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Toyota Forklift SM 12 SMH 16 SLL 16 SM 10 SM 12F SM 12S Master Service Manual 168568-040 – PDF DOWNLOAD
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Toyota Forklift SM 12 SMH 16 SLL 16 SM 10 SM 12F SM 12S Master Service Manual 168568-040 – PDF DOWNLOAD
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Description
Toyota Forklift SM 12 SMH 16 SLL 16 SM 10 SM 12F SM 12S Master Service Manual 168568-040 – PDF DOWNLOAD
FILE DETAILS:
Toyota Forklift SM 12 SMH 16 SLL 16 SM 10 SM 12F SM 12S Master Service Manual 168568-040 – PDF DOWNLOAD
Language : English
Pages : 284
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Toyota Forklift SM 12 SMH 16 SLL 16 SM 10 SM 12F SM 12S Master Service Manual 168568-040 – PDF DOWNLOAD
SM 12 SMH 16 SLL 16 SM 10 SM 12F SM 12S......................................................................... 1 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 T-code.................................................................................................. 11 Model................................................................................................... 11 Serial No............................................................................................... 11 Notes................................................................................................... 11 1. Presentation of the pedestrian stackers.................................................................. 11 1.1. Intended application of the truck.................................................................. 11 1.2. Forbidden application of the truck................................................................. 12 1.3. Truck data......................................................................................... 12 Truck type.......................................................................................... 12 SM 12............................................................................................... 12 SM 10............................................................................................... 12 SM 12S.............................................................................................. 12 1.4. Truck dimensions SM 12............................................................................. 13 1.5. Truck dimensions SM 10............................................................................. 14 1.6. Truck dimensions SM 12S............................................................................ 15 1.7. Type plate......................................................................................... 16 Item................................................................................................ 16 Text................................................................................................ 16 Unit................................................................................................ 16 1.8. Capacity plate..................................................................................... 16 Item................................................................................................ 16 Text................................................................................................ 16 Unit................................................................................................ 16 1.9. Modification plate................................................................................. 17 Item................................................................................................ 17 Text................................................................................................ 17 2. Main components.......................................................................................... 18 1. Tiller arm: The truck is to be controlled by the operator walking. 204 degrees steering angle........ 18 2. Type plate: With type designation,manufacturing number, year of manufacture, service weight, b....... 18 3. Hoods: Removable which provides good accessibility when servicing.................................... 18 4. Instrument (accessory): Combined hour meter/battery guard or hour meter only......................... 18 5. Hydraulic control: For controlling lifting and lowering functions.................................... 18 6. Hydraulic unit: Pump motor, pump, valves and oil tank integrated in a compact unit................... 18 7. Hydraulic valves: The valves are located to provide easy access...................................... 18 8. Battery isolator/Recharging connector: The battery is recharged via the fixed mounted charging....... 18 9. Drive unit with brake: Fixed drive unit with a spring loaded brake, drive motor, gear and driv....... 18 10. Machine number: The manufacturing number plate fitted to the chassis................................ 18 11. Electric panel: Removable, which provides good access when servicing. 24 volt electrical syst....... 18 12. Support/Castor wheels: Two support castor wheels to ensure stability. NOTE: On SM 12/10 only........ 18 13. Battery: 24V with different Ah values............................................................... 18 14. Mast: Fitted with a finger protection which covers the operators normal range of reach from t....... 18 3. Warning and information signs............................................................................ 20 1. Hydraulic control: Lifting........................................................................... 20 2. Travel direction..................................................................................... 20 3. Signal/Horn.......................................................................................... 20 4. Lifting capacity..................................................................................... 20 5. Machine signs........................................................................................ 20 6. Hydraulic control: Lowering.......................................................................... 20 7. Machine number....................................................................................... 20 8. Hydraulic oil, filling point......................................................................... 20 9. Maximum lift height for rated capacity............................................................... 20 10. Do not walk under lifted load....................................................................... 20 11. Lifting points...................................................................................... 20 12. Modification plate.................................................................................. 20 General product information..................................................................................... 21 Valid from serial number:................................................................................... 21 T-code.................................................................................................. 21 Model................................................................................................... 21 Serial number........................................................................................... 21 Notes................................................................................................... 21 1. Presentation of the truck................................................................................ 21 2. Intended use of the truck................................................................................ 21 3. Forbidden use of the truck............................................................................... 22 4. Truck data............................................................................................... 23 Truck type.............................................................................................. 23 SM 12F.................................................................................................. 23 5. Truck dimensions......................................................................................... 24 Dimensions.............................................................................................. 25 Values (mm)............................................................................................. 25 6. Type plate............................................................................................... 26 Item.................................................................................................... 26 Text.................................................................................................... 26 Unit.................................................................................................... 26 7. Capacity plate........................................................................................... 26 Item.................................................................................................... 26 Text.................................................................................................... 26 Unit.................................................................................................... 26 8. Modification plate....................................................................................... 27 Item.................................................................................................... 27 Text.................................................................................................... 27 9. Main components.......................................................................................... 28 1. Tiller arm: The truck is operated by the driver when walking. Steering range 204 degrees. The ....... 28 2. Type plate: With type designation, machine number, year of manufacturer, weight without batter....... 28 3. Hoods: Easily removable, providing good accessibility when servicing................................. 28 4. Instrument (Accessory): Combined running meter/battery guard or just running meter................... 28 5. Hydraulic control: For control of the lifting and lowering functions................................. 28 6. Hydraulic unit: Pump motor, pump and oil tank are integrated into a compact unit..................... 28 7. Hydraulic valves: The valves are located in an easily accessible position............................ 28 8. Battery switch and Charging plug: The battery is charged via the fixed charging plug................. 28 9. Drive unit with brakes: Fixed drive unit with spring loaded mechanical brakes, travel motor, d....... 28 10. Machine number: Punched plate on the chassis........................................................ 28 11. Electrical panel: Removable, providing good accessibility for servicing. 24volt electrical s....... 28 12. Support castor wheel: 2 support castors to ensure stability......................................... 28 13. Battery: 24 V with different Ah-rates. The battery is automatically locked in the battery com....... 28 14. Mast: Fitted with finger guard to cover the driver’s normal reach................................... 28 15. Pump motor fuse: 160 A.............................................................................. 29 16. Drive motor fuse: 100 A............................................................................. 29 17. Control fuse: 7.5 A................................................................................. 29 10. Warning and information plates.......................................................................... 30 1. Hydraulic control: Lifting/lowering of the support arms.............................................. 30 2. Travel direction..................................................................................... 30 3. Hydraulic control: Lifting/lowering of the forks..................................................... 30 4. Horn................................................................................................. 30 5. Lifting capacity..................................................................................... 30 6. Type plate, CE....................................................................................... 30 7. Hydraulic control: Lowering.......................................................................... 30 8. Machine number....................................................................................... 30 9. Hydraulic oil refilling point........................................................................ 30 10. Modification plate.................................................................................. 30 11. Max. height for classified lifting capacity......................................................... 30 12. Do not walk under a suspended load.................................................................. 30 13. Lifting points...................................................................................... 30 Technical data.................................................................................................. 31 Valid from serial number:................................................................................... 31 T-code...................................................................................................... 31 Model....................................................................................................... 31 Serial No................................................................................................... 31 Notes....................................................................................................... 31 MODEL....................................................................................................... 31 SM 10....................................................................................................... 31 SM 12S...................................................................................................... 31 Drive motor............................................................................................. 31 Transmission/gear....................................................................................... 31 Wheels.................................................................................................. 31 HYDRAULIC UNIT.......................................................................................... 32 Fuses................................................................................................... 32 Batteries............................................................................................... 33 Driving speeds.......................................................................................... 33 Lifting/lowering time................................................................................... 33 CURRENT CONSUMPTION..................................................................................... 33 Technical data.................................................................................................. 35 Valid from serial number:................................................................................... 35 T-code.................................................................................................. 35 Model................................................................................................... 35 Serial No............................................................................................... 35 Notes................................................................................................... 35 MODEL....................................................................................................... 35 SLL 16...................................................................................................... 35 Drive motor............................................................................................. 35 Transmission/drive gear................................................................................. 35 Wheels.................................................................................................. 35 Hydraulic system........................................................................................ 36 Oil quantities for different types of frames............................................................ 37 Fuses................................................................................................... 38 Batteries............................................................................................... 38 Driving speeds.......................................................................................... 38 Lifting/lowering times.................................................................................. 38 Power consumption....................................................................................... 38 Technical data.................................................................................................. 39 Valid from serial number:................................................................................... 39 T-code.................................................................................................. 39 Model................................................................................................... 39 Serial number........................................................................................... 39 Notes................................................................................................... 39 Model....................................................................................................... 39 SM 12F...................................................................................................... 39 Drive motor............................................................................................. 39 Transmission/drive gear................................................................................. 39 Wheels.................................................................................................. 39 Hydraulic system........................................................................................ 40 Fuses................................................................................................... 40 Batteries............................................................................................... 40 Driving speeds.......................................................................................... 41 Lifting/lowering times.................................................................................. 41 Power consumption....................................................................................... 41 Quality Parts................................................................................................... 43 Valid from serial number:................................................................................... 43 T-code...................................................................................................... 43 Model....................................................................................................... 43 Serial No................................................................................................... 43 Notes....................................................................................................... 43 1. Issued Quality Parts..................................................................................... 43 T-code.................................................................................................. 43 Model................................................................................................... 43 Serial No............................................................................................... 43 Order number............................................................................................ 43 Issued.................................................................................................. 43 Contents, P..................................................................................................... 45 1. Preventive Maintenance................................................................................... 45 Introduction, maintenance....................................................................................... 47 1. Safety regulations with maintenance work................................................................. 47 WARNING!................................................................................................ 47 WARNING!................................................................................................ 48 WARNING!................................................................................................ 48 NOTE!................................................................................................... 48 CAUTION!................................................................................................ 48 2. Cleaning and washing..................................................................................... 49 NOTE!................................................................................................... 49 2.1. External cleaning.................................................................................. 49 NOTE!............................................................................................... 49 2.2. Cleaning the motor compartment..................................................................... 49 NOTE!............................................................................................... 49 2.3. Electrical components.............................................................................. 50 NOTE!............................................................................................... 50 3. Safe lifting............................................................................................. 50 WARNING!................................................................................................ 50 Preventive maintenance.......................................................................................... 51 Valid from serial number:................................................................................... 51 T-code...................................................................................................... 51 Model....................................................................................................... 51 Serial No................................................................................................... 51 Notes....................................................................................................... 51 1. Service schedule......................................................................................... 51 Item.................................................................................................... 51 Work required........................................................................................... 51 Interval in hours................................................................................... 51 5................................................................................................... 51 20.................................................................................................. 51 80.................................................................................................. 51 250................................................................................................. 51 500................................................................................................. 51 1000................................................................................................ 51 3000................................................................................................ 51 Interval in Days/Weeks/Months....................................................................... 51 1 d................................................................................................. 51 1 w................................................................................................. 51 1 m................................................................................................. 51 3 m................................................................................................. 51 6 m................................................................................................. 51 12 m................................................................................................ 51 36 m................................................................................................ 51 0000................................................................................................ 51 Chassis............................................................................................. 51 0640................................................................................................ 51 Operator Controls................................................................................... 51 0840................................................................................................ 51 Drivers Protection.................................................................................. 51 1700................................................................................................ 52 Drive Moter......................................................................................... 52 2550................................................................................................ 52 Drive Gear.......................................................................................... 52 3100................................................................................................ 52 Brake............................................................................................... 52 3500................................................................................................ 52 Wheels.............................................................................................. 52 4100................................................................................................ 53 Tiller Arm.......................................................................................... 53 5110................................................................................................ 53 Battery............................................................................................. 53 5200................................................................................................ 53 Instrument Panel.................................................................................... 53 5300................................................................................................ 53 Electrical Control System........................................................................... 53 5400................................................................................................ 53 Electrical Panel.................................................................................... 53 5710................................................................................................ 54 Electronic Card..................................................................................... 54 6000................................................................................................ 54 Hydraulic System.................................................................................... 54 7100................................................................................................ 54 Lifting Mast........................................................................................ 54 7310................................................................................................ 55 Lift Cylinder....................................................................................... 55 7400................................................................................................ 55 Lifting Device...................................................................................... 55 2. Lubrication chart........................................................................................ 57 Pos no.................................................................................................. 57 Service point........................................................................................... 57 Interval/Running hours.................................................................................. 57 Lubricant............................................................................................... 57 500h................................................................................................ 57 1000h............................................................................................... 57 3000h............................................................................................... 57 Preventive maintenance.......................................................................................... 59 Valid from serial number:................................................................................... 59 T-code.................................................................................................. 59 Model................................................................................................... 59 Serial No............................................................................................... 59 Notes................................................................................................... 59 1. Service schedule......................................................................................... 59 Pos. no................................................................................................. 59 Work to carry out....................................................................................... 59 Intervals in hours.................................................................................. 59 5................................................................................................... 59 20.................................................................................................. 59 80.................................................................................................. 59 250................................................................................................. 59 500................................................................................................. 59 1000................................................................................................ 59 3000................................................................................................ 59 Intervals in Days/Weeks/Months...................................................................... 59 1 D................................................................................................. 59 1 W................................................................................................. 59 1 M................................................................................................. 59 3 M................................................................................................. 59 6 M................................................................................................. 59 12 M................................................................................................ 59 36 M................................................................................................ 59 0000................................................................................................ 59 Chassis............................................................................................. 59 1700................................................................................................ 59 Motors.............................................................................................. 59 2550................................................................................................ 59 Drive unit.......................................................................................... 59 3370................................................................................................ 60 Brakes.............................................................................................. 60 3500................................................................................................ 60 Wheels.............................................................................................. 60 4110................................................................................................ 60 Tiller arm.......................................................................................... 60 4380................................................................................................ 60 Steering bearings................................................................................... 60 5000................................................................................................ 61 Electrical operations............................................................................... 61 5110................................................................................................ 61 Battery............................................................................................. 61 5400................................................................................................ 61 Power system driving................................................................................ 61 5700................................................................................................ 61 Electronic Card..................................................................................... 61 6000................................................................................................ 62 Hydraulic system.................................................................................... 62 6600................................................................................................ 62 Cylinders........................................................................................... 62 7000................................................................................................ 62 Mast................................................................................................ 62 2. Lubrication chart........................................................................................ 64 Pos no.................................................................................................. 64 Service point........................................................................................... 64 Interval/Running hours.................................................................................. 64 Lubricant............................................................................................... 64 500h................................................................................................ 64 1000h............................................................................................... 64 3000h............................................................................................... 64 Preventive maintenance.......................................................................................... 65 Valid from serial number:................................................................................... 65 T-code...................................................................................................... 65 Model....................................................................................................... 65 Serial No................................................................................................... 65 Notes....................................................................................................... 65 1. Service schedule......................................................................................... 65 Item.................................................................................................... 65 Work required........................................................................................... 65 Interval in hours................................................................................... 65 5................................................................................................... 65 20.................................................................................................. 65 80.................................................................................................. 65 250................................................................................................. 65 500................................................................................................. 65 1000................................................................................................ 65 3000................................................................................................ 65 Interval in Days/Weeks/Months....................................................................... 65 1 d................................................................................................. 65 1 w................................................................................................. 65 1 m................................................................................................. 65 3 m................................................................................................. 65 6 m................................................................................................. 65 12 m................................................................................................ 65 36 m................................................................................................ 65 0000................................................................................................ 65 Chassis............................................................................................. 65 0640................................................................................................ 65 Operator Controls................................................................................... 65 0840................................................................................................ 66 Drivers Protection.................................................................................. 66 1700................................................................................................ 66 Drive Motor......................................................................................... 66 2550................................................................................................ 66 Drive Gear.......................................................................................... 66 3100................................................................................................ 66 Brake............................................................................................... 66 3500................................................................................................ 66 Wheels.............................................................................................. 66 4100................................................................................................ 67 Tiller Arm.......................................................................................... 67 5110................................................................................................ 67 Battery............................................................................................. 67 5200................................................................................................ 67 Instrument Panel.................................................................................... 67 5300................................................................................................ 67 Electrical Control System........................................................................... 67 5400................................................................................................ 67 Electrical Panel.................................................................................... 67 5710................................................................................................ 68 Electronic Card..................................................................................... 68 6000................................................................................................ 68 Hydraulic System.................................................................................... 68 7100................................................................................................ 68 Lifting mast........................................................................................ 68 7310................................................................................................ 69 Lift Cylinder....................................................................................... 69 7400................................................................................................ 69 Lifting device...................................................................................... 69 2. Lubrication chart........................................................................................ 71 Pos no.................................................................................................. 71 Service point........................................................................................... 71 Interval/Running hours.................................................................................. 71 Lubricant............................................................................................... 71 500h................................................................................................ 71 1000h............................................................................................... 71 3000h............................................................................................... 71 Oil and grease specification.................................................................................... 73 Valid from serial number:................................................................................... 73 T-code.................................................................................................. 73 Model................................................................................................... 73 Serial No............................................................................................... 73 Notes................................................................................................... 73 1. Approved oil’s and grease for SM12, SM10 and SM12S.................................................... 73 Lubticant............................................................................................... 73 Specification........................................................................................... 73 Application area........................................................................................ 73 > - 15 C............................................................................................ 73 < - 15 C............................................................................................ 73 Oil and grease specification.................................................................................... 75 Valid from serial number:................................................................................... 75 T-code.................................................................................................. 75 Model................................................................................................... 75 Serial No............................................................................................... 75 Notes................................................................................................... 75 Lubticant................................................................................................... 75 Specification............................................................................................... 75 Application area............................................................................................ 75 > - 15 C................................................................................................ 75 < - 15 C................................................................................................ 75 Contents, S..................................................................................................... 77 1. Service instructions..................................................................................... 77 Support arm chassis............................................................................................. 79 Valid from serial number:................................................................................... 79 T-code.................................................................................................. 79 Model................................................................................................... 79 Serial No............................................................................................... 79 Notes................................................................................................... 79 1. General.................................................................................................. 79 2. Main components.......................................................................................... 80 Pos no.................................................................................................. 80 Description............................................................................................. 80 3. Maintenance.............................................................................................. 80 4. Adjustment of the support arm width...................................................................... 81 Warning!................................................................................................ 81 5. Exchange of support arms................................................................................. 82 Pump motor...................................................................................................... 83 Valid from serial number:................................................................................... 83 T-code.................................................................................................. 83 Model................................................................................................... 83 Serial No............................................................................................... 83 Notes................................................................................................... 83 1. General.................................................................................................. 83 1.1. Mechanical construction............................................................................ 84 1.2. Special tools...................................................................................... 85 Tool................................................................................................ 85 2. Removal/Refitting........................................................................................ 85 2.1. Removing the motor from the truck.................................................................. 85 2.2. Refitting.......................................................................................... 85 3. Service/Repairs.......................................................................................... 86 3.1. Cleaning........................................................................................... 86 3.2. Dismantling........................................................................................ 87 3.3. Re-assembling...................................................................................... 88 3.4. Armature bearings.................................................................................. 88 3.4.1. Changing bearings............................................................................ 89 3.5. Carbon brushes and brush holder.................................................................... 89 3.5.1. Changing carbon brushes...................................................................... 89 3.6. Commutator......................................................................................... 90 3.6.1. Machining the commutator..................................................................... 90 4. Storage/Transport........................................................................................ 91 4.1. Storage............................................................................................ 91 5. Data..................................................................................................... 92 Torque.................................................................................................. 92 Nm...................................................................................................... 92 Component............................................................................................... 92 Item.................................................................................................... 92 Min..................................................................................................... 92 Max..................................................................................................... 92 Unit.................................................................................................... 92 Drive motor..................................................................................................... 93 Valid from serial number:................................................................................... 93 T-code.................................................................................................. 93 Model................................................................................................... 93 Serial No............................................................................................... 93 Notes................................................................................................... 93 1. General.................................................................................................. 93 1.1. Mechanical construction............................................................................ 94 1.2. Special tools...................................................................................... 95 Tool................................................................................................ 95 2. Removal/Refitting........................................................................................ 95 2.1. Removing the motor from the truck.................................................................. 95 WARNING!............................................................................................ 96 2.2. Re-assembling...................................................................................... 96 3. Service/Repairs.......................................................................................... 97 3.1. Cleaning........................................................................................... 97 3.2. Dismantling........................................................................................ 98 3.3. Re-assembling...................................................................................... 99 3.4. Armature bearings..................................................................................100 3.4.1. Changing the drive end bearing...............................................................100 3.4.2. Changing the commutator end bearing..........................................................100 3.5. Carbon brushes and brush holder....................................................................101 3.5.1. Changing carbon brushes......................................................................101 3.6. Commutator.........................................................................................102 3.6.1. Machining the commutator.....................................................................102 4. Storage/Transport........................................................................................103 4.1. Storage............................................................................................103 5. Data.....................................................................................................104 Torque..................................................................................................104 Nm......................................................................................................104 Grease specification....................................................................................104 Component...............................................................................................104 Item....................................................................................................104 Min.....................................................................................................104 Max.....................................................................................................104 Unit....................................................................................................104 Drive motor.....................................................................................................105 Valid from serial number:...................................................................................105 T-code..................................................................................................105 Model...................................................................................................105 Serial No...............................................................................................105 Notes...................................................................................................105 1. General..................................................................................................105 1.1. Mechanical contruction.............................................................................106 1.2. Special tools......................................................................................107 Tool................................................................................................107 2. Removal/Refitting........................................................................................107 2.1. Removing the motor from the truck..................................................................107 2.2. Reassembly.........................................................................................108 3. Service/Repairs..........................................................................................109 3.1. Cleaning...........................................................................................109 3.2. Removal of motor...................................................................................110 3.3. Refitting of motor.................................................................................111 3.4. Armature bearings..................................................................................112 3.4.1. Changing the drive end bearing...............................................................112 3.4.2. Changing the commutator end bearing..........................................................112 3.5. Carbon brushes and brush holder....................................................................113 3.5.1. Changing carbon brushes......................................................................113 3.6. Commutator.........................................................................................114 3.6.1. Turning the commutator.......................................................................114 4. Storage/Transport........................................................................................115 4.1. Storage............................................................................................115 5. Data.....................................................................................................116 Torque..................................................................................................116 Nm......................................................................................................116 Grease specification....................................................................................116 Component...............................................................................................116 Item....................................................................................................116 Min.....................................................................................................116 Max.....................................................................................................116 Unit....................................................................................................116 Drive gear......................................................................................................117 Valid from serial number:...................................................................................117 T-code..................................................................................................117 Model...................................................................................................117 Serial No...............................................................................................117 Notes...................................................................................................117 1. General technical description............................................................................117 1.1. Technical data.....................................................................................118 Data................................................................................................118 Description.........................................................................................118 1.2. Gear components....................................................................................119 Pos No..............................................................................................119 Component...........................................................................................119 1.3. Special tools......................................................................................120 Pos No..............................................................................................120 Tool................................................................................................120 2. Removing the gear from the truck.........................................................................121 3. Change of seal on the drive shaft........................................................................122 4. Reconditioning of the gear...............................................................................124 Mechanical brakes...............................................................................................129 Valid from serial number:...................................................................................129 T-code..................................................................................................129 Model...................................................................................................129 Serial No...............................................................................................129 Notes...................................................................................................129 1. General..................................................................................................129 Position................................................................................................129 Description.............................................................................................129 2. Function.................................................................................................130 2.1. Releasing the brakes...............................................................................130 2.2. Braking............................................................................................130 3. Maintenance..............................................................................................131 Position................................................................................................131 Adjustment measurement..................................................................................131 Electromagnetic brake...........................................................................................133 Valid from serial number:...................................................................................133 T-code..................................................................................................133 Model...................................................................................................133 Serial No...............................................................................................133 Notes...................................................................................................133 1. General..................................................................................................133 2. Function.................................................................................................134 2.1. Releasing the brake................................................................................134 2.2. Braking............................................................................................134 3. Maintenance..............................................................................................135 3.1. Adjustment of gap..................................................................................136 3.1.1. Adjustment procedure.........................................................................136 3.2. Exchange of brake disc/magnetic coil...............................................................137 3.2.1. Exchange procedure...........................................................................137 3.2.2. Transport securing screws....................................................................138 3.3. Check/adjustment of the braking force..............................................................139 Warning!............................................................................................139 Electric parking brake, magnetic brake..........................................................................141 Valid from serial number:...................................................................................141 T-code..................................................................................................141 Model...................................................................................................141 Serial No...............................................................................................141 Notes...................................................................................................141 1. General..................................................................................................141 2. Function.................................................................................................142 2.1. Releasing the brake................................................................................142 2.2. Braking............................................................................................143 3. Maintenance..............................................................................................144 3.1. Adjustment of gap..................................................................................144 3.1.1. Adjustment procedure:........................................................................144 3.2. Exchange of brake disc/magnetic coil...............................................................145 3.2.1. Exchange procedure:..........................................................................145 3.3. Check/adjustment of the braking force..............................................................146 WARNING!............................................................................................146 Electrical system...............................................................................................147 Valid from serial number:...................................................................................147 T-code..................................................................................................147 Model...................................................................................................147 Serial No...............................................................................................147 Notes...................................................................................................147 1. Electrical panel, components.............................................................................147 2. List of symbols and electrical diagram...................................................................148 2.1. List of symbols....................................................................................148 Symbol..............................................................................................148 Description.........................................................................................148 Function............................................................................................148 Remark..............................................................................................148 2.2. Electrical diagram 1(4)............................................................................150 2.3. Electrical diagram 2(4)............................................................................151 2.4. Electrical diagram 3(4)............................................................................152 2.5. Electrical diagram 4(4)............................................................................153 3. Operating description....................................................................................154 3.1. General............................................................................................154 3.2. Description........................................................................................154 3.3. Ignition lock S17 in the ON position...............................................................155 3.4. The tiller arm in drive position, S10..............................................................155 3.5. Driving, fork direction............................................................................155 3.6. Driving, steer wheel direction.....................................................................156 3.7. Reversing/motor brake fork direction to steer wheel direction......................................156 3.8. Reversing/motor brake steer wheel direction to fork direction......................................157 3.9. Emergency reverse function.........................................................................157 3.10. Lifting the forks.................................................................................158 3.11. Horn..............................................................................................158 4. Options..................................................................................................158 4.1. Electrical lowering of the forks...................................................................158 4.2. Onboard charger....................................................................................158 Electrical system...............................................................................................159 Valid from serial number:...................................................................................159 T-code..................................................................................................159 Model...................................................................................................159 Serial No...............................................................................................159 Notes...................................................................................................159 1. Electrical panel, components.............................................................................159 2. List of symbols and electrical diagrams..................................................................160 2.1. List of symbols....................................................................................160 Symbol..............................................................................................160 Description.........................................................................................160 Function............................................................................................160 Remark..............................................................................................160 2.2. Electrical diagram 1(3)............................................................................162 2.3. Electrical diagram 2(3)............................................................................163 2.4. Electrical diagram 3(3)............................................................................164 3. Operating description....................................................................................165 3.1. General............................................................................................165 3.2. Description........................................................................................165 3.3. Ignition lock S17 in the ON position...............................................................166 3.4. The tiller arm in drive position, S10..............................................................166 3.5. Driving, fork direction............................................................................167 3.6. Driving, steer wheel direction.....................................................................168 3.7. Reversing/motor brake fork direction to steer wheel direction......................................169 3.8. Reversing/motor brake steer wheel direction to fork direction......................................169 3.9. Emergency reverse function.........................................................................170 3.10. Lifting the support arms..........................................................................171 3.11. Driving and simultaneously lifting the support arms...............................................171 3.12. Lowering the support arms.........................................................................172 3.13. Lifting the forks.................................................................................172 3.14. Driving and simultaneously lifting the forks......................................................173 3.15. Lowering the forks................................................................................173 3.16. Horn..............................................................................................174 Electrical system...............................................................................................175 Valid from serial number:...................................................................................175 T-code..................................................................................................175 Model...................................................................................................175 Serial No...............................................................................................175 Notes...................................................................................................175 1. Electrical panel, components.............................................................................175 2. List of symbols and electrical diagrams..................................................................176 2.1. List of symbols....................................................................................176 Symbol..............................................................................................176 Description.........................................................................................176 Function............................................................................................176 Remark..............................................................................................176 2.2. Electrical diagram 1(3)............................................................................178 2.3. Electrical diagram 2(3)............................................................................179 2.4. Electrical diagram 3(3)............................................................................180 3. Description of function..................................................................................181 3.1. General............................................................................................181 3.2. Description........................................................................................181 3.3. Ignition lock S17 in the ON position...............................................................181 3.4. The tiller arm in drive position, S10..............................................................182 Note!...............................................................................................182 3.5. Driving, fork direction............................................................................183 3.6. Driving, steer wheel direction.....................................................................184 3.7. Load dependent current limit.......................................................................185 S59.................................................................................................185 Min (kg)............................................................................................185 Max (kg)............................................................................................185 3.8. Reversing/motor brake fork direction to steer wheel direction......................................186 3.9. Reversing/motor brake steer wheel direction to fork direction......................................186 3.10. Emergency reverse function........................................................................187 3.11. Lifting the support arms..........................................................................188 3.12. Lowering the support arms.........................................................................188 3.13. Lifting the forks.................................................................................189 3.14. Horn..............................................................................................189 3.15. Platform switch function (option).................................................................190 Note! Function without platform switch..............................................................190 3.15.1. Driving with platform folded up.............................................................190 3.15.2. Driving with platform folded down...........................................................190 3.15.3. Stepping off the platform whilst driving....................................................191 Electrical system...............................................................................................193 Valid from serial number:...................................................................................193 1. Electrical panel, components.............................................................................193 2. List of symbols and electrical diagrams..................................................................194 2.1. List of symbols....................................................................................194 Symbol..............................................................................................194 Description.........................................................................................194 Function............................................................................................194 Notes...............................................................................................194 2.2. Electrical diagram 1/6.............................................................................196 2.3. Electrical diagram 2/6.............................................................................197 2.4. Electrical diagram 3/6.............................................................................198 2.5. Electrical diagram 4/6.............................................................................199 2.6. Electrical diagram 5/6.............................................................................200 2.7. Electrical diagram 6/6.............................................................................201 3. Operating description....................................................................................202 3.1. General............................................................................................202 3.2. Description........................................................................................202 3.3. Ignition switch S17 in ON position.................................................................203 3.4. Tiller arm in driving position, S10................................................................203 3.5. Driving, direction of the forks....................................................................203 3.6. Driving, direction of the steering wheel...........................................................204 3.7. Reversing/motor brake, direction of forks to direction of steering wheel...........................204 3.8. Reversing/motor brake, direction of steering wheel to direction of forks...........................205 3.9. Emergency reversing................................................................................205 3.10. Lifting the forks.................................................................................206 3.11. Lowering the forks................................................................................206 3.12. Lifting the support arm...........................................................................206 3.13. Lowering the support arm..........................................................................206 3.14. Horn..............................................................................................206 Battery controller/hourmeter....................................................................................207 Valid from serial number:...................................................................................207 T-code..................................................................................................207 Model...................................................................................................207 Serial No...............................................................................................207 Notes...................................................................................................207 1. General..................................................................................................207 2. Electrical...............................................................................................208 2.1. Voltage............................................................................................208 2.1.1. The contact voltage and current ratings for switching resistive loads........................208 2.1.2. Memory Retention.............................................................................208 3. Battery Controller.......................................................................................208 3.1. General............................................................................................208 3.1.1. Discharge Adjustment.........................................................................209 SETTING.........................................................................................209 VPC.............................................................................................209 Pin No..........................................................................................210 Function........................................................................................210 NOTE:.......................................................................................210 NOTE:.......................................................................................210 3.2. Reset..............................................................................................211 3.3. Keyswitch..........................................................................................211 3.4. Hourmeter..........................................................................................211 4. Trouble shooting.........................................................................................212 4.1. Battery Discharge Indicator........................................................................212 4.1.1. No reset.....................................................................................212 4.1.2. Always resets after break in power...........................................................212 NOTE:...........................................................................................212 4.1.3. No discharge, gauge does not run down........................................................213 4.1.4. No lockout...................................................................................213 4.1.5. No lift......................................................................................213 4.1.6. Early lockout................................................................................213 4.1.7. LEDs don’t light.............................................................................214 4.2. Hour meter.........................................................................................214 4.2.1. No display...................................................................................214 4.2.2. Hour glass icon does not flash...............................................................214 4.2.3. Hour meter glass icon always flashes.........................................................214 Transistor regulator............................................................................................215 Valid from serial number:...................................................................................215 T-code......................................................................................................215 Model.......................................................................................................215 Serial number...............................................................................................215 Notes.......................................................................................................215 1. General..................................................................................................215 1.1. Characteristics and functions......................................................................215 2. Connections..............................................................................................216 Connection pin..........................................................................................216 Connection..............................................................................................216 2.1. Connection to the control circuits.................................................................217 Pin No..............................................................................................217 Connection..........................................................................................217 Contactor driving...............................................................................217 Connections for throttle........................................................................217 Basic control signals...........................................................................217 3. Technical specification..................................................................................218 Range...................................................................................................218 Unit....................................................................................................218 Description.............................................................................................218 4. Parameters...............................................................................................219 Parameter (1307-display)................................................................................219 Range...................................................................................................219 Std. value..............................................................................................219 Unit....................................................................................................219 Description.............................................................................................219 5. Diagnostics and trouble shooting.........................................................................221 5.1. Trouble shooting...................................................................................221 5.2. Error codes........................................................................................221 5.2.1. LED indications..............................................................................222 LED code............................................................................................222 Programmer’s LCD- display...........................................................................222 Explanation.........................................................................................222 Probable cause......................................................................................222 5.3. Testing circuits for error detection...............................................................224 6. Maintenance..............................................................................................224 NOTE!...................................................................................................224 6.1. Safety.............................................................................................224 WARNING.............................................................................................224 6.2. Cleaning...........................................................................................225 7. Curtis 1307 hand terminal................................................................................226 Pos.....................................................................................................227 Function................................................................................................227 Notes...................................................................................................227 8. Using the hand terminal..................................................................................228 8.1. Using the PROGRAM mode, checking and adjusting parameters..........................................229 NOTE!...............................................................................................229 8.1.1. Using the key MORE INFO in PROGRAM mode......................................................230 8.2. Using SPECIAL PROGRAM mode.........................................................................230 8.3. Using TEST mode....................................................................................231 Test value..........................................................................................232 Description.........................................................................................232 8.4. Using DIAGNOSTICS mode.............................................................................233 NOTE................................................................................................233 8.5. Using SPECIAL DIAGNOSTICS mode.....................................................................233 Transistor regulator............................................................................................235 Valid from serial number:...................................................................................235 T-code..................................................................................................235 Model...................................................................................................235 Serial number...........................................................................................235 Notes...................................................................................................235 1. General..................................................................................................235 1.1. Characteristics and functions......................................................................235 2. Connections..............................................................................................236 Connection pin..........................................................................................236 Connection..............................................................................................236 2.1. Connection to the control circuits.................................................................237 Pin No..............................................................................................237 Connection..........................................................................................237 Contactor driving...............................................................................237 Connections for throttle........................................................................237 Basic control signals...........................................................................237 3. Technical specification..................................................................................238 Range...................................................................................................238 Unit....................................................................................................238 Description.............................................................................................238 4. Parameters...............................................................................................239 Parameter (1307-display)................................................................................239 Range...................................................................................................239 Std. value..............................................................................................239 Unit....................................................................................................239 Description.............................................................................................239 4.1. Mode 1 and 2.......................................................................................240 5. Diagnostics and trouble shooting.........................................................................240 5.1. Trouble shooting...................................................................................240 5.2. Error codes........................................................................................241 5.2.1. LED indications..............................................................................241 LED code............................................................................................241 Programmer’s LCD- display...........................................................................241 Explanation.........................................................................................241 Probable cause......................................................................................241 5.3. Testing circuits for error detection...............................................................243 6. Maintenance..............................................................................................243 NOTE!...................................................................................................243 6.1. Safety.............................................................................................243 WARNING.............................................................................................243 6.2. Cleaning...........................................................................................244 7. Curtis 1307 hand terminal................................................................................245 Connection to Curtis 1207...............................................................................245 Connection to Curtis 1207A..............................................................................245 Pos.....................................................................................................246 Function................................................................................................246 Notes...................................................................................................246 8. Using the hand terminal..................................................................................247 8.1. Using the PROGRAM mode, checking and adjusting parameters..........................................248 NOTE!...............................................................................................248 8.1.1. Using the key MORE INFO in PROGRAM mode......................................................249 8.2. Using SPECIAL PROGRAM mode.........................................................................249 8.3. Using TEST mode....................................................................................250 Example.............................................................................................250 Test value..........................................................................................250 Description.........................................................................................250 8.4. Using DIAGNOSTICS mode.............................................................................251 NOTE................................................................................................251 8.5. Using SPECIAL DIAGNOSTICS mode.....................................................................252 Electronic card.................................................................................................253 Valid from serial number:...................................................................................253 T-code..................................................................................................253 Model...................................................................................................253 Serial No...............................................................................................253 Notes...................................................................................................253 1. Electronic card..........................................................................................253 2. Connectors and adjustments...............................................................................254 Position................................................................................................254 Connection/Adjustment...................................................................................254 3. Terminals and LED’s......................................................................................255 Terminal No.............................................................................................255 LED No..................................................................................................255 Connection..............................................................................................255 Function................................................................................................255 Electronic card.............................................................................................257 Valid from serial number:...............................................................................257 T-code..............................................................................................257 Model...............................................................................................257 Serial No...........................................................................................257 Notes...............................................................................................257 1. Electronic card......................................................................................257 2. Connections and adjustments..........................................................................258 Position............................................................................................258 Connection/Adjustment...............................................................................258 Terminal No.........................................................................................258 LED No..............................................................................................258 Connection..........................................................................................258 Function............................................................................................258 Electronic card.................................................................................................261 Valid from serial number:...................................................................................261 T-code..................................................................................................261 Model...................................................................................................261 Serial number...........................................................................................261 Notes...................................................................................................261 1. General..................................................................................................261 2. Connections/adjustments..................................................................................262 Position................................................................................................262 Connections/adjustments.................................................................................262 3. Connections for inputs and outputs.......................................................................262 Pin No..................................................................................................262 LED No..................................................................................................262 I/O.....................................................................................................262 Signal name.............................................................................................262 Function................................................................................................262 Electronic card.................................................................................................265 Valid from serial number:...................................................................................265 T-code..................................................................................................265 Model...................................................................................................265 Serie No................................................................................................265 Note....................................................................................................265 1. General..................................................................................................265 2. Connections and adjustment...............................................................................266 Position................................................................................................266 Connection/Adjustment...................................................................................266 3. Input/output terminals...................................................................................267 Terminal no.............................................................................................267 Signal name.............................................................................................267 Function................................................................................................267 Hydraulic system................................................................................................271 Valid from serial number:...................................................................................271 T-code..................................................................................................271 Model...................................................................................................271 Serial No...............................................................................................271 Notes...................................................................................................271 1. General..................................................................................................271 2. Description of function..................................................................................272 2.1. Hydraulic diagram and components...................................................................272 2.2. Main components....................................................................................272 Pos No..............................................................................................272 Description.........................................................................................272 Remark..............................................................................................272 2.3. Description........................................................................................273 2.3.1. Lift.........................................................................................273 2.3.2. Lower, mechanical............................................................................273 2.3.3. Lower, electrical............................................................................273 2.3.4. Operating pressure...........................................................................273 2.3.5. Relief valve.................................................................................273 Hydraulic system............................................................................................275 Valid from serial number:...............................................................................275 T-code..............................................................................................275 Model...............................................................................................275 Serial No...........................................................................................275 Notes...............................................................................................275 1. General..............................................................................................275 2. Description of function..............................................................................276 2.1. Hydraulic diagram and components...............................................................276 Pos. No.........................................................................................276 Description.....................................................................................276 Remark..........................................................................................276 2.2. Electrical connections.........................................................................277 2.3. Description....................................................................................278 2.3.1. Support arm lift.........................................................................278 2.3.2. Support arm lower........................................................................278 2.3.3. Fork lift................................................................................278 2.3.4. Fork lower...............................................................................278 2.3.5. Priority.................................................................................278 Hydraulic system................................................................................................279 Valid from serial number:...................................................................................279 T-code..................................................................................................279 Model...................................................................................................279 Serial No...............................................................................................279 Notes...................................................................................................279 1. General..................................................................................................279 2. Hydraulic diagram........................................................................................281 3. Symbol list..............................................................................................282 Symbol..................................................................................................282 Description.............................................................................................282 Function................................................................................................282 Notes...................................................................................................282 4. Functional description...................................................................................283 4.1. Lifting the forks..................................................................................283 4.2. Lowering the forks.................................................................................283 4.3. Switch, S59........................................................................................283 5. Adjustments..............................................................................................284 5.1. Adjustment procedure...............................................................................284 WARNING.............................................................................................284
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