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Toyota Forklift PM 14 PM 16 PML 20 PLL 22 PM 20 Master Service Manual – PDF DOWNLOAD
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Description
Toyota Forklift PM 14 PM 16 PML 20 PLL 22 PM 20 Master Service Manual – PDF DOWNLOAD
FILE DETAILS:
Toyota Forklift PM 14 PM 16 PML 20 PLL 22 PM 20 Master Service Manual – PDF DOWNLOAD
Language : English
Pages : 262
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Toyota Forklift PM 14 PM 16 PML 20 PLL 22 PM 20 Master Service Manual – PDF DOWNLOAD
Introduction to Master Service Manual:
This Service manual contains product information regarding the current trucks including the technical data and instructions for maintenance and service. It includes the operator’s Instruction Manual, Spare Part Handbook and oil and grease specifications:
M Machine information
P Preventive maintenance
S Service instructions
O Options
- At the top of each page you can find information on which section the page belongs: Section M4 means that it is Technical Data; F-Code means it deals with this specific truck family; T-Code means specific products; Data and Version Number give information on when the page was issued and which version.
- It is our ambition to send modification notifications concerning improvements to you as soon as possible. It’s stated on the notifications which section/s in the binder should be replaced. Notifications should be inserted immediately so that the binder always contains current service information.
TABLE OF CONTENTS:
Toyota Forklift PM 14 PM 16 PML 20 PLL 22 PM 20 Master Service Manual – PDF DOWNLOAD
PM 14/16 PML 20 PLL 22 PM 20........................................................................................ 1 Table of contents Master Service Manual (MSM)....................................................................... 3 Valid from serial number:....................................................................................... 3 T-code.......................................................................................................... 3 Model........................................................................................................... 3 Serial No....................................................................................................... 3 Notes........................................................................................................... 3 1. Document list................................................................................................ 3 Section..................................................................................................... 3 C-code...................................................................................................... 3 T-code...................................................................................................... 3 Document.................................................................................................... 3 Issued...................................................................................................... 3 Introduction to Master Service Manual............................................................................... 5 Contents, M......................................................................................................... 7 1. Truck information............................................................................................ 7 Operator’s manual................................................................................................... 9 Valid from serial number:....................................................................................... 9 T-code.......................................................................................................... 9 Model........................................................................................................... 9 Serial No....................................................................................................... 9 Notes........................................................................................................... 9 1. General...................................................................................................... 9 1.1. Issued operator’s manuals.............................................................................. 9 T-code.................................................................................................. 9 Model................................................................................................... 9 Serial number........................................................................................... 9 Order number............................................................................................ 9 Issued.................................................................................................. 9 General product information......................................................................................... 11 Valid from serial number:....................................................................................... 11 1. Presentation of the truck.................................................................................... 11 2. Intended use of the truck.................................................................................... 11 3. Forbidden use of the truck................................................................................... 11 4. Truck data................................................................................................... 12 Truck type.................................................................................................. 12 PML 20...................................................................................................... 12 5. Truck dimensions............................................................................................. 13 PML 20 240Ah................................................................................................ 13 PML 20 320Ah................................................................................................ 13 6. Type plate................................................................................................... 14 Item........................................................................................................ 14 Text........................................................................................................ 14 Unit........................................................................................................ 14 7. Modification plate........................................................................................... 14 Character................................................................................................... 14 Text........................................................................................................ 14 8. Main components.............................................................................................. 15 1. Tiller arm: The truck is operated by the driver when walking. Steering range 208 degrees. The ........... 15 2. Hoods: Easily removable, providing good accessibility when servicing..................................... 15 3. Battery switch and Charging plug: The battery is charged via the fixed charging plug..................... 15 4. Hydraulic unit: Pump motor and pump are integrated into a compact unit................................... 15 5. Drive unit with brakes: Fixed drive unit with spring loaded mechanical brakes, travel motor, d........... 15 6. Machine number: Punched plate on the chassis............................................................. 15 7. Support castor wheel: 2 support castors to ensure stability.............................................. 15 8. Electrical panel: Removable, providing good accessibility for servicing. 24volt electrical sy........... 15 9. Fork carriage: The forks are kept parallel by a link system. The fork carriage is lubrication ........... 15 10. Battery: 24 V with different Ah-rates................................................................... 15 11. Instruments: Combined running meter/battery guard or just a running meter............................... 15 12. Type plate: Indicating the type designation, machine number, year of manufacture, weight with........... 15 13. Platform: Collapsible ride-on platform, which is automatically raised when it is not loaded............. 15 9. Warning and information plates............................................................................... 17 1. Horn..................................................................................................... 17 2. Hydraulic control: Lower................................................................................. 17 3. Hydraulic control: Lift.................................................................................. 17 4. Direction of travel...................................................................................... 17 5. Hydraulic oil filling point.............................................................................. 17 6. Machine number........................................................................................... 17 7. Lifting points........................................................................................... 17 8. Type plate............................................................................................... 17 9. Modification plate....................................................................................... 17 General product information......................................................................................... 19 Valid from serial number:....................................................................................... 19 T-code...................................................................................................... 19 Model....................................................................................................... 19 Serial No................................................................................................... 19 Notes....................................................................................................... 19 1. Presentation of the truck.................................................................................... 19 CAUTION!.................................................................................................... 19 1.1. Intended application of the truck...................................................................... 20 1.2. Forbidden application of the truck..................................................................... 20 2. Truck data................................................................................................... 21 Truck type.................................................................................................. 21 PLL 22...................................................................................................... 21 PLL 22-8.................................................................................................... 21 3. Truck dimensions............................................................................................. 22 PLL 22-8.................................................................................................... 22 PLL 22...................................................................................................... 23 Item........................................................................................................ 23 Measurement in mm........................................................................................... 23 Item........................................................................................................ 23 Measurement in mm........................................................................................... 23 PLL 22.................................................................................................. 23 PLL 22-8................................................................................................ 23 PLL 22.................................................................................................. 23 PLL 22-8................................................................................................ 23 4. Identification plate CE...................................................................................... 24 Item........................................................................................................ 24 Text........................................................................................................ 24 Unit........................................................................................................ 24 5. Modification plate........................................................................................... 24 Item........................................................................................................ 24 Text........................................................................................................ 24 6. Main components.............................................................................................. 25 1. Tiller arm: The truck can be controlled by the operator standing on the rideon platform or wa........... 25 2. Identification plate: With model designation, serial number, year of manufacture, weight witho........... 25 3. Protective gates: A higher speed of 9,5 km/h is possible with the gates folded out, while the ........... 25 4. Covers: Easily opened and removable which allows good access when servicing.............................. 25 5. Drive unit with brake: Suspended drive unit with two stage electromagnetic brake, drive motor,........... 25 6. Hydraulic unit: Pump motor, pump, valves and oil tank integrated in a compact unit....................... 25 7. Platform: Folding rideon platform which automatically folds up when not loaded.......................... 25 8. Platform switch: Switch for control of the speed range and brake function................................ 25 9. Support castor wheels: Two support castor wheels to ensure stability. Fitted with rubber guard........... 25 10. Electric panel: Can be swung, which provides good access when servicing. 24 volt electrical s........... 25 11. Lift cylinders: Located along the sides of the truck.................................................... 25 12. Fork carriage: The forks are held horizontal by a link system. The fork carriage requires no ........... 25 13. Serial number: Serial number plate fitted to the chassis. Partly hidden by the emergency disc........... 25 14. Emergency disconnector and battery connector: The battery is charged via the permanently fitt........... 26 15. Battery: 24 V with different Ah values. Stands on rollers to facilitate replacement..................... 26 7. Warning and information plates and symbols................................................................... 27 1. Signal/Horn.............................................................................................. 27 2. Hydraulic control: Lower................................................................................. 27 3. Hydraulic control: Lift.................................................................................. 27 4. Travel direction......................................................................................... 27 5. Hydraulic oil filling.................................................................................... 27 6. Lifting points........................................................................................... 27 7. Serial number............................................................................................ 27 8. Identification plate..................................................................................... 27 9. Modification plate....................................................................................... 27 Technical data...................................................................................................... 29 Valid from serial number:....................................................................................... 29 T-kod........................................................................................................... 29 Modell.......................................................................................................... 29 Maskinnr........................................................................................................ 29 Anm............................................................................................................. 29 Model........................................................................................................... 29 PM 14........................................................................................................... 29 PM 16........................................................................................................... 29 PM 20........................................................................................................... 29 Drive motor................................................................................................. 29 Transmission/gear........................................................................................... 29 Wheels...................................................................................................... 29 Hydraulic unit.............................................................................................. 30 Fuses....................................................................................................... 30 Batteries................................................................................................... 30 All models.................................................................................................. 30 Driving speeds.............................................................................................. 31 Lifting/lowering time....................................................................................... 31 Current consumption......................................................................................... 31 Technical data...................................................................................................... 33 Valid from serial number:....................................................................................... 33 T-code.......................................................................................................... 33 Model........................................................................................................... 33 Serial No....................................................................................................... 33 Notes........................................................................................................... 33 MODEL........................................................................................................... 33 PML 20.......................................................................................................... 33 Drive motor................................................................................................. 33 Transmission/drive gear..................................................................................... 33 Wheels...................................................................................................... 33 Hydraulic unit.............................................................................................. 34 Fuses....................................................................................................... 34 Batteries................................................................................................... 34 Driving speeds.............................................................................................. 34 Lifting and lowering times.................................................................................. 35 Power consumption........................................................................................... 35 Technical data...................................................................................................... 37 Valid from serial number:....................................................................................... 37 T-code...................................................................................................... 37 Model....................................................................................................... 37 Serial No................................................................................................... 37 Notes....................................................................................................... 37 Model........................................................................................................... 37 PLL 22.......................................................................................................... 37 Drive motor................................................................................................. 37 Transmission/drive gear..................................................................................... 37 Wheels...................................................................................................... 37 Hydraulic system............................................................................................ 38 Fuses....................................................................................................... 38 Batteries................................................................................................... 38 Driving speed............................................................................................... 38 Lifting-/lowering speed..................................................................................... 39 Power consumption........................................................................................... 39 Quality Parts....................................................................................................... 41 Valid from serial number:....................................................................................... 41 T-code.......................................................................................................... 41 Model........................................................................................................... 41 Serial No....................................................................................................... 41 Notes........................................................................................................... 41 1. Issued Quality Parts......................................................................................... 41 T-code...................................................................................................... 41 Model....................................................................................................... 41 Serial No................................................................................................... 41 Order number................................................................................................ 41 Issued...................................................................................................... 41 Contents, P......................................................................................................... 43 1. Preventive Maintenance....................................................................................... 43 Introduction, maintenance........................................................................................... 45 1. Safety regulations with maintenance work..................................................................... 45 WARNING!.................................................................................................... 45 WARNING!.................................................................................................... 46 WARNING!.................................................................................................... 46 NOTE!....................................................................................................... 46 CAUTION!.................................................................................................... 46 2. Cleaning and washing......................................................................................... 47 NOTE!....................................................................................................... 47 2.1. External cleaning...................................................................................... 47 NOTE!................................................................................................... 47 2.2. Cleaning the motor compartment......................................................................... 47 NOTE!................................................................................................... 47 2.3. Electrical components.................................................................................. 48 NOTE!................................................................................................... 48 3. Safe lifting................................................................................................. 48 WARNING!.................................................................................................... 48 Preventive maintenance.............................................................................................. 49 Valid from serial number:....................................................................................... 49 T-kod........................................................................................................... 49 Modell.......................................................................................................... 49 Maskinnr........................................................................................................ 49 Anm............................................................................................................. 49 1. Service schedule............................................................................................. 49 Pos. n ..................................................................................................... 49 Work to carry out........................................................................................... 49 Interval in hours....................................................................................... 49 5....................................................................................................... 49 20...................................................................................................... 49 80...................................................................................................... 49 160..................................................................................................... 49 250..................................................................................................... 49 500..................................................................................................... 49 1000.................................................................................................... 49 Interval in Days/Weeks/Months........................................................................... 49 1d...................................................................................................... 49 1v...................................................................................................... 49 1m...................................................................................................... 49 2m...................................................................................................... 49 3m...................................................................................................... 49 6m...................................................................................................... 49 1m...................................................................................................... 49 0000.................................................................................................... 49 Chassis................................................................................................. 49 0380.................................................................................................... 49 Fork Carriage........................................................................................... 49 0640.................................................................................................... 49 Operator Controls....................................................................................... 49 0840.................................................................................................... 49 Drivers Protection...................................................................................... 49 1700.................................................................................................... 50 Drive Motor............................................................................................. 50 2550.................................................................................................... 50 Drive Gear.............................................................................................. 50 3100.................................................................................................... 50 Brake................................................................................................... 50 3500.................................................................................................... 50 Wheels.................................................................................................. 50 4100.................................................................................................... 50 Tiller Arm.............................................................................................. 50 5110.................................................................................................... 51 Battery................................................................................................. 51 5200.................................................................................................... 51 Instrument Panel........................................................................................ 51 5300.................................................................................................... 51 Electrical Control System............................................................................... 51 5400.................................................................................................... 51 Electrical Panel........................................................................................ 51 5710.................................................................................................... 51 Electronic Card......................................................................................... 51 6000.................................................................................................... 52 Hydraulic System........................................................................................ 52 7310.................................................................................................... 52 Lift Cylinder........................................................................................... 52 Preventive maintenance.............................................................................................. 53 Valid from serial number:....................................................................................... 53 T-code.......................................................................................................... 53 Model........................................................................................................... 53 Serial No....................................................................................................... 53 Notes........................................................................................................... 53 1. Service schedule............................................................................................. 53 Pos. No..................................................................................................... 53 Work to carry out........................................................................................... 53 Interval in hours....................................................................................... 53 5....................................................................................................... 53 20...................................................................................................... 53 80...................................................................................................... 53 160..................................................................................................... 53 250..................................................................................................... 53 500..................................................................................................... 53 1000.................................................................................................... 53 Interval in days/weeks/months........................................................................... 53 1d...................................................................................................... 53 1w...................................................................................................... 53 1m...................................................................................................... 53 2m...................................................................................................... 53 3m...................................................................................................... 53 6m...................................................................................................... 53 12m..................................................................................................... 53 0000.................................................................................................... 53 Chassis................................................................................................. 53 0380.................................................................................................... 53 Fork carriage........................................................................................... 53 0560.................................................................................................... 53 Platform and brackets................................................................................... 53 0640.................................................................................................... 54 Control devices......................................................................................... 54 0840.................................................................................................... 54 Driver protection....................................................................................... 54 1700.................................................................................................... 54 Drive motor............................................................................................. 54 2550.................................................................................................... 54 Drive shaft............................................................................................. 54 3100.................................................................................................... 54 Brakes.................................................................................................. 54 3500.................................................................................................... 55 Wheels.................................................................................................. 55 4100.................................................................................................... 55 Tiller arm.............................................................................................. 55 5110.................................................................................................... 55 Battery................................................................................................. 55 5200.................................................................................................... 55 Control panel........................................................................................... 55 5300.................................................................................................... 55 Control system.......................................................................................... 55 5400.................................................................................................... 56 Electrical panel........................................................................................ 56 5710.................................................................................................... 56 Electronic card......................................................................................... 56 6000.................................................................................................... 56 Hydraulic system........................................................................................ 56 7310.................................................................................................... 56 Lift cylinder........................................................................................... 56 Preventive maintenance.............................................................................................. 57 Valid from serial number:....................................................................................... 57 T-code...................................................................................................... 57 Model....................................................................................................... 57 Serial No................................................................................................... 57 Notes....................................................................................................... 57 1. Service schedule............................................................................................. 57 Pos. nr..................................................................................................... 57 Work to carry out........................................................................................... 57 Interval in hours....................................................................................... 57 5....................................................................................................... 57 20...................................................................................................... 57 80...................................................................................................... 57 160..................................................................................................... 57 250..................................................................................................... 57 500..................................................................................................... 57 1000.................................................................................................... 57 Interval in days/weeks/months........................................................................... 57 1d...................................................................................................... 57 1w...................................................................................................... 57 1m...................................................................................................... 57 2m...................................................................................................... 57 3m...................................................................................................... 57 6m...................................................................................................... 57 12m..................................................................................................... 57 0000.................................................................................................... 57 Chassis................................................................................................. 57 0380.................................................................................................... 57 Fork carriage........................................................................................... 57 1700.................................................................................................... 57 Motors.................................................................................................. 57 2550.................................................................................................... 58 Drive unit.............................................................................................. 58 3100.................................................................................................... 58 Brake................................................................................................... 58 3500.................................................................................................... 58 Wheels.................................................................................................. 58 5110.................................................................................................... 58 Battery................................................................................................. 58 4110.................................................................................................... 59 Tillerman............................................................................................... 59 4380.................................................................................................... 59 Steering bearing........................................................................................ 59 5000.................................................................................................... 59 Electrical operations................................................................................... 59 5400.................................................................................................... 59 Power system driving.................................................................................... 59 5700.................................................................................................... 59 Electronic card......................................................................................... 59 6100.................................................................................................... 59 Hydraulic system........................................................................................ 59 6600.................................................................................................... 60 Lift cylinders.......................................................................................... 60 2. Lubrication chart............................................................................................ 62 Pos no...................................................................................................... 62 Service point............................................................................................... 62 Interval/Running hours...................................................................................... 62 Lubricant................................................................................................... 62 250h.................................................................................................... 62 1000h................................................................................................... 62 3000h................................................................................................... 62 Oil and grease specification........................................................................................ 63 Valid from serial number:....................................................................................... 63 T-code.......................................................................................................... 63 Model........................................................................................................... 63 Serial No....................................................................................................... 63 Notes........................................................................................................... 63 Lubricant....................................................................................................... 63 Type of lubricant............................................................................................... 63 Specification................................................................................................... 63 To be used for.................................................................................................. 63 > -15 C.................................................................................................... 63 < -15o C.................................................................................................... 63 Oil and grease specification........................................................................................ 65 Valid from serial number:....................................................................................... 65 T-code.......................................................................................................... 65 Model........................................................................................................... 65 Serial No....................................................................................................... 65 Notes........................................................................................................... 65 Lubricant....................................................................................................... 65 Type of lubricant............................................................................................... 65 Specification................................................................................................... 65 Use............................................................................................................. 65 > -15 C.................................................................................................... 65 < -15o C.................................................................................................... 65 Oil and grease specification........................................................................................ 67 Valid from serial number:....................................................................................... 67 T-code...................................................................................................... 67 Model....................................................................................................... 67 Serial No................................................................................................... 67 Notes....................................................................................................... 67 Lubricant....................................................................................................... 67 Specification................................................................................................... 67 Application area................................................................................................ 67 > - 15 C.................................................................................................... 67 < - 15 C.................................................................................................... 67 Contents, S......................................................................................................... 69 1. Service instructions......................................................................................... 69 Drive motor......................................................................................................... 71 Valid from serial number:....................................................................................... 71 T-code.......................................................................................................... 71 Model........................................................................................................... 71 Serial number................................................................................................... 71 Notes........................................................................................................... 71 1. General...................................................................................................... 71 1.1. Mechanical construction................................................................................ 72 1.2. Special tools.......................................................................................... 73 Tool.................................................................................................... 73 2. Removal/Refitting............................................................................................ 74 2.1. Removing the motor from the truck...................................................................... 74 WARNING!................................................................................................ 75 2.2. Re-assembling.......................................................................................... 76 3. Service/Repairs.............................................................................................. 77 3.1. Cleaning............................................................................................... 77 3.2. Dismantling the motor.................................................................................. 78 3.3. Re-assembling the motor................................................................................ 79 3.4. Armature bearings...................................................................................... 80 3.4.1. Changing the drive end bearing................................................................... 80 3.4.2. Changing the commutator end bearing.............................................................. 80 3.5. Carbon brushes and brush holder........................................................................ 81 3.5.1. Changing carbon brushes.......................................................................... 81 3.6. Commutator............................................................................................. 82 3.6.1. Machining the commutator......................................................................... 82 4. Storage/Transport............................................................................................ 83 4.1. Storage................................................................................................ 83 5. Data......................................................................................................... 84 Torque...................................................................................................... 84 Nm.......................................................................................................... 84 Grease specification........................................................................................ 84 Component................................................................................................... 84 Item........................................................................................................ 84 Min......................................................................................................... 84 Max......................................................................................................... 84 Unit........................................................................................................ 84 Drive motor......................................................................................................... 85 Valid from serial number:....................................................................................... 85 T-code.......................................................................................................... 85 Model........................................................................................................... 85 Serial number................................................................................................... 85 Notes........................................................................................................... 85 1. General...................................................................................................... 85 1.1. Mechanical construction................................................................................ 86 1.2. Special tools.......................................................................................... 87 Tool.................................................................................................... 87 2. Removal/Refitting............................................................................................ 88 2.1. Removing the motor from the truck...................................................................... 88 2.2. Re-assembly............................................................................................ 89 3. Service/Repairs.............................................................................................. 90 3.1. Cleaning............................................................................................... 90 3.2. Removal of motor....................................................................................... 91 3.3. Refitting of motor..................................................................................... 92 3.4. Armature bearings...................................................................................... 93 3.4.1. Changing the drive end bearing................................................................... 93 3.4.2. Changing the commutator end bearing.............................................................. 93 3.5. Carbon brushes and brush holder........................................................................ 94 3.5.1. Changing carbon brushes.......................................................................... 94 3.6. Commutator............................................................................................. 95 3.6.1. Turning the commutator........................................................................... 95 4. Storage/Transport............................................................................................ 96 4.1. Storage................................................................................................ 96 5. Data......................................................................................................... 97 Torque...................................................................................................... 97 Nm.......................................................................................................... 97 Grease specification........................................................................................ 97 Component................................................................................................... 97 Item........................................................................................................ 97 Min......................................................................................................... 97 Max......................................................................................................... 97 Unit........................................................................................................ 97 Drive motor......................................................................................................... 99 Valid from serial number:....................................................................................... 99 T-code.......................................................................................................... 99 Model........................................................................................................... 99 Serial number................................................................................................... 99 Notes........................................................................................................... 99 1. General...................................................................................................... 99 1.1. Mechanical construction................................................................................100 1.2. Special tools..........................................................................................101 Tool....................................................................................................101 2. Removal/Refitting............................................................................................101 2.1. Removing the motor from the truck......................................................................101 2.2. Re-assembly............................................................................................103 3. Service/Repairs..............................................................................................104 3.1. Cleaning...............................................................................................104 3.2. Removal of motor.......................................................................................105 3.3. Refitting of motor.....................................................................................106 3.4. Armature bearings......................................................................................107 3.4.1. Changing the drive end bearing...................................................................107 3.4.2. Changing the commutator end bearing..............................................................107 3.5. Carbon brushes and brush holder........................................................................108 3.5.1. Changing carbon brushes..........................................................................108 3.6. Commutator.............................................................................................109 3.6.1. Turning the commutator...........................................................................109 4. Storage/Transport............................................................................................110 4.1. Storage................................................................................................110 5. Data.........................................................................................................111 Torque......................................................................................................111 Nm..........................................................................................................111 Grease specification........................................................................................111 Component...................................................................................................111 Item........................................................................................................111 Min.........................................................................................................111 Max.........................................................................................................111 Unit........................................................................................................111 Drive gear..........................................................................................................113 Valid from serial number:.......................................................................................113 T-code......................................................................................................113 Model.......................................................................................................113 Serial No...................................................................................................113 Notes.......................................................................................................113 1. General technical description................................................................................113 1.1. Technical data.........................................................................................114 Data....................................................................................................114 Description.............................................................................................114 1.2. Gear components........................................................................................115 Pos No..................................................................................................115 Component...............................................................................................115 1.3. Special tools..........................................................................................116 Pos No..................................................................................................116 Tool....................................................................................................116 2. Removing the gear from the truck.............................................................................117 3. Change of seal on the drive shaft............................................................................118 4. Reconditioning of the gear...................................................................................120 Mechanical brakes...................................................................................................125 Valid from serial number:.......................................................................................125 T-code......................................................................................................125 Model.......................................................................................................125 Serial No...................................................................................................125 Notes.......................................................................................................125 1. General......................................................................................................125 Position....................................................................................................125 Description.................................................................................................125 2. Function.....................................................................................................126 2.1. Releasing the brakes...................................................................................126 2.2. Braking................................................................................................126 3. Maintenance..................................................................................................127 Position....................................................................................................127 Adjustment measurement......................................................................................127 Electromagnetic brake...............................................................................................129 Valid from serial number:.......................................................................................129 T-code......................................................................................................129 Model.......................................................................................................129 Serial No...................................................................................................129 Notes.......................................................................................................129 1. General......................................................................................................129 2. Function.....................................................................................................130 2.1. Releasing the brake....................................................................................130 2.2. Braking................................................................................................131 3. Maintenance..................................................................................................132 3.1. Adjustment of gap......................................................................................132 3.1.1. Adjustment procedure:............................................................................132 3.2. Exchange of brake disc/magnetic coil...................................................................133 3.2.1. Exchange procedure:..............................................................................133 3.2.2. Transport securing screws........................................................................134 3.3. Check/adjustment of the braking force..................................................................135 WARNING!................................................................................................135 Electrical system...................................................................................................137 Valid from serial number:.......................................................................................137 T-code..........................................................................................................137 Model...........................................................................................................137 Serial No.......................................................................................................137 Notes...........................................................................................................137 1. Electrical panel, components.................................................................................137 1.1. List of symbols........................................................................................138 Symbol..................................................................................................138 Description.............................................................................................138 Function................................................................................................138 Remark..................................................................................................138 1.2. Electrical diagram 1(3)................................................................................140 1.3. Electrical diagram 2(3)................................................................................141 1.4. Electrical diagram 3(3)................................................................................142 2. Description of function......................................................................................143 2.1. General................................................................................................143 2.2. Ignition lock S17 in the ON position...................................................................143 2.3. The tiller arm in drive position, S10..................................................................143 2.4. Driving, fork direction................................................................................144 2.5. Driving, steer wheel direction.........................................................................144 2.6. Reversing/motor brake fork direction to steer wheel direction..........................................144 2.7. Reversing/motor brake steer wheel direction to fork direction..........................................145 2.8. Safety reversing.......................................................................................145 2.9. Lifting the forks......................................................................................146 2.10. Driving and simultaneously lifting the forks..........................................................146 2.11. Lowering the forks....................................................................................146 2.12. Horn..................................................................................................146 Electrical system...............................................................................................147 Valid from serial number:...................................................................................147 1. Electrical panel, components.............................................................................147 2. Electrical diagram and list of symbols...................................................................148 2.1. List of Symbols....................................................................................148 Symbol..............................................................................................148 Description.........................................................................................148 Function............................................................................................148 Notes...............................................................................................148 2.2. Electrical diagram 1/6.............................................................................150 2.3. Electrical diagram 2/6.............................................................................151 2.4. Electrical diagram 3/6.............................................................................152 2.5. Electrical diagram 4/6.............................................................................153 2.6. Electrical diagram 5/6.............................................................................154 2.7. Electrical diagram 6/6.............................................................................155 3. Operating description....................................................................................156 3.1. General............................................................................................156 3.2. Description........................................................................................156 3.3. Ignition switch S17 in the ON position.............................................................156 3.4. Tiller arm in driving position, S10................................................................157 3.5. Driving, direction of the forks....................................................................157 3.6. Driving, direction of the steering wheel...........................................................158 3.7. Reversing/speed reduction, direction of forks to direction of steering wheel.......................159 3.8. Reversing/speed reduction, direction of steering wheel to direction of forks.......................159 3.9. Switch for safety reversing........................................................................160 3.10. Lifting the forks.................................................................................161 3.11. Driving and lifting the forks at the same time....................................................161 3.12. Lowering the forks................................................................................161 3.13. Horn..............................................................................................161 Electrical system...................................................................................................163 Valid from serial number:.......................................................................................163 T-code..........................................................................................................163 Model...........................................................................................................163 Serial number...................................................................................................163 Notes...........................................................................................................163 1. Electrical panel.............................................................................................163 2. List of symbols..............................................................................................164 Symbol......................................................................................................164 Description.................................................................................................164 Function....................................................................................................164 Notes.......................................................................................................164 2.1. Electrical diagram 1/5.................................................................................166 2.2. Electrical diagram 2/5.................................................................................167 2.3. Electrical diagram 3/5.................................................................................168 2.4. Electrical diagram 4/5.................................................................................169 2.5. Electrical diagram 5/5.................................................................................170 3. Operating description........................................................................................171 3.1. General................................................................................................171 3.2. Description............................................................................................171 3.3. Ignition switch S17 in ON position.....................................................................171 3.4. Tiller arm in driving position, S10....................................................................172 3.5. Driving, direction of the forks........................................................................173 3.6. Driving, steer wheel direction.........................................................................174 3.7. Switch function for platform (option)..................................................................175 3.7.1. Driving with the platform raised.................................................................175 3.7.2. Driving with the platform lowered................................................................175 3.7.3. Alighting from the platform while driving........................................................175 3.7.4. Load dependent current limit.....................................................................176 3.7.5. S59 Activation range.............................................................................176 S59.....................................................................................................176 Min (kg) load...........................................................................................176 Max (kg) load...........................................................................................176 3.7.6. Reversing/motor brake, fork direction to steer wheel direction...............................177 3.7.7. Reversing/motor brake, steer wheel direction to fork direction...............................177 3.7.8. Safety reversing function....................................................................178 3.7.9. Lifting the forks............................................................................179 3.7.10. Lowering the forks..........................................................................179 3.7.11. Horn........................................................................................180 Electrical system...................................................................................................181 Valid from serial number:.......................................................................................181 T-code..........................................................................................................181 Model...........................................................................................................181 Serial number...................................................................................................181 Note............................................................................................................181 1. Electrical panel.............................................................................................181 2. List of symbols..............................................................................................182 Symbol......................................................................................................182 Description.................................................................................................182 Function....................................................................................................182 Notes.......................................................................................................182 2.1. Electrical diagram 1/5.................................................................................184 2.2. Electrical diagram 2/5.................................................................................185 2.3. Electrical diagram 3/5.................................................................................186 2.4. Electrical diagram 4/5.................................................................................187 2.5. Electrical diagram 5/5.................................................................................188 3. Operating description........................................................................................189 3.1. General................................................................................................189 4. Description..................................................................................................189 4.1. Ignition switch S17 in the ON position.................................................................189 4.2. Tiller arm in driving position, S10 in the On position.................................................191 4.3. Driving in the fork direction..........................................................................192 Driving permitted Speed.................................................................................192 YES 6 km/h..............................................................................................192 NO......................................................................................................192 YES 6 km/h..............................................................................................192 YES 9.5km/h.............................................................................................192 4.4. Driving in the steer wheel direction...................................................................193 Driving permitted Speed.................................................................................193 YES 6 km/h..............................................................................................193 NO......................................................................................................193 YES 6 km/h..............................................................................................193 YES 9.5 km/h............................................................................................193 4.5. Load dependent current limit...........................................................................194 4.6. S59 Activation range...................................................................................195 S59.....................................................................................................195 Min (kg) load...........................................................................................195 Max (kg) load...........................................................................................195 4.7. Reverse/motor brake, fork direction to steer wheel direction...........................................195 4.8. Reverse/motor brake, steer wheel direction to fork direction...........................................196 4.9. Safety reversing function..............................................................................196 4.10. Lifting the forks.....................................................................................197 4.11. Lowering the forks....................................................................................198 4.12. Horn..................................................................................................198 4.13. Switch operation for the platform and gates...........................................................199 4.13.1. Driving with the platform raised and without using the gates....................................199 4.13.2. Driving with the platform lowered and without using the gates...................................199 4.13.3. Driving with the platform lowered and using the gates...........................................200 4.13.4. Brake function when alighting from the platform.................................................200 Battery controller/hourmeter........................................................................................201 Valid from serial number:.......................................................................................201 T-code......................................................................................................201 Model.......................................................................................................201 Serial No...................................................................................................201 Notes.......................................................................................................201 1. General......................................................................................................201 2. Electrical...................................................................................................202 2.1. Voltage................................................................................................202 2.1.1. The contact voltage and current ratings for switching resistive loads............................202 2.1.2. Memory Retention.................................................................................202 3. Battery Controller...........................................................................................202 3.1. General................................................................................................202 3.1.1. Discharge Adjustment.............................................................................203 SETTING.............................................................................................203 VPC.................................................................................................203 Pin No..............................................................................................204 Function............................................................................................204 NOTE:...........................................................................................204 NOTE:...........................................................................................204 3.2. Reset..................................................................................................205 3.3. Keyswitch..............................................................................................205 3.4. Hourmeter..............................................................................................205 4. Trouble shooting.............................................................................................206 4.1. Battery Discharge Indicator............................................................................206 4.1.1. No reset.........................................................................................206 4.1.2. Always resets after break in power...............................................................206 NOTE:...............................................................................................206 4.1.3. No discharge, gauge does not run down............................................................207 4.1.4. No lockout.......................................................................................207 4.1.5. No lift..........................................................................................207 4.1.6. Early lockout....................................................................................207 4.1.7. LEDs don’t light.................................................................................208 4.2. Hour meter.............................................................................................208 4.2.1. No display.......................................................................................208 4.2.2. Hour glass icon does not flash...................................................................208 4.2.3. Hour meter glass icon always flashes.............................................................208 Transistor regulator................................................................................................209 Valid from serial number:.......................................................................................209 T-code..........................................................................................................209 Model...........................................................................................................209 Serial number...................................................................................................209 Notes...........................................................................................................209 1. General......................................................................................................209 1.1. Characteristics and functions..........................................................................209 2. Connections..................................................................................................210 Connection pin..............................................................................................210 Connection..................................................................................................210 2.1. Connection to the control circuits.....................................................................211 Pin No..................................................................................................211 Connection..............................................................................................211 Contactor driving...................................................................................211 Connections for throttle............................................................................211 Basic control signals...............................................................................211 3. Technical specification......................................................................................212 Parameter...................................................................................................212 Range.......................................................................................................212 Unit........................................................................................................212 Description.................................................................................................212 4. Parameters...................................................................................................213 Parameter (1307-display)....................................................................................213 Range.......................................................................................................213 Std. value..................................................................................................213 Unit........................................................................................................213 Description.................................................................................................213 5. Diagnostics and trouble shooting.............................................................................215 5.1. Trouble shooting.......................................................................................215 5.2. Error codes............................................................................................216 5.2.1. LED indications..................................................................................216 LED code................................................................................................216 Programmer’s LCD- display...............................................................................216 Explanation.............................................................................................216 Probable cause..........................................................................................216 5.3. Testing circuits for error detection...................................................................218 6. Maintenance..................................................................................................218 NOTE!.......................................................................................................218 6.1. Safety.................................................................................................219 WARNING.................................................................................................219 6.2. Cleaning...............................................................................................219 7. Curtis 1307 hand terminal....................................................................................220 Pos.........................................................................................................221 Function....................................................................................................221 Notes.......................................................................................................221 8. Using the hand terminal......................................................................................222 8.1. Using the PROGRAM mode, checking and adjusting parameters..............................................223 NOTE!...................................................................................................223 8.1.1. Using the key MORE INFO in PROGRAM mode..........................................................224 8.2. Using SPECIAL PROGRAM mode.............................................................................224 8.3. Using TEST mode........................................................................................225 Test value..............................................................................................226 Description.............................................................................................226 8.4. Using DIAGNOSTICS mode.................................................................................227 NOTE....................................................................................................227 8.5. Using SPECIAL DIAGNOSTICS mode.........................................................................227 Transistor regulator................................................................................................229 Valid from serial number:.......................................................................................229 T-code..........................................................................................................229 Model...........................................................................................................229 Serial number...................................................................................................229 Notes...........................................................................................................229 1. General......................................................................................................229 1.1. Characteristics and functions..........................................................................229 2. Connections..................................................................................................230 Connection pin..............................................................................................230 Connection..................................................................................................230 2.1. Connection to the control circuits.....................................................................231 Pin No..................................................................................................231 Connection..............................................................................................231 Contactor driving...................................................................................231 Connections for throttle............................................................................231 Basic control signals...............................................................................231 3. Technical specification......................................................................................232 Parameter...................................................................................................232 Range.......................................................................................................232 Unit........................................................................................................232 Description.................................................................................................232 4. Parameters...................................................................................................233 Parameter (1307-display)....................................................................................233 Range.......................................................................................................233 Std. value..................................................................................................233 Unit........................................................................................................233 Description.................................................................................................233 4.1. Mode 1 and 2...........................................................................................234 5. Diagnostics and trouble shooting.............................................................................234 5.1. Trouble shooting.......................................................................................234 5.2. Error codes............................................................................................235 5.2.1. LED indications..................................................................................235 LED code................................................................................................235 Programmer’s LCD- display...............................................................................235 Explanation.............................................................................................235 Probable cause..........................................................................................235 5.3. Testing circuits for error detection...................................................................237 6. Maintenance..................................................................................................237 NOTE!.......................................................................................................237 6.1. Safety.................................................................................................237 WARNING.................................................................................................237 6.2. Cleaning...............................................................................................238 7. Curtis 1307 hand terminal....................................................................................239 Pos.........................................................................................................240 Function....................................................................................................240 Notes.......................................................................................................240 8. Using the hand terminal......................................................................................241 8.1. Using the PROGRAM mode, checking and adjusting parameters..............................................242 NOTE!...................................................................................................242 8.1.1. Using the key MORE INFO in PROGRAM mode..........................................................243 8.2. Using SPECIAL PROGRAM mode.............................................................................243 8.3. Using TEST mode........................................................................................244 Test value..............................................................................................245 Description.............................................................................................245 8.4. Using DIAGNOSTICS mode.................................................................................246 NOTE....................................................................................................246 8.5. Using SPECIAL DIAGNOSTICS mode.........................................................................246 Electronic card.....................................................................................................247 Valid from serial number:.......................................................................................247 T-code..........................................................................................................247 Model...........................................................................................................247 Serial No.......................................................................................................247 Notes...........................................................................................................247 1. Connection card, transistor control..........................................................................247 1.1. Connections/adjustments................................................................................248 Position................................................................................................248 Connection/Adjustment...................................................................................248 Terminal No.............................................................................................248 LED No..................................................................................................248 Connection..............................................................................................248 Function................................................................................................248 Electronic card.....................................................................................................251 Valid from serial number:.......................................................................................251 T-code..........................................................................................................251 Model...........................................................................................................251 Serial number...................................................................................................251 Notes...........................................................................................................251 1. General......................................................................................................251 2. Components...................................................................................................251 2.1. Connections/adjustments................................................................................252 Position................................................................................................252 Connections/adjustments.................................................................................252 2.2. Connections for inputs/outputs.........................................................................252 Pin No..................................................................................................252 LED No..................................................................................................252 I/O.....................................................................................................252 PLL.....................................................................................................252 Function................................................................................................252 Signal name.............................................................................................252 Electronic card.....................................................................................................255 Valid from serial number:.......................................................................................255 T-code..........................................................................................................255 Model...........................................................................................................255 Serial number...................................................................................................255 Notes...........................................................................................................255 1. General......................................................................................................255 2. Components...................................................................................................255 2.1. Connection/adjustments.................................................................................256 Position................................................................................................256 Connection/ adjustment..................................................................................256 2.2. Connections for inputs and outputs.....................................................................256 Pin No..................................................................................................256 LED No..................................................................................................256 I/O.....................................................................................................256 PLL.....................................................................................................256 Function................................................................................................256 Signal name.............................................................................................256 Hydraulic system....................................................................................................259 Valid from serial number:.......................................................................................259 T-code..........................................................................................................259 Model...........................................................................................................259 Serial number...................................................................................................259 Notes...........................................................................................................259 1. General......................................................................................................259 2. Hydraulic chart and list of symbols..........................................................................260 2.1. List of Symbols........................................................................................260 Symbol..................................................................................................260 Description.............................................................................................260 Function................................................................................................260 Notes...................................................................................................260 3. Operating description........................................................................................261 3.1. Lifting the forks......................................................................................261 3.2. Lowering the forks.....................................................................................261 3.3. Switch, S59............................................................................................261 4. Adjustments..................................................................................................262 4.1. Adjusting the pressure limit valve.....................................................................262 1. Cover nut............................................................................................262 2. Adjuster screw, pressure limit. Adjusting clockwise results in increased pressure. Adjusting a.......262
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