MBB PALFINGER Customer Service

Training Class

Hinz, Dec. 2010

Agenda

- MBB Introduction
- Tail lift program and product design
- Assemblies
- Power pack
- Cylinder
- Hydraulics
- Electrical
- Trouble shooting
- Diagnosis Software
- Onlineordering
- Warranty Claims
- Open points and Discussion
MBB Palfinger GmbH

• Headquarter in Ganderkesee
• about 260 employees
• Revenue 2008  62 Mio. Euro
• Top 3 in Tail lift business
• 4o years of product Know-how
• Innovative product portfolio
• ISO 9001 certified
• High quality product
• Wide service coverage
Tail lift program

6.17 / 6.18
Tail lift program

Standard K Tail lift

Tail lift program

Standard K Tail lift

Tail lift program

K1TR
Tail lift program

KF
Tail lift program

KFL
Tail lift program

KUZ
Tail lift program

KUZ
Tail lift program

KUZF / BDF
Characteristics of the K plus - line

In the middle of 2004, MBB introduces its second generation of our advanced Sensor-control-system. The new
control box is essentially smaller and trough the ergonomic design of the control switches more operator friendly.
Additionally it is equipped with a translucent lit operating panel, optimised for operating at night.

The operator guidance is kept as previous controls for easier acclimatisation with the new controls. Furthermore,
at the control box there is only one cable used.

The p.c. board is now suited inside the beam behind an easy accessible cover.This makes it better protected against
influences from outside and easier access for inspection and maintenance.
Furthermore, it is possible to specify the p.c. board trough simple changes of the program. The cables are guided
with the hydraulic piping to the p.c. board through an innovative sealing system. Because of this there are no tight
bends and cable breaks are avoided. The new p.c. board will be now used in all Tail Lifts with the sensor – control –
system, making the spare part p.c. board much easier.

Possible faults are now easily traced using the integrated diagnostic feature. This guarantees a fast error correction
and minimising down time. Additionally, the new control system provides a fast power in check without using a PC.
The p.c. board has an optical fault diagnose module, i.e. the status of the controls shown through the flashing light
on the platform, while bridging specific contacts. Maintenance intervals are also shown in the cabin control device.

This reminds users when maintenance is due, which also benefits the life span of the tail lift. The counter registers
every operation permanently. Optionally the control system can be controlled with a key code. This prevents
unauthorised use.
Structure MBB standard tail lift

Overview with electric

Nr. Description
1 On-Off-switch / Cab switch
2 Control Box
3 Ground tilt switch B13
4 Inclination sensor B15
5 Rubber cap
6 Pc Board
7 Foot control

1.4
 Set up MBB standard tail lift

Mount frame
KTL coated

Valveblock and
hydraulic pipes

Power packs and control units on

Serial Tag and product number passenger side
always on left side
Set up MBB standard tail lift

Mount frame

Valveblock and
hydraulic pipes
Set up MBB standard tail lift

Lift arm
KTL coated

Hole center to center on each

side indicates the arm length

Pitch Available (mm):

1300 or 1310 mm 600
in most cases 700
800
900
1000
1100
Depending on model
Set up MBB standard tail lift

Cylinder
Lift cylinder Powered one way
Tilt cylinder Powered both ways
 Set up MBB standard tail lift

Platform

Roll stops Warning lights

Serial
Tag

Platform
cable
and Foot control
Sensor Clevis
and Ground
roller
Set up MBB standard tail lift

Pins, Bushings and restrictor valves

Number on valve descripes the

fluidflow (l/min)

Pin diameter indicates lift capacity

Power packs

- Parts
- Different Types
- Functionality
Power Pack

1. Motor 12/24 V
2. Plastic tank
3. Hydraulic pump
4. Connector
5. S5 shiftvalve
6. Pressure relief valve
7. Shuttle valve
8. Restrictor valve R5
9. Pressure gauge

5.8
MBB Powerpack
Flutec Powerpack (not common)
Flutec Power pack small units

500 and 750 Kg

MBB Power pack

Manual engaging of S5-Valve

Look for breather oil

cap before mounting
new lift.
Cylinder

- Design
- Restrictor valves
Set up Structure on a 4-Cylinder and retractable gate

Lift frame

Lift cylinder
inside
Tilt cylinder
outside
Cylinder

Lift cylinder – power one way

Tilt cylinder – power both ways

Cylinders
Cylinder
Liftcylinder – power one way
Restrictor Valve ( R1 & R2)

Lift cylinder Restrictor Valve # Lift cylinder

5.11
Cylinder
Tilt cylinder -
power both ways

Restrictor Valve
(R3 & R4)

Tilt cylinder Restrictor Valve # Tilt cylinder

5.11
Hydraulic

- Symbols
- Plans
- Routing
Hydraulik symbols in schematics

4/2 Valve S5
Motor with Pump

DBV Pressure relief Pressure gauge

valve

2/2 Valve single

Shuttle valve / locking
(Flow divider)

Restrictor valve

1.2
 Blue:
Under pressure from
pump

Red:
Returning line

Open with Motor

M+S3+S4

Open with Motor 3.2.1

 Open
S3+S4

Open 3.2.2
 Lowering
S1+S2+S5

Lowering 3.2.3
 Ground levelling
S1 to S5

All valves at lift-

and tilt cylinders,
and S5-Valve at
Power pack engaged

DS = old style up to mid

90`s

Auto Ground tilt 3.2.4

 Horizontal levelling
M+S5

Horizontal Levelling 3.2.5

 Lift
M

Lift 3.2.6
 Close
M+S5

Close 3.2.7
 Hydraulic with stabilizer cylinder

Out: M + S8
in: M + S7

/ S11

Program B1/B2 like KUZ:

Jumper inner E on J1 to hot wire on J2:
Allows to fully close the platform
Attention with small tilt cylinders
 Retractable KUZ

Out: M + S8
in: M + S7

/ S11

Functions:
Lift: M + S1 + S2
Lower: S1 + S2 + S5 + S11
Open: S3 + S4
Close: M + S5
Out: M + S8
In: M + S7
Electric

- Schematics
- Electrical components
- Set up at gate
K-Plus control board
(compared to K1-Plus)
B16
Platform
B15 2015796
Platform
1332485

PC Board PC Board
K-Plus B13 liftarm K1-Plus
2007193 Standard K-Plus & K1-Plus
1332476 2015340
programable
K-Plus control board set up

Picture displays K-Plus setup

K1-Plus slightly different at J41
and has not all ports
Main Electric ports

Cab Switch J11 Sensor J41 Platform cable J3

-2 Permanent Hot - B13 -> Blue, Black, Brown -7 Signal f. Lights
-4 Control Power - B15 -> Brown, Blue, Black -5 lift
- Ground -6 lower
-1 LED Signal -4 Control power

Control Box J30

- 4 Control Power
Valves J4 - 5 lift
- 14 Tilt cylinder - 6 lower
Main Power J1 -14 open
- 15 Lift cylinder
- 27 Power for processor - 3 Close
- 2 Permanent Hot - Ground
- Ground
- 3 Motor Solenoid
- E Special input
- 12 Shift Valve
- E Special input
Open (with Motor)

Only for 12V

Open function
Lowering (with Auto tilt)

Only for 12V

Lowering function
Lift (with horizontal levelling)

Only for 12V

Lift function
Close

Only for 12V

Close function
Signal

Only for 12V

Sensor monitoring
-K- Style -> same as K-Plus

works the same way, just different board design

-KUZ

Slide out (same for KUZF BDF)

Lowering
Lift
Slide in (same for KUZF BDF)
Slide out

4.25
Lower

4.26
Lowering with Ground tilt

4.27
Lift with Horizontal levelling

4.25
Slide in

4.25
-KUZF BDF

- most likely only in Germany

- Schematic from lowering on wheel as sample

(German)
SAMPLE DIAGRAM
-Basic Control

2 versions:

- with and without automatich ground tilt

- Openschematic as sample
K-Basic (with auto ground levelling)

B13 B16
Liftarm Platform
2014705 2017442

Circuit board
K-Basic
2015213
Open (with Motor)
Lowering (with ground tilting)
Lift (with horizontal levelling)
Close
K-Basic (without auto ground levelling)

B13
Liftarm
70077183
Circuit Board
K-Basic
2015213
Open (with Motor)
 Control systems in comparison

Pos. K basic ("Export control") K1 plus ("Compact control") K plus ("Sensor control")
1 Control board in protected cap ● ● ●
2 CE Conformity ○ ● ●
3 Foot control ○ ○
4 Warning lights ○ only withPos.2 ○ ○
5 Hand control ○ ○ ○
6 Wireless remote ○ ○ ○
7 Vorrangschaltung ○ ● ●
8 Standard Control Box ● ● ●
9 Background light ● ● ●
10 Standard Cab switch ○ only withPos.2 ● ●
11 VEHH Code A ○ only withPos.2 ○ ○
12 VEHH Code B (+ and - cable) ○ ○ ○
13 Batterie protection 12V/24V connector ○ ○ ○
14 Board programable ● ●
15 Diagnosis function ● ●
16 Aux lighting incl. activation ● max 100W
17 Load security (Software) ○
18 12V extra lead ○ ○
20 Automatic ground tilt function ○ ● ●

Notes Board can be delivered fully

sealed / protected
● Standard
○ Option
not available
Setup MBB Cab-cut-off-switch

optional
Blue
u /
Bla
Rot / Red #2 Schwarz / Black
Blau / Blue #4 SW /Blk
Yellow/Green - Gelb/Grün J11
Weiß / White #1 SW /Blk
Kontrollgerät / Cab Cut-Off Switch
 B13 switch belonging and setting
Color Wires Control Part number

blue 2 H 70077183

green 3 H 1313006

red 3 K+H1 same as purple

purple 3 K, K-Plus, K1 Plus, H1 1332476

black 2 Athlet 1404177

yellow 3 K-Basic 2014705

Setting the ground tilt switch
It is preferable to set the time when the platform should start tilting after reaching the ground. Turn the b13 switch
clockwise a few mm, the tilting procedure starts earlier e.g. before the platform has reached the ground. Turn the
b13 switch anti-clockwise a few mm, the
tilting procedure starts later e.g. after the
platform has reached the ground. Test
the function, tighten the fixing screw once

~
the setting has been made, and finally
bend the securing shim plate.
How the B15-Sensor works
Platform closed
Travel position
~ 1,1 V

Platform 20° open

Warnlights and Aux engaged
LEDs at cab activated
~ 1,4 V

Platform half way open

Motor stops -> travel by gravity
~ 2,2 V

Platform horizontal
Now S5 additionaly engaged
~ 3,8 V

Platform max opening

Tiltcylinder autom. Stopped
~ 4,0 V
B 15 Sensor
How the new B16-Sensor works
J41

Platform closed GN BR GE WS
+ - + +

J41
Platform 15° open
GN BR GE WS
Lights on, LEDs
In cab switch on + - +

3 Types:

Color Wires Control Part number

purple 4 K1 Plus 2015796
J41
black 3 Athlet (old) 1404176
Platform tilted
GN BR GE WS yellow 5 K-Basic 2017442
downwards
Max opening reached - +
Motor shut off
 How all B16-Switch function

B16
Black Purple Yellow

12 or 24V = 1

Yellow

Yellow
Brown

Brown

Brown
=0

Green

Green
White

White
Black
0V

Grey
Blue
Wire
Ground = -
Blinksignal =2

Closed 90° 1 1 1 1 1 1 - 0 1 0 -

1 only when switch for lift is activated

Start opening 75° 1 1 0 0 1 1 - 2 1 0 -
Open 0° 1 1 0 0 1 1 - 2 1 0 -
lowering 0° 1 1 0 0 1 1 - 2 1 0 -
Platform

auto tilt at ground -10° 1 0 0 0 1 0 - 2 1 1* -

automatic levelling 0° 1 1 0 0 1 1 - 2 1 1* -
lift 0° 1 1 0 0 1 1 - 2 1 0 -
start closing 0° 1 1 0 0 1 1 - 2 1 0 -
almost closed 75° 1 1 1 1 1 1 - 0 1 0 -
closed 90° 1 1 1 1 1 1 - 0 1 0 -

* only if signal for

lift
Standardized VEHH* interface

*= Organization of the leading European Tail Lift manufacturer

Additional Service Functionality

- Reset Service counter

- Serive plug with quick diagnosis
- Diagnosis Software
- Cab switch
Service Plug
Reset Service Counter

-Turn cab switch on and bring tail lift in closed position

-Plug off J11 and J30
-Put the service plug onto J30 and put afterwards J11 back on. The service counter is now resetted.
-Detach the service plug and put J30 back in place
-Take off and on J11 one more time. The gate is back in normal operation mode

Quick diagnosis with service plug

-Turn cab switch on and open platform to horizontal postition
-Plug off J11 and J30
-Put the service plug onto J30 and put afterwards J11 back on. Leave Ground open !
-Detach the service plug and put J30 back in place
-You can test now all inputs
-Take off and on J11 one more time. The gate is back in normal operation mode

6.12
MBB Diagnosis-Software

Service and Diagnosis a step ahead

Your new possibilities at a glance:

- Mobile Diagnosis at all times

- Diagnosis control in- and outputs
- Display of sensor malfunction
- Automatic update of lift software
- Display of electric schematics and hydraulik plans

Your advantages:

- Time saving while troubleshooting due to simple usage

- Reducing of truck down time
- Stay up to date with automatic software version check
 User interface
Input: Monitoring:
Commands from Cycle counters,
the operator Software infos

Outputs:
Shows what is
activated

Sensor control: Interface:

Reports defective Communicating
sensors or wrong and electrical
conditions diagrams
 ***Diagnose 2.0 – New Features***

• Reset of service counter per mouse click

• Creating a semi automatic service record for lift history or reporting

• Comparing of available programs and options

• Will be a available late 2010

electronic Spare parts catalogue (German: eETK)

- Registry and Log in

- Search per lift serial number
- Ordering with ident number
Onlineshop – www.mbbpalfinger.com

812345
********

Take advantage of the onlineshop – 24 / 7!

As a registered Customer you just enter your 6-digit Customer-Nr

and your personalized password.
Select „English“ and hit the Button „Anmelden“
Spare parts via Serialnumber

83305656 (Example)

Enter your Serial number.

It works with all MBB lifts that have the

eight digits long serial number starting
with an 8 from 2001 on.

Hit the „Search“ Button.

Now the system is connecting to our

database and makes a query to give you just
the parts that have been used on that lift.
 Spare parts via Serialnumber

Active Drawing -
select the part that you need or
with a double-click go into the
next level.

Overview

Table of the above drawing

 Spare parts via Serialnumber

Zoom in

List price as well as

your prices are shown

Enter the desired

quantity

After selection move on to basket

 Order process
Orders

• Via telephone standard

• Fax 2% Fax rebate
• Online 3% eETK rebate

New customer
Registers online or via Fax formular

Order process

Create Job Packing List Shipping List Invoice

(Service) (Warehouse) (Shipping Dept) (Controlling)
 Via telephone
Claim
Via formular

Spare parts Invoice on hold

shipment Warranty claim form
Return of claimed parts

Inhouse testing Customer service

Quality control dept.

Result Accepted
Declined

Inform Customer
Warranty Claim
Service Center
Availability:
Monday to Thursday 7:30 am to 5:00 pm
Freitag 7:30 am to 4:00 pm (German times)

Emergency line for troubleshooting outside business hours.

Onlineshop can be used 24h / 7 days a week

Team:
Jürgen Blum (Manager) Jesus Otero
Dennis Meyer (Asst.) Heike Schröder
Thomas Bröer Frank Tingelhoff
Sven Cronjäger Marcel Kutzner
Andreas Kutzner Tel +49 (0) 4221 853 355
Andreas Lange Fax +49 (0) 4221 87536
Andreas Löscher www.MBBPalfinger.com
Open points and discussion
Cab switch
Operation Panel / Control Box
Closed control cap
Control board in place
Power pack with fuses
Control system
B13 Switch
B15 Sensor
Foot control
Warning light
Hand control
Tilt cylinder

Lift cylinder
Single lock valve with restictor valve in tilt cylinder base
Guide rings and seals for lift cylinder
Single lock valve
S5 Shift valve Double lock valve