Toyota Forklift SP10 SP10S Service Manual SN 904526 - PDF DOWNLOAD

Service Manual en

SP10, SP10S Valid from serial number: 904526-

Order number: 235568-040 Issued: 2006-04-10 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:

Issue date

Order number

Changes

2006-04-10

235568

Completely new issue.

This manual covers following truck models:

T-code

Model

Serial number

795

SP10

904526-

795

SP10S

904526-

© TIEE SARL

Service Manual

SP10, SP10S

Table of contents Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

1- Table of contents 1- Table of contents ................................................................................. 1-1 2- Technical data ..................................................................................... 2-1 2.1 General tightening torques............................................................. 2-4 3- Maintenance ........................................................................................ 3-1 3.1 Safety regulations with maintenance work ..................................... 3-1 3.2 Cleaning and washing.................................................................... 3-3 3.2.1 External cleaning ............................................................. 3-3 3.2.2 Cleaning the motor compartment .................................... 3-3 3.2.3 Electrical components ..................................................... 3-3 3.3 Safe lifting ...................................................................................... 3-4 3.4 Lifting the truck............................................................................... 3-5 3.5 Placing the truck on its side............................................................ 3-6 3.6 Maintenance Schedule .................................................................. 3-7 3.7 Lubrication chart .......................................................................... 3-11 4- Oil and grease specification ............................................................... 4-1 5- Tools ..................................................................................................... 5-1 5.1 Super Seal connectors................................................................... 5-1 5.2 AMP connectors............................................................................. 5-2 5.2.1 AMP Connectors, 040 series ........................................... 5-3 5.3 Molex connectors........................................................................... 5-3 5.4 Grease guns .................................................................................. 5-4 5.5 Other tools ..................................................................................... 5-5 6- Chassis - 0000 ..................................................................................... 6-1 6.1 Support arms SP10........................................................................ 6-1 6.1.1 Placement of supportarms ............................................... 6-2 6.2 Support arms SP10S ..................................................................... 6-3 6.2.1 General ............................................................................ 6-3 6.2.2 Main Components ........................................................... 6-3 6.2.3 Maintenance .................................................................... 6-4 6.2.4 Adjusting the support arm width ...................................... 6-4 6.2.5 Replacing support arms ................................................... 6-5 7- Drive unit/drive gear – 2000 ................................................................ 7-1 7.1 Component parts ........................................................................... 7-1 7.2 Service and repairs ........................................................................ 7-2 7.2.1 Dismantling the motor from the truck ............................... 7-2 7.2.2 Inspection/replacement of the carbon brushes ................ 7-2 7.2.3 Replacing the drive gear .................................................. 7-3 7.2.4 Cleaning .......................................................................... 7-3 7.2.5 Brakes, Maintenance ....................................................... 7-4 7.2.6 Replacing the brake disc ................................................. 7-4 8- Wheel system - 3000 ........................................................................... 8-1 8.1 Swivel wheel suspension ............................................................... 8-1 8.1.1 Components .................................................................... 8-1 © TIEE SARL

Service Manual

SP10, SP10S

1- 1

Table of contents T-code 795

Valid from serial number 9045268.1.2 8.1.3

Date 2006-04-10

Order number 235568-040

Lubricating the nipples ..................................................... 8-1 Adjusting the swivel wheel pressure ................................ 8-2

9- Steering system – 4000 ....................................................................... 9-1 9.1 Components .................................................................................. 9-1 10- Electrical system – 5000 ................................................................. 10-1 10.1 General ........................................................................................ 10-1 10.1.1 Firmware (truck control software) .................................. 10-1 10.2 Nomenclature .............................................................................. 10-1 10.3 Electrical equipment overview ..................................................... 10-2 10.3.1 Electric component overview ......................................... 10-4 10.4 Accessing main electrical panel ................................................... 10-6 10.5 Electrical circuit overview ............................................................. 10-7 10.6 Symbol list.................................................................................... 10-8 10.7 Electrical wiring diagram ............................................................. 10-9 10.8 Functional description ................................................................ 10-14 10.8.1 Theory of operation ..................................................... 10-14 10.8.2 Transistor regulator ..................................................... 10-18 General ........................................................................ 10-18 Safety .......................................................................... 10-18 10.8.3 On-board battery charger ............................................ 10-20 General ........................................................................ 10-20 Charging ...................................................................... 10-20 10.8.4 Battery charge status ................................................... 10-21 Battery display (option) ................................................ 10-21 10.8.5 Speed limitation ........................................................... 10-22 10.8.6 Hour meter ................................................................... 10-22 10.8.7 Hand terminal .............................................................. 10-23 General ........................................................................ 10-23 Connecting the hand terminal ...................................... 10-23 Hand terminal overview ............................................... 10-23 Hand terminal menus .................................................. 10-25 10.9 Diagnostic and troubleshooting.................................................. 10-26 10.9.1 General ........................................................................ 10-26 10.9.2 Display of error codes .................................................. 10-26 Direct display of error codes ........................................ 10-26 Hand terminal display of error codes ........................... 10-26 Error code history ........................................................ 10-27 10.9.3 List of error codes ........................................................ 10-28 10.9.4 TESTER function ......................................................... 10-31 10.10 Parameters & adjustments......................................................... 10-33 10.10.1 General ........................................................................ 10-33 10.10.2 Adjusting parameters ................................................... 10-33 10.10.3 List of parameters ........................................................ 10-34 10.10.4 Description of parameters ........................................... 10-35 Acceleration ramp time (ACC.DELAY) ........................ 10-35 Deceleration ramp time (DECELER.DELAY) .............. 10-35 Neutral braking intensity (RELEASE BRAKING) ......... 10-35 Reverse braking intensity (INVERSION BRAKING) .... 10-35 Maximum travel speed (CUTBACK SPEED 3) ............ 10-35 Reset service counter (CHECK UP DONE) ................ 10-35 Select service warning type (CHECK UP TYPE) ........ 10-35 “Time to next service” (CHECK UP HOURS) .............. 10-36 10.10.5 Transferring parameter sets ........................................ 10-36 1- 2

Service Manual

SP10, SP10S

© TIEE SARL

Table of contents Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

General ........................................................................ 10-36 From the truck to the hand terminal ............................. 10-37 From the hand terminal to the truck ............................. 10-38 10.10.6 Calibrating the speed potentiometer ............................ 10-38 General ........................................................................ 10-38 Procedure .................................................................... 10-39 10.11 Technical specifications ............................................................. 10-40 10.11.1 Transistor regulator SEM-X ......................................... 10-40 11- Hydraulic system - 6000 ................................................................. 11-1 11.1 General ........................................................................................ 11-1 11.2 Hydraulics diagram and components........................................... 11-2 11.3 Description ................................................................................... 11-4 Lift .................................................................................. 11-4 Lower ............................................................................. 11-4 Operating pressure ........................................................ 11-4 Pressure limit valve ....................................................... 11-4 11.4 Adjustments ................................................................................. 11-5 Adjustment of the pressure limit valve ........................... 11-5 11.5 Tools ............................................................................................ 11-6 12- Lift mast – 7000 ............................................................................... 12-1 12.1 Main mast .................................................................................... 12-1 12.1.1 Components .................................................................. 12-1 12.1.2 Maintenance .................................................................. 12-2 Mounting ........................................................................ 12-2 Lubrication ..................................................................... 12-2 12.1.3 Cylinder ......................................................................... 12-3 Disassembly .................................................................. 12-3 Assembly ....................................................................... 12-3 12.2 Fork carriage................................................................................ 12-4 12.2.1 Maintenance .................................................................. 12-4 12.3 Main lift chain system................................................................... 12-5 12.3.1 Checking the chain setting ............................................ 12-5 12.3.2 Chain inspection ............................................................ 12-5 Noise ............................................................................. 12-5 Surface rust ................................................................... 12-5 Rusty links ..................................................................... 12-5 Stiff links ........................................................................ 12-5 Bolt rotation ................................................................... 12-6 Loose bolts .................................................................... 12-6 Outline wear .................................................................. 12-6 Stretching ...................................................................... 12-7 Damage ......................................................................... 12-8 Damaged discs .............................................................. 12-8 Damaged bolts .............................................................. 12-8 Dirty chain ...................................................................... 12-8 12.3.3 Cleaning ........................................................................ 12-8 12.3.4 Lubrication ..................................................................... 12-9 13- Accessories – 9000 ......................................................................... 13-1 13.1 Automatic height adjustment........................................................ 13-1 13.1.1 General .......................................................................... 13-1 13.1.2 Electrical wiring diagram ................................................ 13-3 © TIEE SARL

Service Manual

SP10, SP10S

1- 3

Table of contents T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

14- Destruction instructions ................................................................. 14-1 14.1 General ........................................................................................ 14-1 14.2 Procedure .................................................................................... 14-1 14.3 Abbreviations ............................................................................... 14-2 14.4 Sorting ......................................................................................... 14-2 14.5 Chassis (0300)............................................................................. 14-3 Disassembly .................................................................. 14-3 Material handling ........................................................... 14-3 14.6 Hoods, hatches (0340)................................................................. 14-3 Disassembly .................................................................. 14-3 Material handling ........................................................... 14-3 14.7 Electric Pump Motor (1710) ........................................................ 14-3 Disassembly .................................................................. 14-3 Material handling ........................................................... 14-3 14.8 Drive assembly/drive motor (1760/2550) ..................................... 14-4 Disassembly .................................................................. 14-4 Material handling ........................................................... 14-4 14.9 Wheels (3500).............................................................................. 14-5 Disassembly .................................................................. 14-5 Material handling ........................................................... 14-5 14.10 Tiller arm (4110)........................................................................... 14-5 Disassembly .................................................................. 14-5 Material handling ........................................................... 14-5 14.11 General electrical equipment (5100) ............................................ 14-6 Disassembly .................................................................. 14-6 Material handling ........................................................... 14-6 14.12 Hydraulic unit (6100) .................................................................... 14-7 Disassembly .................................................................. 14-7 Material handling ........................................................... 14-7 14.13 Hydraulic cables/cylinders (6230/6610) ....................................... 14-8 Disassembly .................................................................. 14-8 Material handling ........................................................... 14-8 14.14 Main mast and fork carriage (7100) ............................................. 14-9 Disassembly .................................................................. 14-9 Material handling ........................................................... 14-9

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Service Manual

SP10, SP10S

© TIEE SARL

Technical data Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

2- Technical data Model

SP10

SP10S

Type

TSL115-16

TSL115-16

Output

0,5 kW

0,5 kW

Duty cycle

S2, 60 min

S2, 60 min

Minimum carbon brush length

14,5 mm

14,5 mm

Nominal commutator diameter

43 mm

43 mm

Minimum commutator diameter

40 mm

40 mm

Resistance, shunt field winding, at 25 C°

1,3 Ω

1,3 Ω

Resistance, armature winding, at 24 C°

0,0156 Ω

0,0156 Ω

Insulation resistance between windings and motor casing

>=1 Mohm

>=1 Mohm

Weight

25 kg

25 kg

Type

891.270.0

891.270.0

Brake power

9 Nm

9 Nm

Output

28 W

28 W

Resistance, coil

20,8 Ω

20,8 Ω

Minimum thickness brake disc

6,75 mm

6,75 mm

Thickness of new brake disc

6,90 mm

6,90 mm

Type

2-stage wheel gear

2-stage wheel gear

Gear ratio

24,8:1

24,8:1

Grease volume

0,36 kg

0,36 kg

Grease type

ESSO UNIREX N2

ESSO UNIREX N2

Drive motor

Brakes

Transmission/drive gear

© TIEE SARL

Service Manual

SP10, SP10S

2- 1

Technical data T-code 795

Valid from serial number 904526-

Model

Date 2006-04-10

Order number 235568-040

SP10

SP10S

Drive wheel

Ø250x60 mm

Ø250x60 mm

Axle pressure without load

210 kg

440 kg

Axle pressure at rated load

360 kg

580 kg

Tightening torque for wheel bolts

20 Nm

20 Nm

Fork wheels

Ø85 mm

Ø85 mm

Axle pressure without load

2x60 kg

2x80 kg

Axle pressure at rated load

2x500 kg

2x515 kg

Support arm wheels

Ø100x40 mm

-

Axle pressure without load

2x70 kg

-

Axle pressure at rated load

2x70 kg

-

Output

1,4 kW

1,4 kW

Duty cycle

3,5 %

3,5 %

Minimum carbon brush length

10 mm

10 mm

Minimum commutator thickness/diameter

28,6 mm

28,6 mm

Pressure at rated load

190 bar

190 bar

Overflow pressure

210 bar

210 bar

Pump flow

4,5 l/min

4,15 l/min

Tank volume

2l

2l

Oil type at normal temperature

ISO-L-HM32

ISO-L-HM32

Oil type <15 °C

ISO-L-HV32

ISO-L-HV32

Drive motor circuit (shared with pump)

100 A

100 A

Pump motor circuit (shared with drive motor)

100 A

100 A

Control circuits

5A

5A

Battery charger

10 A

10 A

Dimension L x W x H

278x175x190 mm

278x175x190 mm

Capacity

50 Ah

50 Ah

Weight

2x20 kg

2x20 kg

Wheels

Hydraulic system

Fuses

Battery compartment, Batteries

2- 2

Service Manual

SP10, SP10S

© TIEE SARL

Technical data Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

Model

T-code 795

SP10

SP10S

Without load

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)

Lifting without load

0,22 m/s

0,19 m/s

Lift with rated load, s

0,12 m/s

0,10 m/s

Lowering without load, s

0,14 m/s

0,14 m/s

Lowering with rated load, s

0,15 m/s

0,15 m/s

Driving speeds

Lift/lowering speed

Power consumption (truck at room temperature) Driving without load

20 A

20 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%

Without load

10 %

10 %

Measurments L2

530 mm

530 mm

Turning radius WA

1340 mm

1365 mm

Lift height

1580 mm / 2000 mm

1540 mm / 1960 mm

420 kg / 430 kg

560 kg / 580 kg

Hill-climbing ability

Measurement

Weight Truck without battery

© TIEE SARL

Service Manual

SP10, SP10S

2- 3

Technical data General tightening torques T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

2.1 General tightening torques Millimetre thread M3 to M24.

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

Table 1: General tightening torques [Nm] M3

M4

M6

M8

M10

B

C

B

C

B

C

B

C

B

C

B

C

1,15

1,2

2,8

2,9

5,5

5,7

9,5

9,8

23

24

45

47

12,9 2,0

2,1

4,7

4,9

9,3

9,7

16,3

17,0

38,5

40,0

75,8

79,0

A 8,8

M12 A

M5

8,8

M14

M16

M20

M24

B

C

B

C

B

C

B

C

B

C

77,7

81

123

128

189

197

369,6

385

638,5

665

649

1075

1120

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

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

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Service Manual

SP10, SP10S

© TIEE SARL

Maintenance Safety regulations with maintenance work Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

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

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

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

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

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

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

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

WARNING! Short-circuiting/Burns.

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

Remove watches, rings or other types of metal jewellery.

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

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

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

Service Manual

SP10, SP10S

3- 1

Maintenance Safety regulations with maintenance work T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

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

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

WARNING! Risk of burns.

Hot transmission and hydraulic oil.

Let the truck cool before changing the oil.

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

WARNING! The hydraulic system can be damaged.

If the oil is contaminated hydraulic components can be damaged.

Always use new and clean oil in the hydraulic system.

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

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

• Disconnect the battery when welding on the truck.

NOTE! The battery can be damaged.

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

The battery should therefore be disconnected.

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

CAUTION! Harmful gases.

Paint that is heated gives off harmful gases.

Remove 100 mm of paint from the work area.

3- 2

Service Manual

SP10, SP10S

© TIEE SARL

Maintenance Cleaning and washing Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

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.

© TIEE SARL

Service Manual

SP10, SP10S

3- 3

Maintenance Safe lifting T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

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

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

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

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

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

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

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

This reduces the risk of the truck tipping over.

- so that the truck cannot roll.

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

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

WARNING! Risk of crushing.

A badly supported truck can fall.

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

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Service Manual

SP10, SP10S

© TIEE SARL

Maintenance Lifting the truck Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

3.4 Lifting the truck • 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.

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

550

700

100 mm

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

3- 5

Maintenance Placing the truck on its side T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

3.5 Placing the truck on its side 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.

3- 6

Service Manual

SP10, SP10S

© TIEE SARL

Maintenance Maintenance Schedule Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

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

Pos.

Work to carry out Interval in days/weeks/months – can vary depending on the application

1d

1 wk 12 m 36 m

0000

Chassis

0000.1

Check for cracks and damage

I

I

0000.2

Check the signs and decals

I

I

0000.3

Check the hood’s mounting and operation

I

I

0000.4

Visual inspection of the bolt joint between the chassis and the support arms.

I

I

1700

Drive motor

1700.1

Check for loose connections

I

I

1700.2

Check the carbon brushes in the drive motor

M

M

1700.3

Clean the drive motor

C

C

1700.5

Check for abnormal noise in the bearings

I

I

2550

Drive transmission

2550.1

Check for leakage

2550.2

Check for abnormal noise

I

I

2550.3

Check the mountings and play in the steering bearings

I

I

2550.4

Change the grease in the drive transmission

3100

Brakes

3100.1

Clean

C

C

3100.2

Check for wear to the brake discs

M

M

3100.3

Check the operation of the brake

M

M

© TIEE SARL

I1

Service Manual

SP10, SP10S

L

3- 7

Maintenance Maintenance Schedule T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

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

Pos.

Work to carry out Interval in days/weeks/months – can vary depending on the application

3500

Wheels

3500.1

Remove string and other debris

3500.2

1d

1 wk 12 m 36 m

I

I

I

I

Check the drive wheel for wear and check the tightening torque of the bolts

I/T2

I/T2

3500.3

Check the spiral pin in the fork wheels.

I

I

3500.4

Check for wear on the fork wheels.

I

I

3500.5

Check that the swivel wheels rotate and swing freely

I

I

3500.6

Check for wear on the swivel wheels

I

I

3500.7

Press in grease in the grease nipples for the swivel wheels

I/L

I/L

3500.8

Check the drive wheel pressure through the swivel wheel setting in relation to the drive wheel.

I/M

I/M

4110

Tiller arm

4110.1

Check the mountings

I

I

4110.2

Check the gas cartridge's force

I

I

4110.3

Check the touch guard

I

I

5000

Electrical functions

5000.1

Check the operation of the brake microswitch

I

I

I

I

5000.2

Check the function of the safety switch that prevents collisions

I

I

I

I

5000.3

Check the horn function

I

I

I

I

5000.4

Check for wear on the cables

I

I

5000.5

Check the operation of the driver's controls

I

I

I

I

5000.6

Check the emergency switch

I

I

I

I

5000.7

Check the charger plug and ignition lock

I

I

I

I

5000.8

Check the battery indicator (option)

I

I

5110

Battery

5110.1

Check the connections to the battery, truck and charger

I

I

I

5110.2

Check that the batteries are not damaged

I

I

I

5110.3

Check the battery lock

I

I

I

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Service Manual

SP10, SP10S

© TIEE SARL

Maintenance Maintenance Schedule Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

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

Pos.

Work to carry out Interval in days/weeks/months – can vary depending on the application

1d

1 wk 12 m 36 m

5400

Power system

5400.1

Clean and check the chassis mountings

C/T

C/T

5400.2

Tighten the cable connections

T

T

5400.3

Check the contactors' operation

I

I

5400.4

Check the cable insulation

I

I

6100

Hydraulic system

6100.1

Inspect hoses and connections for leakage

I

I

6100.2

Check hoses for wear and damage

I

I

6100.3

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

I

I

6100.4

Check that the oil level is correct

I

I

6100.5

Change the oil and clean the filter

L3

L3

6600

Lift cylinders

6600.1

Check for leakage

I

I

6600.2

Check the mountings

I

I

7100

Mast

7100.1

Check for cracks and damage

I

I

7100.2

Visual inspection of the bolt joint between the mast and the chassis.

I

I

7100.3

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

I

I

7100.4

Check the adjustment of the lift chain

I

I

7100.5

Check the cylinder cover on the mast

I

I

7420

Fork carriage

7420.1

Check for cracks and damage

I

I

7420.2

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

I

I

7420.3

Check for wear on the steering pivots and grease them

I/L

I/L

I

1 = Check for leakage in connection with the first grease change.

2 = Wheels are replaced when the wheel diameter is < 245 mm. Wheel bolts are checked by tightening every 12 months at 20 Nm. 3 = The oil is changed and the filter cleaned for the first time after 12 months and then every 24 months. © TIEE SARL

Service Manual

SP10, SP10S

3- 9

Maintenance Maintenance Schedule T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

7100

5400

4110 5000

6600

5110

0000

7420

6100

STRADDLE

2550 1700

3500

3100

7420 3500

3- 10

Service Manual

SP10, SP10S

© TIEE SARL

Maintenance Lubrication chart Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

3.7 Lubrication chart Pos.

Service check

Interval/Operating hours 12 mo.

Lubrication type

36 mo.

2550

Steering bearing

2550

Drive transmission

3500

Wheel bearings

3500

Grease nipples

L

D

6100

Hydraulic system

O2

B

7100

Mast beam

L

E

7100

Lift chain

L

F

L = Lubricate

I = Inspect

I

L

G

G1

C

L

A

O = Oil change

G = Grease change

1 = Grease is changed every 36 months.

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

© TIEE SARL

Service Manual

SP10, SP10S

3- 11

Maintenance Lubrication chart T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

This page is intentionally left blank

3- 12

Service Manual

SP10, SP10S

© TIEE SARL

Oil and grease specification Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

4- Oil and grease specification Table 3: Oil and grease specification Lubrication type

Specification

Use

> -15 °C

< -15 °C

A

Grease

223690 Q8 Rembrandt EP2

223690 Q8 Rembrandt EP2

Bearings and bushings

B

Hydraulic oil

ISO-L-HM32

ISO-VG32

Hydraulic system

C

Grease

ESSO UNIREX N2

ESSO UNIREX N2

Gears

D

Grease

223690 Q8 Rembrandt EP2

223690 Q8 Rembrandt EP2

Grease nipples

E

Grease

29586 Gleitmo 805

29586 Gleitmo 805

Inside of beam ribs

223690 Q8 Rembrandt EP2

223690 Q8 Rembrandt EP2

Inside of beam flanges

F

Grease

See table below

See table below

Chains

G

Grease

Staburags NBU 8EP

Staburags NBU 8EP

Steering bearing

Ambient temperature

Viscosity class

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

> -40°C < -30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> -30°C < +5°C

VG 68

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

> +5°C < +45°C

VG 150

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

> +45°C < +80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

© TIEE SARL

Service Manual

SP10, SP10S

4- 1

Oil and grease specification T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

This page is intentionally left blank

4- 2

Service Manual

SP10, SP10S

© TIEE SARL

Tools Super Seal connectors Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

5- Tools 5.1 Super Seal connectors 1 3

3 2

Figure

© TIEE SARL

Number

Application

159232

Tools for fitting pins/sleeves

159229

Tools for loosening locks (1)

159230

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

159231

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

159228

Tools for removing pins/sleeves (3)

Service Manual

SP10, SP10S

5- 1

Tools AMP connectors T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

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

Figure

2

1

Number

Application

151080 (PT)

Tools for removing pins/sleeves

213296 (JPT)

Tools for removing pins/sleeves

213298 (MPT)

Tools for removing pins/sleeves

1=163787 2=163788

Tools for fitting sleeves

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

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

2

5- 2

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

1

Service Manual

SP10, SP10S

© TIEE SARL

Tools Molex connectors Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

5.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

5.3 Molex connectors 16 9 8 1 Figure

© TIEE SARL

Service Manual

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

SP10, SP10S

5- 3

Tools Grease guns T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

5.4 Grease guns Figur

fif

5- 4

Nummer

Användning

24981

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

755132

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

755142

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

755152

Two-hand grease gun with hose and nozzle.

755146

Grease hose 450 mm.

Grease hose 750 mm.

Grease hose 1500 mm.

202154PM

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

Fits grease guns with hose and discharge pipe.

Length 125 mm.

755140

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

Service Manual

SP10, SP10S

© TIEE SARL

Tools Other tools Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

5.5 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

5- 5

Tools Other tools T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

This page is intentionally left blank

5- 6

Service Manual

SP10, SP10S

© TIEE SARL

Chassis - 0000 Support arms SP10 Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

6- Chassis - 0000 6.1 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

6- 1

Chassis - 0000 Support arms SP10 T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

6.1.1 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

6- 2

Service Manual

Hole

Width of forks

1

550 ,mm

2

685 mm

1

536

SP10, SP10S

© TIEE SARL

Chassis - 0000 Support arms SP10S Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

6.2 Support arms SP10S 6.2.1 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.

6.2.2 Main Components

© TIEE SARL

Service Manual

SP10, SP10S

6- 3

Chassis - 0000 Support arms SP10S T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

Pos.

Name

1

Support arms

2

Clamps (mounting)

3

Screws and nuts, MC6S16x100

4

Locking screw and nut, M6S 12x60H

6.2.3 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.

6.2.4 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.

6- 4

Service Manual

SP10, SP10S

© TIEE SARL

Chassis - 0000 Support arms SP10S Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

6.2.5 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.

• 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

6- 5

Chassis - 0000 Support arms SP10S T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

This page is intentionally left blank

6- 6

Service Manual

SP10, SP10S

© TIEE SARL

Drive unit/drive gear – 2000 Component parts Order number 235568-040

27 26

Date 2006-04-10

Valid from serial number 904526-

T-code 795

7- Drive unit/drive gear – 2000

31

24 23

30 29 28

7.1 Component parts

22

25

Table 4: 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

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

Pos

Service Manual

SP10, SP10S

7- 1

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

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

7.2 Service and repairs 7.2.1 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.

7.2.2 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.

7- 2

Service Manual

SP10, SP10S

© TIEE SARL

Drive unit/drive gear – 2000 Service and repairs Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

7.2.3 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.

7.2.4 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

7- 3

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

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

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

7.2.6 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.

7- 4

Service Manual

SP10, SP10S

© TIEE SARL

Wheel system - 3000 Swivel wheel suspension Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

8- Wheel system - 3000 8.1 Swivel wheel suspension 8.1.1 Components

1

2 3

4

5 6

Table 5: Components, swivel wheel suspension Pos.

Name

Pos.

Name

1

Swivel wheel, complete

4

Nut

2

Stop screw

5

Holder

3

Washer

6

Grease nipple

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

© TIEE SARL

Service Manual

SP10, SP10S

8- 1

Wheel system - 3000 Swivel wheel suspension T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

8.1.3 Adjusting the swivel wheel pressure Table 6: Adjusting the swivel wheel pressure Description 1

Pictures

The swivel 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 swivel wheel meets with some degree of resistance when rotated.

3 mm

8- 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

© TIEE SARL

Steering system – 4000 Components Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

9- Steering system – 4000 9.1 Components 1 2 3 4

5

Table 7: Components, steering system

© TIEE SARL

Pos.

Name

Pos.

Name

1

Switch

4

Restorer

2

Gas damper

5

Cover

3

Spring

Service Manual

SP10, SP10S

9- 1

Steering system – 4000 Components T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

This page is intentionally left blank

9- 2

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 General Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

10- Electrical system – 5000 10.1 General The electrical system of the truck is based on the SEM-X system.

• The main power source is a 24 V DC traction battery.

• The travel drive motor is a separate excitation type (SEM). The travel drive motor is operated by a self-contained transistor regulator relying on pulse width modulation (PWM) technology.

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

• A set of parameters used to adjust the truck’s performance and braking characteristics is stored in the transistor regulator. The regulator also monitors error conditions that may occur.

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

The firmware stored in the transistor regulator cannot be updated or changed.

10.2 Nomenclature Items shown in square brackets [ ] refer to electrical component designations as stated in the electrical wiring diagrams. See “10.3.1 Electric component overview” on page 4.. {high} refers to a voltage level that is approximately the same as the supply voltage level. {low} refers to a voltage level of approximately 0 Volt. s/c = short circuit. o/c = open circuit.

© TIEE SARL

Service Manual

SP10, SP10S

10- 1

Electrical system – 5000 Electrical equipment overview T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.3 Electrical equipment overview

L1 S20

R1 S15 S16 S18

S34 S41

Fig. 1

10- 2

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Electrical equipment overview Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

F51 F50 S170 H81 S17 S21

H1 PTC A30 A1

S171

CONS K10

F1

K30

S10

M3 Y41 G1

G2 Y1 M1

Fig. 2

© TIEE SARL

Service Manual

SP10, SP10S

10- 3

Electrical system – 5000 Electrical equipment overview T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.3.1 Electric component overview The following table shows a summary of the major electric components of this truck.

Table 8: Component designation overview Inf.

G1, G2

Main electrical power source

Traction battery 12 V

Fig. 5

Fig. 2

S170

Start interlock

Interlock device

Fig. 6

Fig. 2

K10

Main contactor

Contactor

Fig. 5

Fig. 2

S171

Secondary interlock

Auxiliary contactor switch

Fig. 5

Fig. 2

PTC

Temporary supply

PTC resistor

Fig. 5

Fig. 2

Designation

Picture ref.

Component type

Diagram ref.

Function

Energy and main power isolation

2

Equipment protection F1

Traction & pump motor protection

Fuse 100 A

Fig. 5

Fig. 2

F 50

Operating circuit protection A1

Fuse 5 A

Fig. 5

Fig. 2

F 51

Battery charger protection A30

Fuse 10 A

Fig. 5

Fig. 2

Control and Signal processing A1

Traction & braking power control

Transistor regulator

Fig. 5, Fig. 6

Fig. 2

S17

Key switch on

Switch

Fig. 6

Fig. 2

H81

Battery status indication (BDI)

LED

Fig. 6

Fig. 2

Safety and braking S21

Emergency switch-off

Switch

Fig. 6

Fig. 2

S10

Tiller in drive position

Switch

Fig. 6

Fig. 2

S20

Emergency reverse (belly button)

Switch

Fig. 6

Fig. 1

Y1

Mechanical brake

Electromagnetic brake

Fig. 5

Fig. 2

H1

Audible warning signal -Horn

Horn

Fig. 6

Fig. 2

S18

Horn activation

Switch

Fig. 6

Fig. 1

10- 4

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Electrical equipment overview Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

Component type

Picture ref.

L1

Speed control and travel direction selector (butterfly)

Lever

-

Fig. 1

S15

Travel in forks direction

Switch

Fig. 6

Fig. 1

S16

Travel in drive wheel direction

Switch

Fig. 6

Fig. 1

R1

Speed control

Potentiometer

Fig. 6

Fig. 1

M1

Traction

Motor

Fig. 5

Fig. 2

Designation

Function

Diagram ref.

Table 8: Component designation overview Inf.

Traction 1

Lifting / lowering forks S34

Fork lifting control

Switch

Fig. 6

Fig. 1

S41

Fork lowering control

Switch

Fig. 6

Fig. 1

Y41

Fork lowering -hydraulic control

Magnetic valve

Fig. 5

Fig. 2

K30

Fork lifting (Pump motor power switching)

Contactor

Fig. 5

Fig. 2

M3

Pump motor

Motor

Fig. 5

Fig. 2

A30

On-board battery charging

Battery charger

Fig. 7

Fig. 2

CONS

Connection point for hand terminal

Connector

-

Fig. 2

Other 3

Footnotes to the table above: 1 - L1 refers to the physical control lever (butterfly) only. It is not explicitly referred to in the electrical diagrams.

2 - This switch is mounted directly on the main contactor. It operates when the contactor opens or closes.

3 - Consult “10.8.7 Hand terminal” on page 23 for information regarding use of the hand terminal.

© TIEE SARL

Service Manual

SP10, SP10S

10- 5

Electrical system – 5000 Accessing main electrical panel T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.4 Accessing main electrical panel Access must be gained to the main electrical panel - Fig. 3 B when performing any of the following: • Checking the alarm status LED. • Connecting the hand terminal to the transistor regulator.

• Checking / changing any of the fuses.

• Checking / changing any of the components mounted on the panel.

• For inspection of the traction motor or hydraulic unit.

A

B

NOTE! Before removing the electrical panel ensure the key switch [S17] is off and the charger’s mains plug is neither plugged into the start interlock [S170] or any mains outlet socket. For maximum safety it is advisable to also remove the negative connection from battery [G2].

• Remove the screws securing the main cover (Fig. 3 A) and lift the cover free of the truck.

Fig. 3 Access to electrical panel

• Remove the two securing screws holding the main electrical panel in place (Fig. 3 B).

• Lift the panel vertically approx. 1 cm.

• The upper edge of the panel can now be lifted away from the truck and the panel can be “folded out”. The panel can now be positioned allowing it to “rest” in the folded out position.

• Ensure no undue strain is put on any cables in the wiring loom.

Fig. 4 “folded out” electrical. panel

10- 6

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Electrical circuit overview Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

10.5 Electrical circuit overview A/C IN.

PTC

A30

F1 K10

H1 S18

F51

S170 F50 +

-

+

-

G2

S10

G1

S21

S17

H81 OUT.BATT.IND

INP.KEY SWITCH

K10 OUT.NEG.MAIN CONTACTOR INP.SUPPLY MAIN CONTACTOR

INP.LOWER S41 M3 A1

A1

A2

M

Y41 K30 OUT.NEG K30/Y41 S171(K10)

R1

INP.SPEED CONTROL.

S34 INP.LIFT M1

INP.DRIVE WHEEL DIR. S16 + BATT

A1

OUT.FIELD 1

E1

INP.FORK WHEEL DIR. S15

M S

A2

E2

OUT.FIELD 2 ARMATURE

INP.BELLY BUTTON

Y1

S20 OUT. BRAKE INP.TILLER SWITCH

- BATT

based on 181444 rev.D © TIEE SARL

Service Manual

SP10, SP10S

10- 7

Electrical system – 5000 Symbol list T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.6 Symbol list Table 9: Symbol list Symbol

A1

E1

M S

Description

Symbol

Description

Truck battery

Horn

Fuse

Emergency stop switch, NC

Resistor (PTC)a

Switch, key operated, NO

DC motorb (SEM type)c

Microswitch, NO

DC motor

Microswitch (push button), NO

Contactor

Variable resistor (potentiometer)

Brake coil (normally applied)

Coil for hydraulic magnetic valve

A2

E2

Multi-pin connector

NO = Normally Open NC = Normally closed

a. PTC = Positive Temperature Coefficient (resistance increases as temperature increases) b. DC = Direct Current c. SEM = Separately Excited Motor

10- 8

Service Manual

SP10, SP10S

© TIEE SARL

© TIEE SARL

Service Manual

SP10, SP10S

1

2

1

LOWER VALVE Y41 43

A2

K10

A1

2

2

A2

K30 A1

1

-

43

PUMP MOTOR M3 8 A1 A2 M

+

G2

14

13

X31

S171

F2

A1

1

Y1 2

FIELD

M

M1

F1

A2

X31

33

43

23

42

31

41

5

4

6

3

40

A10

A2

A15

A14

A4

A11

F2

F1

VMN

INP, LIFT

1/5

181444

PROD E

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. 5 Sheet 1 of 5

33

23

31

2

R2

PTC

F1

100A

+

G1

Valid from serial number 904526-

Sh. 2

Sh. 2

Sh. 2

34

40

F51

1

Date 2006-04-10

Sh. 2

Sh. 2

BK

RD

9

10A

5A

F50

Order number 235568-040

Sh. 4

Sh. 4

Sh. 3

Sh. 2

20

ELECTRONIC CARD A1

Electrical system – 5000 Electrical wiring diagram

T-code 795

10.7 Electrical wiring diagram

10- 9

10- 10

Service Manual

SP10, SP10S

34

NO

RD 57

COM NO

X30

HORN SWITCH S18 X30

BK

H1

2

COM

COM

S20

3K3

S16

NC

NO

NO

COM

NC

13

COM

JUMPER, TRUCK WITH MAST

COM

S15 NO

S206

S41

14

NO

NC

NO

FORK LIFT S34

COM

LIFT LIMIT, TRUCK WITHOUT MAST S31

3

R1 1

X30

X30

X30

35

X30

X30

X30

X30

X30

X30

H81

60

34

55

54

53

52

51

50

59

22

A8

A13

A5

A7

A6

A9

A1

A3

A12

A16

181444

PROD D

Fig. 6 Sheet 2 of 5

2/5

INP. "TURTLE" FUNCTION

INP, LOWER

INP, BELLY BUTTON.

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

Date 2006-04-10

Sh. 1

33

31

COM

TILLER SWITCH S10

1

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

(*)

2

KEY S17

Valid from serial number 904526-

Sh. 1

Sh. 1

X30

40

23

23:B

23:A

PLUG:B

PLUG:A

23

T-code 795

Sh. 1 3

Sh. 1

Sh. 4

Sh. 4

Sh. 3

Sh. 3

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

ELECTRONIC CARD A1

Electrical system – 5000

Electrical wiring diagram Order number 235568-040

© TIEE SARL

Electrical system – 5000 Electrical wiring diagram Date 2006-04-10

Valid from serial number 904526-

© TIEE SARL

PROD 3/5 INP, GROUND

INP, MAINS VAC PLUG:B Sh. 2

Sh. 2

Sh. 2

Sh. 1

PLUG:A

INP, MAINS VAC

OUT, NEGATIVE CHARGER VOLTAGE 40 40

OUT, POSITIVE CHARGER VOLTAGE 9 9

ONBOARD CHARGER A30

Fig. 7 Sheet 3 of 5

T-code 795

181444

Order number 235568-040

Service Manual

SP10, SP10S

10- 11

10- 12

BK

Service Manual

Sh. 2

Sh. 2

23:B

23:A

2-

1-

20A

F52

-

H80 +

INP, HOSTING VEHICLE POSITIVE

INP, HOSTING VEHICLE NEHATIVE

INP, TRUCK DISABLE RELAY CONTACT

OUT, TRUCK DISABLE RELAY CONTACT

OUT, +24VDC, LED INDICATOR

OUT, GND, LED INDICATOR

RD

BK

BK

BK

RD

BU

Fig. 8 Sheet 4 of 5

Date 2006-04-10

SP10, SP10S

181444

PROD D

OUT, NEGATIVE CHARGER VOLTAGE

BK

Valid from serial number 904526-

4/5

OUT, POSITIVE CHARGER VOLTAGE

RD

CHARGER/BOOSTER ONBOARD LORRIES A15

T-code 795

2+

1+

POWER INP. CONNECTOR

Sh. 1

Sh. 1

RD

OPTION

Electrical system – 5000

Electrical wiring diagram Order number 235568-040

Note!

Not applicable for this truck model

© TIEE SARL

© TIEE SARL

Service Manual

SP10, SP10S

1

Option: "Battery Indicator”

2

106

3

4

6

106

B2

B3

105

105

B4

104

104

B5

102

B6

B1

101

7

NCLRXD

PCLTXD

NCLTXD

5/5

PROD E

8

8

181444

+12VDC SUPPLY VOLTAGE

GND

PCLRXD

ELECTRONIC CARD A1

7

Fig. 9 Sheet 5 of 5

F

6

103

5

103

102

101

OPTION

4

F

E

D

C

B

A

Valid from serial number 904526-

E

5

PCLTXD

6

4

NCLTXD

NCLRXD

3

2

GND

12VDC SUPPLY VOLTAGE

1

PCLRXD

3

Date 2006-04-10

D

C

DISPLAY; MDI A6

2

Order number 235568-040

B

A

1

Electrical system – 5000 Electrical wiring diagram

T-code 795

10- 13

Electrical system – 5000 Functional description T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.8 Functional description 10.8.1 Theory of operation This section describes basic theory of operation of the truck’s main functions in tabular form. It describes, in simple terms, what happens when performing any of the truck’s main operations.

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

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

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

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

• Resulting conditions - Describes key occurrences which can be checked to confirm that a function operates correctly.

• Logic - Shows the logic relationship between inputs and outputs relating to a specific event.

Note that “resulting conditions” show what is expected when no error conditions are present.

Table 10: Theory of operation Event:

1. Battery connected

Preceding event

-

Action(s)

Insert mains plug for charger [A30] in the start interlock device [S170].

Influencing elements

Operating circuit fuse ok [F50].

Emergency switch-off not depressed [S21].

Resulting conditions

Truck is ready for switch-on.

Quick-test: press signal horn button [S18]! Signal horn shall sound.

10- 14

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Functional description Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

Table 10: Theory of operation Event:

2. Switch-on

Preceding event

1

Action(s)

Turn key switch [S17].

Influencing elements

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

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

Lift / lower switches not activated [S34, S41], Inputs [A1:INP.LIFT] & [A1:INP.LOWER] {low}.

[L1] in neutral position.

Resulting conditions

Battery status indication [H81] lights for 2 seconds then extinguishes. This indicates battery charge level > 60%.

Main contactor [K10] remains open [A1:OUT.NEG.MAIN CONTACTOR] {high} Mechanical brake remains on [Y1, A1:OUT.NGATIVE MAGNETIC BRAKE] {high} Truck is ready for operation.

Event:

3. Tiller handle lowered for driving

Preceding event

2

Action(s)

Lower tiller handle.

Influencing elements

Tiller switch [S10].

Main contactor [K10].

Secondary interlock [S171].

Resulting conditions

Tiller switch [S10] activated.

Input [A1:INP TILLER SWITCH] is {high}.

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

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

Event:

4. Traction, forks first

Preceding event

3

Action(s)

Move butterfly [L1]in forks drive direction.

Influencing elements

Fuse [F1] Travel in forks direction switch [S15] Speed control potentiometer [R1] Battery charge level (can limit maximum speed) Operation of fork lift / lower (limits maximum speed when used while driving)

Resulting conditions

input [A1:DRIVE FORK DIRECTION] goes {high} R1 supplies a d.c. voltage to input [A1:INP.WIPER DRIVE POT] (0 to 4,7V) [A1:OUT. NEG. MAGNETIC BRAKE] goes {low} Brake coil [Y1] energises, mechanical brake releases Current fed to traction motor field winding (F1 +ve and F2 -ve) Pulsed current fed to traction motor armature proportional to butterfly deflection

© TIEE SARL

Service Manual

SP10, SP10S

10- 15

Electrical system – 5000 Functional description T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

Table 10: Theory of operation Event:

5. Traction, drive wheel first

Preceding event

3

Action(s)

Move butterfly [L1] in drive wheel drive direction.

Influencing elements

Fuse [F1].

Travel in drive wheel direction switch[S16].

Speed control potentiometer[R1].

Battery charge level (can limit maximum speed).

Operation of fork lift (limits maximum speed when used while driving).

Resulting conditions

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

R1 supplies a d.c. voltage to input [A1:INP.WIPER DRIVE POT] (0 to 4,7V) [A1:OUT. NEG. MAGNETIC BRAKE] goes {low}.

Brake coil [Y1] energises, mechanical brake releases.

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

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

Event:

6. Neutral braking

Preceding event

4 or 5

Action(s)

Let butterfly [L1] return to neutral position while truck is in motion.

Influencing elements

Parameter settings [RELEASE BRAKING].

Resulting conditions

Traction motor [M1] acts as generator and via transistor regulator [A1] converts the truck’s energy of motion into electrical energy thus reducing the truck’s speed. The braking intensity is dependant on a parameter setting.

The mechanical brake [Y1] activates after the truck comes to a complete stand still. Input [A1:OUT. NEG. MAGNETIC BRAKE] goes {high}.

Event:

7. Reverse braking

Preceding event

4 or 5

Action(s)

Move butterfly [L1] to opposite travel direction.

Influencing elements

Parameter settings [INVERSION BRAKING].

Resulting conditions

Traction motor [M1] acts as generator and via transistor regulator [A1] converts the truck’s energy of motion into electrical energy thus reducing the truck’s speed. The braking effect increases the more the butterfly is deflected. The mechanical brake [Y1] activates after the truck comes to a complete stand still. Input [A1:OUT. NEG. MAGNETIC BRAKE] goes {high}.

10- 16

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Functional description Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

Table 10: Theory of operation Event:

8. Mechanical brake operation

Preceding event

4 or 5

Action(s)

Move tiller unit handle to upper or lower position.

Influencing elements

Tiller switch [S10].

Resulting conditions

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

Brake coil [Y1] deactivated, mechanical brake applied.

Event:

9. Fork lifting

Preceding event

2

Action(s)

Depress the fork lift button [S34].

Influencing elements

Fuse [F1].

Main contactor [K10].

Forks lift button [S34].

Secondary interlock [S171].

Battery charge status.

Resulting conditions

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

Pump contactor [K30] activates.

Pump motor [M3] starts.

Event:

10. Fork lowering

Preceding event

9

Action(s)

Depress the fork lowering button [S41].

Influencing elements

Main contactor [K10].

Forks lower button [S41].

Secondary interlock [S171].

Resulting conditions

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

Magnetic valve - fork lowering [Y41] activated.

© TIEE SARL

Service Manual

SP10, SP10S

10- 17

Electrical system – 5000 Functional description T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.8.2 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. 10 SEM-X transistor regulator

B-

VMN

General The ZAPI SEM-X transistor regulator drives the traction motor. It controls the speed by varying the rotor voltage using pulse width modulation (PWM). This also includes varying the “ON” time of the MOS transistors used to regulate rotor current.

Changing the truck’s travel direction is achieved by reversing the polarity in the field winding (F1-F2). The regulator features a transistorised four-quadrant bridge and a single-quadrant bridge for the rotor winding.

A status LED (Fig. 10 AL) displays eventual error conditions which may be present.

Fig. 10 B shows the connector for the hand terminal.

NOTE! In order to see the alarm status LED or gain access to the connector for the hand terminal it is necessary to fold out the main electrical panel. See “10.4 Accessing main electrical panel” on page 6..

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

WARNING! Risk of short-circuiting.

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

10- 18

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Functional description Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

Table 11: Transistor regulator connections Pin

Ref.

Description

A

Connector for signal control

A1

CPOT

Input from potentiometer wiper [R1]

A2

NLIFT

Connection for internal suppression / protection components

A3

PPOT

Provides a +ve voltage supply from the transistor regulator to the potentiometer [R1], protected against short to B+ and B-

A4

TILLER

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

A5

BELLY

Input from safety reversing switch [S20], used for immediate travel direction reversal, active high (B+). 3K3 to B+ when released.

A6

FW

Input from travel in drive wheel direction switch [S16], active high (B+)

A7

REV

Input from travel in forks direction switch [S15], active high (B+)

A8

H&S

Reserved for future use

A9

NPOT

Provides -ve supply connection to potentiometer [R1]

A10

PLIFT

Input from fork lift control switch [S34]

A11

NEB

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

A12

NLED

Output to drive Battery status indication LED [H81], 100mA max.

A13

PEVD

Input from fork lower control switch [S41]

A14

NMC

Output to Main contactor coil [K10], 1.0A continuous, protected against shortcircuit.

A15

PMC

Connection for suppression of main contactor [K10].

A16

KEY

Transistor regulator control supply, input from key switch [S17].

B

Connector for hand terminal

B1

--

B2

NCLRXD

-”-

B3

PCLTXD

-”-

B4

NCLTXD

-”-

B5

GND

-”-

B6

+12

-”-

B7

--

-”-

B8

--

Power connections +B

Positive Supply from Battery

-B

Negative Supply from Battery

VMN

Negative Supply (via controller) to Motor

F1, F2

Connections to Drive Motor Field Winding

© TIEE SARL

Service Manual

SP10, SP10S

10- 19

Electrical system – 5000 Functional description T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.8.3 On-board battery charger General The charger is optimised for gel valve regulated lead batteries. The charger is protected against dust and water jets (IP65).

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

Charging Connect the charger’s mains plug (Fig. 11 A) to the mains supply. If a discharged battery is connected, the charger will start with the main charge (yellow LED (Fig. 11 B) and 28.8 V). When the battery is fully charged, maintenance charging starts (yellow and green LED (Fig. 11 B & C) and 27.6 V). This continues until the charger switches off. If a fully charged battery is connected to the charger or if the charger does not find a connected battery the maintenance charge is started (yellow and green LED 27.6 V). The charger starts with the main charge (yellow LED and 28.8 V) after a power failure if a discharged battery is connected.

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

Charging for at least 30 min. is gentle and consequently does not shorten the life of the battery. It is however necessary for the truck to be recharged once a week over night or for at least 10 hours.

B C

A Fig. 11 On-board battery charger

10- 20

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Functional description Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

10.8.4 Battery charge status The battery status indication LED [H81] gives an indication as to the remaining charge capacity in the batteries.

Table 12: Battery charge status LED Status [H81]

Remaining battery charge

Off

> 60% charge remaining

Blinking

< 60% charge remaining

Continuously on

< 40% charge remaining

Battery display (option) A more detailed display regarding the battery charge status is available as an option. The battery display is connected to the hand terminal connector [CONS] on the transistor regulator [A1].

The display (Fig. 12) has 4 green LEDs and 1 red LED which indicate the battery charge status according to the following table.

Table 13: Battery display LEDs Battery power LEDs 100 %

4 green LEDs

70 %

3 green LEDs

60 %

2 green LEDs

50 %

1 green LED

40 %

1 green LED flashes (means time to charge)

35 %

1 red LED

Fig. 12 Battery display (option) 30 % 25 %

1 red LED + reduced speed 1 red LED + extremely reduced speed

NOTE! The battery display is only updated when the drive motor is active.

That means if only the lift motor is used for some time (and the truck is not moved) the display may show a too large remaining charge.

© TIEE SARL

Service Manual

SP10, SP10S

10- 21

Electrical system – 5000 Functional description T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.8.5 Speed limitation The truck's maximum travel speed is limited depending on a combination of factors: • Load and remaining battery capacity.

• Whether the lift function is operating.

• The transistor regulator temperature.

• Extended use after service warning.

• Parameter settings also affect maximum speed.

See List of parameters on page 34 for more information. The table below summarises the speed limitations and assumes that all relevant parameters are set to 100%. Note that the speeds given are nominal.

When a combination of limiting factors are present the lowest speed will be active.

Table 14: Summary of speed limitations Remaining charge in Battery [H81]

Lift status

Transistor regulator temperature °C

Hours of use after service warning

Maximum 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.Dependant on parameter settings. See Select service warning type (CHECK UP TYPE) on page 35. b.Dependant on parameter settings. See Select service warning type (CHECK UP TYPE) on page 35.

10.8.6 Hour meter

H

Fig. 13 Activity time

The truck’s control system stores the elapsed activity time (drive motor) in units of hours. A “time to next service” counter can optionally be activated. When this service counter time reaches the “time to next service” value the transistor regulator emits an audible signal and the Battery charge status [H81] LED flashes continuously.

To check the present activity time value connect the hand terminal. The activity time is displayed as shown in Fig. 13 “H”

10- 22

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Functional description Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

10.8.7 Hand terminal General It is necessary to have access to a hand terminal to perform the following: • Modify parameters stored in the transistor regulator.

• Upload or download parameter set-ups to/from the transistor regulator.

• Display error and diagnostic information.

• Perform calibration.

A

Fig. 14 Hand terminal

Connecting the hand terminal To connect the hand terminal: • Ensure the key switch is off [S17].

• Fold out the main electrical panel. See “10.4 Accessing main electrical panel” on page 6..

• Connect the hand terminal’s connector (Fig. 14 A) to the transistor regulator’s diagnostic connector (Fig. 10 B).

• Turn on the key switch [S17].

Hand terminal overview The hand terminal consists of an alpha-numeric display (Fig. 15 A) and six control buttons.

© TIEE SARL

Service Manual

SP10, SP10S

10- 23

Electrical system – 5000 Functional description T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

A

B

E

D

C

Fig. 15 Hand terminal overview When the hand terminal is connected and the Key switch turned on the following will be displayed: The hand terminal version is first displayed.

Confirmation of connection to a SEM-X transistor regulator and firmware version.

A

A - Transistor regulator’s firmware version.

B - Supply voltage.

C - Transistor regulator’s rated current.

B

C

D

D - Present hour meter value.

• Press ENTER (Fig. 15 C) to display the first menu.

• Cycle through the menus by repeatedly pressing the ROLL buttons (Fig. 15 B).

• Press OUT(Fig. 15 D) to leave the present menu.

• Buttons PARAM SET (Fig. 15 E) are used to adjust parameter values.

10- 24

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Functional description Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

Hand terminal menus OUT

SEM-X 24v

75A

V..

00000

Normal hand terminal display

ENTER

*

MAIN MENU * PARAMETER CHANGE

Menu for changing or setting parameters

ROLL *

MAIN MENU STEER TABLE

*

This is menu is not applicable

ROLL *

MAIN MENU PROGRAM VACC

*

Menu for calibration of speed control potentiometer [R1]

ROLL *

MAIN MENU ALARMS

*

Menu for displaying error history

*

Menu for downloading a parameter set-up from the hand terminal to the transistor controller

*

Menu for uploading a parameter set-up from the transistor controller to the hand terminal

*

Menu for diagnostic functions

ROLL *

MAIN MENU RESTOR PARAM. ROLL

*

MAIN MENU SAVE PARAM. ROLL

*

MAIN MENU TESTER ROLL

To enter one of the main menu modes: • Press ENTER from the initial display and then...

• Repeatedly press ROLL until the relevant menu is shown then...

• Press ENTER. See following sections for detailed information regarding each menu function.

© TIEE SARL

Service Manual

SP10, SP10S

10- 25

Electrical system – 5000 Diagnostic and troubleshooting T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.9 Diagnostic and troubleshooting 10.9.1 General The truck’s electronic control system incorporates built-in error code display and logging. This capability works as a powerful complement in assessing the cause of eventual truck malfunctions. Error conditions encountered by the transistor regulator are displayed as a sequence of flashes of the status LED (Fig. 10 AL). The sequence always starts with a number of “long” flashes followed by a number of “short” flashes. See table 15 on page 28.

The 5 most recent error codes will be stored in a log along with the hour meter reading, number of occurrences and transistor regulator temperature when the error occurred.

The first time an error code is generated it is advisable to check if the condition persists by switching the truck off completely, then switching back on again. Check to see if the error code is displayed again.

Use the hand terminal’s TESTER function to test basic truck characteristics.

10.9.2 Display of error codes Direct display of error codes To check for an eventual error condition by directly inspecting the status LED carry out the following: • Fold out the main electrical panel. See “10.4 Accessing main electrical panel” on page 6..

Under normal conditions the Status LED is off, otherwise an error condition exists.

• Count the number of “long” (and “short”) flashes in the sequence to determine the error code.

• Refer to Table 15, “List of error codes,” on page 28.

Hand terminal display of error codes To check an existing error condition or to consult the error history using the hand terminal carry out the following: • Ensure the key switch is off [S17].

• Fold out the main electrical panel. See “10.4 Accessing main electrical panel” on page 6..

• Connect the hand terminal’s connector (Fig. 14 A) to the transistor regulator’s diagnostic connector (Fig. 10 B).

• Turn on the key switch [S17].

10- 26

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Diagnostic and troubleshooting Order number 235568-040

*

Date 2006-04-10

ALARM INCORRECT START

*

Valid from serial number 904526-

T-code 795

If an error condition is present on the truck it will be immediately displayed.

• Refer to Table 15, “List of error codes,” on page 28.

Fig. 16 Typical error display

NOTE! The status LED is continuously on while the hand terminal is connected.

Error code history To check the error code history log carry out the following: With the hand terminal connected as described in 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. 17 Menu tree for error code history display

A *

00015h

VFIELD NOT OK * #01 27°C

B

C

D

The log will display up to 5 most recent error types with the following information for each error.

A - Error code description.

B - Hour meter value when fault occurred.

C - Number of occurrences of specific error.

D - Transistor regulator temperature when fault occurred.

The error code history log can be optionally cleared when exiting the ALARM menu.

© TIEE SARL

Service Manual

SP10, SP10S

10- 27

Electrical system – 5000 Diagnostic and troubleshooting T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.9.3 List of error codes NOTE! It is important to understand that certain Status LED codes can be caused by different error codes. The most accurate diagnosis will be made when using the hand terminal.

Table 15: List of error codes Status LED code

Error code description

Possible cause / Hint or Solution

¤ (1)

Watch-dog

Electronic card and/or software failure. / Replace transistor regulator.

EEPROM KO

EEPROM or Logic problem. / Replace transistor regulator.

EB DRIVER SHORT

Output for electromagnetic brake coil [Y1] s/c to -BATT. / Check wiring to brake coil.

EB DRIVER KO

Output for electromagnetic brake coil [Y1] not functioning. / Replace transistor regulator.

CONTACTOR DRIVER

Main contactor[K10] not responding when driven. / Check Main contactor coil and wiring.

DRIVER SHORTED

The main contactor coil is either s/c, o/c or not connected.

Main contactor o/p s/c to -BATT. / Check Main contactor coil and wiring.

CONTACTOR CLOSED

Main contactor tips [K10] are fused.

Field circuit problem.

Problem detected by the safety micro processor. / Check Main contactor tips are not fused. Check field winding connections. If above is ok replace transistor regulator.

CONTACTOR OPEN

Unexpected drop in battery voltage after Main contactor closes. / Check Main contactor and wiring. Check battery charge condition.

POWER FAILURE #1

s/c detected on driver output to main contactor [K10] or brake coil [Y1]. / Check for s/c in main contactor and brake coil circuit. If above is ok replace transistor regulator.

¤¤ (2)

¤ ¤¤ (1+2)

¤ ¤¤¤ (1+3)

10- 28

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Diagnostic and troubleshooting Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

Table 15: List of error codes Status LED code

Error code description

Possible cause / Hint or Solution

¤¤ ¤ (2+1)

CAPACITOR CHARGE

Capacitors are not charged within 500 ms after Key switch is closed / Check [PTC] resistor circuit. / If above is ok replace transistor regulator.

VMN NOT OK

VMN armature driver problem. Incorrect motor connection s/c in motor windings to chassis.

Transistor regulator defect. / Check armature connections [M1] are correct and no internal s/c exists. If above is ok replace transistor regulator.

VFIELD NOT OK

Field Voltage problem. Traction motor’s [M1] field winding s/c or o/c.

Field winding incorrectly connected to the transistor regulator. Transistor regulator defect. / Check field connections [M1] are correct and no motor s/c exists. If above is ok replace transistor regulator.

NO FIELD CUR

Field current abnormally low. Traction motor’s [M1] field winding s/c or o/c.

Field winding incorrectly connected to the transistor regulator. Transistor regulator defect. / Check field connections [M1] are correct and no motor s/c exists. If above is ok replace transistor regulator.

FW HIGH FIELD CURR.

Field current abnormally high in drive wheel direction. Traction motor´s [M1] field winding s/c or o/c.

Field winding incorrectly connected to the transistor regulator. Transistor regulator defect. / Check field connections [M1] are correct and no motor s/c exists. If above is ok replace transistor regulator.

BW HIGH FIELD CURR.

Field current abnormally high in forks direction. Traction motor´s [M1] field winding s/c or o/c.

Field winding incorrectly connected to the transistor regulator. Transistor regulator defect. / Check field connections [M1] are correct and no motor s/c exists. If above is ok replace transistor regulator.

STBY I HIGH

Armature current abnormally high whilst in stand-by. Transistor regulator defect. / Replace transistor regulator.

I=0 EVER

Armature current abnormally low whilst driving. / Check armature connections, check or replace carbon brushes.If above is ok replace transistor regulator.

CURR. PROTECTION

Armature current abnormally high whilst driving. / Check armature connections for s/c. If above is ok replace transistor regulator.

¤¤ ¤¤ (2+2)

¤¤ ¤¤¤ (2+3)

© TIEE SARL

Service Manual

SP10, SP10S

10- 29

Electrical system – 5000 Diagnostic and troubleshooting T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

Table 15: List of error codes Status LED code

Error code description

Possible cause / Hint or Solution

¤¤¤ ¤ (3+1)

TH. PROTECTION

Working temperature of transistor regulator is abnormally high or low (outside range >70°C or <10°C). Transistor regulator defect. / First determine whether truck’s operating environment and conditions are normal! Allow truck to regain a normal temperature and attempt normal use. If fault persists replace transistor regulator.

¤¤¤ ¤¤¤ (3+3)

VACC NOT OK

Problem with speed potentiometer[R1].

[L1] not in neutral position when truck switched on. Fault in potentiometer wiring or in potentiometer. Incorrect calibration values. / Check wiring to potentiometer. Check and if necessary replace potentiometer. If necessary calibrate potentiometer. See “10.10.6 Calibrating the speed potentiometer” on page 38.

¤¤¤ ¤¤¤¤¤ (3+5)

INCORRECT START

Starting sequence incorrect for travel. Emergency reverse switch [S20] operated during start. o/c in main contactor coil circuit [K10]. Tiller switch [S10] operated during start. / Check wiring to [S10] & [S20]. Adjust or replace these switches. Check wiring to [K10] coil & check or replace[K10].

¤¤¤ ¤¤¤¤¤¤ (3+6)

FORW+BACK

Conflicting travel direction order. / Check wiring to [S15] & [S16], check operation of [S15] & [S16].

¤¤¤ ¤¤¤¤¤¤¤ (3+7)

BELLY SW ERROR

No connection to emergency reverse switch [S20]. / Check wiring to [S20], Check 3K3 resistor.

¤¤¤ ¤¤¤¤¤¤¤¤ (3+8)

CHECK UP NEEDED

A scheduled service is due!

Time since last service > CHECK UP HOURS. The service counter may not have been reset following the previous service visit. / Establish service requirements and situation.

Perform the scheduled service and reset service counter as appropriate.

See Reset service counter (CHECK UP DONE) on page 35.

¤.............¤ 32 short

BATTERY LOW

Battery charge less than 50% of nominal value. / Charge batteries.

10- 30

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Diagnostic and troubleshooting Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

10.9.4 TESTER function The hand terminal can be used to test a number of basic truck functions and characteristics.

To use the TESTER function carry out the following: • Connect the hand terminal. See “ Connecting the hand terminal” on page 23.

SEM-X 24v

75A

V..

00000

BATTERY CHARGE BELLY SWITCH

ENTER * * *

ROLL

* * * *

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 from the menu and press ENTER. • Scroll through the various available test functions by pressing ROLL buttons.

© TIEE SARL

Service Manual

SP10, SP10S

10- 31

Electrical system – 5000 Diagnostic and troubleshooting T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

Table 16: TESTER functions in hand terminal Display

Function

approx. value(s)

BATTERY VOLTAGE

Battery voltage measured at key switch input.

24-26 V

VMN

Voltage measured between VMN and B-.

Standstill BATT.VOLTAGE - 0,1 Max. speed- 0,3V

MOTOR CURRENT

Armature current, traction motor.

Standstill- 0A Max.load and/or incline- 75A

FIELD CURRENT

Field current, traction motor.

Standstill (brake on)- 0A Max.speed- 5 to 6A Motor braking- 6 to10A

TEMPERATURE

Temperature measured at MOSFET transistors’ cooling element (Transistor regulator).

Dependant on environment

ACCELERATOR

Voltage, wiper of speed control potentiometer [R1].

The left-hand side of the display shows the voltage and the right-hand side the value as a percentage.

[L1] in neutral- 0V 0% for both travel directions: min. speed- 0,5V 1% max. speed- 4,9V 100%

TILLER SWITCH

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

OFF/GND = inactive input, switch open.

Tiller upright- OFF Tiller in drive pos.- ON

FORWARD SWITCH (TRAVEL IN DRIVE WHEEL DIR.SWITCH)

Level on digital input pin A6 for travel in drive wheel direction switch[S16]: ON/+VB = active input, switch closed.

OFF/GND = inactive input, switch open.

[L1] in neutral- OFF [L1] in drive wheel dir. - ON

BACKWARD SWITCH (TRAVEL IN FORKS DIR. SWITCH)

Level on digital input pin A7 for travel in forks direction switch [S15]: ON/+VB = active input, switch closed.

OFF/GND = inactive input, switch open.

[L1] in neutral- OFF [L1] in forks dir.- ON

H&S

Level on digital input pin A8: For future use (“Turtle” function).

OFF

DIGITAL INPUT #2

Level on digital input for forks lift & lower: ON/GND = active input, switch closed.

OFF/+VB = inactive input, switch open.

No lift or lower- OFF. Lift or lower operated- ON.

BELLY SWITCH/ (SAFETY REVERSING)

Level on digital input pin A5, safety reversing switch [S20}: ON/+VB = active input, B SW closed.

OFF/GND = inactive input, B SW open.

With tiller arm in drive pos.: [S20] not pressed- 1,8V [S20 pressed- 3,8V

BATTERY CHARGE Battery charge indication in %.

10- 32

Service Manual

SP10, SP10S

Dependant on charge status

© TIEE SARL

Electrical system – 5000 Parameters & adjustments Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

10.10 Parameters & adjustments 10.10.1 General The truck’s control system stores a number of parameters. These parameters are used to configure the truck for correct operation in the particular application for which it was designed. The parameters are adjusted using the hand terminal.

10.10.2 Adjusting parameters To adjust a parameter use the PARAMETER CHANGE function in the hand terminal: • Connect hand terminal. See “ Connecting the hand terminal” on page 23.

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 from the menu and press ENTER. • Press ROLL buttons to display the required parameter.

• Adjust the setting of the parameter with the PARAM SET buttons.

• Press OUT followed by ENTER to store the new parameter setting or.

• Press OUT followed by OUT to return to the main menu without changing the existing parameter setting.

NOTE! Truck handling.

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

Do not change any parameters without the necessary know how.

© TIEE SARL

Service Manual

SP10, SP10S

10- 33

Electrical system – 5000 Parameters & adjustments T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.10.3 List of parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in the sections Adjusting parameters on page 33.

See also section Speed limitation on page 22 for information regarding the maximum speeds of the truck.

Table 17: Overview of parameters Parameter name (display)

Function

Min.

Max.

Std.

ACC.DELAY

Determines acceleration ramp time.

0

9

6

Note

A 9:

0:

A= acceleration DECELER.DELAY

RELEASE BRAKING

Determines deceleration ramp when speed control is reduced.

0

Determines neutral braking intensity.

0

9

5 D 9:

0:

D= deceleration 9

5 B 0:

9:

B= braking intensity INVERSION BRAKING

Determines reverse braking intensity.

0

9

9 B 0:

9:

B= braking intensity CUTBACK SPEED 3

Determines truck’s max. speed.

0

9

9 S 0:

9:

S= maximum speed CHECK UP DONE

Resets service hours counter to zero.

-

-

OFF

CHECK UP TYPE

Selects type of service warning.

0

3

NONE

CHECK UP HOURS

Determines “Time to next service”.

0

9

2

10- 34

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Parameters & adjustments Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

10.10.4 Description of parameters Acceleration ramp time (ACC.DELAY) Determines the acceleration ramp time. Increasing this value will result in a longer time for the speed to increase and thus gentler acceleration.

Deceleration ramp time (DECELER.DELAY) Determines the deceleration ramp time when the speed control [L1] is reduced. Increasing this value will result in a longer time for the speed to decrease and thus a gentler deceleration.

Adjusting this parameter has only a limited effect.

Neutral braking intensity (RELEASE BRAKING) Increasing the parameter value will result in harder braking.

Neutral braking is defined as the reduction of a truck’s speed through motor braking by allowing the speed control [L1] to return to its neutral position.

Reverse braking intensity (INVERSION BRAKING) Increasing the parameter value will result in harder braking.

Reverse braking is defined as the reduction of a truck’s speed through motor braking by moving the speed control [L1] in the opposite direction to the direction of travel.

Maximum travel speed (CUTBACK SPEED 3) Determines the truck's maximum speed. Increasing the parameter will result in an increased maximum travel speed.

Maximum speed = 5,4 X (62 + (p X 4,2))% km/h, where p is the parameter value.

Reset service counter (CHECK UP DONE) Setting this parameter to ON will reset the service hours counter to zero. This should be carried out after each scheduled service.

Select service warning type (CHECK UP TYPE) Determines type of warning when service counter has reached “time to next service” as set in CHECK UP HOURS. Value NONE - No warning will be given (default).

Value 1 - Warning given when service counter has reached CHECK UP HOURS value.

Value 2 - Warning given when service counter has reached CHECK UP HOURS value. After 10 hours continued operation the maximum speed will be reduced. © TIEE SARL

Service Manual

SP10, SP10S

10- 35

Electrical system – 5000 Parameters & adjustments T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

Value 3 - Warning given when service counter has reached CHECK UP HOURS value. After 10 hours continued operation the maximum speed will be reduced. After 20 hours continued operation all truck operation will be blocked.

The warning for “time for service” is: • An audible alarm signal from the transistor regulator.

• The status LED on the transistor regulator will flash 3 short + 8 long.

• The battery charge status [H81] LED flashes continuously.

“Time to next service” (CHECK UP HOURS) Set this value to correspond with number of hours truck activity must increase by when the next service warning must be given.

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

10.10.5 Transferring parameter sets General The Hand terminal can be used to save a parameter set and configuration from a truck. This is useful in the following cases: • To restore a truck’s configuration to a known state or after replacing the transistor regulator.

• To transfer the configuration from one truck which has been configured to a complete group thus ensuring all trucks are identically configured.

The hand terminal can store up to a maximum of 32 unique parameter sets.

10- 36

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Parameters & adjustments Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

From the truck to the hand terminal To transfer a parameter set from the truck to the hand terminal use the PARAMETER CHANGE function in the hand terminal: • Connect the hand terminal. See “ Connecting the hand terminal” on page 23.

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 from the menu and press ENTER. • Press ROLL to select one of the 32 memory slots (Mod 00 to Mod 31).

Empty memory slots will display FREE. Memory slots which contain a V. parameter set will display SEM-X • Press ENTER to save the truck’s parameter set.

NOTE! It is advisable to keep a record of trucks and stored parameter sets.

This will help to ensure that saved parameter sets are restored to the correct truck.

© TIEE SARL

Service Manual

SP10, SP10S

10- 37

Electrical system – 5000 Parameters & adjustments T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

From the hand terminal to the truck To transfer a parameter set from the hand terminal to the truck use the RESTOR PARAMETER function in the hand terminal: • Connect hand terminal. See “ Connecting the hand terminal” on page 23.

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 from the menu and press ENTER. • Press ROLL to select the relevant memory slot (Mod 00 to Mod 31).

• Press ENTER. The parameter set will be restored to the transistor regulator’s memory.

10.10.6 Calibrating the speed potentiometer General The transistor regulator [A1] can be calibrated to allow the speed potentiometer [R1] to give a smooth and symmetrical response over the whole operating range. Perform a calibration in the following circumstances: 10- 38

Service Manual

SP10, SP10S

© TIEE SARL

Electrical system – 5000 Parameters & adjustments Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

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

• If the VACC NOT OK error occurs.

• When [R1] is removed or disturbed or is replaced.

Procedure To perform calibration of the speed potentiometer use the PROGRAM VACC function in the hand terminal: • Connect the hand terminal. See “ Connecting the hand terminal” on page 23.

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 from the menu and press ENTER then ENTER. • Move tiller arm to drive position.

• Slowly move the speed control [L1] from neutral to full deflection first in one direction then the other direction.

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

Service Manual

SP10, SP10S

10- 39

Electrical system – 5000 Technical specifications T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

10.11 Technical specifications 10.11.1 Transistor regulator SEM-X Table 18: Transistor regulator specification SEM-X Item

Value

Unit

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

28.8 V continuously

Undervoltage limit

16,8

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature winding *

75

Amps

for 2 minutes

40

Amps

for 1 hour

12

Amps

for 2 minutes

Max. current of field winding

6,6

Description

for 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

3

Amps

Max

KSI input voltage, Min.

16.8

Volts

Logic input voltage

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

Volts

Operating temperature

-30 to +40

°C

Overtemperature, reduction

70

°C

Undertemperature, reduction to 80%

-10

°C

Maximum temperature limit

90

10- 40

Service Manual

SP10, SP10S

Reduced in proportion to the rise in temperature

© TIEE SARL

Hydraulic system - 6000 General Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

11- Hydraulic system - 6000 11.1 General

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

11- 1

Hydraulic system - 6000 Hydraulics diagram and components T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

11.2 Hydraulics diagram and components

1

2

3 Y41 5

P

4

M3 6

11- 2

Service Manual

SP10, SP10S

© TIEE SARL

Hydraulic system - 6000 Hydraulics diagram and components Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

5 4 Y41 3

P

1 6

2

Table 19: Main Components

© TIEE SARL

Pos.

Name

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

11- 3

Hydraulic system - 6000 Description T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

11.3 Description 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 Operating pressure at rated load is 190 bar.

Pressure limit valve The pressure limit valve opens at 210 bar.

11- 4

Service Manual

SP10, SP10S

© TIEE SARL

Hydraulic system - 6000 Adjustments Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

11.4 Adjustments Adjustment of the pressure limit valve

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.

The truck should be able to lift a load of between 1000 and 1100 kg on the forks.

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.

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

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

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

- 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: - Loosen the lock nut (1) by turning it counter clockwise.

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

- 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

11- 5

Hydraulic system - 6000 Tools T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

11.5 Tools 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).

11- 6

Service Manual

SP10, SP10S

© TIEE SARL

Lift mast – 7000 Main mast Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

12- Lift mast – 7000 12.1 Main mast 12.1.1 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

12- 1

Lift mast – 7000 Main mast T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

12.1.2 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 Fig. 18 Bolt joints

2

12- 2

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

1

2

The inner sides of the beam rib must be lubricated with part no. 29586 (Gleitmo 805).

Service Manual

SP10, SP10S

© TIEE SARL

Lift mast – 7000 Main mast Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

12.1.3 Cylinder Disassembly • Remove the mast cover.

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

• Unscrew the chain guide (Fig. 19).

• Remove the chain sprocket (Fig. 19).

Fig. 19 Removing the chain sprocket • Undo the bolts on the cylinder mounting (Fig. 20).

• Lift the fork carriage up past the cylinder.

• Lift out the cylinder and unscrew the hose (Fig. 20).

Fig. 20 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

12- 3

Lift mast – 7000 Fork carriage T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

12.2 Fork carriage 12.2.1 Maintenance

1

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

• Shim as illustrated (1) if necessary.

12- 4

Service Manual

SP10, SP10S

© TIEE SARL

Lift mast – 7000 Main lift chain system Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

12.3 Main lift chain system 12.3.1 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.

12.3.2 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

12- 5

Lift mast – 7000 Main lift chain system T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

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

The chain should be replaced

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

The chain should be replaced

Outline wear P

H2

H3

P = Pitch H2 = Nominal disc height.

H3 = Minimum disc height.

A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is define as H3 12- 6

Service Manual

SP10, SP10S

© TIEE SARL

Lift mast – 7000 Main lift chain system Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

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

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

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

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

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

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

Type of chain

Nominal disc height H2 ( mm)

Minimum disc height H3 (mm)

Pitch P (mm)

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

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

3/4”, 2x3

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 3x4

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 4x6

17.8

16.9

19.05

381/572/953

389/583/972

1”, 4x4

23,6

22,4

25,4

508/762/1270

518/777/1295

1”, 6x6

23,6

22,4

25,4

508/762/1270

518/777/1295

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

© TIEE SARL

Service Manual

SP10, SP10S

12- 7

Lift mast – 7000 Main lift chain system T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

Damage

The chain should be replaced if damaged in any way.

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

The chain should be replaced.

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

The chain should be replaced.

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

12.3.3 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

12- 8

Service Manual

SP10, SP10S

© TIEE SARL

Lift mast – 7000 Main lift chain system Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

NOTE! Exercise care with degreasing agent as these can contain abrasives.

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

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

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

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

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

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

Ambient temperature

Viscosity class

Recommended Products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5°C

VG 68

> + 5°C < + 45°C

VG 150

>+ 45°C <+ 80°C

VG 220

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

* Equivalent products from another manufacturer may be used.

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

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

© TIEE SARL

Service Manual

SP10, SP10S

12- 9

Lift mast – 7000 Main lift chain system T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

This page is intentionally left blank

12- 10

Service Manual

SP10, SP10S

© TIEE SARL

Accessories – 9000 Automatic height adjustment Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

13- Accessories – 9000 13.1 Automatic height adjustment 13.1.1 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

13- 1

Accessories – 9000 Automatic height adjustment T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

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.

13- 2

Service Manual

SP10, SP10S

© TIEE SARL

© TIEE SARL

Service Manual

SP10, SP10S

F

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-

E

Sh. 2

Sh. 2

Sh. 4

40

9

21

5A

3

Date 2006-04-10

D

C

Sh. 2

Sh. 3

Sh. 4

S21

2

Order number 235568-040

B

A

1

Automatic height adjustment

Accessories – 9000 T-code 795

13.1.2 Electrical wiring diagram

13- 3

13- 4

Service Manual

SP10, SP10S

F

1

134

135

31

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 2006-04-10

Sh. 4

Sh. 4

Sh. 1 4

X30

40

23

PLUG:B

PLUG:A

221

22

3

Valid from serial number 904526-

E

D

Sh. 1 3

Sh. 1

Sh. 3

Sh. 3

Sh. 4

Sh. 4

2

T-code 795

C

B

A

1

Accessories – 9000

Automatic height adjustment Order number 235568-040

© TIEE SARL

© TIEE SARL

Service Manual 3

4

5

6

8

7

Valid from serial number 904526-

SP10, SP10S

8

F

F 3/5 PROD A 218858

E

C

E

1

MAINS; VAC

PLUG:B

MAINS; EARTH

MAINS; VAC

PLUG:A

OUT, NEGATIVE CHARGER VOLTAGE

D

Sh. 2

Sh. 2

40

40

OUT, POSITIVE CHARGER VOLTAGE

ONBOARD CHARGER A30

7

Date 2006-04-10

D

C

9

9

2

6

Order number 235568-040

Sh. 2 4

Sh. 1

5

B

4

B

3 A

2

A

1

Automatic height adjustment

Accessories – 9000 T-code 795

13- 5

13- 6

Service Manual

SP10, SP10S

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 2006-04-10

F

Sh. 2

Sh. 1

Sh. 2

Sh. 2

Sh. 3

Sh. 1

3

Valid from serial number 904526-

E

D

C

B

Sh. 1

Sh. 2

Sh. 2

2

T-code 795

3

A

1

Accessories – 9000

Automatic height adjustment Order number 235568-040

© 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

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 2006-04-10

D

C

DISPLAY; MDI A6

2

Order number 235568-040

B

A

1

Automatic height adjustment

Accessories – 9000 T-code 795

13- 7

Accessories – 9000 Automatic height adjustment T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

This page is intentionally left blank

13- 8

Service Manual

SP10, SP10S

© TIEE SARL

Destruction instructions General Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

14- Destruction instructions 14.1 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.

14.2 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

14- 1

Destruction instructions Abbreviations T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

14.3 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

14.4 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.

14- 2

Service Manual

SP10, SP10S

© TIEE SARL

Destruction instructions Chassis (0300) Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

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

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

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

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

14.7 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

14- 3

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

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

14.8 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.

14- 4

Service Manual

SP10, SP10S

© TIEE SARL

Destruction instructions Wheels (3500) Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

14.9 Wheels (3500) 1 3 2

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

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

4

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

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

• Remove the switch (2).

• Remove the potentiometer (3).

• Remove the sensor (4).

Material handling

3

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, potentiometer and sensor should be placed in containers intended for electronic scrap.

2

© TIEE SARL

Service Manual

SP10, SP10S

14- 5

Destruction instructions General electrical equipment (5100) T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

14.11 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.

14- 6

Service Manual

SP10, SP10S

© TIEE SARL

Destruction instructions Hydraulic unit (6100) Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

14.12 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

© TIEE SARL

Service Manual

SP10, SP10S

14- 7

Destruction instructions Hydraulic cables/cylinders (6230/6610) T-code 795

Valid from serial number 904526-

Date 2006-04-10

Order number 235568-040

14.13 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.

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Service Manual

SP10, SP10S

© TIEE SARL

Destruction instructions Main mast and fork carriage (7100) Order number 235568-040

Date 2006-04-10

Valid from serial number 904526-

T-code 795

14.14 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.

© TIEE SARL

Service Manual

SP10, SP10S

14- 9

©TOYOTA Industrial Equipment Europe SARL Ancenis, France