Toyota Forklift SP10 SP10S PP13 Service Manual SN 904526- (SP10 SP10S) 914369- (PP13) - PDF DOWNLOAD

Service Manual en

SP10, SP10S, PP13 Valid from serial number: 904526- (SP10, SP10S) 914369- (PP13)

Order number: 242330-040 Issued: 2006-09-29 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:

Issue date

Order number

Changes

2006-09-29

242330-040

Completely new issue. Manual replaces part number: 235568 and 208588 (now combined to one manual).

This manual covers following truck models:

T-code

Model

Serial number

795

SP10

904526-

795

SP10S

904526-

675

PP13

914369-

© TIEE SARL

Service Manual

SP10, SP10S, PP13

Table of Contents Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

1- Table of Contents 2- Technical data ..................................................................................... 2-1 2.1 General tightening torques............................................................. 2-4 3- Maintenance ........................................................................................ 3-1 3.1 Safety regulations with maintenance work ..................................... 3-2 3.2 Cleaning and washing.................................................................... 3-4 3.2.1 External cleaning ............................................................. 3-4 3.2.2 Cleaning the motor compartment .................................... 3-4 3.2.3 Electrical components ..................................................... 3-4 3.3 Safe lifting ...................................................................................... 3-5 3.4 Lifting the truck SP10, SP10S ........................................................ 3-6 3.5 Lifting the truck PP13 ..................................................................... 3-8 3.5.1 Using a lifting device ........................................................ 3-8 3.5.2 Lifting points, using another fork lift truck ........................ 3-8 3.6 Placing the truck on its side SP10, SP10S..................................... 3-9 3.7 Maintenance Schedule ................................................................ 3-10 3.8 Oil and lubricants ......................................................................... 3-14 4- Tools ..................................................................................................... 4-1 4.1 Super Seal connectors................................................................... 4-1 4.2 AMP connectors............................................................................. 4-2 4.2.1 AMP Connectors, 040 series ........................................... 4-3 4.3 Molex connectors........................................................................... 4-3 4.4 Grease guns .................................................................................. 4-4 4.5 Other tools ..................................................................................... 4-5 5- Chassis - 0000 ..................................................................................... 5-1 5.1 Support arms SP10........................................................................ 5-1 5.1.1 Placement of supportarms ............................................... 5-2 5.2 Support arms SP10S ..................................................................... 5-3 5.2.1 General ............................................................................ 5-3 5.2.2 Main Components ........................................................... 5-3 5.2.3 Maintenance .................................................................... 5-4 5.2.4 Adjusting the support arm width ...................................... 5-4 5.2.5 Replacing support arms ................................................... 5-4 6- Drive unit/drive gear – 2000 ................................................................ 6-1 6.1 Component parts ........................................................................... 6-1 6.2 Service and repairs ........................................................................ 6-2 6.2.1 Dismantling the motor from the truck ............................... 6-2 6.2.2 Inspection/replacement of the carbon brushes ................ 6-2 6.2.3 Replacing the drive gear .................................................. 6-3 6.2.4 Cleaning .......................................................................... 6-3 6.2.5 Maintenance of brakes .................................................... 6-4 6.2.6 Replacing the brake disc ................................................. 6-4 7- Wheel system - 3000 ........................................................................... 7-1 7.1 Castor wheel suspension SP10/SP10S ......................................... 7-1 7.1.1 Components .................................................................... 7-1 7.1.2 Lubricating the nipples ..................................................... 7-2 © TIEE SARL

Service Manual

SP10, SP10S, PP13

1- 1

Table of Contents T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

7.2

Date 2006-09-29

Order number 242330-040

7.1.3 Adjusting the castor wheel pressure ................................ 7-2 Castor wheel PP13 ........................................................................ 7-3 7.2.1 Lubricating the nipples ..................................................... 7-4

8- Steering system – 4000 ....................................................................... 8-1 8.1 Components .................................................................................. 8-1 9- Electrical system – 5000 ..................................................................... 9-1 9.1 General .......................................................................................... 9-1 9.1.1 Firmware (truck control software) .................................... 9-1 9.2 Names of parts............................................................................... 9-1 9.3 Electric equipment list summary .................................................... 9-2 9.3.1 Electric component overview ........................................... 9-4 9.4 Access to the main electric panel................................................... 9-7 9.5 Electric circuit overview.................................................................. 9-8 9.6 Symbol list...................................................................................... 9-9 9.7 Electric wiring diagram ................................................................. 9-10 9.8 Automatic height adjustment........................................................ 9-16 9.9 Functional description .................................................................. 9-22 9.9.1 Operating principle ........................................................ 9-22 9.9.2 Transistor regulator ....................................................... 9-26 General .......................................................................... 9-26 Safety ............................................................................ 9-26 9.9.3 Battery charging on-board the truck (machine number 947624-) 9-28 Charging ........................................................................ 9-28 Technical data ............................................................... 9-29 Alarm indications on charger ......................................... 9-30 9.9.4 Battery charge level status ............................................ 9-31 Battery display (option) .................................................. 9-31 9.9.5 Built-in charger for charging on a lorry - PP13 .............. 9-32 General .......................................................................... 9-32 Installation recommendations for the “connection point” on a lorry .......................................... 9-32 Installation on the truck .................................................. 9-33 Charging ........................................................................ 9-35 Troubleshooting ............................................................. 9-35 Technical data ............................................................... 9-35 9.9.6 Limiting the travel speed ................................................ 9-36 9.9.7 Hour meter modes ......................................................... 9-36 9.9.8 Hand-held terminal ........................................................ 9-37 General .......................................................................... 9-37 Connecting the hand-held terminal ................................ 9-37 Hand-held terminal overview ......................................... 9-37 Hand-held terminal menus ............................................ 9-39 9.10 Troubleshooting ........................................................................... 9-40 9.10.1 General .......................................................................... 9-40 9.10.2 Displaying error codes ................................................... 9-40 Direct error code display ................................................ 9-40 Displaying error code on the hand-held terminal ........... 9-40 Error history ................................................................... 9-41 9.10.3 Error code list ................................................................ 9-42 9.10.4 TESTER function ........................................................... 9-45 9.11 Parameters and settings .............................................................. 9-47 1- 2

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Table of Contents Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9.11.1 9.11.2 9.11.3 9.11.4

9.12

General .......................................................................... 9-47 Setting the parameters .................................................. 9-47 Parameter list ................................................................ 9-48 Parameter description ................................................... 9-49 Acceleration ramp time (ACC.DELAY) .......................... 9-49 Deceleration ramp time (ACC.DELAY) .......................... 9-49 Release breaking intensity (RELEASE BRAKING) ....... 9-49 Inversion braking intensity (INVERSION BRAKING) ..... 9-49 Maximum speed (CUTBACK SPEED 3) ....................... 9-49 Reset service counter (CHECK UP DONE) .................. 9-49 Select service warning type (CHECK UP TYPE) .......... 9-49 ”Time to next service” (CHECK UP HOURS) ................ 9-50 9.11.5 Transferring parameter settings .................................... 9-50 General .......................................................................... 9-50 From the truck to the hand-held terminal ....................... 9-51 From the hand-held terminal to the truck ....................... 9-52 9.11.6 Speed potentiometer calibration .................................... 9-52 General .......................................................................... 9-52 Procedure ...................................................................... 9-53 Technical data.............................................................................. 9-54 9.12.1 SEM-X transistor regulator ............................................ 9-54

10- Hydraulic system – 6000 ................................................................. 10-1 10.1 SP10/SP10S ................................................................................ 10-1 10.2 Hydraulics diagram and main components SP10, SP10S ........... 10-2 10.3 Hydraulics diagram and components PP13 ................................. 10-4 10.4 Description SP10, SP10S, PP13 ................................................. 10-6 Lift .................................................................................. 10-6 Lower ............................................................................. 10-6 Operating pressure and pressure limitation ................... 10-6 10.5 Adjustments ................................................................................. 10-7 10.5.1 Adjustment of the pressure limit valve SP10, SP10S ................................................................. 10-7 10.5.2 Adjustment of the pressure limit valve PP13 ................. 10-8 10.6 Tools SP10, SP10S, PP13........................................................... 10-9 11- Lift mast SP10, SP10S – 7000 ......................................................... 11-1 11.1 Main mast .................................................................................... 11-1 11.1.1 Components .................................................................. 11-1 11.1.2 Maintenance .................................................................. 11-2 Mounting ........................................................................ 11-2 Lubrication ..................................................................... 11-2 11.1.3 Cylinder ......................................................................... 11-3 Disassembly .................................................................. 11-3 Assembly ....................................................................... 11-3 11.2 Fork carriage................................................................................ 11-4 11.2.1 Maintenance .................................................................. 11-4 11.3 Main lift chain system................................................................... 11-5 11.3.1 Checking the chain setting ............................................ 11-5 11.3.2 Chain inspection ............................................................ 11-5 Noise ............................................................................. 11-5 Surface rust ................................................................... 11-5 Rusty links ..................................................................... 11-5 Stiff links ........................................................................ 11-5 Bolt rotation ................................................................... 11-6 © TIEE SARL

Service Manual

SP10, SP10S, PP13

1- 3

Table of Contents T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

Loose bolts .................................................................... 11-6 Outline wear .................................................................. 11-7 Stretching ...................................................................... 11-8 Damage ......................................................................... 11-8 Damaged discs .............................................................. 11-9 Damaged bolts .............................................................. 11-9 Dirty chain ...................................................................... 11-9 11.3.3 Cleaning ........................................................................ 11-9 11.3.4 Lubrication ................................................................... 11-10 12- Accessories – 9000 ......................................................................... 12-1 12.1 Automatic height adjustment SP10, SP10S ................................. 12-1 12.1.1 General .......................................................................... 12-1 12.1.2 Electrical wiring diagram ................................................ 12-3 13- Destruction instructions ................................................................. 13-1 13.1 General ........................................................................................ 13-1 13.2 Procedure .................................................................................... 13-1 13.3 Abbreviations ............................................................................... 13-2 13.4 Sorting ......................................................................................... 13-2 13.5 Chassis (0300)............................................................................. 13-3 Disassembly .................................................................. 13-3 Material handling ........................................................... 13-3 13.6 Hoods, hatches (0340)................................................................. 13-3 Disassembly .................................................................. 13-3 Material handling ........................................................... 13-3 13.7 Electric Pump Motor (1710) ........................................................ 13-3 Disassembly .................................................................. 13-3 Material handling ........................................................... 13-3 13.8 Drive assembly/drive motor (1760/2550) ..................................... 13-4 Disassembly .................................................................. 13-4 Material handling ........................................................... 13-4 13.9 Wheels (3500).............................................................................. 13-5 Disassembly .................................................................. 13-5 Material handling ........................................................... 13-5 13.10 Tiller arm (4110)........................................................................... 13-6 Disassembly .................................................................. 13-6 Material handling ........................................................... 13-6 13.11 General electrical equipment (5100) ............................................ 13-7 Disassembly .................................................................. 13-7 Material handling ........................................................... 13-7 13.12 Hydraulic unit (6100) .................................................................... 13-8 Disassembly .................................................................. 13-8 Material handling ........................................................... 13-8 13.13 Hydraulic cables/cylinders (6230/6610) ....................................... 13-9 Disassembly .................................................................. 13-9 Material handling ........................................................... 13-9 13.14 Main mast and fork carriage (7100) ........................................... 13-10 Disassembly ................................................................ 13-10 Material handling ......................................................... 13-10

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Technical data Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

2- Technical data Model

SP10

SP10S

PP13

Type

TSL115-16

TSL115-16

TSL115-16

Output

0.5 kW

0.5 kW

0.5 kW

Duty cycle

S2, 60 min

S2, 60 min

S2, 60 min

Minimum carbon brush length

14.5 mm

14.5 mm

14.5 mm

Nominal commutator diameter

43 mm

43 mm

43 mm

Minimum commutator diameter

40 mm

40 mm

40 mm

Resistance, shunt field winding, at 25 C°

1.3 Ω

1.3 Ω

1.3 Ω

Resistance, armature winding, at 24 C°

0.0156 Ω

0.0156 Ω

0.0156 Ω

Insulation resistance between windings and motor casing

>=1 Mohm

>=1 Mohm

>=1 Mohm

Weight

25 kg

25 kg

25 kg

Type

891.270.0

891.270.0

891.270.0

Brake power

10 Nm

10 Nm

10 Nm

Output

28 W

28 W

28 W

Resistance, coil

20,8 Ω

20,8 Ω

20,8 Ω

Minimum thickness brake disc

6.75 mm

6.75 mm

6.75 mm

Thickness of new brake disc

6.90 mm

6.90 mm

6.90 mm

Type

2-stage wheel gear

2-stage wheel gear

2-stage wheel gear

Gear ratio

24,8:1

24,8:1

24,8:1

Drive motor

Brakes

Transmission/drive gear

© TIEE SARL

Service Manual

SP10, SP10S, PP13

2- 1

Technical data T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Model

Date 2006-09-29

Order number 242330-040

SP10

SP10S

PP13

Drive wheel

Ø250x60 mm

Ø250x60 mm

Ø250x60 mm

Axle pressure without load

210 kg

440 kg

175 kg

Axle pressure at rated load

360 kg

580 kg

570 kg

Tightening torque for wheel bolts

20 Nm

20 Nm

20 Nm

Fork wheels

Ø85 mm

Ø85 mm

Ø85 mm

Axle pressure without load

2x60 kg

2x80 kg

2x18 kg

Axle pressure at rated load

2x500 kg

2x515 kg

2x496 kg

Support arm wheels

Ø100x40 mm

-

Ø100x40 mm

Axle pressure without load

2x70 kg

-

2x30 kg

Axle pressure at rated load

2x70 kg

-

2x24 kg

Output

1.4 kW

1.4 kW

1.2 kW

Duty cycle

3.5 %

3.5 %

10 %

Minimum carbon brush length

10 mm

10 mm

7.5 mm

Minimum commutator thickness/diameter

28,6 mm

28,6 mm

4.75 mm

Pressure at rated load

190 bar

190 bar

110 bar

Overflow pressure

210 bar

210 bar

130 bar

Pump flow

4.5 l/min

4.15 l/min

4.7 l/min

Tank volume

2l

2l

1l

Capacity

63 Ah

63 Ah

63 Ah

Weight

2x23 kg

2x23 kg

2x23 kg

Without load

5.4 km/h (1.5 m/s)

5.4 km/h (1.5 m/s)

5.4 km/h (1.5 m/s)

With rated load

4.3 km/h (1.2 m/s)

4.3 km/h (1.2 m/s)

4.0 km/h (1.1 m/s)

Lifting without load

0.22 m/s

0.19 m/s

1.7 s

Lift with rated load

0.12 m/s

0.10 m/s

3.0 s

Lowering without load

0.14 m/s

0.14 m/s

3.0 s

Lowering with rated load

0.15 m/s

0.15 m/s

3.0 s

Wheels

Hydraulic system

Batteries

Driving speeds

Lift/lowering speed

2- 2

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Technical data Order number 242330-040

Date 2006-09-29

Model

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

SP10

T-code 795, 675

SP10S

PP13

Power consumption (truck at room temperature) Driving without load

20 A

20 A

13 A

Driving with rated load

26 A

26 A

-

Lifting without load

39 A

39 A

-

Lifting with rated load

132 A

132 A

-

With rated load

5%

5%

5%

Without load

10 %

10 %

10 %

Measurments L2

530 mm

530 mm

420 mm

Turning radius WA

1340 mm

1365 mm

1410 mm

Lift height

1580 mm / 2000 mm

1540 mm / 1960 mm

205 mm

420 kg / 430 kg

560 kg / 580 kg

200 kg

Hill-climbing ability

Measurement

Weight Truck without battery

© TIEE SARL

Service Manual

SP10, SP10S, PP13

2- 3

Technical data General tightening torques T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

2.1 General tightening torques Millimetre thread M3 to M24.

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

Table 1: General tightening torques [Nm] M3

M4

M5

M6

M8

M10

B

C

B

C

B

C

B

C

B

C

B

C

1,15

1,2

2,8

2,9

5,5

5,7

9,5

9,8

23

24

45

47

12,9 2,0

2,1

4,7

4,9

9,3

9,7

16,3

17,0

38,5

40,0

75,8

79,0

A 8,8

M12 A 8,8

M14

M16

M20

M24

B

C

B

C

B

C

B

C

B

C

77,7

81

123

128

189

197

369,6

385

638,5

665

649

1075

1120

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

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

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Maintenance Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

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

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

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

3- 1

Maintenance Safety regulations with maintenance work T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

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

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

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

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

WARNING! Short-circuiting/Burns.

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

Remove watches, rings or other types of metal jewellery.

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

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

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

• 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.

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Maintenance Safety regulations with maintenance work Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

• 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.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

3- 3

Maintenance Cleaning and washing T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

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

• Carry out general cleaning and washing weekly.

NOTE! Risk of short-circuiting.

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

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

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

• Rinse off loose grime using tepid water.

NOTE! Jamming, corrosion.

Mechanical components can be damaged.

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

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

NOTE! Risk of short-circuiting.

The electrical system can be damaged.

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

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

• Rinse off loose grime using tepid water.

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

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

NOTE! Risk of short-circuiting.

Electrical components can be damaged.

Do not break the guarantee seal on the electronic board.

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Maintenance Safe lifting Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

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

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

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

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

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

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

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

This reduces the risk of the truck tipping over.

- so that the truck cannot roll.

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

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

WARNING! Risk of crushing.

A badly supported truck can fall.

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

3- 5

Maintenance Lifting the truck SP10, SP10S T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

3.4 Lifting the truck SP10, SP10S • Lift the truck from the marked lifting points when using a lifting device.

WARNING! Risk of overturning.

The truck can overturn if it is lifted from the wrong lifting points.

Always lift the truck from the marked lifting points.

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Maintenance Lifting the truck SP10, SP10S Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

• Lift from the truck’s centre of gravity when using another fork lift truck.

550

100 mm

700

100 mm

• Secure the truck to the lifting truck’s forks.

• Lift with the greatest of care.

WARNING! Risk of overturning.

The truck can overturn if it is lifted incorrectly.

Always lift the truck secured to, and with the centre of gravity between, the lifting truck’s forks.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

3- 7

Maintenance Lifting the truck PP13 T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

3.5 Lifting the truck PP13 3.5.1 Using a lifting device Lift the truck at the marked out lifting points with the lifting equipment.

WARNING! Risk of overturning.

The truck can overturn if it is lifted from the wrong lifting points.

Always lift the truck from the marked lifting points.

3.5.2 Lifting points, using another fork lift truck WARNING! Risk of overturning.

The truck can overturn if it is lifted incorrectly.

Always lift the truck secured to, and with the centre of gravity between, the lifting truck’s forks.

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Maintenance Placing the truck on its side SP10, SP10S Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

3.6 Placing the truck on its side SP10, SP10S In order to perform certain service checks, the truck must be placed on its side.

Table 2: Placing the truck on its side Description

Pictures

1

Plug both air filters, for example by placing a piece of soft plastic between the air filter and the filling pipe.

2

Loosen the battery cables and remove both batteries. Also place a suitable mat beside the truck. The lift up one side of the truck, using, for example, a jack.

3

Use the mast and lower the truck onto its side. The underside of the truck will then be completely accessible for service checks for the drive axle and the wheels, for example.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

3- 9

Maintenance Maintenance Schedule T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

3.7 Maintenance Schedule A = PP13 B = SP10, SP10S

Pos.

Work to carry out

Operator

Service technician

Interval in days/weeks/months - can vary depending on application

1 d 1 w 12 m

36 m

0000

Chassis

0000.1

Inspect links and locking pins

A

A

0000.2

Inspect for cracking and other damage

AB

AB

0000.3

Visually inspect the bolt joints between the chassis and support arms.

B

B

0000.4

Press grease into the lubricant nipples

B

B

0000.5

Inspect cover locking

AB

AB

AB

AB

0000.6

Inspect signs and stickers

AB

AB

AB

AB

0380.1

Inspect for cracking and other damage

A

A

0380.2

Inspect the bushings for play

A

A

0380.3

Press grease into the lubricant nipples

A

A

1000

Motors

1700.1

Inspect the connections

AB

AB

1700.2

Inspect the drive motor carbon-brushes

AB

AB

1700.3

Clean the drive motor

AB

AB

1700.4

Retighten the drive motor mounting bolts (45 Nm)

AB

AB

2000

Drive gear

2550.1

Inspect the guide bearing for play

AB

AB

2550.2

Replace grease

2550.3

Retighten the mounting bolts

2550.4

Inspect for abnormal noise

3100

Brake

3100.1 3100.2

3- 10

AB AB

AB

AB

AB

Inspect brake disc wear

AB

AB

Clean

AB

AB

Service Manual

AB

SP10, SP10S, PP13

AB

© TIEE SARL

Maintenance Maintenance Schedule Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

A = PP13 B = SP10, SP10S

Pos.

Work to carry out

Operator

Service technician

Interval in days/weeks/months - can vary depending on application

1 d 1 w 12 m

36 m

3500

Wheels

3500.1

Inspect drive wheel wear (A: Ø >235 mm, B: Ø >245 mm) and bolts (20 Nm)

AB

AB

3500.2

Inspect castor wheel wear

AB

AB

3500.3

Inspect fork/support arm wheel wear

AB

AB

3500.4

Press grease into the greasable bushings of the castor wheel

AB

AB

3500.5

Check whether the castor wheel swings freely

AB

AB

3500.6

Inspect the drive wheel pressure using the castor wheel setting in relation to the drive wheel

B

B

3500.7

Remove strings and other rubbish

AB

AB

4000

Control system

4100.1

Inspect tiller arm mounting

AB

AB

4100.2

Inspect the strength of the gas strut and the locking performance

AB

AB

5000

Electrical system

5000.1

Inspect connectors and cabling

AB

AB

5000.2

Clean electronic components and check for secure mounting

AB

AB

5000.3

Retighten cable connections

AB

AB

5000.4

Inspect the contactors

AB

AB

5000.5

Inspect the battery indicator and the hour meter (option)

AB

AB

5000.6

Inspect the fork lift height switch

A

A

A

A

5000.7

Inspect brake switch operation

AB

AB

AB

AB

5000.8

Inspect emergency stop switch operation

AB

AB

AB

AB

5000.9

Check the function of the horn

AB

AB

AB

AB

5000.10

Inspect collision safety switch operation

AB

AB

AB

AB

5000.11

Inspect charging plug/start prevention device

AB

AB

AB

AB

5110.1

Inspect battery locking

AB

AB

5110.2

Inspect connections to battery, truck and charger

AB

AB

AB

5110.3

Inspect the battery tray, cell and pole protectors for damage

AB

AB

AB

© TIEE SARL

Service Manual

AB

AB

SP10, SP10S, PP13

AB

AB

3- 11

Maintenance Maintenance Schedule T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

A = PP13 B = SP10, SP10S

Pos.

Work to carry out

Operator

Service technician

Interval in days/weeks/months - can vary depending on application

1 d 1 w 12 m

36 m

6000

Hydraulics

6000.1

Inspect hoses and pipes for wear

AB

AB

6000.2

Replace the oil and clean the oil tank

AB1

AB1

6000.3

Replace or clean the oil filter

AB1

AB1

6000.4

Inspect the oil level

AB

AB

AB

6000.5

Inspect for leakage

AB

AB

AB

6600.1

Inspect cylinder mounting

AB

AB

7000

Lifting mast

7100.1

Inspect for cracks and other damage

B

B

7100.2

Inspect the lifting chains and chain rollers for wear

B

B

7100.3

Lubricate the mast rails at the guide rollers

B

B

7100.4

Retighten the mast mounts.

B

B

7100.5

Adjust the lifting chain if necessary

B

B

7100.6

Inspect the chain bolt pins and the split cotter pins

B

B

7100.7

Lubricate the lifting chain To prevent corrosion damage, make sure the lifting chain has been properly greased.

B

B

7100.8

Inspect the mast top covers

B

B

7420.1

Inspect for cracking and other damage

B

B

7420.2

Inspect the guides for wear

B

B

7420.3

Inspect the play between the mast girder and the fork carriage rollers

B

B

AB

1 = Replace the oil and clean the filter the first time after 12 months and then every 24 months.

3- 12

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Maintenance Maintenance Schedule Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

4100

6000

6600 5110

0000

5000

7000

0380

1700 2550

3100

7420 3500

© TIEE SARL

Service Manual

SP10, SP10S, PP13

3- 13

Maintenance Oil and lubricants T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

3.8 Oil and lubricants Table 3: Lubrication chart Service point

12 months

24 months

1

Hydraulic system

Oa

O

2

Driving gear (0,35 kg grease)

K

3

Pilot bearing

4

Bearings and bushings

S

5

Mast: Inside surfaces of beam flanges

S

6

Mast: Inside surfaces of beam ribs

S

7

Lifting chain

S

36 months F S

S = Lubricate, K = Check, O = Oil replacement, F = Grease replacement a.Replace the oil and clean the filter the first time after 12 months and then every 24 months.

TRUCK WITH MAST 5, 6, 7

1

4

2

3

1

4 2

3- 14

3

TRUCK WITHOUT MAST

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Maintenance Oil and lubricants Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Table 4: Oil and Grease Specification

1

Lubricant

Specification

Product name

Part number

Hydraulic oil >-15°C

ISO-VG32 Quality level: ISO 6743-4 category HM DIN 51524 del 2 category HLP

Toyota Industrial Hydraulic Oil 32

4x5 litres: W5020-F0011-99 208 litres: W5020-F0010-99 Bulk: W5020-F0015-99

Hydraulic oil <-15°C

ISO-VG27,5 Quality level: ISO 6743-4 category HV DIN 51524 del 3 category HVLP

Statoil 131

1 litre: 233916-001 5 litres: 233916-002 20 litres: 233916-003 208 litres: 233916004 Bulk: 233916-005

2

Grease

Esso, Unirex N2

3

Grease

Staburags NBU 8EP, Klüber Lubrication

4

Grease

-30°C – +130°C Quality level: ISO 6743 DIN 51502

Q8, Rembrandt EP2

Cartridge: 223690001 18 kg: 223690-002 180 kg: 223690-003

Grease

-20°C – +110°C

Gleitmo 805

29586

<-15°C

Gleitmo 805K

VG150 -10°C – +150°C

Rexoil, Rexnord Kette

VG15 -40°C – -30°C

Klüberoil 4UH 1-15, Klüber Lubrication

VG68 -30°C – +5°C

Klüberoil 4UH 1-68N, Klüber Lubrication

5 6 7

Chain oil

236794

Anticorit LBO 160 TT, Fuchs DEA VG150 +5°C – +45°C

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

VG220 +45°C – +80°C

© TIEE SARL

Service Manual

Klüberoil 4UH 1-220N, Klüber Lubrication

SP10, SP10S, PP13

3- 15

Maintenance Oil and lubricants T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

This page is intentionally left blank

3- 16

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Tools Super Seal connectors Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

4- Tools 4.1 Super Seal connectors 1 3

3 2

Figure

© TIEE SARL

Number

Application

159232

Tools for fitting pins/sleeves

159229

Tools for loosening locks (1)

159230

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

159231

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

159228

Tools for removing pins/sleeves (3)

Service Manual

SP10, SP10S, PP13

4- 1

Tools AMP connectors T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

4.2 AMP connectors PT = Power Timer (4,8. 5,8. 6,3 mm) JPT = Junior Power Timer (2,8 mm) MPT = Micro Power Timer (1,5 mm)

Figure

2

1

Number

Application

151080 (PT)

Tools for removing pins/sleeves

213296 (JPT)

Tools for removing pins/sleeves

213298 (MPT)

Tools for removing pins/sleeves

1=163787 2=163788

Tools for fitting sleeves

1=213336 (MPT) 2=213337 (MPT)

1=213336 (JPT) 2=213549 (JPT)

2

4- 2

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

1

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Tools Molex connectors Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

4.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

4.3 Molex connectors 16 9 8 1 Figure

© TIEE SARL

Service Manual

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

SP10, SP10S, PP13

4- 3

Tools Grease guns T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

4.4 Grease guns Figur

fif

4- 4

Nummer

Användning

24981

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

755132

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

755142

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

755152

Two-hand grease gun with hose and nozzle.

755146

Grease hose 450 mm.

Grease hose 750 mm.

Grease hose 1500 mm.

202154PM

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

Fits grease guns with hose and discharge pipe.

Length 125 mm.

755140

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

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Tools Other tools Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

4.5 Other tools Figure

-1 -2

Number

Application

08-13022

Driving gear puller

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

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

207881

Hand terminal for communication with the transistor regulator.

Needed for the following uses:

-3 -4

• Changing parameters.

• Uploading and downloading parameter settings.

• Display of error messages.

• Calibration.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

4- 5

Tools Other tools T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

This page is intentionally left blank

4- 6

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Chassis - 0000 Support arms SP10 Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

5- Chassis - 0000 5.1 Support arms SP10

2 3 1 4

If the bolt joint between the chassis and the support arms are to be adjusted or if the support arms are to be replaced, the bolts must be replaced with new ones. Two guides (4) should be at both position 1 and 2. Tightening is done first to 20 Nm of torque at 1 and 2 in order.

Then full tightening is done in the same order to 200 Nm of torque.

Finally position 3 is tightened to 200 Nm of torque.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

5- 1

Chassis - 0000 Support arms SP10 T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

5.1.1 Placement of supportarms

1

1

2

2

B

A

Pos.

Name

1

Inner hole

2

Outer hole

3

Marking

3

Same supportarm can be used for different width. Check for correct measure between supportarms. To do that, check the marking for each supportarm according to the table below:

Marking

5- 2

Service Manual

Hole

Width of forks

1

550 ,mm

2

685 mm

1

536

SP10, SP10S, PP13

© TIEE SARL

Chassis - 0000 Support arms SP10S Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

5.2 Support arms SP10S 5.2.1 General The truck is composed of a unit assembled so that the support arm chassis and the separate assembly points for the mast and the support arms are screwed onto the drive section.

The support arms on the support arm chassis are adjustable for different interior support arm widths from 900 mm to 1300 mm to accommodate different pallet sizes. Normally, the support arm width is only adjusted prior to delivery to a customer.

5.2.2 Main Components

© TIEE SARL

Pos.

Name

1

Support arms

2

Clamps (mounting)

3

Screws and nuts, MC6S16x100

4

Locking screw and nut, M6S 12x60H

Service Manual

SP10, SP10S, PP13

5- 3

Chassis - 0000 Support arms SP10S T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

5.2.3 Maintenance If the bolt joint between the chassis and the support arms are to be adjusted or if the support arms are to be replaced, the bolts must be replaced withnew ones. Tightening of the clamp bolts (3) is done using a torque wrench set at 220 Nm.

5.2.4 Adjusting the support arm width To adjust the distance between the support arms, proceed as follows: • Lift up one side of the truck.

WARNING !

The truck can tip over.

Do not lift up both support arms at the same time.

Lift one side at a time and support it while you work.

• Loosen the locking nut and the locking screw (4) on the front of the cross bar.

• Loosen the screws and nuts of the clamp (3).

• Adjust the support arm, ensuring that the setting is the same on both sides.

• Tighten the lock.

• Insert new screws and nuts and tighten them loosely (crosswise) using a spanner.

• Loosen the lock slightly and then tighten the nuts to 220+/-12 Nm.

5.2.5 Replacing support arms

2a

2b

1b

7

1a

3

6

5

4

Replacing a support arm is a more extensive task than adjusting the width • Lift out the battery.

5- 4

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Chassis - 0000 Support arms SP10S Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

• Lift up the side of the truck where the support arm is to be replaced.

• Loosen the locking bolt on the front of the cross bar (4).

• Loosen the bolts of the clamp (3).

• Pull out the support arm.

• Install the new support arm and adjust the width as per the chapter “Adjusting the support arm width”.

• Lower the truck to the floor.

• Lift in the battery.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

5- 5

Chassis - 0000 Support arms SP10S T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

This page is intentionally left blank

5- 6

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Drive unit/drive gear – 2000 Component parts Order number 242330-040

27 26

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

6- Drive unit/drive gear – 2000

31

24 23

30 29 28

6.1 Component parts

22

25

Table 5: Components drive gear

21 20

25

19 18 17 16

15 14 13 12 11 10 9 8 7 6 5 4

39 38 37

Pos

Name

Pos

Name

1

Screw, 7 pcs

21

Rotor

2

Washer

22

Carbon brush, 4 pcs

3

Cap

23

Locking ring

4

Locking ring

24

Ball bearing

5

Ball bearing

25

Driver

6

Key

26

Screw

7

Axle

27

Connector

8

Venting nipple

28

Guide pin

9

Gear housing

29

Locking ring

10

Screw, 8 pcs

30

Stropping

11

Sealing ring

31

Brake complete

12

Gear ring

32

Gear wheel

13

O-ring

33

Locking ring

14

Ball bearing

34

Gear wheel

15

Locking ring

35

Sealing ring

16

Drive track

36

Locking ring

17

Screw, 8 pcs (20 Nm)

37

Washer

18

Locking ring

38

Ball bearing

19

Magnetic coil

39

Sealing ring

20

Key

36 4

3

35 34 33 5

2 1

32 4

© TIEE SARL

T-code 795, 675

Service Manual

SP10, SP10S, PP13

6- 1

Drive unit/drive gear – 2000 Service and repairs T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

6.2 Service and repairs 6.2.1 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.

• Assembly takes place in the reverse order.

6.2.2 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.

6- 2

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Drive unit/drive gear – 2000 Service and repairs Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

6.2.3 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.

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

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

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

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

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

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

6- 3

Drive unit/drive gear – 2000 Service and repairs T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

6.2.5 Maintenance of brakes 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.

6.2.6 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.

6- 4

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Wheel system - 3000 Castor wheel suspension SP10, SP10S Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

7- Wheel system - 3000 7.1 Castor wheel suspension SP10, SP10S 7.1.1 Components

1

2 3

4

5 6

Table 6: Components, castor wheel suspension

© TIEE SARL

Pos.

Name

Pos.

Name

1

Castor wheel, complete

4

Nut

2

Stop screw

5

Holder

3

Washer

6

Grease nipple

Service Manual

SP10, SP10S, PP13

7- 1

Wheel system - 3000 Castor wheel suspension SP10, SP10S T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

7.1.2 Lubricating the nipples The nipples should be greased regularly according to the maintenance schedule. The nipples are located above the castor wheels and are most easily accessed when the truck is placed on its side.

7.1.3 Adjusting the castor wheel pressure Table 7: Adjusting the castor wheel pressure Description 1

Pictures

The castor wheel pressure should be 40+/-10 kg. To check this, place a 3 mm high flat iron bar under the drive wheel and check that the castor wheel meets with some degree of resistance when rotated.

3 mm

7- 2

2

If the pressure is incorrect, proceed as follows: Place the truck on its side (see separate chapter on maintenance). Unscrew the nut and the stop screw.

3

Screw the entire holder clockwise for lower drive wheel pressure and counter clockwise for higher drive wheel pressure.

Ensure that the holder’s notch lines up with the stop screw.

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Wheel system - 3000 Castor wheel PP13 Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

7.2 Castor wheel PP13 5

3

2

1

4

Table 8: Components, castor wheel

© TIEE SARL

Pos.

Name

Pos.

Name

1

Castor wheel

4

Ball bearing

2

Castor wheel fork

5

Greasing nipple

3

Bush

Service Manual

SP10, SP10S, PP13

7- 3

Wheel system - 3000 Castor wheel PP13 T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

7.2.1 Lubricating the nipples The nipples are to be greased regularly according to the maintenance schedule. The nipples are located above the castor wheels and are most easily accessed via holes (A) in the chassis. See the following picture.

A

7- 4

Service Manual

A

SP10, SP10S, PP13

© TIEE SARL

Steering system – 4000 Components Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

8- Steering system – 4000 8.1 Components 1 2 3 5 4

12

6 7 8 9

10 11

Table 9: Steering system components Handle Pos. Designation 1 2

Screw Washer

3 4

Handle Screw

9 10 11 12

Switch Cylindrical roller bearing Axle Nut

Tiller arm bracket 5 6 7 8 © TIEE SARL

Tiller arm bracket Gas spring Bundling tie holder Bracket Service Manual

SP10, SP10S, PP13

8- 1

Steering system – 4000 Components T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

This page is intentionally left blank

8- 2

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 General Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9- Electrical system – 5000 9.1 General The truck's electrical system is based on the SEM-X system.

• The main power source consists of two 12 V DC traction batteries.

• The drive motor is a Separate Excitation Motor (SEM). The drive motor is controlled by an independent transistor regulator using Pulse Width Modulation (PWM).

• The lift unit motor is a standard DC motor without any external field winding connections. The electric motor in hydraulic unit is activated using a contactor.

• A set of parameters used to adjust truck performance and brake characteristics is stored in the transistor regulator. The regulator also monitors any error conditions that may appear.

9.1.1 Firmware (truck control software) The current firmware version used in the transistor regulator is V1.10.

The firmware in the transistor regulator cannot be updated or modified.

9.2 Names of parts Information in square brackets [ ] refers to the component names used in the electric wiring diagrams. See “9.3.1 Electric component overview” on page 4. {high} is a voltage level that is approximately of the same magnitude as the supply voltage level. {low} is a voltage level of approximately 0 volt. s/c = short-circuit. o/c = open circuit.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 1

Electrical system – 5000 Electric equipment list summary T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

9.3 Electric equipment list summary A2:S300-311 A2:S312-318

A2

A2:S317 A2:S321 A2:S320

S227 S226

S62

S18

A2:S321 A2:S320

OPTION AUT. HEIGHT ADJUST.

L1

A2:S317 L1

S31

Fig. 1

9- 2

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Electric equipment list summary Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

F51 F50

T-code 795, 675

S170 H81 F52 H80 S17 S21

H1 A30 A40 PTC S171 F1 A1 K30 CONS K10 X30

S10

M3 A6

A15 Y41 G1

G2 Y1 M1

Fig. 2 © TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 3

Electrical system – 5000 Electric equipment list summary T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

9.3.1 Electric component overview The table below is a summary of the most important electric components on the truck.

Table 10: Component name overview Symbol

Function

Component type

Diagram ref.

Picture ref.

Inf.

Power and shut-off of main power supply G1, G2

Main electric power source

Traction battery 12 V

Fig. 4

Fig. 2

S170

Start interlock

Interlocking device

Fig. 5

Fig. 2

K10

Main contactor

Contactor

Fig. 4

Fig. 2

S171

Secondary interlock

Auxiliary contactor switch

Fig. 4

Fig. 2

R2

Temporary supply

PTC resistor

Fig. 4

Fig. 2

2

Truck part protection F1

Drive and pump motor protection

Fuse 125 A

Fig. 4

Fig. 2

F50

A1 operation circuit protection

Fuse 5 A

Fig. 4

Fig. 2

F51

A30 battery charger protection

Fuse 10 A

Fig. 4

Fig. 2

F52

A15 battery charger protection

Fuse 20 A

Fig. 7

Fig. 2

4

Control and signal handling A1

Drive and brake power control

Transistor regulator

Fig. 4, Fig. 5

Fig. 2

A2

Truck control

Electronic board

Fig. 6

Fig. 1

A6

Detailed battery status

Display

Fig. 8

Fig. 2

S17

Key switch

Switch

Fig. 5

Fig. 2

H80

Battery status indicator

LED

Fig. 7

Fig. 2

H81

Battery status indicator (BDI)

LED

Fig. 5

Fig. 2

4 4

Safety and brakes S21

Emergency switch

Switch

Fig. 5

Fig. 2

S10

Tiller arm in drive position

Switch

Fig. 5

Fig. 2

A2:S317

Emergency reverse

Hall sensor

-

Fig. 1

Y1

Mechanical brake

Electromagnetic brake

Fig. 4

Fig. 2

H1

Warning signal

Horn

Fig. 6

Fig. 2

S18

Horn actuation

Switch

Fig. 6

Fig. 1

S62

Horn actuation

Switch

Fig. 6

Fig. 1

9- 4

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Electric equipment list summary Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Table 10: Component name overview Symbol

Function

Component type

Diagram ref.

Picture ref.

Inf.

L1

Speed control and travel direction selector (toggle switch)

Lever

-

Fig. 1

1

A2:S300-318

Speed control

Hall sensor

-

Fig. 1

M1

Driving

Motor

Fig. 4

Fig. 2

Driving

Lifting/lowering of forks S31

Lift height limiter

Switch

Fig. 6

Fig. 1

A2:S320

Fork lifting control

Hall sensor

-

Fig. 1

A2:S321

For lowering control

Hall sensor

-

Fig. 1

Y41

Fork lowering – hydraulic control

Magnetic valve

Fig. 4

Fig. 2

K30

Fork lifting (pump motor activation)

Contactor

Fig. 4

Fig. 2

M3

Pump motor

Motor

Fig. 4

Fig. 2

5

Automatic height adjustment A40

Automatic height adjustment control

Electronic board

Fig. 12

Fig. 2

4

H97

Automatic height adjustment indication

Lamp

Fig. 12

Fig. 1

4

S22

Emergency switch

Switch

Fig. 12

Fig. 1

4

S32

Stopping lowering of forks when forks < 15 cm

Magnetic switch

Fig. 12

Fig. 1

4

S33

Stopping lifting of forks when forks are in top position

Magnetic switch

Fig. 12

Fig. 1

4

S225

Detection of correct load height

Photocell

Fig. 12

Fig. 1

4

S226

Fork lifting control

Switch

Fig. 12

Fig. 1

4

S227

Fork lowering control

Switch

Fig. 12

Fig. 1

4

A15

Battery charging on lorry

Battery charger

Fig. 7

Fig. 2

4

A30

Onboard truck battery charging

Battery charger

Fig. 6

Fig. 2

CONS

Hand-held terminal connector

Adapter

-

Fig. 2

X30

Flexible lead connector

Miscellaneous

3

Fig. 2

Footnotes to the table above:

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 5

Electrical system – 5000 Electric equipment list summary T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

1 – L1 refers only to the physical control device (toggle switch). There is no explicit reference to this device in the system's electric wiring diagrams.

2 – This switch is installed directly on the main contactor. It is activated with the contactor opens or closes.

3 – For more information on the hand-held terminal, see “9.9.8 Handheld terminal” on page 37.

4 – Option.

5 – Only PP13.

9- 6

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Access to the main electric panel Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9.4 Access to the main electric panel Access to the main electric panel - Fig. 3 B is required in case one of the following procedures needs to be performed: • Checking the alarm status using the LEDs. • Connecting the hand-held terminal to the transistor regulator.

• Checking/replacing fuses.

• Checking/replacing components mounted on the panel.

• Inspecting the drive motor or hydraulic unit.

A

B

NOTE: Before removing the electric panel, make sure the key switch [S17] has been switched off and the mains plug of the charger has been disconnected from the start interlocking device [S170] and the wall outlet. To ensure maximum safety, disconnect the minus terminal from the battery [G2].

• Remove the screws securing the main cover (Fig. 3 A) and remove the cover from the truck.

Fig. 3 Access to the electric panel

• Remove the two mounting screws securing the main electric panel (Fig. 3 B).

• Lift the panel straight up approx. 1 cm.

• The upper edge of the panel can now be lifted away from the truck, allowing the panel to ”swing out”. Swing out the panel to allow it to ”rest” in this position.

• Check to make sure no cables in the wiring harness are subject to unnecessary strain.

Fig. 1 Electric panel ”swung out” © TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 7

Electrical system – 5000 Electric circuit overview T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

9.5 Electric circuit overview 1

A30

ONBOARD CHARGER A/C IN.40 9 F51

F50

20

21 S21

1

K10

OPTION AUTO H. ADJ.

PTC (R2)

F1

S170

S22

G1 23

G2

H81 BK BK RD

F52 POWER INP.

22

RD BK

S10

OUT.BATT.IND 59

INP.KEY SWITCH

S17

K10 OUT.NEG.MAIN CONTACTOR 42 INP.SUPPLY MAIN CONTACTOR 23 3 + BATT

A15 LORRY CHARGER

M1 A1

H80 BU RD BK

OUT.FIELD 1

A1

4

E1

M S

A2

E2

OUT.FIELD 2 5 6 ARMATURE

OPTION

S171(K10)

S18

OUT.NEG K30/Y41

H1 57

INP.LOWER

INP.LIFT

34

33

51 INP.SPEED CONTROL. 6 53 INP.DRIVE STEERED WHEEL DIR. 54 - BATT 40 INP.DRIVE FORK DIR. 55 INP.BELLY BUTTON 41 31 INP.TILLER SWITCH OUT.NEG.MAG.BRAKE

22 +24 VDC 40 0 VDC

A2

M3 A2

K30

43

S62

8 A1 M

Y41

TRUCK WITHOUT MAST

OPTION

S31

A6

DISPLAY Y1

31 34 35 AUT. HEIGHT ADJUSTMENT OPTION ON TRUCK WITH MAST

134 34 LOWER LOWER 35 135 PUMP LIFT 22 24 VDC 200 PHOTO CELL 202 24 VDC 203 AUTO UP REQ.

201 S225

204 S226

205 S32

207 H97

S227

A40

FORKS <150 MM

INP.TILLER ARM 31 208 LIFT LIMIT AUTO S33 40 0 VDC 201 AUTO ENABLED

Based on 232993 rev. E 9- 8

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Symbol list Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9.6 Symbol list Table 11: Symbol list Symbol

A1

E1

M S

Description

Symbol

Description

Truck battery

Horn

Fuse

Emergency stop switch, NC

PTC resistora

Switch, key operated, NO

DC motorb (SEM type)c

Micro-switch, NO

DC motor

Micro-switch (pushbutton), NO

Contactor

Switch (with coil), NC

Brake coil (usually active)

Hydraulic-magnetic valve coil

Terminal

LED

Switch with photocell, NC

Magneto switch, NO

A2

E2

Lamp

NO = Normally Open NC = Normally Closed

a. PTC = Positive Temperature Coefficient (resistance increases as temperature increases) b. DC = Direct Current

c. SEM = Separate Excitation Motor © TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 9

9- 10

Service Manual

SP10, SP10S, PP13

1

43

A2

K10

A1

1

F1

125A

1

A2

K30 A1

2

-

-

43

PUMP MOTOR M3 8 A1 A2 M

+

G2

14

13

X31

S171

F2

A1

1

Y1 2

FIELD

M

M1

F1

A2

X31

A2

A10

33

A15

23

43

A14

A4

31

42

A11

F2

F1

VMN

INP, LIFT

1/6 PROD A 232993

OUT, NEG, PUMP CONTACTOR/LOWER VALVE

IN, SUPPLY, MAIN CONTACTOR

OUT, NEGATIVE, MAIN CONTACTOR

INP, TILLER SWITCH

OUT, NEGATIVE, MAGNETIC BRAKE

FIELD WINDING

FIELD WINDING

ARMATURE WINDING

+ BATT INP. POWER SUPPLY 24VDC

- BATT INP. POWER SUPPLY 0VDC

41

5

4

6

3

40

Fig. 4

33

2

LOWER VALVE Y41

2

R2

PTC

+

G1

Date 2006-09-29

Sh.3

23

31

34

40

BK

F51

1

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Sh.2

Sh.2

Sh.2

Sh.3

Sh.5

Sh.5

RD

9

10A

5A

F50

T-code 795, 675

Sh.4

Sh.2

20

ELECTRONIC CARD A1

Electrical system – 5000

Electric wiring diagram Order number 242330-040

9.7 Electric wiring diagram

© TIEE SARL

© TIEE SARL

Service Manual

SP10, SP10S, PP13

Sh.1 3

Sh.3

Sh.3

A7

54

55

34

54

55

34

A13

A5

A6

53

53

X30

A12

A1

NO

59

A16

51

COM

TILLER SWITCH S10

H81

22

51

22

X30

NOTE: WHEN ONBOARD LORRY OPTION; CONNECT RECEPTACLE 23:A TO START INTERLOCK AND TAB 23:B TO CABLE 23.

1

INP, LOWER

INP, BELLY BUTTON.

2/6 PROD A 232993

INP, DRIVE, FORK DIRECTION.

INP, DRIVE, STEERED WHEEL DIRECTION.

INP, WIPER, DRIVE POT.

OUT, BATTERY INDICATOR

INP, 24VDC KEY SWITCH

Fig. 5

Sh.3

Sh.3

Sh.3

31

23

23:B

23:A

PLUG:B

2

KEY S17

Date 2006-09-29

Sh.1

Sh.1

Sh.5

Sh.5

Sh.4

Sh.4

(*)

23

Order number 242330-040

PLUG:A

EMERGENCY SWITCH OFF S21 START INTERLOCK 20 (*) 21 Sh.1 1 2 S170

ELECTRONIC CARD A1

Electrical system – 5000 Electric wiring diagram

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13) T-code 795, 675

9- 11

9- 12

Service Manual

SP10, SP10S, PP13 NC

X30

53

54

X30

54

53

51

X30

51

35

34

X30

X30

JUMPER, SP10/SP10S

COM

34

33

A2:8

A2:7

A2:4

A2:3

A2:2

A2:1

A2:6

A2:5

3/6 PROD A 232993

OUT. DRIVE WHEEL DIRECTION

OUT. DRIVE FORK DIRECTION

OUT. SPEED REF. VALUE

OUT. LOWER

OUT. LIFT

OUT. BELLY BUTTON

INP. 0V DC

INP. +24V

Date 2006-09-29

Sh.2

Sh.2

Sh.2

COM

55

S62

X30

NO

55

57

40

X30

COM

X30

LIFT LIMIT, PP13 S31

RD

S18

22

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Sh.2

Sh.1

Sh.2

BK

H1

NO

X30

40

22

T-code 795, 675

Sh.1 4

Sh.2

ELECTRONIC CARD TILLER ARM A2

Electrical system – 5000

Electric wiring diagram Order number 242330-040

Fig. 6

© TIEE SARL

Electrical system – 5000 Electric wiring diagram Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

© TIEE SARL

Service Manual

4/6 PROD A 232993 INP, GROUND

INP, MAINS VAC PLUG:B

SP10, SP10S, PP13

Sh.2

INP, MAINS VAC PLUG:A Sh.2

OUT, NEGATIVE CHARGER VOLTAGE 40 Sh.3

40

OUT, POSITIVE CHARGER VOLTAGE 9 9 Sh.1

ONBOARD CHARGER A30

Fig. 6

T-code 795, 675

9- 13

9- 14

Service Manual

SP10, SP10S, PP13

Sh.2

+

OUT, GND, LED INDICATOR

5/6 PROD A 232993

OUT, +24VDC, LED INDICATOR

OUT, TRUCK DISABLE RELAY CONTACT

INP, TRUCK DISABLE RELAY CONTACT

Date 2006-09-29

BU

RD

BK

23:B H80

BK

INP, HOSTING VEHICLE NEHATIVE

INP, HOSTING VEHICLE POSITIVE

OUT, NEGATIVE CHARGER VOLTAGE

OUT, POSITIVE CHARGER VOLTAGE

Fig. 7

23:A

BK

RD

BK

RD

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Sh.2

2-

1-

2+

1+

POWER INP. CONNECTOR

BK

20A

F52

CHARGER/BOOSTER ONBOARD LORRIES A15

T-code 795, 675

Sh.1

Sh.1

RD

OPTION

Electrical system – 5000

Electric wiring diagram Order number 242330-040

© TIEE SARL

Electrical system – 5000 Electric wiring diagram Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

NCLRXD 106 106

B2

PCLTXD 105 105

B3

NCLTXD 104 104

B4

+12VDC SUPPLY VOLTAGE 103 103

B6

GND 102 102

B5

PCLRXD B1

101 101 1

2

3

4

5

6

GND

12VDC SUPPLY VOLTAGE

NCLTXD

PCLTXD

NCLRXD

DISPLAY; MDI A6

PCLRXD

OPTION

ELECTRONIC CARD A1

6/6 PROD A 232993

Fig. 8

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 15

9- 16

Service Manual

SP10, SP10S, PP13

F51

10A

5A

F50

2

1

LOWER VALVE Y41 43

1

A2

K10

A1

2

PTC

R2

1

F1

125A

+

G1

1

A2

K30 A1

2

-

-

43

14

13

PUMP MOTOR M3 8 A1 A2 M

+

G2

X31

S171

F2

A1

1

Y1 2

FIELD

M

M1

F1

A2

X31

35

43

23

42

31

41

5

4

6

3

40

A10

A2

A15

A14

A4

A11

F2

F1

VMN

INP, LIFT

1/6 PROD A 233150

OUT, NEG, PUMP CONTACTOR/LOWER VALVE

IN, SUPPLY, MAIN CONTACTOR

OUT, NEGATIVE, MAIN CONTACTOR

INP, TILLER SWITCH

OUT, NEGATIVE, MAGNETIC BRAKE

FIELD WINDING

FIELD WINDING

ARMATURE WINDING

+ BATT INP. POWER SUPPLY 24VDC

- BATT INP. POWER SUPPLY 0VDC

Fig. 9

35

2

20

Date 2006-09-29

Sh.4

23

31

34

40

1

S21

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Sh.2

Sh.2

Sh.2

Sh.3

9

21

T-code 795, 675

Sh.5

Sh.4

ELECTRONIC CARD A1

Electrical system – 5000

Automatic height adjustment Order number 242330-040

9.8 Automatic height adjustment

© TIEE SARL

© TIEE SARL

Service Manual

SP10, SP10S, PP13

Sh.1 4

Sh.3

Sh.3

A6

A7

A5

A13

54

55

34

54

55

34

A12

53

59

53

X30

H81

A1

NO

1

A16

51

COM

TILLER SWITCH S10

2

22

51

22

X30

23

INP, LOWER

INP, BELLY BUTTON.

2/6 PROD A 233150

INP, DRIVE, FORK DIRECTION.

INP, DRIVE, STEERED WHEEL DIRECTION.

INP, WIPER, DRIVE POT.

OUT, BATTERY INDICATOR

INP, 24VDC KEY SWITCH

Fig. 10

Sh.3

Sh.3

Sh.3

31

23

PLUG:B

S170

START INTERLOCK

Date 2006-09-29

Sh.1 4

Sh.1

Sh.5

PLUG:A

221

ELECTRONIC CARD A1

Order number 242330-040

Sh.5

Sh.4

KEY S17

Electrical system – 5000 Automatic height adjustment

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13) T-code 795, 675

9- 17

9- 18

Service Manual

SP10, SP10S, PP13

51

54

53

X30

X30

X30

51

54

53

134

X61

134

A2:8

A2:7

A2:4

A2:3

A2:2

A2:1

A2:6

Fig. 11 3/6 PROD A 233150

OUT. DRIVE WHEEL DIRECTION

OUT. DRIVE FORK DIRECTION

OUT. SPEED REF. VALUE

OUT. LOWER

OUT. LIFT

OUT. BELLY BUTTON

INP. 0V DC

INP. +24V

Date 2006-09-29

Sh.2

Sh.2

Sh.2

135

X61

135

COM

55

S62

X30

NO

55

57

A2:5

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Sh.4

Sh.4

Sh.2

X30

COM

40

RD

S18

22

X30

BK

H1

NO

X30

40

22

T-code 795, 675

Sh.1 4

Sh.2 4

ELECTRONIC CARD TILLER ARM A2

Electrical system – 5000

Automatic height adjustment Order number 242330-040

© TIEE SARL

© TIEE SARL

Sh.1

Sh.2

Service Manual

Sh.2

Sh.1

RD/YE

GN/WH

X60

X60

21

X2

H97

BN

BU

201

221

SP10, SP10S, PP13 COM

COM

X1

S227

S226

NC

NO

NC

NO

X61

X61

X61

X61

X61

40

X62

X62

1

S225 4

BK

2

X60

207

204

1

1

S33

S32

2

X60

X62

X62

16

9

201

8

18

17

12

13

2

10

14

1

15

3

11

208

206

205

203

202

200

135

40

135

X61

134

X30

35

134

40

X61

X30

35

34

31

X61

X61

22

X61

X30

X30

34

31

22

4/6 PROD A 233150

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

OUT. AUTO ENABLED

INP. LIFT LIMIT AUTO MODE

INP. AUTO LOWER REQ.

INP. FORKS <150MM

INP. AUTO UP REQ.

OUT. 24VDC TO SWITCHES

INP. PHOTO CELL

INP. LIFT FORKS

INP. LOWER FORKS

INP. 0VDC

OUT. PUMP CONTACTOR

OUT. LOWER VALVE

INP. TILLER ARM SWITCH

INP. 24VDC

Date 2006-09-29

Sh.3

Sh.3

Sh.3 5

Fig. 12

Sh.2

Sh.3

Order number 242330-040

3

ELECTRONIC CARD A40

Electrical system – 5000 Automatic height adjustment T-code 795, 675

9- 19

Electrical system – 5000 Automatic height adjustment T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

9- 20

Service Manual

5/6 PROD A 233150 INP, GROUND

INP, MAINS VAC PLUG:B Sh.2

INP, MAINS VAC PLUG:A

SP10, SP10S, PP13

Sh.2

OUT, NEGATIVE CHARGER VOLTAGE 40 40 Sh.4

OUT, POSITIVE CHARGER VOLTAGE 9 9 Sh.1

ONBOARD CHARGER A30

Fig. 13

Order number 242330-040

© TIEE SARL

Electrical system – 5000 Automatic height adjustment Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

NCLRXD B2

106 106

PCLTXD B3

105 105

NCLTXD B4

104 104

+12VDC SUPPLY VOLTAGE B6

103 103

GND B5

102 102

PCLRXD B1

101 101 1

2

3

4

5

6

GND

12VDC SUPPLY VOLTAGE

NCLTXD

PCLTXD

NCLRXD

DISPLAY; MDI A6

PCLRXD

OPTION

ELECTRONIC CARD A1

6/6 PROD A 233150

Fig. 14

© TIEE SARL

Service Manual

SP10, SP10S, PP13

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Electrical system – 5000 Functional description T-code 795, 675

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Date 2006-09-29

Order number 242330-040

9.9 Functional description 9.9.1 Operating principle This section uses tables to describe the basic principles of main truck functions. The table briefly describes what happens when one of the main truck functions operates.

• Event – The main operating steps for the main truck functions are referred to as ”events”. Each separate event is numbered.

• Prior event – Indicates the event number that must have taken place immediately prior to the current event in order for this to operate correctly.

• Measure(s) – One or more necessary interventions by the operator required to execute the event.

• Influencing elements – Conditions that must be fulfilled in order for an event to occur. The result of the event may also be influenced by specific parameter settings.

• Resulting conditions – These describe important occurrences that can be checked to verify that a function operates as it is supposed to.

• Logic – Indicates the logic relationship between input data and output data for a specific event.

Please note that ”resulting conditions” indicate what is expected when an error state is not present.

9- 22

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Table 12: Operating principle Event:

1. Connection of battery

Prior event

-

Measure(s)

Connect the mains plug from the charger [A30] to the start interlocking unit [S170].

Influencing elements

Operation circuit fuse OK [F50].

Emergency stop switch not depressed [S21].

Resulting conditions

Truck is ready for switch-on.

Quick test: Depress the horn button [S18]/[S62]! The horn should sound.

Event:

2. Switch-on

Prior event

1

Measure(s)

Turn the key switch [S17].

Influencing elements

[A1:INP 24VDC KEY SWITCH] input {high}.

Tiller arm switch not activated [S10], [A1:INP TILLER SWITCH] input {low}.

Lift/lowering switches not active, [A1:INP.LIFT] and [A1:INP.LOWER] inputs {low}.

[L1] in neutral position.

Resulting conditions

Battery status indicator [H81] lights up for 2 seconds and then goes out.

This indicates that the battery charge level > 60%.

Main contactor [K10] remains in open position, [A1:OUT.NEG.MAIN CONTACTOR] {high} The mechanical brake is applied, [Y1, A1:OUT.NEGATIVE MAGNETIC BRAKE] {high} Truck is ready for operation.

Event:

3. Tiller arm lowered for driving

Prior event

2

Measure(s)

Lower the tiller arm handle.

Influencing elements

Tiller arm switch [S10].

Main contactor [K10] Secondary interlocking device [S171].

Resulting conditions

Tiller arm switch [S10] active.

[A1:INP TILLER SWITCH] input {high}.

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

Main contactor [K10] closes and auxiliary switch [S171] closes.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

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Date 2006-09-29

Order number 242330-040

Table 12: Operating principle Event:

4. Driving in the fork direction

Prior event

3

Measure(s)

Set the toggle switch [L1] to the fork direction travel position.

Influencing elements

Fuse [F1].

Toggle switch [L1].

Battery charge level (can limit the maximum travel speed).

Lifting/lowering of forks (limits the maximum travel speed if used during truck travel).

Resulting conditions

[A1:DRIVE FORK DIRECTION] input goes {high}.

[A2] feeds DC voltage to [A1:SPEED CONTROL] input (1-10 V).

[A1:OUT. NEG. MAGNETIC BRAKE] goes {low}.

Brake coil [Y1] is activated, and the mechanical brake is released.

Current fed to traction motor field winding (F1 +ve and F2 -ve).

Pulsating current feed to the drive motor armature in proportion to the inclination of the toggle switch [L1].

Event:

5. Driving in the drive wheel direction

Prior event

3

Measure(s)

Set the toggle switch [L1] to the drive wheel direction travel position.

Influencing elements

Fuse [F1].

Toggle switch [L1].

Battery charge level (can limit the maximum travel speed).

Use of fork lifting (limits the maximum travel speed if used during truck travel).

Resulting conditions

[A1:DRIVE STEERED WHEEL DIRECTION] input goes {high}.

[A2] feeds DC voltage to [A1:SPEED CONTROL] input (1-10 V).

[A1:OUT. NEG. MAGNETIC BRAKE] goes {low}.

Brake coil [Y1] is activated, and the mechanical brake is released.

Current fed to traction motor field winding (F1 -ve and F2 +ve).

Pulsating current feed to the drive motor armature in proportion to the inclination of the toggle switch [L1].

Event:

6. Neutral braking

Prior event

4 or 5

Measure(s)

Let the toggle switch [L1] return to the neutral position while the truck is moving.

Influencing elements

Parameter settings [RELEASE BRAKING].

Resulting conditions

The traction motor [M1] acts as a generator, which converts the truck's kinetic energy into electrical energy via the transistor regulator [A1], thus reducing the travel speed. The brake force depends on a parameter setting.

The mechanical brake [Y1] is activated when the truck comes to a standstill. [A1:OUT. NEG. MAGNETIC BRAKE] goes {high}.

9- 24

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Table 12: Operating principle Event:

7. Inversion brake

Prior event

4 or 5

Measure(s)

Set the toggle switch [L1] to the opposite travel direction.

Influencing elements

Parameter settings [INVERSION BRAKING].

Resulting conditions

The traction motor [M1] acts as a generator, which converts the truck's kinetic energy into electrical energy via the transistor regulator [A1], thus reducing the travel speed. The brake force is proportional to the inclination of the toggle switch. The mechanical brake [Y1] is activated when the truck comes to a standstill. [A1:OUT. NEG. MAGNETIC BRAKE] goes {high}.

Event:

8. Using the mechanical brake

Prior event

4 or 5

Measure(s)

Set the tiller arm to the top or lower position.

Influencing elements

Tiller arm switch [S10].

Resulting conditions

[A1:INP TILLER SWITCH] input goes {low}.

Brake coil [Y1] is deactivated, and the mechanical brake is applied.

Event:

9. Fork lifting

Prior event

2

Measure(s)

Depress the fork lift button.

Influencing elements

Fuse [F1].

Main contactor [K10] Fork lift button.

Secondary interlocking device [S171].

Battery charge level status.

Resulting conditions

[A1: INP.LIFT] goes {high}.

The pump contactor [K30] is activated.

The pump motor [M3] starts.

Event:

10. Lowering forks

Prior event

9

Measure(s)

Depress the fork lowering button.

Influencing elements

Main contactor [K10] Fork lowering button.

Secondary interlocking device [S171].

Resulting conditions

[A1:INP.LOWER] goes {high}.

The magnetic valve - fork lowering [Y41] is activated.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

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Date 2006-09-29

Order number 242330-040

9.9.2 Transistor regulator

1

B 1

2

3

4

6

5

7

8

B F1 1

A 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

A F2

AL

ALARM B+

Fig. 15 SEM-X transistor regulator

B-

VMN

General The ZAPI SEM-X transistor regulator controls the drive motor. Using pulse width modulation (PWM, it adjusts the revolutions by varying the armature voltage. At the same time, the activation time of the MOS transistors used to adjust the armature current is varied.

The travel direction of the truck changes by switching the polarity in the field winding (F1-F2). The regulator is fitted with a four-quadrant transistor bridge and a single-quadrant transistor bridge for the armature winding.

A status LED (Fig. 15 AL) is used to indicate possible error conditions that may have occurred.

Fig. 15 B shows the connector for the hand-held terminal.

NOTE: To check the alarm status LED or gain access to the connector for the hand-held terminal, the main electric panel must be swung open. See “9.4 Access to the main electric panel” on page 7.

Safety The regulator is a heavy-current 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, removing watches and jewellery, and only using insulated tools. Other measures may also become necessary.

WARNING! Risk of short-circuiting.

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

9- 26

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Table 13: Transistor regulator connections Pin

Ref.

Description

A

Signal check connector

A1

CPOT

Input signal from cable 51 from [A2]

A2

NLIFT

Connector for internal noise suppression/protective components

A3

PPOT

Not used

A4

TILLER

Input signal from tiller arm switch [S10], active when high (B+)

A5

BELLY

Input signal from cable from [A2], which is used for instant reversal of travel direction, active when high (B+). 3K3 to B+ when not operated.

A6

FW

Input signal from cable 53 from [A2] for driving in the drive wheel direction, active when high (B+)

A7

REV

Input signal from cable 54 from [A2] for driving in the fork direction, active when high (B+)

A8

H&S

Reserved for future use

A9

NPOT

Not used

A10

PLIFT

Input signal from cable 33 from [A2] for fork lifting

A11

NEB

Output for electromagnetic brake coil [Y1], 1.5 A continuous, protected against short-circuits

A12

NLED

Output for powering the battery status LED [H81], max. 100 mA.

A13

PEVD

Input signal from cable 34 from [A2] for fork lowering

A14

NMC

Output for main contactor coil [K10], 1.0 A continuous, protected against short-circuits

A15

PMC

Connector for noise suppression of main contactor [K10]

A16

KEY

Transistor regulator control voltage, input signal from key switch [S17]

B

Hand terminal connector

B1

--

B2

NCLRXD

-”-

B3

PCLTXD

-”-

B4

NCLTXD

-”-

B5

GND

-”-

B6

+12

-”-

B7

--

-”-

B8

--

Voltage connections +B

Positive feed from battery

-B

Negative feed from battery

VMN

Negative feed (via controller) to motor

F1, F2

Connectors for drive motor field winding

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 27

Electrical system – 5000 Functional description T-code 795, 675

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Date 2006-09-29

Order number 242330-040

9.9.3 Battery charging on-board the truck (machine number 947624-) The trucks are fitted with: • Valve-regulated traction gel batteries with increased battery capacity • Charger with improved charger status display NOTE: If only the charger is replaced (and not the cabling), the mains connection must be modified. See the instructions supplied with the charger.

The new batteries have the same characteristics as the previous batteries and as such can be used with previously delivered SP10, SP10S and PP13 trucks.

c

Charging The batteries should be charged when the LED [H81] (C) starts blinking. If charging is not performed and truck operation continues, the LED will eventually light continuously, and the truck's travel speed will be reduced in two steps. Please note that in the second step, the truck will hardly move. In this case, perform charging until the green LED on the charger lights.

Charging for a minimum of 30 minutes is more gentle to the batteries and will not shorten the battery service life. However, it is necessary to charge the truck batteries over night at least once a week or until the green LED on the charger lights.

NOTE: If the old charger is used to charge the new batteries, charging could last one or two hours longer depending on the degree of battery discharge.

Always be sure to switch off the truck prior to battery charging by turning the start key to the 0 position and removing the key.

A

B

1. Disconnect the charging plug (A) from the truck’s start prevention device.

2. Pull out the flexible cable and connect it to a wall outlet. Charging of the truck batteries starts automatically.

- When main charging is in progress, only a yellow LED lights on the charger. The LEDs on the charger can be seen through the mains lead hole in the truck’s electric panel.

- When main charging is complete, the yellow LED continues to light while a green LED on the charger also lights up. This indicates equalising charging.

- When equalising charging is complete, the yellow LED goes out and only the green LED remains lit. This indicates the truck is ready for use.

3. Return the flexible cable and reconnect the charging plug to the truck's start prevention device.

9- 28

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Technical data

© TIEE SARL

Batteries and chargers

Value

Battery capacity

63 Ah

Battery charger

8A

Voltage

2x12 V

Battery weight

2x23 kg

Service Manual

SP10, SP10S, PP13

9- 29

Electrical system – 5000 Functional description T-code 795, 675

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Order number 242330-040

Alarm indications on charger See the table below regarding the various alarm indications that may appear during battery charging.

Red

Yellow Green

Reason Mains lead not connected Time limit exceeded. Incomplete charging.

High battery voltage. Charging interrupted.

High battery voltage. Charging interrupted (option).

High battery voltage. Charging interrupted (option).

High charger temperature. Reduced charging current.

Battery not connected.

Low battery voltage. Low phase of current.

Low charger temperature or sensor error.

Maximum Ah limit exceeded.

High battery temperature (option).

Low battery temperature or low temperature sensor error (option).

Defective charger Very low battery voltage. Pulse charging.

Explanation of symbols: = Off 9- 30

Service Manual

= On SP10, SP10S, PP13

= Blinking © TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9.9.4 Battery charge level status The battery status LED [H81] indicates the remaining battery charge level in the batteries.

Table 14: Battery charge level status LED [H81] condition

Energya

Battery capacityb

Off

> 45% energy remains

> 60% charging remains

Blinks

< 45% energy remains

< 60% charging remains

Lit

< 15% energy remains

< 40% charging remains

a.Energy that can be consumed from the battery. b.Battery capacity according to the hand-held terminal. If the battery capacity becomes less than 30%, the battery service life will become shorter.

Battery display (option) As an option, more detailed monitoring of the battery charge level is available. The battery display is connected to the hand-held terminal connector [CONS] on the transistor regulator [A1].

The display (Fig. 16) has four green LEDs and a red LED that indicate the battery charge level according to the table below.

Fig. 16 Battery display (option)

Table 15: Battery display LEDs Energya

Battery capacityb

LEDs

100 %

100 %

4 green LEDs

60%

70%

3 green LEDs

45%

60%

2 green LEDs

30%

50%

1 green LED

15%

40%

1 green LED blinks (time for battery charging)

5%

35%

1 red LED

0%

30%

1 red LED + reduced speed

-

25%

1 red LED + extremely slow speed

a.Energy that can be consumed from the battery. b.Battery capacity according to the hand-held terminal. If the battery capacity becomes less than 30%, the battery service life will become shorter.

NOTE: The battery display is only updated when the drive motor is operating.

This implies that the remaining charge level can be indicated as high if only the lift motor has been used for some time (without the truck moving). © TIEE SARL

Service Manual

SP10, SP10S, PP13

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Order number 242330-040

9.9.5 Built-in charger for charging on a lorry PP13 General The truck can be fitted with an additional charger for charging the batteries on a lorry with a 24 V electric system.

This means that it is not necessary to have access to a 230 V outlet every day, since this charging on a lorry can boost the truck operating time even if the travel time between different loading/unloading points is only 15-20 minutes.

Keep in mind that this kind of charging is merely a supplement and does not replace charging via the 230 V mains. The batteries should be charged on the 230 V mains for minimum 10 hours at least once a week or whenever the battery indicator indicates the need for charging.

The battery of the lorry is given highest priority during charging, and the battery of the forklift truck is only charged while the lorry is driving.

The charger has a start limit switch that prevents operation of the forklift truck while charging. To prevent overheating the batteries and in order to optimise charging at varying environmental temperatures, the charger features a temperature compensation circuit.

This option includes a connection cable for connection to the lorry's rear platform lift.

NOTE: For correct operation, it is important that the installation is made according to the instructions of the supplier.

Installation recommendations for the “connection point” on a lorry • In order for this option to work, a connection point protected by a fuse on the lorry is required.

• The connection point must be of high standard, e.g. voltage supply to the rear platform lift or another connector with a min. cable dimension of 16 mm2.

• Be sure to connect a 20 A fuse for the voltage supply line of the connection point, as close as possible to the lorry battery.

• Also ensure that the connection point and cable have sufficient mechanical protection.

• A sealed connection box or similar is ideal as a connection point, to which the supplied cable can be connected.

9- 32

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Installation on the truck Install the lorry charger according to instruction drawing 219205. See the pictures below.

23112 (2x) 218353 218856 29918 (2x)

218068 42322 (4x) 22006 (4x) 20235 (4x) 21307 (8x)

© TIEE SARL

Service Manual

SP10, SP10S, PP13

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Electrical system – 5000 Functional description T-code 795, 675

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Date 2006-09-29

Order number 242330-040

Note: 1: • Disconnect cable 23 from the start protection device and connect to the contact housing on the harness from the lorry charger.

• Connect the cable with the 4.8 sleeve from the lorry charger to the start prevention device.

• Strap the harness with the standard harness.

Note: 2: • Disconnect the yellow rubber plug on the electric panel.

• Install the yellow indicator lamp on the electric panel, and connect the red cable from the lorry charger to the brass coloured pin on the indicator lamp.

Not. 2

9- 34

Service Manual

SP10, SP10S, PP13

Not. 1

© TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Charging Connect the connection cable from the lorry to the terminal (A) on the truck. Charging automatically starts when the voltage level from the lorry reaches 25.5 V.

A

Troubleshooting • Check whether the charger receives line voltage.

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

• Check whether the charger is overheated.

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

Technical data Charging voltage Charging current Temperature compensation Start prevention device Charging start point Charging interruption point Cable dimension

© TIEE SARL

Service Manual

28,4 V 8 - 15 A YES YES 25,5 V 24,8 V 4 x 2.5 mm2

SP10, SP10S, PP13

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9.9.6 Limiting the travel speed The maximum travel speed of the truck is limited depending on several different, interacting conditions: • Load and remaining battery capacity.

• Whether or not the lifting function is used.

• The transistor regulator temperature.

• Too long use after receiving the service warning message.

• The parameter settings can also be used to affect the maximum travel speed.

See Parameter list on page 48 for more information. The table below summarises the travel speed limits. The values are presented on the assumption that all relevant parameters have been set to 100%. Please note that the indicated speeds are nominal. If a combination of limiting conditions exists, the lowest speed will be applied.

Table 16: Summary of travel speed limits Remaining energy in battery [H81]

Lifting status

Transistor regulator temperature °C

Operating hours after service warning

Max. speed km/h

>30%

Off

< 75

< 10

5.4

On

3.2 > 75

3.2

< 30%

-

-

-

2.2

-

-

-

>10

1.6 a

-

-

-

> 20

0b

a.Depends on the parameter settings. See Select service warning type (CHECK UP TYPE) on page 49. b.Depends on the parameter settings. See Select service warning type (CHECK UP TYPE) on page 49.

9.9.7 Hour meter modes

Fig.

17

H

Operating

The truck controller stores the number of operating hours (drive motor).

Alternatively, a "time to next service" counter can be activated. When this counter reaches the value for ”service required”, the transistor regulator sounds a signal and the battery status LED [H81] starts blinking continuously.

The actual number of operating hours can be checked by connecting the hand-held terminal. Operating hours are displayed as in Fig. 17 ”H”

9- 36

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9.9.8 Hand-held terminal General The hand-held terminal is required for the following tasks: • Changing parameters stored in the transistor regulator.

• Uploading and downloading parameter settings to or from the transistor regulator.

• Displaying errors and diagnostic information.

• Performing calibrations.

A

Fig. 18 Hand-held ter-

Connecting the hand-held terminal Connect the hand-held terminal as follows: • Check that the key switch has been switched off [S17].

• Swing out the main electric panel See “9.4 Access to the main electric panel” on page 7.

• Connect the hand-held terminal connector (Fig. 18 A) to the diagnostic connector on the transistor regulator (Fig. 15 B).

• Switch on the key switch [S17].

Hand-held terminal overview The hand-held terminal uses an alphanumeric display (Fig. 19 A) and six operation buttons.

© TIEE SARL

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SP10, SP10S, PP13

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Order number 242330-040

A

B

E

D

C

Fig. 19 Hand-held terminal overview When the hand-held terminal is connected and the key switch is switched on, the following is displayed: First the hand-held terminal version is displayed.

Connection confirmation to a SEM-X transistor regulator and the firmware version.

A

A - The transistor regulator's firmware version.

B - Voltage supply.

C - The transistor regulator's rated current.

B

C

D

D - The hour meter.

• Press ENTER (Fig. 19 C) to display the first menu.

• It is possible to scroll through the menus by repeatedly pressing the ROLL buttons (Fig. 19 B).

• Press OUT (Fig. 19 D) to leave the selected menu.

• The PARAM SET buttons (Fig. 19 E) are used to adjust the parameter values.

9- 38

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Functional description Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Hand-held terminal menus OUT

SEM-X 24v

75A

V..

00000

Initial display on hand-held terminal

ENTER

*

MAIN MENU * PARAMETER CHANGE

Menu to change or set parameters

ROLL *

MAIN MENU STEER TABLE

*

This menu is not applicable

ROLL *

MAIN MENU PROGRAM VACC

*

Menu for calibrating the speed controller potentiometer [R1]

ROLL *

MAIN MENU ALARMS

*

Menu for displaying the error history

*

Menu for downloading parameter settings from the hand-held terminal to the transistor regulator

*

Menu for uploading parameter settings from the transistor regulator to the hand-held terminal

*

Menu for diagnostic functions

ROLL *

MAIN MENU RESTOR PARAM. ROLL

*

MAIN MENU SAVE PARAM. ROLL

*

MAIN MENU TESTER ROLL

Proceed as follows to open one of the main menus: • Press ENTER from the initial display and...

• Repeatedly press ROLL until the desired menu is displayed...

• then press ENTER For more information about the various menu options, see the subsequent sections.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

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Electrical system – 5000 Troubleshooting T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

9.10 Troubleshooting 9.10.1 General The electronic control system of the truck features display of error codes and stores errors in a log. These functions constitute powerful support when troubleshooting and pinpointing faults on the truck. All error conditions detected by the transistor regulator are displayed as a blinking sequence via the status LED (Fig. 15 AL). The blinking sequence always start with ”long” blinks followed by a number of ”short” blinks. See table 17 on page 42.

The five error codes that have occurred last are stored in the error log together with the hour meter reading, the number of occurrences and the transistor regulator temperature when each error occurred.

The first time an error code is generated, it is recommended to check whether the condition remains when the trucks is switched off and then on again. Check to see if the error code is displayed again.

Used the TESTER function of the hand-held terminal to test basic truck functions.

9.10.2 Displaying error codes Direct error code display Proceed as follows to check a possible error condition by observing the status LED: • Swing out the main electric panel See “9.4 Access to the main electric panel” on page 7.

Normally, the status LED should be extinguished. If not, an error has occurred.

• Determine the error code by counting the number of ”long” (and ”short”) blinks in the sequence.

• See Table 17, “Error code list,” on page 42.

Displaying error code on the hand-held terminal Proceed as follows to check an existing error condition or to check the error history using the hand-held terminal: • Check that the key switch has been switched off [S17].

• Swing out the main electric panel. See “9.4 Access to the main electric panel” on page 7.. *

ALARM INCORRECT START

*

• Connect the hand-held terminal connector (Fig. 18 A) to the diagnostic connector on the transistor regulator (Fig. 15 B).

• Switch on the key switch [S17].

Fig. 20 Typical error display

If an error condition exists in the truck, it is displayed immediately.

9- 40

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Troubleshooting Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

• See Table 17, “Error code list,” on page 42.

NOTE: The status LED lights continuously when the hand-held terminal is connected.

Error history Proceed as follows to check the error code history log: The hand-held terminal must have been connected as explained in the previous section.

Navigate to the ALARM menu.

SEM-X 24v

75A

V..

00000

ENTER *

MAIN MENU * PARAMETER CHANGE MAIN MENU * STEER TABLE MAIN MENU * PROGRAM VACC MAIN MENU * ALARMS

*

ROLL * *

CODE ROLL

CODE

OUT

CODE ENTER

CODE 00001

#01

20 C

OUT ENTER

OUT

ENTER OUT

G

LOG BOOK CLEARED (PRESS OUT)

Fig. 21 Menu tree for displaying the error history The log shows the last five error types together with information about each error.

A – Error code description.

A *

VFIELD NOT OK * 00015h #01 27°C

B

C

D

B – Hour meter reading when the error occurred.

C – Number of occurrences for a specific error.

D - Transistor regulator temperature when the error occurred.

As an alternative, the error code history log can be cleared when the ALARM menu is closed.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 41

Electrical system – 5000 Troubleshooting T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

9.10.3 Error code list NOTE: It is important to know that some of the status LED codes can be caused by different error codes. The hand-held terminal provides the most reliable diagnoses.

Table 17: Error code list Status LED code

Description of error code

Possible cause / Hint or Solution

¤ (1)

Watch dog

Defective logic card and/or firmware. / Replace the transistor regulator.

EEPROM KO

Problem with EEPROM or logic. / Replace the transistor regulator.

EB DRIVER SHORT

Electromagnetic brake coil [Y1] output, short-circuit with BATT. / Check the brake coil connecting lead.

EB DRIVER KO

The electromagnetic brake coil [Y1] output does not operate. / Replace the transistor regulator.

CONTACTOR DRIVER

The main contactor [K10] does not respond during operation. / Check the main contactor coil and cabling.

DRIVER SHORTED

The main contactor coil has either short-circuited, the connection is defective or it is not connected. Main contactor, connection fault or short-circuit with -BATT. / Check the main contactor coil and cabling.

CONTACTOR CLOSED

The main contactor tips [K10] have melted away.

Problem with the field circuit.

Problem detected by the safety microprocessor. / Check that main contactor tips have not melted away. Check the field winding connections. If the above are OK, then replace the transistor regulator.

CONTACTOR OPEN

Unexpected drop in battery voltage after the main contactor has closed. / Check the main contactor cabling. Check the battery charge level.

POWER FAILURE #1

Short-circuit detected on the drive unit output to the main contactor [K10] or brake coil [Y1]. / Check whether the main contactor or brake coil circuit has short-circuited. If the above are OK, then replace the transistor regulator.

¤¤ (2)

¤ ¤¤ (1+2)

¤ ¤¤¤ (1+3)

9- 42

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Troubleshooting Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Table 17: Error code list Status LED code

Description of error code

Possible cause / Hint or Solution

¤¤ ¤ (2+1)

CAPACITOR CHARGE

The capacitors are charged within 500 ms after the key switch has closed. / Check the PTC resistor circuit. / If the above is OK, then replace the transistor regulator.

VMN NOT OK

Problem in the VMN armature drive unit. Incorrect motor connection, short-circuit between the motor windings and the chassis.

Defective transistor regulator / Check that the armature connections [M1] are correct and that an internal short-circuit has not occurred. If the above are OK, then replace the transistor regulator.

VFIELD NOT OK

Field voltage problem. Drive motor [M1] field winding, shortcircuit or connection fault.

The field winding has been incorrectly connected to the transistor regulator. Defective transistor regulator / Check that the armature connections [M1] are correct and that a shortcircuit in the motor has not occurred. If the above are OK, then replace the transistor regulator.

NO FIELD CUR

Field current abnormally low. Drive motor [M1] field winding, short-circuit or connection fault.

The field winding has been incorrectly connected to the transistor regulator. Defective transistor regulator / Check that the armature connections [M1] are correct and that a shortcircuit in the motor has not occurred. If the above are OK, then replace the transistor regulator.

FW HIGH FIELD CURR.

Field current abnormally high in the drive wheel direction.

Drive motor [M1] field winding, short-circuit or connection fault.

The field winding has been incorrectly connected to the transistor regulator. Defective transistor regulator / Check that the armature connections [M1] are correct and that a shortcircuit in the motor has not occurred. If the above are OK, then replace the transistor regulator.

BW HIGH FIELD CURR.

Field current abnormally high in the fork direction. Drive motor [M1] field winding, short-circuit or connection fault.

The field winding has been incorrectly connected to the transistor regulator. Defective transistor regulator / Check that the armature connections [M1] are correct and that a shortcircuit in the motor has not occurred. If the above are OK, then replace the transistor regulator.

¤¤ ¤¤ (2+2)

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 43

Electrical system – 5000 Troubleshooting T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

Table 17: Error code list Status LED code

Description of error code

Possible cause / Hint or Solution

¤¤ ¤¤¤ (2+3)

STBY I HIGH

Armature current abnormally high in standby. Defective transistor regulator / Replace the transistor regulator.

I=0 EVER

Armature current abnormally low during truck travel. / Check the armature connections, check or replace the carbon brushes. If the above are OK, then replace the transistor regulator.

CURR. PROTECTION

Armature current abnormally high during truck travel. / Check the armature connections for short-circuits. If the above is OK, then replace the transistor regulator.

¤¤¤ ¤ (3+1)

TH. PROTECTION

The transistor regulator operating temperature is abnormally high or low (outside the range >70°C or <10°C). Defective transistor regulator / First check that the operating environment of the truck and the operating conditions are normal!

Let the truck return to normal operating temperature and try operating the truck normally. If the error remains, then replace the transistor regulator.

¤¤¤ ¤¤¤ (3+3)

VACC NOT OK

Incorrect voltage of the speed value signal from [A2] when the truck is switched on. / Check the cabling between [A1] and [A2].

¤¤¤ ¤¤¤¤¤ (3+5)

INCORRECT START

Incorrect start sequence for truck travel. The emergency reversing switch [A2:S317] is operated during the start sequence. Faulty connection in the main contactor coil circuit [K10]. The tiller arm switch [S10] is operated during the start sequence. / Inspect the cabling to [S10] and [A2]. Adjust or replace [S10]. Inspect the cabling to the coil [K10] and replace [K10] if necessary.

¤¤¤ ¤¤¤¤¤¤ (3+6)

FORW+BACK

Conflict between travel direction commands. / Inspect cabling to [A2], inspect operation of [A2:S300-S318].

¤¤¤ ¤¤¤¤¤¤¤ (3+7)

BELLY SW ERROR

No connection to [A2:S317] on [A2]. / Inspect cabling to [A2], inspect operation of [A2:S317].

¤¤¤ ¤¤¤¤¤¤¤¤ (3+8)

CHECK UP NEEDED

Time for scheduled service!

Time since last service intervention > CHECK UP HOURS. The service counter may not have been reset at the last service intervention. / Determine the service requirements and the current situation. Perform scheduled service and then reset the service counter according to the guidelines.

See Reset service counter (CHECK UP DONE) on page 49.

¤¤¤ ¤¤ (3+2)

BATTERY LOW

The battery charge level is less than 50% of the nominal value. / Charge the batteries.

9- 44

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Troubleshooting Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9.10.4 TESTER function The hand-held terminal can be used to test a number of basic truck functions and features.

Proceed as follows to use the TESTER function: • Connect the hand-held terminal. See “ Connecting the hand-held terminal” on page 37.

SEM-X 24v

75A

V..

00000

BELLY SWITCH

ENTER * * *

ROLL

* * * *

BATTERY CHARGE DIGITAL INPUT # 2

HARD & SOFT MAIN MENU * PARAMETER CHANGE BACKWARD SWITCH MAIN MENU * ROLL FORWARD SWITCH STEER TABLE TILLER SWITCH MAIN MENU * PROGRAM VACC ACCELERATOR MAIN MENU * TEMPERATURE ALARMS FIELD CURRENT MAIN MENU * RESTOR PARAM. MOTOR CURRENT MAIN MENU * SAVE PARAM. VMN MAIN MENU * BATTERY VOLTAGE TESTER ENTER

OUT

• Select TESTER on the menu and press ENTER. • Scroll through the various test functions by pressing the ROLL buttons.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 45

Electrical system – 5000 Troubleshooting T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

Table 18: Hand-held terminal TESTER functions Display

Function

Value(s), approx.

BATTERY VOLTAGE VMN

Battery voltage measured at key switch input.

Voltage measured between VMN and B-.

24-26 V

MOTOR CURRENT

Armature current, drive motor.

FIELD CURRENT

Field current, drive motor.

TEMPERATURE

Temperature measured on MOSFET transistor heat sink (transistor regulator).

ACCELERATOR Voltage on cable 51 from [A2] used to control the truck travel speed.

The voltage is displayed on the left, while the value on the right is a percentage.

TILLER SWITCH Level on digital input pin A4 of tiller arm switch [S10]: ON/+VB = active input, switch closed.

OFF/GND = inactive input, switch open.

FORWARD SWITCH Level on digital input pin A6 for travelling in (TRAVEL IN DRIVE the drive wheel direction: ON/+VB = active input, switch closed.

WHEEL OFF/GND = inactive input, switch open.

DIR.SWITCH) BACKWARD Level on digital input pin A7 for travelling in SWITCH the fork direction: (TRAVEL IN FORKS ON/+VB = active input, switch closed.

OFF/GND = inactive input, switch open.

DIR. SWITCH) H&S Level on digital input pin A8: For future use (”turtle” function).

DIGITAL INPUT #2 Level on digital input for lifting/lowering the forks: ON/GND = active input, switch closed.

OFF/+VB = inactive input, switch open.

BELLY SWITCH/ Level on digital input pin A5, safety revers(SAFETY REVERS- ing switch: ING) ON/+VB = active input, B SW closed.

OFF/GND = inactive input, B SW open.

BATTERY CHARGE Battery charge level indicated as %.

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Service Manual

SP10, SP10S, PP13

BATT.VOLTAGE - 0.1 at standstill Max. speed - 0.3 V Standstill – 0 A Max. load and/or ramp – 75 A Standstill (brake applied) – 0 A Max. speed - 5 to 6 A Motor braking - 6 to 10 A Depends on environment [L1] in neutral position – 0 V 0% for both travel directions: min. speed - 0.5 V 1% max. speed - 10.1 V 100% Tiller arm in vertical position OFF Tiller arm in drive mode - ON [L1] in neutral position - OFF [L1] in drive wheel direction ON [L1] in neutral position - OFF [L1] in fork direction - ON

OFF No lifting or lowering - OFF. Lifting or lowering operated ON. With tiller arm in travel position: [A2:S317] not active approx.12 V [A2:S317] active - >20 V Depends on charge status

© TIEE SARL

Electrical system – 5000 Parameters and settings Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9.11 Parameters and settings 9.11.1 General A number of parameters are stored in the truck controller. These parameters are used to configure the truck to adapt it for correct operation in the environment it has been designed for. The parameters can be set using the hand-held terminal.

9.11.2 Setting the parameters The parameters can be adjusted using the PARAMETER CHANGE function of the hand-held terminal: • Connect the hand-held terminal. See “ Connecting the hand-held terminal” on page 37.

VALUE NOT CHANGE CHANGED

ARE YOU SURE ?

YES=ENTER NO= OUT

VALUE CHANGED

CHECK UP HOURS

0-9

CHECK UP TYPE ROLL SEM-X 24v

75A

V..

00000

*

CHECK UP DONE CUTBACK SPEED 3

0-9

INVERSION BRAKING

0-9

RELEASE BRAKING

ENTER

DECELER DELAY

MAIN MENU * PARAMETER CHANGE

0-3 OFF

ENTER ACC.DELAY

OUT

0-9 0-9 0-9

ROLL = CHOOSE PARAMETER PARAM SET = CHANGE VALUE

• Select PARAMETER CHANGE on the menu and press ENTER. • Display the desired parameters using the ROLL buttons.

• Adjust the parameter setting using the PARAM SET buttons.

• Press OUT and then ENTER to store the new parameter setting, or • Press OUT and then OUT again to return to the main menu without changing the existing parameter setting.

NOTE: Truck handling.

When specific truck parameters are changed, truck handling will be affected.

Do not change any parameters unless you are sure what results the change will bring.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 47

Electrical system – 5000 Parameters and settings T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

9.11.3 Parameter list NOTE: Before changing any parameters, be sure you have read and understood the instructions for displaying and changing parameters in the section Setting the parameters on page 47.

See also section Limiting the travel speed on page 36 for information regarding the maximum travel speeds of the truck.

Table 19: Parameter overview Parameter name (display)

Function

Min.

Max.

Stand Remarks ard

ACC.DELAY

Determines acceleration ramp time.

0

9

6 A 9:

0:

A= acceleration DECELER.DELAY

RELEASE BRAKING

Determines the ramp time for braking when speed control actuation is reduced.

0

Determines braking intensity.

0

9

5 D 9:

0:

D = deceleration (braking) 9

5 B 0:

B = braking intensity INVERSION BRAKING

Determines inversion braking intensity.

0

9

9:

9 B 0:

9:

B = braking intensity CUTBACK SPEED 3

Determines max. travel speed

0

9

9 S 0:

9:

S= maximum speed CHECK UP DONE

Resets the service counter.

-

-

OFF

CHECK UP TYPE

Selects service warning type.

0

3

NONE

CHECK UP HOURS

Determines ”Time to next service”.

0

9

2

9- 48

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Parameters and settings Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

9.11.4 Parameter description Acceleration ramp time (ACC.DELAY) Determines the acceleration ramp time. If this value is increased, the speed increase will be slower, and acceleration as a result will be smoother.

Deceleration ramp time (ACC.DELAY) Determines the ramp time for braking when speed control [L1] actuation is reduced. If this value is increased, deceleration will be slower, and truck slowdown as a result will be smoother.

Adjustment of this parameter only has limited effect.

Release breaking intensity (RELEASE BRAKING) When this parameter value is increased, braking becomes harder.

Release braking is defined as a reduction of the truck travel speed using motor braking when the speed control [L1] is returned to the neutral position.

Inversion braking intensity (INVERSION BRAKING) When this parameter value is increased, braking becomes harder.

Inversion braking is defined as a reduction of the truck travel speed using motor braking when the speed control [L1] is set to the opposite travel direction.

Maximum speed (CUTBACK SPEED 3) Determines the maximum travel speed. An increase in this parameter value causes an increase in the maximum travel speed.

The maximum speed = 5.4 X (62 + (p X 4.2))% km/h, where p is the parameter value.

Reset service counter (CHECK UP DONE) When this parameter is set to ON, the service counter is reset. This is done after each scheduled service intervention.

Select service warning type (CHECK UP TYPE) Determines the warning type when the service counter reaches ”Time for next service” according to the setting of CHECK UP HOURS. Value NONE – No warning is made (standard setting).

Value 1 - Warning is made when the service counter reaches the value CHECK UP HOURS.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 49

Electrical system – 5000 Parameters and settings T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

Value 2 - Warning is made when the service counter reaches the value CHECK UP HOURS. After ten hours of continuous operation, the maximum speed is reduced.

Value 3 - Warning is made when the service counter reaches the value CHECK UP HOURS. After ten hours of continuous operation, the maximum speed is reduced. After 20 hours of continuos operation, all truck functions become blocked.

The ”Time for service” warning consists of: • An acoustic signal from the transistor regulator.

• 3 long + 8 short blinks from the status LED on the transistor regulator.

• The battery status LED [H81] blinks continuously.

”Time to next service” (CHECK UP HOURS) Set this value to coincide with the increase in the number of operation hours at which the next scheduled service intervention should be signalled.

Time to next service = 200 + (p X 50) hours, where p = parameter value.

9.11.5 Transferring parameter settings General The hand-held terminal can be used to download parameter settings and configurations from the trucks. This is especially convenient in the following situations: • To reset the truck configuration to a known condition or following replacement of the transistor regulator.

• To transfer the configuration from one truck to a group of trucks that will then receive identical configurations.

The hand-held terminal can store up to 32 unique parameter settings.

9- 50

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Parameters and settings Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

From the truck to the hand-held terminal To transfer the parameter setting from the truck to the hand-held terminal, use the PARAMETER CHANGE function in the hand-held terminal: • Connect the hand-held terminal. See “ Connecting the hand-held terminal” on page 37.

SEM-X 24v

75A

V..

00000

ENTER * * *

ROLL

* * *

MAIN MENU * PARAMETER CHANGE MAIN MENU * STEER TABLE SELECT Mod 31 MAIN MENU * PROGRAM VACC SELECT Mod 03 ROLL MAIN MENU * SELECT Mod 02 ALARMS SELECT Mod 01 MAIN MENU * FREE RESTOR PARAM. SELECT Mod 00 MAIN MENU * SAVE PARAM. V ENTER SEM -X

ENTER ENTER

OUT OVERWRITE DATA? YES = ENTER NO = OUT

Memory location occupied

ENTER READING Run all parameters

Memory location free

• Select SAVE PARAM on the menu and press ENTER. • Use the ROLL buttons to select one of the 32 memory positions (mode 00 to mode 31).

FREE indicates an empty memory position. SEM-X memory positions that contain a parameter setting.

V indicates

• Press ENTER to download the truck's parameter setting.

NOTE: It is recommended to keep a file of the trucks and their associated, stored parameter setting. This will ensure that stored parameter settings can be returned to the correct truck.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 51

Electrical system – 5000 Parameters and settings T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

From the hand-held terminal to the truck To transfer a parameter setting from the hand-held terminal to the truck, use the RESTOR PARAMETER function in the hand-held terminal: • Connect the hand-held terminal. See “ Connecting the hand-held terminal” on page 37.

SEM-X 24v

75A

V..

00000

ENTER * * ROLL

* * *

MAIN MENU * PARAMETER CHANGE MAIN MENU * STEER TABLE MAIN MENU * SELECT Mod 31 PROGRAM VACC ROLL SELECT Mod 02 MAIN MENU * SELECT Mod 01 ALARMS MAIN MENU * ENTER SELECT Mod 00 RESTOR PARAM. SEM-X V

ENTER

NO DATA FOR THIS CHOPPER! (OUT)

OUT ARE YOU SURE ?

YES = ENTER

NO = OUT

ENTER STORING Run all parameters

• Select RESTOR PARAM on the menu and press ENTER. • Use the ROLL buttons to select the correct memory position (mode 00 to mode 31).

• Press ENTER The parameter setting is restored in the transistor regulator memory.

9.11.6 Speed potentiometer calibration General The transistor regulator [A1] can be calibrated so that the speed potentiometer [R1] provides a smooth, symmetric response across the entire operating range. Calibration should be used in the following cases: 9- 52

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Electrical system – 5000 Parameters and settings Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

• If the speed control response is not uniform in both travel directions.

• If the VACC NOT OK error occurs.

• If [R1] has been disassembled, suffers from interference or has been replaced.

Procedure Use the PROGRAM VACC function in the hand-held terminal to calibrate the speed potentiometer: • Connect the hand-held terminal. See “ Connecting the hand-held terminal” on page 37.

SEM-X 24v

75A

V..

00000

ENTER * ROLL

* *

MAIN MENU * PARAMETER CHANGE MAIN MENU * STEER TABLE MAIN MENU * PROGRAM VACC

ENTER

VACC SETTING

ENTER

0.4

4.7 OUT

MIN 0.0

VACC -

MAX 0.0 Slowly move the speed control towards max in both directions

MIN 0.5

VACC

MAX 4.8

OUT

ARE YOU SURE ?

OUT

YES = ENTER NO = OUT ENTER

• Select PROGRAM VACC on the menu, press ENTER and ENTER once more.

• Set the tiller arm to the travel position.

• Slowly move the speed control [L1] from neutral position to the end stop first in one direction, then in the other direction.

• Press OUT and then ENTER. The transistor regulator and potentiometer have now been calibrated. © TIEE SARL

Service Manual

SP10, SP10S, PP13

9- 53

Electrical system – 5000 Technical data T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

9.12 Technical data 9.12.1 SEM-X transistor regulator Table 20: SEM-X transistor regulator data Feature

Value

Unit

Operating voltage

24

Volts

Overvoltage limit

33

Volts

28.8 V continuously

Undervoltage limit

16,8

Volts

Minimum operating voltage

Electrical insulation towards cold chassis

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

6.6

Amps

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.; High <9.2; Low

Volts

Operating temperature

-30 to +40

°C

Overtemperature, reduction

70

°C

Undertemperature, reduction to 80%

-10

°C

Max. temperature limit

90

Max. current of field winding

9- 54

Service Manual

Description

Reduced in proportion to the temperature increase

SP10, SP10S, PP13

© TIEE SARL

Hydraulic system – 6000 SP10, SP10S Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

10- Hydraulic system – 6000 10.1 SP10, SP10S

The hydraulic system consists of a compact hydraulic unit and has no return filter. The system has a solenoid valve for lowering the forks and a pressure limit valve.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

10- 1

Hydraulic system – 6000 Hydraulics diagram and main components SP10, SP10S T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

10.2 Hydraulics diagram and main components SP10, SP10S

1

2

3 Y41 5

P

4

M3 6

10- 2

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Hydraulic system – 6000 Hydraulics diagram and main components SP10, SP10S Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

5 4 Y41 3

P

1 6

2

© TIEE SARL

Pos.

Name SP10, SP10S

1

Lift cylinder, forks

2

Hose breakage valve

3

Non-return valve

4

Flow regulation valve

5

Pressure limit valve

6

Intake filter (suction sieve)

M3

Pump motor

P

Pump

Y41

Lowering valve

Service Manual

SP10, SP10S, PP13

10- 3

Hydraulic system – 6000 Hydraulics diagram and components PP13 T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

10.3 Hydraulics diagram and components PP13

1

A Y41

4

2 3

M3

P

5 T

10- 4

Pos nr.

Description main components PP13

1

Lift cylinder for the forks

2

Preasure relief valve

3

Flow control valve

4

Non-return valve

5

Filter

6

Filler tuber

M3

Pump motor

P

Pump

T

Tank

Y41

Lowering valve for the forks

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Hydraulic system – 6000 Hydraulics diagram and components PP13 Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

M3

2 4 3 Y41

P

6 5

T

© TIEE SARL

Service Manual

SP10, SP10S, PP13

10- 5

Hydraulic system – 6000 Description SP10, SP10S, PP13 T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

10.4 Description SP10, SP10S, PP13 Lift The lifting motion occurs when the pump motor (M3) is run. Lift speed depends on load weight.

The non-return valve prevents leakage through the pump. When the load is in the lifted position, it is held in place by the non-return valve and the closed electric lowering valve (Y41).

Lower By opening the electric lowering valve (Y41), the load is lowered and the maximum lowering speed of the forks is regulated by the flow control valve.

A pressure limit valve (overflow valve) prevents overload and protects the pump motor from overpressure. A hose rupture valve is located at the cylinder to prevent the load from falling uncontrollably in the event of a hose rupturing.

Operating pressure and pressure limitation

10- 6

SP10, SP10S

PP13

Operating pressure at rated load

190 bar

110 bar

The pressure limit valve opens at

210 bar

130 bar

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Hydraulic system – 6000 Adjustments Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

10.5 Adjustments 1

2

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

• 1 = Lock nut.

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

When the screw is turned counter clockwise pressure decreases.

10.5.1 Adjustment of the pressure limit valve SP10, SP10S The truck should be able to lift a load of between 1000 and 1100 kg on the forks.

Place a load of 1000 kg on the forks and check that the truck can lift it.

If the truck cannot lift 1000 kg: 1. Loosen the lock nut (1) by turning it counter clockwise.

2. Turn the adjuster screw (2) clockwise until the truck is able to lift the load without problems.

3. Tighten the lock nut (1) by turning it clockwise.

If the truck can lift 1000 kg, place a further 100 kg on the forks. Check that the truck cannot lift the load.

If the truck can lift 1100 kg: 1. Loosen the lock nut (1) by turning it counter clockwise.

2. Turn the adjuster screw (2) counter clockwise until the truck is unable to lift the load.

3. Tighten the lock nut (1) by turning it clockwise.

NOTE! A special tool is required to adjust the lock nut and adjuster screw.

See the section on tools below.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

10- 7

Hydraulic system – 6000 Adjustments T-code 795, 675

1

2

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

10.5.2 Adjustment of the pressure limit valve PP13 The truck should be able to lift a load of between 1300 and 1400 kg on the forks.

Place a load of 1300 kg on the forks and check that the truck can lift it.

If the truck cannot lift 1300 kg: 1. Loosen the lock nut (1) by turning it counter clockwise.

2. Turn the adjuster screw (2) clockwise until the truck is able to lift the load without problems.

3. Tighten the lock nut (1) by turning it clockwise.

If the truck can lift 1300 kg, place a further 100 kg on the forks. Check that the truck cannot lift the load.

If the truck can lift 1400 kg: 1. Loosen the lock nut (1) by turning it counter clockwise.

2. Turn the adjuster screw (2) counter clockwise until the truck is unable to lift the load.

3. Tighten the lock nut (1) by turning it clockwise.

NOTE! A special tool is required to adjust the lock nut and adjuster screw.

See the section on tools below.

10- 8

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Hydraulic system – 6000 Tools SP10, SP10S, PP13 Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

10.6 Tools SP10, SP10S, PP13 Two special tools are required to adjust the pressure limit valve of the hydraulic system.

A

26,5

8

12

B

13,5

• A – Socket for loosening or tightening the adjuster screw for pressure limitation (part number 0816530).

• B – Socket for loosening or tightening the lock nut (part number 0816530/1).

© TIEE SARL

Service Manual

SP10, SP10S, PP13

10- 9

Hydraulic system – 6000 Tools SP10, SP10S, PP13 T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

This page is intentionally left blank

10- 10

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Lift mast SP10, SP10S – 7000 Main mast Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

11- Lift mast SP10, SP10S – 7000 11.1 Main mast 11.1.1 Components 3

7

4 5

6 1

8 2

© TIEE SARL

Pos.

Name

1

Cover

2

Main lift cylinder

3

Plate (cylinder cover)

4

Lift chain

5

Roller

6

Mounting bolt

7

Plate (chain guide)

8

Mounting bolts

Service Manual

SP10, SP10S, PP13

11- 1

Lift mast SP10, SP10S – 7000 Main mast T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

11.1.2 Maintenance 8

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

The tightening torque must be 150+/-15 Nm.

Lubrication Lubricating the beam 1

The inner sides of the beam flanges must be lubricated with Q8 Rembrandt EP2.

2

The inner sides of the beam rib must be lubricated with Gleitmo 805.

Fig. 23 Bolt joints

11- 2

Service Manual

1

SP10, SP10S, PP13

2

© TIEE SARL

Lift mast SP10, SP10S – 7000 Main mast Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

11.1.3 Cylinder Disassembly • Remove the mast cover.

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

• Unscrew the chain guide (Fig. 24).

• Remove the chain sprocket (Fig. 24).

Fig. 24 Removing the chain sprocket • Undo the bolts on the cylinder mounting (Fig. 25).

• Lift the fork carriage up past the cylinder.

• Lift out the cylinder and unscrew the hose (Fig. 25).

Fig. 25 Removing the cylinder NOTE: If the hose is difficult to reach, remove one of the truck’s batteries and loosen the other end of the hose.

Assembly Assembly takes place in the reverse order.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

11- 3

Lift mast SP10, SP10S – 7000 Fork carriage T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

11.2 Fork carriage 11.2.1 Maintenance

1

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

• Shim as illustrated (1) if necessary.

11- 4

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Lift mast SP10, SP10S – 7000 Main lift chain system Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

11.3 Main lift chain system 11.3.1 Checking the chain setting The lift chains must be adjusted at regular periods due to stretching, see below. The chain setting is checked during servicing as set out in the maintenance schedule.

Any adjustment is made with the chain mounting bolts.

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

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

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

The chain should be replaced.

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

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

The chain should be replaced

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

The chain should be replaced.

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

The chain should be replaced. © TIEE SARL

Service Manual

SP10, SP10S, PP13

11- 5

Lift mast SP10, SP10S – 7000 Main lift chain system T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

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

The chain should be replaced

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

The chain should be replaced

11- 6

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Lift mast SP10, SP10S – 7000 Main lift chain system Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

Outline wear P

H2

H3

P = Pitch H2 = Nominal disc height.

H3 = Minimum disc height.

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

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

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

11- 7

Lift mast SP10, SP10S – 7000 Main lift chain system T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

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

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

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

Type of chain

Nominal disc height H2 ( mm)

Minimum disc height H3 (mm)

Pitch P (mm)

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

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

3/4”, 2x3

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 3x4

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 4x6

17.8

16.9

19.05

381/572/953

389/583/972

1”, 4x4

23,6

22,4

25,4

508/762/1270

518/777/1295

1”, 6x6

23,6

22,4

25,4

508/762/1270

518/777/1295

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

Damage

The chain should be replaced if damaged in any way.

11- 8

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Lift mast SP10, SP10S – 7000 Main lift chain system Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

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

The chain should be replaced.

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

The chain should be replaced.

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

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

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

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

11- 9

Lift mast SP10, SP10S – 7000 Main lift chain system T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

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

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

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

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

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

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

Ambient temperature

Viscosity class

Recommended Products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5°C

VG 68

> + 5°C < + 45°C

VG 150

>+ 45°C <+ 80°C

VG 220

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

* Equivalent products from another manufacturer may be used.

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

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

11- 10

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Accessories – 9000 Automatic height adjustment SP10, SP10S Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

12- Accessories – 9000 12.1 Automatic height adjustment SP10, SP10S 12.1.1 General The truck can be fitted with a photocell, which in the automatic mode controls lifting and lowering of the forks to maintain a preset height when the sensor detects the load.

C

The photocell is located in the holder (C) on the mast.

• Set an ergonomically correct work height by moving the holder up or down to the desired height.

© TIEE SARL

Service Manual

SP10, SP10S, PP13

12- 1

Accessories – 9000 Automatic height adjustment SP10, SP10S T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

The holder features an emergency stop switch (D) and an indicator lamp (E), which lights when the function is active.

• Depress the emergency stop switch to switch off all truck functions.

D

E

The controls for automatic height adjustment are placed on the tiller arm.

• Lift the forks by pressing A. They will then be lifted automatically until the photocell detects the load.

• Lower the forks by pressing B. They will then be lowered automatically until the photocell detects the load.

B A

The truck has an end position switch that switches off the pump when the forks reach the maximum lift height.

The truck has one more end position switch that detects when the forks reach the safety clearance to the ground. To lower the forks further and prevent crushing the operator's feet, further lowering must be performed manually.

Lifting/lowering of the forks can also be done in the same way as on a standard truck. When manual operation is switched on, automatic operation is cancelled.

12- 2

Service Manual

SP10, SP10S, PP13

© TIEE SARL

© TIEE SARL

Service Manual

SP10, SP10S, PP13

Sh. 4

1

35

23

31

34

1

2

X61

X61

20

X30

X30

10A

F51

F50

2

2

1

2

1

LOWER VALVE Y41 43

A1

2

3

A2

K10

R2

PTC

F1

100A

1

2

-

A2

K30 A1

1

+

G1

-

43

4

PUMP MOTOR M3 A2 8 A1 M

+

G2

4

14

13

S171

X31

5

5

F2

A1

1

Y1 2

FIELD

M

M1

F1

A2

X31

6

6

35

43

23

42

34

31

41

5

4

6

3

40

A10

A2

A15

A14

A13

A4

A11

F2

F1

VMN

8

7

INP, LIFT

8

1/5 PROD A 218858

OUT, NEG, PUMP CONTACTOR/LOWER VALVE

IN, SUPPLY, MAIN CONTACTOR

OUT, NEGATIVE, MAIN CONTACTOR

INP, LOWER

INP, TILLER SWITCH

OUT, NEGATIVE, MAGNETIC BRAKE

FIELD WINDING

FIELD WINDING

ARMATURE WINDING

+ BATT INP. POWER SUPPLY 24VDC

- BATT INP. POWER SUPPLY 0VDC

ELECTRONIC CARD A1

7

F

E

D

C

B

A

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

F

E

Sh. 2

Sh. 2

Sh. 4

40

9

21

5A

3

Date 2006-09-29

D

C

Sh. 2

Sh. 3

Sh. 4

S21

2

Order number 242330-040

B

A

1

Automatic height adjustment SP10, SP10S

Accessories – 9000 T-code 795, 675

12.1.2 Electrical wiring diagram

12- 3

12- 4

Service Manual

SP10, SP10S, PP13

F

1

134

135

31

X30

40

COM

2

NO

TILLER SWITCH S10

S170

START INTERLOCK

H1 RD

NO

NO

COM

3

S41 NO

FORK LOWER

COM

FORK LIFT S34

COM

HORN SWITCH S18

BK

23

X61

X61

X30

X30

57

2

KEY S17 1

4

4

3

R1 1 2

COM

COM

S20

3K3

S16

NC

NO

NO

5

5

COM

S15 NO

6

X30

X30

X30

X30

X30

X30

H81

6

55

54

53

52

51

50

59

22

A5

A7

A6

A9

A1

A3

A12

A16

7

INP, BELLY BUTTON.

8

8

2/5 PROD A 218858

INP, DRIVE, FORK DIRECTION.

INP, DRIVE, STEERED WHEEL DIRECTION.

OUT, GND, SUPPLY DRIVE POT.

INP, WIPER, DRIVE POT.

OUT, POS, SUPPLY DRIVE POT.

OUT, BATTERY INDICATOR

INP, 24VDC KEY SWITCH

ELECTRONIC CARD A1

7

F

E

D

C

B

A

Date 2006-09-29

Sh. 4

Sh. 4

Sh. 1 4

Sh. 1 3

23

PLUG:B

PLUG:A

221

22

3

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

E

D

C

Sh. 1

Sh. 3

Sh. 3

Sh. 4

Sh. 4

2

T-code 795, 675

B

A

1

Accessories – 9000

Automatic height adjustment SP10, SP10S Order number 242330-040

© TIEE SARL

Accessories – 9000 Automatic height adjustment SP10, SP10S

F F

7

MAINS; VAC PLUG:B

MAINS; EARTH

MAINS; VAC PLUG:A

OUT, NEGATIVE CHARGER VOLTAGE 40 40

OUT, POSITIVE CHARGER VOLTAGE 9 9

ONBOARD CHARGER A30

© TIEE SARL

Service Manual

1

Sh. 2

Sh. 2

C

Sh. 2 4

Sh. 1

1

2

2

3

3

4

4

5

5

6

6

7

8

E E

3/5 PROD A 218858

D

T-code 795, 675

D

C

B B

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

8

A

Date 2006-09-29

A

Order number 242330-040

SP10, SP10S, PP13

12- 5

12- 6

Service Manual

SP10, SP10S, PP13

X60 GN/WH

221

1

X60

21

2

X60

X2

H97

3

COM

COM

X1

AUTO ENABLED

S227

S226

BU

BN

4

1

S225 4 BK

X60

NO NC

NO NC

X61

X61

X61

X61

X61

40

X62

X62

207

204

S33

5

1

2

MAST SWITCHES S32 1 2

X60

X62

X62

6

201

208

206

205

203

202

200

135

9

16

8

18

17

12

13

2

10

134

134

135

14

40

40

1

15

34

34

35

3

31

31

35

7

7

OUT. AUTO ENABLED

INP. LIFT LIMIT AUTO MODE

INP. AUTO LOWER REQ.

INP. FORKS < 150MM

INP. AUTO UP REQ.

OUT. 24VDC TO SWITCHES

INP. PHOTO CELL

INP. LIFT FORKS

INP. LOWER FORKS

INP. 0 VDC

OUT. PUMP CONTACTOR

OUT. LOWER VALVE

INP. TILLER ARM SWITCH

INP. 24VDC

ELECTRONIC CARD A40

11

201

6

22

EMERGENCY SWITCH OFF S22 2 RD/YE 1

5

22

CONTROL BOX ON MAST

4

8

4/5 PROD A 218858

8

F

E

D

C

B

A

Date 2006-09-29

F

Sh. 2

Sh. 1

Sh. 2

Sh. 2

Sh. 3

Sh. 1

3

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

E

D

C

B

Sh. 1

Sh. 2

Sh. 2

2

T-code 795, 675

3

A

1

Accessories – 9000

Automatic height adjustment SP10, SP10S Order number 242330-040

© TIEE SARL

© TIEE SARL

Service Manual

2

3

4

5

6

B2

106

106

7

NCLRXD

PCLTXD

5/5 PROD A 218858

C

B

A

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

SP10, SP10S, PP13

8

F

B3

105

105

NCLTXD

+12VDC SUPPLY VOLTAGE

GND

PCLRXD

8

F

B4

104

B6

103

103

104

B5

B1

102

101

ELECTRONIC CARD A1

7

E

1

6

E

6

NCLRXD

5

102

101

OPTION

4

D

5

PCLTXD

4

3

12VDC SUPPLY VOLTAGE

NCLTXD

2

1

GND

PCLRXD

3

Date 2006-09-29

D

C

DISPLAY; MDI A6

2

Order number 242330-040

B

A

1

Automatic height adjustment SP10, SP10S

Accessories – 9000 T-code 795, 675

12- 7

Accessories – 9000 Automatic height adjustment SP10, SP10S T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

This page is intentionally left blank

12- 8

Service Manual

SP10, SP10S, PP13

© TIEE SARL

Destruction instructions General Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

13- Destruction instructions 13.1 General These instructions have been drawn up as part of the truck manufacturer’s environmental management program. An important motive is, by taking nature into consideration, to economise with resources. In other words, you should try to recycle all material as far as possible. This is to minimise the discharge of environmentally-hazardous substances.

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

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

13- 1

Destruction instructions Abbreviations T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

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

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

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

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

• Iron and steel scrap are sorted separately.

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

• Oil is collected in the intended container.

• Oil filters are collected in the intended container.

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

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

• Electronic scrap should be sorted from other scrap.

• Cables should be removed and collected separately.

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

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Destruction instructions Chassis (0300) Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

13.5 Chassis (0300) Disassembly • Remove the chassis from the truck.

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

13.6 Hoods, hatches (0340) Disassembly • Remove the hood.

Material handling The hood is to be placed in a container intended for ABS.

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

• Remove hydraulic cables.

• Remove the pump motor including the pump.

Material handling Oil should be treated as dangerous waste.

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

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

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Destruction instructions Drive assembly/drive motor (1760/2550) T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

13.8 Drive assembly/drive motor (1760/ 2550)

1

2

Disassembly • Remove the cables.

• Remove the drive motor including the electric parking brake (1) from the gearbox.

• Empty the oil from the gearbox.

• Remove the drive wheel (2).

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

The oil should be treated as dangerous waste.

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

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Destruction instructions Wheels (3500) Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

13.9 Wheels (3500) 1 3 2

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

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

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Destruction instructions Tiller arm (4110) T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

13.10 Tiller arm (4110) Disassembly • Remove the cables.

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

• Remove the switch (2).

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

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

1

The switch should be placed in containers intended for electronic scrap.

2

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Destruction instructions General electrical equipment (5100) Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

13.11 General electrical equipment (5100)

+

-

+

-

Disassembly • Remove the cables.

• Remove batteries.

• Remove the electronic devices.

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

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

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

Service Manual

SP10, SP10S, PP13

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Destruction instructions Hydraulic unit (6100) T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

13.12 Hydraulic unit (6100) Disassembly 2

• Empty the oil from the hydraulics.

• Remove hydraulic cables.

• Remove the oil tank (1).

• Empty the oil from the tank.

• Remove the hydraulic unit (motor + pump) (2) (see 1710).

Material handling Oil should be treated as dangerous waste.

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

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

1

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Destruction instructions Hydraulic cables/cylinders (6230/6610) Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

13.13 Hydraulic cables/cylinders (6230/ 6610) Disassembly • Remove the cylinder (1).

• Empty the oil from the cylinder.

• Cut the cylinder in half • Remove the hydraulic cables (2).

• Remove the hydraulic hoses.

1

2

Material handling The oil should be treated as dangerous waste.

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

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

© TIEE SARL

Service Manual

SP10, SP10S, PP13

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Destruction instructions Main mast and fork carriage (7100) T-code 795, 675

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

Date 2006-09-29

Order number 242330-040

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

• Remove plastic components from the main mast.

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

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

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Service Manual

SP10, SP10S, PP13

© TIEE SARL

Destruction instructions Main mast and fork carriage (7100) Order number 242330-040

Date 2006-09-29

Valid from serial number 904526- (SP10, SP10S) 914369- (PP13)

T-code 795, 675

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© TIEE SARL

Service Manual

SP10, SP10S, PP13

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©TOYOTA Industrial Equipment Europe SARL Ancenis, France