Toyota Forklift PM14 PM16 PM20 PML20 PLL22 Service Manual PDF

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Toyota Forklift PM14 PM16 PM20 PML20 PLL22 Service Manual – PDF DOWNLOAD

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Toyota Forklift PM14 PM16 PM20 PML20 PLL22 Service Manual – PDF DOWNLOAD

Language : English
Pages : 262
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Toyota Forklift PM14 PM16 PM20 PML20 PLL22 Service Manual – PDF DOWNLOAD

Part number: 168569-040

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
11 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
11 Intended application of the truck 20
12 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
21 External cleaning 47
NOTE! 47
22 Cleaning the motor compartment 47
NOTE! 47
23 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
> – 15C 67
< – 15C 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
11 Mechanical construction 72
12 Special tools 73
Tool 73
2 Removal/Refitting 74
21 Removing the motor from the truck 74
WARNING! 75
22 Re-assembling 76
3 Service/Repairs 77
31 Cleaning 77
32 Dismantling the motor 78
33 Re-assembling the motor 79
34 Armature bearings 80
341 Changing the drive end bearing 80
342 Changing the commutator end bearing 80
35 Carbon brushes and brush holder 81
351 Changing carbon brushes 81
36 Commutator 82
361 Machining the commutator 82
4 Storage/Transport 83
41 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
11 Mechanical construction 86
12 Special tools 87
Tool 87
2 Removal/Refitting 88
21 Removing the motor from the truck 88
22 Re-assembly 89
3 Service/Repairs 90
31 Cleaning 90
32 Removal of motor 91
33 Refitting of motor 92
34 Armature bearings 93
341 Changing the drive end bearing 93
342 Changing the commutator end bearing 93
35 Carbon brushes and brush holder 94
351 Changing carbon brushes 94
36 Commutator 95
361 Turning the commutator 95
4 Storage/Transport 96
41 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
11 Mechanical construction100
12 Special tools101
Tool101
2 Removal/Refitting101
21 Removing the motor from the truck101
22 Re-assembly103
3 Service/Repairs104
31 Cleaning104
32 Removal of motor105
33 Refitting of motor106
34 Armature bearings107
341 Changing the drive end bearing107
342 Changing the commutator end bearing107
35 Carbon brushes and brush holder108
351 Changing carbon brushes108
36 Commutator109
361 Turning the commutator109
4 Storage/Transport110
41 Storage110
5 Data111
Torque111
Nm111
Grease specification111
Component111
Item111
Min111
Max111
Unit111
Drive gear113
Valid from serial number:113
T-code113
Model113
Serial No113
Notes113
1 General technical description113
11 Technical data114
Data114
Description114
12 Gear components115
Pos No115
Component115
13 Special tools116
Pos No116
Tool116
2 Removing the gear from the truck117
3 Change of seal on the drive shaft118
4 Reconditioning of the gear120
Mechanical brakes125
Valid from serial number:125
T-code125
Model125
Serial No125
Notes125
1 General125
Position125
Description125
2 Function126
21 Releasing the brakes126
22 Braking126
3 Maintenance127
Position127
Adjustment measurement127
Electromagnetic brake129
Valid from serial number:129
T-code129
Model129
Serial No129
Notes129
1 General129
2 Function130
21 Releasing the brake130
22 Braking131
3 Maintenance132
31 Adjustment of gap132
311 Adjustment procedure:132
32 Exchange of brake disc/magnetic coil133
321 Exchange procedure:133
322 Transport securing screws134
33 Check/adjustment of the braking force135
WARNING!135
Electrical system137
Valid from serial number:137
T-code137
Model137
Serial No137
Notes137
1 Electrical panel, components137
11 List of symbols138
Symbol138
Description138
Function138
Remark138
12 Electrical diagram 1(3)140
13 Electrical diagram 2(3)141
14 Electrical diagram 3(3)142
2 Description of function143
21 General143
22 Ignition lock S17 in the ON position143
23 The tiller arm in drive position, S10143
24 Driving, fork direction144
25 Driving, steer wheel direction144
26 Reversing/motor brake fork direction to steer wheel direction144
27 Reversing/motor brake steer wheel direction to fork direction145
28 Safety reversing145
29 Lifting the forks146
210 Driving and simultaneously lifting the forks146
211 Lowering the forks146
212 Horn146
Electrical system147
Valid from serial number:147
1 Electrical panel, components147
2 Electrical diagram and list of symbols148
21 List of Symbols148
Symbol148
Description148
Function148
Notes148
22 Electrical diagram 1/6150
23 Electrical diagram 2/6151
24 Electrical diagram 3/6152
25 Electrical diagram 4/6153
26 Electrical diagram 5/6154
27 Electrical diagram 6/6155
3 Operating description156
31 General156
32 Description156
33 Ignition switch S17 in the ON position156
34 Tiller arm in driving position, S10157
35 Driving, direction of the forks157
36 Driving, direction of the steering wheel158
37 Reversing/speed reduction, direction of forks to direction of steering wheel159
38 Reversing/speed reduction, direction of steering wheel to direction of forks159
39 Switch for safety reversing160
310 Lifting the forks161
311 Driving and lifting the forks at the same time161
312 Lowering the forks161
313 Horn161
Electrical system163
Valid from serial number:163
T-code163
Model163
Serial number163
Notes163
1 Electrical panel163
2 List of symbols164
Symbol164
Description164
Function164
Notes164
21 Electrical diagram 1/5166
22 Electrical diagram 2/5167
23 Electrical diagram 3/5168
24 Electrical diagram 4/5169
25 Electrical diagram 5/5170
3 Operating description171
31 General171
32 Description171
33 Ignition switch S17 in ON position171
34 Tiller arm in driving position, S10172
35 Driving, direction of the forks173
36 Driving, steer wheel direction174
37 Switch function for platform (option)175
371 Driving with the platform raised175
372 Driving with the platform lowered175
373 Alighting from the platform while driving175
374 Load dependent current limit176
375 S59 Activation range176
S59176
Min (kg) load176
Max (kg) load176
376 Reversing/motor brake, fork direction to steer wheel direction177
377 Reversing/motor brake, steer wheel direction to fork direction177
378 Safety reversing function178
379 Lifting the forks179
3710 Lowering the forks179
3711 Horn180
Electrical system181
Valid from serial number:181
T-code181
Model181
Serial number181
Note181
1 Electrical panel181
2 List of symbols182
Symbol182
Description182
Function182
Notes182
21 Electrical diagram 1/5184
22 Electrical diagram 2/5185
23 Electrical diagram 3/5186
24 Electrical diagram 4/5187
25 Electrical diagram 5/5188
3 Operating description189
31 General189
4 Description189
41 Ignition switch S17 in the ON position189
42 Tiller arm in driving position, S10 in the On position191
43 Driving in the fork direction192
Driving permitted Speed192
YES 6 km/h192
NO192
YES 6 km/h192
YES 95km/h192
44 Driving in the steer wheel direction193
Driving permitted Speed193
YES 6 km/h193
NO193
YES 6 km/h193
YES 95 km/h193
45 Load dependent current limit194
46 S59 Activation range195
S59195
Min (kg) load195
Max (kg) load195
47 Reverse/motor brake, fork direction to steer wheel direction195
48 Reverse/motor brake, steer wheel direction to fork direction196
49 Safety reversing function196
410 Lifting the forks197
411 Lowering the forks198
412 Horn198
413 Switch operation for the platform and gates199
4131 Driving with the platform raised and without using the gates199
4132 Driving with the platform lowered and without using the gates199
4133 Driving with the platform lowered and using the gates200
4134 Brake function when alighting from the platform200
Battery controller/hourmeter201
Valid from serial number:201
T-code201
Model201
Serial No201
Notes201
1 General201
2 Electrical202
21 Voltage202
211 The contact voltage and current ratings for switching resistive loads202
212 Memory Retention202
3 Battery Controller202
31 General202
311 Discharge Adjustment203
SETTING203
VPC203
Pin No204
Function204
NOTE:204
NOTE:204
32 Reset205
33 Keyswitch205
34 Hourmeter205
4 Trouble shooting206
41 Battery Discharge Indicator206
411 No reset206
412 Always resets after break in power206
NOTE:206
413 No discharge, gauge does not run down207
414 No lockout207
415 No lift207
416 Early lockout207
417 LEDs don’t light208
42 Hour meter208
421 No display208
422 Hour glass icon does not flash208
423 Hour meter glass icon always flashes208
Transistor regulator209
Valid from serial number:209
T-code209
Model209
Serial number209
Notes209
1 General209
11 Characteristics and functions209
2 Connections210
Connection pin210
Connection210
21 Connection to the control circuits211
Pin No211
Connection211
Contactor driving211
Connections for throttle211
Basic control signals211
3 Technical specification212
Parameter212
Range212
Unit212
Description212
4 Parameters213
Parameter (1307-display)213
Range213
Std value213
Unit213
Description213
5 Diagnostics and trouble shooting215
51 Trouble shooting215
52 Error codes216
521 LED indications216
LED code216
Programmer’s LCD- display216
Explanation216
Probable cause216
53 Testing circuits for error detection218
6 Maintenance218
NOTE!218
61 Safety219
WARNING219
62 Cleaning219
7 Curtis 1307 hand terminal220
Pos221
Function221
Notes221
8 Using the hand terminal222
81 Using the PROGRAM mode, checking and adjusting parameters223
NOTE!223
811 Using the key MORE INFO in PROGRAM mode224
82 Using SPECIAL PROGRAM mode224
83 Using TEST mode225
Test value226
Description226
84 Using DIAGNOSTICS mode227
NOTE227
85 Using SPECIAL DIAGNOSTICS mode227
Transistor regulator229
Valid from serial number:229
T-code229
Model229
Serial number229
Notes229
1 General229
11 Characteristics and functions229
2 Connections230
Connection pin230
Connection230
21 Connection to the control circuits231
Pin No231
Connection231
Contactor driving231
Connections for throttle231
Basic control signals231
3 Technical specification232
Parameter232
Range232
Unit232
Description232
4 Parameters233
Parameter (1307-display)233
Range233
Std value233
Unit233
Description233
41 Mode 1 and 2234
5 Diagnostics and trouble shooting234
51 Trouble shooting234
52 Error codes235
521 LED indications235
LED code235
Programmer’s LCD- display235
Explanation235
Probable cause235
53 Testing circuits for error detection237
6 Maintenance237
NOTE!237
61 Safety237
WARNING237
62 Cleaning238
7 Curtis 1307 hand terminal239
Pos240
Function240
Notes240
8 Using the hand terminal241
81 Using the PROGRAM mode, checking and adjusting parameters242
NOTE!242
811 Using the key MORE INFO in PROGRAM mode243
82 Using SPECIAL PROGRAM mode243
83 Using TEST mode244
Test value245
Description245
84 Using DIAGNOSTICS mode246
NOTE246
85 Using SPECIAL DIAGNOSTICS mode246
Electronic card247
Valid from serial number:247
T-code247
Model247
Serial No247
Notes247
1 Connection card, transistor control247
11 Connections/adjustments248
Position248
Connection/Adjustment248
Terminal No248
LED No248
Connection248
Function248
Electronic card251
Valid from serial number:251
T-code251
Model251
Serial number251
Notes251
1 General251
2 Components251
21 Connections/adjustments252
Position252
Connections/adjustments252
22 Connections for inputs/outputs252
Pin No252
LED No252
I/O252
PLL252
Function252
Signal name252
Electronic card255
Valid from serial number:255
T-code255
Model255
Serial number255
Notes255
1 General255
2 Components255
21 Connection/adjustments256
Position256
Connection/ adjustment256
22 Connections for inputs and outputs256
Pin No256
LED No256
I/O256
PLL256
Function256
Signal name256
Hydraulic system259
Valid from serial number:259
T-code259
Model259
Serial number259
Notes259
1 General259
2 Hydraulic chart and list of symbols260
21 List of Symbols260
Symbol260
Description260
Function260
Notes260
3 Operating description261
31 Lifting the forks261
32 Lowering the forks261
33 Switch, S59261
4 Adjustments262
41 Adjusting the pressure limit valve262
1 Cover nut262
2 Adjuster screw, pressure limit Adjusting clockwise results in increased pressure Adjusting a262PM 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
11 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
11 Intended application of the truck 20
12 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
21 External cleaning 47
NOTE! 47
22 Cleaning the motor compartment 47
NOTE! 47
23 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
> – 15C 67
< – 15C 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
11 Mechanical construction 72
12 Special tools 73
Tool 73
2 Removal/Refitting 74
21 Removing the motor from the truck 74
WARNING! 75
22 Re-assembling 76
3 Service/Repairs 77
31 Cleaning 77
32 Dismantling the motor 78
33 Re-assembling the motor 79
34 Armature bearings 80
341 Changing the drive end bearing 80
342 Changing the commutator end bearing 80
35 Carbon brushes and brush holder 81
351 Changing carbon brushes 81
36 Commutator 82
361 Machining the commutator 82
4 Storage/Transport 83
41 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
11 Mechanical construction 86
12 Special tools 87
Tool 87
2 Removal/Refitting 88
21 Removing the motor from the truck 88
22 Re-assembly 89
3 Service/Repairs 90
31 Cleaning 90
32 Removal of motor 91
33 Refitting of motor 92
34 Armature bearings 93
341 Changing the drive end bearing 93
342 Changing the commutator end bearing 93
35 Carbon brushes and brush holder 94
351 Changing carbon brushes 94
36 Commutator 95
361 Turning the commutator 95
4 Storage/Transport 96
41 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
11 Mechanical construction100
12 Special tools101
Tool101
2 Removal/Refitting101
21 Removing the motor from the truck101
22 Re-assembly103
3 Service/Repairs104
31 Cleaning104
32 Removal of motor105
33 Refitting of motor106
34 Armature bearings107
341 Changing the drive end bearing107
342 Changing the commutator end bearing107
35 Carbon brushes and brush holder108
351 Changing carbon brushes108
36 Commutator109
361 Turning the commutator109
4 Storage/Transport110
41 Storage110
5 Data111
Torque111
Nm111
Grease specification111
Component111
Item111
Min111
Max111
Unit111
Drive gear113
Valid from serial number:113
T-code113
Model113
Serial No113
Notes113
1 General technical description113
11 Technical data114
Data114
Description114
12 Gear components115
Pos No115
Component115
13 Special tools116
Pos No116
Tool116
2 Removing the gear from the truck117
3 Change of seal on the drive shaft118
4 Reconditioning of the gear120
Mechanical brakes125
Valid from serial number:125
T-code125
Model125
Serial No125
Notes125
1 General125
Position125
Description125
2 Function126
21 Releasing the brakes126
22 Braking126
3 Maintenance127
Position127
Adjustment measurement127
Electromagnetic brake129
Valid from serial number:129
T-code129
Model129
Serial No129
Notes129
1 General129
2 Function130
21 Releasing the brake130
22 Braking131
3 Maintenance132
31 Adjustment of gap132
311 Adjustment procedure:132
32 Exchange of brake disc/magnetic coil133
321 Exchange procedure:133
322 Transport securing screws134
33 Check/adjustment of the braking force135
WARNING!135
Electrical system137
Valid from serial number:137
T-code137
Model137
Serial No137
Notes137
1 Electrical panel, components137
11 List of symbols138
Symbol138
Description138
Function138
Remark138
12 Electrical diagram 1(3)140
13 Electrical diagram 2(3)141
14 Electrical diagram 3(3)142
2 Description of function143
21 General143
22 Ignition lock S17 in the ON position143
23 The tiller arm in drive position, S10143
24 Driving, fork direction144
25 Driving, steer wheel direction144
26 Reversing/motor brake fork direction to steer wheel direction144
27 Reversing/motor brake steer wheel direction to fork direction145
28 Safety reversing145
29 Lifting the forks146
210 Driving and simultaneously lifting the forks146
211 Lowering the forks146
212 Horn146
Electrical system147
Valid from serial number:147
1 Electrical panel, components147
2 Electrical diagram and list of symbols148
21 List of Symbols148
Symbol148
Description148
Function148
Notes148
22 Electrical diagram 1/6150
23 Electrical diagram 2/6151
24 Electrical diagram 3/6152
25 Electrical diagram 4/6153
26 Electrical diagram 5/6154
27 Electrical diagram 6/6155
3 Operating description156
31 General156
32 Description156
33 Ignition switch S17 in the ON position156
34 Tiller arm in driving position, S10157
35 Driving, direction of the forks157
36 Driving, direction of the steering wheel158
37 Reversing/speed reduction, direction of forks to direction of steering wheel159
38 Reversing/speed reduction, direction of steering wheel to direction of forks159
39 Switch for safety reversing160
310 Lifting the forks161
311 Driving and lifting the forks at the same time161
312 Lowering the forks161
313 Horn161
Electrical system163
Valid from serial number:163
T-code163
Model163
Serial number163
Notes163
1 Electrical panel163
2 List of symbols164
Symbol164
Description164
Function164
Notes164
21 Electrical diagram 1/5166
22 Electrical diagram 2/5167
23 Electrical diagram 3/5168
24 Electrical diagram 4/5169
25 Electrical diagram 5/5170
3 Operating description171
31 General171
32 Description171
33 Ignition switch S17 in ON position171
34 Tiller arm in driving position, S10172
35 Driving, direction of the forks173
36 Driving, steer wheel direction174
37 Switch function for platform (option)175
371 Driving with the platform raised175
372 Driving with the platform lowered175
373 Alighting from the platform while driving175
374 Load dependent current limit176
375 S59 Activation range176
S59176
Min (kg) load176
Max (kg) load176
376 Reversing/motor brake, fork direction to steer wheel direction177
377 Reversing/motor brake, steer wheel direction to fork direction177
378 Safety reversing function178
379 Lifting the forks179
3710 Lowering the forks179
3711 Horn180
Electrical system181
Valid from serial number:181
T-code181
Model181
Serial number181
Note181
1 Electrical panel181
2 List of symbols182
Symbol182
Description182
Function182
Notes182
21 Electrical diagram 1/5184
22 Electrical diagram 2/5185
23 Electrical diagram 3/5186
24 Electrical diagram 4/5187
25 Electrical diagram 5/5188
3 Operating description189
31 General189
4 Description189
41 Ignition switch S17 in the ON position189
42 Tiller arm in driving position, S10 in the On position191
43 Driving in the fork direction192
Driving permitted Speed192
YES 6 km/h192
NO192
YES 6 km/h192
YES 95km/h192
44 Driving in the steer wheel direction193
Driving permitted Speed193
YES 6 km/h193
NO193
YES 6 km/h193
YES 95 km/h193
45 Load dependent current limit194
46 S59 Activation range195
S59195
Min (kg) load195
Max (kg) load195
47 Reverse/motor brake, fork direction to steer wheel direction195
48 Reverse/motor brake, steer wheel direction to fork direction196
49 Safety reversing function196
410 Lifting the forks197
411 Lowering the forks198
412 Horn198
413 Switch operation for the platform and gates199
4131 Driving with the platform raised and without using the gates199
4132 Driving with the platform lowered and without using the gates199
4133 Driving with the platform lowered and using the gates200
4134 Brake function when alighting from the platform200
Battery controller/hourmeter201
Valid from serial number:201
T-code201
Model201
Serial No201
Notes201
1 General201
2 Electrical202
21 Voltage202
211 The contact voltage and current ratings for switching resistive loads202
212 Memory Retention202
3 Battery Controller202
31 General202
311 Discharge Adjustment203
SETTING203
VPC203
Pin No204
Function204
NOTE:204
NOTE:204
32 Reset205
33 Keyswitch205
34 Hourmeter205
4 Trouble shooting206
41 Battery Discharge Indicator206
411 No reset206
412 Always resets after break in power206
NOTE:206
413 No discharge, gauge does not run down207
414 No lockout207
415 No lift207
416 Early lockout207
417 LEDs don’t light208
42 Hour meter208
421 No display208
422 Hour glass icon does not flash208
423 Hour meter glass icon always flashes208
Transistor regulator209
Valid from serial number:209
T-code209
Model209
Serial number209
Notes209
1 General209
11 Characteristics and functions209
2 Connections210
Connection pin210
Connection210
21 Connection to the control circuits211
Pin No211
Connection211
Contactor driving211
Connections for throttle211
Basic control signals211
3 Technical specification212
Parameter212
Range212
Unit212
Description212
4 Parameters213
Parameter (1307-display)213
Range213
Std value213
Unit213
Description213
5 Diagnostics and trouble shooting215
51 Trouble shooting215
52 Error codes216
521 LED indications216
LED code216
Programmer’s LCD- display216
Explanation216
Probable cause216
53 Testing circuits for error detection218
6 Maintenance218
NOTE!218
61 Safety219
WARNING219
62 Cleaning219
7 Curtis 1307 hand terminal220
Pos221
Function221
Notes221
8 Using the hand terminal222
81 Using the PROGRAM mode, checking and adjusting parameters223
NOTE!223
811 Using the key MORE INFO in PROGRAM mode224
82 Using SPECIAL PROGRAM mode224
83 Using TEST mode225
Test value226
Description226
84 Using DIAGNOSTICS mode227
NOTE227
85 Using SPECIAL DIAGNOSTICS mode227
Transistor regulator229
Valid from serial number:229
T-code229
Model229
Serial number229
Notes229
1 General229
11 Characteristics and functions229
2 Connections230
Connection pin230
Connection230
21 Connection to the control circuits231
Pin No231
Connection231
Contactor driving231
Connections for throttle231
Basic control signals231
3 Technical specification232
Parameter232
Range232
Unit232
Description232
4 Parameters233
Parameter (1307-display)233
Range233
Std value233
Unit233
Description233
41 Mode 1 and 2234
5 Diagnostics and trouble shooting234
51 Trouble shooting234
52 Error codes235
521 LED indications235
LED code235
Programmer’s LCD- display235
Explanation235
Probable cause235
53 Testing circuits for error detection237
6 Maintenance237
NOTE!237
61 Safety237
WARNING237
62 Cleaning238
7 Curtis 1307 hand terminal239
Pos240
Function240
Notes240
8 Using the hand terminal241
81 Using the PROGRAM mode, checking and adjusting parameters242
NOTE!242
811 Using the key MORE INFO in PROGRAM mode243
82 Using SPECIAL PROGRAM mode243
83 Using TEST mode244
Test value245
Description245
84 Using DIAGNOSTICS mode246
NOTE246
85 Using SPECIAL DIAGNOSTICS mode246
Electronic card247
Valid from serial number:247
T-code247
Model247
Serial No247
Notes247
1 Connection card, transistor control247
11 Connections/adjustments248
Position248
Connection/Adjustment248
Terminal No248
LED No248
Connection248
Function248
Electronic card251
Valid from serial number:251
T-code251
Model251
Serial number251
Notes251
1 General251
2 Components251
21 Connections/adjustments252
Position252
Connections/adjustments252
22 Connections for inputs/outputs252
Pin No252
LED No252
I/O252
PLL252
Function252
Signal name252
Electronic card255
Valid from serial number:255
T-code255
Model255
Serial number255
Notes255
1 General255
2 Components255
21 Connection/adjustments256
Position256
Connection/ adjustment256
22 Connections for inputs and outputs256
Pin No256
LED No256
I/O256
PLL256
Function256
Signal name256
Hydraulic system259
Valid from serial number:259
T-code259
Model259
Serial number259
Notes259
1 General259
2 Hydraulic chart and list of symbols260
21 List of Symbols260
Symbol260
Description260
Function260
Notes260
3 Operating description261
31 Lifting the forks261
32 Lowering the forks261
33 Switch, S59261
4 Adjustments262
41 Adjusting the pressure limit valve262
1 Cover nut262
2 Adjuster screw, pressure limit Adjusting clockwise results in increased pressure Adjusting a262

S.V 27/02/2025