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7SLL12.5, 7SLL16, 7SLL20, 7SLL13.5S, 7SLL12.5F, 7SLL16F, 7SLL20F Valid from serial number: 985777-

Order number: 249896-040 Issued: 2007-05-11 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:

Issue date

Order number

Changes

2004-12-20

222641-040

Completely new issue.

2005-12-02

230087-040

M4, P2, P3, P4, 0000 (new), 4300 (new), 5000, TruckCom

2006-03-06

230087-040

Updated chapters: Technical data, Maintenance (new chapter replaces P1, P2 and P3), 0000 (spring replacement), 5000, 6000, 7000 (replaces 7120)

2007-03-23

230087-040

New truck model: 7SLL20, 7SLL20F Updated chapters: Technical data, 1760, 2550, 5000.

2007-05-11

249896-040

Updated chapters: Technical data, 2550, 5000, 6000.

This manual covers following truck models:

T-code

Model

Serial number

789

7SLL12.5, 7SLL16

985777-

790

7SL13.5S

985777-

791

7SL12.5F, 7SLL16F

985777-

817

7SLL20

985777-

818

7SLL20F

985777-

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Table of contents Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

1- Table of contents 2- Technical data ..................................................................................... 2-1 2.1 General tightening torques............................................................. 2-7 2.1.1 Galvanised, non-oiled bolts ............................................. 2-7 2.1.2 Untreated, oiled bolts ....................................................... 2-7 3- Maintenance ........................................................................................ 3-1 3.1 Safety rules during maintenance work ........................................... 3-1 3.2 Cleaning and washing.................................................................... 3-3 3.2.1 External cleaning ............................................................. 3-3 3.2.2 Cleaning the motor compartment .................................... 3-3 3.2.3 Electric components ........................................................ 3-3 3.3 Safe lifting ...................................................................................... 3-4 3.4 Lifting the truck............................................................................... 3-5 3.5 Maintenance schedule ................................................................... 3-6 3.6 Lubrication chart .......................................................................... 3-12 3.7 Oil and grease specification ......................................................... 3-14 4- Tools ..................................................................................................... 4-1 4.1 Super Seal connectors................................................................... 4-1 4.2 AMP connectors............................................................................. 4-2 4.2.1 AMP Connectors, 040 series ........................................... 4-3 4.3 Molex connectors........................................................................... 4-3 4.4 Grease guns .................................................................................. 4-4 4.5 Other tools ..................................................................................... 4-5 5- Chassis – 0000 ..................................................................................... 5-1 5.1 Support arms ................................................................................. 5-1 5.1.1 General ............................................................................ 5-1 5.1.2 Main components ............................................................ 5-2 5.1.3 Maintenance .................................................................... 5-2 5.1.4 Adjusting the support arm width ...................................... 5-3 5.1.5 Support arm replacement ................................................ 5-4 5.2 Engine suspension......................................................................... 5-5 5.2.1 Components .................................................................... 5-5 5.2.2 Disassembly .................................................................... 5-5 5.2.3 Spring replacement ......................................................... 5-6 5.3 Platform ......................................................................................... 5-7 5.3.1 Components .................................................................... 5-7 5.3.2 Disassembly .................................................................... 5-7 6- Electric drive motor – 1760 ................................................................. 6-1 6.1 Included components..................................................................... 6-1 6.2 Disassembly/assembly of the truck motor...................................... 6-3 6.2.1 Disassembly .................................................................... 6-3 6.2.2 Assembly ......................................................................... 6-3 6.3 Service/repairs ............................................................................... 6-4 6.3.1 Disassembly of the motor ................................................ 6-4 6.3.2 Motor installation ............................................................. 6-4 6.3.3 Cleaning .......................................................................... 6-5

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

1- 1

Table of contents T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

7- Drive unit/gear – 2550 ......................................................................... 7-1 7.1 General .......................................................................................... 7-1 7.2 Included components..................................................................... 7-2 7.3 Disassembly of the drive unit from the truck................................... 7-4 7.4 Assembly of the drive unit in the truck............................................ 7-4 7.5 Oil inspection or changing oil ......................................................... 7-5 7.5.1 Oil inspection/replenishment ........................................... 7-5 7.5.2 Changing oil ..................................................................... 7-5 7.6 Replacing the gasket ring............................................................... 7-5 7.6.1 Disassembly .................................................................... 7-5 7.6.2 Assembly ......................................................................... 7-6 7.7 Leakage from top cover ................................................................. 7-6 8- Electromagnetic brake – 3370 ............................................................ 8-1 8.1 Main components of the brake ....................................................... 8-1 8.2 Maintenance .................................................................................. 8-2 8.2.1 Basic adjustment of the play ............................................ 8-2 8.2.2 Brake disc replacement ................................................... 8-3 9- Support/Castor Wheels - 3540 ........................................................... 9-1 9.1 Tightening torque ........................................................................... 9-1 10- Electrical steering system – 4300 .................................................. 10-1 10.1 Electrical steering servo ............................................................... 10-1 10.1.1 General .......................................................................... 10-1 10.2 Steering servo components ......................................................... 10-2 10.3 Adjustment ................................................................................... 10-3 10.3.1 Reference sensor .......................................................... 10-3 10.3.2 Calibration ..................................................................... 10-3 Parameter 36 ................................................................. 10-3 Parameter 37 ................................................................. 10-3 11- Electrical systems – 5000 ............................................................... 11-1 11.1 General ........................................................................................ 11-1 11.1.1 Part numbers ................................................................. 11-1 11.1.2 Nomenclature ................................................................ 11-2 11.2 Electrical equipment overview ..................................................... 11-3 11.2.1 Component placement .................................................. 11-3 11.2.2 Component list ............................................................... 11-5 11.3 Electrical wiring diagram .............................................................. 11-9 11.3.1 Symbol list ..................................................................... 11-9 11.3.2 Overview ...................................................................... 11-10 11.3.3 Detailed wiring diagram ............................................... 11-11

1- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Table of contents Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

11.4

11.5

T-code 789, 790, 791, 817, 818

Functional description ................................................................ 11-27 11.4.1 Principle of operation ................................................... 11-27 11.4.2 Description of steering system .................................... 11-32 11.4.3 Spider expansion unit (SEU) ....................................... 11-32 11.4.4 Speed limitation ........................................................... 11-34 11.4.5 Hour meter and battery condition ................................ 11-35 11.4.6 TLS - Truck log system (optional) ................................ 11-36 General ........................................................................ 11-36 Registration ................................................................. 11-36 Logging in/out SD16 .................................................... 11-36 Logging in/out S16 ....................................................... 11-36 Collision sensor ........................................................... 11-37 Settings ........................................................................ 11-37 11.4.7 ID unit (optional) .......................................................... 11-37 Parameters ................................................................................ 11-38 11.5.1 General ........................................................................ 11-38 11.5.2 Viewing parameters -CAN key not connected ............. 11-38 11.5.3 Viewing parameters - CAN key connected .................. 11-39 11.5.4 Setting Driver parameters ............................................ 11-40 11.5.5 Setting Service parameters ......................................... 11-40 11.5.6 Summary of driver parameters .................................... 11-41 11.5.7 Description of driver parameters ................................. 11-42 # 2 - Maximum speed, high range ............................... 11-42 # 3 - Maximum acceleration ........................................ 11-42 # 4 - Neutral braking effect .......................................... 11-42 # 6 - Maximum speed, low range ................................ 11-42 # 7 - Maximum speed, “Turtle” mode .......................... 11-42 11.5.8 Summary of service parameters .................................. 11-43 11.5.9 Description of service parameters ............................... 11-45 # 10 - PIN code ............................................................ 11-45 To enter a new PIN-code: ............................................ 11-45 To remove an existing PIN-code: ................................ 11-46 # 14 - Creep speed ...................................................... 11-46 #15 - Non-configurable options ................................... 11-46 Setting Non-configurable options ................................ 11-46 #16 - Configurable option #1 ....................................... 11-47 #17 - Configurable option #2 ....................................... 11-47 #18 - Configurable option #3 ....................................... 11-47 #19 - Configurable option #4 ....................................... 11-48 # 20 - Hour meter selection ......................................... 11-48 # 21 - Battery size ........................................................ 11-49 # 22 - Maximum fork lowering speed ........................... 11-49 # 23 - Fork lower stop ramp ......................................... 11-49 # 25 - Service interval .................................................. 11-49 # 26 - Selection of hydraulic unit ................................. 11-49 # 35 - Log off ............................................................... 11-50 # 36 - Calibrate ............................................................ 11-50 # 37 - Steering offset ................................................... 11-53 # 38 - Steer servo activated ......................................... 11-53 # # 39 - Log-in method & operator parameter access . 11-54 Extended keypad - General ......................................... 11-54 Extended keypad - Programming ................................ 11-55 11.5.10 Configurable “Option” Parameters ............................... 11-57 General ........................................................................ 11-57 Parameter #16 to #19 Configurable options ................ 11-58

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

1- 3

Table of contents T-code 789, 790, 791, 817, 818

Valid from serial number 98577711.6

11.7

Date 2007-05-11

Order number 249896-040

Diagnostic and troubleshooting.................................................. 11-71 11.6.1 General ........................................................................ 11-71 11.6.2 Fault code history ........................................................ 11-72 11.6.3 List of fault codes ......................................................... 11-73 11.6.4 Transistor regulator ..................................................... 11-80 General ........................................................................ 11-80 Transistor regulator errors ........................................... 11-81 Resetting errors ........................................................... 11-82 Safety .......................................................................... 11-82 11.6.5 Built-in Test Function ................................................... 11-83 Digital inputs/outputs test mode .................................. 11-85 11.6.6 Display test mode ........................................................ 11-88 Technical specifications – Curtis 1243 ....................................... 11-89

12- Hydraulic system – 6000 ................................................................. 12-1 12.1 Hydraulic diagram ........................................................................ 12-1 12.1.1 With support arm lift ....................................................... 12-1 12.1.2 Without support arm lift .................................................. 12-2 12.2 Main Components........................................................................ 12-3 With support arm lift ....................................................... 12-3 Without support arm lift .................................................. 12-3 12.3 Description ................................................................................... 12-4 12.3.1 Lifting system ................................................................. 12-4 12.3.2 The PowerTrak system .................................................. 12-4 12.3.3 Working pressure .......................................................... 12-5 12.3.4 Overflow valve ............................................................... 12-5 12.3.5 Pressure sensor ............................................................ 12-5 13- Lift mast – 7000 ............................................................................... 13-1 13.1 Mast incline .................................................................................. 13-1 13.2 Main lift chain system................................................................... 13-2 13.2.1 Checking the chain setting ............................................ 13-2 13.2.2 Chain inspection ............................................................ 13-2 Noise ............................................................................. 13-2 Surface rust ................................................................... 13-2 Rusty links ..................................................................... 13-2 Stiff links ........................................................................ 13-2 Bolt rotation ................................................................... 13-3 Loose bolts .................................................................... 13-3 Outline wear .................................................................. 13-3 Stretching ...................................................................... 13-4 Damage ......................................................................... 13-5 Damaged discs .............................................................. 13-5 Damaged bolts .............................................................. 13-5 Dirty chain ...................................................................... 13-5 13.2.3 Cleaning ........................................................................ 13-5 13.2.4 Lubrication ..................................................................... 13-6

1- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Table of contents Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

14- TruckCom ........................................................................................ 14-1 14.1 General ........................................................................................ 14-1 14.2 Connection................................................................................... 14-1 14.3 Layout .......................................................................................... 14-2 14.3.1 Main program screen ..................................................... 14-2 14.3.2 Nodes ............................................................................ 14-2 14.3.3 Icons .............................................................................. 14-3 14.3.4 Tool buttons and menu bar ............................................ 14-3 14.3.5 Information window ........................................................ 14-4 14.3.6 Status bar ...................................................................... 14-4 14.4 Connection function .................................................................... 14-4 14.5 Disconnection function................................................................. 14-4 14.6 Downloading program function .................................................... 14-5 14.6.1 Normal downloading (truck with key) ............................. 14-5 14.6.2 Normal downloading (truck with keypad) ....................... 14-5 14.6.3 Emergency downloading (truck with keypad) ................ 14-6 14.6.4 Emergency downloading (truck with keypad) ................ 14-6 14.6.5 Downloading in old versions of logic card ..................... 14-6 14.7 Truck report function .................................................................... 14-7 14.8 Parameters function..................................................................... 14-8 14.9 Diagnostics function..................................................................... 14-8 14.9.1 Representation of signal colours ................................... 14-9 14.9.2 “Tiller arm” tab ............................................................... 14-9 14.9.3 “Drive Controller” tab (transistor regulator driving) ..... 14-10 14.9.4 “Pump controller” tab (transistor regulator pump) ....... 14-11 14.9.5 “EPS” (steering servo tab) ........................................... 14-12 14.9.6 SEU tab (Extra I/O module) ......................................... 14-13 14.10 Other menu functions................................................................. 14-13 14.10.1 Save to file ................................................................... 14-13 14.10.2 Download from file ....................................................... 14-13 14.10.3 Reset CAN adapter ..................................................... 14-14 14.10.4 Delete error code log ................................................... 14-14 14.10.5 Reset hour meter ......................................................... 14-14 14.10.6 Read error code log ..................................................... 14-14 14.10.7 Adjust date and time .................................................... 14-14 14.10.8 Adjusting the hour meter on older cards ...................... 14-14 14.10.9 Help ............................................................................. 14-14 About the TruckCom application ................................. 14-14 14.10.10 Exit ............................................................................. 14-14 14.11 Specifications............................................................................. 14-15 14.12 Installation.................................................................................. 14-15 14.12.1 Installation on a PC with Windows® 95/98 .................. 14-15 14.12.2 Installation on a PC with Windows XP/2000 ................ 14-16 Changes in Windows® Control Panel ......................... 14-18 14.12.3 Installation on a PC with Windows NT ......................... 14-21 14.12.4 In case of communication problems with CAN ............ 14-21 14.12.5 To uninstall .................................................................. 14-21

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

1- 5

Table of contents T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

15- Destruction instructions ................................................................. 15-1 15.1 General ........................................................................................ 15-1 15.2 Procedure .................................................................................... 15-1 15.3 Abbreviations ............................................................................... 15-2 15.4 Sorting ......................................................................................... 15-2 15.5 Chassis (0300)............................................................................. 15-3 15.5.1 Dismantling .................................................................... 15-3 15.5.2 Material handling ........................................................... 15-3 15.6 Hoods, covers (0340)................................................................... 15-4 15.6.1 Dismantling .................................................................... 15-4 15.6.2 Material handling ........................................................... 15-4 15.7 Fork structure (low-lifter) (0380)................................................... 15-5 15.7.1 Dismantling .................................................................... 15-5 15.7.2 Material handling ........................................................... 15-5 15.8 Travel platform including mount (0560)........................................ 15-6 15.8.1 Dismantling .................................................................... 15-6 15.8.2 Material handling ........................................................... 15-6 15.9 Overhead guard (option) (0810)................................................... 15-7 15.9.1 Dismantling .................................................................... 15-7 15.9.2 Material handling ........................................................... 15-7 15.10 Operator protective device (0840)................................................ 15-8 15.10.1 Dismantling .................................................................... 15-8 15.10.2 Material handling ........................................................... 15-8 15.11 Electric pump motor (1710).......................................................... 15-9 15.11.1 Dismantling .................................................................... 15-9 15.11.2 Material handling ........................................................... 15-9 15.12 Electric travel drive motor (1760) ............................................... 15-10 15.12.1 Dismantling .................................................................. 15-10 15.12.2 Material handling ......................................................... 15-10 15.13 Drive unit/gear (2550) ................................................................ 15-11 15.13.1 Dismantling .................................................................. 15-11 15.13.2 Material handling ......................................................... 15-11 15.14 Wheels (3500)............................................................................ 15-12 15.14.1 Dismantling .................................................................. 15-12 15.14.2 Material handling ......................................................... 15-12 15.15 Steering arm (4110) ................................................................... 15-13 15.15.1 Dismantling .................................................................. 15-13 15.15.2 Material handling ......................................................... 15-13 15.16 Steering arm (4110) ................................................................... 15-14 15.16.1 Dismantling .................................................................. 15-14 15.16.2 Material handling ......................................................... 15-14 15.17 General electric equipment (5100)............................................. 15-15 15.17.1 Dismantling .................................................................. 15-15 15.17.2 Material handling ......................................................... 15-15 15.18 Cabling (5590) ........................................................................... 15-16 15.18.1 Dismantling .................................................................. 15-16 15.18.2 Material handling ......................................................... 15-16 15.19 Steering and protective electronics (5700)................................. 15-17 15.19.1 Dismantling .................................................................. 15-17 15.19.2 Material handling ......................................................... 15-17 15.20 Lift/lowering sensor (5820) and safety sensor (5830) ................ 15-18 15.20.1 Dismantling .................................................................. 15-18 15.20.2 Material handling ......................................................... 15-18 1- 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Table of contents Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

15.21 Hydraulic unit (6100) .................................................................. 15-19 15.21.1 Dismantling .................................................................. 15-19 15.21.2 Material handling ......................................................... 15-19 15.22 Main mast (7100) ....................................................................... 15-20 15.22.1 Dismantling .................................................................. 15-20 15.22.2 Material handling ......................................................... 15-20 15.23 Chassis-mounted hydraulic oil lines (6230) (and main lift cylinder (6610))..................................................... 15-21 15.23.1 Dismantling .................................................................. 15-21 15.23.2 Material handling ......................................................... 15-21 15.24 Battery charger connector (9380) .............................................. 15-22 15.24.1 Dismantling .................................................................. 15-22 15.24.2 Material handling ......................................................... 15-22

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

1- 7

Table of contents T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

1- 8

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Technical data Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

2- Technical data Table 1: Technical data Drive motor Type

TSL140B-DS41

Output

1,7 kW

Duty cycle

S2, 60 min

Minimum carbon brush length

13 mm

Nominal commutator diameter

Ø63 mm

Minimum commutator diameter

Ø60 mm

Resistance, shunt field winding, at 25 C°

0,498 Ω (26C°)

Resistance armature winding, at 24 °C

0,0161 Ω (26C°)

Insulation resistance between the windings and motor casing

>= 1 Mohm

Weight

17 kg

Brake Type

BFK458-12

Braking force

32 Nm

Output

40 W

Resistance coil

14,4 Ω

Nominal play in actuated position

0,3-0,5 mm

Minimum thickness brake disc

8,8 mm

Thickness of a new brake disc

10,0 mm

Transmission/drive gear Type

2-stage angle transmission

Gear ratio

16,29:1

Oil volume

1,0 litre

Oil type

Hypoid oil

Oil type at normal temperature

SAE 80W/90

Oil type at temperature < -15oC

SAE 75W

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

2- 1

Technical data T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 1: Technical data Wheels (See note 1)

7SLL12.5

7SLL12.5F

7SLL13.5S

Drive wheel

Ø215x70 mm

Axle pressure without load

390 kg

Axle pressure at rated load

530 kg

Tightening torque for wheel bolts

65 Nm

Fork wheel

Ø85x75 mm

Ø85x75 mm Ø140x60 mm

Axle pressure without load

340 kg

360 kg

250 kg

Axle pressure at rated load

1420 kg

1440 kg

870 kg

Support castors

Ø125x50 mm

Axle pressure without load

600 kg

620 kg

335 kg

Axle pressure at rated load

630 kg

650 kg

20 kg

7SLL16

7SLL16F

7SLL20

Drive wheel

Ø215x70 mm

Axle pressure without load

390 kg

400 kg

Axle pressure at rated load

620 kg

595 kg

Tightening torque for wheel bolts

65 Nm

Fork wheel

Ø85x75 mm

Axle pressure without load

410 kg

430 kg

410 kg

Axle pressure at rated load

1810 kg

1830 kg

2220 kg

Support castors

Ø125x50 mm

Axle pressure without load

640 kg

660 kg

670 kg

Axle pressure at rated load

610 kg

630 kg

665 kg

7SLL20F Drive wheel

Ø215x70 mm

Axle pressure without load

400 kg

Axle pressure at rated load

595 kg

Tightening torque for wheel bolts

65 Nm

Fork wheel

Ø85x75 mm

Axle pressure without load

410 kg

Axle pressure at rated load

2220 kg

Support castors

Ø125x50 mm

Axle pressure without load

690 kg

Axle pressure at rated load

685 kg

2- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Technical data Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 1: Technical data Hydraulic system Output

3,0 kW

Duty cycle

11 %

Minimum carbon brush length

15 mm

Minimum commutator thickness/diameter

47 mm

Pressure at rated load

110 bar

Overflow pressure

210 bar

Pump flow, at rated load

13 litre/min

Tank volume

12 litre

Oil type

Hydraulic oil

Oil type at normal temperature

ISO-L-HM32

Oil type at temperature < -15oC

ISO-L-HV32

Fuses Drive motor circuits

130 A

Pump motor circuits

175 A

Control circuits

7,5 A

Battery compartment, Batteries Dimensions LxWxH, small/large

168x763x660/264x763x660 mm

Capacity

250/450 Ah

Weigh, max./min.

200/320 kg

Driving speed

7SLL20, 7SLL20F

Without load

8,0 km/h (2,22 m/s)

6 km/h

With rated load

7,0 km/h (1,94 m/s)

5 km/h

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

2- 3

Technical data T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 1: Technical data Lift/lowering speed (see note 2 & 3)

7SLL12.5

7SLL12.5F

7SLL13.5S

Lifting without load, above free-lift

0,31 m/s

Lifting without load, under free-lift

0,26 m/s

Lifting with rated load, above free-lift

0,16 m/s

Lifting with rated load, under free-lift

0,15 m/s

Lowering without load, above free-lift

0,51 m/s

Lowering without load, under free-lift

0,21 m/s

Lowering with rated load, above free-lift

0,44 m/s

Lowering with rated load, under free-lift

0,36 m/s

7SLL16

7SLL16F

7SLL20

Lifting without load, above free-lift

0,26 m/s

Lifting without load, under free-lift

0,23 m/s

Lifting with rated load, above free-lift

0,12 m/s

Lifting with rated load, under free-lift

0,12 m/s

Lowering without load, above free-lift

0,45 m/s

Lowering without load, under free-lift

0,18 m/s

Lowering with rated load, above free-lift

0,41 m/s

Lowering with rated load, under free-lift

0,36 m/s

7SLL20F Lifting without load, above free-lift

0,26 m/s

Lifting without load, under free-lift

0,23 m/s

Lifting with rated load, above free-lift

0,12 m/s

Lifting with rated load, under free-lift

0,12 m/s

Lowering without load, above free-lift

0,45 m/s

Lowering without load, under free-lift

0,18 m/s

Lowering with rated load, above free-lift

0,41 m/s

Lowering with rated load, under free-lift

0,36 m/s

2- 4

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Service Manual

Technical data Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 1: Technical data Power consumption

7SLL12.5

7SLL12.5F

Driving without load

30 A

Driving with rated load

50 A

Lifting without load, above free-lift

100 A

Lifting without load, under free-lift

80 A

Lifting with rated load, above free-lift

215 A

Lifting with rated load, under free-lift

170 A

7SLL16

7SLL16F

Driving without load

55 A

Driving with rated load

70 A

Lifting without load, above free-lift

100 A

Lifting without load, under free-lift

80 A

Lifting with rated load, above free-lift

215 A

Lifting with rated load, under free-lift

170 A

7SLL13.5S

7SLL20

170 A

7SLL20F Driving without load Driving with rated load Lifting without load, above free-lift Lifting without load, under free-lift Lifting with rated load, above free-lift Lifting with rated load, under free-lift

Incline climbing ability With rated load

10%

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

2- 5

Technical data T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 1: Technical data Measurement, L2

7SLL12.5

7SLL12.5F

7SLL13.5S

Small battery compartment Large battery compartment (see note 1)

880 mm 978 mm

921 mm 1019 mm

1370 mm 1468 mm

Turning radius WA (see note 1)

1716 mm

1696 mm

1633 mm

Max. lifting height (depends on the mast type)

23505400 mm

7SLL16

7SLL16F

7SLL20

Small battery compartment Large battery compartment (see note 1)

907 mm 1005 mm

948 mm 1046 mm

882 mm 980 mm

Turning radius WA (see note 1)

1716 mm

1696 mm

1681 mm

Max. lifting height (depends on the mast type)

23505400 mm

21503950 mm

7SLL20F Small battery compartment Large battery compartment (see note 1)

923 mm 1021 mm

Turning radius WA (see note 1)

1709 mm

Max. lifting height (depends on the mast type)

21503950 mm

Weight

7SLL12.5

7SLL12.5F

7SLL13.5S

Truck without battery, max./min.

960/1220 kg

940/1200 kg

1040/1250 kg

7SLL16

7SLL16F

7SLL20

1056/1340 kg

1030/1320 kg

1050/1090 kg

Truck without battery, max./min.

7SLL20F Truck without battery, max./min.

1030/1170 kg

Note 1 applies to the specification: Triplex mast 415, fork length 1150, small battery compartment, battery weight 220 kg, truck width 850. Note 2 applies to the specification:Duplex hilo 415 mast. Note 3 applies to the specification:Duplex hilo 335 mast.

2- 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Technical data General tightening torques Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

2.1 General tightening torques Millimetre thread M3 to M24. The following applies under ideal conditions, e.g. steel against steel.

2.1.1 Galvanised, non-oiled bolts Tightening torques (Nm) Strength class:

8,8

10,9

12,9

1,1

1,6

2,0

2,8

3,8

4,7

5,5

7,7

9,3

9,5

M10

M12

109

130

M14

123

174

208

M16

189

266

320

M20

370

519

623

M24

638

898

1075

2.1.2 Untreated, oiled bolts Tightening torques (Nm) Strength class:

8,8

10,9

12,9

1,2

1,7

2,1

2,9

4,0

4,9

5,7

8,1

9,7

9,8

M10

M12

114

136

M14

128

181

217

M16

197

277

333

M20

385

541

649

M24

665

935

1120

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

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

2- 7

Technical data General tightening torques T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

2- 8

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Maintenance Safety rules during maintenance work Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

3- Maintenance To assure maximum safety and minimum downtime, all items in the service programme should be covered. The service intervals are only guidelines and need not be strictly followed. The operator of the truck should adapt these to local requirements, however, it is important that the minimum requirements as stated by TOYOTA are observed. The service intervals are based on truck operating hours and can be adapted to most common 8-hour shifts. When calculating the service intervals, the following operating hours have been used: Day time:

08.00-17.00 (20 hours/week)

Double shift:

06.00-14.00, 14.00-22.00 (40 hours/week)

Triple shift:

06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hours/week)

Make sure the truck receives the necessary regular maintenance service according to the maintenance schedule. The truck's safety, efficiency and service life rely on the service and maintenance the truck receives. For service and repairs, only use spare parts approved by TOYOTA.

3.1 Safety rules during maintenance work Only technicians who have received the necessary training for service and repairs of this truck type may carry out service and repair work. • Do not perform any repair work on the truck unless properly trained and possessing the necessary skills to perform such work. • Keep the service site clean. Oil and water on the floor could make it slippery. • Never wear loose items and jewellery when working on the truck. WARNING! Short-circuiting/Burn injuries. When working on the truck's electrical system, short-circuiting/burn injuries may occur if metal objects come into contact with live electrical connections. Remove any watches, rings and other metal jewellery.

• Unless otherwise indicated in this service handbook, always disconnect the battery connector prior to performing maintenance work on the truck. • Prior to opening any covers to the drive unit and the electrical system, be sure to disconnect the power supply to the truck.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

3- 1

Maintenance Safety rules during maintenance work T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

• Prior to commencing any work on the hydraulic system of the truck, be sure to slowly depressurize the system. • Use paper or a thick paper board to inspect possible hydraulic oil leaks. Do NOT use your hand. • Keep in mind that the transmission oil and hydraulic system oil may be burning hot. WARNING! Risk of burn injuries. Hot transmission and hydraulic oil. Allow the truck to cool down prior to replacing the oil.

• Use only new and clean oil when refilling the hydraulic oil system WARNING! Risk of damaging the hydraulic system. If the oil is contaminated, the hydraulic system components will be damaged. Always use new and clean oil in the hydraulic system.

• Store and transport replaced oil in accordance with local regulations. • Do not flush solvents, etc. used for cleaning into drains that are not specifically suited for this. Follow local regulations with regards to destruction of oil, solvents, etc. • Disconnect the battery prior to performing welding work on the truck. NOTE! The battery could become damaged. When using an electric welding system, the welding current could reach the battery. Be sure to first disconnect the battery.

• Prior to welding or grinding on painted surfaces, be sure to scrape off the paint at least 100 mm around the welding/grinding site using blasting or a paint remover. CAUTION! Unhealthy gasses. Paint, which is heated, generates unhealthy gasses. Remove the paint 100 mm around the working place.

3- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Maintenance Cleaning and washing Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

3.2 Cleaning and washing Cleaning and washing of the truck is important to assure a high level of reliability. • Clean and wash the truck once a week. NOTE! Risk of short-circuiting. The electrical system can become damaged. Prior to washing, be sure to disconnect the battery by disconnecting the battery connector.

3.2.1 External cleaning • Remove dirt, chips, etc. from the wheels daily. • Use a well-known degreasing agent, diluted to a suitable concentration. • Wash off loose dirt using lukewarm water. NOTE! Seizure, corrosion. Mechanical parts could become damaged. Following washing of the truck, lubricate it according to the lubrication schedule in the Maintenance section.

3.2.2 Cleaning the motor compartment • Prior to washing, cover all electric motors, connectors and valves. NOTE! Risk of short-circuiting. The electrical system can become damaged. Electric components must not be washed with a high-pressure jet.

• Wash the motor compartment with a well-known degreasing agent diluted to a suitable concentration. • Wash off loose dirt using lukewarm water.

3.2.3 Electric components • Use compressed air to blow clean the electric motors. • Clean electric panels, logic cards, connectors, valves, etc. with a rag moistened with water and a suitable detergent. NOTE! Risk of short-circuiting. Electric components can become damaged. Avoid breaking the warranty seals on the logic cards.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

3- 3

Maintenance Safe lifting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

3.3 Safe lifting Perform all lifts on level, slip-proof and firm surfaces. Avoid newly laid asphalt on warm summer days. • Always apply the parking brake to prevent the truck from moving during lifting. If the brake wheel needs to be lifted, be sure to block the other wheels to make sure the truck will stand still. • Select a lifting point that will make the lift as light as possible (one corner at a time). If the lifting point on the truck are indicated on the lower part of the chassis, be sure to use this to assure balanced lifting. • Ensure that the surface where the jack is placed is clean and free from oil. • Use clean hands and make sure the jack handle is free from grease and oil. • Use the handle supplied with the jack. Too short a handle will require more strength than necessary. Too long a jack may result in overloading of the jack. • Secure the truck with trestles, etc.: - As close to the lifted part of the chassis as possible in order to reduce the falling height if the truck should collapse. - To prevent the truck from rolling. - Never chock up the jack in order to achieve a higher lifting height. - Never work under a lifted truck unless it has been securely chocked up. WARNING! Risk of crushing. A poorly chocked up truck may fall down. Never work under a truck unless it has been securely chocked up using trestles or other safe hoisting gear.

3- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Maintenance Lifting the truck Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

600+-100

3.4 Lifting the truck

600+-100

• Lift the truck at its centre of gravity using another fork lift truck. • Fasten the truck to the forks of the lifting truck. • Lift it very carefully. WARNING! Risk of tipping. The truck may tip over if it is lifted incorrectly. Always lift the truck when it has been fastened to the forks of the lifting truck and its centre of gravity between the forks.

• Only lift the truck at the indicated lifting points using suitable lifting equipment. WARNING! Risk of tipping.. The truck may tip over if it is lifted in the wrong places. Always lift the truck at the indicated lifting points.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

3- 5

Maintenance Maintenance schedule T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

3.5 Maintenance schedule Table 2: 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 - may vary due to application

500

1000

3000

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

12m

36m

0000

Chassis

0000.1

Inspect all shafts, links and clamping pins

0000.2

Inspect possible damage on the chassis; open the battery cover and use it as an aid

0000.3

Check the cover locks

0000.4

Check finger guard

0000.5

Check signs and stickers

0000.6

Inspect the operator platform

0350

Support arm

0350.1

Tightening torque inspection of the cap bolts (Note 7)

0380

Fork carriage

0380.1

Check for crack formation and damage

0380.2

Check clearance in bushes and links

0380.3

Press grease into grease nipples (Note 6)

0380.4

Check the lift limit switch

0380.5

Inspect the guides for wear and lubricate them (Note 6)

I/L

0380.6

Inspect the load support (Option)

0450

Frame-mounted components

0450.0

Inspect the motor plate links and turning pipe

3- 6

Service Manual

I T

I/L I

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Maintenance Maintenance schedule Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 2: 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 - may vary due to application

500

1000

3000

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

12m

36m

I/T1

I/T

1700

Drive motors

1700.1

Check clearance in connections

1700.2

Inspect the carbon brushes in the drive motor and lift motor

1700.3

Clean the drive motor and lift motor

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

2550

Drive unit

2550.1

Check for leakage

2550.2

Check the oil level

2550.3

Check for abnormal noise

2550.4

Check the attachment and clearance in steering bearing

2550.5

Change the oil in the drive gear

2550.6

Lubricate the gear rim

3100

Brake

3100.1

Clean and verify correct operation of the service brake and parking brake

3100.2

Inspect brake disc weak and verify correct tightening torque (32 Nm)

3100.3

Check the clearance in disengaged position. (0,2-0,3 mm)

Service Manual

T2 I I

L4 L C/I

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

3- 7

Maintenance Maintenance schedule T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 2: 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 - may vary due to application

500

1000

3000

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

12m

36m

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts New wheel: Tread thickness = 30 mm Tightening torque = 65 Nm) (3500,2)

3500.3

Check whether the castor wheel rotates and swings freely; lubricate the horizontal bearing. Inspect the castor wheels for wear and correct installation. New wheel: Tread thickness = 10 mm)

4110

Tiller arm

4110.1

Check the mountings

4110.2

Inspect the steering couplings for excessive play and the return spring

4110.3

Inspect the gear of the steering servo unit. (Option)

5000

Electrical functions

5000.1

Inspect brake switch operation

5000.2

Inspect correct operation of the emergency stop switch

5000.3

Check the function of the collision safety switch

5000.4

Inspect lifting/lowering operation of the forks (and support arms 7SLL12.5F, 7SLL16F)

5000.5

Inspect correction operation of the platform switch

5000.6

Inspect the side guard switch for correct operation

5000.7

Check the function of the horn

5000.8

Check for wear on cabling

5000.9

Check the function of the driver’s control

5000.10

Inspect the error code log, operating hours and all segments in the display panel

3- 8

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Maintenance Maintenance schedule Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 2: 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 - may vary due to application

500

1000

3000

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

12m

36m

5110

Battery

5110.1

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

5110.2

Check connections to battery, truck and charge

5110.3

Check that the cell and pole guards are undamaged

5110.4

Check the fluid density and temperature

5110.5

Remove overflow fluid from the battery trough

5110.6

Check the battery locking

5400

Power system

5400.1

Clean and inspect the mounting devices

C/T

5400.2

Re-tighten cable connections

5400.3

Check the contactor points on K10

5400.4

Check the movement of the contactors

5400.5

Check the cable insulation

6000

Hydraulic system

6000.1

Check hoses and connections for wear

6000.2

Check hoses for wear and damage

6000.3

Check the oil tank for cracks, leakage and damaged mountings

6000.4

Check that the oil level is correct

6000.5

Replace the oil and clean the reservoir

Service Manual

I L5

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

3- 9

Maintenance Maintenance schedule T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 2: 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 - may vary due to application

500

1000

3000

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

12m

36m

6600

Lift cylinder

6600.1

Check for leakage

6600.2

Check the mountings

7100

Mast

7100.1

Check for any cracks and other damage

7100.2

Tighten the mast mounting bolts (tightening torque = 197 Nm)

7100.3

Inspect the play between the mast member and the mast stabiliser rollers inside the mast

7100.4

Inspect lateral play in the mast stabiliser

7100.5

Inspect the lifting chains and chain rollers for wear

7100.6

Inspect correct adjustment of the lifting chains

7100.7

Inspect the chain pin shafts and split cotters

1 = The connections are re-tightened for the first time after 500h and then every 1000 /h. 2 = The attachment bolts are re-tightened after 500h to 45 Nm. 3 = Check for leakage in conjunction with the first oil change 4 = The oil is changed for the first time after 500h/6 month and then every 3000 h/36 months. 5 = Replace the oil and clean the reservoir the first time after 500 hours/ 1 month, and then every 1000 hours/12 months. 6 = If the truck is used in cold stores or other severe conditions, perform this item every 250 hours. 7 = Tightening torque of 110 Nm (+/- 12 Nm). When points with higher hour intervals are carried out the points with lower hour intervals should also be carried out unless otherwise specified above.

3- 10

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Maintenance Maintenance schedule Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

5000

7100

6600 0350

4110

5000

3500 0450 5100

1700

3100

6000

2550 5400 3500

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

3- 11

Maintenance Lubrication chart T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

3.6 Lubrication chart Table 3: Lubrication chart Pos no

Service point

Interval/Running hours 500h

1000h

Lubricant

3000h

Wheel bearing, bushings

Mast beam

Lifting chains

Hydraulic system

Steering bearings

Drive gear

Bushings

G O

C A

L= Lubrication C = Check O= Oil change

3- 12

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Maintenance Lubrication chart Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

4 7

Service Manual

67SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

3- 13

Maintenance Oil and grease specification T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

3.7 Oil and grease specification Table 4: Oil and grease specification Lubricant

Specification

Application area

> - 15°C

< - 15°C

Grease

223690 Q8 Rembrandt EP2

Bearings and bushings

Hydraulic oil

ISO-HM32

ISO-VG32

Hydraulic system

Transmission oil

Hypoid oil SAE 80W/90

Hypoid oil SAE 75W

Gears

Grease

See table below

Chains

Grease

055-70111

055-74320

Mast

Grease

Staburags NBU 8EP

Steering bearings

Ambient temperature

Viscosity class

Recommended products (Similar products from other manufacturers may be used)

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5° C

VG 68

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

> + 5° C < +45°C

VG 150

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

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

3- 14

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Tools Super Seal connectors Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

4- Tools 4.1 Super Seal connectors 1 3

3 2

Figure

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

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

4- 1

Tools AMP connectors T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

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

Figure

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)

4- 2

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

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Tools Molex connectors Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

4.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

4.3 Molex connectors 16 9 8 1 Figure

Service Manual

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

4- 3

Tools Grease guns T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

4.4 Grease guns Figur

fif

4- 4

Nummer

Användning

24981

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

755132

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

755142

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

755152

Two-hand grease gun with hose and nozzle.

755146

Grease hose 450 mm. Grease hose 750 mm. Grease hose 1500 mm.

202154PM

Pointed nozzle for grease guns used to apply grease in recessed nipples. Fits grease guns with hose and discharge pipe. Length 125 mm.

755140

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

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Tools Other tools Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

4.5 Other tools Figure

Service Manual

Number

Application

179915

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

08-13022

Driving gear puller

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

4- 5

Tools Other tools T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

4- 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Chassis – 0000 Support arms Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

5- Chassis – 0000 5.1 Support arms 5.1.1 General Only available on straddle version.

The truck has been assembled to a single unit by bolting the support arm chassis and the separate mast and support arm mounting locations to the drive unit. The support arms of the support arm chassis can be adjusted to different support arm widths ranging from 900 mm to 1300 mm to enable handling of different pallet sizes. Normally, the support arm width has been preadjusted prior to delivery.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

5- 1

Chassis – 0000 Support arms T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

5.1.2 Main components 6 4

1 2

Pos. no.

Designation

Support arm wheels, bogie type

Support arm wheels, single type (option)

Support arms

Cap, screws and nuts, support arms M6S M16x110

Safety catch, support arms

Drive unit

Mast mount

Locking screws and locking nuts, support arms M6S M12x60

5.1.3 Maintenance Proper fixing of the support arms must be inspected at the regular 500 hour service interval. Inspect the tightening torque (pos. no. 4 in the section ”Main components”) using a torque wrench set to 110 Nm.

5- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Chassis – 0000 Support arms Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

5.1.4 Adjusting the support arm width B

2b 5

4 1b

Proceed as follows when adjusting the A measure between the support arms: • Lift one side of the truck. WARNING! The truck can topple over. Do not lift both support arms at the same time. Lift one side at a time and arrange sufficient support under the truck during this work procedure.

• Loosen the locking nuts and locking screws on the front of the cross member (1a,1b, 2a and 2b). • Loosen the cap screws and nuts (3, 4, 5, 6). • Pull out (or retract) the support arm. To obtain the A measure, the B measure must equal A/2 - 374 mm. Make sure the B measure is identical on both sides. If the support arm is pulled too far out, the safety catch (7) will lock the support arm to prevent it from falling out of the cross member. • Following adjustment of the support arm width, tighten the screws and nuts (1a,1b, 2a, 2b) by hand. Tightening order: 1a, 1b, 2a, 2b • Finger tighten the nuts (3, 4, 5, 6) and then tighten them to a torque of 55 Nm. Tightening order: 3, 4, 5, 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

5- 3

Chassis – 0000 Support arms T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

• Slightly loosen 1a and 2a. Then tighten the nuts to a torque of 110 Nm +- 12 Nm. Tightening order: 3, 4, 5, 6

5.1.5 Support arm replacement

Replacement of a support arm is a more comprehensive task than simply adjusting the width. • Lift out the battery. • Disassemble the safety catch (7) from the support arm cap. • Lift up the truck side on which the support arm shall be replaced. • Loosen the locking bolts on the front of the cross member (1a,1b, 2a and 2b). • Loosen the cap bolts (3, 4, 5, 6). • Pull out the support arm. • Insert the new support arm and adjust the width as explained in the section “Adjusting the support arm width”. • Lower the truck to the floor. • Install the safety catch (7) once the cap bolts have been tightened. • Reinstall the battery.

5- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Chassis – 0000 Engine suspension Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

5.2 Engine suspension 5.2.1 Components 1 2 3 4

Pos.

Description

Axle for torsion tubes

Threaded hole

Washer

Screw

5.2.2 Disassembly Remove the power unit as follows: • Unscrew the four screws (4) holding the power unit in place. • Insert the screws (4) in the threaded holes (2). The torsion tube axles (1) will then be pulled out automatically.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

5- 5

Chassis – 0000 Engine suspension T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

5.2.3 Spring replacement • A = 85 mm • B = 274 mm

5- 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Chassis – 0000 Platform Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

5.3 Platform 5.3.1 Components 2

4 1

5 3

Pos.

Description

Gas damper

Screws

Compression springs

Inductive sensor S19

Inductive sensor S59

5.3.2 Disassembly The platform can be removed to allow easy access to the drive wheel, for example. This is done by removing the two screws (2) holding the platform in place. The platform is then loose and can be removed.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

5- 7

Chassis – 0000 Platform T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

5- 8

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electric drive motor – 1760 Included components Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

6- Electric drive motor – 1760 6.1 Included components

24 23

16 13

19 10

12 7

6 5 3

2 1

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

6- 1

Electric drive motor – 1760 Included components T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 5: Included components

6- 2

Pos.

Name

Notes

Screw

M6x25

Bearing plate

Locking ring

Bearing

Carbon brush bridge

Screw

M5x12

Screw

M5x20

Carbon brush

Rotor

Wedge

Plug

Armature

Cable

Adjuster bush

Fan

Bearing plate

Screw

Seal

Bearing

Washer

Locking ring

Washer

Locking ring

Service Manual

M6x25

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electric drive motor – 1760 Disassembly/assembly of the truck motor Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

6.2 Disassembly/assembly of the truck motor 6.2.1 Disassembly • Switch off the truck and disconnect the battery connector. • Remove the motor compartment covers. • Disconnect the cables from the motor and the tiller arm. • Loosen the four nuts from the motor mounts on the driving gear. • Disconnect the cables for the start switch and the emergency stop switch. At the same time, remove all cables from the cable recess in the cover. • Remove the cover that covers the motor compartment and the tiller arm mount from the motor. Remove the cover that covers the motor compartment together with the tiller arm. • Carefully lift the motor straight up while being careful not to damage the driving gear sealing surfaces, and place the motor on a clean surface. • Protect the driving gear against contamination by covering all ports with suitable means, e.g. a plastic sheet. It is now possible to commence with the necessary service and repairs of the motor.

6.2.2 Assembly • Assembly is done in reverse. • Carefully lower the motor into the drive gear while making sure the seals and gear wheels are not damaged. • Tighten the pin bolt nuts to the prescribed torque of 27 Nm. • Install and adjust the brake according to the instructions. Secure the cover and tiller arm with screws and connect the cables that were previously disconnected. Verify that the polarity is correct. • Following completed installation, perform operational testing of the brake before the truck is operated again.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

6- 3

Electric drive motor – 1760 Service/repairs T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

6.3 Service/repairs 6.3.1 Disassembly of the motor • Loosen the brake disc tappet by first removing the groove ring together with the washer at the end of the rotor shaft. It is then possible to remove the tappet by lifting it. It may be necessary to use a suitable tool to free it. • Us the four plugs that cover the carbon brushes, fold away the carbon brush springs and pull out the carbon brushes. • Disassemble the bearing plate at the end of the commutator together with the carbon brush bridge and the carbon brushes by removing the eight screws. Then set down the motor, arrest it properly to the edge of the bearing plate and carefully knock at the end of the rotor shaft with a rubber mallet. • Disassemble the drive end of the bearing plate together with the rotor. Be careful not to damage the motor windings when the rotor is remove from the motor cover. • Once the motor bearing plates have been disassembled and the rotor has been removed from the motor cover, loosen the gear wheel at the rotor drive end. This is done by loosening the gear wheel nut and then pulling out the gear wheel with a puller. Please note that the gear wheel has been secured to the rotor shaft with Loctite. • Then loosen the inner groove ring together with the washer below the ring. Pull out the rotor shaft from the bearing. • Loosen the outer groove ring together with its washer, and remove the bearing from the bearing plate. • Remove the bearing plate seal and carefully clean the bearing plate. • Install a new seal in the bearing plate.

6.3.2 Motor installation Install the motor in reverse. • Carefully check whether the rotor can move freely when rotating and that the carbon brushes press against the commutator. • Check the insulation resistance of the motor (between each winding and the motor cover). On a new motor, the measured value should be 2 - 3 MOhm. When the motor has become dirty, an insulation resistance down to approx. 1 MOhm is acceptable. • Install a new O-ring on the bearing plate at the drive shaft end and a new seal on the bearing plate collar.

6- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electric drive motor – 1760 Service/repairs Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

6.3.3 Cleaning Keep the motor as clean as possible since this is a decisive factor for correct operation. Regularly inspect the motor and motor compartment for build-up of dust, oil and other contaminants. If the motor windings and internal compartments are dry, use a vacuum cleaner with a suitable nozzle to clean the motor. Compressed air can be used together with a vacuum cleaner for cleaning. If this is the case, make sure the compressed air is clean and dry. If deposits have formed on the windings, use a lint-free cloth to remove them. If required, moisten the cloth with an organic, volatile grease solvent that will not damage the windings. However, do not use too much cleaning agent as it could penetrate into the motor parts. If grease deposits are left on the surface, use a suitable solvent to remove cleaning agent remains. If the motor components are heavily contaminated, it may be necessary to use a solvent that is sprayed onto the parts. It is especially important for the rotor that the cleaning agent is applied in a manner that avoids contaminants from penetrating into the motor section. One method to clean the rotor is to submerge it in solvent. If this method is used, be sure to later dry the motor using a heat source. During the drying process, arrange good ventilation and allow the components to dry until repeated insulation resistance measurements show similar and approved values.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

6- 5

Electric drive motor – 1760 Service/repairs T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

6- 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Drive unit/gear – 2550 General Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

7- Drive unit/gear – 2550 7.1 General These service instructions cover descriptions of service performed at the customer site. Complete reconditioning of the driving gear must be performed in the workshop by trained technicians.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

7- 1

Drive unit/gear – 2550 Included components T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

7.2 Included components

1 2 3

5 16 13

12 10

7- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Drive unit/gear – 2550 Included components Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Pos.

Designation

Note

Bleeder valve

Cover

Dip stick

Seal

Screw

Upper cover and gear housing Tightening torque 26.6 Nm Secure with Loctite 242.

Nut

Tightening torque 300 Nm Lock with centre punch

Washer

Conical roller bearing

Shims

Bolt

Cover

Seal

Conical roller bearing

Shims

Sealing

Drive shaft

Lower cover and gear housing Tightening torque 25 Nm Secure with Loctite 242.

Nuts (assembly of motor - gear housing)

Tightening torque 26.6 Nm

Wheel nuts

Tightening torque 65 Nm

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

7- 3

Drive unit/gear – 2550 Disassembly of the drive unit from the truck T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

7.3 Disassembly of the drive unit from the truck 1. Jack up the truck until the wheel clears the floor. Support the truck with trestles in a safe manner. 2. Disassemble the drive wheel. 3. Drain all oil from the driving gear. 4. Disconnect the motor cables. 5. Disconnect the cables to the brake. 6. Loosen and remove the drive motor bolts and lift away the drive motor. 7. Secure the drive unit from below. 8. Loosen and remove the nuts securing the drive unit to the chassis. 9. Lower the drive unit enabling removal from under the truck. 10. Place the drive unit on a workbench or similar.

7.4 Assembly of the drive unit in the truck 1. Lift the gear unit into place in the chassis. 2. Fit a new O-ring on the drive motor bearing cage. 3. Assemble the drive motor and gear case. Proceed with caution to prevent damage to the O-ring. 4. Tighten the nuts to the torque indicated in the table. Prior to assembly, apply grease on the nuts. 5. Connect the motor cables. 6. Connect the cable to the brake unit. 7. Fill the driving gear with oil. 8. Assemble the drive wheel. Tighten the wheel nuts diagonally to the torque indicated in the table. 9. Lower the truck to the ground and assemble the motor cover.

7- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Drive unit/gear – 2550 Oil inspection or changing oil Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

7.5 Oil inspection or changing oil 7.5.1 Oil inspection/replenishment Inspect the oil level in the gear case according to the maintenance chart. 1. Check the oil level in the gear case by removing the oil filling plug on the upper part of the gear housing. 2. Fill up with oil according to the indication on the dip stick.

7.5.2 Changing oil Change the gear case oil in accordance with the maintenance chart. 1. Drain the old oil by removing the lower cover. Use a new seal and apply Loctite when refitting the cover. 2. Fill with oil according to the oil filling instructions.

7.6 Replacing the gasket ring It is easiest to replace the drive shaft gasket ring when the drive unit has been disassembled from the truck. If oil leaks from the drive shaft, follow the instructions below.

7.6.1 Disassembly 1. Disassemble the drive unit from the truck. 2. Remove the lower cover. 3. Loosen the nut. Remove the nut and washer. 4. Press out the drive shaft. 5. Pull of the bearing from the drive shaft is a bearing remover. 6. Verify that the bearing plates are free from damage. If the plates have been damaged by the bearing remover, then measure the total thickness of the spacing washers and replace them prior to assembly. 7. Remove the gasket ring from the drive shaft.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

7- 5

Drive unit/gear – 2550 Leakage from top cover T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

7.6.2 Assembly Following replacement of the gasket ring, follow the instructions below. 1. Position the outer bearing of the drive shaft in the gear housing. 2. Press the new gasket ring into the gear housing. When pressing the gasket ring into place, exercise care to make sure it is correctly positioned. 3. Press the drive shaft into the gear. Check to make sure the drive shaft splines interconnect with the drive wheel splines. 4. Screw on the nut and tighten to the torque indicated in the table. Be sure to always to use a new nut. Prior to assembly, apply grease on the nut. 5. Before fitting the lower cover, assemble a new seal and apply Loctite. 6. Replace the cover and tighten the bolts to the torque indicated in the table. Make sure the seal is not damaged. Prior to assembly, apply grease on the bolts. 7. Fill with oil. 8. Assemble the drive wheel and tighten the wheel nuts diagonally to the torque indicated in the table. Prior to assembly, apply grease on threads. 9. Install the drive unit in the truck.

7.7 Leakage from top cover Follow the instructions below in case of leakage from the gear case top cover. 1. Disassemble the gear case from the truck. 2. Loosen all bolts securing the top cover to the gear housing and remove the cover. 3. Carefully clean the sealing surfaces of the cover and gear housing. 4. Apply Loctite on the sealing surfaces. 5. Insert the bolts in the cover and tighten the bolts to the torque indicated in the table. Prior to assembly, apply grease on the bolts. 6. Fill with oil. 7. Assemble the gear case and drive motor. Install the drive unit in the truck.

7- 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electromagnetic brake – 3370 Main components of the brake Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

8- Electromagnetic brake – 3370 8.1 Main components of the brake 9

8 2

Table 6: Main components of the brake

Pos. no.

Description

Magnet coil

Electric cable

Pressure plate

Pressure spring

Friction plate

Adjusting locking nut

Brake disc

Mounting bolts

Hub

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

8- 1

Electromagnetic brake – 3370 Maintenance T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

8.2 Maintenance In normal use, the brake should not require any maintenance. The preventive maintenance diagram, however, recommends regular inspection of the brake disc for wear and also to ensure the play between the magnet coil housing and pressure plate is correct.

8.2.1 Basic adjustment of the play 9,5 Nm

0,3

The specified play between the magnetic coil housing and the pressure plate should be 0.3 mm when applying the brake. The maximum play prior to adjustment becoming necessary is 0.8 mm. Adjustment • Slightly loosen the tightening of the three mounting bolts. • Turn the locking nuts counter-clockwise and lightly tighten the bolts while at the same time checking the play in three places using a 0.3 feeler gauge. • Tighten the mounting bolts to a torque of 9.5 Nm and reverify the play using the feeler gauge.

8- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electromagnetic brake – 3370 Maintenance Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

8.2.2 Brake disc replacement Replace the brake disc when its entire thickness has become 8,8 mm. • Disconnect the electric cables from the brake. • Loosen and remove the three mounting bolts and the brake coil. • Replace the brake disc on the hub and inspect the friction plate for wear. If the surface is uneven, then replace the friction plate. • Unscrew the locking nuts on the coil at least 6 mm to assure there is a large play between the coil and the pressure plate when the coil is later reinstalled. • Attach the coil to the motor end and adjust the play as described in the section ”Basic adjustment of the play”. • Reconnect the electric cables.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

8- 3

Electromagnetic brake – 3370 Maintenance T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

8- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Support/Castor Wheels - 3540 Tightening torque Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

9- Support/Castor Wheels - 3540 9.1 Tightening torque

Pos.

Tightening torque

160 Nm

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

9- 1

Support/Castor Wheels - 3540 Tightening torque T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

9- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical steering system – 4300 Electrical steering servo Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

10- Electrical steering system – 4300 10.1 Electrical steering servo NOTE: Steering servo is an option.

10.1.1 General The electrical steering servo consists of twin potentiometers connected to an electronic module in the motor compartment. The electronic module, which is also referred to as the EPS (Electrical Power Steering), is directly mounted on a Brush-Less Permanently Magnetised servo motor (BLPM). The motor has a power amplifier that consists of 2-stage planetary gearing with a gear wheel mounted on a trailing journal and locked with a nut. The gear wheel is meshed with the gear ring on the driving wheel gear, and as such the drive unit also handles steering of the truck. The steering system is electric and uses a "Steer-By-Wire" design. This means there is no mechanical contact between the steering unit and the truck's steering wheel. The electronic module monitors all electrically connected components. Monitoring is continuous enabling instant detection of possible cable interruptions. Electrical faults detected in potentiometers, cables and the electronic module result in automatic switch-off of the truck's drive mode and application of the electromechanical brake. An automatic drive reference measurement is performed at each startup after a no-voltage state. During this calibration, the truck cannot be driven. The drive reference mode safety-checks the system and simultaneously calibrates the wheel position. Steering is progressive, implying slow-down of the travel speed at large steering angle throws. This promotes safe and efficient truck travel. Maximum acceleration depending on steering angle Transport mode High-speed range

Transport mode Low-speed range

Steering mode Safety mode

<20°

100%, approx. 8 km/h

100%, approx. 6 km/h

100%, approx. 5 km/h

20° to 90°

Linear from 100% to 62%

Linear from 100% to 83%

100%

>90°

62%, approx. 5 km/h

83%, approx. 5 km/h

100%, approx. 5 km/h

Steering angle

A certain steering response from the steering arm results in an increasingly greater steering response in the steering wheel. This is because the arm can turn maximum 70°, while the wheel can turn 90°.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

10- 1

Electrical steering system – 4300 Steering servo components T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

10.2 Steering servo components

10- 2

Pos.

Designation

Following tightening of the locking nut (2), the torque when rotating the securing plate should be 6.5 +/-0.5 Nm.

Tighten the nut so that the above applies.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical steering system – 4300 Adjustment Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

10.3 Adjustment 10.3.1 Reference sensor If replacement or adjustment of the reference sensor should be required, screw it all the way down until it touches the highest part of the gear ring (12). Then unscrew it 2 turns and lock it with the nut. Calibrate the system using parameters 36 and 37.

10.3.2 Calibration Calibration and adjustment of the steering servo is accomplished using parameters 36 and 37.

Parameter 36 Parameter 36 calibrates the steering servo and must be adjusted when the following components are replaced. • Complete steering servo assembly or parts of the steering servo assembly. • Reference sensor. • Potentiometer. • Following any work on the steering unit. Detailed instructions as to the function of parameter 36 are presented in C code 5000.

Parameter 37 Parameter 37 adjusts the drive wheel centre position. The wheel can be adjusted 30 degrees to either side. Prior to adjustment of parameter 37, parameter 36 must be adjusted to ascertain the wheel's zero position. Detailed instructions as to the function of parameter 37 are presented in C code 5000.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

10- 3

Electrical steering system – 4300 Adjustment T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

10- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 General Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11- Electrical systems – 5000 11.1 General The electrical system of the truck is based on the PowerDrive platform. • The main energy source comprises a 24 V DC truck battery. • The traction drive motor is a separate excitation type (SEM). The travel drive motor is operated by an enclosed transistor regulator relying on pulse width modulation (PWM) technology. • The lift unit motor is a conventional DC motor without any external field winding connections. Switch-on of the hydraulic unit's electric motor is achieved using a contactor. • All electric units communicate via a CAN bus with an IC card in the steering unit handle. This card contains a processor and software that controls and monitors truck functions. A set of parameters used to adjust truck functions and characteristics is stored in the card. The card also monitors error conditions that may occur.

11.1.1 Part numbers To select part number display mode carry out the following procedure: • Ensure the battery is connected. • Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold [S18] depressed until “Pn” is displayed, then release [S18]. Fig. 1 Fig. 1

The display will now show the part numbers for the control program, the hardware part number and hardware serial number. The part numbers are displayed by repeatedly operating speed control [L1]. The display will first show the starting portion of the number then the ending portion.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 1

Electrical systems – 5000 General T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.1.2 Nomenclature [ ] = reference to electrical component in the wiring diagram.

Table 7: Part numbers Display

Meaning Software (Control program) part number

Hardware part number

Hardware serial number

11- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Electrical equipment overview Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.2 Electrical equipment overview 11.2.1 Component placement S53 S56

S90

S31 S33

Y59 Y58 Y41

S10 S21

X1 B4 G1

Y52 X41

Y10

S19 S59

F50 R2

F52 F53 K10

M1 S65

Service Manual

A36

F1 H1

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 3

Electrical systems – 5000 Electrical equipment overview T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

A2:S17

A17

S18:1

S18:2

A2:S20 A2:S19 R14

11- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Electrical equipment overview Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.2.2 Component list The following table shows a summary of the major electrical components of this truck.

Table 8: Electrical equipment list summary Symbol

Function

Description

Associated signal names

Inf.

A1:OUT MAIN CONTACTOR

Energy and main power isolation G1

Main electrical power source

Traction battery 24 V

Battery connection / isolation

Connector

K10

Main contactor

Contactor

Equipment protection F1

Drive motor protection

Fuse 130 A

Pump motor protection

Fuse 175 A

F 50

Operating circuit protection, A2

Fuse 7,5A

F 51

Operating circuit protection A1

Fuse 7,5 A

F 52

Steer servo motor protection

Fuse 30 A

F 53

Operating circuit protection, A5

Fuse 3 A

A5:INPUT ENABLE B+ A5:POWER SUPPLY 24VDC 3

Control and Signal processing A1

Traction and peripherals power control

Transistor regulator

Control of truck functions

Electronic card

Lift power and signal control

Transistor regulator

Steering servo

Electronic card

3, 2

Display of truck functions

Display unit

A17

PIN log in and data entry

Keypad

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 5

Electrical systems – 5000 Electrical equipment overview T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 8: Electrical equipment list summary Symbol

Function

Description

Associated signal names

Inf.

Braking, Safety & Supervision S21

Emergency switch-off

Switch

A1:INP.SUPPLY 24VDC

S10

Tiller arm in drive position (Mechanical brake activation)

Inductive proximity switch

A1:INP.TILLER ARM I N DRIVE POS

7, 10

Mechanical brake

Electromechanical brake

A1:OUT.BRAKE A

A2:S17

Emergency reverse

Hall sensor

A2:BELLY BUTTON

S19

Platform staying down supervision

Inductive proximity switch

A1:INP.MAN ON PLATFORM

7, 3

S59

Platform not up supervision

Inductive proximity switch

A1:INP.PLATFORM N OT FOLDED UP

7, 10

S53

Gates up supervision

Inductive proximity switch

A1:INP GATES UP

7, 10

S56

Gates down supervision

Inductive proximity switch

A1:INP GATES DOWN

7, 10

S33/1

Supervision -Max. permitted lift height for powertrak

Magnetic switch

A1:INP LIFT LIMIT POWER TRAC 1,< 1.8M

7,9

S33/2

Supervision -Max. permitted lift height with gates up

Magnetic switch

A3:INP.LIFT LIMIT <1, 8M

7,9

Audible warning signal -Horn

Horn

A1:OUT.SIGNAL HORN

S18:1

Horn activation

Switch

A2:INP.HORN1

7, 4

S18:2

Horn activation

Switch

A2:INP.HORN2

7, 4

Traction & traction control L1

Speed control and travel direction selector (butterfly)

Hall sensor

S113

“Turtle” function

Switch

Truck traction

Motor

Y58

Powertrak drain-hydraulic control

Y59 B5

11- 6

6, 7 A2:TURTLE

Magnetic valve

A1:OUT.POWERTRAK DRAIN VALVE

Powertrak open-hydraulic control

Magnetic valve

A1:OUT.POWERTRAK FILL-UP VALVE

Powertrak pressure supervision

Pressure sensor

A3:INP.PRESSURE PT

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Electrical equipment overview Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 8: Electrical equipment list summary Symbol

Function

Description

Associated signal names

Inf.

Steering angle signal

Potentiometer

A5:A_IN0 , A_IN1

S65

Drive wheel in centre reference

Inductive proximity switch

A5:REF

Drive wheel steering

Motor

Steering

3,2

Forks lift R14

Fork lift/ lower control

Hall sensor unit

A2:A_IN

Y10

Fork lower -hydraulic control

Proportional magnetic valve

A3:OUT MAGNET VALVE PWM

7,8

Load supervision

Pressure sensor

A3:INP.PRESSURE LIFT

Hydraulic pressure

Motor

Support arm lift A2:S19

Support arm lift control

Hall sensor

5,7,8

A2:S20

Support arm lower control

Hall sensor

5,7.8

Y41

Support arm lower -hydraulic control

Magnetic valve

A3:OUT.SUPPORT ARM LOWER VALVE

7,8

Y52

Support arm / fork lift selection

Magnetic valve

A3:OUT. FORK/ SUP.ARM VALVE

7,8

S31

Support arms at top supervision

Inductive proximity switch

A1:INP.SUPPORT ARM AT TOP

7,8 10

S90

Support arms at bottom supervision

Inductive proximity switch

A1:INP.SUPPORT ARM AT BOTTOM

7,8,10

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 7

Electrical systems – 5000 Electrical equipment overview T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 8: Electrical equipment list summary Symbol

Function

Description

Associated signal names

Inf.

Power supply

PTC-resistor 10 Ohm

X41

CAN communication (external)

Connection point

CAN communication (extra I/O)

Connection point

Y16

Hydraulic control of special function.

Magnetic valve

A3:OUT.3 HYD. FUNC 1A

Y17

Hydraulic control of special function.

Magnetic valve

A3:OUT.3 HYD. FUNC 1B

Y18

Hydraulic control of special function.

Magnetic valve

A3:OUT.4 HYD. FUNC 2A

Y19

Hydraulic control of special function.

Magnetic valve

A3:OUT.4 HYD. FUNC 2B

S114

Activation of special function.

Switch

S115

Activation of special function.

Switch

Other

Footnotes to the table above: 1. Situated in the tiller arm handle and communicates via the CAN bus 2. The steering servo controller, servo motor and mechanics are integrated into one single unit. 3. Optional function 4. [S18:1] represents the left side button and [S18:2] represents the right side button. 5.These inputs signals are processed directly via Hall effect sensors mounted on the A2 card and are handled via the CAN bus. 6. Speed control signals from [L1] are processed by Hall element sensors mounted on the A2 card. Sensors [A2:S1-9] control speed control signals for driving in fork direction. Sensors [A2:S10-18] control speed control signals for driving in drive wheel direction. 7. Signals to/ from these elements can be checked via the Built-in Test function. See “11.6.5 Built-in Test Function” on page 83 8. Only valid for truck with support arm lift 9. Output is low when sensor is activated. 10. Output is high when sensor is activated.

11- 8

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Electrical wiring diagram Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.3 Electrical wiring diagram 11.3.1 Symbol list Table 9: Symbol list Symbol

M S

Description

Symbol

Description

Truck battery

Horn

Fuse

Emergency stop switch NC

Resistor (PTC)1

Brake coil (normally applied)

DC motor2 (SEM type)3

Sensor, inductive NO

Contactor

Coil for hydraulic magnetic valve

Switch, NO

Pressure sensor P

Magnetic switch, NC

Connector

NO = Normally Open, NC = Normally closed 1. PTC = Positive Temperature Coefficient (resistance increases as temperature increases) 2. DC = Direct Current 3. SEM = Separately Excited Motor

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 9

Electrical systems – 5000 Electrical wiring diagram T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.3.2 Overview

PLATFORM SPECIFIC S19

57 S59 58 S53 59 S56

FIELD (S2) (13) MAN ON PLATFORM FIELD (S1) (14) PLATFORM NOT FOLDED UP (10) GATES UP MAIN CONTACTOR (4) (11) GATES DOWN

DRAIN VALVE (2)

FILL-UP VALVE (3) S10 78 S33/1

(12) TILLER ARM

M1 A2

S2/E2 E2 S

S1/E1

2 40

K10

50 60

Y58

Y59

F51

21 S21

A1 52

ARMATURE (M)

A1 24 (+) POWER 24VDC (16) SUPPLY 24VDC 40 (-) POWER 0VDC

SIGNAL HORN (7)

(15) FORKS<1,8M BRAKE RELEASE (5) (1/8) CAN H/L

53 51 Y1

24 A1 79 (+) POWER +24VDC (15) FORKS<1,8M 40 (-) POWER 0VDC

S33/2

ARMATURE (M)

M3 A2

S2/F1 F1 S FIELD (S2) S1/F2 119/120 (1/8) CAN H/L FIELD (S1) 73 24 (16) SUPPLY +24V M.VALVE PWM (9) Y10 55 (10) PRESSURE 70 SUP.ARM LOWER (5) 75 (11) PRESSURE L. 72 FORK/SUP.ARM (6)

EXT. EQUIP.

ONLY INITIAL LIFT Y41 Y52

A3 3 HYD.FUNC. 1A (2) ONLY INITIAL LIFT

S31 77 S90

3 HYD.FUNC. 1B (3) (13) SUP.ARM AT TOP (14) SUP.ARM AT BOTTOM

4 HYD.FUNC. 2A (4) 4 HYD.FUNC. 2B (7)

ONLY 3 & 4 HYD. FUNC. Y16

81 Y17 82 Y18 83 Y19

F50

CAN

ONLY 3 & 4 HYD. FUNC.

X41

CAN X9

S115 S114 S113

40 (X3:3/7) 20 (X3:6) 0VDC CAN (X3:2) +24VDC A2:S17 BLUE2 (X2:2/5) Hall BLACK2 (X2:2/3) A2:S19 (X2:1/2) TURTLE Hall (X1:1) HORN 2 (X4:1) HORN 1

S18:2 S18:1

KEYBOARD A17 11- 10

A2:S20

Hall

A2:S1-S9 A2:S10-S18 (X4:2) Hall Hall (X1:2) (X2:1/3) BLACK1 (X2:2/2) 5VDC (X8:1) BLUE1 (X2:2/4) (X11) (X12) 0VDC (X8:4) (X8:2) A_IN

Service Manual

ONLY STEER SERVO STEER R2 ANGLE SENSOR

F52 F53 22 23 (2/10) (6) (8/16) CAN H/L ENABLE +24V

91/93/92/94 (4/13/5/14) 95 (3) +12V 96 A5 (11) REF. 40 (7/15) 0V (12) 0V S65 97

R14

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

M M6

DISPLAY A6

(X1)

Service Manual

Sh. 2

Sh. 3

Sh. 2

7,5A

F51

7,5A

F50

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F S

S10

130A

Y1 2

A1 S

DRIVE MOTOR

S1/E1

S2/E2

OUT. SIGNAL HORN

OUT. BRAKE RELEASE

1/16 PROD G 220241

INP. TILLER ARM IN DRIVE POS.

OUT. MAIN CONTCTOR

OUT. FIELD

OUT ARMATURE

INP. POWER SUPPLY +24V DC

INP. POWER SUPPLY 0V DC

TRANSISTOR REGULATOR A1

Valid from serial number 985777-

K10 A1 A2

PTC 10~E

G1 24V + -

EXTERNAL EQUIPMENT

Date 2007-05-11

Sh. 5

Sh. 9

Order number 249896-040

Sh. 3

Electrical systems – 5000 Electrical wiring diagram

T-code 789, 790, 791, 817, 818

11.3.3 Detailed wiring diagram

11- 11

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Sh. 3

119

120

119

120

CAN LOW

CAN HIGH

2/16 PROD G 220241

INP. LIFT LIMIT POWER TRAK 1, <1.8M

OUT. POWER TRAK FILL-UP VALVE

OUT. POWER TRAK DRAIN VALVE

Date 2007-05-11

Sh. 3

S33/2 1 4

S33/1 3 2

INP. SUPPLY +24V DC

Service Manual 16

11- 12

Sh. 4

Y59 1 2

Y58 1 2

Valid from serial number 985777-

TRANSISTOR REGULATOR A1

T-code 789, 790, 791, 817, 818

Sh. 1 3

Sh. 1

EMERGENCY SWITCH OFF S21 1 2

Electrical systems – 5000

Electrical wiring diagram Order number 249896-040

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Sh. 2 4

120

S1/F2

S2/F1

120

119

PUMP MOTOR

INP. SUPPLY +24V DC

CAN LOW

CAN HIGH

OUT FIELD

OUT. ARMATURE

3/16 PROD G 220241

INP. POWER SUPPLY +24V DC

INP. POWER SUPPLY 0V DC

Valid from serial number 985777-

Sh. 2 5

175A

Date 2007-05-11

Order number 249896-040

Sh. 1 9

Sh. 1 4

TRANSISTOR REGULATOR A3

Electrical systems – 5000 Electrical wiring diagram

T-code 789, 790, 791, 817, 818

11- 13

Electrical systems – 5000 Electrical wiring diagram Valid from serial number 985777-

11- 14

Service Manual

Date 2007-05-11

Order number 249896-040

INP. LIFT LIMIT, <1.8M 15

INP. PRESSURE LIFT 11

INP. PRESSURE PT 10

OUT. MAGNET VALVE PWM 9

Sh. 2

P 40 Sh. 3 5

Sh. 3 8

Y10 1 2

TRANSISTOR REGULATOR A3

4/16 PROD G 220241

T-code 789, 790, 791, 817, 818

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Service Manual

Sh. 4 8

Sh. 3 9

X41

119

120

FORK LIFT/LOWER

CAN CONNECTION

40 119

X9 1

120

119

INP. A_IN

OUT. 0V DC

X8:2

X8:4

A2:S20

OUT. +5V DC

A2:S19

A2:S1-S9 A2:S10-S18

A2:S17

INP. OV DC

CAN LOW

CAN HIGH

INP. +24V DC

X8:1

X3:6

X3:7

X3:3

X3:2

5/16 PROD G 220241

SUPPORT ARM LIFT/LOWERING

SPEED REF. VALUE

BELLY BUTTON

Valid from serial number 985777-

CAN, SERVICE CONNECTOR

120

Date 2007-05-11

119

Order number 249896-040

Sh. 3 9

Sh. 1

ELECTRONIC CARD TILLER ARM A2

Electrical systems – 5000 Electrical wiring diagram

T-code 789, 790, 791, 817, 818

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 15

11- 16

8 8 8 8

DISPLAY A6

Service Manual S18:1 1 2

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

OPTION

S113 2

X2:1/3

X2:1/2

TURTLE

OUT. 0V DC HORN 2 X1:2

6/16 PROD G 220241

Date 2007-05-11

INP. HORN 2 X1:1

OUT. OV DC HORN 1 X4:2

Valid from serial number 985777-

S18:2 1 2

INP. HORN 1

0V DC

LCLK

ENABLE

X4:1

X12:6

X12:5

X1 5

X1 6

X12:4

SCK

+5V DC

T-code 789, 790, 791, 817, 818

X1 4

X12:3

X12:2

X1 2

X1 3

X12:1

X1 1

ELECTRONIC CARD TILLER ARM A2

Electrical systems – 5000

Electrical wiring diagram Order number 249896-040

Electrical systems – 5000 Electrical wiring diagram Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

I 0

LED_GREEN

LED_RED

X11:8

X11:9

X11:10 0V DC

-0# X11:7

789

9 8 7

X11:6

456 X11:5

5 4

123 X11:4

369# X11:3

3 2

2580 X11:2

KEY BOARD A17

147X11:1

ELECTRONIC CARD TILLER ARM A2

7/16 PROD G 220241

Order number 249896-040

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 17

Sh. 5 9

S31

S90 2

Y52 1 2

Date 2007-05-11

8/16 PROD G 220241

INP. SUPPORT ARM AT BOTTOM

INP. SUPPORT ARM AT TOP

OUT. FORK/SUP. ARM VALVE

OUT. SUPPORT ARM LOWERING VALVE

Service Manual Y41 1 2

11- 18

Valid from serial number 985777-

TRANSISTOR REGULATOR A3

T-code 789, 790, 791, 817, 818

Sh. 4

ONLY TRUCKS WITH SUPPORT ARM LIFT

Electrical systems – 5000

Electrical wiring diagram Order number 249896-040

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Service Manual

120

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

F53

30A

F52

S65

STEER ANGLE SENSOR R2

X10 3 X10 4

X10 2

X10 1

120

119

INP. ENABLE

OUT. SUPPLY 0V DC

INP. REFERENCE SWITCH

OUT. SUPPLY +12V DC

OUT. SUPPLY 0V DC

INP. A_IN1

INP. A_IN0

OUT. SUPPLY +5V DC

CAN LOW

CAN HIGH

POWER SUPPLY +24V DC

POWER SUPPLY 0V DC

POWER SUPPLY OV DC

9/16 PROD G 220241

Valid from serial number 985777-

Sh. 1

Sh. 5

119

Date 2007-05-11

Sh. 5

Sh. 3

Sh. 8 10

ELECTRONIC CARD STEER SERVO A5

Order number 249896-040

ONLY TRUCKS WITH SERVO

Electrical systems – 5000 Electrical wiring diagram

T-code 789, 790, 791, 817, 818

11- 19

Sh. 9 11

S56 2

OVERHEAD GUARD

S59

S53 2

X:S19

INP. GATES DOWN

INP. GATES UP

10/16 PROD G 220241

INP. PLATFORM NOT FOLDED UP

INP. MAN ON PLATFORM

Service Manual X:S19

11- 20 3

Valid from serial number 985777-

TRANSISTOR REGULATOR A1

T-code 789, 790, 791, 817, 818

Sh. 8 11

PLATFORM FOLDING UP, WITH GATES

Electrical systems – 5000

Electrical wiring diagram Date 2007-05-11 Order number 249896-040

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Service Manual

Sh. 10 12

S59

S56 2

OVERHEAD GUARD

1 3

S19

S53 2

INP. GATES DOWN

INP. GATES UP

11/16 PROD G 220241

INP. PLATFORM NOT FOLDED UP

INP. MAN ON PLATFORM

TRANSISTOR REGULATOR A1

Valid from serial number 985777-

Order number 249896-040

Sh. 10 12

PLATFORM STAYING DOWN, WITH GATES

Electrical systems – 5000 Electrical wiring diagram

T-code 789, 790, 791, 817, 818

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 21

S19

X:S59

X:S53

X:S56

X:S59

X:S53

X:S56

INP. GATES DOWN

INP. GATES UP

12/16 PROD G 220241

INP. PLATFORM NOT FOLDED UP

INP. MAN ON PLATFORM

Service Manual 1

11- 22

Valid from serial number 985777-

TRANSISTOR REGULATOR A1

T-code 789, 790, 791, 817, 818

Sh. 11 14

Sh. 11 13

BACK PROTECTION, WITH FIXED PLATFORM SIDE PROTECTION, WITH FIXED PLATFORM

Electrical systems – 5000

Electrical wiring diagram Date 2007-05-11 Order number 249896-040

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Electrical wiring diagram T-code 789, 790, 791, 817, 818

INP. GATES DOWN

INP. GATES UP 10

INP. PLATFORM NOT FOLDED UP 14

X:S56 X:S56 Sh. 12 14

NO PLATFORM, NO GATES

INP. MAN ON PLATFORM

13/16 PROD G 220241

Valid from serial number 985777-

Date 2007-05-11

TRANSISTOR REGULATOR A1

Order number 249896-040

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 23

Electrical systems – 5000 Electrical wiring diagram

INP. GATES DOWN

14/16 PROD G 220241

X:S56

TRANSISTOR REGULATOR A1 S19

S59

X:S56

3 40 Sh. 12 15

Sh. 13 15

PLATFORM STAYING DOWN, WITHOUT GATES

INP. GATES UP

Service Manual

Order number 249896-040

11- 24

Date 2007-05-11

INP. PLATFORM NOT FOLDED UP

Valid from serial number 985777-

INP. MAN ON PLATFORM

T-code 789, 790, 791, 817, 818

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Electrical wiring diagram

Service Manual

S59

INP. GATES DOWN

X:S56

INP. GATES UP

INP. PLATFORM NOT FOLDED UP 57

INP. MAN ON PLATFORM 13

56 X:S19 X:S19

Sh. 14

1 Sh. 14 16

PLATFORM FOLDING UP, WITHOUT GATES

T-code 789, 790, 791, 817, 818

15/16 PROD G 220241

Valid from serial number 985777-

TRANSISTOR REGULATOR A1

Date 2007-05-11

Order number 249896-040

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 25

Sh. 15

X11

Y18 1 2 X11

X11

OUT. FOURTH HYD.FUNCTION (2B)

OUT. FOURTH HYD.FUNCTION (2A)

OUT. THIRD HYD.FUNCTION (1B)

OUT. THIRD HYD.FUNCTION (1A)

S115

S114

BLUE1

BLUE2

BLACK1

BLACK2

X2:2/4 OUT. 0VDC

X2:2/5 INP. OPTION BUTTON 5

X2:2/2 OUT. 0VDC

X2:2/3 INP. OPTION BUTTON 4

16/16 PROD G 220241

Service Manual X11

X11

11- 26

Y19 1 2

Y17 1 2

Y16 1 2

Valid from serial number 985777-

TRANSISTOR REGULATOR A3

ELECTRONIC CARD TILLER ARM A2

T-code 789, 790, 791, 817, 818

THIRD AND FOURTH HYD.FUNCTION

OPTION

Electrical systems – 5000

Electrical wiring diagram Date 2007-05-11 Order number 249896-040

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Functional description Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.4 Functional description means constantly on

means flashing.

This section gives basic electrical descriptions of the truck’s main functions in tabular form. It describes, in simple terms, what happens when performing any of the truck’s main operations. • Event - The main stages in performing any of the truck’s main functions are referred to as “Events”. Each event is numbered. • Prior events - Indicates the event number which must have taken place immediately before in order for current event function correctly. • Action(s) - A required action from the operator for the event to occur • Influencing elements - conditions which must be fulfilled in order for the event to occur. Certain parameter settings may also affect the outcome of the event. • Resulting conditions - Describes key occurrences which can be checked to confirm operation. Note that “resulting conditions” show what is expected when no error conditions are present. Items shown in square brackets [ ] refer to electrical component designations as stated in the electrical wiring diagrams. Unless otherwise stated, high ≈ 24 V and low ≈ 0 V

11.4.1 Principle of operation Table 10: Principle of operation Event:

1. Battery connected

Action(s)

Connect the traction battery [X1, G1]

Influencing elements

Main power fuses ok [F1, F3] Operating circuit fuses ok [F50, F51, F52, F53] PTC resistor ok [R1]

Resulting conditions

24V (control) supplied directly to [A2], [A5] and via R1 to [A1], [A3], [A5] Curtis status LED blinks once every 5 seconds.[A1]

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 27

Electrical systems – 5000 Functional description T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 10: Principle of operation Event:

2. Switch on (PIN-code entry)

Prior event(s)

Action(s) Enter valid PIN-code and press

[A17]

Influencing elements

Emergency switch-off closed [S21] [INP.SUPPLY +24V] high Tiller arm in drive not activated [S10] [INP.TILLER ARM IN DRIVE POS] low

Resulting conditions

Power lamp and

lights. Main display shows hour meter reading for 4 seconds followed by battery condition as a per-

centage of full charge and

[A6]

Mechanical brake remains on [Y1, A1:OUT.BRAKE] high Main contactor output remains high [A1:OUT.MAIN CONTACTOR] and Main contactor remains open [K10]

Event:

3. Tiller am lowered for driving

Prior event(s)

Action(s)

Lower tiller arm handle

Influencing elements

Tiller arm in drive sensor [S10]

Resulting conditions

Tiller arm in drive sensor activates [S10] [INP.TILLER ARM IN DRIVE POS.] high Brake solenoid control [A1:OUT.BRAKE] remains high Brake remains on [Y1] Main contactor output [A1:OUT.MAIN CONTACTOR] goes low Main contactor closes [K10] 24V (power) supplied to [A1],[A3] & [A5]

Event:

4. Traction, forks first

Prior event(s)

Action(s)

Move butterfly [L1] in forks drive direction.

Influencing elements

Butterfly Hall sensors [A2:S10-18] Platform staying down sensor [S19]. Platform not up sensor [S59] Gates up sensor [S53], Gates down sensor [S56] Fork load supervision sensor [B4] Parameter settings. See “11.4.4 Speed limitation” on page 34

Resulting conditions

[A1:OUT.BRAKE A] goes low Brake solenoid control [A1:OUT.BRAKE] goes low & brake coil [Y1] energises, mechanical brake releases Current fed to traction motor field winding (S2 +ve and S1 -ve) Pulsed current fed to traction motor armature proportional to butterfly deflection

11- 28

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Functional description Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 10: Principle of operation Event:

5. Traction, drive wheel first

Prior event(s)

Action(s)

Move butterfly [L1] in drive wheel drive direction.

Influencing elements

Butterfly Hall sensors [A2:S1-9] Platform staying down sensor [S19]. Platform not up sensor [S59] Gates up sensor [S53], Gates down sensor [S56] Fork load supervision sensor [B4 See “11.4.4 Speed limitation” on page 34

Resulting conditions

[A1:OUT.BRAKE A] goes low Brake solenoid control [A1:OUT.BRAKE] goes low & brake coil [Y1] energises Current fed to traction motor field winding (S2 -ve and S1 +ve) Pulsed current fed to traction motor armature proportional to butterfly deflection

Event:

6. Neutral braking

Prior event(s)

4 or 5

Action(s)

Let butterfly [L1] return to neutral position.

Influencing elements

Fork load supervision sensor [B4] Parameter settings

Resulting conditions

Traction motor [M1] acts as generator and via transistor controller [A1] converts the trucks energy of motion into electrical energy thus reducing the truck’s speed. The excess electrical energy is fed back to the battery helping to recharge it [G1]. The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes to a complete stand still

Event:

7. Reverse braking

Prior event(s)

4 or 5

Action(s)

Move butterfly [L1] so as to reverse the direction of travel

Influencing elements

Man-on platform switch [S19] Fork load supervision sensor [B4]

Resulting conditions

Traction motor [M1] acts as generator and via transistor controller [A1] converts the trucks energy of motion into electrical energy thus reducing the truck’s speed. The excess electrical energy is fed back to the battery helping to recharge it [G1]. The braking effect increases the more the butterfly is deflected The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes to a complete stand still

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 29

Electrical systems – 5000 Functional description T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 10: Principle of operation Event:

8. Mechanical brake operation

Prior event(s)

4 or 5

Action(s)

Move tiller arm handle to upper or lower position

Influencing elements

Tiller arm in drive sensor goes low [S10]

Resulting conditions

The mechanical brake [Y1, A1:OUT.BRAKE A] activates

Event:

9. Steering

Prior event(s)

Action(s)

Steer tiller unit handle to left or right

Influencing elements

Steering angle potentiometer [R2] Steering reference switch [S65, A5:INP.REFERENCE SWITCH] Man on platform switch [S19, A1:INP.DRIVER ON PLATFORM]

Resulting conditions

Steer servo motor positions drive wheel according to tiller handle’s deflection [A5, M6] (See section “11.4.2 Description of steering system”.)

Event:

10. Fork lifting

Prior event(s)

Action(s)

Operate fork lift control [R14] in lifting direction

Influencing elements

Forks lift control [R14] Battery status ok (>20% charge left) Gates up sensor [S53], Gates down sensor [S56] Max permitted lift height with gates up sensor [S33/2] Support arms at bottom sensor [S90] Fork load supervision sensor [B4]

Resulting conditions

Current fed to lift motor [M3] field winding (S2 -ve and S1 +ve) Pulsed current fed to lift motor armature proportional to lift control deflection Pump motor [M3] operates

Event:

11. Fork lowering

Prior event(s)

Action(s)

Operate fork lift control [R14] in lowering direction

Influencing elements

Forks lift control [R14]

Resulting conditions

[A1:OUT.MAGNET VALVE PWM] sends pulsed signal to fork lowering hydraulic valve [Y10]. Valve opens proportionally to signal allowing a variable lower speed.

11- 30

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Functional description Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 10: Principle of operation Event

12. Support arms lifting

Prior event(s)

Action(s)

Operate support arm lift button [A2:S19] i

Influencing elements

Support arm lift button [A2:S19] Battery status ok (>20% charge left) Support arm at top sensor [S31] Fork load supervision sensor [B4]

Resulting conditions

[A3:OUT.FORK/SUP:ARM VALVE] goes low & valve Y52 operates A set current is fed to lift motor [M3] field winding (S2 -ve and S1 +ve) Pulsed current fed to lift motor armature Pump motor [M3] operates & hydraulic pressure fed to support arm lift circuit

Event

13. Support arms lowering

Prior event(s)

Action(s)

Operate support arm lower button [A2:S20] i

Influencing elements

Support arm lower button [A2:S19] Support arm at bottom sensor [S90]

Resulting conditions

[A3:OUT.SUPPORT ARM LOWERING VALVE] goes low & valve Y41 operates support arm lift circuit pressure is drained to tank and support arms lower.

Event

14. Powertrak operation

Prior event(s)

10 / 11 / 12 / 13

Action(s)

Lift a load on forks and/or support arms

Influencing elements

Max permitted lift height for PowerTrak sensor [S33/1] Signal from pressure sensor [B4] and [B5]

Resulting conditions

System monitors pressure differences between [B4] [A3: INP. PRESSURE LIFT] and [B5] [INP. PRESSURE PT] and switches [Y58] [OUT. POWER TRAK DRAIN VALVE] and [Y59] [OUT POWER TRAK FILL-UP VALVE] to maintain a similar pressure in PowerTrak circuit. [A1:OUT POWERTRAK FILL-UP VALVE] low & [A1:OUT POWERTRAK DRAIN] high while fork lift height <1,8 m Lift pressure applied to PowerTrak cylinder. Fork lift height goes over 1.8m and [S33/1] [A3INP LIFT LIMIT POWER TRAK 1, <1,8M] goes low [A1:OUT POWERTRAK DRAIN VALVE] then goes low and valve [Y58] opens thus draining pressure from Powertrak cylinder

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

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Electrical systems – 5000 Functional description T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.4.2 Description of steering system The servo steering system on this truck comprises a synchronous DC motor [M6] with permanently magnetized rotor which is also brushless. This type of motor is ideal for truck steering applications due to light weight and high torque even from stand still. The motor directly drives the drive wheel gear unit, via an integrated 2 stage planetary gear. The steer motor is controlled by a fully electronic 4-quadrant regulator [A5] which is mounted directly in the servo motor casing. Hall sensors (H) in the servo motor provide timing information for commutation control. The sensors also provide the steer servo with position information. A double potentiometer [R2] situated below the tiller arm mounting provides steer angle information from the operator. Every time the traction battery is connected and the truck switched on the steer system performs a reference search for "straight ahead" position. An inductive proximity switch [S65] mounted in the final drive gear mounting plate registers a change in state (either ON to OFF or OFF to ON depending on drive wheel's initial position) and feeds this signal back to the steer servo. From this point on, the steer servo "knows" the position of the drive wheel. Only after the traction battery is next disconnected, is a new reference search carried out. The steer servo communicates fully via the CAN bus. All steer servo errors codes are transmitted to the truck's control system and displayed on the tiller unit's display.

11.4.3 Spider expansion unit (SEU) The Spider expansion unit ,referred to as the SEU, allows the main control card to handle a greater number of inputs & outputs. The SEU allows up to 8 extra digital inputs and 4 digital outputs which can be addressed and controlled via the CAN bus. The SEU contains firmware but this is only for internal configuration. No truck control logic is present in the SEU. This means a faulty SEU can be exchanged without affecting the truck’s functions in any way. There are 3 cases covering the usage of SEU: a) The SEU can be fitted if the truck is modified according to a customer special request. In this case, correct operation of the modification is acheived by adjustment of service parameters 16 to 19. b) The SEU is fitted as standard in certain truck models, to allow control of standard features. Such trucks do not require that service parameters 16 to 19 be activated. (parameters 16 to 19 shall be set to “0”.) c) Trucks fitted with an SEU as standard can also have additional modifications using “configurable options”. These additional modifications are controlled by the setting of service parameters 16 to 19. Refer to section Parameter #16 to #19 Configurable options on page 58 for more detailed information. .

Fig. 2 shows how the SEU is used to allow a greater number of functions to be controlled via the CAN bus. The SEU has one 42-pin mul11- 32

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Functional description Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

A2 Electronic card TLS

A3 Pump controller

Extra / Customised function(s)

CAN bus

A5 Steer servo

A36 SEU

X41

CAN service connector

A1 Traction controller Fig. 2 Connection architecture for SEU tipin connector which handles all inputs, outputs, CAN and supply signals.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 33

Electrical systems – 5000 Functional description T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.4.4 Speed limitation The truck’s maximum speed is limited by a combination of, fork lift height, fork load and operator’s driving position. Driver parameter settings also affect maximum speed. See “11.5.6 Summary of driver parameters” on page 41 for more information. The table below summarises the speed limitations and assumes that all relevant driver parameters are set to 100%. Note that the speeds given are nominal.

Table 11: Summary of speed limitations Load (kg)

Fork lift height (mm)

Driver position or mode

Max. speed (km/h)

<800

<1800

Platform down, gates up (transportation mode)

Platform down, gates down1

Platform up, gates down (pedestrian mode)1

Platform up, gates up

Platform down, gates up

Platform down, gates down1

Platform up, gates down (pedestrian mode)1

Platform up, gates up

Platform down, gates up (transportation mode)

8 - 72

Platform down, gates down1

Platform up, gates down (pedestrian mode)1

Platform up, gates up

Platform down, gates up (transportation mode)

Platform down, gates down1

Platform up, gates down (pedestrian mode)1

Platform up, gates up

<800

>800

>1800

<1800

>1800

Turtle mode is controlled by parameter # 7

Snail speed mode

≈ 1,6

Error / Warning code mode

≈ 2,5

1.The 7SLL20 & 7SLL20F do not have side guards; from an electric viewpoint, the side guards are considered to be in the lowered position. 2.Max. speed determined by actual load and will ramp between 8 & 7 km/h

11- 34

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Functional description Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.4.5 Hour meter and battery condition At switch on, the hour meter is displayed and the hour meter symbol lights for 4 seconds. Fig. 3 Fig. 3

Fig. 4

The display will then change to show the battery’s remaining capacity expressed as a percentage of full charge and the battery symbol lights. Fig. 4 The truck’s control system stores 5 different elapsed time values in units of hours. The time value normally shown depends on the setting of service parameter #20. (See “ # 20 - Hour meter selection” on page 48). However, any of these time values can be temporarily displayed on the hour meter. To choose which value to display carry out the following procedure: • Ensure the battery is connected. • Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold [S18] depressed until “H” is displayed, then release [S18]. Fig. 5

Fig. 5

Hour meter symbol lights. The different hour meter modes are displayed by repeatedly operating speed control [L1]. The actual time value will be displayed momentarily after the mode is selected.

Table 12: Hour meter modes Description

Display

Key time: Total time truck has been switched on Activity time: Combined time either pump or drive motor has been in operation (Default display mode) Drive motor time: Total time drive motor has been in operation Pump motor time: Total time pump motor has been in operation Remaining time to next service (Parameter #25 controls the initial value) See “ # 25 - Service interval” on page 49 for more information.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 35

Electrical systems – 5000 Functional description T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.4.6 TLS - Truck log system (optional) General The truck log system, which is CAN based, is either an integrated system (SD16) or a freestanding supplementary system (S16). A collision sensor can also be connected. The TLS communicates wirelessly with a base station (RG3) once the truck is within range. The base station then receives information on what the truck has done since they last communicated with one another.

Built-in system

A2 Electronic card

RG3

TLS SD16 CAN bus

CAN bus

Add-on system

Shock sensor

A1 Traction controller

TLS S16

Shock sensor

I/O-unit Registration To register the truck with the base station, follow the instructions below: • Position the truck close to the base station. • Press and hold the green button for approx. 5-10 seconds until three LEDs on the base station start flashing at the same time. The base station can now communicate with the truck whenever it is within range.

Logging in/out SD16 Logging in and out is performed as usual via the keyboard on the handle (or by using an ID unit). The difference is that communication passes through the TLS, which makes all the decisions.

Logging in/out S16 Logging in and out is performed using the keyboard on the TLS. 11- 36

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7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Functional description Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Collision sensor If there is a collision sensor installed on the CAN bus, it registers when the truck bumps into something. If the impact exceeds a certain level, it is classified as a collision and the truck comes to a halt. It can be reset by entering the PIN code for “resetting the collision sensor” (see table below).

Settings Additional equipment (software and wiring) from Davis Derby is required to change the TLS settings.

Table 13: Settings TLS Function

Description

Default setting

PIN code

PIN code for different driver profiles.

00001 (profile 1) 00002 (profile 2) 00003 (profile 3) 11111 (resetting the collision sensor)

Logoff time

Time in minutes (1-254) that the truck is inactive before it is switched off.

255 (not switched off)

Impact level

Determines how sensitive the truck is to an impact.

5 % (sideways) 5 % (forwards/backwards)

Department

Only applies when ID unit is installed.

Type of truck

Only applies when ID unit is installed.

11.4.7 ID unit (optional) See the separate manual that is included with the software.

Service Manual

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Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.5 Parameters 11.5.1 General The truck’s control system stores a number of parameters. These parameters are used to configure the truck for correct operation in the particular application for which it was designed. The parameters are divided into two groups, Driver parameters and Service parameters. • Driver parameters (1 to 9) - These parameters are used to tailor the driving characteristics of a truck for a specific driver or operation. Up to 10 sets of driver parameters can be stored. Driver parameters can be adjusted directly without the requirement for a suitable CAN service key.1 • Service parameters (10 to 39) - These parameters are used to tailor the truck’s performance / operation characteristics and include all other parameters not designated as driver parameters. Service parameters can ONLY be adjusted when a suitable CAN service key is plugged into the truck.2

11.5.2 Viewing parameters -CAN key not connected To select Parameter display mode carry out the following procedure: • Ensure the battery is connected. • Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig. 6

Fig. 6

Parameters symbol lights. The different parameters are now displayed by repeatedly operating speed control [L1]. Driver parameters can be both viewed and changed.1

1.Driver parameters can only be set without a CAN key if parameter #39 is set to value 3. See “ # # 39 - Log-in method & operator parameter access” on page 54 2.Service parameters can be viewed without a CAN key being plugged in but they cannot be adjusted. 11- 38

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.5.3 Viewing parameters - CAN key connected • Ensure the battery is connected. • Connect a suitable CAN-service key to [X41]. • Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button [S18] for at least 1 second and then press

on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig. 7

Fig. 7

Parameters symbol lights. Operating speed control [L1] in the forward direction causes the display to show the first set of driver parameters. Continued operation of speed control [L1] in the forward direction will then cause display to show the next set of driver parameters (for driver no.2) and so on, up to the last driver (Driver no. 10). See Fig. 8

Driver parameter no. Parameter set no. Fig. 8

After the ten sets of driver parameters have been displayed, the trucks service parameters will be displayed when operating the speed control [L1] in the forward direction The truck’s service parameters can be displayed first by operating speed control [L1] in the backward direction. This will cause parameter #40 to be displayed and then parameter #39 etc.1

1.Certain parameters numbers displayed are not active in this truck model. © TIEE SARL

Service Manual

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11- 39

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.5.4 Setting Driver parameters To change the value of a particular driver parameter carry out the following: • Switch on the truck and log in with the appropriate PIN-code. This is important if the truck has more than one set of Driver parameters active. Any changes made will only be in effect when that particular “driver” is logged in. • Select the required parameter using [L1]. • Press Horn button [S18].

Parameter symbol flashes.

• Set parameter value by repeatedly operating speed control [L1] up or down • Press Horn button [S18] once to confirm the new setting.

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing

on the keypad

You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid. For detailed descriptions and effects of these parameters.see the section “11.5.6 Summary of driver parameters” on page 41

11.5.5 Setting Service parameters To set any of the Service parameters, a suitable CAN service key must be plugged into the truck’s external CAN connector [X41]. Service parameters are not driver specific. When a CAN service key is plugged in, it is not necessary to enter a PIN-code prior to pressing on the key pad. Once the CAN service key is plugged in, the procedure is the same as setting Driver parameters. For detailed descriptions and effects of these parameters see the section “11.5.8 Summary of service parameters” on page 43. NOTE! Truck handling. Modifying specific truck parameters will change the driving characteristics of the truck. Do not change any parameters without the necessary know how.

11- 40

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.5.6 Summary of driver parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in sections “11.5.2 Viewing parameters -CAN key not connected” on page 38 and “11.5.6 Summary of driver parameters” on page 41

See also section “11.4.4 Speed limitation” on page 34 for information regarding the maximum speeds of the truck.

Parameter

Table 14: Summary of driver parameters

Name

Unit

Min. Max. Step Std. Note

Maximum speed, high range

100

100 S 10:

100:

S= maximum speed 03

Maximum acceleration

100

80 A 10:

100:

A= maximum acceleration 04

Neutral braking effect

100

70 F 5:

100:

F= neutral brake force 06

Maximum speed -low range

100

100 S 10:

100:

S= maximum speed 07

Maximum speed- “Turtle”

100

60 S 10:

100:

S= maximum speed

Service Manual

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Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.5.7 Description of driver parameters # 2 - Maximum speed, high range Allows adjustment of the maximum speed of the truck in the high speed range. The high speed range is active when the gates are folded out, the platform is down and the forks are below 1,8 m.

# 3 - Maximum acceleration Allows adjustment of the truck’s maximum acceleration. The lower the value of the parameter the longer it takes to accelerate the truck to the demanded speed control lever position [L1].

# 4 - Neutral braking effect Allows adjustment of the neutral braking force applied when speed control lever [L1] returns to the neutral position. The lower the value of the parameter the longer it takes to bring the truck to a standstill.

# 6 - Maximum speed, low range Allows for adjustment of the maximum speed of the truck in the low speed range. The low speed range is active when the gates are folded down and ptatform folded up. This parameter also affects the stacking speed mode when the forks are above 1,8 m.

# 7 - Maximum speed, “Turtle” mode Allows for adjustment of the maximum speed of the truck in the “Turtle” mode.

11- 42

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.5.8 Summary of service parameters NOTE! Before changing any parameters, ensure you have read and understood the procedures for viewing and setting parameters in sections “11.5.3 Viewing parameters - CAN key connected” on page 39 and “11.5.8 Summary of service parameters” on page 43

Service Manual The CAN service key must be connected to the external CAN connector [X41] before adjusting any Service parameters

Table 15: Summary of service parameters Unit Min.

Max.

Step Std. Note

PIN-code

9999

Creep speed

-10

Parameter

Name

PIN code assignment. NOTE: Not applicable if Parameter #39 has been set to the value 5, 6, 7 or 8. S -10:

+10:

S= Speed at first sensor 15

Non-configurable options 0 to 9

Standard value = “0” See Service Manual“11.5.10 Configurable “Option” Parameters” on page 57

Configurable option #1

Configurable option #2

Configurable option #3

Configurable option #4

These parameters provide correct operation of trucks which have been modified with an approved special request modification. If no such modifications are present on the truck, these parameters shall all be set to “0” See“11.5.10 Configurable “Option” Parameters” on page 57

Hour meter selection

Select which hour meter is normally displayed

Battery size

Battery size selection

Maximum fork lowering speed

255

180 L 1:

255:

L= max. lowering speed 23

Fork lower stop ramp

7 T 1:

20:

T= Stop ramp time © TIEE SARL

Service Manual

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Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

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Order number 249896-040

Table 15: Summary of service parameters Unit Min.

Max.

Step Std. Note

Service interval

2000

Setting of service intervaltimer.

Selection of hydraulic unit

Selection of hydraulic unit 0: Previous model 1: Current model.

Log off

min.

Time interval to automatic log off

Calibrate

Calibrate fork lift OR steer servo

Steering offset

1/10°

-50

Trim steering -300:30° to left 300:30° to right

Steer servo activated

Activates steer servo, when fitted

Access code

State which level of authorization the driver has to the driver parameters. Odd values indicate open operator parameters, while even values indicate that the operator parameters must be opened with a CAN key.

Parameter

Name

11- 44

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Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.5.9 Description of service parameters # 10 - PIN code NOTE: On delivery of the truck, the PIN code for driver 1 must be changed to a four-digit code to prevent unauthorised use.

NOTE: The functionality of parameter #10 is ignored if the value of parameter #39 has been set to 5, 6, 7 or 8. PIN code input is facilitated via the extended keypad. For detailed information, see the section Extended keypad - General on page 54.

The parameter stores the truck’s active PIN-codes. The truck can store up to ten PIN-codes. Each PIN-code has a set of parameters associated with it, called driver Parameters. Entering a particular PIN-code at start-up will make the selected PIN-code’s driver parameters active. This allows up to ten operators to individually adjust the characteristics of the truck. On delivery the truck has one default PIN-code stored which is “1“.

To enter a new PIN-code: • Operate [L1] repeatedly in the forward direction to select parameter #10. After one second, the display will show the PIN-code for this driver. • Repeat the step above until parameter#10 for the next driver is displayed, the display will either show PIN-code for that driver OR “0”(zero). • Repeat the step above until the PIN-code displayed is “0”(zero) • Press Horn button [S18]

Parameter symbol flashes.

• Operate [L1] to set the desired value of the new PIN-code.1 • Press Horn button [S18]

Parameters symbol lights. (stops flashing). The new PIN-code has now been entered.

1.Operating [L1] lightly will step the value in increments of 1. Operating [L1] fully will step the value in increments of 100 Valid values are 1 to 9999 © TIEE SARL

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Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

To remove an existing PIN-code: • Operate [L1] repeatedly in the forward direction to select parameter #10. After one second, the display will show the PIN-code for this driver. • Repeat the step above until the PIN-code to be removed is displayed. • Press Horn button [S18]

Parameter symbol flashes.

• Operate [L1] to set the PIN-code value to “0”(zero). • Press Horn button [S18]

Parameters symbol lights. (stops flashing). The selected PIN-code has now been removed. To check whether a PIN-code will start the truck follow the procedure in Table 10, “Principle of operation,” on page 27 (Event 2 -Switch on (PIN code entry) Parameter #10 cannot be displayed without the CAN service key.

# 14 - Creep speed This parameter allows adjustment of the initial speed when the first Hall sensor is activated in the speed control [L1].

#15 - Non-configurable options Up to 16 so called sub-parameters are stored and accessed via parameter #15. These options are either switched ON or switched OFF and require no other adjustments. They are therefore called non-configurable options. The number of available options is dependant on the truck type. Consult table Parameter #15 Non-configurable options on page 47 for available options.

Setting Non-configurable options • Ensure the truck is in the parameter mode.

The parameters symbol lights. • Select parameter #15 using [L1]. The first sub-parameter will be displayed Continued operation of the speed control [L1] will display the next subparameter. Note also that only relevant sub-parameters will be displayed. 11- 46

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Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

After 1 second the value of the sub-parameter will be displayed • Press horn button [S18].

Parameter symbol flashes.

• Set the sub-parameter value by repeatedly operating speed control [L1] up or down. See Table 21: for details. • Press horn button [S18] once to confirm the new setting.

The parameters symbol lights. (stops flashing).

• Switch off the truck by pressing

on the keypad.

The non-configurable option will now be activated. • Ensure the option operates correctly before returning the truck for normal use. P

Sub-parameter No.

Option name

Function ON

Function OFF

Default setting

Table 16: Parameter #15 Non-configurable options Value

NOTE!

"Turtle" function

Safety reversing audible signal

3 to 16

N/A at present

#16 - Configurable option #1 See “11.5.10 Configurable “Option” Parameters” on page 57.

#17 - Configurable option #2 See “11.5.10 Configurable “Option” Parameters” on page 57.

#18 - Configurable option #3 See “11.5.10 Configurable “Option” Parameters” on page 57. © TIEE SARL

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 47

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

#19 - Configurable option #4 See “11.5.10 Configurable “Option” Parameters” on page 57.

# 20 - Hour meter selection This parameter determines which hour meter mode to display during normal use.

Table 17: Hour meter parameter selection Value

Description

Key time: Total time truck has been switched on

Activity time: Combined time either pump or drive motor has been in operation (Default display mode)

Drive motor time: Total time drive motor has been in operation

Pump motor time: Total time pump motor has been in operation

Remaining time to next service (Parameter #25 controls the initial value) See “ # 25 - Service interval” on page 49 for more information

11- 48

Display

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

# 21 - Battery size This parameter matches the discharge indication to the characteristics of the battery fitted. To adjust the disconnection point of the battery discharge indicator, measure according to: • Acid concentration when fully charged battery. To check quality of battery. Shall be between 1,27-1,29. • When you get lift cut-out (80% discharged of battery capacity) you shall have close to 1,15 not less. The acid concentration can vary depending on battery brand.

Table 18: Battery size parameter Value

Function

↑

Less discharged

Battery (Ah) 450 Ah

6 7

More discharged

↓

250 Ah

9 WARNING! Ensure you have set the parameter correctly. The battery may otherwise be irreparably damaged.

# 22 - Maximum fork lowering speed This parameter allows adjustment of the maximum fork lowering speed

# 23 - Fork lower stop ramp This parameter adjusts the time interval between releasing the fork lower control and fork lower valve completely closing. Decreasing the parameter value will shorten the time interval resulting in a “harder” fork stop. Increasing the parameter value will make the fork stop more “gentle”

# 25 - Service interval This parameter determines the time value in hours to the next service from 0 to 2000 hours in steps of 50 hours. Whenever this value is changed the timer is reset and will start counting activity time up to the set value. On reaching the set value caution code 29 (C29) will be shown on the display.

# 26 - Selection of hydraulic unit This parameter sets the model of the hydraulic unit installed on the truck. © TIEE SARL

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 49

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

# 35 - Log off This parameter determines the time interval before the truck automatically logs off when truck has been idle. A value of “0”(zero) disables the function.

# 36 - Calibrate This parameter is used to perform calibration of fork lower start point, automatic calibration of maximum load, manual calibration of maximum load and steering servo: NOTE: During calibration, the CAN key must have been connected and the brake applied. The gates and support arms should be in the lowered position. Value 0 : No calibration value active (default value) Value 1 : Calibration of the steering servo potentiometer • Select parameter #36 and set its value to 1. • Switch off the truck by pressing

Press

on the keypad.

on the keypad. The display shows

• Turn the steering lever to the left all the way to the mechanical end stop and depress the horn button [S18].

The display shows • Turn the steering lever to the right all the way to the mechanical end stop and depress the horn button [S18].

The display shows • Switch off the truck by pressing

on the keypad.

Value 2 : Valve startpoint for fork lower To optimize the fork lowering function it is necessary to “trim” the control signal for the proportional lowering valve. The point when the valve just starts to open is called the valve start point. To calibrate the valve start point perform following procedure: • Select parameter #36 and set its value to 2. • Switch off the truck by pressing

11- 50

Service Manual

on the keypad.

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

Press

T-code 789, 790, 791, 817, 818

on the keypad. The display shows

• With a load on the forks (between 300 kg & max. load) lift to approximately 1 m above the floor. • Press and hold depressed the horn button [S18]. The display will show a counter value representing the valve control signal. After a delay, the forks will begin to lower. • Release the horn button [S18] immediately the forks begin to lower. SAFETY NOTE! Releasing the horn button [S18] before the calibration is complete stops all truck’s functions and therefore functions as a “dead man’s handle”

The display will show the calibration value for 3 seconds followed by . • Switch off the truck by pressing • Press

on the keypad.

on the keypad. Valve start point calibration is now complete

Value 3 : Automatic calibration of maximum load • Select parameter #36 and set its value to 3. • Switch off the truck by pressing

• Press

on the keypad.

on the keypad. The display shows

• With truck’s rated load + 100 kg on the forks, lift the forks above the initial lift height. • Press and hold depressed the horn button [S18]. The calibration sequence will now commence. The lift pump motor will start and the forks will lift. During this procedure the system pressure is analysed and the calibrated value is shown on the display. The whole procedure lasts approximately 6 seconds. After the lift pump motor stops the display will show the calibration value for 3 seconds followed by

• Release the horn button [S18]. SAFETY NOTE! Releasing the horn button [S18] before the calibration is complete stops all truck’s functions and therefore functions as a “dead man’s handle” © TIEE SARL

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 51

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

• Switch off the truck by pressing Press

Order number 249896-040

on the keypad.

on the keypad. Automatic max. load calibration is now complete

Value 4 : Manual calibration of maximum load SAFETY NOTE! Under no circumstances shall the maximum load setting be increased above the truck’s rated load capacity + 100 kg.

The maximum load can be set manually in this mode without the requirement of a test load on the forks. It is necessary, therefore to establish the correct value to be entered. See Table 19: below • Select parameter #36 and set its value to 4. • Switch off the truck by pressing • Press stored.

on the keypad.

on the keypad. The display shows the present value

• Press the horn button [S18] • Set parameter value by repeatedly operating speed control [L1] up or down. See Table 19: • Press the horn button [S18] to store the new value. The display will .

show

Table 19: Man. max.load calibration values Mast

1250

1600

DxTele

≈ 270-280

DxHiLo

≈280-290

TxHiLo

≈ 280-290

NOTE! The values given in the table above are nominal and based on brand new, cold machines. Minor adjustment of these values may be necessary to compensate for stiffness in mast guides, chains etc.

- Value 1 : Calibrate the steer servo. The calibration establishes the steering centre position (straight ahead). The system calculates the steering straight position by measuring the difference between “steer full left” and “steer full right”. Situations which may require that this calibration be performed are: • The truck deviates from a straight line when tiller arm is in neutral position. • Occurrences of error codes E121 or E135 11- 52

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Before performing this calibration, ensure the drive wheel in centre sensor [S65] is functioning and correctly adjusted. To calibrate the steer servo perform following procedure: • Select parameter #36 and set its value to 1. • Switch off the truck by pressing

• Press

on the keypad.

on the keypad. The display shows

• Turn the tiller arm fully to the left until end stop is reached.

• Press horn button [S18]. Display now shows • Turn the tiller arm fully to the right until end stop is reached.

• Press horn button [S18]. Display now shows • Switch off the truck by pressing • Press

on the keypad.

on the keypad. Steering calibration is now complete

# 37 - Steering offset This parameter can be used to “trim” the actual steering position of the drive wheel in relation to the position of the steering tiller. It should only be adjusted after having performed a steering calibration (parameter #36) A situation which may require that this parameter be adjusted is if the truck tends to drift away from a straight ahead course when driving over longer distances Many factors can contribute to this. It is therefore advisable to make adjustments to this parameter on a trial and error basis. Whenever this parameter is adjusted, it is necessary to restart the truck. (Disconnect and reconnect battery)

# 38 - Steer servo activated If the truck is equipped with steer servo it must be activated by setting this parameter. Value 0 - Steer servo not activated (default) Value 1 - Steer servo activated

Service Manual

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11- 53

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

# # 39 - Log-in method & operator parameter access This parameter determines which function will used for log-in and whether or not the operator is allowed to adjust the operator parameter settings. • Value 1 - Key switch installed - Operator parameters accessible without CAN service key. • Value 2 - Key switch installed - Operator parameters NOT accessible without CAN service key. • Value 3 - Keypad (standard 10 PIN codes) - Operator parameters accessible without CAN service key. • Value 4 - Keypad (standard 10 PIN codes) - Operator parameters NOT accessible without CAN service key. • Value 5 - Extended keypad (100 PIN codes) - Operator parameters accessible without CAN service key. • Value 6 - Extended keypad (100 PIN codes) - Operator parameters NOT accessible without CAN service key. • Value 7 - Extended keypad (100 PIN codes) + TLS - Operator parameters accessible without CAN service key. • Value 8 - Extended keypad (100 PIN codes) + TLS - Operator parameters NOT accessible without CAN service key. • Value 9 – ID unit – Driver parameters accessible without CAN service key. • Value 10 – ID unit – Driver parameters NOT accessible without CAN service key. • Value 11 – ID unit + TLS – Driver parameters accessible without CAN service key. • Value 12 – ID unit + TLS – Driver parameters NOT accessible without CAN service key.

Extended keypad - General The truck can be programmed with a maximum of 10 operator profiles. The extended keypad then enables a maximum of 10 PIN codes to be assigned to each operator profile. This makes it possible to handle up to 100 different PIN codes. If the extended keypad is activated, handling of standard PIN codes that are normally accessible via parameter #10 is ignored.

11- 54

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Extended keypad - Programming A group of PIN codes can be made accessible by defining them as a block. Block no. 0 is activated in the default setting. This means that 3 different operator profiles can be accessed from the very start. Activation of other blocks will make all the PIN codes for that block accessible (see Table 21:). If all 10 blocks have been activated, then 10 PIN codes will be accessible for the operator profile. The truck firmware stores a standard PIN code set as depicted in Table 21: These PIN codes can be adjusted to any value, however, it is advisable to avoid identical PIN codes in different operator profiles. Starting programming using the extended keypad: • Connect a suitable CAN service key to [X41]. • Enter code 341671 and depress

on the keypad.

• Select a programming command from Table 20:

Table 20: Programming commands - extended keypad Programming

Function

Note

Reset to default settings

Blocks 1 - 9 are disabled. The original PIN codes are reset according to Table 21: B = Block no. 0 - 9

Depress “2” + B +

The PIN codes in the block can be used

B = Block no. 0 - 9

Depress “3” + B +

The PIN codes in the block cannot be used

Depress “4” + B + F + NNNN +

Programming of a new PIN code

B = Block no. 0 - 9 F = Operator profile no. 0 - 9 NNNN = PIN code

Depress “1” +

• Switch off the truck by pressing

on the keypad.

Programming of the extended keypad is now complete. Parameter #39 must be set to the value 5, 6, 7 or 8 in order for the new PIN codes to take effect. Perform a test by logging in with one of the new PIN codes. It is important to verify that the correct operator profile is enabled when a specific PIN code is entered, especially if an operator profile has been programmed for a specific application or special goods handling.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 55

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 21: The table shows the standard PIN codes in the firmware. These can be activated for use or changed according to the preferences of the operator. One or more of these blocks can be activated. When logging in normally, an operator profile is activated when any of the PIN codes in an activated block is entered. The truck firmware will deny log-in if PIN code “0000” is used. Service technicians are requested to keep notes on activated blocks, PIN code changes and special operator profile settings. NOTE: If the extended keypad is reset, this does NOT affect the operator profile settings.

Table 21: Standard Pin-code assignment with extended keypad Driver Profile no

Profile 0

Profile 1

Profile 2

Profi le3

Profile 4

Profile 5

Profile 6

Profile 7

Profile 8

Profile 9

Block 0

0000

0001

0002

0003

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

11- 56

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.5.10 Configurable “Option” Parameters WARNING! The information in this section is not intended as a programming reference and is included solely to allow the reader to gain a thorouth understanding of parameter setting / checking. Do not attempt to make any adjustments to these parameters unless you have sufficient knowledge of the truck’s options/ modified functions. This manual only covers the truck’s standard equipment. Specially modified trucks may require that you have access to special service information. Improper adjustment of the option service parameters may compromise safe operation and / or result in a malfunction.

General Parameters #16 to #19 are reserved in the truck’s control system for extra truck options and/or special product modifications. The parameters configure and control the behavior of the Spider expansion unit (SEU) which must be fitted in the truck. See “11.4.3 Spider expansion unit (SEU)” on page 32. This method of implementation allows the standard software program to be used without the need for a specialised software. Normally, these parameters are configured by the manufacturer when the truck is modified or customized. It is advisable to upload the parameter settings from trucks which are modified. In the event the main control card[A2] is changed, the original parameter settings can then be transferred to the new card thus ensuring the special option functions correctly. Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a maximum of 4 preprogrammed “base options” to be activated and configured to suit a specific special option or customisation. See table below.

Table 22: Summary of base options Base option no.

Function

Refer to..

Pressing an option button controls a digital o/p

table 23 on page 60

Activating a digital input will reduce maximum drive speed

table 24 on page 61

Specific truck movement(s) activates a digital o/p

table 25 on page 62

Activating a digital input causes main contactor to close

table 26 on page 65

Activating digital inputs will operate lift /lower

table 27 on page 66

Lift height can be restricted by activating a digital input + ability to override by pressing an option button

table 28 on page 68

Single-acting hydraulic function

table 29 on page 69

Double-acting hydraulic function

table 30 on page 70

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 57

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Parameter #16 to #19 Configurable options • Each parameter can be designated to hold a particular base option. • Each designated option has up to 4 arguments associated with it. • Each argument holds a value which configures that option.

16 - 0 - 1

Parameter no. (range 16-19) Argument: #0 holds option designator (displayed for 2 s only) Argument value (range 0 - 63) 0= no base option is activated for this parameter 1 to 6 = Base option no. See See separate tables)

OPTION ASSIGNATION

16 - 1- 1

Argument: #1, #2, #3 & #4 hold configurable values for the option Argument value (range depends on argument) Value depends on option and argument selected See separate table OPTION CONFIGURATION

Fig. 9 Configurable option layout Setting Configurable options To activate a configurable option the base option must first be assigned to one of the parameters #16 to #19. This is achieved by setting argument #0 to the base option number. Once it is assigned, the option’s arguments must be configured. This is achieved by setting a value for arguments #1, #2, #3 and #4. • Ensure the truck is in parameter mode.

Parameters symbol lights. • Select parameter #16, #17, #18 or #19 using [L1]. Argument #0 will be displayed After 1 second the argument’s value will be displayed. A value of “0” indicates no option is assigned to this parameter, in which case continued operation of the speed control [L1] will display the next parameter • Press Horn button [S18].

11- 58

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Parameter symbol flashes.

• Set argument #0 value by repeatedly operating speed control [L1] up or down. Refer to base option list Table 22: • Press Horn button [S18] once to confirm the new setting.

Parameters symbol lights. (stops flashing). • Select argument #1 by operating speed control [L1]. After 1 second the value of argument #1 will be displayed. • Press Horn button [S18].

Parameter symbol flashes.

• Set argument #1 value by repeatedly operating speed control [L1] up or down. Refer to base option list Table 22: • Press Horn button [S18] once to confirm the new setting.

Parameters symbol lights. (stops flashing). Adjust arguments #2, #3 and #4 using the same method as above. • Switch off the truck by pressing

on the keypad

The special option shall now be activated. • Ensure the special option operates correctly before returning the truck for normal use.

Service Manual

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11- 59

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 23: Base option 1 - Option button controls SEU output Argument #0

Option designator

Initial display

Values

Meaning

Sets relevant parameter to handle base option 1

(value shown after 2s)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

option is handled by SEU unit 1 [A36]

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s)

Argument #2

Selection of SEU digital output

Initial display

Values

Meaning

Pin no.

activate SEU digital o/p 1 (1,6A)

activate SEU digital o/p 2 (1,6A)

activate SEU digital o/p 3 (1,6A)

activate SEU digital o/p 4 (1,6A)

(value shown after 2s)

Argument #3

Selection of option button

Initial display

Values

Meaning

activated by option button 1

activated by option button 2

activated by option button 3

activated by option button 4

activated by option button 5

activated by option button 6

(value shown after 2s)

Argument #4

Type of switching

Initial display

Values

Meaning

activated when button is depressed

option is toggled when button is pressed

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

(value shown after 2s)

11- 60

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 24: Base option 2 - Reduced drive speed by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

Sets relevant option parameter to handle base option 2

(value shown after 2s)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

option is handled by SEU unit 1 [A36]

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s)

Argument #2

Selection of SEU digital input

Initial display

Values

Meaning

Pin no.

activate SEU digital i/p 1 (1mA)

activate SEU digital i/p 2 (1mA)

activate SEU digital i/p 3 (1mA)

activate SEU digital i/p 4 (1mA)

activate SEU digital i/p 5 (7mA)

activate SEU digital i/p 6 (7mA)

activate SEU digital i/p 7 (7mA)

activate SEU digital i/p 8 (7mA)

(value shown after 2s)

Argument #3

Speed limitation as a percentage of max. speed

Initial display

Values

Meaning

0-12

Max. speed adjustable from 40-100% formula: =40+5*Arg.3 e.g. 40+5*4=60%

(value shown after 2s)

Argument #4

Speed range

Initial display

Values

Meaning

Affects only high speed range

Affects only low speed range

Affects both speed ranges

(value shown after 2s)

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Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 25: Base option 3 - Truck movement activates SEU O/P Argument #0

Option designator

Initial display

Values 3

Meaning Sets relevant option parameter to handle base option 3

(value shown after 2s)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values 0 1

(value shown after 2s)

Meaning option is handled by SEU unit 1 [A36] option is handled by SEU unit 2 (second SEU unit)

Argument #2

Selection of SEU digital output

Initial display

Values 0 1 2 3

(value shown after 2s)

Meaning activate SEU digital o/p 1 (1,6A) activate SEU digital o/p 2 (1,6A) activate SEU digital o/p 3 (1,6A) activate SEU digital o/p 4 (1,6A)

Pin no. 16 30 1 2

...table continued on next page

11- 62

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 25: Base option 3 - Truck movement activates SEU O/P ...continued from previous page

Argument #3

Selection of activating movement

Initial display

Values

Drive forward

(value shown after 2s)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

X X

Drive backward

X X

X X X X

X X X X X X X X

X X

X X X X

X X

Any other movement

X X X X

X X

Lower forks

X X

Lift forks

X X

X X X X

X X X X X X X X

X X X X X X X X X X X X X X X X

...table continued on next page

Service Manual

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Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 25: Base option 3 - Truck movement activates SEU O/P ...continued from previous page

Argument #4

Output switching mode

Initial display

Values 0 1 2

(value shown after 2s)

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Service Manual

Meaning Output continuously on Output switches at 1Hz Output switches at 2Hz

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 26: Base option 4 - Activate main contactor by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

Sets relevant option parameter to handle base option 4

(value shown after 2s)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

option is handled by SEU unit 1 [A36]

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s)

Argument #2

Selection of SEU digital input

Initial display

Values

Meaning

Pin no.

activated by SEU digital i/p 1 (1mA)

activated by SEU digital i/p 2 (1mA)

activated by SEU digital i/p 3 (1mA)

activated by SEU digital i/p 4 (1mA)

activated by SEU digital i/p 5 (7mA)

activated by SEU digital i/p 6 (7mA)

activated by SEU digital i/p 7 (7mA)

activated by SEU digital i/p 8 (7mA)

(value shown after 2s)

Argument #3

Hold time in minutes

Initial display

Values

Meaning

0-30

Contactor is held on from 0 to 30 minutes after digital i/p is activated

(value shown after 2s)

Argument #4

Not used

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11- 65

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 27: Base option 5 - Activate lift/lower by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

Sets relevant option parameter to handle base option 5

(value shown after 2s)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

option is handled by SEU unit 1 [A36]

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s)

Argument #2

Selection of SEU digital inputs

Initial display

Values

Meaning

Pin no.

Lift - SEU digital i/p 1 Lower - SEU digital i/p 2 Lower inhibit - SEU digital i/p 3

5 19 33

Lift - SEU digital i/p 2 Lower - SEU digital i/p 3 Lower inhibit - SEU digital i/p 4

19 33 6

Lift - SEU digital i/p 3 Lower - SEU digital i/p 4 Lower inhibit - SEU digital i/p 5

33 6 20

Lift - SEU digital i/p 4 Lower - SEU digital i/p 5 Lower inhibit - SEU digital i/p 6

6 20 34

Lift - SEU digital i/p 5 Lower - SEU digital i/p 6 Lower inhibit - SEU digital i/p 7

20 34 7

Lift - SEU digital i/p 6 Lower - SEU digital i/p 7 Lower inhibit - SEU digital i/p 8

34 7 21

(value shown after 2s)

...table continued on next page

11- 66

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 27: Base option 5 - Activate lift/lower by SEU i/p ...continued from previous page

Argument #3

Enable / Idisable lower inhibit

Initial display

Values

Meaning

Lower inhibit disabled

Lower inhibit enabled

(value shown after 2s)

Argument #4

Selection of fork / support arm

Initial display

Values

Meaning

Selects fork lift / Lower

Selects support arm lift / lower

(value shown after 2s)

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 67

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 28: Base option 6 - Lift height restriction by SEU i/p & override Argument #0

Option designator

Initial display

Values

Meaning

Sets relevant option parameter to handle base option 6

(value shown after 2s)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

option is handled by SEU unit 1 [A36]

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2s)

Argument #2

Selection of SEU digital input for restriction switch

Initial display

Values

Meaning

Pin no.

activate SEU digital i/p 1 (1mA)

activate SEU digital i/p 2 (1mA)

activate SEU digital i/p 3 (1mA)

activate SEU digital i/p 4 (1mA)

activate SEU digital i/p 5 (7mA)

activate SEU digital i/p 6 (7mA)

activate SEU digital i/p 7 (7mA)

activate SEU digital i/p 8 (7mA)

(value shown after 2s)

Argument #3

Selection of option button to override

Initial display

Values

Meaning

activated by option button 1

activated by option button 2

activated by option button 3

activated by option button 4

activated by option button 5

activated by option button 6

(value shown after 2s)

Argument #4

11- 68

Not used

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Parameters Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 29: Basic option 9 - Single-acting hydraulic function Argument #0

Option designator

Initial display

Values

Meaning

Sets relevant option parameter to handle base option 9

(value shown after 2s)

Argument #1

Selection of output on A3 card.

Initial display

Values

Meaning

this option is controlled via outputs A3:2 and A3:3.

this option is controlled via outputs A3:4 and A3:7.

(value shown after 2s)

Argument #2

Selection of option button for single-acting hydraulic function

Initial display

Values

Meaning

activated with option button 2 and 5.

activated with option button 1.

activated with option button 2.

activated with option button 3.

activated with option button 4.

activated with option button 5.

activated with option button 6.

activated with option button 3 and 4.

(value shown after 2s)

Argument #3

Pump motor power reduction

Initial display

Values

Meaning

0-7

Max. pump power adjustable from 30 to 100% formel: = 30 + 10*Arg.3 E.g. 30 + 10*4 = 70%

(value shown after 2s)

Argument #4

Pump motor current reduction

Initial display

Values

Meaning

0-7

Max. current to pump motor adjustable from 30 to 100% formula: = 30 + 10*Arg.4 E.g. 30 + 10*4 = 70%

(value shown after 2s)

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 69

Electrical systems – 5000 Parameters T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 30: Basic option 10 - Double-acting hydraulic function Argument #0

Option designator

Initial display

Values

Meaning

Sets relevant option parameter to handle base option 10

(value shown after 2s)

Argument #1

Selection of output on A3 card.

Initial display

Values

Meaning

this option is controlled via outputs A3:2 and A3:3.

this option is controlled via outputs A3:4 and A3:7.

(value shown after 2s)

Argument #2

Selection of option button for double-acting hydraulic function

Initial display

Values

Meaning

activated with option button 2 and 5.

activated with option button 1.

activated with option button 2.

activated with option button 3.

activated with option button 4.

activated with option button 5.

activated with option button 6.

activated with option button 3 and 4.

(value shown after 2s)

Argument #3

Power motor power reduction

Initial display

Values

Meaning

0-7

Max. pump power adjustable from 30 to 100% formula: = 30 + 10*Arg.3 E.g. 30 + 10*4 = 70%

(value shown after 2s)

Argument #4

Pump motor current reduction

Initial display

Values

Meaning

0-7

Max. current to pump motor adjustable from 30 to 100% formula: = 30 + 10*Arg.4 E.g. 30 + 10*4 = 70%

(value shown after 2s)

11- 70

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.6 Diagnostic and troubleshooting means constantly on

means flashing.

11.6.1 General

Fig. 10

The trucks’s electronic control system incorporates built-in fault code display and logging. This capability works as a powerful complement in assessing the cause of eventual truck malfunctions. When a fault code occurs the code number is displayed and the fault condition LED flashes. Fig. 10. The codes can be broadly divided into two groups: • Caution codes - denoted by prefix “C”. These codes alert the operator to the presence of a caution condition. Caution codes in the range C51 to C99 will limit the truck’s maximum speed to creepspeed. The conditions which cause such codes can usually be easily remedied without further attention. Caution codes C1 to C50 are not stored in the code history log. • Error codes - denoted by prefix “E”. These codes alert the operator to the presence of a fault condition in the truck. Error codes E100 and higher will stop all truck driving functions until the error code is cleared. The first time any fault code is displayed it is advisable to check if the condition persists by switching the truck off completely. i.e. disconnect the battery and then switch back on. Check to see if the fault code is again displayed.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 71

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.6.2 Fault code history Up to 50 of the most recently occurred fault codes will be stored in a log along with the hour meter reading when the fault occurred. When the fault code log is displayed, it shows the fault codes in chronological order with the newest code first. Carry out the following to display the fault code log: • Ensure the battery is connected. • Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold [S18] depressed until “E” is displayed, then release [S18]. Fig. 11

Fig. 11

Fault symbol lights. The most recently occurred error will be displayed. The display will alternate between the fault code and the hour meter reading when the fault occurred. If the fault code log contains more than one fault code, these can be displayed by repeatedly operating the speed control [L1].

11- 72

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.6.3 List of fault codes NOTE! The text “Restart the truck!” in the following tables always means switching the truck off completely by removing the battery connector [X1], reconnecting and then switching the truck on again.

Table 31: List of fault codes Cod e

Description

Possible cause / Hint or Solution

TLS: Shock sensor values above limit

A shock sensor has reported values above limit. Driving may be too tough Make sure that the shock sensor limits are correct. Make sure that the shock sensor is correct located./Brake activates and stops the truck. A TLS reset command activates the truck.

TLS: Truck set out of use

Possibility to set the truck “out of use” with a TLS command. / Truck can´t be used before a TLS command sets the truck “in use”

C19

Default parameter value warning

"Certain parameter value(s) may be outside their normal maxmin range. These parameter values will be reset to their default values. / " It may be necessary to check the settings of all parameters if this code is displayed

C20

Butterfly warning

Problem with butterfly sensor [L1]. Butterfly may have been activated during start up or faulty sensor(s).[A2] / Check action of butterfly

C21

Lift/Lower control warning

Lift / Lower control for the forks may have been activated during start up or faulty sensor / Check action of Lift / Lower control

C28

Emergency switch warning

Emergency switch activated [S21] No voltage supply to Traction transistor regulator [A1]. Harness problem. / Check emergency switch is not depressed. Check wiring.

C29

Service time warning

Next service is due / Check service counter. It may not be reset after latest service See “ # 25 - Service interval” on page 49 for setting of parameter #25.

C30

Max.fork load exceeded

The load on the forks has exceeded the truck’s classified lift capacity. / Ensure the load to be lifted does not exceed the classified lift capacity Check that lifting is not performed against the mechanical stop. This applies to both fork lifting and support arm lifting. Ensure the mast sections and lifting chains move freely Check pressure sensor o/p [B1:INP.PRESSURE LIFT] voltage ≈ 0,5V with no load & lowered forks / support arms Perform a Max. load calibration See “ # 36 - Calibrate” on page 50

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 73

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 31: List of fault codes Cod e

Description

Possible cause / Hint or Solution

C35

Steer servo -Internal temperature warning

The internal temperature of the steer servo[A5] has exceeded +68° C / Steering may be too intensive

C41

Battery undervoltage war-ning -traction transistor re-gulator

Traction transistor regulator[A1] has detected battery voltage < 17V Battery parameter not correctly adjusted. See “ # 21 - Battery size” on page 49 for setting of parameter #21 Battery due for charging

C42

Battery overvoltage warning -traction transistor regulator

Traction transistor regulator[A1] has detected battery voltage > 33V / Can be caused by fully-charged battery and energy return feed to the battery during heavy reverse braking

C43

Traction transistor regulator thermal cutback

Driving may be too intensive Defective Traction transistor regulator [A1]

C47

Battery under voltage warning -pump transistor regulator

Pump transistor regulator[A3] has detected battery voltage < 17V / Battery parameter not correctly adjusted. See “ # 21 - Battery size” on page 49 for setting of parameter #21 Battery due for charging

C48

Battery overvoltage pump transistor regulator

Pump transistor regulator[A3] has detected battery voltage > 33V

C49

Pump transistor regulator -thermal cutback

Lifting may be too intensive Defective pump transistor regulator [A3]

C60

Pressure sensor error, Lift system

Voltage at i/p [B4:INP.PRESSURE LIFT] outside range +0,3V to +7,7V / Check pressure sensor [B4] wiring and function Defective pressure sensor [B4]

C61

Pressure sensor error powertrak

Voltage at i/p [B5:INP.PRESSURE PT] outside range +0,3V to +7,7V / Check pressure sensor [B5] wiring and function Defective pressure sensor [B5]

C62

Powertrak error

Unexpected pressure level in Powertrak system / Check wiring & connections to Powertrak related components [Y58], [Y59], [B4] & [B5] Mechanical failure in powertrak valves

C63

Powertrak valve output error

Valve defective [Y59] or fault in o/p from traction transistor regulator [A1:OUT.POWERTRAK FILL UP VALVE]

C64

Powertrak valve output error

Valve defective [Y58] or fault in o/p from traction transistor regulator [A1:OUT.POWERTRAK DRAIN VALVE]

C 70

Pump motor field circuit open

Shunt field open [M3], harness broken, pump transistor regulator defective [A3]./ Check wiring and connections to shunt field [M3]

11- 74

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 31: List of fault codes Cod e

Description

Possible cause / Hint or Solution

C 71

M minus error - Pump transistor regulator [A3]

Problem with switch transistor in armature circuit inside Pump transistor regulator [A3] Defective Pump transistor regulator [A3].

C 72

Current sensor error Pump transistor regulator [A3]

Armature current sensor fault in pump transistor regulator [A3] Defective pump transistor regulator [A3]

C73

CAN timeout error Pump transistor regulator [A3]

Pump transistor regulator [A3] reports unexpected loss of data flow from tiller head [A2]./ Check CAN bus signal cables and connections.[A3, A2] Restart the truck

C74

Data not received Pump transistor regulator [A3]

Data from [A3] not received by [A2] Broken CAN wire / Check CAN bus signal cables and connections.[A3, A2] Restart the truck

C75

Transmission to Pump transistor controller[A3] failed

Data from [A2] not received by [A3] Broken CAN wire Defective Pump transistor regulator [A3] /Check CAN bus signal cables and connections.[A3, A2] Restart the truck

C76

Pump transistor regulator [A3] incompatible with the type of truck

Incorrect type of pump transistor regulator is fitted / Check correct transistor regulator type is fitted

C77

Lift potentiometer [R14] connection error

Analogue potentiometer control not detected. / Check wiring & connections between potentiometer [R14] & [A2]

C80

Steer servo - Reference sensor current error

Steer servo reference current < 0,1A Supply fault to home reference sensor [S65] Defective home reference sensor [S65] / Check wiring to sensor

C81

Steer servo - Reference sensor supply error

Sensor supply from Defective home reference sensor [S65] / Check supply voltage is 12V between wires 95-97 / Check Wiring to sensor Check condition of [F50]

C82

Steer servo - drive current warning

Steer servo drive current is exceeding 80% of maximum. Steering activity may be too intensive See also code E132

C90

Communication problem with the SEU 1 unit.

Verify the voltage supplied to the SEU 1 unit (A36 POWER SUPPLY 24 VDC) and check that the CAN cabling is OK If no configurable option is fitted, ensure that service parameter #16-#19 are set to “0”

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 75

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 31: List of fault codes Cod e

Description

Possible cause / Hint or Solution

C91

Communication problem with the SEU 2 unit

Verify the voltage supplied to the second SEU and check that the CAN cabling is OK If no configurable option is fitted, ensure that service parameter #16-#19 are set to “0”

C92

Programming warning SEU 1 unit (A36)

Incorrect programming of the SEU 1 unit 1 [A36]. The truck travels at creep speed. / May have been caused by incorrect allocation of an output during adjustment of the option parameters (16 to 19). Verify all settings of any option parameters./ If no configurable option is fitted, ensure that service parameter #16-#19 are set to “0”

C93

Programming warning SEU 2 unit

Incorrect programming of the SEU 2 unit. The truck travels at creep speed. / May have been caused by incorrect allocation of an output during adjustment of the option parameters (16 to 18). Verify all settings of any option parameters. If no configurable option is ffitted, ensure that service parameter #16-#19 are set to “0”

E100

Steer servo - configuration error

Presence of steer servo and parameter #38 setting do not match/ Ensure parameter #38 is set correctly

E101

Traction transistor regulator [A1] incompatible with the type of truck

Incorrect type of traction transistor regulator is fitted / Check correct transistor regulator type is fitted

E104

Brake switch transistor output in Traction transistor regulator [A1] shorted

Defective Traction transistor regulator [A1] / Check cables and magnetic coil to the brake [Y1]

E106

Digital output fault or field current limit

Attempting to drive more current than specified from outputs. OR problem regulating field current. Internal Traction transistor regulator fault. [A1]

E107

Main contactor not activated [K10]

Problem with main contactor tips or cabling (open circuit). Contactor control wire not connected. Contactor drive output in controller faulty (off) / Check main contactor tips. Check control wires to main contactor. Check contactor drive output goes low. [A1]

E108

Main contactor tips welded or open circuit in coil.[K10]

Main contactor tips welded. Contactor drive output in controller faulty (on) / Check main contactor tips Check contactor drive output goes high. [A1]

E110

Fault in armature current reading

Possible defect in the transistor regulator [A1]. Can be caused by excessive moisture inside regulator. / Restart the truck

11- 76

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 31: List of fault codes Cod e

Description

Possible cause / Hint or Solution

E112

Steer servo- wheel position error

Error when comparing actual wheel position (reference sensor signal) with steer servo’s calculated position. / Check reference sensor[S65] functions correctly Check steer servo pinion is not loose and in contact with drive unit’s gear ring Restart the truck

E113

Unspecified steer servo fault

Control system has detected a fault condition but is unable to ascertain the exact cause. / Restart the truck

E114

Steer servo phase error [A5, M6]

Loss of motor phase to steer servo motor. / Check internal motor cable connections in steer servo[A5, M6]

E115

Steer servo initialisation error [A5]

Faulty Servo [A5] Internal logical fault Wrong parameters / Restart the truck

E116

Steer servo checksum error [A5]

Can occur after new firmware has been loaded into truck / Restart the truck

E117

Steer servo communication error

Shall not occur under normal conditions./ Contact support organisation

E118

Command mode error

Shall not occur under normal conditions./ Contact support organisation

E119

Steer servo error during homing operation (Time out)

Home position (steering straight) not achieved within preset time. Home reference sensor [S65] not adjusted correctly Faulty reference sensor / Check reference sensor gap is adjusted correctly, check wiring to sensor

E120

Steer servo- potentiometer error

Comparison of voltages between IN_0 & IN_1 is out of range. / Check potentiometer inputs

E121

Steer servo error -steering angle value check

Restart the truck Check that sum of voltages between wire nos. 92-94 and 93-94 ≈ 5V Re calibrate steering (See “ # 36 - Calibrate” on page 50)

E122

Steer servo -reference supply out of range

Defective steer servo [A5] / Check voltage between wire nos. 91-94 = 4,5 to 5,5 V

E123

Steer servo - Hall sensor fault

Intermittent contacts inside steer servo Defective steer servo [A5] / Check internal connections from Hall sensors to main circuit board in steer servo [A5]

E124

Steer servo - overvoltage [A5]

May occur when performing heavy reverse braking on newly charged battery (Voltage exceeded 39V) / Restart the truck

E125

Steer servo - internal short circuit [A5, M6]

Defective steer servo [A5,M6] / Check wiring for short-circuit Restart the truck

E126

Steer servo - current offset error [A5, M6]

Defective steer servo [A5,M6] / Restart the truck

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 77

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 31: List of fault codes Cod e

Description

Possible cause / Hint or Solution

E127

Steer servo - temperature error[A5, M6]

Steer servo internal temperature outside range -40 to +85º C Steering activity may be too intensive Defective steer servo [A5,M6] / Restart the truck (See also code C35)

E128

Not applicable in this truck

E129

Steer servo - supply undervoltage

Battery charge too low Intermittent connection in servo supply circuit [A5] Steer servo fuse [F52] faulty or blown. / Check condition of Fuse [F52] Charge battery

E130

Steer servo - analogue steer signal input fault

Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5] / Check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.

E131

Steer servo - analogue steer signal input 0 fault

Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN0] / Check 0,4 to 4.8V between wires 94-93, check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.

E132

Steer servo - current limit reached

Output current to steer motor exceeding 80% of maximum for longer than 5 seconds. Steered portion of drive unit not moving freely./ Check for free movement of drive wheel on floor. Check steering drive train is free of dirt or other foreign objects.(See also code C82)

E133

Steer servo - analogue steer signal input 1 fault

Faulty steer angle potentiometer [R2] Intermittent connection in potentiometer circuit [R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires 94-92 , check wiring to potentiometer [R2] Move tiller handle in all directions to ensure no wiring problems exist.

E134

Steer servo - analogue steer signal input short circuit

Faulty steer angle potentiometer [R2] or wiring short circuit between [A5:INP.A_IN1 and INP.A_IN0] / Check wiring to potentiometer [R2], Move tiller handle in all directions to ensure no wiring problems exist.

E135

Steer servo - offset value error

Voltage difference between [A5:INP.A_IN1 and INP.A_IN0] is too great Requires re calibration / Re calibrate steering (parameter #36) See “ # 36 - Calibrate” on page 50

11- 78

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 31: List of fault codes Cod e

Description

Possible cause / Hint or Solution

E136

Steer servo - steer angle potentiometer error

Calibrated neutral position value is out of range. Defective potentiometer [R2] / Ensure potentiometer is fitted correctly. Re calibrate steering (parameter #36). See “ # 36 - Calibrate” on page 50

E137

Steer servo - checksum error on received data

Faulty wiring / Check CAN bus signal cables and connections.[A5, A2] Restart the truck

E138

CAN data not received

Data from traction transistor regulator not received by [A2] Faulty wiring / Check CAN bus signal cables and connections.[A1, A2] Restart the truck

E139

Steer servo - data transmission to servo failed

Faulty wiring / Check CAN bus signal cables and connections.[A5, A2] Restart the truck

E140

Checksum error

Faulty internal micro controller [A2], faulty software

E141

Software problem

Faulty internal micro controller [A2], faulty software / New software may need loading via CAN

E150

Data not received - Traction transistor controller

Traction transistor regulator [A1] does not answer, bad connections or faulty Traction transistor regulator [A1].

E151

Transmission to traction transistor regulator failed

Broken CAN-wire. Traction transistor regulator [A1] defective

E157

Bus off error

CAN-bus problem, wiring harness or hardware problem.[A2] / Check CAN wiring

E159

Over-run error

CAN-bus problem, wiring harness or hardware problem.[A2] / Check CAN wiring

E160

Error -safety switch against collision

Error in Hall sensor for safety switch against collision “belly button”/ Check switch is not activated.

E200

Drive motor field circuit open

Shunt field open [M1], harness broken, Traction transistor regulator defective [A1]. / Check wiring and connections to shunt field [M1]

E201

M minus error

Problem with switch transistor in armature circuit inside Traction transistor regulator [A1] Defective Traction transistor regulator [A1].

E202

Current sensor error traction transistor regulator [A1]

Armature current sensor fault in Traction transistor regulator [A1]. Defective Traction transistor regulator [A1].

E214

CAN-timeout error - traction transistor regulator [A1]

Traction transistor regulator reports unexpected loss of data flow from tiller head [A2]./ Check CAN bus signal cables and connections

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 79

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.6.4 Transistor regulator

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

General Curtis 1243 is a regulator [A1] & [A3] for controlling shunt motors. Varying the voltage applied through the armature primarily controls the speed. The voltage is varied through use of pulse-width modulation (PWM). This involves varying the “on” time of the MOS-FET transistors regulating the armature current.

STATUS

11- 80

MODEL

VOLTAGE

SERIAL

CURRENT

Switching of the rotational direction is achieved by switching the polarity on the field winding (S1-S2). The regulator is fitted with a four-quadrant transistor bridge for the field winding and a single-quadrant transistor bridge for the armature winding.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Transistor regulator errors The table below depicts the error codes that may be shown by the STATUS LED or read using the hand-held terminal.

Table 32: Transistor regulator error code STATUS LED

Hand-held terminal display

Explanation

Possible cause

LED off

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

Defective regulator

1,1

¤¤

CURRENT SHUNT FAULT

Built-in current shunt defective

Armature current sensor fault in motor controller.

1,2

¤ ¤¤

HW FAILSAFE

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs. Problem to regulate field current. Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shunt field open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

1. Battery voltage <17 volts 2. Corroded battery terminals 3. Loose battery or regulator connections

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

1. Battery voltage > 33 volts

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Over-/under-temperature reduction

1. Temp. >85oC or < - 25oC 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11- 81

Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Resetting errors To reset an error turn [S17] to off and then on again.

Error

Reset when

OVERVOLTAGE

Battery voltage falls below 33 V

THERMAL CUTBACK

The temperature is within allowed range

THROTTLE FAULT 1, 2

Error has been fixed

LOW BATTERY VOLTAGE

When battery voltage exceeds 16 V

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

11- 82

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.6.5 Built-in Test Function The truck’s control system provides a number of useful built-in test functions • Connect CAN-key in [X41] and press

[A17].

• Battery status is shown. • Press Horn [S18] repeatedly to choose Built-in Test mode. NOTE! All truck functions operate as normal in this mode. Care should be taken when operating the truck and reading the display at the same time!

Table 33: Built-in test modes Flashing symbol

Displayed data

Unit

Speed reference value sent to traction transistor controller.

Lift / lower command value sent to pump transistor controller.

Service Manual

Main control card signals [A2) See Table 36:

Inputs / outputs traction transistor regulator & pump transistor regulator. See Table 34: & Table 35:

Battery voltage

Armature current to traction motor [M1]

Field current to traction motor [M1]

Armature PWM to traction motor [M1]

Armature current to pump motor [M3]

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 33: Built-in test modes Flashing symbol

11- 84

Service Manual

Displayed data

Unit

Field current to pump motor [M3]

Armature PWM to pump motor [M3]

Signal from pressure sensor [B4] (Hydraulic pressure in lift circuit)

bar

Signal from pressure sensor [B5] (Hydraulic pressure in powertrak circuit)

bar

Maximum lift pressure setting.

bar

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Digital inputs/outputs test mode In the digital inputs/outputs mode, the operation of both inputs and outputs can be checked by checking the individual segments of the main display as given in the following tables.

Table 34: Transistor regulator inputs Function

Segment

Tiller arm in drive pos.[S10], input A1:INP.TILLER ARM IN DRIVE POS: Platform not folded up switch [S59], input A1:PLATFORM NOT FOLDED UP Man on platform switch [S19], input A1:INP.MAN ON PLATFORM Gates up switch [S53], input A1:GATES UP

Gates down switch [S56], input A1:GATES DOWN Support arms at top switch [S31], input A3:INP.SUPPORT ARM AT TOP Support arms at bottom switch [S90], input A3:INP.SUPPORT ARM AT BOTTOM Forks < 1800mm [S33/2] magnetic switch , input A3:LIFT LIMIT <1,8M Powertrak lift limit [S33/1] magnetic switch, input A1:LIFT LIMIT POWERTRAK 1,<1,8M Powertrak fill up valve watchdog (Senses whether Y59 is drawing current correctly should normally show the inverse of output signal) Powertrak drain valve watchdog (Senses whether Y58 is drawing current correctly should normally show the inverse of output signal)

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

Table 35: Transistor regulator outputs Function

Segment

Signal horn [H1], output A1.SIGNAL HORN

Brake solenoid [Y1], output A1.BRAKE RELEASE Main contactor [K10], output OUT.MAIN.CONTACTOR Powertrak fill up valve [Y59], output A1:OUT.POWERTRAK FILL UP VALVE Powertrak drain valve [Y58], output A1:OUT.POWERTRAK DRAIN VALVE Fork / support arm valve [Y52], output A3.OUT.FORK SUP.ARM VALVE Support arm lower valve [Y41], output A3.SUPPORT ARM LOWERING VALVE

11- 86

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Diagnostic and troubleshooting Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 36: Main control card signals [A2] Function

Segment

Support arms down [A2:S20]

Support arms up [A2:S19]

Signal horn [S18]

Option switch -lefthand outer

Option switch -lefthand middle

Option switch -lefthand inner

Option switch -righthand inner

Option switch -righthand middle

Option switch -righthand outer

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

11.6.6 Display test mode The digital display [A6] itself can be tested to verify all the segments of the display function correctly. To select Display test mode carry out the following procedure: • Ensure the battery is connected. • Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid PIN-code and then press Fig. 12

on the keypad.

• Hold [S18] depressed until “d” is displayed, then release [S18]. Fig. 12 All number segments on the display and symbol lamps should flash sequentially. Fig. 13

Fig. 13

11- 88

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Electrical systems – 5000 Technical specifications – Curtis 1243 Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

11.7 Technical specifications – Curtis 1243 Table 37: Technical specification -Curtis 1243 Item

Traction Lift

Unit

Rated operating voltage

Volts

Overvoltage limit

Volts

Undervoltage limit

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

kHz

Max. current of armature winding *

200

300

Amps

for 2 minutes

100

Amps

for 1 hour

Amps

for 2 minutes

Contactor voltage

Volts

Same as battery voltage

Contactor current

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

Volts

KSI input current

Logic input voltage

>7.5; High <1; Low

Volts

Logic input current

Operating temperature

-40 to +50

°C

Overtemperature, reduction

°C

Undertemperature, reduction

-25

°C

Max. current of field winding

Explanation

for 1 hour

* During specific test conditions. WARNING! The regulators ([A1] & [A3]) cannot be swapped.

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

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Electrical systems – 5000 Technical specifications – Curtis 1243 T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

11- 90

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Hydraulic system – 6000 Hydraulic diagram Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

12- Hydraulic system – 6000 12.1 Hydraulic diagram 12.1.1 With support arm lift TANK

POWER TRAK

SUPPORT FORKS ARMS B4

Y59

Y41

CV3

OR2

OR1

LS OR4

Y58

Y10 SB2 CV1 CV2

SB1 Y52 PV

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

12- 1

Hydraulic system – 6000 Hydraulic diagram T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

12.1.2 Without support arm lift TANK

POWER TRAK

FORKS B4

Y59

OR2

OR1 OR4

Y58

Y10

SB1

CV PV

12- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Hydraulic system – 6000 Main Components Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

12.2 Main Components Pos.

Designation

Pressure sensor, fork lift/support arm lift

Pressure sensor, PowerTrak

Load selector valve (only trucks with support arm lift)

Pump motor

Overflow valve, max. 210 bar

SB1

Pressure-compensation valve

SB2

Lowering brake valve (only trucks with support arm lift)

Y10

Proportional valve, lowering forks

Y41

Lowering valve, lowering support arms (only trucks with support arm lift)

Y52

Selector valve, fork/support arms (only trucks with support arm lift)

Y58

PowerTrak valve, draining PowerTrak cylinder

Y59

PowerTrak valve, filling PowerTrak cylinder

With support arm lift

M3 LS

Y41

Y52 PV

Y59

Y58

SB1

Y10

Without support arm lift M3

B4 PV

Y58

Service Manual

Y10

SB1

Y59

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

12- 3

Hydraulic system – 6000 Description T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

12.3 Description 12.3.1 Lifting system NOTE: This system description refers to machines with support arm lift.

The pump motor (M) features speed control for continuous adjustment of the fork lifting speed. Two non-return valves (CV1,CV2), one for fork lifting and one for support arm lifting, are installed to prevent leakage through the pump. The routing valve (Y52) controls selection of support arm lifting or fork lifting. An overflow valve (RV) prevents overpressure in the system. The pressure sensor (B4) detects the cylinder pressure, providing data about the load on the forks, and it is also used to monitor possible overloading. This allows limitation of the speed when carrying loads heavier than 800 kg and also serves as a warning in case the max. load is exceeded. The proportional valve (Y10) enables stepless adjustment of the speed when lowering the forks. The maximum fork lowering speed is controlled by the pressure-compensation valve (SB1) in combination with the proportional valve (Y10). The lowering valve (Y41) controls lowering of the support arms. The maximum support arm lowering speed is adjusted by a flow limiting valve (SB2). There is no return filter in the hydraulic system.

12.3.2 The PowerTrak system The truck is equipped with the BT patented PowerTrak system, which adapts the drive wheel pressure in accordance with the load on the forks and the drive wheel wear. This results in less wear on the drive wheel and promotes safer load handling. The PowerTrak cylinder operates when the forks have been lifted to maximum 1800 mm, however system operation varies depending on the mast type. The pressure sensor (B5) detects the pressure and is used to control and monitor the PowerTrak system. This prevents excessive drive wheel pressure when handling loads at lifting heights >1800 mm. The PowerTrak system uses two valves (Y58,Y59), one for filling and another for draining. When the machine receives no power, both valves are shut off in order to maintain the pressure in the PowerTrak cylinder. Replenishment and draining are done by switching on the power to either valve. A load sensing valve (LS) controls the amount of pressure applied on the PowerTrak cylinder. The check valve (OR2) operates to dampen cylinder movement.

12- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Hydraulic system – 6000 Description Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

12.3.3 Working pressure The working pressure shows the classified weight: 110 bar.

12.3.4 Overflow valve The overflow valve opens at the following pressure: 210 bar.

12.3.5 Pressure sensor The pressure sensor is used to adjust the speed and is affected by the load. Load < 800 kg. Travel speed = 8.0 km/h Load >800 kg. Travel speed = 7.0 km/h (Declines linearly to 7.0 km/h at maximum load)

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

12- 5

Hydraulic system – 6000 Description T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

This page is intentionally left blank

12- 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Lift mast – 7000 Mast incline Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

13- Lift mast – 7000 13.1 Mast incline NOTE Only applies to trucks with height-adjustable support arms.

1 • The mast’s backward incline is adjusted using shims (1). The adjacent angle on the frame must be 0.3+/-0.2° (5.2+/-3.5 mm/m). • The mast’s side incline is adjusted using shims (2). The adjacent angle on the mast must be a maximum of 0.1° (1.7 mm/m).

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

13- 1

Lift mast – 7000 Main lift chain system T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

13.2 Main lift chain system 13.2.1 Checking the chain setting The lift chains must be adjusted at regular periods due to stretching, see below. The chain setting is checked during servicing as set out in the maintenance schedule. Any adjustment is made with the chain mounting bolts. Adjust the fork height according to C code 7100, 7420, 7700 and 7800 as applicable.

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

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

Surface rust Surface rust is easy to recognize as the chain will be reddish brown. Deep-seated rust has generally started and the chain has impaired strength. The chain should be replaced

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

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

13- 2

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Lift mast – 7000 Main lift chain system Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

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

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

Outline wear P

P = Pitch H2 = Nominal disc height. H3 = Minimum disc height. A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is define as H3 © TIEE SARL

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

13- 3

Lift mast – 7000 Main lift chain system T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

in the figure and denotes the minimum permitted value of the disc height. Maximal permitted outline wear is 5% of the height H2. If a lift chain reaches the maximum level of wear, the chain should be replaced.

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

Stretching The amount of stretch on a lift chain is measured on the part of the chain that runs over the chain sprocket. The amount of stretch may, at the most, be 2% on the most worn section of the chain. Measurement is suitably made over 300-1000 mm of the chain. The nominal and maximum permitted chain lengths for lift chains are stated in the table below.

Table 38: Stretching Type of chain

Nominal disc height H2 ( mm)

Minimum disc height H3 (mm)

Pitch P (mm)

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

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

3/4”, 2x3

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 3x4

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 4x6

17.8

16.9

19.05

381/572/953

389/583/972

1”, 4x4

23,6

22,4

25,4

508/762/1270

518/777/1295

1”, 6x6

23,6

22,4

25,4

508/762/1270

518/777/1295

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

13- 4

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Lift mast – 7000 Main lift chain system Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Damage The chain should be replaced if damaged in any way.

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

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

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

13.2.3 Cleaning If a chain is very dirty it is recommended that it is replaced. Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol. The chain should be blown dry using compressed air and lubricated directly after cleaning NOTE! Exercise care with degreasing agent as these can contain abrasives. © TIEE SARL

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

13- 5

Lift mast – 7000 Main lift chain system T-code 789, 790, 791, 817, 818

Valid from serial number 985777-

Date 2007-05-11

Order number 249896-040

13.2.4 Lubrication Mineral and synthetic oils can be used to relubricate Rexnord chains. NOTE! Lubricant must not contain substances such as molybdenum disulphide, PTFE or the like.

A lift chain should be offloaded from the weight of the fork carriage (hanging free) when lubricated. • Lubrication intervals: - 500 hours with normal operations - 100 hours when driving in rugged environments such as cold stores and corrosive environments. The chains are sprayed with lubricant. Note the entire chain must be lubricated, even the fastening bolts. It is especially important that the part of the chain which runs over the chain sprocket is well lubricated. The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below. The following lubricants are recommended:

13- 6

Service Manual

7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

Lift mast – 7000 Main lift chain system Order number 249896-040

Date 2007-05-11

Valid from serial number 985777-

T-code 789, 790, 791, 817, 818

Table 39: Recommended Product Ambient temperature

Viscosity class