Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 - PDF DOWNLOAD

Service Manual en

7PM18, 7PM20, 7PML20 Valid from serial number: 723984--

Order number: 222995-040 Issued: 2005-02-02 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Issue date

Resp.

Changes

2005-02-02

ITS

Completely new issue

This manual covers following truck models:

T-code

Model

Serial number

677

7PM18

723984-

678

7PM20

723984-

679

7PML20

723984-

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Table of contents Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

1- Table of contents Technical data – M4

2-1

Introduction Maintenance – P1

3-1

Safety regulations with maintenance work.... 1 Cleaning and washing .................................. 2 3.2.1 External cleaning ................................................ 3 3.2.2 Cleaning the motor compartment ....................... 3 3.2.3 Electrical components ........................................ 3

Safe lifting..................................................... 4

Preventive maintenance – P2

4-1

Maintenance schedule.................................. 1 Lubrication schedule..................................... 6

Oil and grease specifica tion – P3

5-1

Tools – P4

6-1

Super Seal connectors ................................. 1 AMP connectors ........................................... 2 6.2.1 AMP Connectors, 040 series .............................. 3

Molex connectors ......................................... 3 Other tools .................................................... 4

Engine suspension– 0450

7-1

Component parts .......................................... 1 7.1.1 Component List .................................................. 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

1- 1

Table of contents T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Electric drive motor – 1760

8-1

Component parts .......................................... 1 8.1.1 Dismantling/assembling of motor from truck ....... 2 8.1.2 Assembling ......................................................... 3

Service/Repairs ............................................ 3 8.2.1 Dismantling of motor ........................................... 3 8.2.2 Assembling of motor ........................................... 4 8.2.3 Cleaning .............................................................. 5

Technical data .............................................. 6

Mechanical drive gear unit – 2550

9-1

Component parts .......................................... 2 9.1.1 Technical data .................................................... 3

Leakage from top cover ................................ 4 Dismantling ......................................................... 4 Assembling ......................................................... 4

Changing of the drive shaft’s sealing ring ..... 4 Dismantling ......................................................... 4 Assembling ......................................................... 5

Electro magnetic brake – 3370

10-1

Main components ......................................... 1 Maintenance ................................................. 2 10.2.1 Exchange of brake disc ...................................... 2

Electro magnetic brake – 3370

11-1

Main components ......................................... 1 Maintenance ................................................. 2 11.2.1 Basic Adjustment of gap ..................................... 2 Adjustment: ......................................................... 2 11.2.2 Exchange of brake disc ...................................... 3

1- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Table of contents Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Steering system – 4000

12-1

Component parts, tiller arm .......................... 1 Adjustments.................................................. 2 12.2.1 Adjusting of brake microswitch ........................... 2

Tiller arm handle ........................................... 3 12.3.1 Dismantling/Assembling ..................................... 4 Change from ignition key to keyboard (2) ........... 5 Change from keyboard to ignition key (2) ........... 5 Changing of signal button/switch (9, 10) ............ 6 Changing of lift/lowering button (13) ................... 6 Changing of pushbutton (16) .............................. 7

Electrical System – 5000

13-1

Electrical components .................................. 1 Symbol List and Wiring Diagram................... 3 13.2.1 Wiring diagram 1(5) ............................................ 5 13.2.2 Wiring diagram 2(5) ............................................ 6 13.2.3 Wiring diagram 3(5) ............................................ 7 13.2.4 Wiring diagram 4(5) ............................................ 8 13.2.5 Wiring diagram 5(5) ............................................ 9 13.2.6 Wiring diagram 1(5) .......................................... 10 13.2.7 Wiring diagram 2(5) .......................................... 11 13.2.8 Wiring diagram 3(5) .......................................... 12 13.2.9 Wiring diagram 4(5) .......................................... 13 13.2.10 Wiring diagram 5(5) ........................................ 14

Operating description .................................. 15 13.3.1 Starting truck .................................................... 15 13.3.2 Driving speed £ 6 km/h .................................... 15 13.3.3 Braking in neutral mode ................................... 15 13.3.4 Braking in neutral mode on a slope .................. 15 13.3.5 Braking ............................................................. 16 13.3.6 Lifting the forks ................................................. 16 13.3.7 Lowering the forks ............................................ 16 13.3.8 Horn ................................................................. 16

Hour meter................................................... 16 Error codes .................................................. 17 Parameters .................................................. 31 13.6.1 Operator parameters ........................................ 31 13.6.2 Parameter description ...................................... 32 Parameter 1 ...................................................... 32 © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

1- 3

Table of contents T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Parameter 2 ...................................................... 32 Parameter 3 ...................................................... 32 Parameter 4 ...................................................... 32 Parameter 5 ...................................................... 32 13.6.3 Service parameters .......................................... 33 13.6.4 Parameter description ...................................... 34 Parameter 10 .................................................... 34 Parameter 14 .................................................... 35 Parameter 15 - Non-configurable option ........... 35 Parameter 16 - Configurable option #1 ............. 35 Parameter 17 - Configurable option #2 ............. 35 Parameter 18 - Configurable option #3 ............. 35 Parameter 19 - Configurable option #4 ............. 35 Option parameters ............................................ 35 General ............................................................. 35 Parameter #15 Non-configurable options ......... 35 Changing non-configurable options .................. 36 Parameter #16 to 19 configurable optional functions ........................................................... 37 Changing configurable optional functions ......... 37 Parameter 20 .................................................... 42 Parameter 21 .................................................... 42 Recommendation on parameter setting for freely ventilated batteries ............................................ 43 Instructions for verifying parameter setting ....... 44 Recommendation on parameter setting for valve-controlled batteries (VRLA) ..................... 45 Instructions for verifying parameter setting ....... 46 Parameter 22 .................................................... 46 Parameter 25 .................................................... 46 Parameter 28 .................................................... 46 Parameter 39 .................................................... 47 Login method and driver parameter access ..... 47 Expanded keypad - General ............................. 47 Expanded keypad - Programming .................... 47 Service indication .............................................. 49

Part number ................................................. 52 Transistor panel ........................................... 52 13.8.1 General ............................................................. 52

Troubleshooting ........................................... 53 13.9.1 Error codes and troubleshooting ...................... 53 13.9.2 Reset error ....................................................... 54 13.9.3 Safety ............................................................... 54

Technical specifications – Curtis 1243......... 55 1- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Table of contents Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Hydraulic/Pneumatik – 6000

14-1

General......................................................... 1 Hydraulic chart and list of symbols ............... 1 14.2.1 List of Symbols ................................................... 1

Adjustments 7PM18 ..................................... 2 14.3.1 Adjusting the pressure limit valve ....................... 2 14.3.2 Tools .................................................................. 3

Adjustments 7PM20 ..................................... 4 14.4.1 Adjusting the pressure limit valve ....................... 4

Hydraulic chart and list of symbols ............... 5 14.5.1 List of Symbols ................................................... 5

Adjusting the pressure limit valve ................. 6

PowerTrak cylinder – 6680

15-1

Component parts .......................................... 1 Dismantling of PowerTrak cylinder ............... 2

Battery charger (Inbuilt) – 8340

16-1

General......................................................... 1 Charging ....................................................... 1 Troubleshooting and service......................... 2 Technical data .............................................. 2 Charging settings.......................................... 3 16.5.1 Freely ventilated batteries .................................. 3 16.5.2 Valve regulated batteries ................................... 3

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

1- 5

Table of contents T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Control/computer equipment – 8700 17-1 General ......................................................... 1 Connection ................................................... 1 Layout ........................................................... 2 17.3.1 Main program screen ......................................... 2 17.3.2 Nodes ................................................................. 2 17.3.3 Icons ................................................................... 3 17.3.4 Tool buttons and menu bar ................................ 3 17.3.5 Information window ............................................ 4 17.3.6 Status bar ........................................................... 4

Connection function ..................................... 4 Disconnection function.................................. 4 Downloading program function ..................... 5 17.6.1 Normal downloading (truck with key) ................. 5 17.6.2 Normal downloading (truck with keypad) ........... 5 17.6.3 Emergency downloading (truck with keypad) ..... 6 17.6.4 Downloading in old versions of logic card .......... 6 17.6.5 Emergency downloading (truck with keypad) ..... 6

Truck report function ..................................... 7 Parameters function...................................... 8 Diagnostics function...................................... 8 17.9.1 Representation of signal colours ........................ 9 17.9.2 “Tiller arm” tab .................................................... 9 17.9.3 “Drive Controller” tab (transistor regulator - travel) 10 17.9.4 “Pump controller” tab (transistor regulator - pump) 11 17.9.5 “EPS” steering servo tab .................................. 12

Other menu functions .................................. 13 17.10.1 Save to file ...................................................... 13 17.10.2 Download from file .......................................... 13 17.10.3 Reset CAN adapter ........................................ 13 17.10.4 Delete error code log ...................................... 13 17.10.5 Reset hour meter ............................................ 13 17.10.6 Read error code log ........................................ 13 17.10.7 Adjust date and time ....................................... 14 17.10.8 Adjusting the hour meter on older cards ........ 14 17.10.9 Help ................................................................ 14 About the TruckCom application ....................... 14 17.10.10 Exit ............................................................... 14 1- 6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Table of contents Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Specifications .............................................. 14 Installation ................................................... 15 17.12.1 Installation on a PC with Windows® 95/98 15 17.12.2 Installation on a PC with Windows XP/2000 .. 16 17.12.3 Installation on a PC with Windows NT ........... 21 17.12.4 In case of communication problems with CAN 21 17.12.5 To uninstall ..................................................... 21

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

1- 7

Table of contents T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

1- 8

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Technical data – M4 Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

2- Technical data – M4 Model

7PM18

7PM20

7PML20

Type

TSL140S-DS20

TSL140S-DS30

TSL140S-DS40

Output, kW

1.0

1.2

1,7

Duty cycle

S2, 60 min

S2,60 min

S2,60 min

Minimum carbon brush length, mm

13

13

13

Nominal commutator diameter, mm

47

47

60

Minimum commutator diameter, mm

47

47

60

Resistance, shunt field winding, Ω at 25 C°

0,55

0,55

0,55

Resistance armature winding, Ω at 24 °C

0.0156

0,0156

0,0161

Insulation resistance between the windings and motor casing

>=1 Mohm

>= 1Mohm

>= 1Mohm

Weight, kg

14

14

17

Type

BFK457-08

BFK457-08

BFK458-12

Braking force, Nm

16

16

32

Output, W

25

25

40

Resistance coil, Ω

23

23

14.4

Nominal play in actuated position, mm

0.2-0.4

0.2-0.4

0.3-0.5

Minimum thickness brake disc, mm

5.5

5.5

8.8

Thickness of a new brake disc, mm

7.0

7.0

10.0

Type

2-stage angle transmission

2-stage angle transmission

2-stage angle transmission

Gear ratio

19,14:1

19,14:1

16,29:1

Oil volume, litre

1.0

1.0

1.0

Oil type at normal temperature at temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

Drive motor

Brake

Transmission/drive gear

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

2- 1

Technical data – M4 T-code 677, 678, 679 Date 2005-02-02

Model

Valid from serial number 723984-Order number 222995-040

7PM18

7PM20

7PML20

Drive wheel, mm

Dia 215x70

Dia 215x70

Dia 215x70

Axle pressure without load, kg

275

295

350

Axle pressure at rated load, kg

680

755

550

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

65 Nm

Fork wheel, mm

Dia 85x75

Dia 85x75

Dia 85x75

Axle pressure without load, kg

2x40 (240)

2x65 (240)

2x65 (240)

Axle pressure at rated load, kg

2x710 (240)

2x790 (240)

2x790 (240)

Support castors, mm

Dia 125x40

Dia 125x40

Dia 125x40

Axle pressure without load

2X70 (240)

2X75 (240)

2x75 (240)

Axle pressure at rated load, kg

2x80 (240)

2x210 (240)

2x210 (240)

Output, kW

1.2

2.2

2.2

Duty cycle,%

10

10

10

Minimum carbon brush length, mm

7.5

12

12

Minimum commutator thickness/diameter, mm

4.75

4.7

4.7

Pressure at rated load, bar

110

150

150

Overflow pressure, bar

130

170

170

Pump flow, litre/minute

4.7

4.6

4,6

Tank volume, litre

0,5

1,0

1,0

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

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

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

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

Drive motor circuits, A

130

130

130

Pump motor circuits, A

125

125

125

Control circuits, A

7,5

7,5

7,5

Wheels

Hydraulic system

Fuses

2- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Technical data – M4 Valid from serial number 723984-Order number 222995-040

Model

T-code 677, 678, 679 Date 2005-02-02

7PM18

7PM20

7PML20

Dimensions LxWxH, mm

193x642x450

193x642x450-510

193x642x450-510

Capacity, Ah

160-320

240-320

240-320

Weigh, kg

165-250

210-250

210-250

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

6,0 1.7

6,0 1.7

8,0 2.22

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

6,0 1,7

6,0 1,7

7.2 2.0

Lift without load, s

2.2

1.7

1.7

Lift with rated load, s

3.4

2.3

2.3

Lowering without load, s

2.6

1.4

1.4

Lowering with rated load, s

3.1

1.5

1.75

Driving without load, A

38

29

46

Driving with rated load, A

45

46

65

Lift without load, A

39

49

49

Lift with rated load, A

80

52

52

8%

9%

9%

Short Medium Lång

519 565 613

519(7PM20) 660 1008

660 1008

Turning radius WA

1466

1960

1960

Lift height

205

205

205

295

420

440

Battery compartment, Batteries

Driving speed

Lift/lowering speed

Power consumption

Incline climbing ability With rated load

Measurement, L2

Weight Truck without battery, Medium

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

2- 3

Technical data – M4 T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

2- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Introduction Maintenance – P1 Safety regulations with maintenance work Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

3- Introduction Maintenance – P1 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 © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

3- 1

Introduction Maintenance – P1 Cleaning and washing T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

• Relieve the system pressure slowly before starting work on the truck’s hydraulic system • Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand • Bear in mind that the oil in the transmission or the hydraulic system can be hot WARNING! Risk of burns.

Hot transmission and hydraulic oil.

Let the truck cool before changing the oil.

• Only fill the hydraulic system with new and clean oil WARNING! The hydraulic system can be damaged.

If the oil is contaminated hydraulic components can be damaged.

Always use new and clean oil in the hydraulic system.

• Store and dispose of changed oil in accordance with local directives • Do not release solvents and the like, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local directives that apply for disposal • Disconnect the battery when welding on the truck NOTE! The battery can be damaged.

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

The battery should therefore be disconnected.

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

Paint that is heated gives off harmful gases.

Remove 100 mm of paint from the work area.

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

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Introduction Maintenance – P1 Cleaning and washing Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

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 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

3- 3

Introduction Maintenance – P1 Safe lifting T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

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.

3- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Preventive maintenance – P2 Maintenance schedule Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

4- Preventive maintenance – P2 4.1 Maintenance schedule I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

0000

Chassis

0000.1

Check all links and locking pins

l

0000.2

Check wear on cover/battery locking

l

0000.3

Check of cracking and damage

l

0000.4

Check the cover locks

I

0000.5

Check finger guard

I

0000.6

Check signs and stickers

I

0000.7

Press grease into grease nipples

0380

Fork carriage

0380.1

Check for crack formation and damage

l

0380.2

Check clearance in bushes and links

I

0380.3

Press grease into grease nipples (Option)

0380.4

Check the lift limit switch

0560

Platform and mountings

0560.1

Check for any cracks or damage

l

0560.2

Check gas damper and cup springs

l

1700.

Drive motor

1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

© TIEE SARL

I/L6

I/L6 l

I/T1

I/T

T2 l

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

4- 1

Preventive maintenance – P2 Maintenance schedule T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

2550

Drive gear

2550.1

Check for leakage

2550.2

Check the oil level

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in steering bearing

I

2550.5

Change the oil in the drive gear

3100.

Brake

3100.1

Clean

3100.2

Check for wear on the brake disc

M

3100.3

Check the clearance in disengaged position

M

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

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

I/T

3500.3

Check that the support wheel turns and rotates freely

I

3500.4

Check for wear on the support wheel

I

4110

Tiller arm

4110.1

Check the mountings

4110.2

Check the power in the gas damper

5000

Electrical functions

5000.1

Check the operation of the brake microswitch in the upper and lower brake positions. Lubricate the switch head.

I

5000.2

Check the function of the collision safety switch

I

5000.3

Check the function of the gate switches

I

4- 2

© TIEE SARL

I

I3

L

L4

C

I

I I

Service Manual 7PM18, 7PM20, 7PML20

I/L

I

Approved by: L-G Andersson

Preventive maintenance – P2 Maintenance schedule Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

5000.4

Check the function of platform switch

I

I

5000.5

Check the function of the horn

I

I

5000.6

Check for wear on cabling

5000.7

Check the function of the driver’s control

I

I

5000.8

Check the error code log and operating times

I

I

5110

Battery

5110.1

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

M

5110.2

Check connections to battery, truck and charger

I

5110.3

Check that the cell and pole guards are undamaged

I

5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

5400

Power system

5400.1

Cleaning and checking of mounting in chassis

C/T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

5700

Electronic circuit board

5700.1

Check connectors and cables

5700.2

Check all segments on the display

© TIEE SARL

I

I

T1

I

C/T

I I

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

4- 3

Preventive maintenance – P2 Maintenance schedule T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

6100

Hydraulic system

6100.1

Check hoses and connections for wear

I

6100.2

Check hoses for wear and damage

I

6100.3

Check the oil tank for cracks, leakage and damaged mountings

I

6100.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

6680

Power Trak

6680.1

Check if there is any damage or cracks on the PowerTrak spring

6680.2

Grease in the contact pressure spring’s guides

I L

L5

I C/L

1 = The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months.

2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm. 3 = Check for leakage in conjunction with the first oil change.

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months 5 = The oil is changed and the filter cleaned for the first time after 80 h/ 1 month, and then every 1000 h/12 months.

6 = If the truck goes into a refrigerated environment or other harsh environment, the point is addressed at more frequent intervals.

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

4- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Preventive maintenance – P2 Maintenance schedule Valid from serial number 723984-Order number 222995-040

5000

T-code 677, 678, 679 Date 2005-02-02

5000

6680 4110 5110 5700

5000

6600 5400 3100 1700 0380

6100

0560

0000

2550 5000 3500

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

4- 5

Preventive maintenance – P2 Lubrication schedule T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

4.2 Lubrication schedule Pos. No.

Service point

Interval/Operating hours

0380

Lubricating nipples (Option)

2550

Drive gear

O4

C

6100

Hydraulic system

O5

O

80 h

L = Lubrication

500

1000 h

3000 h

L

Type of lubricant E

C = Check

O

C B

O = Oil change

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months 5= The oil is changed and the filter cleaned for the first time after 80 h/1 month, and then every 1000 h/12 months.

6100 0000 2550

0380

4- 6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Oil and grease specifica tion – P3 Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

5- Oil and grease specifica tion – P3 Pos.

Type of lubricant

Specification > -15° C

< -15o C

A

Grease

26777 (Spray)

26777 (Spray)

Bearings and bushes

B

Hydraulic oil

ISO-L-HM32

ISO-L-VG 32

Hydraulic system

C

Transmission oil

Hypoid oil SAE 80W/90

Hypoid oil SAE 75W

Gears

D

Grease

Staburags NBU 8EP

Staburags NBU 8EP

Guide bearing

E

Grease

73942XX5 TOTAL N3942

73942XX5 TOTAL N3942

Lubricating nipples, Contact pressure spring

© TIEE SARL

Application

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

5- 1

Oil and grease specifica tion – P3 T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

5- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Tools – P4 Super Seal connectors Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

6- Tools – P4 6.1 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 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

6- 1

Tools – P4 AMP connectors T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

6.2 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 6- 2

© TIEE SARL

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

1

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Tools – P4 Molex connectors Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

6.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

6.3 Molex connectors 16 9 8 1 Figure

© TIEE SARL

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

6- 3

Tools – P4 Other tools T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

6.4 Other tools Figure

6- 4

© TIEE SARL

Number

Application

179915

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

08-13022

Driving gear puller

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Engine suspension– 0450 Component parts Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

7- Engine suspension– 0450 7.1 Component parts

1 6680

2

3 20

21 4

5

6

19 7 8 18

11

9 14

13 12

10

15

17 16

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

7- 1

Engine suspension– 0450 Component parts T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

7.1.1 Component List

7- 2

© TIEE SARL

Pos.

Description

Notes

1

Screw

2x M6S 8x30

2

Plate

3

Circlip

4

Console

5

Washer

8x

6

Screw

2x M6S 12x45

7

Lock bracket

8

Screw

9

Axle

10

Screw

2x M6S 12x90

11

Grease nipple

2x

12

Pivot pipe

13

Grease nipple

4x

14

Bushing

4x

15

Engine bracket

16

Screw

2x M6S 6x10

17

Axle

2x

18

Washer

(0.5 mm) Number as required

18

Washer

(1 mm) Number as required

19

Bushing

4x

20

Link

2x

21

Grease nipple

2x

6680

PowerTrak system

See chapter 6680 “PowerTrak cylinder”

Service Manual 7PM18, 7PM20, 7PML20

MC6S 8x12

Approved by: L-G Andersson

Electric drive motor – 1760 Component parts Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

8- Electric drive motor – 1760 8.1 Component parts 16 21 14

18

13

19

20

17 10

15

12 11

8

9

7 5

6

4 3 1 2

© TIEE SARL

Pos

Description

Note

1

Screw

M6x25

2

Bearing shield

3

Locking ring

4

Bearing

5

Carbon brush bridge

6

Screw

M5x12

7

Screw

M5x20

8

Carbon brush

9

Rotor

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

8- 1

Electric drive motor – 1760 Component parts T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Pos

Description

10

Key

11

Plug

12

Stator

13

Cable

14

Cable

15

Bearing shield

16

Screw

17

Seal

18

Bearing

19

Washer

20

Locking ring

21

Locking ring

Note

M6x25

8.1.1 Dismantling/assembling of motor from truck • Switch off the truck and pull out the battery plug.

• Remove the covers for the motor compartment.

• Release the cables for the motor and tiller arm.

• Unscrew the four nuts for the attachment of the motor to the drive gear.

• Loosen the cables for the key switch and emergency switch. Pull out all the cables from the cover’s cable duct.

• Loosen the cover over the motor compartment and the tiller arm’s mounting from the motor. Remove the cover over the motor compartment together with the tiller arm.

• Carefully lift the motor straight up, without damaging the sealing surfaces to the drive gear and place the motor on a clean surface.

• Protect the drive gear from impurities by covering over its opening in an appropriate manner, e.g. with a piece of plastic.

The requisite service and repair of the motor can now be carried out.

8- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electric drive motor – 1760 Service/Repairs Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

8.1.2 Assembling Assembling is carried out in the reverse order.

• Carefully lift down the motor in the drive gear to avoid damaging the seals and gear wheels.

• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm. • Fit and adjust the brakes as per the instructions. Screw tight the cover and tiller arm, and connect the cables that were previously removed. Check that the polarity is correct.

• The function of the brakes should be checked before the truck is moved.

8.2 Service/Repairs 8.2.1 Dismantling of motor 16 21 14

18

13

19

20

17 10

15

12 11

8

9

7 5

6

4 3 1 2

• Release the brake disc’s companion flange by first removing the locking ring together with the washer in the end of the rotor shaft.

The companion flange can now be lifted off. It may be necessary to unclamp it with an appropriate tool.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

8- 3

Electric drive motor – 1760 Service/Repairs T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

• Remove the four plugs that cover the carbon brushes, move the springs on the carbon brushes to one side and pull out the carbon brushes.

• Dismantle the commutator end’s bearing shield (2) together with the carbon brush bridge (5) and carbon brushes (8) by unscrewing the eight screws (1). Now put down the motor with a firm resting point against the edge of the bearing shield, and carefully tap on the rotor shaft’s end with a rubber mallet.

• Dismantle the drive end’s bearing shield (15) together with the rotor (9). Make sure not to damage the motor windings when the rotor is removed from the motor housing.

• After dismantling the motor’s bearing shields and removing the rotor from the motor housing, the gear wheel in the rotor’s drive end is removed. This is done by unscrewing the nuts on the gear wheel and then pulling the gear wheel off with a puller. Note that the gear wheel is locked with Loctite to the rotor shaft.

• Now release the inner locking ring together with the underlying washer. Pull out the rotor shaft from the bearing (18).

• Release the outer locking ring together with its washer, and remove the bearing from the bearing shield.

• Remove the bearing shield’s seal (17) and carefully clean the bearing shield.

• Fit a new seal in the bearing shield.

8.2.2 Assembling of motor Assemble the motor in the reverse order.

• Carefully check that the rotor can move freely in the direction of rotation and that the carbon brushes are flush with the commutator.

• Check the motor’s insulation resistance (between respective winding and the motor housing). For a new motor this should lie between 2 - 3 Mohm. When a used motor has been exposed to impurities an insulation resistance down to approx. 1 Mohm is acceptable.

• Fit a new O-ring in the drive shaft end’s bearing shield and a new seal on the collar of the bearing shield.

8- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electric drive motor – 1760 Service/Repairs Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

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

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

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

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

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

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

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

8- 5

Electric drive motor – 1760 Technical data T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

8.3 Technical data

8- 6

Type of machine

7PM18

7PM20

7PML20-6/8

Type

TSL140S-DS20

TSL140S-DS30

TSL140B-DS40

Output (kW)

1.0

1.2

1,7

Intermittence

S2 60 min

S2 60 min

S2 60 min

Minimum length of carbon brush (mm)

13

13

13

Minimum commutator diameter (mm)

47

47

60

Resistance, shunt field winding Ω at 26 C°

0,55

0,55

0,498

Resistance, armature winding,Ω at 26C°

0,0156

0,0156

0,0161

Insulation resistance between windings and motor housing

>= 1Mohm

>= 1Mohm

>= 1Mohm

Weight (kg)

14

14

17

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Mechanical drive gear unit – 2550 Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

9- Mechanical drive gear unit – 2550

2 3 4 5

6

01

7 8

24

9 27

25 26

10 11

28 13 12 14 32 29

15

18

16

19

17 20

23 21

© TIEE SARL

30

31

22

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

9- 1

Mechanical drive gear unit – 2550 Component parts T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

9.1 Component parts

9- 2

© TIEE SARL

Pos

Description

Note

01

Drive gear complete

2

Air valve

3

Cover

4

Oil stick

5

Washer

6

Gasket

7

Nut

8

Washer

9

Gear wheel

10

Conical roller bearing

11

Shims

12

Screw

13

Shims

14

Conical roller bearing

15

Pinion/ Crown gear

Cog clearance 0.09-0.15 mm Pretension bearing with 2-5/100 Stamped size on pinion adjusted with shims

16

Nut

Tightening torque 300 Nm Locked with punch mark

17

Shims

18

Conical roller bearing

19

Shims

20

Screw

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

21

Screw

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

Tightening torque 70 Nm Locked with punch mark

Primary gear

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

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Mechanical drive gear unit – 2550 Component parts Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Pos

Description

Note

22

Cover

23

Gasket

24

Gear wheel

25

Washer

26

Nut

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

27

Screw

Motor and gear housing

28

Nut

Tightening torque 26.6 Nm Lock with Loctite 242

29

Conical roller bearing

30

Shims

31

Seal

32

Drive shaft

Motor gear

9.1.1 Technical data

© TIEE SARL

Type of truck

7PM18/20, 7PML20-6

7PML20-8

Type of gear

2-step angle gear

2-step angle gear

Gear ratio

19,14:1

16,29:1

Oil volume, litres

1,0

1,0

Oil type

Hypoid oil

Hypoid oil

Viscosity, normal temperature

SAE 80W/90

SAE 80W/90

Viscosity, <-15°C

SAE 75W

SAE 75W

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

9- 3

Mechanical drive gear unit – 2550 Leakage from top cover T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

9.2 Leakage from top cover Dismantling • Lift up the truck, and block up to ensure that it is stable.

• Unscrew the drive wheel.

• Unscrew the M8 nuts (28), that hold the gear and motor, with a box wrench. Support the gear so that it does not drop.

• Release the M8 bolts (12), that hold the cover (3), with a 6 mm hex socket wrench.

• Change the gasket (6).

Assembling Assemble in reverse order.

• Tighten the four M8 bolts and the four M8 nuts to a torque of 26.6 Nm Lock with Loctite 242.

• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.

9.3 Changing of the drive shaft’s sealing ring The drive shaft’s sealing ring can be changed with the gear mounted in the truck.

Follow the instructions below if oil is leaking from the drive shaft.

Dismantling • Unscrew the drive wheel 1).

• Remove the lower cover and drain off the oil (22).

• Release the drive shaft nut. Remove the nut and washer (16,17).

• Carefully tap out the drive shaft with a brass drift and hammer (32).

• Pull off the bearing from the drive shaft with tool 08-13022 (29).

• Check that the bearing washers are not damaged. If they have been damaged by the puller tool, measure the total thickness of the shim washers and change them before assembling (30).

• Remove the sealing ring from the drive shaft (31).

9- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Mechanical drive gear unit – 2550 Changing of the drive shaft’s sealing ring Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Assembling Assemble the gear after changing the drive shaft’s sealing ring in reverse order.

Pay special attention to the following during assembling: • Fill the sealing ring with grease after fitting it on the drive shaft.

• Make sure that only undamaged shim washers with the same total thickness as the originals are put on the drive shaft.

• Press the bearing on the drive shaft and make sure not to damage the bearing’s shim washers.

• When fitting the drive shaft with bearing, shim washers and seal, make sure that the shaft keys correspond with the crown gear’s keys and that the bearing and seal are correctly positioned in the gear housing before the shaft is pressed in completely.

• Put the distance ring on the drive shaft end, and put on the shaft nut.

Always use a new nut. Tighten the shaft nut to a torque of 300 Nm and lock it with a punch mark in the middle. The drive shaft nut should be lubricated before it is put on the shaft.

• Change the gasket before fitting the bottom cover. Make sure that it is not damaged. Fit the cover and tighten the bolts to a torque of 26.6 Nm. The bolts should be lubricated before they are fitted. Fill up with oil in accordance with the instructions for replenishing the oil.

Fit the drive gear and tighten the bolts to a torque of 65 Nm.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

9- 5

Mechanical drive gear unit – 2550 Changing of the drive shaft’s sealing ring T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

9- 6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electro magnetic brake – 3370 Main components Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

10- Hamulec elektromagnetyczny 7PM18, 7PM20, 7PML 20-6 9

1 2

8

3

4

7

6

5

© TIEE SARL

Nr pozycji

Opis

1

Cewka magnetyczna

2

Sruby dysku

3

Wiazka elektryczna

4

Dysk dociskowy

5

Nakretka regulacyjna

6

Sprezyny

7

Stopka

8

Sruby mocujace

9

Tarcza hamulca

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

10- 1

Electro magnetic brake – 3370 Maintenance T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Pos No

Description

9

Brake disc

10

Hub

10.2 Maintenance Basically the brake is maintenance free in normal work environments.

However it is recommended according to the preventive maintenance schedule to check the brake disc for wear.

10.2.1 Exchange of brake disc The brake disc shall be exchanged when its total thickness has been reduced to 5,5 mm.

• Disconnect the electrical wires of the brake.

• Undo and remove the two fastening bolts.

• Loosen the brake disc from the hub and check for wear and tear. Replace the brake disc if the surface is unevenly worn.

• Reassemble the brake.

• Reconnect the electrical wiring.

10- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electro magnetic brake – 3370 Main components Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

11- Electro magnetic brake – 3370 7PML20-8

11.1 Main components 9

1

8 2

7

3

6

4

5

© TIEE SARL

Pos No

Description

1

Magnetic coil

2

Electrical wire

3

Pressure plate

4

Pressure springs

5

Friction plate

6

Adjustment locking nut

7

Brake disc

8

Mounting bolts

9

Hub

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

11- 1

Electro magnetic brake – 3370 Maintenance T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Ustawianie szczeliny hamulca 9,5 Nm

0,3

Nominalna szczelina powinna wynosic 0,3 mm. Jednakze w niektorych przypadkach ze wzgledu na duze zapylenie szczelina powinna wynosic max. 0,5 mm .

Regulacja: • Loosen the tension of the three mounting bolts .

• Turn the lock nuts anti-clockwise and tighten the bolts slightly while checking the gap on three points with a 0.3 mm feeler gauge.

• Tighten the mounting bolts 9,5 Nm and recheck the gap with the feeler gauge.

11- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electro magnetic brake – 3370 Maintenance Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

11.2.2 Exchange of brake disc The brake disc shall be exchanged when its total thickness has been reduced to 6 mm.

• Disconnect the electrical wires of the brake.

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

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

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

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

• Reconnect the electrical wiring.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

11- 3

Electro magnetic brake – 3370 Maintenance T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

11- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Steering system – 4000 Component parts, tiller arm Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

12- Steering system – 4000 12.1 Component parts, tiller arm 1 2 3

4

5 6

8 7 9

13

11

12

15 17

10

14

16

18 19 20 21 22

© TIEE SARL

Pos

Description

Note

1

Screw

4

2

Washer

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

12- 1

Steering system – 4000 Adjustments T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Pos

Description

Note

3

Handle

4

Screw

4

5

Washer

2

6

Cable holder

7

Gas damper

8

Bracket

9

Stop screw

10

Screw

11

Ball joint

12

Screw

13

Distance

14

Bush

2

15

Damper

2

16

Axle

17

Cam

18

Distance

19

Screw

20

Distance

21

Distance

22

Switch

4

S 10

12.2 Adjustments 12.2.1 Adjusting of brake microswitch Switch (23) is always adjusted to its lowest position.

• Unscrew the screws (13, 20) that hold the switch and the distance.

• Press down the switch and tighten the screws.

• Check that the switch is actuated by the cam (18) in the arm’s top and bottom position.

12- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Steering system – 4000 Tiller arm handle Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

12.3 Tiller arm handle 28 29

27 26 24 25

14 23 22

17 18

21 20

16

19

15 14 14

30 31 10 9 8

32

35

34

14

12 11

13

33

5

7

6

4

1

2 3

© TIEE SARL

Pos

Description

1

Screw

2

Cover

3

Handle

4

Electronic card

5

Screw

6

Display card

7

Top cover

8

Pushbutton

9

Signal switch

10

Signal button

11

Display glass

12

Arm

13

Pushbutton

14

Plate

15

Spring

Note Keyboard option

Option

Lift/Lower

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

12- 3

Steering system – 4000 Tiller arm handle T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Pos

Description

Note

16

Pushbutton

Not used

17

Arm

18

Holder

19

Spring

20

Control switch

21

Axle

22

Sliding bearing

23

Control stop

24

Arm

25

Spring holder

26

Spring

27

Spring holder

28

Sliding bearing

29

Control switch

30

Button for safe reversing

31

Arm

32

Spring

33

Lower cover

34

Screw

M4x40

35

Screw

2xM5x45 - 2xM5x60

12.3.1 Dismantling/Assembling • Dismantle cover (2), (keyboard option).

• Remove the screws (35), hold top cover firm (7).

• Disconnect the cable connected to the electronic card (4).

• Remove the screws (34).

• Carefully lift off the lower cover (33), and place a finger between the lower cover (33) and button (30) to hold the button (30) in place.

Assemble in reverse order.

NOTE! Static electricity!

Risk of static discharge that can damage the electronics.

Make sure to take the necessary precautions before working with the electronics.

12- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Steering system – 4000 Tiller arm handle Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Change from ignition key to keyboard (2) • Connect the CAN-key to the truck.

• Enter parameter mode (P).

• Change parameter 39 to value = 3 or 4.

• Set the required PIN-code by using parameter 10.

• Switch off the truck.

• Dismantle the cover(2) on the tiller arm.

• Fit the keyboard.

• Remove the ignition key, fit the strap.

• Fit the cover in the key hole.

• Start the truck using the chosen PIN-code.

Change from keyboard to ignition key (2) • Connect the CAN-key to the truck.

• Enter parameter mode (P).

• Change parameter 39 to value = 1 or 2.

• Switch off the truck.

• Remove the keyboard (2) on the tiller arm.

• Fit the cover.

• Remove the strap.

• Remove the cover.

• Fit the ignition key.

• Start the truck.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

12- 5

Steering system – 4000 Tiller arm handle T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Changing of signal button/switch (9, 10) • Dismantle the button as per the diagram.

• Disconnect the connection for the switch on the electronic card (4).

• Press out the switch from its mounting.

Assemble in reverse order.

Changing of lift/lowering button (13) • Remove the button by placing a screwdriver in the hole (A) as per the diagram below.

A

A

• Unscrew the holder (18) so that the arm (12) comes loose.

Assemble in everse order.

12- 6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Steering system – 4000 Tiller arm handle Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Changing of pushbutton (16) • Press the button by hand sideways.

• Place a screwdriver as per the diagram and carefully pry the button loose.

• Unscrew the button’s holder and arm.

Assemble in reverse order.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

12- 7

Steering system – 4000 Tiller arm handle T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

12- 8

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Electrical components Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13- Electrical System – 5000 13.1 Electrical components S17

S10

S31

S21

X41 X5 X1

Y1

F50 M3

F51 F1

Y41

R1 K10 F3

M1

K30 A1 H1

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 1

Electrical System – 5000 Electrical components T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

A17

13- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Symbol List and Wiring Diagram Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.2 Symbol List and Wiring Diagram Symbol

Description

A1

Transistor regulator

A2

Electronic card

A6

Display

Display of truck functions

A17

Keypad

Login with PIN code

Option

F1

Fuse

Drive motor circuits

130 A

F3

Fuse

Pump motor circuits

130 A

F 50

Fuse

Working circuit A5

7.5 A

F 51

Fuse

Working circuit A1

7.5 A

F 52

Fuse

Optional equipment

Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

A2:S1-S9 A2:S10S18

Speed controls

Forward/backward

M1

Motor

Drive motor

M3

Motor

Pump motor

P1

Pressure sensor

Load monitoring

Digital (Applies to 7PML20-8)

R1

PTC resistance

Power supply

15 Ohm

© TIEE SARL

Function

Comments

24 V

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 3

Electrical System – 5000 Symbol List and Wiring Diagram T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Symbol

Description

Function

S111

Switch

Option

S112

Switch

Option

S113

Switch

Option

S114

Switch

Option

S115

Switch

Option

S116

Switch

Option

S10

Inductive switch

Mechanical activation of the brake

S17

Switch

Key

S18

Switch

Button for horn

S19

Switch

Man on the platform

A2:S17

Switch

Emergency reversing

S21

Switch

Emergency switch

S31

Switch

Lift height limiter

A2:S19

Switch

Fork lift (Standard)

A2:S20

Switch

/Fork lowering (Standard)

A2:S21

Switch

Fork lift (Alternative, see parameter 28)

A2:S20

Switch

/Fork lowering (Alternative, see parameter 28)

S53

Switch

Gates

(Applies to 7PML20-8)

S59

Switch

Platform in folded position

(Applies to 7PML20-8)

Y1

Electromechanical brake

Mechanical brake

Y41

Solenoid valve

Fork lowering

X1

Coupling

Battery

X9

Connection point

CAN communication (Extra I/O)

X41

Connection point

CAN communication (External)

13- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Comments

Brake handle

(Applies to 7PML20-8)

Approved by: L-G Andersson

Electrical System – 5000 Symbol List and Wiring Diagram Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.2.1 Wiring diagram 1(5) 7PM18/20, 7PML20-6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 5

Electrical System – 5000 Symbol List and Wiring Diagram T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

13.2.2 Wiring diagram 2(5) 7PM18/20, 7PML20-6

13- 6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Symbol List and Wiring Diagram Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.2.3 Wiring diagram 3(5) 7PM18/20, 7PML20-6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 7

Electrical System – 5000 Symbol List and Wiring Diagram T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

13.2.4 Wiring diagram 4(5) 7PM18/20, 7PML20-6

13- 8

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Symbol List and Wiring Diagram Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.2.5 Wiring diagram 5(5) 7PM18/20, 7PML20-6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 9

Electrical System – 5000 Symbol List and Wiring Diagram T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

13.2.6 Wiring diagram 1(5) 7PML20-8

13- 10

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Symbol List and Wiring Diagram Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.2.7 Wiring diagram 2(5) 7PML20-8

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 11

Electrical System – 5000 Symbol List and Wiring Diagram T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

13.2.8 Wiring diagram 3(5) 7PML20-8

13- 12

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Symbol List and Wiring Diagram Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.2.9 Wiring diagram 4(5) 7PML20-8

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 13

Electrical System – 5000 Symbol List and Wiring Diagram T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

13.2.10 Wiring diagram 5(5) 7PML20-8

13- 14

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Operating description Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.3 Operating description 13.3.1 Starting truck To enable the truck to be started, the battery plug must be connected, the emergency switch (S21) closed and the start key (S17) in the ON position.

13.3.2 Driving speed ≤ 6 km/h When driving at a speed of 6 km/h - the switch for driving brake (S10) must be closed, and the - Speed controls must be activated in any direction.

A1 BS1 T1

Ish A2

A A1

T2

K10

B+

• when the speed controls are in neutral mode, the engine functions as a generator. The braking energy is fed back to the battery.

• The brake (Y1) is engaged when the truck stops completely even if the tiller arm is in drive position.

• Energy is fed back to the battery (see diagram below).

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

A1 BS1

Ish + Ia

T1

S2

MShunt

Ia

13.3.3 Braking in neutral mode

MShunt

+

S2

A2

A A1

T2 K10

B+

13.3.4 Braking in neutral mode on a slope If the driver releases the speed control on a slope and the truck does not stop within a certain space of time, the electrical brake is automatically engaged.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 15

Electrical System – 5000 Hour meter T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

13.3.5 Braking The brake is always engaged when the truck is started with the tiller arm in the top or bottom position (S10 open). The brake is released once all the requirements for driving have been fulfilled, and the truck begins to move.

Requirements for the truck to be able to brake: • S10 open.

13.3.6 Lifting the forks • S34 • S31 closed.

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

13.3.7 Lowering the forks • S41 activated.

13.3.8 Horn • S18 activated.

13.4 Hour meter • Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until H = hour meter is displayed.

• You have now selected H = hour meter. The “B” symbol lights up.

• You can now select type of hour meter by pressing the speed control.

1A = Key time 2b = Movement time

A

3c = Drive motor time 4d =Pump motor time 5s = Time remaining until service

E

13- 16

D

C

B

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Error codes Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.5 Error codes • Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until E = error codes is displayed.

• When E is selected, the “E” symbol will light up as an indication of what is shown in the display.

• The 50 most recent error codes are stored. The latest error is displayed first. The display shows the error code first, followed by the time when the error occurred.

• The error codes are divided into two groups, C = caution and E = error.

• C codes are not stored. They are only cautions and remain lit in the display as long as the fault remains.

• If there is only one error registered in the memory, the other empty entry lines appear as follows: Error: E - - - and time: - - - - .

© TIEE SARL

Code

C3

Description

TLS: Shock sensors registered values outside the limits

Possible error cause

A shock sensor has reported values that exceed the truck’s tolerance values.

Driving may be too hard Check that the shock sensor’s limit values are correctly set.

Check that the shock sensor is correctly positioned./The brake engages and stops the truck.

The TLS reset command activates the truck

Code

C4

Description

TLS: Use of the truck has been blocked

Possible error cause

Truck use can be “blocked” by a TLS command. / The truck cannot be used until a new TLS command cancels the blocking of the truck

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 17

Electrical System – 5000 Error codes T-code 677, 678, 679 Date 2005-02-02

13- 18

© TIEE SARL

Valid from serial number 723984-Order number 222995-040

Code

C19

Description

Parameter caution. Displayed for 5 seconds.

Possible error cause

The parameters have probably been changed.

When changing/updating the program the parameters have automatically been changed to default values (only applies to old program versions).

In later program versions the parameters are only changed if they are outside the values permitted by the new program.

Action

1. This means that the special parameters must be reset manually.

Code

C20

Description

Speed control caution.

Possible error cause

Problem with the speed control sensors.

The toggle switch may have been activated when starting or there may be a fault on one of the sensors on the electronic card. (tiller arm head)

Action

1. Restart with the speed control in neutral position.

2. Replace the electronic card.

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Error codes Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Code

C28

Description

Emergency switch caution

Possible error cause

The emergency switch has been activated.

No current to the travel regulator, input. A1/16.

Action

1. Check fuse F51.

2. Check the emergency switch.

3. Check the cables from the battery and the battery contacts.

4. If PTC resistor R1 is very hot, remove the battery contact and allow the resistor to cool.

Restart.

© TIEE SARL

Code

C29

Description

Service warning

Possible error cause

Time for service.

The service counter has not been reset since the last service.

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 19

Electrical System – 5000 Error codes T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

7PML20-6, 7PML20-8

13- 20

© TIEE SARL

Code

C31

Description

Pressure switch warning.

Possible error cause

A problem with the pressure switch. Check that the voltage is approximately 24 V between cables 24 and 40 connected to the pressure sensor.

Check the voltage between cable 40 and 63 connected to the pressure sensor. The output voltage should be 0.5 Volt (unloaded machine) - 5 Volt (max load).

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Error codes Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Code

C41

Description

Warning of low battery voltage

Possible error cause

Battery voltage < 17 volt.

The battery parameters are not correctly set.

Time to charge up the battery.

Action

1. Check parameter 21, battery size and type.

2. Check the battery contact and the pole connections on the battery 3. Check the key switch, S17, poor contact causes unpermitted voltage drop.

The electrical system measures the voltage inside the travel regulator.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 21

Electrical System – 5000 Error codes T-code 677, 678, 679 Date 2005-02-02

13- 22

© TIEE SARL

Valid from serial number 723984-Order number 222995-040

Code

C42

Description

Warning of high battery voltage

Possible error cause

Battery voltage > 33 volt.

Energy return feed to battery during motor braking with a fully-charged battery.

Action

1. The fault disappears after a few lifts, once the battery has been run down slightly.

2. Check the cabling, the battery contact and the contact points on main contactor K10.

Code

C43

Description

The travel regulator shuts off due to excess or subnormal temperature.

Possible error cause

Too intensive operation or ambient temperature too cold.

Error in the travel regulator.

Temperature levels below -25oC or above +85oC reduce running speed.

Action

1. Check that the M12 fan is functioning. (Applies to P 24) 2. Check that the travel regulator is installed with good contact with the chassis.

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Error codes Valid from serial number 723984-Order number 222995-040

© TIEE SARL

T-code 677, 678, 679 Date 2005-02-02

Code

C90 (Option)

Description

Extra I/0 (0) CAN communication error

Possible error cause

Data from extra I/0 box /(0) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C91 (Option)

Description

Extra I/0 (1) CAN communication error

Possible error cause

Data from extra I/0 box /(1) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C92 (Option)

Description

Configuration error Extra I/0 (0)

Possible error cause

Incorrect setting of options in the extra I/0 box (0) Check the outputs’ allocation on the I/0 expansion box (0)

Code

C93 (Option)

Description

Configuration error Extra I/0 (1)

Possible error cause

Incorrect setting of options in the extra I/0 box (1) Check the outputs’ allocation on the I/0 expansion box (1)

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 23

Electrical System – 5000 Error codes T-code 677, 678, 679 Date 2005-02-02

13- 24

© TIEE SARL

Valid from serial number 723984-Order number 222995-040

Code

E101

Description

Travel regulator does not correspond with the type of truck

Possible error cause

Incorrect travel regulator or electronic card has been installed. The truck has a built-in control function that checks to ensure the wrong combination of travel regulator and electronic card has not been installed.

Action

Check travel regulator and electronic card.

Code

E104

Description

Switch-transistor to brake is short-circuited

Possible error cause

Error in the travel regulator, output. A1/3.

Incorrect value on parameter 22

Action

Check cabling and contacts. Measure Ohms on the magnet coil (Y1) for the brake. Value 13-15 ohm.

Check parameter 22

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Error codes Valid from serial number 723984-Order number 222995-040

© TIEE SARL

T-code 677, 678, 679 Date 2005-02-02

Code

E106

Description

Digital outputs short-circuited or exceeding field current limit.

Possible error cause

Problem regulating the field current.

Internal monitoring error.

Action

1. Check the output for main contactor K10 (A1/ 4), check cabling and contacts and measure ohms for the coil. Value 25-30 ohm. Check the output for the brake coil K10 (A1/3), check cabling and contacts and measure ohms for the coil. Value 13-15 ohm.

2. Check the output for horn (A1/7), check cabling and contacts.

3. Check the drive motor’s shunt winding and cabling and contacts. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 25

Electrical System – 5000 Error codes T-code 677, 678, 679 Date 2005-02-02

13- 26

© TIEE SARL

Valid from serial number 723984-Order number 222995-040

Code

E107

Description

Contactor K10 does not close.

Possible error cause

Problem with main contactor points or coil.

Contactor’s operating cabling off/not connected.

Interruption in the travel regulator’s output, A1/4.

Action

1. Check if the contactor is activated.

2. If the contactor is working, check the contact points and accompanying cabling.

3. If the contactor is not working, check the coil and accompanying cabling. Measure Ohms for the coil. Value 25-30 ohm.

4. Check the travel regulator’s output, A1/4.

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Error codes Valid from serial number 723984-Order number 222995-040

© TIEE SARL

T-code 677, 678, 679 Date 2005-02-02

Code

E108

Description

Contactor K10 does not open.

Possible error cause

Main contactor points welded.

Short circuit in the travel regulator’s output A1/4.

Action

1. Check that the contactor’s contact points are not welded together.

2. Check that the R1 resistor is not shortcircuited.

3. If the contact points are OK, but the contactor engaged, check cable 64 and the travel regulator’s output A1/4.

Code

E110

Description

System error.

Possible error cause

Temporary error/error in the travel regulator.

Action

1. Restart the machine.

2. Replace travel regulator.

Code

E140

Description

Error in control total.

Possible error cause

Fault on the internal micro-monitoring (tiller arm head), incorrect software or circuit board.

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 27

Electrical System – 5000 Error codes T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Code

E141

Description

Software problem.

Possible error cause

Fault on the internal monitoring (tiller arm head), incorrect software or circuit board.

Action

1. Restart the machine.

2. Download the program again.

3. Replace the electronic card

Code

E150

Description

Fault in the data communication.

Possible error cause

Break on the CAN cable.

Action

1. Check the 119 and 120 cables and their contacts.

2. Replace travel regulator.

Code

E151

Description

Tx error in data communication.

Possible error cause

Travel regulator not responding.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

Code

E157

Description

Bus shut off.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

w

13- 28

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Error codes Valid from serial number 723984-Order number 222995-040

© TIEE SARL

T-code 677, 678, 679 Date 2005-02-02

Code

E159

Description

Transgression error.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

Code

E160

Description

Error in safety reversing function

Possible error cause

Error in important sensor part.

Action

1. Replace the electronic card

Code

E200

Description

Open field.

Possible error cause

Shunt field’s circuit open.

Action

1. Check the field winding connections E1 and E2. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

2. Check cables 4 and 5 and outputs S1 and S2 3. Replace travel regulator

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 29

Electrical System – 5000 Error codes T-code 677, 678, 679 Date 2005-02-02

13- 30

© TIEE SARL

Valid from serial number 723984-Order number 222995-040

Code

E201

Description

M minus error.

Possible error cause

Problem with switch transistor in the armature circuit inside the travel regulator.

Action

1. Check cable and connections between A1/M on the travel regulator and connection A2 on drive motor.

2. Replace travel regulator.

Code

E202

Description

Fault on sensor in travel regulator

Possible error cause

Fault on armature current sensor in travel regulator

Action

Replace travel regulator

Code

E214

Description

CAN timeout in power amplifier.

Possible error cause

The motor monitor is reporting an unexpected data loss from the electronic card in the tiller arm head.

Action

1. Check cables 119 and 120 between electronic card and travel regulator.

2. Replace electronic card 3. Replace travel regulator.

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.6 Parameters A

• Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until P = parameters is displayed.

• You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

E

D

C

• Press L1 up or down and scroll to the parameter you want to change or view.

B

• Press S18 once to access the parameter.

• Press L1 up or down to specify the parameter value.

• Press S18 once to confirm the change.

• Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine.

NOTE: Truck handling When you change specific truck parameters, the truck’s driving characteristics are also changed.

Do not change any parameters unless you really know what you are doing.

13.6.1 Operator parameters Parameter

Description

Unit

Min.

Max.

Step

Std.

Description

01

Speed, Turtle button

%

40

100

5

100

Speed, Turtle button 10: slow speed 100: maximum speed.

02

Max. speed

%

40

100

5

100

Max. speed 10: slow speed 100: maximum speed

03

Acceleration

10

100

5

50

10: slow acceleration 100: maximum acceleration

04

Braking in neutral mode

5

100

5

50

Specifies motor braking once the lever is put into neutral.

5: weak braking power 100: maximum breaking power

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 31

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Parameter

Description

Unit

Min.

Max.

Step

Std.

Description

05

Logout

1min

0

20

1

0 20

The time it takes for the truck to switch off when the keypad is used. The time counts down from the moment the last power-consuming unit is used. Value = 0 gives 4 hours.

In steps of 1

13.6.2 Parameter description Parameter 1 The speed of use of the turtle button can be adjusted.

Parameter 2 The maximum speed can be adjusted.

Parameter 3 The lower the parameter value, the longer it takes for the truck to achieve maximum speed.

Parameter 4 Specifies the motor braking power when the lever (L1) is put into neutral. The lower the parameter value, the longer the braking time.

Parameter 5 The time it takes for the truck to switch off when the keypad is used.

The time counts down from the moment the last power-consuming unit is used.

Value = 0 gives 4 hours.

13- 32

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.6.3 Service parameters • Connect the CAN key to X41.

A

• Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until P = parameters is displayed.

• You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

E

D

C

B

• Press L1 up or down and scroll to the parameter you want to change or view.

• Press S18 once to access the parameter.

• Press L1 up or down to specify the parameter value.

• Press S18 once to confirm the change.

• Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine.

NOTE: Truck handling When you change specific truck parameters, the truck’s driving characteristics are also changed.

Do not change any parameters unless you really know what you are doing.

Parameter

Description

10

Min .

Max .

Step

Std .

Description

PIN-code

0

9999

1

1

Facility for specifying up to 10 PIN codes (10 different drivers).

14

Crawling speed

-10

10

1

0

The amount of power the monitor should emit when you reach the first speed sensor can be specified here.

-10: low speed for the first speed sensor.

10: high speed for the first speed sensor

15

Non-configurable option 0 to 9

© TIEE SARL

Unit

See “Option parameters” on page 35,

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 33

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Parameter

Description

Unit

16

Configurable option #1

See “Option parameters” on page 35,

17

Configurable option #2

18

Configurable option #3

19

Configurable option #4

20

Hour meter option

1

5

1

2

Select hour meter.

21

Battery size

1

20

1

95

Selection of battery size.

22

Inductive sensor

0

1

1

1

0: Mechanical switch 1: Inductive sensor

25

Service interval

0

2000

50

100

Option for setting service timer

28

Lift button selection

1

3

1

1

Button selection

39

Password

1

12

1

1

States which level of authorization the driver has for the parameters.

Odd values specify open driver parameters, even values specify that driver parameters must be opened using the CAN key

1h

Min .

Valid from serial number 723984-Order number 222995-040

Max .

Step

Std .

Description

13.6.4 Parameter description Parameter 10 NOTE! The functionality of parameter #10 is set aside if the value of parameter #39 is set to 5,6,7 or 8. The PIN codes are managed using the socalled expanded keypad. See section Expanded keypad - General on page 47 for more detailed information.

Ten drivers can have their own PIN code to gain access to the truck.

Each driver can set all driver parameters individually.

On delivery the PIN code is set to 1 and this only applies for driver no. 1.

Code 0 is not accepted as a solitary code.

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

When you want to switch off the truck, press the red button numbered 0.

When the CAN key is connected, you can start the truck by simply pressing the green button numbered 1. Switch off by pressing the red button numbered 0.

13- 34

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Parameter 14 Specifies the speed you will have when you reach the first speed sensor.

Parameter 15 - Non-configurable option See “Option parameters” on page 35,

Parameter 16 - Configurable option #1 See “Option parameters” on page 35,

Parameter 17 - Configurable option #2 See “Option parameters” on page 35,

Parameter 18 - Configurable option #3 See “Option parameters” on page 35,

Parameter 19 - Configurable option #4 See “Option parameters” on page 35,

Option parameters WARNING !

Do not try to change these parameter unless you have specific knowledge of the truck options or truck modifications. This service manual only covers the truck’s standard equipment. Specially modified trucks may require you to have access to particular service information. Incorrect adjustment of option parameters may result in incorrect function.

General Parameters #15 to #19 have been reserved in the truck control system for extra options and/or specific product modifications. These parameters are normally configured by the manufacturer on modification or customisation of the truck. It is recommended that the parameter settings be loaded up from the truck when carrying out any modification. If, for example, the main electronic card [A2] must be replaced, the original parameter settings can then be simply transferred to the new card, which ensures that all the special options function correctly.

Parameter #15 Non-configurable options Up to 16 so-called sub-parameters are stored under parameter #15.

Their status is either ON or OFF and they do not require any other adjustments. They are therefore called non-configurable options.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 35

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Changing non-configurable options • Ensure the truck is in parameter mode.

The parameter symbol is lit.

• Select parameter #15 using [L1].

The first set-up of sub-parameters is displayed The next set-up of sub-parameters is displayed if you continue to activate the speed control L1. Ensure that only the relevant sub-parameters are displayed.

The value of the sub-parameters is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

.

• Enter the sub-parameter value by repeatedly operating the speed control L1 in either direction. See Table 1: for more information.

• Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

• Switch off the truck by pressing

on the keypad.

The non-configurable option is now activated.

• Check that the function works correctly before the truck is put back in operation.

P

13- 36

Sub-parameter no.

Function name

Function ON

Function OFF

Basic setting

Table 1: Parameter #15 Non-configurable option

1

"Turtle" function

1

0

0

2 to 9

For future use

-

-

-

© TIEE SARL

Value

Note!

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Parameter #16 to 19 configurable optional functions Parameter no. #16, #17, #18 & #19 can be adjusted to activate up to a maximum of 4 pre-programmed functions and configure these to suit optional equipment or customisation of the truck. See “Table 2:List of configurable optional functions” on page 39. These are thus called the configurable optional functions.

• Each parameter can be programmed to cover a specific optional function.

• Each optional function can have up to 4 independent variables associated with it.

• Each independent variable has a value you can change to configure the function.

Parameter no. (range 16-19) Independent variable: #0 is the option designation

16 - 0 - 1

Independent variable value (range 0-63) 0= no option has been activated for this parameter 1 to 63 = Pre-programmed option number. See separate table.)

SETTING THE OPTIONAL FUNCTION

Independent variable: #1, #2, #3 & #4 contain the optional function valu

16 - 1- 1

Independent variable value (the range depends on the function referred The value depends on the option and independent variable selected.

See separate table CONFIGURING THE OPTIONAL FUNCTION

Fig. 1Summary – option parameter

Changing configurable optional functions In order to activate a configurable optional function, it must first be assigned a parameter from #16 to #19. This is done by changing independent variable #0 to the pre-programmed option number. Once this has been done, the independent variable for the option must be configured. This is done by changing the values for independent variables #1, #2, #3 and #4.

• Ensure the truck is in parameter mode.

The parameter symbol is lit. © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 37

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

• Select parameter #16, #17, #18 or #19 using [L1].

Independent variable #0 is displayed The independent variable value is displayed after 1 second. The value “0” means that an optional function has not been assigned to this parameter, and the speed control L1 in this case displays the next parameter if you continue to activate it.

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction. See Table 2: • Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

• Select independent variable #1 by activating the speed control L1.

Independent variable value #1 is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #1 by repeatedly operating the speed control L1 in either direction. See the list of optional functions in Table 2: • Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

Adjust independent variables #2, #3 and #4 in the same way as above.

• Switch off the truck by pressing

on the keypad.

The optional function is now activated.

• Check that the optional function works correctly before the truck is put back in operation.

13- 38

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Table 2: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 1: The option button controls the spider output 0:Spider 0 1:Spider 1

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

1-6:option button 1-6

Type of function: 0:instantaneous 1:butterfly switch

Independent variable #0 = 2:Reduced running speed controlled by the spider’s digital input 0:Spider 0 1:Spider 1

0-7:Digital input 1-8

0-12:reduced speed 40-100% (i.e. 40+5*arg3 e.g.

4: 40+5*4=60%)

0:high-speed range 1:low-speed range 2: both ranges

Independent variable #0 = 3:Activate the spider output for specific movements 0:Spider 0 1:Spider 1

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

Select movements.

See Table 3:

Initial position: 0: shines constantly 1: flashes 1 Hz 2: flashes 2 Hz

Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input 0:Spider 0 1:Spider 1

0-7:Digital input 1-8

0-30:Holding time 030 minutes

Not used

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 39

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Table 2: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs 0:Spider 0 1:Spider 1

0: Lift, digital input 1 Lowering, digital input 2 Blocking of lowering, input 3 1: Lift, digital input 2 Lowering, digital input 3 Blocking of lowering, input 4 2: Lift, digital input 3 Lowering, digital input 4 Blocking of lowering, input 5 3: Lift, digital input 4 Lowering, digital input 5 Blocking of lowering, input 6 4: Lift, digital input 5 Lowering, digital input 6 Blocking of lowering, input 7 5: Lift, digital input 6 Lowering, digital input 7 Blocking of lowering, input 8

0: Blocking of lowering disconnected 1: Blocking of lowering connected

0: Fork lift/lowering 1: Support arm lift/lowering

Independent variable #0 = 6:Lift height limitation with by-pass 0:Spider 0 1:Spider 1

13- 40

0-7: Limit switch for digital input 1-8

© TIEE SARL

1-6: By-pass, option switch 1-6

Service Manual 7PM18, 7PM20, 7PML20

Not used

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Table 3: Option 3 – Choice of movement

© TIEE SARL

Selected movement

Independent variable #3

-

0

Driving forward

1

Driving backward

2

Driving forward or backward

3

Fork lift

4

Fork lift or driving forward

5

Fork lift or driving backward

6

Fork lift or driving forward or driving backward

7

Fork lowering

8

Fork lowering or driving forward

9

Fork lowering or driving backward

10

Fork lowering or driving forward or driving backward

11

Fork lift or fork lowering

12

Fork lift or fork lowering or driving forward

13

Fork lift or fork lowering or driving backward

14

Fork lift or fork lowering or driving forward or driving backward

15

All other movements = AOM

16

Driving forward or AOM

17

Driving backward or AOM

18

Driving forward or driving backward or AOM

19

Fork lift or AOM

20

Fork lift or driving forward or AOM

21

Fork lift or driving backward or AOM

22

Fork lift or driving forward or driving backward or AOM

23

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 41

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Table 3: Option 3 – Choice of movement Selected movement

Independent variable #3

Fork lowering or AOM

24

Fork lowering or driving forward or AOM

25

Fork lowering or driving backward or AOM

26

Fork lowering or driving forward or driving backward or AOM

27

Fork lift or fork lowering or AOM

28

Fork lift or fork lowering or driving forward or AOM

29

Fork lift or fork lowering or driving backward or AOM

30

Fork lift or fork lowering or driving forward or driving backward or AOM

31

Parameter 20 You decide yourself what the hour meter will show.

1A = Key time 2b = Movement time 3c = Drive motor time 4d =Pump motor time 5s = Time for service

Parameter 21 You must specify the type of battery the truck is equipped with.

In order to set the meter for the battery’s level of discharge, the following should be taken into account: • Acid concentration when the battery is fully charged, to check the grade of the battery. Must be between 1.27-1.29.

• When the lifting capacity is disconnected (the battery is 80 % discharged), the value must be close to, but not below, 1.14.

The acid concentration can vary depending on the battery make.

13- 42

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Recommendation on parameter setting for freely ventilated batteries Parameter 21

Battery size 7PM18/20, 7PML20-6

Battery size 7PML20-8

1 Less discharge

2 3 4 5

260Ah - 320Ah Standard value

6

190Ah - 250Ah

7

120Ah - 180Ah

260Ah - 320Ah Standard value

8

190Ah - 250Ah

9

120Ah - 180Ah

10 11 Greater discharge

12 13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below. © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 43

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Remove the battery from the truck and allow to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the acid weight of the battery at room temperature. If the acid weight is less than 1.15 g/cm3, the parameter value must be reduced. If the value significantly exceeds 1.15 g/cm3, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

13- 44

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Recommendation on parameter setting for valvecontrolled batteries (VRLA) Parameter 21

Battery size 7PM18/20, 7PML20-6

Battery size 7PML20-8

1 Less discharge

2

260Ah - 320Ah

3

190Ah - 250Ah

4

120Ah - 180Ah

260Ah - 320Ah

5

190Ah - 250Ah

6

120Ah - 180Ah

7 8 9 10 11 12 Greater discharge

13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 45

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Disconnect the battery from the truck and allow the battery to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the battery voltage at room temperature. If the voltage is less than Uend, see the table below, the parameter value must be reduced. If the value significantly exceeds Uend, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

Battery type

Battery voltage at rest, Uend

Hawker Evolution

24,24 V

Parameter 22 You must specify the type of brake switch the truck is equipped with.

Mechanical switch = 0 Inductive sensor= 1

Parameter 25 Using this parameter you can specify a limit for when the next service is to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for a service, warning 29 (C29) is shown in the display.

Parameter 28 Using this parameter you can select which button is to be used for lift/ lower.

1 = Bottom lift/lower button activated (default) 2 = Top lift/lower button activated 3 = Both lift/lower buttons are activated

13- 46

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Parameter 39 Login method and driver parameter access This parameter determines which function is to be used for login and whether the operator can adjust the driver parameter settings.

• Value 1 – Key switch fitted – Driver parameters accessible (without CAN service key).

• Value 2 – Key switch fitted – Driver parameters NOT accessible (without CAN service key).

• Value 3 – Keypad (Standard 10 PIN code)- Driver parameters accessible (without CAN service key) NB! this is the original setting.

• Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT accessible (without CAN service key).

• Value 5 – Expanded keypad (100 PIN code)- Driver parameters accessible (without CAN service key) • Value 6 – Expanded keypad (100 PIN code)- Driver parameters NOT accessible (without CAN service key) • Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parameters accessible (without CAN service key) • Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parameters NOT accessible (without CAN service key)

Expanded keypad - General The truck can contain a maximum of 10 individual driver profiles. The expanded keypad function thus allows you to assign a maximum of 10 PIN codes for each of the driver profiles. This allows you to manage a maximum of 100 unique PIN codes.

If the expanded keypad function is activated, the standard management of PIN codes normally accessible via parameter #10 is set aside.

Expanded keypad - Programming A number of PIN codes can be made accessible by activating the socalled block. Block no. 0 is activated as standard. This means that 3 different driver profiles are available from the start. Activation of other blocks means that all PIN codes for the block are accessible (See Table 5:). If all 10 blocks are activated, there will be 10 PIN codes available for the driver profile.

The truck program stores a standard list of PIN codes as per Table 5: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 47

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

To start programming the expanded keypad: • Connect an appropriate CAN service key to X41 • Enter code 341671 and press

on the keypad.

• Select the programming command from Table 4:

Table 4: Programming command - expanded keypad Progamming

Function

Notes

Reset to factory settings

Block 1 - 9 is deactivated. Original PIN codes reset as per Table 5: B= Block no. 0 - 9

Press “2” + B +

PIN codes in the block can be used PIN codes in the block cannot be used

B= Block no. 0 - 9

Press “3” + B +

Programming a new PIN code

B= Block no. 0 - 9 F= Driver profile no.

0-9 NNNN = PIN code

Press “1” +

Press “4” + B + F + NNNN +

• Switch off the truck by pressing

on the keypad.

The expanded keypad programming is now complete Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN codes to be valid.

Carry out a practical test by logging in using some of the new PIN codes. It is important to establish that the correct driver profile has been activated when a certain PIN code has been entered, especially if a specific driver profile has been set for a specific application/goods handling.

Table 5: shows the PIN codes available as standard in the program.

These can be activated for use or changed according to the driver’s wishes.

One or more of these blocks can be activated.

A driver profile is activated, on normal login, by all PIN codes whose block no. is activated.

The truck program does not approve login using the PIN code “0000”.

Service personnel should keep notes on activated blocks, changed PIN codes and specially-set driver profiles.

NOTE! Resetting the expanded keypad does NOT affect the driver profile settings.

13- 48

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Table 5: Standard PIN code assignment with the expanded keypad Driver profile

0

1

2

3

4

5

6

7

8

9

Block 0

0000

0001

0002

0003

0000

0000

0000

0000

0000

0000

Block 1

5421

7901

1437

3731

1049

9439

7265

1322

2869

1574

Block 2

1787

4854

2907

9175

5799

1490

3031

7392

5622

5023

Block 3

4659

3174

1026

3815

6703

1179

5152

7514

5668

3215

Block 4

9197

7110

5477

3846

9491

5918

8222

6923

8139

7025

Block 5

2549

6276

9879

9658

1690

4042

5201

9807

4332

9715

Block 6

7474

4142

8620

3754

8432

8788

7430

1948

2595

8527

Block 7

1930

1482

7135

2395

7365

7092

4611

2831

4185

6067

Block 8

2876

4731

1022

5377

3257

7334

9009

7881

8843

7436

Block 9

3242

3162

5878

2828

1910

6907

2136

5730

2957

7691

no.

_

Service indication A

• Connect CAN key to X41 and start the truck • Battery status is shown and symbol “D” is lit • Press S18 to go to display mode.

See the table below.

E

D

C

B

Flashing symbol

Data

B

A speed reference value has been sent to Curtis

C

Digital inputs to Curtis and hall sensors. * See explanation below

BC

Battery voltage (V)

D

Armature voltage (A)

BD

Field current (A)

CD

PWM (pulse width modulation) armature in percentage

BCD

Status of Curtis

*These are displayed by segments of three of the figures being marked (A). © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 49

Electrical System – 5000 Parameters T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

• The figure with the highest value is active (marked with an arrow).

• Power amplifier, inputs.

A

T

Segment

Function

A

E

D

B

C A

F

G

S31, input A1:15

D

S10, input A1:12

F

C DP

D

C

E

B

E

B

G

S10, input A1:5

DP

• The figure with the second highest value is active (marked with an arrow).

A

• Power amplifier, inputs

Segment

Function

A

E

D

B

C

A F

G

E D

13- 50

B C DP

© TIEE SARL

B C

Y41, output A1:2

D

Y1, output A1:3

E

K10, output A1:4

F

H1, output A1:7

G

Y1, output A1:5

DP

K30, output A1:6

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Parameters Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

• The figure with the third highest value is active (marked with an arrow).

A

• Digital input from control sensors.

Segment

Function

A

E

D

B

C

B C

A F

B

G

E

C DP

D

D

Forks up

E

Forks down

F

Support arm up

G

Support arm down

DP

Horn

• The figure with the fourth highest value is active (marked with an arrow).

A

E

D

C

B

Segment

Function

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

Extra function 3

E

Extra function 2

F

Extra function 1

G DP

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 51

Electrical System – 5000 Part number Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.7 Part number A

• Press and hold S18 while turning S17 to “ON” position.

• Press S18 until Pn = part number is displayed.

E

D

C

• You have now selected Pn = part number and the symbol ”D” is lit as an indication of what is now shown in the display. Initially, Pn = number is displayed for the component’s entire unit.

B

• By scrolling with L1, you can get the following information: • SPn = Part number for software.

• HPn = Part number for hardware.

• HSn = Serial number for hardware.

13.8 Transistor panel

STATUS

B+

A1

M-

M

A2

MODEL

VOLTAGE

SERIAL

CURRENT

13.8.1 General Curtis 1243 is a regulator that controls shunt motors. What primarily controls the speed is the variation in the voltage in the rotor. The voltage is varied by means of pulse width modulation (PWM). This also includes variation in "on" time for the MOS transistors that regulate the rotor current.

The rotation direction is changed by changing the polarity in the field winding (S1-S2). The regulator is equipped with a transistor-fitted fourquadrant bridge for the field winding and a single-quadrant bridge for the rotor winding.

S1

© TIEE SARL

S2

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 52

Electrical System – 5000 Troubleshooting Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.9 Troubleshooting 13.9.1 Error codes and troubleshooting

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The table below describes the error codes that can be displayed with the status light or read on the hand unit.

STATUS LED

Text on hand unit

Explanation

Possible cause

LED off

-

No voltage or error in the regulator.

Defective fuse, poor contact, not connected, error in the regulator.

LED on

-

Error in the regulator.

Error in the regulator.

1,1

¤¤

CURRENT SHUNT FAULT

Error in the built-in current shunt.

Error in the rotor current sensor in the motor monitor.

1,2

¤ ¤¤

HW FAILSAFE

CAN timeout in power amplifier.

The motor monitor is reporting an unexpected data loss from the tiller arm head.

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short circuited to B-.

Problem with switch transistor in the rotor circuit inside the motor monitor.

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Voltage too high for contactor feed or short-circuited field winding.

Attempt to extract more current than the output device can manage.

Problem regulating the field current.

Internal monitoring error.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding.

Shunt field open, defective cable, defective motor monitor.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage.

1. Battery voltage < 17 volt.

2. Battery poles affected by corrosion.

3. Loose battery or regulator connections.

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Voltage too high.

1. Battery voltage > 33 volt.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 53

Electrical System – 5000 Troubleshooting T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

STATUS LED

Text on hand unit

Explanation

Possible cause

4,3

THERMAL CUTBACK

Too high/too low temperature reduction.

1. Temp. > 85oC or < -25oC 2. The truck is overloaded.

3. Incorrectly installed transistor regulator.

4. Operation under extreme conditions.

¤¤¤¤ ¤¤¤

13.9.2 Reset error When you want to clear an error, first turn S17 to the “OFF” position and then “ON” again.

Error

Reset when

OVERVOLTAGE

The battery voltage is below 33 V.

THERMAL CUTBACK

The temperature is within the permitted interval.

THROTTLE FAULT 1, 2

The fault has been dealt with.

LOW BATTERY VOLTAGE

When the battery voltage exceeds 16 V.

13.9.3 Safety The regulator is a heavy current component. When it is used on a battery-powered vehicle, all necessary safety measures must be taken.

This means, among other things, that the driver must have suitable training, use goggles, avoid loose clothing, take off watches and jewellery and only use insulated tools. It may also be necessary to take other measures.

WARNING !

Risk of short circuiting Remove watches, jewellery and always use insulated tools only.

13- 54

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Electrical System – 5000 Technical specifications – Curtis 1243 Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

13.10 Technical specifications – Curtis 1243 Value

Unit

Operating voltage

24

Volt

Top voltage limit

33

Volt

Bottom voltage limit

16

Volt

Minimum operating voltage

Electrical insulation against cold chassis

500

V AC

Minimum

PWM frequency

16

kHz

Maximum current in rotor winding*

150

Ampere

for 2 minutes

100

Ampere

for 1 hour

20

Ampere

for 2 minutes

Maximum current in field winding

20

Explanation

for 1 hour

Contactor voltage

24

Volt

The same as for the battery

Contactor current

2

Ampere

Max (valid limit for 2.5 ampere)

KSI input voltage, min.

16,8

Volt

KSI input current

50

mA

Logical voltage value in

> 7.5; High < 1; Low

Volt

Logical input current value

15

mA

Operating temperature

-40 to +50

°C

Upper temperature limit, reduction

85

°C

Lower temperature limit, reduction

-25

°C

* Under special test conditions.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

13- 55

Electrical System – 5000 Technical specifications – Curtis 1243 T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

13- 56

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Hydraulic/Pneumatik – 6000 General Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

14- Hydraulic/Pneumatik – 6000 14.1 General To avoid functional problems with the lowering valve (Y41), such as unintentional lowering of forks, the valve must be cleaned and the function checked before replacing the valve.

14.2 Hydraulic chart and list of symbols 7PM18, 7PM20 n

1

A Y41

4

2 3

M3

P

5 T

14.2.1 List of Symbols Pos No

Description

Function

1

Lift cylinder

Lifting the forks

2

Preasure relief valve

3

Flow control valve

4

Non-return valve

5

Filter

M3

Motor

P

Pump

T

Tank

Y41

Valve

© TIEE SARL

Remarks

Pump motor 1,2 litre (B20 0,5 litre) Lowering valve for the forks

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

14- 1

Hydraulic/Pneumatik – 6000 Adjustments 7PM18 T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

14.3 Adjustments 7PM18 14.3.1 Adjusting the pressure limit valve The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 1850-1900 kg.

1 2 3

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

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

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

• Loosen the locking nut (1) using a special tool (see drawing 3.2).

Place a load of 1800 kg on the forks and check that the truck can lift it.

• If the truck lifts 1800 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

• If the truck lifts 1900 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.

14- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Hydraulic/Pneumatik – 6000 Adjustments 7PM18 Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

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

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

A

26,5

© TIEE SARL

8

12

B

13,5

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

14- 3

Hydraulic/Pneumatik – 6000 Adjustments 7PM20 T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

14.4 Adjustments 7PM20 14.4.1 Adjusting the pressure limit valve The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or the complete hydraulic unit is replaced.

The truck should be capable of lifting a load of between 2050-2100 kg.

1. Locking nut.

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

• Loosen the locking nut (1) using a 13 mm spanner.

• Place a load of 2000 kg on the forks and check that the truck can lift it.

• If the truck lifts 2000 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

• If the truck lifts 2100 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.

14- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Hydraulic/Pneumatik – 6000 Hydraulic chart and list of symbols Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

14.5 Hydraulic chart and list of symbols 7PML20-6, 7PML 20-8 n

2

1

A Y41

5

3 4

M3

P

6 T

14.5.1 List of Symbols Pos No

Description

Function

Remarks

1

Lift cylinders

Lifting the forks

2 pieces

2

Powertrakcylinder

Increase the pulling quality when loaded

3

Preasure relief valve

4

Flow control valve

5

Non-return valve

6

Filter

M3

Motor

P

Pump

T

Tank

Y41

Valve

© TIEE SARL

Pump motor

1.2 litre Lowering valve for the forks

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

14- 5

Hydraulic/Pneumatik – 6000 Adjusting the pressure limit valve T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

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

The truck should be capable of lifting a load of between 2050-2100 kg.

1. Locking nut.

2. Adjuster screw, pressure limit.

Adjusting clockwise results in increased pressure.

Adjusting anticlockwise results in decreased pressure.

• Loosen the locking nut (1) using a 13 mm spanner.

• Place a load of 2000 kg on the forks and check that the truck can lift it.

• If the truck lifts 2000 kg, place a further 100 kg on the forks. Check whether the truck can lift the load.

• If the truck lifts 2100 kg, adjust the pressure limit by turning the adjuster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load.

14- 6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

PowerTrak cylinder – 6680 Component parts Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

15- PowerTrak cylinder – 6680 15.1 Component parts 3

2

4

1

© TIEE SARL

Pos

Description

1

PowerTrak spring

2

PowerTrak cylinder

3

Spring guide

4

Drive unit

Note

2

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

15- 1

PowerTrak cylinder – 6680 Dismantling of PowerTrak cylinder T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

15.2 Dismantling of PowerTrak cylinder Make sure that the truck is unloaded and that the forks are lowered.

1

• Turn the key to neutral and pull out the battery plug.

2 3

• Dismantle top covers and head.

• Release the hydraulic hose (1).

4

• Carefully unscrew the screws (2) to the clamp (3) that holds the spring guides.

• Lift out the PowerTrak cylinder (4).

Assemble in reverse order.

49

The measurement between washer and screw head should be 49 mm.

WARNING! Risk of injury.

There is a risk of personal injury in conjunction with work on the PowerTrak system.

Follow the instructions carefully.

15- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Battery charger (Inbuilt) – 8340 General Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

16- Battery charger (Inbuilt) – 8340 16.1 General SMCI is a battery charger intended for valve-regulated or freely ventilated lead acid batteries. It is adapted for batteries from about 100 Ah up to 320 Ah.

A

B

The charger which uses advanced switch techniques is connected to a normal (grounded 230 V single phase) socket (B) and the built-in micro controller then controls charging following the pre-set charging curve.

During charging the charging process is displayed with a status indicator on the standby housing (A).

The micro controller also controls charging with respect to charging time and temperature in the charger so that charging can be limited, e.g. if a fault occurs in some cell in the battery or when there is insufficient cooling of the charger.

SMCI 300 is delivered pre-set for 24 v and with software intended for charging valve-regulated or freely ventilated lead acid batteries.

C

The size and type of the battery are selected using the switch on the side of the fan(C) which is accessible via a slotted head screwdriver.

16.2 Charging Connect the charger to the mains. When charging starts after a few seconds, the orange status indicator on the standby housing(A) lights up. Yhis indicator remains lit until the battery is fully charged and the indicator turns to green.

Charging time varies depending on the type of battery and the degree of discharge. Normally the charger is started after working hours and the battery is fully charged the next morning. A highly discharged freely ventilated battery of 320 Ah may need up to 14 hours re-charging time, a VR battery even longer.

Some time after charging (depending on, for example, type of battery) SMCI 300 switches to maitenance charging. The green indicator remains lit to show that the battery is fully cgarged.

When charging is completed, the mains plug is placed in the standby housing.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

16- 1

Battery charger (Inbuilt) – 8340 Troubleshooting and service T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

16.3 Troubleshooting and service First check whether the charger indicates an error. A red, blinking indicator means that the charger cannot detect that any battery is connected. Check the cables, pole terminals and other connections to the batteries. Measure battery voltage.

If the charger still doesn´t work, send it to your supplier for repair.

16.4 Technical data

16- 2

© TIEE SARL

Size

250x115x67 mm

Weight

1,6 kg

Ambient temperature

-25°C till +40°C

Mains voltage

90-255 V AC 45-400 Hz (Reduced charging current for mains voltage below 200 V

Rated voltage

24 V DC

Rated current

30 A

Max output

750 W

Efficiency

> 86%

Battery type

Freely ventilated lead batteries (with water refilling). Valve regulated (VR) lead batteries.

Protection

IP 20

General

Temperature regulated cooling fan, protected against faulty polarisation

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Battery charger (Inbuilt) – 8340 Charging settings Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

16.5 Charging settings 16.5.1 Freely ventilated batteries Switch

Batterysize

Output current

I2 current

Max current maintenance

0

No charging (red LED is lit)

-

-

-

1

100-119 Ah

30 A

5,5 A

0,5 A

2

120-144 Ah

30 A

6,6 A

0,6 A

3

145-174 Ah

30 A

8A

0,8 A

4

175-209 Ah

30 A

9,6 A

1,0 A

5

210-249 Ah

30 A

11,5 A

1,2 A

6

250-299 Ah

30 A

13,7 A

1,4 A

7

300-350 Ah

30 A

16,2 A

1,6 A

16.5.2 Valve regulated batteries Switch

Batterysize

Output current

I2 current

Max current maintenance

8

No charging

-

-

-

9

300-350 Ah

30 A

3,9 A

1,6 A

A

250-299 Ah

30 A

3,3 A

1,4 A

B

210-249 Ah

30 A

2,75 A

1,2 A

C

175-209 Ah

30 A

2,3 A

1,0 A

D

145-174 Ah

25 AA

1,9 A

0,8 A

E

120-144 Ah

21 A

1,58 A

0,6 A

F

100-119 Ah

17 A

1,32 A

0,5 A

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

16- 3

Battery charger (Inbuilt) – 8340 Charging settings T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

16- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 General Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

17- Control/computer equipment – 8700 TruckCom 3.5 User Manual -for trucks using the “PowerDrive” platform.

This Manual is valid for version 3.5 of TruckCom p/n 182147-008.

17.1 General TruckCom is a communication program which communicates with trucks equipped with CAN (Controller Area Network) communication.

It enables the following tasks to be performed: • downloading truck control software.

• viewing and adjusting operator / truck parameters and hour meters.

Additionally, the truck’s parameter set (including hour meter values) can be saved to file and reloaded later.

• viewing diagnostic data for various digital inputs / outputs and analogue data including voltages, currents and certain temperatures.

The program is a Windows program running under Windows® 95/98, Windows® XP/2000 and Windows® NT.

17.2 Connection A CAN interface of the CPC-PP type is needed to connect it to the truck, with attendant cable. Connect the interface via the printer port on a PC. Connect the cable between the interface and the truck's CAN terminal.

The CAN interface is supplied with power from the truck electronics and is protected from any high voltages in the truck if a fault should occur.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 1

Control/computer equipment – 8700 Layout T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

17.3 Layout 17.3.1 Main program screen Information window

Menu bar

Tool buttons

Nodes Icons

Tool button bar

Fig. 2Main TruckCom program screen The Main window opens when the program is started. This shows the menu bar, tool buttons, workspace, log window and status window.

17.3.2 Nodes Devices which are connected to and communicate via the CAN interface are called nodes. The nodes detected on the bus are shown in the node window. The current node status and input component/information is shown with different icons.

Fig. 3A typical node window display

17- 2

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Layout Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

17.3.3 Icons Icon

Description Node OK is shown when contact is made with a node and no errors have been reported.

Node not connected is shown when there is no contact with a node in the network.

Node not OK is shown when an error has been reported by a node. Click on node to obtain more information.

Program version is shown when information is available on which software is installed. Click to obtain more information.

Information is shown when a node has information on, for example, error codes.

Truck report GB“17.7Truck report function” on page 7 Parameters is shown when a node has information on a parameter.

Diagnostics

Exit

17.3.4 Tool buttons and menu bar The tool button bar allows direct access to the program’s most common functions. The menu bar allows access to all the program functions.

Explanations of each menu bar item are given in the relevant section.

Search for units

Disconnect Download from PC

Truck report

Parameters Diagnostics Information Fig. 4Tool button bar © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

Exit

17- 3

Control/computer equipment – 8700 Connection function T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

17.3.5 Information window The right section of the main window contains a status window where different messages are shown.

To see previous messages, use the scroll arrows in the right margin.

17.3.6 Status bar There is a status bar at the bottom of the main window, which shows variable status when the program is run.

REC

MACHINE

The following are shown from the left: Help text "pop-up" via the mouse cursor, connected/not connected to network, truck type connected, initiation result of CAN interface and the present time.

17.4 Connection function To connect the PC the network, select the Scan units function. This can be done with the menu <Nodes | Scan units> or with the tool button [Scan nodes].

This should also be done when the truck is supplied with voltage and in normal drive mode.

The program will now run a check and installation of the CAN interface.

A diagnosis will also be carried out to check which units are connected in the system. The result of this diagnosis is shown in the Node window.

17.5 Disconnection function Select the Disconnect function to disconnect from the network. This can be done with the menu <Nodes | Set PC off-Line > or with the tool button [Set PC off-Line].

The CAN interface is then reset and the CAN cable can be disconnected if so required. This enables connection to another truck without having to close the program.

17- 4

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Downloading program function Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

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

Type 123456

17.6.1 Normal downloading (truck with key) Select Open.. to open the file to be downloaded into a node. The file name, file type and version number are shown in the window for file information. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by selecting Start... and by restarting the truck by turning the key off and on twice.

Restart must be made within 20 seconds from when the Start button has been activated.

Close the download window when the download is ready, and then disconnect the PC from the network. A new connection can now be made to verify the new program.

17.6.2 Normal downloading (truck with keypad) Select Open to open the file to be downloaded into a node. The file name, file type and version number are shown in the file information dialogue box. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by depressing and then releasing the red key on the keypad. © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 5

Control/computer equipment – 8700 Downloading program function T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

The truck must be restarted within 20 seconds from the time the Start key has been actuated.

When downloading has been completed, close the download dialogue box and then disconnect the PC from the network. It is now possible to reconnect to verify the new application.

17.6.3 Emergency downloading (truck with keypad) • Disconnect the battery connector.

• Select OK in the dialogue box.

• Keep the red key on the keypad depressed while reconnecting the battery connector.

• Release the red key to commence downloading.

17.6.4 Downloading in old versions of logic card To download to older versions of electronic cards which do not support restart with key, the button Old card... should be used instead of Start...

Downloading is carried out in the same way, except that restart is done by using the battery lug instead of the key.

17.6.5 Emergency downloading (truck with keypad) E141 will be shown in the truck’s display when starting, if for any reason there is no program in the electronics card (interrupted downloading).

Communication with the truck via the PC will then be minimised. Use “E141” to download the program in the card.

On some trucks, a counter, which continuously counts up, is displayed.

NOTE! Once programmed, the logic cards in some trucks can only be upgraded with the same basic firmware. In other words, it is not possible to replace the basic firmware (other machine type).

17- 6

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Truck report function Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

17.7 Truck report function It is possible to generate a report to a file or disk with the truck’s configuration and status. Select menu <Tools | Generate truck report...> or with the tool button Truck report. Save the report in Report.file.

NAME

Example of information generated in the truck report: [GENERAL] REPORT DATE-TIME=2004-01-19 11:11:58 CPC-PP SERIAL No=8002041 MACHINE NUMBER=555555 CUSTOMER=CUSTOMER 1 TECHNICIAN=NONAME COMPANY=Other NOTES=Test report [CAN NODES] MAIN CARD=0 CURTIS DRIVE CONTROLLER=16 [MAIN CARD CONFIGURATION] SOFTWARE=181179-001 HARDWARE=167833-004 SERIAL NO=53676 [DRIVE CONTROLLER CONFIGURATION] SOFTWARE=5 DRIVE CURRENT LIMIT (A)=300 FIELD MAXIMUM (A)=34 SERIAL NO=52857 MFG Date:=26/05/03 HOUR METERS] A IGNITION TIME=81 B TOTAL MOVEMENT=7 C DRIVE MOTOR TIME=7 D PUMP MOTOR TIME=0 S SERVICE TIME=7

[ERROR LOG] 01=104 00007.5 02=104 00007.5 03=104 00007.5 04=104 00007.5 05=104 00007.5 09=104 00005.0

[DRIVER PARAMETERS] 1=100 2=100 3=75 100=0

[TRUCK PARAMETERS] 11=0 12=0 13=0

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

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 7

Control/computer equipment – 8700 Parameters function T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

17.8 Parameters function To change the truck parameters, select the Parameter function. This can be done with the menu <Tools | Change parameters > or with the tool button Parameters.

NOTE! The truck must in Normal mode (i.e. not Parameter mode) when connecting TruckCom. Otherwise TruckCom will report “Unable to determine truck brand”

The parameter numbers follow the description in the respective truck Service Manuals, section 5000.

The parameter window shows the information and the current settings for all parameters. The parameters are divided into 4 tabs.

• [Driver] - driver; driver parameters and PIN code storing • [Truck] - truck; service parameters • [Time] - time; time-related service parameters • [Option parameters] - option parameters. (no. 15 to 19) WARNING! Do not attempt to make any adjustments to the option parameters unless you have sufficient knowledge of the truck’s options/ modified functions. Specially modified trucks may require that you have access to special service information.

Improper adjustment of the option service parameters may result in a malfunction.

17.9 Diagnostics function To access diagnostics, select the Diagnostic function. This can be done with the menu <Tools | Diagnostic...> or with the tool button Diagnostic.

NOTE! If the value “---” is shown in a field, or a “read status LED” is red, the communication has been interrupted for some reason and error data cannot be shown.

NOTE! The tab information displayed in the diagnostics mode depends on the type of truck connected.

17- 8

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Diagnostics function Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

17.9.1 Representation of signal colours The screen dumps shown in the following section have been modified to improve legibility in black & white print.

WHITE GREEN RED

17.9.2 “Tiller arm” tab

Clicking on the tiller arm tab will display a dialogue showing the following: • Speed lever -the status of the speed control and travel direction selector. The status of each individual hall element is displayed.

• Buttons -The status of the control buttons is displayed. “Sxx” refers to the switch designations as given in the circuit diagram.

• Option -Status of option buttons • Battery -The measured battery voltage • R14 -Shows the measured signal voltage from the lift/lower control • R15 -Not used at present © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 9

Control/computer equipment – 8700 Diagnostics function T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

17.9.3 “Drive Controller” tab (transistor regulator - travel)

Clicking on the Drive Controller tab will display a dialogue showing the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM - The effective power output supplied to the field circuit as a percentage.

• Armature PWM - The effective power output supplied to the armature circuit as a percentage • Field current - The current flowing in the field circuit in Amperes.

• Armature current - The current flowing in the Armature circuit in Amperes • Raw throttle data - The received speed control signal as a percentage.

• Temperature - The temperature of the output stage of the transistor controller in degrees Celsius • Inp pin 10 - The input voltage from the mode/pressure sensor. “digital o” indicates the digital status of the input.

• Inp pin 11-The input voltage from the man-on platform sensor. “digital o” indicates the digital status of the input.

17- 10

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Diagnostics function Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

17.9.4 “Pump controller” tab (transistor regulator - pump)

If the truck is equipped with a lift/lower transistor regulator, the Pump controller tab displays the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM, Armature PWM, Field current, Armature current, Temperature - Measured values from the transistor regulator for the pump motor. See the explanation on page 10 • Raw throttle data - The received lift/lower signal as a percentage.

• Out pin9 - The output signal to the proportional lowering valve as a percentage.

• Inp pin 10 - The input voltage from the pressure sensor. “digital o” indicates the digital status of the input.

• Inp pin 11 - The input voltage from the pressure sensor. “digital o” indicates the digital status of the input.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 11

Control/computer equipment – 8700 Diagnostics function T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

17.9.5 “EPS” steering servo tab

Clicking on the “EPS” tab will display a dialogue showing the following: “Status” • “Operational” - Indicates the status of the servo’s control system • “EPS enabled” - Indicates the status of the servo’s power stage output.

• “Reference switch reached” - indicates status of drive wheel in centre reference switch.

• “Reference position found” - indicates whether a successful steering in centre has been performed.

• “EPS in power save mode” - Shows whether the steering servo is in the standby mode (following a certain amount of inactivity).

“Actual values” (Measured values) • “Temperature EPS” - The temperature of the steering servo output stage in degrees Celsius.

• “DC bus voltage” - Supply voltage to steering servo • “Wheel position” - Shows the estimated steering angle of the drive wheel.

• “Voltage analog input 1, pin5”- The measured DC input signal (0) from the steering potentiometer.

17- 12

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Other menu functions Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

• “Voltage analog input 2, pin13”- The measured DC input signal (1) from the steering potentiometer.

• “Current” - the measured current supplied to the steer servo motor in Ampere • “Actual velocity” -The measured rotational speed of the steer servo motor shaft in r.p.m.

17.10 Other menu functions 17.10.1 Save to file The truck parameters can be saved in the PC for downloading at a later date.

Select <File | Save to file | Parameters >. All parameters in the nodes which are connected to the bus will be scanned in and saved in a file.

If only the hour meters are needed, select <File | Save to file | Hour meters >.

17.10.2 Download from file A set of parameters can be downloaded from the PC to the truck. Select <File | Load from file | Parameters >. The parameters in the file will be copied to the nodes connected to the bus. If only the hour meter settings are needed, select <File | Load from file | Hour meters >.

17.10.3 Reset CAN adapter If problems should occur when resetting the CAN adapter connected to the PC, this can normally be done manually by making sure that the adapter is supplied with voltage and then selecting <Nodes | Reset CPC-PP >.

17.10.4 Delete error code log To delete the truck’s error code log, start the truck in parameter mode and then select < Tools | Erase error log >.

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

17.10.6 Read error code log To show the truck’s error code log, select < Tools | Read error log >. © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 13

Control/computer equipment – 8700 Specifications T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

17.10.7 Adjust date and time To quickly adjust the truck’s data and time, select < Tools | Adjust date & time >. The time given in the PC will now be downloaded into the truck.

NOTE! This does not apply to trucks without a real-time clock.

17.10.8 Adjusting the hour meter on older cards To adjust the hour meter on trucks with older cards, select < Tools | Adjust Hour meters >. The time given in the PC will now be downloaded into the truck.

17.10.9 Help About the TruckCom application To see program information, select <Help | About TruckCom... > or use the tool button [Information].

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

17.11 Specifications Table 6: CAN interface specification

17- 14

© TIEE SARL

Description

Value

Unit

Power consumption

40-120

mA

Supply voltage

11-28

V

Transfer rate

125

kbit/s

Storage temperature

-20-80

0

Operating temperature

0-60

0

Service Manual 7PM18, 7PM20, 7PML20

C C

Approved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

17.12 Installation NOTE! The program must be installed from the hard disk.

NOTE! The software application in the computer can be damaged, which is why the PC installation should be performed by someone with the required knowledge. TOYOTA does not accept any responsibility for any errors that occur during the installation.

NOTE! All references to PC operating system actions, menus and commands are based on the English language version of Windows®.

17.12.1 Installation on a PC with Windows® 95/98 If a previous version of the TruckCom application has been installed on the PC, it will be necessary to edit the System.ini file.

Start the Msconfig.exe application by selecting the Start button, selecting Run and then typing msconfig.

Click on System.ini and open the folder (386Enh).

Unmark the option at Device=C:\Windows\Cpcppvd.vxd.

Save the change and close the application.

Now continue with installation The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.

Then follow the on-screen instructions.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 15

Control/computer equipment – 8700 Installation T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

17.12.2 Installation on a PC with Windows XP/ 2000 To make the application work, it is necessary to first enter a value in the Windows® Registry and then make a few changes in the Windows® Control panel.

Due to the built-in Windows® security, this must be done manually.

The instructions below provide step-by-step guidance to enable these changes and make the interface operate under Windows XP and Windows 2000.

The changes can be made either before or after TruckCom is installed.

• Open the Registry Editor. To do this, select the Start button, then Run, type regedit and hit Enter.

• Mark the Enum folder which can be found under HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the Registry Editor.

17- 16

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Select the Edit option, then Find and type PortName to search for the correct folder.

NOTE! The location of the folder differs between different computers (some may be .. \Enum\Root\.., while others could be ...\Enum\ACPI\... etc.).

Thus be sure to search for the correct folder.

When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in the PortName data field and that the folder name is Device Parameters.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 17

Control/computer equipment – 8700 Installation T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Right-click with the mouse in the right box to enter a new value of the DWORD type and with the name

EnableConnectInterruptIoctl.

17- 18

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Change the value in data field 1 by right-clicking on the name and selecting Modify.

EnableConnectInterruptIoctl

The Device Parameters folder should look like the one in the picture.

The Registry change is now complete. Close the Registry Editor.

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 19

Control/computer equipment – 8700 Installation T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

Changes in Windows® Control Panel Select the Start button. Choose Settings, then Control Panel and double-click on System, then select Hardware.

Click on Device Manager and open Ports (Com & LPT).

17- 20

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 723984-Order number 222995-040

T-code 677, 678, 679 Date 2005-02-02

Double-click on the LPT port to be changed, and select the Port Settings tab. Check the "Use any Interrupt assigned to the port" option and click on OK.

The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.

Then follow the on-screen instructions.

17.12.3 Installation on a PC with Windows NT The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.

Then follow the on-screen instructions.

17.12.4 In case of communication problems with CAN Make sure the computer settings for the printer port in the BIOS Setup are as follows: Port address:0378 IRQ:

7

Mode:

Output only

For detailed information on how to change the Setup settings, refer to the User's Guide supplied with the computer.

17.12.5 To uninstall To uninstall TruckCom under Windows®, select the Start button, Settings, Control Panel, Add/Remove Programs. To uninstall you must then select the TruckCom Program and click Change/Remove. © TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 21

Control/computer equipment – 8700 Installation T-code 677, 678, 679 Date 2005-02-02

Valid from serial number 723984-Order number 222995-040

This page is intentionally left blank

17- 22

© TIEE SARL

Service Manual 7PM18, 7PM20, 7PML20

Approved by: L-G Andersson

Control/computer equipment – 8700 Installation Valid from serial number 723984-Order number 222995-040

© TIEE SARL

T-code 677, 678, 679 Date 2005-02-02

Service Manual 7PM18, 7PM20, 7PML20Approved by: L-G Andersson

17- 23

©TOYOTA Industrial Equipment Europe SARL Ancenis, France