

4

Non-return valve

5

Filter

M3

Motor

P

Pump

T

Tank

Y41

Valve

Remarks

Pump motor

1,2 litre Lowering valve for the forks

Service Manual Easymover PP13

Approved by: L-G Andersson

51

Hydraulic system C-code/Section 6000 Version 001

2

T-code 675 Date 2002-06-04

Valid from serial number 555494AAOrder number 208588-040

Adjustments PP13

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

The machine should be capable of lifting a load of between 1350-1400 kg.

1

2 3

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

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

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

• Loosen the locking nut (1) using a special tool (see drawing). Place a load of 1300 kg on the forks and check that the machine can lift it.

• If the machine lifts 1300 kg, place a further 100 kg on the forks.

Check whether the machine can lift the load.

• If the machine lifts 1400 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the machine cannot lift the load.

52

Service Manual Easymover PP13

Approved by: L-G Andersson

Hydraulic system Valid from serial number 555494AAOrder number 208588-040

T-code 675 Date 2002-06-04

C-code/Section 6000 Version 001

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

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

A

26,5

Service Manual Easymover PP13

8

12

B

13,5

Approved by: L-G Andersson

53

Hydraulic system C-code/Section 6000 Version 001

54

T-code 675 Date 2002-06-04

Service Manual Easymover PP13

Valid from serial number 555494AAOrder number 208588-040

Approved by: L-G Andersson