Professional Documents
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PP13
PP13
en
PP13
Valid from serial number: 914369-
1- Table of contents
Tools - P4 6-1
Grease guns.................................................. 5
Other tools..................................................... 6
Components ................................................. 1
General ......................................................... 1
9.1.1 Firmware (truck control software) ....................... 1
Nomenclature ............................................... 1
Functional description.................................. 14
9.8.1 Theory of operation ........................................... 14
9.8.2 Transistor regulator ........................................... 18
General ............................................................. 18
Safety ................................................................ 18
9.8.3 On-board battery charger ................................. 20
General ............................................................. 20
Charging ........................................................... 20
9.8.4 Battery charge status ........................................ 21
Battery display (option) ..................................... 21
9.8.5 Built-in battery charger for charging on trucks .. 22
General ............................................................. 22
Installation recommendations for ‘connection
point’ on truck ................................................... 22
Installation in truck ............................................ 23
1- 4 Service Manual PP13 © TIEE SARL
Table of contents
Order number Date Valid from serial number T-code
208588-040 2005-10-28 914369- 675
Charging ........................................................... 25
Troubleshooting ................................................ 25
Technical data .................................................. 25
9.8.6 Speed limitation ................................................ 26
9.8.7 Hour meter ....................................................... 26
9.8.8 Hand terminal ................................................... 27
General ............................................................. 27
Connecting the hand terminal .......................... 27
Hand terminal overview .................................... 28
Hand terminal menus ....................................... 29
Diagnostic and troubleshooting ................... 30
9.9.1 General ............................................................. 30
9.9.2 Display of error codes ...................................... 30
Direct display of error codes ............................. 30
Hand terminal display of error codes ................ 30
Error code history ............................................. 31
9.9.3 List of error codes ............................................. 32
9.9.4 TESTER function .............................................. 35
Parameters & adjustments .......................... 37
9.10.1 General ............................................................ 37
9.10.2 Adjusting parameters ....................................... 37
9.10.3 List of parameters ............................................ 38
9.10.4 Description of parameters ................................ 39
Acceleration ramp time (ACC.DELAY) ............. 39
Deceleration ramp time (DECELER.DELAY) ... 39
Neutral braking intensity (RELEASE
BRAKING) ........................................................ 39
Reverse braking intensity (INVERSION
BRAKING) ........................................................ 39
Maximum travel speed (CUTBACK SPEED 3) 39
Reset service counter (CHECK UP DONE) ..... 39
Select service warning type (CHECK UP
TYPE) ............................................................... 39
“Time to next service” (CHECK UP HOURS) ... 40
9.10.5 Transferring parameter sets ............................. 40
General ............................................................. 40
From the truck to the hand terminal ................. 41
From the hand terminal to the truck ................. 42
9.10.6 Calibrating the speed potentiometer ................ 43
General ............................................................. 43
Procedure ......................................................... 43
Technical specifications .............................. 44
9.11.1 Transistor regulator SEM-X ............................. 44
Description.................................................... 2
Lift ....................................................................... 2
Lower .................................................................. 2
Operating pressure ............................................. 2
Pressure limit valve ............................................. 2
Adjustments .................................................. 2
Adjustment of the pressure limit valve ................ 2
Tools ............................................................. 3
General ......................................................... 1
Procedure ..................................................... 1
Abbreviations ................................................ 2
Sorting .......................................................... 2
Chassis (0300).............................................. 3
Disassembly ....................................................... 3
Material handling ................................................ 3
Hoods, hatches (0340) ................................. 3
Disassembly ....................................................... 3
Material handling ................................................ 3
Electric Pump Motor (1710) ......................... 3
Disassembly ....................................................... 3
Material handling ................................................ 3
Drive assembly/drive motor (1760/2550) ...... 4
Disassembly ....................................................... 4
Material handling ................................................ 4
Wheels (3500) .............................................. 5
Disassembly ....................................................... 5
Material handling ................................................ 5
Tiller arm (4110) ........................................... 6
Disassembly ....................................................... 6
Material handling ................................................ 6
2- Technical data – M4
Model PP13
Drive motor
Type TSL115-16
Output 0,5 kW
Duty cycle S2, 60 min
Minimum carbon brush length 14,5 mm
Nominal commutator diameter 43 mm
Minimum commutator diameter 40 mm
Resistance, shunt field winding at 25 C° 1,3 Ω
Resistance armature winding at 24 °C 0,0156 Ω
Insulation resistance between the windings and motor casing >=1 Mohm
Weight 25 kg
Brake
Type 891.270.0
Braking force 9 Nm
Output 28 W
Resistance coil 20,8 Ω
Minimum thickness brake disc 6,75 mm
Thickness of a new brake disc 6,90 mm
Transmission/drive gear
Type 2-stage drive gear
Gear ratio 24,8:1
Volume of grease 0,3 kg
Type of grease SHELL RETINAX G
Model PP13
Wheels
Drive wheel Ø250x60 mm
Axle pressure without load 175 kg
Axle pressure at rated load 570 kg
Tightening torque for wheel bolts 20 Nm
Fork wheel Ø85x75 mm
Axle pressure without load 2x18 kg
Axle pressure at rated load 2x496 kg
Support castors Ø100x40 mm
Axle pressure without load 2x30 kg
Axle pressure at rated load 2x24 kg
Hydraulic system
Output 1,2 kW
Duty cycle 10 %
Minimum carbon brush length 7,5 %
Minimum commutator thickness/diameter 4,75 mm
Pressure at rated load 110 bar
Overflow pressure 130 bar
Pump flow 4,7 litre/minute
Tank volume 1,0 litre
Oil type Hydraulic oil
Normal temperature ISO-L-HM32
Fuses
Drive motor circuits (Common with the pump) 50 A
Pump motor circuits (Common with the drive motor) 50 A
Control circuits 5A
Battery charger 10 A
Model PP13
Battery compartment, Batteries
Dimensions LxWxH 278x175x190 mm
Capacity 50 Ah
Weigh 2x18 kg
Driving speed
Without load 5,4 km/h (1,5 m/s)
With rated load 4,0 km/h (1,1 m/s)
Lift/lowering speed
Lift without load 1,7 s
Lift with rated load 3,0 s
Lowering without load 3,0 s
Lowering with rated load 3,0 s
Power consumption
Driving without load 13 A
Driving with rated load ?
Lift without load ?
Lift with rated load ?
Incline climbing ability
With rated load 5%
Without load 10 %
Measurement, L2 420 mm
Turning radius WA 1410 mm
Lift height 205 mm
Weight
Truck without battery, Medium 200 kg
3- Introduction Maintenance – P1
All points in the service program should be carried out to attain the high-
est safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with TOYOTA’s minimum requirements.
The service intervals are based on the running times and can be adapt-
ed to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
- Day time: 08.00-17.00 (20 hr./week)
- 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00
(60 hr./week)
Ensure the truck is given a regular maintenance service after every 500
driving hours. The truck’s safety, efficiency and service life is depend-
ent on the service and maintenance it is given.
Only use TOYOTA approved spare parts when service and repair work
are carried out.
• Use paper or a rigid sheet of cardboard when checking for oil leak-
age. Never use your hand.
• Bear in mind that the oil in the transmission or the hydraulic system
can be hot.
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil.
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be damaged.
Always use new and clean oil in the hydraulic system.
• Store and dispose of changed oil in accordance with local directives.
• Do not release solvents and the like, which are used for cleaning/
washing, into drains that are not intended for this purpose. Follow
the local directives that apply for disposal.
• Disconnect the battery when welding on the truck.
NOTE!
The battery can be damaged.
When welding using an electric power source the welding current can
enter the battery.
The battery should therefore be disconnected.
• Remove at least 100 mm of paint around the welding/grinding area
through sand-blasting or the use of a paint stripper when welding or
grinding on painted surfaces.
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.
• Ensure that your hands and the jack’s lever are free from oil and
grease.
• Use the lever that belongs to the jack. A lever that is too short re-
quires more force than is necessary. If the lever is too long there is a
risk of the jack being overloaded.
• Support the truck:
- as close as possible to the part of the chassis that is to be lifted.
This reduces the risk of the truck tipping over.
- so that the truck cannot roll.
• Never lift up the jack in order to lift higher.
• Never work under a lifted truck unless it is well supported.
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-blocks and
secured by a lifting device.
4- Maintenance, Lubrication
schedule – P2
5000
5000
4110
5000
0380
0000
3500
5700
6600
5400
3100
2550
1700
0380
6100
2550
0380
6100
2550
6- Tools - P4
3
3
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2
1
2
-3
-4
207881 Hand terminal for communica-
tion with the transistor regulator.
Needed for the following uses:
• Changing parameters.
• Uploading and downloading
parameter settings.
• Display of error messages.
• Calibration.
27
31
7- Drive unit/drive gear – 2000
26
30
24 29 7.1 Component parts
23 28
22 25 Table 2: Components drive gear
21 Pos Name Pos Name
25
20 1 Screw, 7 pcs 21 Rotor
2 Washer 22 Carbon brush, 4 pcs
19
3 Cap 23 Locking ring
7.2.4 Cleaning
An extremely critical factor to ensure correct functioning of the motor is
that it is kept as clean as possible. The motor and the motor compart-
ment must be regularly checked for dust, oil, and other impurities.
A vacuum cleaner with an appropriate nozzle can be used to clean the
motor if the motor windings and inner compartment are dry Com-
pressed air can be used in combination with a vacuum cleaner. In which
case the compressed air must be clean and dry.
A cloth of non-fluffing material should be used if the windings have a
coating. The cloth can also be moistened with a grease-dissolving,
organic and volatile detergent that does not damage the windings. Use
detergent sparingly to avoid it penetrating into the parts of the motor.
Residual detergent should be removed with an appropriate solvent, if it
leaves a greasy surface.
If the parts of the motor are heavily fouled it may be necessary to use a
solvent that is sprayed onto the parts. It is important that the detergent
is applied in a way to prevent dirt from penetrating into the parts of the
motor, especially for the rotor.
One method of cleaning the rotor is to dip it in solvent. If this is done
then the rotor must always be dried with the application of heat. There
must be adequate ventilation during the drying process, and the drying
should continue until a number of measurements of the insulation
resistance provide equivalent and approved results.
8.1 Components
2
3
5 4
9.1 General
The electrical system of the truck is based on the SEM-X system.
• The main power source is a 24 V DC traction battery.
• The travel drive motor is a separate excitation type (SEM). The trav-
el drive motor is operated by a self-contained transistor regulator re-
lying on pulse width modulation (PWM) technology.
• The lift unit motor is a conventional DC motor without any external
field winding connections. Switch-on of the hydraulic unit's electric
motor is achieved using a contactor.
• A set of parameters used to adjust the truck’s performance and brak-
ing characteristics is stored in the transistor regulator. The regulator
also monitors error conditions that may occur.
9.2 Nomenclature
Items shown in square brackets [ ] refer to electrical component desig-
nations as stated in the electrical wiring diagrams. See section “12.3.1
Electric component overview” .
{high} refers to a voltage level that is approximately the same as the
supply voltage level.
{low} refers to a voltage level of approximately 0 Volt.
s/c = short circuit.
o/c = open circuit.
L1
S20
R1
S15
S16
S18
S34
S41
Fig. 1
H1
PTC
A30
A1
S171
CONS
K10
F1
K30
S10
M3
Y41
G1 G2
Y1
M1
Fig. 2
Diagram ref.
Designation
Picture ref.
type
Diagram ref.
Designation
Picture ref.
type
Traction
L1 Speed control and travel direction Lever - Fig. 1 1
selector (butterfly)
S15 Travel in forks direction Switch Fig. 6 Fig. 1
S16 Travel in drive wheel direction Switch Fig. 6 Fig. 1
R1 Speed control Potentiometer Fig. 6 Fig. 1
M1 Traction Motor Fig. 5 Fig. 2
Lifting / lowering forks
S34 Fork lifting control Switch Fig. 6 Fig. 1
S41 Fork lowering control Switch Fig. 6 Fig. 1
Y41 Fork lowering -hydraulic control Magnetic valve Fig. 5 Fig. 2
K30 Fork lifting (Pump motor power Contactor Fig. 5 Fig. 2
switching)
M3 Pump motor Motor Fig. 5 Fig. 2
Other
A30 On-board battery charging Battery charger Fig. 7 Fig. 2
CONS Connection point for hand terminal Connector - Fig. 2 3
A30 F1
K10
H1
F51 S18
S170
- + - +
F50
S10
G2 G1 S21 S17
H81
K10
OUT.NEG.MAIN CONTACTOR
INP.SUPPLY MAIN CONTACTOR
INP.LOWER
S41
M3
A1 A2
M
A1 Y41
K30
OUT.NEG K30/Y41
S171(K10)
INP.LIFT
OUT.FIELD 2
INP.BELLY BUTTON ARMATURE
S20 Y1
OUT. BRAKE
INP.TILLER SWITCH
- BATT
E1 S E2
© TIEE SARL
Sh. 2 INP. POWER SUPPLY 0VDC
208588-040
10A
+ - + -
Order number
F51
9
Sh. 3 F1 R2
100A
PTC
RD 2 3
Sh. 4 + BATT INP. POWER SUPPLY 24VDC
1 2
PUMP MOTOR
Date
M3 M1
BK 8 A1 A2 A1 A2 6
Sh. 4 M M VMN ARMATURE WINDING
1 2
2005-10-28
FIELD
40 4
Sh. 2 F1 FIELD WINDING
F2 F1
13
S171 5
LOWER VALVE F2 FIELD WINDING
Y41 14
34 43 Y1
Sh. 2 2 1 X31 X31 41
A11 OUT, NEGATIVE, MAGNETIC BRAKE
914369-
Service Manual
1 2
Fig. 5 Sheet 1 of 5
31 31
Sh. 2 A4 INP, TILLER SWITCH
PP13
K10
42
A14 OUT, NEGATIVE, MAIN CONTACTOR
A1 A2
Valid from serial number
23 23
Sh. 2 A15 IN, SUPPLY, MAIN CONTACTOR
K30
43 43
A2 OUT, NEG, PUMP CONTACTOR/LOWER VALVE
A1 A2
33 33
Sh. 2 A10 INP, LIFT
675
T-code
1/5 PROD E
Electrical system – 5000
Electrical wiring diagram
181444
9- 9
ELECTRONIC CARD
675
9- 10
A1
EMERGENCY SWITCH OFF KEY
S21 START INTERLOCK S17
T-code
20 21 (*) 23 22
Sh. 1 A16 INP, 24VDC KEY SWITCH
1 2 S170 2 1
H81
59
A12 OUT, BATTERY INDICATOR
PLUG:A (*)
Sh. 3
PLUG:B NOTE:
Sh. 3 WHEN ONBOARD LORRY OPTION;
23:A CONNECT RECEPTACLE 23:A TO
Sh. 4 START INTERLOCK AND TAB 23:B X30 50
A3 OUT, POS, SUPPLY DRIVE POT.
23:B TO CABLE 23.
Electrical wiring diagram
Sh. 4
R1 1
23 X30 51
Sh. 1 A1 INP, WIPER, DRIVE POT.
2
H1
3
40 BK RD 57 X30 52
Sh. 1 3 A9 OUT, GND, SUPPLY DRIVE POT.
Electrical system – 5000
TILLER SWITCH
914369-
X30
S10 S16
X30 53
A6 INP, DRIVE, STEERED WHEEL DIRECTION.
COM NO COM NO
Service Manual
HORN SWITCH S15
X30 54
S18 A7 INP, DRIVE, FORK DIRECTION.
X30 COM NO
Fig. 6 Sheet 2 of 5
COM NO
3K3
PP13
Valid from serial number
S20
31 X30 X30 55
Sh. 1 A5 INP, BELLY BUTTON.
COM NO
FORK LIFT
NC
S34
35
COM NO
LIFT LIMIT, LWE130
NC
S31
Date
33 X30
Sh. 1 COM NC
JUMPER, HWE100/HWE100S
2005-10-28
S41
X30 34
A13 INP, LOWER
COM NO
34
Sh. 1
S206
X30 60
A8 INP. "TURTLE" FUNCTION
13 14
208588-040
Order number
2/5 PROD D
© TIEE SARL
181444
Electrical system – 5000
Electrical wiring diagram
Order number Date Valid from serial number T-code
208588-040 2005-10-28 914369- 675
Fig. 7 Sheet 3 of 5
PROD D
181444
OUT, NEGATIVE CHARGER VOLTAGE
OUT, POSITIVE CHARGER VOLTAGE
3/5
INP, MAINS VAC
INP, GROUND
A30
40
9
PLUG:A
PLUG:B
40
9
Sh. 2
Sh. 2
Sh. 1
Sh. 2
9- 12
T-code
OPTION
CHARGER/BOOSTER ONBOARD LORRIES
A15
20A
F52
RD RD
Sh. 1 OUT, POSITIVE CHARGER VOLTAGE
BK BK
Sh. 1 OUT, NEGATIVE CHARGER VOLTAGE
1+ RD
INP, HOSTING VEHICLE POSITIVE
2+
1- BK
INP, HOSTING VEHICLE NEHATIVE
Electrical system – 5000
914369-
2-
23:A BK
Service Manual
Sh. 2 INP, TRUCK DISABLE RELAY CONTACT
Fig. 8 Sheet 4 of 5
23:B BK
Sh. 2 OUT, TRUCK DISABLE RELAY CONTACT
PP13
H80
Valid from serial number
- RD
OUT, +24VDC, LED INDICATOR
+
BU
OUT, GND, LED INDICATOR
Date
2005-10-28
208588-040
4/5 PROD D
Order number
181444
© TIEE SARL
1 2 3 4 5 6 7 8
A A
© TIEE SARL
208588-040
Order number
OPTION
DISPLAY; MDI ELECTRONIC CARD
A6 A1
101 101
PCLRXD 1 B1 PCLRXD
Date
B B
102 102
GND 2 B5 GND
2005-10-28
103 103
12VDC SUPPLY VOLTAGE 3 B6 +12VDC SUPPLY VOLTAGE
104 104
NCLTXD 4 B4 NCLTXD
C C
914369-
Service Manual
105 105
PCLTXD 5 B3 PCLTXD
106 106
NCLRXD 6 B2 NCLRXD
PP13
D D
Valid from serial number
675
E E
T-code
Fig. 9 Sheet 5 of 5
5/5 PROD E
F F
Option: "Battery Indicator” 181444
Electrical system – 5000
Electrical wiring diagram
1 2 3 4 6 7 8
9- 13
Electrical system – 5000
Functional description
T-code Valid from serial number Date Order number
675 914369- 2005-10-28 208588-040
1
B
1 2 3 4 5 6 7 8 B
F1
1
A
1 2 3 4 5 6 7 8 A
9 10 11 12 13 14 15 16 F2
ALARM
AL B+ B-
General
The ZAPI SEM-X transistor regulator drives the traction motor. It con-
trols the speed by varying the rotor voltage using pulse width modula-
tion (PWM). This also includes varying the “ON” time of the MOS tran-
sistors used to regulate rotor current.
Changing the truck’s travel direction is achieved by reversing the polar-
ity in the field winding (F1-F2). The regulator features a transistorised
four-quadrant bridge and a single-quadrant bridge for the rotor winding.
A status LED (Fig. 10 AL) displays eventual error conditions which may
be present.
Fig. 10 B shows the connector for the hand terminal.
NOTE!
In order to see the alarm status LED or gain access to the connector
for the hand terminal it is necessary to fold out the main electrical
panel. See section “12.4 Accessing main electrical panel” .
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.
Charging
Connect the charger’s mains plug (Fig. 11 A) to the mains supply. If a
discharged battery is connected, the charger will start with the main
charge (yellow LED (Fig. 11 B) and 28.8 V). When the battery is fully
charged, maintenance charging starts (yellow and green LED (Fig.
11 B & C) and 27.6 V). This continues until the charger switches off. If a
fully charged battery is connected to the charger or if the charger does
not find a connected battery the maintenance charge is started (yellow
and green LED 27.6 V). The charger starts with the main charge (yellow
LED and 28.8 V) after a power failure if a discharged battery is connect-
ed.
The truck’s mains lead can be connected to the mains supply whenever
the truck is not in use to ensure the batteries are always fully charged.
Charging for at least 30 min. is gentle and consequently does not short-
en the life of the battery. It is however necessary for the truck to be
recharged once a week over night or for at least 10 hours.
B
C
NOTE!
The battery display is only updated when the drive motor is active.
That means if only the lift motor is used for some time (and the truck
is not moved) the display may show a too large remaining charge.
Installation in truck
Install the truck charger as per instruction drawing 219205. See pic-
tures below.
23112 (2x)
218353
218856
29918 (2x)
218068
42322 (4x)
22006 (4x)
20235 (4x)
21307 (8x)
Note 1:
• Disconnect cable 23 from the ignition lock and connect it to the con-
tact housing for cabling from the truck charger.
• Connect cable using 4.8 bushing from the truck charger to the igni-
tion lock.
• Strap the cabling to the standard cabling
Note 2:
• Remove rubber plug on electrical panel
• Install yellow indication lamp on electrical panel and connect the red
cable from the truck charger to the brass-coloured pin on the indica-
tion lamp.
Not. 2
Not. 1
Charging
Connect the connection cable from the truck to the contact (A) on the
truck. Charging begins automatically once the truck’s voltage reaches
25,5 V.
Troubleshooting
• Check that the charger is connected to mains voltage.
• Check the fuse for the charger’s battery cable.
• Check that the charger is not overheating.
• If the charger is still not working, replace the charger.
Technical data
B E
C D
Fig. 15 Hand terminal overview
When the hand terminal is connected and the Key switch turned on the
following will be displayed:
The hand terminal version is first displayed.
A
A - Transistor regulator’s firmware version.
B - Supply voltage.
C - Transistor regulator’s rated current.
B C D D - Present hour meter value.
• Press ENTER (Fig. 15 C) to display the first menu.
• Cycle through the menus by repeatedly pressing the ROLL buttons
(Fig. 15 B).
• Press OUT(Fig. 15 D) to leave the present menu.
• Buttons PARAM SET (Fig. 15 E) are used to adjust parameter val-
ues.
ENTER
ROLL
ROLL
* MAIN MENU *
PROGRAM VACC Menu for calibration of speed control potentiometer [R1]
ROLL
ROLL
Menu for downloading a parameter set-up from the hand terminal
* MAIN MENU * to the transistor controller
RESTOR PARAM.
ROLL
* MAIN MENU * Menu for uploading a parameter set-up from the transistor con-
SAVE PARAM. troller to the hand terminal
ROLL
ROLL
9.9.1 General
The truck’s electronic control system incorporates built-in error code
display and logging. This capability works as a powerful complement in
assessing the cause of eventual truck malfunctions. Error conditions
encountered by the transistor regulator are displayed as a sequence of
flashes of the status LED (Fig. 10 AL). The sequence always starts with
a number of “long” flashes followed by a number of “short” flashes. See
Table 11 on page 32.
The 5 most recent error codes will be stored in a log along with the hour
meter reading, number of occurrences and transistor regulator temper-
ature when the error occurred.
The first time an error code is generated it is advisable to check if the
condition persists by switching the truck off completely, then switching
back on again. Check to see if the error code is displayed again.
Use the hand terminal’s TESTER function to test basic truck character-
istics.
SEM-X V..
24v 75A 00000
ENTER
* MAIN MENU *
PARAMETER CHANGE
* MAIN MENU * CODE
ROLL STEER TABLE ROLL CODE
* MAIN MENU * OUT
PROGRAM VACC CODE
* MAIN MENU * ENTER CODE
ALARMS
00001 #01 20 C
OUT
ENTER
OUT
ENTER
OUT LOG BOOK CLEARED
G
(PRESS OUT)
Fig. 17 Menu tree for error code history display
The log will display up to 5 most recent error types with the following
information for each error.
A - Error code description.
A
B - Hour meter value when fault occurred.
* VFIELD NOT OK *
00015h #01 27°C
C - Number of occurrences of specific error.
B C D
D - Transistor regulator temperature when fault occurred.
The error code history log can be optionally cleared when exiting the
ALARM menu.
¤¤ ¤ CAPACITOR Capacitors are not charged within 500 ms after Key switch is
(2+1) CHARGE closed / Check [PTC] resistor circuit. / If above is ok replace
transistor regulator.
VMN NOT OK VMN armature driver problem. Incorrect motor connection
s/c in motor windings to chassis.
Transistor regulator defect. / Check armature connections
[M1] are correct and no internal s/c exists. If above is ok
replace transistor regulator.
VFIELD NOT OK Field Voltage problem. Traction motor’s [M1] field winding s/c
or o/c.
Field winding incorrectly connected to the transistor regula-
tor. Transistor regulator defect. / Check field connections
[M1] are correct and no motor s/c exists. If above is ok
replace transistor regulator.
¤¤ ¤¤ NO FIELD CUR Field current abnormally low. Traction motor’s [M1] field
(2+2) winding s/c or o/c.
Field winding incorrectly connected to the transistor regula-
tor. Transistor regulator defect. / Check field connections
[M1] are correct and no motor s/c exists. If above is ok
replace transistor regulator.
FW HIGH FIELD Field current abnormally high in drive wheel direction. Trac-
CURR. tion motor´s [M1] field winding s/c or o/c.
Field winding incorrectly connected to the transistor regula-
tor. Transistor regulator defect. / Check field connections
[M1] are correct and no motor s/c exists. If above is ok
replace transistor regulator.
BW HIGH FIELD Field current abnormally high in forks direction. Traction
CURR. motor´s [M1] field winding s/c or o/c.
Field winding incorrectly connected to the transistor regula-
tor. Transistor regulator defect. / Check field connections
[M1] are correct and no motor s/c exists. If above is ok
replace transistor regulator.
¤¤ ¤¤¤ STBY I HIGH Armature current abnormally high whilst in stand-by. Transis-
(2+3) tor regulator defect. / Replace transistor regulator.
I=0 EVER Armature current abnormally low whilst driving. / Check
armature connections, check or replace carbon brushes.If
above is ok replace transistor regulator.
CURR. PROTEC- Armature current abnormally high whilst driving. / Check
TION armature connections for s/c. If above is ok replace transis-
tor regulator.
SEM-X V..
24v 75A 00000 BATTERY CHARGE
BELLY SWITCH
ENTER
DIGITAL INPUT # 2
9.10.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
adjusted using the hand terminal.
SEM-X V..
24v 75A 00000
ENTER
* MAIN MENU *
PARAMETER CHANGE
* MAIN MENU *
STEER TABLE
* MAIN MENU * SELECT Mod 31
ROLL PROGRAM VACC SELECT Mod 03
ROLL
* MAIN MENU * SELECT Mod 02
ALARMS
* MAIN MENU * SELECT Mod 01
RESTOR PARAM. FREE ENTER
* MAIN MENU * SELECT Mod 00
SAVE PARAM. ENTER SEM -X V
ENTER
Memory location
OUT OVERWRITE DATA? occupied
YES = ENTER NO = OUT
ENTER
READING Memory location
free
Run all parameters
ENTER
* MAIN MENU *
PARAMETER CHANGE
* MAIN MENU *
STEER TABLE
ROLL * MAIN MENU * SELECT Mod 31
PROGRAM VACC ROLL SELECT Mod 02
* MAIN MENU * ENTER
ALARMS SELECT Mod 01
* MAIN MENU * ENTER SELECT Mod 00
RESTOR PARAM.
SEM-X V
ENTER
STORING
Run all parameters
Procedure
To perform calibration of the speed potentiometer use the PROGRAM
VACC function in the hand terminal:
• Connect the hand terminal. See “Connecting the hand terminal” on
page 27.
SEM-X V..
24v 75A 00000
ENTER
* MAIN MENU *
PARAMETER CHANGE
ROLL * MAIN MENU *
STEER TABLE
* MAIN MENU * VACC SETTING ENTER
ENTER
PROGRAM VACC
0.4 4.7
OUT
• Select PROGRAM VACC from the menu and press ENTER then
ENTER.
• Move tiller arm to drive position.
• Slowly move the speed control [L1] from neutral to full deflection first
in one direction then the other direction.
• Press OUT followed by ENTER.
The transistor regulator and potentiometer have now been calibrated.
Y41
4
M3 P 5
10.2 Description
Lift
The lifting motion occurs when the pump motor (M3) is run. Lift speed
depends on load weight.
The non-return valve prevents leakage through the pump. When the
load is in the lifted position, it is held in place by the non-return valve
and the closed electric lowering valve (Y41).
Lower
By opening the electric lowering valve (Y41), the load is lowered and
the maximum lowering speed of the forks is regulated by the flow con-
trol valve.
A pressure limit valve (overflow valve) prevents overload and protects
the pump motor from overpressure. A hose rupture valve is located at
the cylinder to prevent the load from falling uncontrollably in the event
of a hose rupturing.
Operating pressure
Operating pressure at rated load is 110 bar.
10.3 Adjustments
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
1 2 replaced.
The truck should be able to lift a load of between 1300 and 1400 kg on
the forks.
1. Lock nut.
2. Adjuster screw, pressure limit
When the screw is turned clockwise pressure increases.
When the screw is turned counter clockwise pressure de-
creases.
• Place a load of 1300 kg on the forks and check that the truck can lift
it.
• If the truck cannot lift 1300 kg:
- Loosen the lock nut (1) by turning it counter clockwise.
- Turn the adjuster screw (2) clockwise until the truck is able to lift
the load without problems.
- Tighten the lock nut (1) by turning it clockwise.
10- 2 Service Manual PP13 © TIEE SARL
Hydraulic system – 6000
Tools
Order number Date Valid from serial number T-code
208588-040 2005-10-28 914369- 675
• If the truck can lift 1300 kg, place a further 100 kg on the forks.
Check that the truck cannot lift the load.
• If the truck can lift 1400 kg:
- Loosen the lock nut (1) by turning it counter clockwise.
- Turn the adjuster screw (2) counter clockwise until the truck is un-
able to lift the load.
- Tighten the lock nut (1) by turning it clockwise.
NOTE
A special tool is required to adjust the lock nut and adjuster screw.
See the section on tools below.
10.4 Tools
Two special tools are required to adjust the pressure limit valve of the
hydraulic system.
A B
12
26,5 13,5
11.1 General
These instructions have been drawn up as part of the truck manufactur-
er’s environmental management program. An important motive is, by
taking nature into consideration, to economise with resources. In other
words, you should try to recycle all material as far as possible. This is to
minimise the discharge of environmentally-hazardous substances.
The dismantling instructions are divided into different C-codes (parts
and functions on the truck.) These C-codes are:
• 0000 Chassis
• 1000 Motors
• 2000 Transmission/drive transmission
• 3000 Brakes/belt/wheel system
• 4000 Steering system
• 5000 Electrical system
• 6000 Hydraulics/pneumatics
• 7000 Working function - lift mast
• 8000 Auxiliary/installation equipment
• 9000 Accessories/extra equipment
The instructions do not tell you the type of material the parts are made
of, but refer you to different material containers where the parts should
be collected. Some plastics are marked, which means some instruc-
tions refer to the marking to determine the collection container to use.
11.2 Procedure
When sorting a component part you must know what plastic parts, liq-
uids, environmentally-hazardous substances and metals it incorpo-
rates.
11.3 Abbreviations
Abbreviations for Service Manuals and plastic materials are used in the
dismantling instructions. The abbreviations used are:
ABS = Acrylonitrile-butadiene-styrene
PA= Polyamide
PMMA = Plexiglass
PP = Polypropylene
SM = Service Manual
11.4 Sorting
The sorting method for component parts is based on how they can be
recycled and whether they must be handled in a special way.
• Plastics must first and foremost be sorted into recyclable and non
recyclable plastics. Plastics that can be recycled must be subdivided
to differentiate between the different types of plastic. Instructions ei-
ther indicate in which container the plastic should be placed or there
is a reference to the material marking on the plastic component. In
those cases where the container is indicated, the type of plastic is
shown by an abbreviation. Sorting is not necessary for non-recycla-
ble plastics. These are placed in containers intended for combusti-
ble material.
• Small plastic and rubber items are placed in the container intended
for combustible material.
• Iron and steel scrap are sorted separately.
• Composite scrap that is difficult to dismantle and which contains dif-
ferent metals such as steel, aluminium, copper and other materials,
for example, plastics, should be sorted separately.
• Oil is collected in the intended container.
• Oil filters are collected in the intended container.
• Parts contaminated by oil, such as hydraulic hoses, should be sort-
ed separately.
• Batteries should be returned to the manufacturer (manufacturer of
the battery or the truck).
• Electronic scrap should be sorted from other scrap.
• Cables should be removed and collected separately.
• Small parts, such as screws, bolts, nuts, washers, etc. are not in-
cluded in the dismantling instructions. These are placed in contain-
ers intended for iron and steel scrap.
Material handling
All parts are to be treated as iron and steel scrap.
Material handling
The hood is to be placed in a container intended for ABS.
Material handling
Oil should be treated as dangerous waste.
Hydraulic cables should be placed in a container for oil-contaminated
components.
The motor, together with the pump, should be placed in a container for
dangerous waste.
Disassembly
• Remove the cables.
• Remove the drive motor including the electric parking brake (1) from
the gearbox.
• Empty the oil from the gearbox.
• Remove the drive wheel (2).
Material handling
Cables are to be placed in a container intended for cables. The motor
and electric parking brake should be placed in a container for danger-
ous waste.
The oil should be treated as dangerous waste.
The gearbox is to be placed in a container intended for iron and steel
scrap.
1
3
Disassembly
• Remove the swivel wheel (1), drive wheel (2) and fork wheel (3).
Material handling
The vulcanised wheels should be placed in a container for vulcanised
wheels.
Disassembly
• Remove the cables.
• Remove the gas dashpot (1) and cut it in half.
• Remove the switch (2).
• Remove the potentiometer (3).
• Remove the sensor (4).
Material handling
Cables are to be placed in a container intended for cables.
Metal parts and gas dashpots should be placed in a container for metal.
The switch, potentiometer and sensor should be placed in containers
3 intended for electronic scrap.
+ - + -
Disassembly
• Remove the cables.
• Remove batteries.
• Remove the electronic devices.
Material handling
Cables are to be placed in a container intended for cables.
The battery (classified as hazardous waste within the EU) should be
returned to the battery manufacturer or the manufacturer's representa-
tive (see the rating plate on the battery). The batteries can also be
handed in to a representative of the truck manufacturer, who bears
responsibility for returning it to the battery manufacturer.
The electronic units should be placed in a container intended for elec-
tronic scrap.
Material handling
Oil should be treated as dangerous waste.
Hydraulic cables should be placed in a container for oil-contaminated
components.
The tank should be placed in a container for PP.
The motor, together with the pump, should be placed in a container for
dangerous waste.
1
2
Material handling
The oil should be treated as dangerous waste.
Cylinder and hydraulic pipes are to be placed in a container intended
for iron and steel scrap.
Hydraulic hoses should be placed in a container for oil-contaminated
components.