Toyota Forklift PP13 Service Manual SN 372000AA - PDF DOWNLOAD

Service Manual GB

PP 13 Valid from serial number: 372000AA-

Order number: 201012-040 Issued: 2001-10-01 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

C-code Version 001

2

TIEE

T-code 675 Date 2001-10-01

Service Manual PP 13

Valid from serial number 372000AAOrder number 201012-040

Approved by: L-G Andersson

Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code Version 001

Table of contents General product information ................................. 5 1 Intended application of the truck ........................... 5 2 Forbidden application of the truck ........................ 5 3 Truck data .................................................................. 6 4 Truck dimensions ..................................................... 7 5 Identification plate .................................................... 8 6 Main components ..................................................... 8 7 Warning and information plates and symbols .. 10

Technical data .............................................................. 13 Introduction Maintenance ..................................... 17 1 Safety regulations with maintenance work ....... 17 2 Cleaning and washing ........................................... 19 3 Safe lifting ................................................................. 20

Maintenance, Lubrication schedule ................ 21 1 Maintenance schedule .......................................... 21 2 Lubrication schedule .............................................. 25

Oil and grease specification ................................ 27 Drive unit/drive gear ................................................. 29 1 Component parts .................................................... 29 2. Service and repairs ................................................ 32 3 Technical data ......................................................... 35

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C-code Version 001

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

Electrical systems ...................................................... 37 1 Electrical parts ......................................................... 37 2 List of symbols and electrical wiring diagram ... 40 3 Functional description ............................................ 44 4 Error codes ............................................................... 45 5 Parameters ............................................................... 48 6 Test ............................................................................ 49 7 Technical specifications – SEM zero ................. 52

Hydraulic system ........................................................ 53 1 Hydraulic chart and list of symbols ..................... 53 2 Adjustments W13 .................................................... 54

In-built battery charger ............................................ 57 1 General ..................................................................... 57 2 Charging ................................................................... 57 3 Trouble shooting ..................................................... 57 4 Technical data ......................................................... 58

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Service Manual PP 13

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General product information Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code Version 001

General product information PP13 is a battery powered support arm truck equipped with a tiller arm for walking operation and castor wheels for extra stability.

PP 13 is a compact truck intended for horizontal transport and for loading and unloading goods in confined areas. The truck is also ideal for use onboard trucks due to its small outside dimensions and low weight.

The truck has a maximum lifting capacity of 1300 kg.

The truck has a 24 V electrical system with variable transistor control that provides gentle control of the speed while driving.

The truck is equipped as standard with a built-in battery charger for 230 V mains supply. This is combined with a start block to prevent the truck from being accidentally driven during charging. The status of the battery is indicated by a single LED on the truck’s electrical panel.

The forks are lifted by means of a powerful and compact hydraulic unit, which is shutoff automatically once the forks have reached the highest lifting height. The automatic shutoff is designed to reduce the sound level when the highest lifting height has been reached, increase the life of hydraulic components and reduce energy consumption from the batteries.

1

Intended application of the truck

The truck is solely designed and manufactured for indoor transportation, collecting and leaving of loads. The truck should be fitted with the appropriate accessories relevant to the application.

2

Forbidden application of the truck

The truck is designed for handling goods indoors. It is not permitted to use the truck for other purposes including the following: - In areas that contain dust or gases which can cause fires or explosions - As a tow-truck for trailers - To tow other trucks - To transport/lift passengers - To drive on gravel or grass TIEE

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General product information C-code Version 001

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T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

Truck data

The table provides information regarding some technical data, which is of value with daily use of the truck.

Truck type

PP13

Rated capacity, kg

1300

Lift height, mm

205

Travel speed without load, km/h

5,4

Travel speed with rated load, km/h

4,0

Gradient with rated load, %

9

Weight without battery, kg

200

Weight with battery, kg

236

Turning radius (Wa), mm

1410

Continuous noise level according to CE prEN 12053, dB A

66

Permitted drive wheel, material

Vulkollan

The truck’s lifting capacity, lift height and weight can be found on the truck’s identification plate.

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T-code 675 Date 2001-10-01

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Truck dimensions

The illustration shows external dimensions for the truck in its standard design.

PP13

1243

678

420

1000,1150

156

700

TIEE

450,520,685

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General product information C-code

T-code 675 Date 2001-10-01

Version 001

5

Valid from serial number 372000AAOrder number 201012-040

Identification plate

The illustration shows the identification plate used on the truck.

Item

Text

Unit

A

MODEL

B

SERIAL NO

C

RATED CAPACITY

kg

D

WEIGHT WITHOUT BATTERY

kg

E

BATTERY WEIGHT

kg kg

F

BATTERY VOLTAGE

6

Main components

MAX MIN

V

1. Tiller arm: The truck is manoeuvred by the driver while walking.

208 degree steering area.

The brakes are applied in the tiller arm’s upper and lower positions.

2. Covers: Easily removable, providing good accessibility for battery replacement.

3. Start block and charging plug: The battery is charged via the in-built charger.

4. Electric panel: Removable, which provides good access when servicing. 24 volt electrical supply. The speed is variably controlled by means of a transistor.

5. Hydraulic unit: Pump motor and pump are integrated in a compact unit.

6. Drive unit with brake: Fixed drive unit with electromagnetic brake, travel motor, gear and drive wheel combined into a compact unit. Steering bearings between motor and gears.

7. Serial number: The serial number plate fitted to the chassis.

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8. Support castor wheels: Two support castor wheels to ensure stability.

9. Battery: 24 V using two 12 V batteries.

10. Fork carriage: The forks are held horizontally by a link system. The fork carriage can be lubricated via the push rods.

11. Identification plate: With model designation, serial number, year of manufacture, weight without battery, battery weight, rated capacity, battery voltage and manufacturer.

1

11

2

3 4

5

6 10

9 8

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General product information C-code Version 001

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T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

Warning and information plates and symbols

The figure shows the position and significance of the plates and symbols located on the truck.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10

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Hydraulic control: Lift Hydraulic control: Lower Travel direction Signal/Horn Passengers prohibited Hydraulic oil filling Serial number Lifting points Identification plate

Service Manual PP 13

Approved by: L-G Andersson

General product information Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code

Service Manual PP 13

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Version 001

TOYOTA

TOYOTA INDUSTRIAL EQUIPMENT EUROPE S.A.R.L.

TIEE

11

General product information C-code Version 001

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T-code 675 Date 2001-10-01

Service Manual PP 13

Valid from serial number 372000AAOrder number 201012-040

Approved by: L-G Andersson

Technical data Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code Version 001

Technical data Model

PP 13

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

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Technical data C-code Version 001

T-code 675 Date 2001-10-01

Model

Valid from serial number 372000AAOrder number 201012-040

PP 13

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

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Technical data Valid from serial number 372000AAOrder number 201012-040

Model

T-code 675 Date 2001-10-01

C-code Version 001

PP 13

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

9

Without load%

18

Measurement, L2

420

Turning radius WA, mm

1410

Lift height, mm

205

Weight Truck without battery, Medium

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Service Manual PP 13

200

Approved by: L-G Andersson

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Technical data C-code Version 001

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T-code 675 Date 2001-10-01

Service Manual PP 13

Valid from serial number 372000AAOrder number 201012-040

Approved by: L-G Andersson

Introduction Maintenance Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 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, shortcircuiting/burns can occur if a metal object comes into contact with live electrical connections.

Remove watches, rings or other types of metal jewellery.

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Introduction Maintenance C-code Version 001

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

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

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

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

• 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.

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Introduction Maintenance Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 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.

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Introduction Maintenance C-code Version 001

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

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 trestleblocks and secured by a lifting device.

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Maintenance, Lubrication schedule Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 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

TIEE

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

1d

1w

12 m

36 m

I4

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Maintenance, Lubrication schedule C-code Version 001

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

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

22

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

Service Manual PP 13

1d

1w

12 m

36 m

I

I

I I

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Maintenance, Lubrication schedule Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 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

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Maintenance, Lubrication schedule C-code

T-code 675 Date 2001-10-01

Version 001

Valid from serial number 372000AAOrder number 201012-040

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

5000 5000 4110

5000

0380

0000

3500 5110 5700 6100

6600

5400

3100 2550 1700

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Maintenance, Lubrication schedule Valid from serial number 372000AAOrder number 201012-040

2 Pos no

T-code 675 Date 2001-10-01

C-code 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.

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Maintenance, Lubrication schedule C-code Version 001

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

0380

6100

2550

26

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Oil and grease specification Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code Version 001

Oil and grease specification Pos.

Type of lubricant Specification

Application

>0°C A

Grease

26777 (Spray)

Bearings and bushes

B

Hydraulic oil

ISO-L-HM32

Hydraulic system

C

Grease

SHELL RETINAX G

Gears

D

Grease

73942XX5 TOTAL N3942

Lubricating nipples

0380

6100

2550

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Oil and grease specification C-code Version 001

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T-code 675 Date 2001-10-01

Service Manual PP 13

Valid from serial number 372000AAOrder number 201012-040

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Drive unit/drive gear Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 2550 Version 001

Drive unit/drive gear Complete 1 1

2

3

4 5 6

Component parts 7

8

9

10

11

12

13

14

40 4

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33

5

34

35 36 4

37

38

15

16

17

18 19

20 21 22 23 25 26 27

24

24 29

30

28

31

32

39

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

Ring

18

Screw

19

Locking ring

Service Manual PP 13

8 st

8 pcs. Tightened to 20Nm

Approved by: L-G Andersson

29

Drive unit/drive gear C-code 2550 Version 001

T-code 675 Date 2001-10-01

Pos

Benämning

20

Magnetic coil

21

Key

22

Rotor

23

Carbon brush

24

Locking ring

25

Ball bearing

26

Driver

27

Screw

28

Connector

29

Guide pin

30

Locking ring

31

Stropping

32

Brake complete

33

Gear wheel

34

Locking ring

35

Gear wheel

36

Sealing ring

37

Locking ring

38

Washer

39

Ball bearing

40

Sealing ring

Valid from serial number 372000AAOrder number 201012-040

Anm.

4 st

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.

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Drive unit/drive gear Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 2550 Version 001

• 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.

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Service Manual PP 13

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Drive unit/drive gear C-code 2550 Version 001

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

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.

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C-code 2550 Version 001

• 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.

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 greasedissolving, 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.

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Service Manual PP 13

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Drive unit/drive gear C-code 2550 Version 001

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

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.

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Drive unit/drive gear Valid from serial number 372000AAOrder number 201012-040

3

T-code 675 Date 2001-10-01

C-code 2550 Version 001

Technical data

Truck type

PP 13

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

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Service Manual PP 13

20 Nm

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Drive unit/drive gear C-code 2550 Version 001

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Service Manual PP 13

Valid from serial number 372000AAOrder number 201012-040

Approved by: L-G Andersson

Electrical systems Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 5000 Version 001

Electrical systems 1

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Electrical parts

Service Manual PP 13

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S41

S18 S34

S15

S16 S20

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Electrical systems

TIEE

Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 5000 Version 001

Service Manual PP 13

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Electrical systems C-code 5000 Version 001

2

40

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

List of symbols and electrical wiring diagram

Symbol

Description

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

K10

Contactor

Main contactor

K30

Contactor

Pump motor

M1

Motor

Drive motor

M3

Motor

Pump motor

S10

Switch

Travel brake

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

Y1

Brake

Y41

Magnetic valve

TIEE

Function

Notes 230 V

Brake lever

Fork lowering

Service Manual PP 13

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Electrical systems Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 5000 Version 001

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Service Manual PP 13

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WIRING DIAGRAM

PP 13

PP 13

ELSCHEMA

Benämning/Title

2.1 Electrical diagram 1 (3)

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Service Manual PP 13

ELSCHEMA PP 13 WIRING DIAGRAM PP13

Benämning/Title

2.2 Electrical diagram 2 (3)

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Electrical systems Valid from serial number 372000AAOrder number 201012-040

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C-code 5000 Version 001

TIEE

Service Manual PP 13

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PP 13

WIRING DIAGRAM

PP 13

ELSCHEMA

Benämning/Title

2.3 Electrical diagram 3(3)

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Electrical systems C-code 5000 Version 001

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T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

Functional description

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

• S21 closed.

• S17 on.

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 • S10 closed.

• S34 activated.

• S31 closed.

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

• Simultaneous driving gives reduced speed.

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Electrical systems Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 5000 Version 001

3.6 Lowering the forks • S10 closed.

• S41activated.

3.7 Horn • S10 closed.

• S18 activated.

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 Description LCD-display

Possible cause

1

¤

Logic failure #1

Problem with Logic or main contactor

Electronic card failure

1

¤

Watch-dog

Electronic card and/or software failure

1

¤

EEPROM KO

EEPROM or Logic problem

2

¤¤

INCORRECT START

Starting sequence for travel not correct

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Service Manual PP 13

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

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Electrical systems C-code 5000 Version 001

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LED-code

Hand terminal Description LCD-display

Possible cause

2

¤¤

FORW+BACK

Multiple direction orders

Wiring error Direction switch fused or faulty Operator starting sequence error

3

¤¤¤

CAPACITOR CHARGE

Power Block problem

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

3

¤¤¤

VMN NOT OK

Chopper problem

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

3

¤¤¤

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

4

¤¤¤¤

VACC NOT OK

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

4

¤¤¤¤

PEDAL WIRE KO Pedal wire not OK

5

¤¤¤¤¤

NO FIELD CUR

Defective field wiring Defective field current sensor Field power unit failure

5

¤¤¤¤¤

HIGH FIELD CUR

Defective field wiring Defective field current sensor Field power unit failure

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Electrical systems Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 5000 Version 001

LED-code

Hand terminal Description LCD-display

Possible cause

5

¤¤¤¤¤

STBY I HIGH

High armature standby current

Defective current sensor Electronic card failure Power unit failure

5

¤¤¤¤¤

I=0 EVER

No armature current

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

6

¤¤¤¤¤¤

CONTACTOR DRIVER

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

6

¤¤¤¤¤¤

COIL SHORTED

Contactor coil shorted

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

6

¤¤¤¤¤¤

CONTACTOR CLOSED

Faulty main contactor points

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

7

¤¤¤¤¤¤¤

TH. PROTECTION

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

32

¤...........¤ BATTERY LOW

TIEE

Low battery voltage

Service Manual PP 13

Battery voltage less than 50% of nominal value

Approved by: L-G Andersson

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Electrical systems C-code 5000 Version 001

5

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

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 knowhow.

5.1 Parameters Parameter

Min Max

ACC. DELAY

0

9

Determines the acceleration ramp

MAX SP BACK FINE

0

9

Maximum speed, fork direction, fine adjustment

MAX SP FORW FINE

0

9

Maximum speed, steer wheel direction, fine adjustment

INVERSION BRAKING

0

9

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

RELEASE BRAKING

0

9

Determines the deceleration ramp when the travel request is released

DECELER DELAY

0

9

Determines the deceleration ramp according to the speed controller position

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Std

Description

Service Manual PP 13

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Electrical systems Valid from serial number 372000AAOrder number 201012-040

6

T-code 675 Date 2001-10-01

C-code 5000 Version 001

Test CONSOLE V1.0

CONNECTED TO: SEM 0

1.03

SEM 0 24v

75A

1.03 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

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MAIN MENU TESTER ROLL

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Electrical systems C-code 5000 Version 001

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6.1 Test functions

50

TIEE

Display

Function

BATTERY VOLTAGE

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

MOTOR VOLTAGE

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

MOTOR CURRENT

Drive motor armature current

FIELD CURRENT

Drive motor field current

VMN

Voltage drop across the MOS as measured between B- and VMN

TEMPERATURE

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

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

FORWARD SWITCH

The level of the steer wheel direction digital input MA (pin B6): ON/+VB = active input, switch closed OFF/GND = non active input, switch open

BACKWARD SWITCH

The level of the fork direction digital input MI (pinB4): ON/+VB = active input, switch closed OFF/GND = non active input, switch open

HANDLE/SEAT 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

QUICK INVERSION SWITCH

The level of the digital input from Belly button micro switch (pin B5): ON/+VB = active input, B SW closed OFF/GND = non active input, B SW open

Service Manual PP 13

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T-code 675 Date 2001-10-01

C-code 5000 Version 001

Display

Function

CUTBACK SWITCH 1

The level of the speed reduction 1 micro switch SR1: ON/GND = active input OFF/+VB = non active input

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.

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Technical specifications – SEM zero Value

Unit

Rated operating voltage

24

Volts

Overvoltage limit

36

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 3 minutes

100

Amps

for 1 hour

35

Amps

for 2 minutes

Max. current of field winding

20

Description

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

-30 to +40

°C

Overtemperature, reduction

70

°C

Undertemperature, reduction to 80%

-10

°C

Maximum temperature limit

80

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Reduced in proportion to the rise in temperature

Approved by: L-G Andersson

Hydraulic system Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 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

TIEE

Remarks

Pump motor 1,2 litre Lowering valve for the forks

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Hydraulic system C-code 6000 Version 001

2

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

Adjustments W13

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.

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C-code 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

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8

12

B

13,5

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Service Manual PP 13

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In-built battery charger Valid from serial number 372000AAOrder number 201012-040

T-code 675 Date 2001-10-01

C-code 8340 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 singlephase wall socket. The charging process is automatic.

A

2

Charging

Connect the charger (A) to the mains supply. If a discharged battery is connected, the charger will start with the main charge (yelB low 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.

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In-built battery charger C-code 8340 Version 001

4

T-code 675 Date 2001-10-01

Valid from serial number 372000AAOrder number 201012-040

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

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