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Service Manual en

7PLL24 Valid from serial number: 723984-

Order number: 222996-040 Issued: 2005-11-04 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:

Issue date

Order number

Changes

2005-01-14

222996-040

Completely new issue.

2005-11-04

222996-040

P2, P3, P4 and TruckCom (previously 8700)

This manual covers following truck models:

T-code

Model

Serial number

497

7PLL24

723984-

Service Manual

7PLL24

Approved by: L-G A

Contents Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

1- Contents 1- Contents ............................................................................................... 1-1 2- Technical data – M4 ............................................................................ 2-1 3- Installation and maintenance instructions – P1 ............................... 3-1 3.1 Installation of the new truck............................................................ 3-1 3.1.1 Lifting the truck ................................................................ 3-1 3.1.2 Fitting the battery ............................................................. 3-3 3.1.3 Start up ............................................................................ 3-3 3.2 Introduction, maintenance.............................................................. 3-5 3.2.1 Safety regulations during maintenance work ................... 3-5 3.2.2 Cleaning and washing ..................................................... 3-6 3.2.3 Cleaning the exterior ....................................................... 3-7 3.2.4 Cleaning the motor compartment .................................... 3-7 3.2.5 Electrical components ..................................................... 3-7 3.3 Safe lifting ...................................................................................... 3-8 4- Preventive maintenance – P2 ............................................................. 4-1 4.1 Maintenance schedule ................................................................... 4-1 4.2 Lubrication chart ............................................................................ 4-5 5- Oil and grease specification – P3 ...................................................... 5-1 6- Tools ..................................................................................................... 6-1 6.1 Super Seal connectors................................................................... 6-1 6.2 AMP connectors............................................................................. 6-2 6.2.1 AMP Connectors, 040 series ........................................... 6-3 6.3 Molex connectors........................................................................... 6-3 6.4 Grease guns .................................................................................. 6-4 6.5 Other tools ..................................................................................... 6-5 7- Fork carriage – 0380 ............................................................................ 7-1 7.1 Component parts ........................................................................... 7-1 7.2 Dismantling the fork carriage ......................................................... 7-3 7.3 Replacing the rollers ...................................................................... 7-5 8- Engine suspension– 0450 .................................................................. 8-1 8.1 Component parts ........................................................................... 8-1 8.1.1 Component List ............................................................... 8-2 9- Electric drive motor – 1760 ................................................................. 9-1 9.1 Component parts ........................................................................... 9-1 9.2 Removing the motor from the truck ................................................ 9-2 9.3 Refitting the motor in the truck ....................................................... 9-3 9.4 Service and repairs ........................................................................ 9-3 9.4.1 Dismantling N-side .......................................................... 9-3 9.4.2 Dismantling D-side .......................................................... 9-3 9.4.3 Cleaning .......................................................................... 9-4

Service Manual

7PLL24

1- 1

Contents T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

10- Mechanical drive gear unit – 2550 ................................................. 10-1 10.1 Component parts ......................................................................... 10-2 10.1.1 Technical data ............................................................... 10-3 10.2 Dismantling/Assembly Leakage from the upper cover ................. 10-3 10.3 Replacing the drive shaft gasket .................................................. 10-4 10.3.1 Dismantling .................................................................... 10-4 10.3.2 Assembling .................................................................... 10-5 10.4 Replacing wheel bolt .................................................................... 10-6 11- Electromagnetic brake – 3370 ........................................................ 11-1 11.1 Component parts ......................................................................... 11-1 11.2 Dismantling .................................................................................. 11-2 11.2.1 Inspection ...................................................................... 11-2 11.3 Assembling .................................................................................. 11-3 11.4 Manual release of the brake......................................................... 11-3 11.5 Adjustment................................................................................... 11-3 11.5.1 Adjusting the play .......................................................... 11-3 12- Steering system – 4000 ................................................................... 12-1 12.1 Component parts, mechanical steering........................................ 12-1 12.2 Component parts, servo steering (Option) ................................... 12-4 12.2.1 Steering axle, servo steering (Option) ........................... 12-5 12.3 Adjustment, steering .................................................................... 12-9 12.3.1 Adjusting the steering servo .......................................... 12-9 12.3.2 Adjusting the steering chain .......................................... 12-9 12.4 Component parts, tiller arm........................................................ 12-10 12.5 Adjustment, tiller arm ................................................................. 12-11 12.5.1 Adjusting the brake microswitch .................................. 12-11 12.6 Tiller arm handle ........................................................................ 12-12 12.7 Dismantling/Assembly, buttons.................................................. 12-14 12.7.1 Replacing the signal button/switch (9, 10) ................... 12-15 12.7.2 Replacing the lift/lower button (13) .............................. 12-15 12.7.3 Replace the pushbutton (16) ....................................... 12-16 13- Electrical systems – 5000 ............................................................... 13-1 13.1 Electrical parts ............................................................................. 13-1 13.2 Symbol list and electrical diagram................................................ 13-3 13.2.1 Electrical wiring diagram 1(5) ........................................ 13-5 13.2.2 Electrical wiring diagram 2(5) ........................................ 13-6 13.2.3 Electrical wiring diagram 3(5) ........................................ 13-7 13.2.4 Electrical wiring diagram 4(5) ........................................ 13-8 13.2.5 Electrical wiring diagram 5(5) ........................................ 13-9 13.2.6 Electrical wiring diagram Servo (Option) ..................... 13-10 13.3 Functional description ................................................................ 13-11 13.3.1 Starting the truck ......................................................... 13-11 13.3.2 Driving without using platform and gates, speed ≤6 km/h ............................................................. 13-11 13.3.3 Driving from platform without using gates, speed ≤6 km/h ............................................................. 13-11 13.3.4 Driving from platform and using gates, speed ≥8 km/h ............................................................. 13-11 13.3.5 Neutral speed reduction .............................................. 13-11 13.3.6 Neutral speed reduction on slopes .............................. 13-12 1- 2

Service Manual

7PLL24

Contents Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.3.7 Braking ........................................................................ 13-12 13.3.8 Lifting the forks ............................................................ 13-12 13.3.9 Lowering the forks ....................................................... 13-12 13.3.10 Horn ............................................................................. 13-12 13.4 Hour meter ................................................................................. 13-13 13.5 Error codes ................................................................................ 13-13 13.6 Parameters ................................................................................ 13-25 13.6.1 Driver parameters ........................................................ 13-25 13.6.2 Parameter description ................................................. 13-26 13.6.3 Service parameters ..................................................... 13-27 13.6.4 Parameter description ................................................. 13-28 13.7 Part numbers ............................................................................. 13-46 13.8 Transistor panel ......................................................................... 13-46 13.8.1 General ........................................................................ 13-46 13.9 Diagnostic and troubleshooting.................................................. 13-47 13.9.1 Error codes and troubleshooting ................................. 13-47 13.9.2 Resetting errors ........................................................... 13-48 13.9.3 Safety .......................................................................... 13-48 13.10 Technical specifications – Curtis 1243 ....................................... 13-49 14- Hydraulic, pneumatic – 6000 .......................................................... 14-1 14.1 General ........................................................................................ 14-1 14.1.1 Hydraulic diagram .......................................................... 14-1 14.1.2 Symbol list ..................................................................... 14-2 14.2 Adjustments ................................................................................. 14-3 14.2.1 Adjustment of the pressure limit valve ........................... 14-3 14.3 Cleaning the filter ......................................................................... 14-4 15- PowerTrak cylinder – 6680 ............................................................. 15-1 15.1 Component parts ......................................................................... 15-1 15.2 Dismantling the PowerTrak cylinder............................................. 15-2 15.2.1 Replacing the gaskets in the PowerTrak cylinder .......... 15-3 15.3 Dismantling/assembling the ground pressure springs.................. 15-4 15.3.1 Component parts ........................................................... 15-4 15.3.2 Dismantling .................................................................... 15-5 15.3.3 Assembling .................................................................... 15-5 15.3.4 Setting and sealing ........................................................ 15-5 15.3.5 Sealing ........................................................................... 15-6 16- TruckCom ........................................................................................ 16-1 16.1 General ........................................................................................ 16-1 16.2 Connection................................................................................... 16-1 16.3 Layout .......................................................................................... 16-2 16.3.1 Main program screen ..................................................... 16-2 16.3.2 Nodes ............................................................................ 16-2 16.3.3 Icons .............................................................................. 16-3 16.3.4 Tool buttons and menu bar ............................................ 16-3 16.3.5 Information window ........................................................ 16-4 16.3.6 Status bar ...................................................................... 16-4 16.4 Connection function .................................................................... 16-4 16.5 Disconnection function................................................................. 16-4 16.6 Downloading program function .................................................... 16-5 16.6.1 Normal downloading (truck with key) ............................. 16-5 © TIEE SARL

Service Manual

7PLL24

1- 3

Contents T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

16.6.2 Normal downloading (truck with keypad) ....................... 16-5 16.6.3 Emergency downloading (truck with keypad) ................ 16-6 16.6.4 Emergency downloading (truck with keypad) ................ 16-6 16.6.5 Downloading in old versions of logic card ..................... 16-6 16.7 Truck report function .................................................................... 16-7 16.8 Parameters function..................................................................... 16-8 16.9 Diagnostics function..................................................................... 16-8 16.9.1 Representation of signal colours ................................... 16-9 16.9.2 “Tiller arm” tab ............................................................... 16-9 16.9.3 “Drive Controller” tab (transistor regulator driving) ..... 16-10 16.9.4 “Pump controller” tab (transistor regulator pump) ....... 16-11 16.9.5 “EPS” (steering servo tab) ........................................... 16-12 16.9.6 SEU tab (Spider Extension Unit) ................................. 16-13 16.10 Other menu functions................................................................. 16-13 16.10.1 Save to file ................................................................... 16-13 16.10.2 Download from file ....................................................... 16-13 16.10.3 Reset CAN adapter ..................................................... 16-14 16.10.4 Delete error code log ................................................... 16-14 16.10.5 Reset hour meter ......................................................... 16-14 16.10.6 Read error code log ..................................................... 16-14 16.10.7 Adjust date and time .................................................... 16-14 16.10.8 Adjusting the hour meter on older cards ...................... 16-14 16.10.9 Help ............................................................................. 16-14 16.10.10 Exit ............................................................................. 16-14 16.11 Specifications............................................................................. 16-15 16.12 Installation.................................................................................. 16-15 16.12.1 Installation on a PC with Windows 95/98 .................... 16-15 16.12.2 Installation on a PC with Windows XP/2000 ................ 16-16 16.12.3 Installation on a PC with Windows NT ......................... 16-21 16.12.4 In case of communication problems with CAN ............ 16-21 16.12.5 To uninstall .................................................................. 16-21

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Service Manual

7PLL24

Technical data – M4 Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

2- Technical data – M4 Model

7PLL24

Drive motor Type

TSL160 A DS60

Output, kW

2.5

Duty cycle

S2, 60 min

Minimum carbon brush length, mm

Nominal commutator diameter, mm

Minimum commutator diameter, mm

Resistance, shunt field winding, Ω at 24 C°

0.346

Resistance armature winding, Ω at 24 °C

0.0098

Insulation resistance between the windings and motor casing

>= 1 Mohm

Weight, kg

Brakes Type

1EB46-11

Braking force, Nm

Output, W

Resistance coil, Ω

Nominal play in actuated position, mm

0.25-0.38

Minimum thickness brake disc, mm

7.7

Thickness of a new brake disc, mm

9.7

Transmission/drive gear

Type

2-stage angle transmission

Gear ratio

14.20:1

Oil volume, litre

1.75

Oil type at normal temperature at temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Service Manual

7PLL24

2- 1

Technical data – M4 T-code 497

Valid from serial number 723984-

Date 2005-11-04

Model

Order number 222996-040

7PLL24

Wheels Drive wheel, mm Drive wheel for servo, mm

250x75 250x105

Axle pressure without load, kg

460

Axle pressure at rated load, kg

770

Wheel pressure at rated load, kg/cm2

Tightening torque wheel bolts, Nm

130

Fork wheel, Bogie, mm

80x74

Axle pressure without load, kg

175-320

Axle pressure at rated load, kg

1800-2300

Wheel pressure at rated load, kg/cm2

47-55

Swivel wheel, mm

150x50

Axle pressure without load

175-605

Axle pressure at rated load, kg

120-790

Wheel pressure at rated load, kg/cm2

12-37

Hydraulic system

2- 2

Output, kW

2.0

Duty cycle

10%

Minimum carbon brush length, mm

Minimum commutator diameter, mm

Pressure at rated load, bar

130

Overflow pressure, bar

145

Pump flow, cc/r

2.5

Tank volume, litre

1.2

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

ISO-L-HM32 ISO-L-HV32

Service Manual

7PLL24

Technical data – M4 Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

Model

T-code 497

7PLL24

Servo steering, Motor (Option) Type

MET 3B 24 V

Output, W

160

Torque constant

0.6 Nm/A

Max current

55 A

Speed, rpm

2550

Minimum carbon brush length, mm

Minimum commutator diameter, mm

Resistance,Ω,armature

0.27

Fuses Control circuits, F50, F51

7.5 A

Drive motor

125 A

Pump motor

160 A

Servo steering (Option)

20 A

Battery compartment, Batteries Battery compartment Dimensions LxWxH, mm Short Long

212x790x775 296x790x775

Capacity, Ah

292-600

Weight, kg

240-500

Driving speed Without load, km/h Without load, m/s

12 3.33 + 5%

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

9,5 2.63 + 5%

Lift/lowering speed

Lift to top with load, s

2.0

Lowering without load, s

2.3

Service Manual

7PLL24

2- 3

Technical data – M4 T-code 497

Valid from serial number 723984-

Date 2005-11-04

Model

Order number 222996-040

7PLL24

Power consumption Driving without load, A

Driving with rated load, A

Lift without load, A

Lift with rated load, A

116

Incline climbing ability Without load

15%, 8.5°

With rated load

8%, 4.5°

Measurement L2 Short Long

730 mm 814 mm

Wa with 1170 mm forks and lift fork

Wa with 1170 mm forks and lift fork, fixed side gates

Wa with 1170 mm forks and lift fork, fixed back rest

Lift height

225 mm

Weight

2- 4

Truck without battery, Max

600 kg

Fixed gates

- kg

Fixed back rest

- kg

Service Manual

7PLL24

Technical data – M4 Date 2005-11-04

Valid from serial number 723984-

T-code 497

185

959

1050

1451

Order number 222996-040

422

800-2350

Service Manual

7PLL24

450-685

790

180

2- 5

Technical data – M4 T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

This page is intentionally left blank

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Service Manual

7PLL24

Installation and maintenance instructions – P1 Installation of the new truck Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

3- Installation and maintenance instructions – P1 3.1 Installation of the new truck 3.1.1 Lifting the truck • Lift the truck from the marked lifting points when lifting using a lifting device.

WARNING Risk of tipping The truck can tip if lifted from the wrong points. Always lift the truck from the marked lifting points.

• Lift at the truck's centre of gravity when lifting with another fork lift truck.

Service Manual

7PLL24

3- 1

Installation and maintenance instructions – P1 Installation of the new truck T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

460

L2=741, 0 Ah L2=741, 320 Ah L2=811, 0 Ah L2=811, 600 Ah

GL=800 Tp=460 Tp=480 Tp=480 Tp=520

GL=2350 Tp=770 Tp=690 Tp=800 Tp=700

770

• Secure the truck on the lifting truck's forks. • Lift with greatest possible care. WARNING! Risk of tipping The truck can tip if lifted in the wrong way. Always lift the truck secured on, and with the centre of gravity between, the lifting truck's forks.

3- 2

Service Manual

7PLL24

Installation and maintenance instructions – P1 Installation of the new truck Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

3.1.2 Fitting the battery Check that the battery cables are correctly connected to the battery. WARNING! Risk of short-circuiting. An incorrectly connected battery can cause a short-circuit. The polarity must correspond. Compare the markings on the cables and the battery poles. C

The battery can be replaced from both sides and from above. Depending on which side you wish to dismantle the battery, the battery lock (A) is fitted as illustrated. Also fit the fixed part (B) on the opposite side. Shims (C) are also supplied with the truck. These are used to take up any play between the battery and battery compartment wall. Fit these if necessary as illustrated.

3.1.3 Start up The following points must be checked before the truck is used.

Position no. Inspection points

Action:

Hydraulic function

Check the function

Throttle

Check the function, forwards/backwards

Safety switch against collisions

Check the function

Horn

Check the function

Steering

Check the function

Gate switch

Check the function

Platform

Check the function (return to the top position)

Hydraulic system

Check the oil levels and check for oil leakage

Drive assembly

Check for noise and oil leakage

Brakes

Check the function

Service Manual

7PLL24

3- 3

Installation and maintenance instructions – P1 Installation of the new truck T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Position no. Inspection points

Action:

Platform/Brake switch

Check the function

Chassis

Inspect damage, remove dirt and the like.

Wheels

Inspect damage, remove oil, metal chips and the like

Lifting equipment

Inspect damage, remove dirt and the like.

Battery

Check the acid and charging level (see battery maintenance)

Running time

Carry out maintenance as set out in the table, chapter Maintenance • Also check that parameters are set to the correct values - Maximum speed - Acceleration - Automatic speed reduction - PIN-codes (Option).

3- 4

Service Manual

7PLL24

Installation and maintenance instructions – P1 Introduction, maintenance Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

3.2 Introduction, maintenance All points in the service program shall be included to attain the highest safety and a least possible truck downtime. The service intervals are only a guide and do not need to be followed strictly. The truck driver must adapt these to local conditions, but it is important that the intervals meet TOYOTA's minimum demands. The service intervals are based on operating times and can be adapted to most normal 8 hour shifts. The following operating hours have be used when calculating the interval. Day time:

08.00-17.00 (20 hours/week)

2-shifts:

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

3-shifts:

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

Ensure the truck is given regular maintenance services according to the maintenance schedule. The truck's safety, efficiency and service life is dependent on the service and maintenance it is given. Only use TOYOTA approved spare parts during service and repairs

3.2.1 Safety regulations during maintenance work Only persons trained in servicing and the repair of this type of truck are qualified to carry out service and repair work. • Do not carry out any maintenance work on the truck if you do not have the right qualifications and know how to carry out the work. • Keep the area where service work is done clean. Oil or water will make the floor slippery. • Never wear loose objects or jewellery when working on the truck. WARNING! short-circuit/Burns short-circuiting and burn injuries can occur if metal objects come into contact with live electrical connections, when working on the truck's electrical system. Remove watches, rings and other metal jewellery.

• Always remove the battery plug when carrying out maintenance on the truck, if the instructions in this service manual do not say otherwise. • Always switch off the truck's power supply before the hoods to the drive assembly and the electrical system are opened. • Offload the system pressure slowly before work on the truck's hydraulic system is started. • Use paper or rigid cardboard when checking a possible oil leakage. Never use your hands.

Service Manual

7PLL24

3- 5

Installation and maintenance instructions – P1 Introduction, maintenance T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

• Bear in mind that the oil in the transmission and hydraulic system can be hot. WARNING! Risk of burn injuries Hot transmission and hydraulic oil. Let the truck cool before changing the oil.

• Only new and clean oil may be used in the hydraulic system. WARNING! The hydraulic system can be damaged. Hydraulic components can be damaged, if the oil is contaminated. Always use new and clean oil in the hydraulic system.

• Store and transport changed oil according to applicable local directions. • Do not flush solvents and the like used for cleaning down drains that are not intended for this purpose. Follow local directions that apply for destruction. • Disconnect the battery when welding on the truck. NOTE! The battery can be damaged. When using electric welding equipment, the welding current can enter the battery. The battery must be disconnected.

• Remove at least 100 mm of paint around the welding/grinding area using sand blasting equipment or paint remover when welding or grinding on painted surfaces. CAUTION! Unhealthy gases. Heated paint gives off unhealthy gases Remove 100 mm of paint from around the working area.

3.2.2 Cleaning and washing Cleaning and washing the truck is a significant measure for the reliability of the truck. • Carry out general cleaning and washing each week. NOTE! Risk of short-circuiting. The electrical system can be damaged. Disconnect the battery before washing by pulling out the battery plug.

3- 6

Service Manual

7PLL24

Installation and maintenance instructions – P1 Introduction, maintenance Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

3.2.3 Cleaning the exterior • Clean rubbish from the wheels each day. • Use a well-known degreasing agent, diluted into an appropriate concentration. • Wash off loose dirt with tepid water. NOTE! Jamming, corrosion Mechanical parts can be damaged. After washing the truck it should be lubricated as set out in the chapter Maintenance and lubrication chart.

3.2.4 Cleaning the motor compartment • Cover the electrical motors, connectors and valves before washing. NOTE! Risk of short-circuiting. The electrical system can be damaged. Electrical components must not be washed with high pressure cleaner.

• Wash the motor component using a well-known degreasing agent, diluted into an appropriate concentration. • Wash off loose dirt with tepid water.

3.2.5 Electrical components • Blow electrical components clean using compressed air. • Clean electrical panels, electronic cards, connectors, contactors, solenoid valves, etc. with a moist cloth and a cleaning agent. NOTE! Risk of short-circuiting. The electrical components can be damaged. Do not break the warranty seal on the electronic card.

Service Manual

7PLL24

3- 7

Installation and maintenance instructions – P1 Safe lifting T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

3.3 Safe lifting All lifting must be carried out on a flat, anti-slip and firm surface. Avoid newly laid asphalt or asphalt on a hot summer day. • Always apply the parking brake to prevent the truck from moving while lifting. If the lift concerns the brake wheel, chock the other wheels so that the truck stands still. • Select the lifting points so that the lift is as easy as possible (one corner at a time). If the truck has marked lifting points on the lower part of the chassis, these should be used to give a well-balanced lift. • Ensure the area where you place the jack is clean and free of oil and grease. • Ensure there is no grease or oil on your hands or the jack lever. • Use the lever belonging to the jack. A too short lever will require more effort than is necessary. If the lever is too long there is a risk that the jack will be overloaded. • Block up the truck. - as close to the lifted part of the chassis as possible to reduce the falling height in the event of a collapse. - so that the truck cannot roll. - Never block up the jack to lift higher. - Never work under a lifted truck without appropriate blocking. WARNING! Risk of being crushed. Bad blocking under a truck can collapse Never work under a truck that is not blocked with pallets and secured in a lifting device.

3- 8

Service Manual

7PLL24

Preventive maintenance – P2 Maintenance schedule Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

4- Preventive maintenance – P2 4.1 Maintenance schedule I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate M: Measure, correct if necessary

Pos. no.

Work to carry out Interval in hours - may vary due to application

500

1000

3000

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

1d 1w 6m

12m

36m

0000.

Chassis

0000.1

Check all links and spiral pins

0000.2

Check for damage to the platform.

0000.3

Check the cover locks

0000.4

Check the finger guard

0000.5

Check signs and stickers

0000.6

Push in grease in the grease nipples

0380

Fork carriage

0380.1

Check for crack formation and damage

0380.2

Check the play in bushings and links

0380.3

Push in grease in the grease nipples

0380.4

Check the lift limit switch

1700.

Motors

1700.1

Check for loose connections

1700.2

Check the carbon brushes in the drive motor

1700.3

Clean the drive motor

1700.4

Tighten the mounting bolts

1700.5

Check for abnormal noise in the bearings

1700.6

Check the steering motor carbon brushes (Option)

2550.

Drive assembly

2550.1

Check for leakage

2550.2

Check oil level

2550.3

Check for abnormal noise

2550.4

Check mountings and play in the steering bearings

2550.5

Change the oil in the drive transmission

2550.6

Lubricate the gear ring (Servo, Option)

I/L6

I/L I

I/T1

I/T

Service Manual

7PLL24

L4 L

4- 1

Preventive maintenance – P2 Maintenance schedule T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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

Pos. no.

Work to carry out Interval in hours - may vary due to application

500

1000

3000

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

1d 1w 6m

12m

36m

3100

Brakes

3100.1

Clean

3100.2

Check for wear to the brake discs

3100.3

Check for play in released position

3500.

Wheels

3500.1

Remove string and other detritus

3500.2

Check for wear on the drive wheel

3500.3

Check that the swivel wheels rotate and swing freely

3500.4

Check for wear to the swivel wheels

4110.

Tiller arm

4110.1

Check for play on steering joints

4110.2

Check the steering force

4110.3

Check the gas cartridge's force

4110.4

Check the adjustment of the steering chain, lubricate

5000.

Electrical functions

5000.1

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

5000.2

Check the function of the safety switch against collision

5000.3

Check the operation of the gate switch

5000.4

Check the operation of the platform switch

5000.5

Check the horn

5000.6

Check for wear to the cables

5000.7

Check the operation of the driver's controls

5000.8

Check the error code log and operatingtimes

4- 2

Service Manual

I L/M I/L

7PLL24

Preventive maintenance – P2 Maintenance schedule Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

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

1d 1w 6m

12m

36m

5110.

Battery

5110.1

Check electrolyte levels, 10-15 mm above the cell plates

5110.2

Check connections on the battery, truck and charger

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 lock

5400

Power system

5400.1

Clean and check the mountings

C/T1

5400.2

Tighten the cable connections

5400.3

Check the contactor points on K10 and K30

5400.4

Check the contactor movement

5700

Electronic card

5700.1

Clean the electrical panel

5700.2

Check the connectors and cables

5700.3

Check all segments on the display

6100.

Hydraulic system

6100.1

Check for leakage from hoses and couplings

6100.2

Check for wear to the hoses

6100.3

Check the tank

6100.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

6600.

Lift cylinders

6600.1

Check for leakage

6600.2

Check the mountings

6680

PowerTrak

6680.1

Check for any damage, cracks on the PowerTrak springs

6680.2

Grease the ground pressure spring's guides

Service Manual

I C/T

C TI

I I

I L5

7PLL24

I C/L

4- 3

Preventive maintenance – P2 Maintenance schedule T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

1= Connections are tightened for the first time after 500 hours and then every 1000 hrs/ 12 months. 2= Mounting bolts are tightened after 500 hrs/6 month to 45 Nm. 3= Check for leakage in connection with the first oil change. 4= The oil is changed for the first time after 500 hrs/6 month and then every 3000 hrs/36 months. 5= The oil is changed and the filter cleaned for the first time after 500 hrs/6 month and then every 1000 hrs/12 months. 6 = If the truck goes into a refrigerated environment or other harsh environment, the point is addressed at more frequent intervals. When points with higher time intervals are addressed, the points with shorter time intervals should also be addressed unless otherwise stated above. 5000 5000

5700 4110

4110 6680

5000

5110 6600 0380

5400 3100

2550

1700 3500 0000

0000 6100 3500 5000

4- 4

Service Manual

7PLL24

Preventive maintenance – P2 Lubrication chart Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

4.2 Lubrication chart Pos. no.

Service point

Interval/Operating hours

0380

Grease nipples (Option)

2550

Drive transmission

2550

Gear ring

4110

Steering chain

6100

Hydraulic system

6680

PowerTrak, ground pressure spring

80 hrs

1000 hrs

Lubrica3000 hrs tion type

L O4

F O

L= LubricateI = InspectionO = Oil change 4= The oil is changed for the first time after 500 hrs/6 month and then every 3000 hrs/36 months. 5= The oil is changed and the filter cleaned for the first time after 500 hrs/6 month and then every 1000 hrs/12 months. 6680 0000

0380

4110

0380

2550

6100

Service Manual

7PLL24

4- 5

Preventive maintenance – P2 Lubrication chart T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

This page is intentionally left blank

4- 6

Service Manual

7PLL24

Oil and grease specification – P3 Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

5- Oil and grease specification – P3 Pos.

Lubrication type

Specification

Use

>-15°C

<-15°C

Grease

223690 Q8 Rembrandt EP2

Bearings and bushings

Hydraulic oil

ISO-L-HM32

ISO-VG32

Hydraulic system

Transmission oil

Hypoid oil SAE 80W/90

Hypoid oil SAE 75W

Gears

Grease

See table below

Chains

Grease

Grafloscon A-G1 (Klüber)

Gear ring

Grease

213366 Q8 Rubens WB

Grease nipples, Ground pressure spring

Ambient temperature

Viscosity class

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

> -40°C < -30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> -30°C < +5°C

VG 68

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

> +5°C < +45°C

VG 150

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

> +45°C < +80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

Service Manual

7PLL24

5- 1

Oil and grease specification – P3 T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

This page is intentionally left blank

5- 2

Service Manual

7PLL24

Tools Super Seal connectors Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

6- Tools 6.1 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

7PLL24

6- 1

Tools AMP connectors T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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

Figure

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)

6- 2

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

Service Manual

7PLL24

Tools Molex connectors Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

6.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

6.3 Molex connectors 16 9 8 1 Figure

Service Manual

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

7PLL24

6- 3

Tools Grease guns T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

6.4 Grease guns Figur

fif

6- 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

7PLL24

Tools Other tools Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

6.5 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

7PLL24

6- 5

Tools Other tools T-code 497

Valid from serial number 723984-

Figure

-1 -2

Date 2005-11-04

Order number 222996-040

Number

Application

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

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

-3 -4

6- 6

Service Manual

7PLL24

Fork carriage – 0380 Component parts Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

7- Fork carriage – 0380 7.1 Component parts 42 43

44,45,46

41 40

25 26 33 34 26 33 15 38 39

Service Manual

7PLL24

7- 1

Fork carriage – 0380 Component parts T-code 497

7- 2

Valid from serial number 723984-

Date 2005-11-04

Pos.

Description

Notes

Roller

Initially lubricated

Circlip

Spring washer

Steering

Grease nipple

Wheel fork

Axle

Spiral pin

Bush

Axle

Spiral pin

Bush

Sleeve

Screw

Washer

Axle

Bush

Axle

Screw

Pivot pipe

Roller

Gas cartridge

Bracket

Screw

Switch

Screw

Nut

Washer

Service Manual

7PLL24

Order number 222996-040

Minimum play with 2-4 spring washer

Option

Fork carriage – 0380 Dismantling the fork carriage Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

7.2 Dismantling the fork carriage

• Remove the battery.

• Place supports under the chassis, as illustrated, on both sides of the truck.

• Dismantle the battery hood.

Service Manual

7PLL24

7- 3

Fork carriage – 0380 Dismantling the fork carriage T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

• Dismantle the gas dashpot.

• Release the hoses, loosen the screws (A) and lift out the lift cylinders.

• Lift out the fork carriage. Assemble in the reverse order. 7- 4

Service Manual

7PLL24

Fork carriage – 0380 Replacing the rollers Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

7.3 Replacing the rollers

12 13 14

• Remove the guide (14) and spring washers (13), remove the circlip (12) and remove the roller (11). Assemble in reverse order. • Minimise the play between the steering (14) and the cross member with 2-4 spring washers (13).

Service Manual

7PLL24

7- 5

Fork carriage – 0380 Replacing the rollers T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

This page is intentionally left blank

7- 6

Service Manual

7PLL24

Engine suspension– 0450 Component parts Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

8- Engine suspension– 0450 8.1 Component parts

1 3 2

15 7

Service Manual

7PLL24

8- 1

Engine suspension– 0450 Component parts T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

8.1.1 Component List

8- 2

Pos.

Description

Plate

Steering pin

Screw

4x MF6S 10x45

Bracket

Axle

Spiral pin

Pivot pipe

Grease nipple

Washer

(0,5 mm) Number as required

Washer

(1 mm) Number as required

Bushing

Washer

Screw

2x M6S 8x16

Axle

Engine bracket

Circlip

Link

Service Manual

7PLL24

Notes

Electric drive motor – 1760 Component parts Order number 222996-040

Date 2005-11-04

9.1 Component parts

5 6 4

Pos.

Description

Notes

Screw

M6x25

Screw

Bearing bracket

N-side

Locking ring

Washer

Bearing

Protective ring

Carbon brush

Carbon bridge

Screw

Rotor

Wedge

Guard

Pole connection

Stator case

Bearing bracket

Fan

Screw

Adjuster bush

18 19

Seal flange

O-ring

Seal

Bearing

Locking ring

Ring

Locking ring

12 14

16 17 20 22 24 26

T-code 497

9- Electric drive motor – 1760

Valid from serial number 723984-

Service Manual

7PLL24

6205 HT24B

M5x20 4x6x16

D-side M5

6204 ZC3

9- 1

Electric drive motor – 1760 Removing the motor from the truck T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

9.2 Removing the motor from the truck • Switch off the truck and remove the battery plug. • Remove the hood over the motor compartment. • Loosen the four screws for the gate console and loosen the connections for the ignition, emergency switch and the gate switch and lift off the gate console. Loosen the four bolts for the gate console bracket.

• Disconnect the motor cables. • Dismantle the brakes • Unscrew the five bolts holding the motor shield against the motor plate.

• Lift out the motor and place it on a clean surface. Cover the drive transmission opening . The necessary service and repairs can now be carried out on the motor.

9- 2

Service Manual

7PLL24

Electric drive motor – 1760 Refitting the motor in the truck Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

9.3 Refitting the motor in the truck • Assemble in reverse order. • Fit a new O-ring on the seal flange (22) on the drive shaft. • Carefully lift the motor down in the drive transmission so that the seals and gears are not damaged. • Tighten the five bolts holding the motor shield on the motor plate to 45 Nm.

1 2 4

• Connect the motor cables. Check that the polarities are correct. Connect the brake.

• Check the operation of the brake.

5 6 4

9.4 Service and repairs

7 9 10

9.4.1 Dismantling N-side • Remove the carbon brushes (8). • Loosen the screws (1). • Loosen the screws (2). • Dismantle the bearing bracket (3).

• Dismantle the locking rings (4). • Dismantle the washers (5).

• Dismantle the bearing (6).

12 14

Assemble in reverse order.

9.4.2 Dismantling D-side 15

• Dismantle the locking ring (26). • Dismantle the ring (25).

• Dismantle the seal flange (20). • Dismantle the locking ring (24). • Dismantle the bearing (23).

17 18 19 20 22

21 23

24 26

• Dismantle the seal (22). • Dismantle the fan (17). Using a slide hammer, if necessary. • Dismantle the adjuster bush (19). Assemble in reverse order.

Service Manual

7PLL24

9- 3

Electric drive motor – 1760 Service and repairs T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

9.4.3 Cleaning For correct functioning, it is important that the motor be kept as clean as possible. The motor and motor compartment must be checked regularly for dust, oil and other contamination. If the motor windings and interior are dry, use a vacuum cleaner with a suitable nozzle to clean the motor. Compressed air can be used in combination with a vacuum cleaner. If so, the compressed air must be clean and dry. If the windings have a coating, use a lint-free cloth, dampened if necessary with an organic and volatile cleaning agent that can dissolve grease but which will not damage the windings. However, the cleaning agent must not be used in such quantities that it enters motor parts. Remnants of the cleaning agent must be removed with a suitable solvent, if it leaves an oily surface. If the motor parts are badly soiled, it may be necessary to spray them with a solvent. It is especially important with the armature that the solvent is applied in such a way that dissolved dirt, etc. does not enter the motor section. One method of cleaning the armature is to dip it in solvent. If this is done, the armature must always be heat dried. Good ventilation is necessary during drying which must continue until a number of insulation measurements give similar and approved results.

9- 4

Service Manual

7PLL24

Mechanical drive gear unit – 2550 Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

10- Mechanical drive gear unit – 2550

2 1

3 4 5 6

16 17

8 9

11 12

Service Manual

7PLL24

10- 1

Mechanical drive gear unit – 2550 Component parts T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

10.1 Component parts

10- 2

Pos.

Description

Motor gear

Lock nut

Primary gear

Conical roller bearing

Shim

Conical roller bearing

Lock nut

Cover

Screw

Shim

Pinion/Crown gear

Drive shaft

Wheel bolt

Tightening torque 90 Nm Lock using Loctite 270

Sealing ring

Fill the sealing ring with grease Seal using Loctite 574

Conical roller bearing

Service Manual

Notes Tightening torque 130 Nm Lock using a centre punch.

Tightening torque 400 Nm Lock using a centre punch.

Tightening torque 25 Nm Lock using Loctite 242

7PLL24

Gear play 0.09-0.15 mm. Pretension the bearing with 2-5/100. Stamped measurement on pinion adjusted using shims.

Mechanical drive gear unit – 2550 Dismantling/Assembly Leakage from the upper cover Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

10.1.1 Technical data Type of truck

7PLL24

Transmission type

2-stage angle transmission

Gear ratio

14,20:1

Oil volume, litre

1.75

Oil type

Hypoid oil

Viscosity, normal temperature

SAE 80W/90

Viscosity, <-15°C

SAE 75W

10.2 Dismantling/Assembly Leakage from the upper cover • Unscrew the platform. • Lift up the truck and block it so it is stable. • Unscrew the drive wheel. • Unscrew the M8 bolts holding the transmission in the transmission cover using an 6 mm allen key. Support the transmission so it does not fall. Assemble in the reverse order • Seal the transmission against the cover using Loctite 547. • Tighten the M8 bolts to a torque of 27 Nm.

Service Manual

7PLL24

10- 3

Mechanical drive gear unit – 2550 Replacing the drive shaft gasket T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

10.3 Replacing the drive shaft gasket The drive shaft sealing ring can be replaced with the transmission fitted in the truck. Follow the instructions below if oil leaks from the drive shaft.

10.3.1 Dismantling

7 6 5

2 3

4 • Remove the drive wheel from the transmission. • Remove the lower transmission cowl and drain the oil (2). • Loosen the drive shaft nut. Remove the nut and the spacer ring (3). • Carefully tap out the drive shaft using a hammer and brass drift (4). • Pull off the bearing from the drive shaft using tool 08-13022 (5). • Check that the bearing discs are not damaged. If they have been damaged by the puller, measure the spacer washers' combined thickness and replace them before assembling (6). • Remove the gasket ring from the drive shaft (7).

10- 4

Service Manual

7PLL24

Mechanical drive gear unit – 2550 Replacing the drive shaft gasket Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

10.3.2 Assembling Assembly of the transmission after replacing the drive shaft's sealing ring is carried out in the reverse order. Bearing in mind the following when assembling. • Fill the sealing ring with grease after fitting it on the drive shaft. • Ensure only undamaged spacer washers with the same overall thickness as the original washers are placed on the drive shaft. • Press the bearing on the drive shaft and make sure the bearing's spacer washers are not damaged. • When the drive shaft with the bearing, spacer washers and seal is fitted, ensure that the shaft keyways correspond with the crown gear's keys and that the bearing and seal sit correctly in the gear housing before the axle is fully pressed in. • Place the distance ring on the end of the drive shaft, and fit the shaft nut. Always use a new nut. Tighten the axle nut to a torque of 400 Nm and lock with a centre punch mark in the centre. The drive shaft nut should be lubricated before it is placed on the shaft. • Replace the O-ring before installing the lower cowl. Make sure it is not damaged. Mount the cowl and tighten the bolts to a torque of 25 Nm. The bolts should be greased before assembly. Fill with oil as set out in the instructions for refilling. Mount the drive wheel and tighten the wheel bolts to a torque of 90 Nm. The bolts should be greased before assembly.

Service Manual

7PLL24

10- 5

Mechanical drive gear unit – 2550 Replacing wheel bolt T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

10.4 Replacing wheel bolt The wheel bolts on the transmission are stud bolts. To replace the wheel bolts, proceed as follows:

• Pull out the battery's emergency disconnector. • Remove the platform. • Lift the machine using a jack and put it on blocks. • Remove the drive wheel. • Wheel bolts with damaged threads are removed using the stud bolt tool. • Broken wheel bolts: • Method 1: Drill a hole in the centre of the bolt and screw out the bolt using a screw extractor for M14 bolts. • Method 2: If the bolt will not come loose with a screw extractor, the bolt must be drilled out. - Drive a centre punch into the centre of the bolt. Be careful to centre the centre punch. - Drill a pilot hole through the bolt using a 5 mm bit. Drill out the bolt using an 11.5 mm bit. - Try to remove the remains of the bolt with pliers or the like. If that does not work, remove the remains by clearing the threads with a screw tap M14x1.5. • Apply LOCTITE 270 on the threads of the wheel bolts. Mount the new wheel bolt with a stud bolt tool. Tightening torque 90 Nm Assemble the drive wheel. Tighten the wheel nuts to xx Nm. • Remove the blocks and lower the truck. • Assemble the platform. • Connect the battery disconnector. 10- 6

Service Manual

7PLL24

Electromagnetic brake – 3370 Component parts Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

11- Electromagnetic brake – 3370 1

3 4 5

12 11 10 9

13 A

A-A

11.1 Component parts

Pos.

Description

Magnet housing

Screw

Pressure plate

Sleeve

Service Manual

Notes 3

7PLL24

11- 1

Electromagnetic brake – 3370 Dismantling T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Pos.

Description

Notes

Shims for adjusting the air gap

1 = 0.5 mm 5 = 0.13 mm on each position

Friction disc, brake disc

Nom. thickness: 9.7 mm Min thickness: 7.7 mm

O-ring

Hub

Mounting plate

Screw

Spring

Cable with connector

Screw for manual release

Not supplied M6

11.2 Dismantling • Loosen the screws (10). • Lift off the brake from the motor axle. • Place the brake on a clean surface. • Unscrew the adjuster screws (2) gradually to reduce the spring tension equally.

11.2.1 Inspection Check the parts for damage and/or wear: • Check the brake disc (6) and the wear surfaces on the pressure plate (3) extra carefully. • Check the springs (11) and the spacers (4, 5) with regard to damage. • Check for signs of damage to the splines on the hub (8) and friction disc (6). • Check for signs of swelling/deformation or damage to the magnet (1) and pressure plate (3).

11- 2

Service Manual

7PLL24

Electromagnetic brake – 3370 Assembling Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

11.3 Assembling • Clean the parts carefully. • Assemble the brake in the reverse order to dismantling. • Bear in mind the following: - That the hole in the pressure plate (3) aligns with the corresponding hole in the magnet housing. - That the right number of springs have been fitted. - That the play 0.25-0.38 mm has been set correctly. Should possibly be adjusted. NOTE! The friction surfaces must not come into to contact with oil or grease as this will seriously reduce the brake’s operation.

11.4 Manual release of the brake

13 A

The brake can be released manually, for example, if the brake is broken A and the truck needs to be moved to the service area or in order to centre the brake disc easier during assembly. To release the brake unscrew the two screws (13) equally and gradually. WARNING!

A-A

Lost braking function. The braking function is lost when the brake is manually released. Drive the truck at reduced speed and pay extra attention. Do NOT forget to remove the screws.

11.5 Adjustment 11.5.1 Adjusting the play 9,5 Nm

0,25-0,38 mm

4 5

• Measure the play in three places. • Adjust the play by removing the shims (5).

Service Manual

7PLL24

11- 3

Electromagnetic brake – 3370 Adjustment T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

This page is intentionally left blank

11- 4

Service Manual

7PLL24

Steering system – 4000 Component parts, mechanical steering Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

12- Steering system – 4000 12.1 Component parts, mechanical steering A 1

4 3

Service Manual

7PLL24

12- 1

Steering system – 4000 Component parts, mechanical steering Date 2005-11-04

Order number 222996-040

9 11 12

26, 27

18, 19

14 15 19

B-B

A-A

Valid from serial number 723984-

T-code 497

12- 2

Service Manual

7PLL24

Steering system – 4000 Component parts, mechanical steering Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

5 10

10 6 9 7

18 19

8 26

15 23

22 21 20

14 13 11 12 17 16 17 2

Service Manual

7PLL24

12- 3

Steering system – 4000 Component parts, servo steering (Option) T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

12.2 Component parts, servo steering (Option) 28 29

31 30

32 10

10 6 9 7

18 19

8 26

15 23

22 21 20

14 13 11 12 17

17 2

12- 4

Service Manual

7PLL24

Steering system – 4000 Component parts, servo steering (Option) Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

12.2.1 Steering axle, servo steering (Option) A

49 50 51 52 53 B-B

35 36 37 38 39 40 41 42 43 44 45

46 47 48

A-A

Service Manual

7PLL24

12- 5

Steering system – 4000 Component parts, servo steering (Option) T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

35 37 36 38 38

51 49 50

40 47 41

43 44

42 45

12- 6

Pos.

Description

Notes

Steering rod

Mechanical steering

Service Manual

7PLL24

Steering system – 4000 Component parts, servo steering (Option) Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Pos.

Description

Gear ring

Sleeve

Locking screw

Sleeve

Steering joint with sprocket

Bearing

Locking ring

Screw

Steering

Sprocket

Screw

M6x20 9.5Nm

Screw

M8x35 23.0 Nm

Steering bearings

Nilos ring

Lock nut

Stud bolt

Lock nut

Sleeve

Dashpot

Washer

Adjustment screw

Tension arm

Chain

Chain lock

Service Manual

7PLL24

Notes

M8x35 23.0 Nm

Tightened so there is no axial play on the tension arm.

12- 7

Steering system – 4000 Component parts, servo steering (Option) T-code 497

Valid from serial number 723984-

Pos.

Description

Date 2005-11-04

Order number 222996-040

Notes

Power steering (Option)

12- 8

Steering unit

Steering axle

Axle

Steering motor

Gear

Washer

Screw

Steering column

Circlip

Sliding bearing

Washer

Axle

Spacer

Ring

Circlip

Bearing

Circlip

Sleeve

Wedge

Screw

Dashpot

Stop screw

Nut

Service Manual

7PLL24

Steering system – 4000 Adjustment, steering Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

12.3 Adjustment, steering 12.3.1 Adjusting the steering servo • Switch off the voltage.. • Lift up the truck so that the drive wheel is free of the ground • Loosen the two screws (A), so that the servo can be easily adjusted laterally. • Start up the truck. • Hold your hand lightly on the servo when the voltage is switched on. Press the servo lightly against the steering column.

NOTE! Risk of being crushed. Press lightly The steering can quickly drift off in either direction.

• Now adjust the servo laterally until the steering stands still. The servo is pressed lightly against the steering column when adjusting. • When the steering stands still the screws (A) are tightened again. • Now test the servo setting by steering to the left and right, then release the steering and make sure the steering stands still, it should not drift in any direction. If the steering drifts the adjustment must be restarted from the point "Switch on the voltage" above. • Lower the truck to the floor and test drive. The distance between the servo unit and the steering column directly affects the gain on the servo. With 4.5° turning of the tiller arm relative to the drive wheel, you can measure 95% of the battery voltage across the steering motor.

12.3.2 Adjusting the steering chain • Check the measurement between the sleeve (21) and the fixed bracket on the drive unit. • Adjust using nut (20).

8-10 mm 21 20

Service Manual

7PLL24

12- 9

Steering system – 4000 Component parts, tiller arm T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

12.4 Component parts, tiller arm 1 2 3

5 6

8 7 9

15 17

18 19 20 21 22

12- 10

Service Manual

7PLL24

Steering system – 4000 Adjustment, tiller arm Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Pos

Benämning

Anm

Screw

4 st

Washer

Handle

Screw

4 st

Washer

2 st

Cable holder

Gas dashpot

Bracket

Stop screw

Screw

Ball joint

Screw

Spacer

Bush

2 st

Dashpot

2 st

Axle

Ridge

Spacer

Screw

Spacer

Switch

4 st

S 10

12.5 Adjustment, tiller arm 12.5.1 Adjusting the brake microswitch The switch (23) is always adjusted to its lowest position. • Loosen the screws (13, 20) holding the switch and spacer. • Press down the switch and tighten the screws. • Check that the switch is actuated by the ridge (18) in the arm's upper and lower positions.

Service Manual

7PLL24

12- 11

Steering system – 4000 Tiller arm handle T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

12.6 Tiller arm handle 28 29

27 26 24 25

14 23 22

17 18

21 20

15 14 14

30 31

12 11

10 9 8

2 3

12- 12

Pos.

Description

Screw

Cover

Handle

Electronic card

Screw

Display card

Upper cover

Pushbutton

Signal switch

Signal button

Display glass

Arm

Pushbutton

Sign

Spring

Pushbutton

Arm

Holder

Service Manual

7PLL24

Notes Keyboard option

Option

Lift/Lower

Not used

Steering system – 4000 Tiller arm handle Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Pos.

Description

Spring

Control rocker

Axle

Sliding bearing

Control stop

Arm

Spring holder

Spring

Spring holder

Sliding bearing

Control rocker

Button for safety reversing

Arm

Spring

Lower cover

Screw

M4x40

Screw

2xM5x45 2xM5x60

Service Manual

7PLL24

Notes

12- 13

Steering system – 4000 Dismantling/Assembly, buttons T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

12.7 Dismantling/Assembly, buttons • Dismantle the cover (2), (keyboard option). • Dismantle the screws (35), hold against the upper cover (7). • Disconnect the cable connected to the electronic card (4). • Remove the screws (34). • Carefully lift off the lower cover (33), place a finger between lower cover (33) and button (30) to hold the button (30) in position. Assembly takes place in the reverse order. NOTE Static electricity! Risk of static discharge that can damage electronics. Ensure you take the necessary actions before working with the electronics.

Change from ignition key to keyboard (2) • Connect the CAN-key to the truck. • Enter parameter mode (P). • Change parameter 39 to value = 3 or 4. • Set the required PIN-code by using parameter 10. • Switch off the truck. • Dismantle the cover(2) on the tiller arm. • Fit the keyboard. • Remove the ignition key, fit the strap. • Fit the cover in the key hole. • Start the truck using the chosen PIN-code.

Change from keyboard to ignition key (2) • Connect the CAN-key to the truck. • Enter parameter mode (P). • Change parameter 39 to value = 1 or 2. • Switch off the truck. • Remove the keyboard (2) on the tiller arm. • Fit the cover. • Remove the strap. • Remove the cover. • Fit the ignition key. • Start the truck.

12- 14

Service Manual

7PLL24

Steering system – 4000 Dismantling/Assembly, buttons Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

12.7.1 Replacing the signal button/switch (9, 10) • Dismantle the button as illustrated.

• Disconnect the connections for the switch on the electronic card (4). • Press out the switch from its bracket. Assembly takes place in the reverse order.

12.7.2 Replacing the lift/lower button (13) • Remove the button by placing a screwdriver in hole (A) as illustrated below.

• Unscrew the holder (18) so that the arm (12) becomes loose. Assembly takes place in the reverse order.

Service Manual

7PLL24

12- 15

Steering system – 4000 Dismantling/Assembly, buttons T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

12.7.3 Replace the pushbutton (16) • Press the button, by hand, sideways. • Place a screwdriver as illustrated and carefully pry out the button.

• Unscrew the button's holder and arm. Assembly takes place in the reverse order.

12- 16

Service Manual

7PLL24

Electrical systems – 5000 Electrical parts Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13- Electrical systems – 5000 13.1 Electrical parts

S10 S53

S17

S21

Y1 M1

A1 F50 M3 F51 X41 R1 F1

Y41

K10 F3 K30 P1

H1 M6

S19

S59

Service Manual

7PLL24

13- 1

Electrical systems – 5000 Electrical parts T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

13- 2

Service Manual

7PLL24

Electrical systems – 5000 Symbol list and electrical diagram Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.2 Symbol list and electrical diagram Symbol

Description

Function

Notes

Transistor regulator

Electronic card

Display

Keypad

PIN-number login

Option

Fuse

Drive motor circuit

175 A

Fuse

Pump motor circuit

130 A

F 50

Fuse

Operating circuit A5

7,5A

F 51

Fuse

Operating circuit A1

7,5 A

F 52

Fuse

Optional equipment

Option

F64

Fuse

Steering motor

20 A Option

Battery

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

Motor

Drive motor

Motor

Pump motor

Motor

Steering motor

option

M12

Motor

Fan

Not cold store

Potentiometer

Load sensor

PTC-resistor

Power supply

24 V

Service Manual

7PLL24

15 Ohm

13- 3

Electrical systems – 5000 Symbol list and electrical diagram T-code 497

13- 4

Valid from serial number 723984-

Date 2005-11-04

Function

Order number 222996-040

Symbol

Description

Switch

Option

Switch

Option

Switch

Option

Switch

Option

Switch

Option

Switch

Option

S10

Switch

Travel brake

S17

Switch

Key

S18

Switch

Horn button

S19

Switch

Man on platform

S20

Switch

Switch for safety reversing

S21

Switch

Emergency switch off

S31

Switch

Lift height limiter

S34

Switch

Fork lifting

S41

Switch

Fork lowering

S53

Switch

Gates

S59

Switch

Platform in upper position

Brake

Y41

Magnetic valve

Fork lowering

Connector

Battery

X41

Connection point

CAN communication

Service Manual

7PLL24

Notes

Brake lever

Electrical systems – 5000 Symbol list and electrical diagram Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.2.1 Electrical wiring diagram 1(5)

Service Manual

7PLL24

13- 5

Electrical systems – 5000 Symbol list and electrical diagram T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

13.2.2 Electrical wiring diagram 2(5)

13- 6

Service Manual

7PLL24

Electrical systems – 5000 Symbol list and electrical diagram Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.2.3 Electrical wiring diagram 3(5)

Service Manual

7PLL24

13- 7

Electrical systems – 5000 Symbol list and electrical diagram T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

13.2.4 Electrical wiring diagram 4(5)

13- 8

Service Manual

7PLL24

Electrical systems – 5000 Symbol list and electrical diagram Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.2.5 Electrical wiring diagram 5(5)

Service Manual

7PLL24

13- 9

Electrical systems – 5000 Symbol list and electrical diagram T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

13.2.6 Electrical wiring diagram Servo (Option)

13- 10

Service Manual

7PLL24

Electrical systems – 5000 Functional description Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.3 Functional description 13.3.1 Starting the truck • Battery connector plugged in. • S21 closed. • S17 on.

13.3.2 Driving without using platform and gates, speed ≤ 6 km/h

A1 BS1

• S59 open.

Ish

• S10 closed.

MA2

Shunt

+ Ia

• L1 activated in any direction.

A A1

B+

K10

13.3.3 Driving from platform without using gates,speed ≤ 6 km/h • S 19 closed. • S10 closed. • L1 activated in any direction.

13.3.4 Driving from platform and using gates, speed ≥ 8 km/h • S 19 closed. • S 53 closed. • S10 closed. • L1 activated in any direction.

13.3.5 Neutral speed reduction

A1 BS1

Ish

• Load sensor P1 determines speed reduction force.

MShunt

S2 A2

A A1

T2 K10

• L1 to neutral position, motor starts to work as generator. Brake energy comes back to battery.

B+

• Y1 will be applied when the truck comes to a stand still even if the tiller arm is in drive position. • Energy back to the battery, see picture. • The transistors (T2) for the generated brake current are not live. T

Service Manual

7PLL24

13- 11

Electrical systems – 5000 Functional description T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

13.3.6 Neutral speed reduction on slopes If the driver release the speed leaver (L1) on a slope and the truck doesn’t come to a stop within a certain time the electrical brake will be applied.

13.3.7 Braking The brake is always applied when the truck is started with the tiller arm in it’s upper or lower position (S10 open). The brake is released in the same moment as the conditions for driving are fulfilled and the truck starts to move. Conditions to brake the truck: • S10 open or S19 open.

13.3.8 Lifting the forks • S34 activated. • S31 closed. • Battery status ok (if battery capacity >20% left).

13.3.9 Lowering the forks • S41activated.

13.3.10 Horn • S18 activated.

13- 12

Service Manual

7PLL24

Electrical systems – 5000 Hour meter Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.4 Hour meter • Press S18 and turn S17 to on at the same time. • Press S18 until you read the H= hour meters.

• You have now choosen H=hourmeters the symbol “B” will be highlighted. • You can now choose type of hourmeter by pressing L1.

1(A)= Key time. 2(b)= Drive motor time. 3(c)= Pump motor time. 4(d)= Activity time. 5(s)= Time left to make service.

13.5 Error codes • Press and hold S18 while turning S17 to “ON” position. • Press and hold S18 until E = error codes is displayed. • When E is selected, the “E” symbol will light up as an indication of what is shown in the display. • The 50 most recent error codes are stored. The latest error is displayed first. The display shows the error code first, followed by the time when the error occurred. • The error codes are divided into two groups, C = caution and E = error. • C codes are not stored. They are only cautions and remain lit in the display as long as the fault remains. • If there is only one error registered in the memory, the other empty entry lines appear as follows: Error: E - - - and time: - - - - .

Code

Description

TLS: Shock sensors registered values outside the limits

Possible error cause

A shock sensor has reported values that exceed the truck’s tolerance values. Driving may be too hard Check that the shock sensor’s limit values are correctly set. Check that the shock sensor is correctly positioned./The brake engages and stops the truck. The TLS reset command activates the truck

Service Manual

7PLL24

13- 13

Electrical systems – 5000 Error codes T-code 497

13- 14

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Code

Description

TLS: Use of the truck has been blocked

Possible error cause

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

Code

C19

Description

Parameter caution. Displayed for 5 seconds.

Possible error cause

The parameters have probably been changed. When changing/updating the program the parameters have automatically been changed to default values (only applies to old program versions). In later program versions the parameters are only changed if they are outside the values permitted by the new program.

Action

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

Code

C20

Description

Speed control caution.

Possible error cause

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

Action

1. Restart with the speed control in neutral position. 2. Replace the electronic card.

Service Manual

7PLL24

Electrical systems – 5000 Error codes Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Code

C28

Description

Emergency switch caution

Possible error cause

The emergency switch has been activated. No current to the travel regulator, input. A1/16.

Action

1. Check fuse F51. 2. Check the emergency switch. 3. Check the cables from the battery and the battery contacts. 4. If PTC resistor R1 is very hot, remove the battery contact and allow the resistor to cool.

Restart.

Code

C29

Description

Service warning

Possible error cause

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

Service Manual

7PLL24

13- 15

Electrical systems – 5000 Error codes T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Code

C31

Description

Pressure switch warning.

Possible error cause

A problem with the pressure switch. Check that the voltage is approximately 24 V between cables 24 and 40 connected to the pressure sensor. Check the voltage between cable 40 and 63 connected to the pressure sensor. The output voltage should be 0.5 Volt (unloaded machine) - 5 Volt (max load).

Code

C41

Description

Warning of low battery voltage

Possible error cause

Battery voltage < 17 volt. The battery parameters are not correctly set. Time to charge up the battery.

Action

1. Check parameter 21, battery size and type. 2. Check the battery contact and the pole connections on the battery 3. Check the key switch, S17, poor contact causes unpermitted voltage drop. The electrical system measures the voltage inside the travel regulator.

13- 16

Service Manual

7PLL24

Electrical systems – 5000 Error codes Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Code

C42

Description

Warning of high battery voltage

Possible error cause

Battery voltage > 33 volt. Energy return feed to battery during motor braking with a fully-charged battery.

Action

1. The fault disappears after a few lifts, once the battery has been run down slightly. 2. Check the cabling, the battery contact and the contact points on main contactor K10.

Code

C43

Description

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

Possible error cause

Too intensive operation or ambient temperature too cold. Error in the travel regulator. Temperature levels below -25oC or above +85oC reduce running speed.

Action

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

Service Manual

7PLL24

13- 17

Electrical systems – 5000 Error codes T-code 497

13- 18

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Code

C90 (Option)

Description

Extra I/0 (0) CAN communication error

Possible error cause

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

Code

C91 (Option)

Description

Extra I/0 (1) CAN communication error

Possible error cause

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

Code

C92 (Option)

Description

Configuration error Extra I/0 (0)

Possible error cause

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

Code

C93 (Option)

Description

Configuration error Extra I/0 (1)

Possible error cause

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

Code

E101

Description

Travel regulator does not correspond with the type of truck

Possible error cause

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

Action

Check travel regulator and electronic card.

Service Manual

7PLL24

Electrical systems – 5000 Error codes Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Code

E104

Description

Switch-transistor to brake is short-circuited

Possible error cause

Error in the travel regulator, output. A1/3. Incorrect value on parameter 22

Action

Check cabling and contacts. Measure Ohms on the magnet coil (Y1) for the brake. Value 13-15 ohm. Check parameter 22

Code

E106

Description

Digital outputs short-circuited or exceeding field current limit.

Possible error cause

Problem regulating the field current. Internal monitoring error.

Action

1. Check the output for main contactor K10 (A1/ 4), check cabling and contacts and measure ohms for the coil. Value 25-30 ohm. Check the output for the brake coil K10 (A1/3), check cabling and contacts and measure ohms for the coil. Value 13-15 ohm. 2. Check the output for horn (A1/7), check cabling and contacts. 3. Check the drive motor’s shunt winding and cabling and contacts. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

Service Manual

7PLL24

13- 19

Electrical systems – 5000 Error codes T-code 497

13- 20

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Code

E107

Description

Contactor K10 does not close.

Possible error cause

Problem with main contactor points or coil. Contactor’s operating cabling off/not connected. Interruption in the travel regulator’s output, A1/4.

Action

1. Check if the contactor is activated. 2. If the contactor is working, check the contact points and accompanying cabling. 3. If the contactor is not working, check the coil and accompanying cabling. Measure Ohms for the coil. Value 25-30 ohm. 4. Check the travel regulator’s output, A1/4.

Service Manual

7PLL24

Electrical systems – 5000 Error codes Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Code

E108

Description

Contactor K10 does not open.

Possible error cause

Main contactor points welded. Short circuit in the travel regulator’s output A1/4.

Action

1. Check that the contactor’s contact points are not welded together. 2. Check that the R1 resistor is not shortcircuited. 3. If the contact points are OK, but the contactor engaged, check cable 64 and the travel regulator’s output A1/4.

Code

E110

Description

System error.

Possible error cause

Temporary error/error in the travel regulator.

Action

1. Restart the machine. 2. Replace travel regulator.

Code

E140

Description

Error in control total.

Possible error cause

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

Service Manual

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13- 21

Electrical systems – 5000 Error codes T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Code

E141

Description

Software problem.

Possible error cause

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

Action

1. Restart the machine. 2. Download the program again. 3. Replace the electronic card

Code

E150

Description

Fault in the data communication.

Possible error cause

Break on the CAN cable.

Action

1. Check the 119 and 120 cables and their contacts. 2. Replace travel regulator.

Code

E151

Description

Tx error in data communication.

Possible error cause

Travel regulator not responding.

Action

1. Check 119 and 120 cables and the connections on the travel regulator. 2. Replace travel regulator.

Code

E157

Description

Bus shut off.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator. 2. Replace travel regulator. 3. Replace the electronic card

Service Manual

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13- 22

Electrical systems – 5000 Error codes Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Code

E159

Description

Transgression error.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator. 2. Replace travel regulator. 3. Replace the electronic card

Code

E160

Description

Error in safety reversing function

Possible error cause

Error in important sensor part.

Action

1. Replace the electronic card

Code

E200

Description

Open field.

Possible error cause

Shunt field’s circuit open.

Action

1. Check the field winding connections E1 and E2. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm. 2. Check cables 4 and 5 and outputs S1 and S2 3. Replace travel regulator

Service Manual

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13- 23

Electrical systems – 5000 Error codes T-code 497

13- 24

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Code

E201

Description

M minus error.

Possible error cause

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

Action

1. Check cable and connections between A1/ M on the travel regulator and connection A2 on drive motor. 2. Replace travel regulator.

Code

E202

Description

Fault on sensor in travel regulator

Possible error cause

Fault on armature current sensor in travel regulator

Action

Replace travel regulator

Code

E214

Description

CAN timeout in power amplifier.

Possible error cause

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

Action

1. Check cables 119 and 120 between electronic card and travel regulator. 2. Replace electronic card 3. Replace travel regulator.

Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.6 Parameters A

• Press S18 and turn S17 to on at the same time. • Press S18 until you read P= parameters. • You have now choosen P=parameters the symbol “C” on display will be highlighted to indicate what’s currently shown on display. • Scroll to the parameter you want to change or look at by pressing the L1 up or down. • Press S18 ones to get access to the parameter. • Set parameter value by pressing L1 up or down. • Press S18 ones to confirm change. • Turn S17 to off. You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid. NOTE ! Truck handling. Modifying specific truck parameters will change the driving characteristics of the truck. Do not change any parameters without the necesarry know-how.

13.6.1 Driver parameters Parameter

Name

Unit

Min

Max

Step

Std

Description

Speed, low Speed

100

10:low Speed 100:highest Speed

Speed, high speed

100

10:low Speed 100:highest Speed.

Acceleration

100

10:low acceleration 100:full acceleration

Neutral speed reduction

100

Defines motor speed reduction force when lever goes to neutral position. 5: low reduction force 100: full reduction force

Logout

The time it takes for the truck to switch off when the keypad is used. The time counts down from the moment the last power-consuming unit is used. Value = 0 gives 4 hours. In steps of 1

1min

Service Manual

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13- 25

Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

13.6.2 Parameter description Parameter 1 Possibility to adjust the speed in the low speed range (when the safety gates are not used).

Parameter 2 Possibility to adjust the speed in the high speed range (when the safety gates are used).

Parameter 3 The lower value of the parameter the longer time it takes to accelerate the truck to top speed.

Parameter 4 Defines motor brake force when lever (L1) goes to neutral position.The lower value of parameter the longer time to reduce speed.

Parameter 5 The time until the truck will be switched off when a key pad is used. Time is counted from when the latest power consumer is used. Value = 0 gives 4 hours.

13- 26

Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.6.3 Service parameters • • • •

Connect CAN-key in X41 Press S18 and turn S17 to on at the same time. Press S18 until you read P= parameters. You have now choosen P=parameters the symbol “C” on display will be highlighted to indicate what’s currently shown on display. • Scroll to the parameter you want to change or look at by pressing the L1 up or down. • Press S18 ones to get access to the parameter. • Set parameter value by pressing L1 up or down. • Press S18 ones to confirm change. • Turn S17 to off. You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid. NOTE ! Truck handling. Modifying specific truck parameters will change the driving characteristics of the truck. Do not change any parameters without the necesarry know-how.

Parameter

Description

Min .

Max .

Step

Std .

Description

PIN-code

9999

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

Crawling speed

-10

The amount of power the monitor should emit when you reach the first speed sensor can be specified here. -10: low speed for the first speed sensor. 10: high speed for the first speed sensor

Non-configurable option 0 to 9

See “Option parameters” on page 29

Configurable option #1

See “Option parameters” on page 29

Configurable option #2

Configurable option #3

Configurable option #4

Unit

Service Manual

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13- 27

Electrical systems – 5000 Parameters T-code 497

Parameter

Description

Valid from serial number 723984-

Date 2005-11-04

Unit

Order number 222996-040

Min .

Max .

Step

Std .

Description

Hour meter option

Select hour meter.

Battery size

Selection of battery size.

Inductive sensor

0: Mechanical switch 1: Inductive sensor

Service interval

2000

100

Option for setting service timer

Lift button selection

Button selection

Password

States which level of authorization the driver has for the parameters. Odd values specify open driver parameters, even values specify that driver parameters must be opened using the CAN key

13.6.4 Parameter description Parameter 10 NOTE! The functionality of parameter #10 is set aside if the value of parameter #39 is set to 5,6,7 or 8. The PIN codes are managed using the socalled expanded keypad. See section “Expanded keypad - General” on page 41 for more detailed information.

Ten drivers can have their own PIN code to gain access to the truck. Each driver can set all driver parameters individually. On delivery the PIN code is set to 1 and this only applies for driver no. 1. Code 0 is not accepted as a solitary code. When you wish to start the truck enter your code and press the green button numbered 1. When you want to switch off the truck, press the red button numbered 0. When the CAN key is connected, you can start the truck by simply pressing the green button numbered 1. Switch off by pressing the red button numbered 0.

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

Parameter 15 - Non-configurable option See “Option parameters” on page 29. 13- 28

Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Parameter 16 - Configurable option #1 See “Option parameters” on page 29.

Parameter 17 - Configurable option #2 See “Option parameters” on page 29.

Parameter 18 - Configurable option #3 See “Option parameters” on page 29.

Parameter 19 - Configurable option #4 See “Option parameters” on page 29.

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

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

Parameter #15 Non-configurable options Up to 16 so-called sub-parameters are stored under parameter #15. Their status is either ON or OFF and they do not require any other adjustments. They are therefore called non-configurable options.

Service Manual

7PLL24

13- 29

Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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

The parameter symbol is lit. • Select parameter #15 using [L1]. The first set-up of sub-parameters is displayed The next set-up of sub-parameters is displayed if you continue to activate the speed control L1. Ensure that only the relevant sub-parameters are displayed. The value of the sub-parameters is displayed after 1 second. • Press the horn button S18.

The parameter symbol flashes.

• Enter the sub-parameter value by repeatedly operating the speed control L1 in either direction. See Table 1: for more information. • Press the S18 horn button once to confirm the new setting.

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

• Switch off the truck by pressing

on the keypad.

The non-configurable option is now activated. • Check that the function works correctly before the truck is put back in operation.

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Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Sub-parameter no.

Function name

Function ON

Function OFF

Basic setting

Table 1: Parameter #15 Non-configurable option Value

Note!

"Turtle" function

2 to 9

For future use

Parameter #16 to 19 configurable optional functions Parameter no. #16, #17, #18 & #19 can be adjusted to activate up to a maximum of 4 pre-programmed functions and configure these to suit optional equipment or customisation of the truck. See Table 2, “List of configurable optional functions,” on page 33. These are thus called the configurable optional functions. • Each parameter can be programmed to cover a specific optional function. • Each optional function can have up to 4 independent variables associated with it. • Each independent variable has a value you can change to configure the function.

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Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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

16 - 0 - 1

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

SETTING THE OPTIONAL FUNCTION

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

16 - 1- 1

Independent variable value (the range depends on the function referred The value depends on the option and independent variable selected. See separate table CONFIGURING THE OPTIONAL FUNCTION

Fig. 1 Summary – option parameter

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

The parameter symbol is lit. • Select parameter #16, #17, #18 or #19 using [L1]. Independent variable #0 is displayed The independent variable value is displayed after 1 second. The value “0” means that an optional function has not been assigned to this parameter, and the speed control L1 in this case displays the next parameter if you continue to activate it. • Press the horn button S18.

The parameter symbol flashes. • Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction. See Table 2: • Press the S18 horn button once to confirm the new setting. 13- 32

Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

The parameter symbol is lit (i.e. stops flashing). • Select independent variable #1 by activating the speed control L1. Independent variable value #1 is displayed after 1 second. • Press the horn button S18.

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

The parameter symbol is lit (i.e. stops flashing). Adjust independent variables #2, #3 and #4 in the same way as above. • Switch off the truck by pressing

on the keypad.

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

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

Independent variable #2

Independent variable #3

Independent variable #4

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

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

1-6:option button 1-6

Type of function: 0:instantaneous 1:butterfly switch

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

0-7:Digital input 1-8

0-12:reduced speed 40-100% (i.e. 40+5*arg3 e.g. 4: 40+5*4=60%)

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

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

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

Service Manual

Select movements. See Table 3:

7PLL24

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

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Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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

Independent variable #2

Independent variable #3

Independent variable #4

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

0-7:Digital input 1-8

0-30:Holding time 030 minutes

Not used

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

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

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

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

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

13- 34

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

Service Manual

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

7PLL24

Not used

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Table 3: Option 3 – Choice of movement

Selected movement

Independent variable #3

Driving forward

Driving backward

Driving forward or backward

Fork lift

Fork lift or driving forward

Fork lift or driving backward

Fork lift or driving forward or driving backward

Fork lowering

Fork lowering or driving forward

Fork lowering or driving backward

Fork lowering or driving forward or driving backward

Fork lift or fork lowering

Fork lift or fork lowering or driving forward

Fork lift or fork lowering or driving backward

Fork lift or fork lowering or driving forward or driving backward

All other movements (AOM)

Driving forward or AOM

Driving backward or AOM

Driving forward or driving backward or AOM

Fork lift or AOM

Fork lift or driving forward or AOM

Fork lift or driving backward or AOM

Fork lift or driving forward or driving backward or AOM

Fork lowering or AOM

Fork lowering or driving forward or AOM

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Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Table 3: Option 3 – Choice of movement Selected movement

Independent variable #3

Fork lowering or driving backward or AOM

Fork lowering or driving forward or driving backward or AOM

Fork lift or fork lowering or AOM

Fork lift or fork lowering or driving forward or AOM

Fork lift or fork lowering or driving backward or AOM

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

Parameter 20 You decide yourself what the hour meter will show. 1A = Key time 2b = Movement time 3c = Drive motor time 4d =Pump motor time 5s = Time for service

Parameter 21 You must specify the type of battery the truck is equipped with. In order to set the meter for the battery’s level of discharge, the following should be taken into account: • Acid concentration when the battery is fully charged, to check the grade of the battery. Must be between 1.27-1.29. • When the lifting capacity is disconnected (the battery is 80 % discharged), the value must be close to, but not below, 1.14. The acid concentration can vary depending on the battery make.

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Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Recommendation on parameter setting for freely ventilated batteries Parameter 21

Battery size 7PLL24 1

Less discharge

2 3 4 5 6 7

Greater discharge

570Ah - 640Ah Standard value

510Ah - 560Ah

430Ah - 500Ah

370Ah - 420Ah

300Ah - 360Ah

13 14 15 16 17 18 19 20

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

Service Manual

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Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display). • Remove the battery from the truck and allow to rest for at least two hours. NB! No charging or discharging during this period. • Measure the acid weight of the battery at room temperature. If the acid weight is less than 1.15 g/cm3, the parameter value must be reduced. If the value significantly exceeds 1.15 g/cm3, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit. • Each change must be accompanied by a new verification of the parameter setting.

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Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

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

Battery size 7PLL24 1 2

Less discharge

3 4 5

570Ah - 640Ah

510Ah - 560Ah

430Ah - 500Ah

370Ah - 420Ah

300Ah - 360Ah

10 11 12 Greater discharge

13 14 15 16 17 18 19 20

Service Manual

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Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display). • Disconnect the battery from the truck and allow the battery to rest for at least two hours. NB! No charging or discharging during this period. • Measure the battery voltage at room temperature. If the voltage is less than Uend, see the table below, the parameter value must be reduced. If the value significantly exceeds Uend, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit. • Each change must be accompanied by a new verification of the parameter setting.

Battery type

Battery voltage at rest, Uend

Hawker Evolution

24,24 V

Parameter 22 You must specify the type of brake switch the truck is equipped with. Mechanical switch = 0 Inductive sensor= 1

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

Parameter 28 Using this parameter you can select which button is to be used for lift/ lower. 1 = Bottom lift/lower button activated (default) 2 = Top lift/lower button activated 3 = Both lift/lower buttons are activated

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Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

Parameter 39 Login method and driver parameter access This parameter determines which function is to be used for login and whether the operator can adjust the driver parameter settings. • Value 1 – Key switch fitted – Driver parameters accessible (without CAN service key). • Value 2 – Key switch fitted – Driver parameters NOT accessible (without CAN service key). • Value 3 – Keypad (Standard 10 PIN code)- Driver parameters accessible (without CAN service key) NB! this is the original setting. • Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT accessible (without CAN service key). • Value 5 – Expanded keypad (100 PIN code)- Driver parameters accessible (without CAN service key) • Value 6 – Expanded keypad (100 PIN code)- Driver parameters NOT accessible (without CAN service key) • Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parameters accessible (without CAN service key) • Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parameters NOT accessible (without CAN service key)

Expanded keypad - General The truck can contain a maximum of 10 individual driver profiles. The expanded keypad function thus allows you to assign a maximum of 10 PIN codes for each of the driver profiles. This allows you to manage a maximum of 100 unique PIN codes. If the expanded keypad function is activated, the standard management of PIN codes normally accessible via parameter #10 is set aside.

Expanded keypad - Programming A number of PIN codes can be made accessible by activating the socalled block. Block no. 0 is activated as standard. This means that 3 different driver profiles are available from the start. Activation of other blocks means that all PIN codes for the block are accessible (See Table 5:). If all 10 blocks are activated, there will be 10 PIN codes available for the driver profile. The truck program stores a standard list of PIN codes as per Table 5: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles.

Service Manual

7PLL24

13- 41

Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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

on the keypad.

• Select the programming command from Table 4:

Table 4: Programming command - expanded keypad Progamming

Function

Notes

Reset to factory settings

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

Press “2” + B +

PIN codes in the block can be used

B= Block no. 0 - 9

Press “3” + B +

PIN codes in the block cannot be used Programming a new PIN code

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

Press “1” +

Press “4” + B + F + NNNN +

• Switch off the truck by pressing

on the keypad.

The expanded keypad programming is now complete Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN codes to be valid. Carry out a practical test by logging in using some of the new PIN codes. It is important to establish that the correct driver profile has been activated when a certain PIN code has been entered, especially if a specific driver profile has been set for a specific application/goods handling. Table 5: shows the PIN codes available as standard in the program. These can be activated for use or changed according to the driver’s wishes. One or more of these blocks can be activated. A driver profile is activated, on normal login, by all PIN codes whose block no. is activated. The truck program does not approve login using the PIN code “0000”. Service personnel should keep notes on activated blocks, changed PIN codes and specially-set driver profiles. NOTE! Resetting the expanded keypad does NOT affect the driver profile settings.

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Service Manual

7PLL24

Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

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

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

no.

Service indication A

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

Flashing symbol

Data

A speed reference value has been sent to Curtis

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

Battery voltage (V)

Armature voltage (A)

Field current (A)

PWM (pulse width modulation) armature in percentage

BCD

Status of Curtis

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Electrical systems – 5000 Parameters T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

• The figure with the highest value is active (marked with an arrow). • Power amplifier, inputs.

Segment

Function

C A

S31, input A1:15

S10, input A1:12

C DP

S10, input A1:5

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

• Power amplifier, inputs

Segment

Function

A F

E D

13- 44

B C DP

B C

Y41, output A1:2

Y1, output A1:3

K10, output A1:4

H1, output A1:7

Y1, output A1:5

K30, output A1:6

Service Manual

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Electrical systems – 5000 Parameters Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

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

• Digital input from control sensors.

Segment

Function

B C

A F

C DP

Forks up

Forks down

Support arm up

Support arm down

Horn

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

Segment

Function

Extra function 6

Extra function 5

Extra function 4

Extra function 3

Extra function 2

Extra function 1

G DP

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Electrical systems – 5000 Part numbers T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

13.7 Part numbers A

• Press S18 and turn S17 to on at the same time. • Press S18 until you read Pn= partnumbers.

• You have now choosen Pn= part numbers the symbol “D” on display will be highlighted to indicate what’s currently shown on display. In the start the Pn = part number complete unit will be shown.

• By scrolling with the L1 you can get the following information: • SPn= Software part number. • HPn= Hardware part number. • HSn= Hardware serial number.

13.8 Transistor panel

STATUS

B+

MODEL

VOLTAGE

SERIAL

CURRENT

M-

13.8.1 General

Curtis 1243 is a regulator 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. 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.

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Service Manual

7PLL24

Electrical systems – 5000 Diagnostic and troubleshooting Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.9 Diagnostic and troubleshooting 13.9.1 Error codes and troubleshooting

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The table below depicts the error codes that may be shown by the STATUS LED or read using the handheld terminal.

STATUS LED

Handheld 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 currrent. Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shuntfield 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

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Electrical systems – 5000 Diagnostic and troubleshooting T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

13.9.2 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

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

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Electrical systems – 5000 Technical specifications – Curtis 1243 Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

13.10 Technical specifications – Curtis 1243 Value

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 *

300

Amps

for 2 minutes

100

Amps

for 1 hour

Amps

for 2 minutes

Max. current of field winding

Explanation

for 1 hour

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

* During specific test conditions.

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Electrical systems – 5000 Technical specifications – Curtis 1243 T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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Service Manual

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Hydraulic, pneumatic – 6000 General Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

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

14.1.1 Hydraulic diagram

1 2

Y41 7

4 P

M3 5

5 T

Service Manual

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Hydraulic, pneumatic – 6000 General T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

14.1.2 Symbol list Symbol

Description

Function

Notes

Lift cylinders

Fork lift

PowerTrak cylinder

Increases the pulling capacity with a loaded machine

Pressure sensor

Input signal to transistor panel that a flow limit change is to be made

Flow valve

Filter

Pressure relief valve

Non-return valve

Motor

Pump

2.5 ccpr

Tank

1.2 litre

Y41

Valve

One filter on the pump's suction side and one on the return

Pump motor

Lowering valve for forks

5 P

5 6

3 Y41

14- 2

Service Manual

7PLL24

Hydraulic, pneumatic – 6000 Adjustments Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

14.2 Adjustments 14.2.1 Adjustment of the pressure limit valve The pressure limit valve is set to the correct value at the factory, but may need to be adjusted if the valve or complete hydraulic unit is replaced. The truck should be able to lift a load of between 2250-2300 kg.

Pos.

Description

Cover nut

Adjuster screw, pressure limit

Notes Adjustment clockwise results in increased pressure Adjustment anticlockwise results in reduced pressure

• Unscrew the cover nut (1) with a spanner, 13 mm. • Place a load, 2200 kg, on the forks and check that the machine lifts this. • If the machine can lift 2200 kg, place a further 100 kg on the forks. Check whether machine can lift the load. • If the machine can lift 2300 kg, adjust the pressure limit valve by screwing the adjuster screw (2) anticlockwise using a 4 mm allen key until the machine cannot lift the load.

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Hydraulic, pneumatic – 6000 Cleaning the filter T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

14.3 Cleaning the filter

4 5

• Dismantle the hydraulic unit from the machine. • Empty the oil from the tank. • Loosen and remove the hose clip (1). • Loosen and remove the two tank holders (2). • Loosen the suction filter (5) and the return filter (3). • Clean the filter in an environment friendly cleaning agent. Assemble in the reverse order.

14- 4

Service Manual

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PowerTrak cylinder – 6680 Component parts Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

15- PowerTrak cylinder – 6680 15.1 Component parts

2 3

Pos.

Description

PowerTrak cylinder

Compression spring

Drive unit

Service Manual

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Notes Secured with immense force!

15- 1

PowerTrak cylinder – 6680 Dismantling the PowerTrak cylinder T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

15.2 Dismantling the PowerTrak cylinder

1 2 4

Make sure the truck is unloaded and the forks lowered. • Switch off the truck and remove the battery plug. • Dismantle the gate console and drive motor.

• Loosen the hydraulic hose using a 19 mm spanner (1). • Unscrew the hydraulic connection from the cylinder with a 27 mm spanner (2). Counter hold the cylinder's piston with a 22 mm spanner. • Unscrew both guide screws with a 6 mm allen key and a 13 mm spanner (3). • Remove the circlip (4). • Lift up the truck so that the drive wheel is free from the ground using a jack or the like. Block up the truck so that it is stable. • Press down the cylinder so that the PowerTrak cylinder and spring can be removed. When the piston is pressed down oil can squirt out from the piston. Assemble in the reverse order.

100

Measurement between the washer and bolt head, 100 mm. WARNING! Risk of injury There is a risk of personal injury in connection with working on the PowerTrak system. Follow the instructions carefully.

15- 2

Service Manual

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PowerTrak cylinder – 6680 Dismantling the PowerTrak cylinder Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

15.2.1 Replacing the gaskets in the PowerTrak cylinder • Pull out the piston from the PowerTrak cylinder. • Remove the gaskets by using a screwdriver or other appropriate tool. • Fit the new gaskets. This is easiest if you heat the gaskets a little, preferably in oil, so they become soft. Fit them using pliers. • Oil the gaskets after assembly. • Carefully press in the piston. If the cylinder or piston are scratched, they should be replaced.

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15- 3

PowerTrak cylinder – 6680 Dismantling/assembling the ground pressure springs T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

15.3 Dismantling/assembling the ground pressure springs 15.3.1 Component parts 1

5 3

15- 4

Pos.

Description

Screw

Spring support

Compression spring

Sliding seal

Lubricated during assembly

Spring tube

Lubricated during assembly

Service Manual

7PLL24

Notes

PowerTrak cylinder – 6680 Dismantling/assembling the ground pressure springs Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

15.3.2 Dismantling Make sure the truck is unloaded and the forks lowered. • Switch off the truck and remove the battery plug. • Dismantle the gate console and drive motor. • Unscrew the allen screw (1) and position the washer 174006 as illustrated. • Screw in the allen key (1) as far as possible. • Lift up the truck so that the drive wheel is free from the ground using a jack or the like. Block up the truck so that it is stable. • Fold out the compression spring through the slot in the drive unit. • Secure the compression spring in a vice.

174006

• Loosen the screw (1) completely.

15.3.3 Assembling Assembly takes place in the reverse order. Ensure you grease the sliding seals and spring tube before assembling.

15.3.4 Setting and sealing The PowerTrak spring on machines supplied without batteries should be adjusted as set out in the table below. Once the adjustment has been made the "lock washer" should be locked and sealed. Table 1: Setting mode corresponding to fork length/U-measurement and battery weight

Fork length/ U-measurement

Short chassis (battery weight)

Long chassis (battery weight)

270 kg

350 kg

300 kg

400 kg

500 kg

950/330

Blocked

1000/330

1150/330

1450/450

1550/650

Blocked

1950/400

2150/750

2350/640

2350/750

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15- 5

PowerTrak cylinder – 6680 Dismantling/assembling the ground pressure springs T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

Table 2: Distance L corresponding to position number: Position L (mm)

Spring load (kg

Drive wheel load (kg)

190

400

240

450

290

500

WARNING ! Note that the stated settings correspond to the lowest drive wheel pressure that allows standard safety for braking. Accordingly, under no circumstances may the initial pressure spring be adjusted so that the wheel pressure falls below the stated minimum value in table 1. However, if the stated setting gives insufficient grip for acceleration the drive wheel pressure can be adjusted upwards from the stated value without TOYOTA's product liability becoming invalid. Nevertheless, note that an excessively high drive wheel pressure can impair the truck's stability. L

15.3.5 Sealing When the spring has been adjusted to the correct position the system should be sealed. This is done by wrapping the wire (S29759) around the threaded sleeve both under and above the setting nut. The wire is then sealed by squeezing the plastic sleeve (S20421) with a pair of pliers.

S20421

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Service Manual

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TruckCom General Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

16- TruckCom User Manual for trucks using the “PowerDrive” platform. This Manual is valid for version 3.5 of TruckCom p/n 182147-008.

16.1 General TruckCom is a communication program which communicates with trucks equipped with CAN (Controller Area Network) communication. It enables the following tasks to be performed: • downloading truck control software. • viewing and adjusting operator / truck parameters and hour meters. Additionally, the truck’s parameter set (including hour meter values) can be saved to file and reloaded later. • viewing diagnostic data for various digital inputs / outputs and analogue data including voltages, currents and certain temperatures. The program is a Microsoft® Windows program running under Microsoft® Windows® 95/98, Microsoft® Windows® XP/2000 and Microsoft® Windows® NT.

16.2 Connection A CAN interface of the CPC-PP type is needed to connect it to the truck, with attendant cable. Connect the interface via the printer port on a PC. Connect the cable between the interface and the truck's CAN terminal. The CAN interface is supplied with power from the truck electronics and is protected from any high voltages in the truck if a fault should occur.

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16- 1

TruckCom Layout T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

16.3 Layout 16.3.1 Main program screen Information window

Menu bar

Tool buttons

Nodes Icons

Tool button bar

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

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

Fig. 3 A typical node window display 16- 2

Service Manual

7PLL24

TruckCom Layout Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

16.3.3 Icons Icon

Description Node OK is shown when contact is made with a node and no errors have been reported. Node not connected is shown when there is no contact with a node in the network. Node not OK is shown when an error has been reported by a node. Click on node to obtain more information. Program version is shown when information is available on which software is installed. Click to obtain more information. Information is shown when a node has information on, for example, error codes. Truck report GB“16.7Truck report function” on page 7 Parameters is shown when a node has information on a parameter. Diagnostics

Exit

16.3.4 Tool buttons and menu bar The tool button bar allows direct access to the program’s most common functions. The menu bar allows access to all the program functions. Explanations of each menu bar item are given in the relevant section. Search for units

Disconnect Download from PC

Truck report

Parameters Diagnostics Information

Exit

Fig. 4 Tool button bar

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16- 3

TruckCom Connection function T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

16.3.5 Information window The right section of the main window contains a status window where different messages are shown.To see previous messages, use the scroll arrows in the right margin.

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

HELPTEXT

REC

MACHINE

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

16.4 Connection function To connect the PC the network, select the Scan units function. This can be done with the menu <Nodes | Scan units> or with the tool button [Scan nodes]. This should also be done when the truck is supplied with voltage and in normal drive mode.The program will now run a check and installation of the CAN interface. A diagnosis will also be carried out to check which units are connected in the system. The result of this diagnosis is shown in the Node window.

16.5 Disconnection function Select the Disconnect function to disconnect from the network. This can be done with the menu <Nodes | Set PC off-Line> or with the tool button [Set PC off-Line]. The CAN interface is then reset and the CAN cable can be disconnected if so required. This enables connection to another truck without having to close the program.

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Service Manual

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TruckCom Downloading program function Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

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

Type 123456

16.6.1 Normal downloading (truck with key) Select Open.. to open the file to be downloaded into a node. The file name, file type and version number are shown in the window for file information. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by selecting Start... and by restarting the truck by turning the key off and on twice. Restart must be made within 20 seconds from when the Start button has been activated. Close the download window when the download is ready, and then disconnect the PC from the network. A new connection can now be made to verify the new program.

16.6.2 Normal downloading (truck with keypad) Select Open to open the file to be downloaded into a node. The file name, file type and version number are shown in the file information dialogue box. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by depressing and then releasing the red key on the keypad. The truck must be restarted within 20 seconds from when the Start key has been activated. © TIEE SARL

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16- 5

TruckCom Downloading program function T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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

16.6.3 Emergency downloading (truck with keypad) • Disconnect the battery connector. • Select OK in the dialogue box. • Keep the red key on the keypad depressed while reconnecting the battery connector. • Release the red key to commence downloading.

16.6.4 Emergency downloading (truck with keypad) E141 will be shown in the truck’s display when starting, if for any reason there is no program in the electronics card (interrupted downloading). Communication with the truck via the PC will then be minimised. Use “E141” to download the program in the card. On some trucks, a counter, which continuously counts up, is displayed. NOTE! Once programmed, the logic cards in some trucks can only be upgraded with the same basic firmware. In other words, it is not possible to replace the basic firmware (other machine type).

16.6.5 Downloading in old versions of logic card To download to older versions of electronic cards which do not support restart with key, the button Old card... should be used instead of Start... Downloading is carried out in the same way, except that restart is done by using the battery lug instead of the key.

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Service Manual

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TruckCom Truck report function Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

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

NAME

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

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

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

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

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

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16- 7

TruckCom Parameters function T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

16.8 Parameters function To change the truck parameters, select the Parameter function. This can be done with the menu <Tools | Change parameters > or with the tool button Parameters. NOTE! The truck must in Normal mode (i.e. not Parameter mode) when connecting TruckCom. Otherwise TruckCom will report “Unable to determine truck brand”

The parameter numbers follow the description in the respective truck Service Manuals, section 5000. The parameter window shows the information and the current settings for all parameters. The parameters are divided into 4 tabs. • [Driver] - Driver; driver parameters and PIN code storing • [Truck] - Truck; service parameters • [Time] - Time; time-related service parameters • [Option parameters] - Option parameters. (no. 15 to 19) WARNING! Do not attempt to make any adjustments to the option parameters unless you have sufficient knowledge of the truck’s options/ modified functions. Specially modified trucks may require that you have access to special service information. Improper adjustment of the option service parameters may result in a malfunction.

16.9 Diagnostics function To access diagnostics, select the Diagnostic function. This can be done with the menu <Tools | Diagnostic...> or with the tool button Diagnostic. NOTE! If the value “---” is shown in a field, or a “read status LED” is red, the communication has been interrupted for some reason and error data cannot be shown.

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

16- 8

Service Manual

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TruckCom Diagnostics function Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

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

WHITE(bialy) GREEN(zielony) RED(czerwony)

16.9.2 “Tiller arm” tab

Clicking on the tiller arm tab will display a dialogue showing the following: • Speed lever -The status of the speed control and travel direction selector. The status of each individual hall element is displayed. • Buttons -The status of the control buttons is displayed. “Sxx” refers to the switch designations as given in the circuit diagram. • Option - Status of option buttons • Battery - The measured battery voltage • R14 - Shows the measured signal voltage from the lift/lower control • R15 - Not used at present

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16- 9

TruckCom Diagnostics function T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

16.9.3 “Drive Controller” tab (transistor regulator driving)

Clicking on the Drive Controller tab will display a dialogue showing the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram. • Field PWM - The effective power output supplied to the field circuit as a percentage. • Armature PWM - The effective power output supplied to the armature circuit as a percentage • Field current - The current flowing in the field circuit in Amperes. • Armature current - The current flowing in the Armature circuit in Amperes • Raw throttle data - The received speed control signal as a percentage. • Temperature - The temperature of the output stage of the transistor controller in degrees Celsius • Inp pin 10 - The input voltage from the mode/pressure sensor. “digital O” indicates the digital status of the input. • Inp pin 11 -The input voltage from the man-on platform sensor. “digital O” indicates the digital status of the input.

16- 10

Service Manual

7PLL24

TruckCom Diagnostics function Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

16.9.4 “Pump controller” tab (transistor regulator pump)

If the truck is equipped with a lift/lower transistor regulator, the Pump controller tab displays the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram. • Field PWM, Armature PWM, Field current, Armature current, Temperature - See explanation in 16.9.3 • Raw throttle data - The received lift/lower signal as a percentage. • Out pin9 - The output signal to the proportional lowering valve as a percentage. • Inp pin 10 - The input voltage from the pressure sensor. “digital O” indicates the digital status of the input. • Inp pin 11 - The input voltage from the pressure sensor. “digital O” indicates the digital status of the input.

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16- 11

TruckCom Diagnostics function T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

16.9.5 “EPS” (steering servo tab)

Clicking on the “EPS” tab will display a dialogue showing the following: “Status” • “Operational” - Indicates the status of the servo’s control system • “EPS enabled” - Indicates the status of the servo’s power stage output. • “Reference switch reached” - indicates status of drive wheel in centre reference switch. • “Reference position found” - indicates whether a successful steering in centre has been performed. • “EPS in power save mode” - Shows whether the steering servo is in the standby mode (following a certain amount of inactivity). “Actual values” (Measured values) • “Temperature EPS” - The temperature of the steering servo output stage in degrees Celsius. • “DC bus voltage” - Supply voltage to steering servo • “Wheel position” - Shows the estimated steering angle of the drive wheel. • “Voltage analog input 1, pin5”- The measured DC input signal (0) from the steering potentiometer. • “Voltage analog input 2, pin13”- The measured DC input signal (1) from the steering potentiometer. • “Current” - The measured current supplied to the steer servo motor in Ampere • “Actual velocity” -The measured rotational speed of the steer servo motor shaft in r.p.m. 16- 12

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TruckCom Other menu functions Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

16.9.6 SEU tab (Spider Extension Unit)

When the truck is equiped with a Spider Extension Unit (former Extra I/ O module) the SEU tab shows following: • “INP X” - Shows the logical status for the digital inputs. • “OUT X” - Shows the logical status for the digital outputs. • “Analog input X” - Shows the voltage level on the analog inputs. See chapter 5000 for more information about the SEU and how the inputs and outputs are connected.

16.10 Other menu functions 16.10.1 Save to file The truck parameters can be saved in the PC for downloading at a later date.Select <File | Save to file | Parameters>. All parameters in the nodes which are connected to the bus will be scanned in and saved in a file.If only the hour meters are needed, select <File | Save to file | Hour meters>.

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

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16- 13

TruckCom Other menu functions T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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

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

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

16.10.6 Read error code log To show the truck’s error code log, select <Tools | Read error log >.

16.10.7 Adjust date and time To quickly adjust the truck’s data and time, select < Tools | Adjust date & time >. The time given in the PC will now be downloaded into the truck. NOTE! This does not apply to trucks without a real-time clock.

16.10.8 Adjusting the hour meter on older cards To adjust the hour meter on trucks with older cards, select <Tools | Adjust Hour meters>. The time given in the PC will now be downloaded into the truck.

16.10.9 Help About the TruckCom application To see program information, select <Help | About TruckCom...> or use the tool button [Information].

16.10.10 Exit To exit the program, select <File | Exit > or use the tool button [Exit].

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Service Manual

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TruckCom Specifications Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

16.11 Specifications Table 6: CAN interface specification Description

Value

Power consumption

40-120 mA

Supply voltage

11-28 V

Transfer rate

125 kbit/s

Storage temperature

-20-80 °C

Operating temperature

0-60 °C

16.12 Installation NOTE! The program must be installed from the hard disk.

NOTE! The software application in the computer can be damaged, which is why the PC installation should be performed by someone with the required knowledge. TOYOTA does not accept any responsibility for any errors that occur during the installation.

NOTE! All references to PC operating system actions, menus and commands are based on the English language version of Windows.

16.12.1 Installation on a PC with Windows 95/ 98 If a previous version of the TruckCom application has been installed on the PC, it will be necessary to edit the System.ini file. Start the Msconfig.exe application by selecting the Start button, selecting Run and then typing msconfig. • Click on System.ini and open the folder (386Enh). • Unmark the option at Device=C:\Windows\Cpcppvd.vxd. • Save the change and close the application. Now continue with installationThe software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.Then follow the on-screen instructions.

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16- 15

TruckCom Installation T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

16.12.2 Installation on a PC with Windows XP/ 2000 To make the application work, it is necessary to enter a value in the Windows Registry and then make a few alterations in the Windows Control panel. Due to the built-in Windows security, this must be done manually. The instructions below provide step-by-step guidance to enable these changes and make the interface operate under Windows XP and Windows 2000.The changes can be made either before or after TruckCom is installed. • Open the Registry Editor. To do this, select the Start button, then Run, type regedit and hit Enter.

• Mark the Enum folder which can be found under HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the Registry Editor.

• Select the Edit option, then Find and type PortName to search for the correct folder.

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TruckCom Installation Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

NOTE! The location of the folder differs between different computers (some may be \Enum\Root\.., while others could be \Enum\ACPI\ etc.). Thus be sure to search for the correct folder.

When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in the PortName data field and that the folder name is Device Parameters. • Right-click with the mouse in the right box to enter a new value of the DWORD type and with the name

EnableConnectInterruptIoctl.

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TruckCom Installation T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

• Change the value in data field 1 by right-clicking on the name and selecting Modify.

EnableConnectInterruptIoctl

The Device Parameters folder should look like the one in the picture. The Registry change is now complete. Close the Registry Editor.

Changes in Windows Control Panel • Select the Start button. • Choose Settings, then Control Panel and double-click on System. • Select Hardware. • Click on Device Manager and open Ports (Com & LPT).

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TruckCom Installation Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

Service Manual

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T-code 497

16- 19

TruckCom Installation T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

• Double-click on the LPT port to be changed, and select the Port Settings tab. • Check the "Use any Interrupt assigned to the port" option and click on OK.

The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.

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TruckCom Installation Order number 222996-040

Date 2005-11-04

Valid from serial number 723984-

T-code 497

16.12.3 Installation on a PC with Windows NT The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.

16.12.4 In case of communication problems with CAN Make sure the computer settings for the printer port in the BIOS Setup are as follows: Port address:0378 IRQ:7 Mode:Output only For detailed information on how to change the Setup settings, refer to the User's Guide supplied with the computer.

16.12.5 To uninstall To uninstall TruckCom under Windows.: • Select the Start button, Settings, Control Panel, Add/Remove Programs. • Then select the TruckCom Program and click Change/Remove.

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TruckCom Installation T-code 497

Valid from serial number 723984-

Date 2005-11-04

Order number 222996-040

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