Rocla Forklift Service Bulletin Collection 2001-2010 – Reach Truck, Stacker, Pallet Truck & Order Picker Repair Bulletins PDF

Description

Rocla Forklift Service Bulletin Collection 2001-2010

This PDF brings together the complete run of Rocla service bulletins released between September 2001 and September 2010 for the reach truck, stacker, pallet truck, order picker and tow tractor families. Every bulletin is reproduced in full with its original photographs, exploded-view drawings, wiring schematics, hydraulic circuit diagrams, parameter tables and step-by-step modification instructions exactly as issued by Rocla Oyj Technical Support. Whether you are maintaining a TW20ac, diagnosing a TP20ac(H) platform fault or updating an SST12 hydraulic system, this collection gives you the factory guidance in one place.

File Details

• Manual type: Service Bulletin Collection
• Brand: Rocla / Rocla Oyj
• Language: English, with multilingual parts lists in Finnish, Swedish, German, French, Spanish, Italian and Portuguese
• Page count: 113 pages
• File format: PDF
• Bulletin period: 24.09.2001 to 29.09.2010

Chapters Covered

The bulletins are arranged chronologically and address the following areas across the Rocla range:

• Gas spring modifications for tiller arms and pedestrian pallet trucks
• AC-2 inverter improvements
• Mast roller clearance and mast operating comfort
• PHL logic unit replacements
• Lift cut-out feature installation
• Bull gear box modification
• Magnetic brake inspection and maintenance
• Reach truck warranty extension
• Bull TWac parameter changes
• Speed controller replacement
• Fork carriage lever shaft locking conversion
• Tiller arm length and gas spring changes
• Safety pedal size changes
• SST12 hydraulic system redesign
• Service manual releases
• Pump contactor improvements
• EL-panel reinforcement
• Multiway reach truck component modification
• Fork plate reinforcement
• Console and laptop program availability
• Humanic brake adjustment and cable checking
• h2 tiller arm introduction, locking and switch assembly
• TP20ac sidebars improvement and modification set
• Humanic display languages
• Controller terminal tightening torque change
• TP20ac(H) platform suspension and modification kit
• Humanic mast mounting modification and mast safety improvement
• SSTac(i) minilever failure control improvement
• New tiller switch for TWac and SWac
• Humanic free lift reference sensor exchange
• TP20ac(H) steering motor gear mounting check
• PS20/PS30t steering panel gas strut release button seal

Reach Truck and Multiway Reach Truck Bulletins

These bulletins cover the Rocla reach truck family and the multiway reach truck line. The AC-2 inverter bulletin describes how to fit a diode across the brake coil in place of the original varistor using adapter 464075, with reference to schematics 3-6781.4 and 3-6805. The HL2 mast roller clearance bulletin explains the changeover to multiple roller sizes from October/November 2002 and details the conventional clearance adjustment roller (item 197398) used during the transition. The reach truck warranty extension announces the move to 2 years or 2500 operating hours for F/S/C/H and TEM models from week 18/2002, serial numbers 5218.xxx onward. The new design of the boomerang product range covers the reinforced truck frame, reach carriage and HL2 mast introduced from serial number 5310. Later bulletins address Humanic load wheel brake adjustment, load wheel brake cable checking, display languages, mast mounting modification, mast safety improvement and free lift reference sensor exchange. The multiway reach truck component modification describes the change to Sauer Danfoss controllers, separated steering controllers and motors, and the new hand-held console 469054.

Bull Product Range – Pallet Trucks, Stackers and Tow Tractors

The Bull range bulletins are the largest group in this collection. The gas spring modification introduces kit 463629 for TW16/20 and SW12/16 (450N gas spring, bracket, four M5x10 screws) and kit 463631 for TP20, SP12/16 and SPD16 (350N gas spring). The old gas spring 450240 is cancelled as a spare part. The lift cut-out feature is covered with kit 465850 for SEM 0 controllers and kit 465852 for SEM 1 controllers, with circuit diagram 3-6814. The Bull gear box modification replaces the pinion shaft locking screw with a circlip, with modification kits 465919 and 465920 for gear boxes 550138 and 550198. The magnetic brake maintenance bulletin provides a detailed table of air gaps, friction disc minimum thicknesses, coil resistances and tightening torques for part numbers 550178, 550202, 184101, 450605 and 550356. The Bull TWac parameter changes bulletin explains how to set Stop mode tiller to 2 and adjust the Dec. belly + tiller parameter using console 469054. The TW20ac speed controller change describes replacing controller 465480 with 473324, machining four M6 thread holes in the electric panel mounting plate, and fitting 5mm/16mm2 terminals to the U, V and W motor phase cables. The TW13/16ac fork carriage lever shaft locking modification moves from a stop screw to a circlip, with new shafts fitting TW13ac all fork widths and TW16ac all fork widths except 480mm. Tiller arm changes include the 90mm shorter tiller arm on TP20 and SP fixed platform models (381mm to 291mm from serial number 5502), the new tiller arm gas spring 473172 on TW13/16/20ac models from serial number 5512, and the AC pedestrian power pallet gas spring modification kit 479611. The T20 safety pedal change brings the pedal to the same dimensions used on SST models from serial number 5512. The SST12 hydraulic system redesign introduces a separated plastic hydraulic oil tank, hydraulic pump, pump motor and proportional valve from serial number 5507402. Pump contactor improvements cover the TW20ac, TW13ac and TW16ac models with new contactor 510593. The EL-panel reinforcement on TW13ac adds part 480715 to prevent fuse breakage through vibration. The TW16ac fork plate reinforcement increases fork plate thickness to 6mm from serial number 5601. The TP20ac sidebars improvement reduces the distance between sidebars from approximately 580-600mm to approximately 500mm from serial number 5722, with modification set 491863 available for older trucks. The TP20ac contactor improvement uses new part numbers K1/K3 490525 and K2 490531 from serial number 5751. The TP20ac(H) platform suspension change introduces a new suspension system where absorbers do not lift the platform when the operator leaves the truck, with updating kit 493981 available. The h2 tiller arm bulletins cover the introduction of the new tiller arm, the locking screw modification from serial number 5821, and correct switch assembly. The SSTac(i) minilever failure control improvement requires Zapi Combi AC1 controller software version 0.37 or newer, with instructions to teach new values for SET ACCELER.MAX (1,6V) and SET ACC.MAX REV (0,3V). The new tiller switch for TWac and SWac replaces the Telemecanique switch with a SICK unit, and on Sauer Danfoss controllers the Tiller Type parameter must be changed from 1 to 0.

PHL Order Pickers, Mast Systems and Service Documentation

The PHL logic bulletin covers the replacement of Siemens CPU214 and relay unit EM223/6ES7 with CPU224 and EM223/1PH22, with new part numbers 464662 (CPU224 base), 464663 (CPU224 cabin) and 464660 (EM223/1PH22 relay unit). The PHL logics availability bulletin explains that old logics 465049 and 465050 are no longer available and provides replacement set 487008 for order pickers manufactured before week 22/2000, or individual replacement parts for later machines. The new service manuals bulletin announces the release of service manuals for AC multiway reach trucks, AC pedestrian power pallets, AC pedestrian stackers and AC reach trucks. The console and laptop program availability bulletin lists the consoles and cables available from spare parts, including the Sevcon MOS90C console (197888), Curtis console (109233), adapter cable 489741 for Curtis 1207A, Zapi console (199256), Zapi adapter cable (450930) and Sauer Danfoss console (469054), plus the Zapi PC console program (471429) and Sauer Danfoss PC console program (483226). The change of tightening torque for the H-X controller terminal bulletin specifies new torque values for the traction controller 481242 and pump controller 481243: U, V and W terminals at 16 plus/minus 1 Nm and P, N terminals at 10 plus/minus 1 Nm. The TP20ac(H) steering motor gear mounting bulletin describes checking the 4x M4x70 gear mounting screws to 3.1 Nm. The PS20 and PS30t steering panel gas strut release button bulletin describes the sealed release knob (seal part number 608210) introduced after March 14, 2011.

What This Rocla Service Bulletin Collection Delivers

IMAGES PREVIEW

This is not a generic repair guide. It is the factory’s own record of every improvement, correction and safety update applied to the Rocla reach truck, stacker, pallet truck, order picker and tow tractor range over nearly a decade. When you are facing an AUX OUTPUT KO alarm on an AC-2 inverter, need the correct tightening torque for a TP20ac(H) steering motor gear bolt, or have to decide whether a TW16ac fork carriage can accept the circlip-type shaft, this collection tells you what Rocla changed, why they changed it and exactly how to apply the same fix in your workshop. Every bulletin includes the part numbers, serial number breakpoints, wiring schematics and step-by-step procedures you need to complete the job correctly the first time. The Rocla forklift service bulletins are delivered as an instant PDF download – no shipping, no waiting. Print the pages you need for the workshop floor or pull the file up on a laptop, tablet or phone. Whether you service one truck or manage a fleet, this Rocla repair bulletin collection is the reference that keeps your equipment running to factory specification.