7, STitt WAGNER | Workshop Manual -EK12 inany form Copyright Copyright protected. Na part ofthis manual Ee MY inden ie a T a >) [Wena EK12 | sw, wo ose 16‘Copyright protec, No part of his manual maybe reproducedin any fom Sopyeght weeoned ae dz M20 | Foreword Foreword This workshop manual provides specifications and describes functional characteristics of the standard truck. This provides you with a comprehensive documentation to ensure better understanding of the vehicle technology and so permit correct maintenance and repair work to be carried out. The workshop manual is always updated by supplementary sheets. Updating of workshop manuals ‘The industrial truck range is subject to continuous further development. This means that certain components or assemblies are exchanged or modified. To ensure that the holder of this manual always has the most up to date version of the documentation, it is important to abide by the following updating system. Issue: 02/99 Replaces Issue: Manual EK12 Sheet no,‘Copyright protec No part of his man nay be reproduced in any form. Sopyeght eared wt ke yk (Foreword Updating WAGNER workshop manuals (Contd.) 1. Exchanging faulty sheets If particular page contains mistakes, for ‘example due to altered setting values, the respective sheet must be exchanged, Page baseline of the existing sheet Anewiy inserted sheet can be recognized by the (saw. 046 altered left-hand baseline (1), Here, the date of | \_Feplaces issue: ‘compilation i updated in the line entitled Insta (2). Inthe line Replaces issue (3) is the Compilation date of the sheet to be replaced. The sheet no. remains the same (4). With every revision the first sheet will be repla- ‘ced. In (9) you see the first issue and the date of the last revision. This tells you the revision state of the whole book. 2. Insertion of supplementary sheets toteaer Msn 9 {1 new, moditied or adaitional components are included in the series truck, it may be necessary to add one or more supplementary sheets. ‘The additional sheet is recognized by the left hand and right-hand page baseline (5+6), Inthe Issue line on the left-hand side is the ‘compilation date (7). On the right, the with continuous index (8). In addition, the table of contents of the respective assembly must also be exchanged. 5 Newly compiled sheets, whether replacements or supplementary sheets, and the new tables of contents are sent by post to all known holders of ‘workshop manuals. Work wish? EKIZ 3 Wesson eKI2 Manual Page baseline of the first sheet Werkshop EK12 senvice.) TRAINING Page baseline of the existing sheet L eoue: 406 Workshop ex ‘Sheet no-, supplementary sheet is marked by the sheet no, (fps sue ama? exre [SP 4 Manual 6 Page baseline of the Supplementary yshect| Wotishop EK2 | | sheeton 4.4) C Issue: 02/99 Workshop Replaces Issue: Manual EK12 ‘Sheet no. i){ Foreword Remarks, imprint No guarantee claims arise as a result of working in accordance with the instructions contained in this manual. This does not affect the guarantee stipula- tions. development of our industrial trucks. Please appreciate that this documentation is subject, 38 —toalteration and error, and that no claims 5% maybe derived from information, illustrations £2 and descriptions contained in the workshop ee manual. a8 u BS S=2 Publisher STILL WAGNER GMBH & Co. KG Trainingezentrum Ernst-Wagner-Weg 1-5 x 72766 Reutlingen-Mittelstadt 2 re ins co ~a2/99 Workshop EK 4D | Sheetno. yyy Replaces Issue: Manual( Chapter Chapter Travel drive Steering system Brake system Electrical system Z=E200 > orm Copyight Hydraulic system Copyright protested No part ofthis manual Issue: 02/09 ~ Workshop ‘Sheet no. Replaces Issue: Manual” EK12No par ofthis manual produces in ay fom, copyright Copy may MY aden { Chapter A Travel drive } Contents Motor, general: Motor terminals... Removing the motor. Removing the gearbox. Commissioning the travel drive system Oil change, gearbo» Maintenance of the drive motor ‘Specifications of the drive motor. Issue: 02/99 Workshop » | Sheet no. (Game Vena” EK 12 Al‘may bo reprodiced in any form sopyigt reserved ‘Copyright protected. No part ofthis manual ae az MY Bix (Chapter A Travel drive } Motor general Id. Nr. W8 002 874 Series-wound motors in a 48 V version are used in the travel drive unit. The armature and field winding are con- nected in series, so ensuring greater torque particularly in the lower speed ranges. ‘Remark: — Series-wound motors must The motor speed is controlled by the stroke ratio of the main thyristor, which is timed by the control circuit board of the pulse control system, never be operated for long periods without load, i.e. without being in gear. Otherwise, they automatically increase their speed to the point of self- destruction . The sense of rotation of the motor is controlled by the flow direction of the current through the field winding. The direction of flow is determined by the travel direction contactors. ef hm hmmm Issue: 02/99 Workshop Sheet no. Replaces Issue: Manual EK 12 A2Copyright protictad No part ofthis manual tray be rebrocucedin sry form copynghe rested MY arden (Chapter A Motor terminals Travel drive ) Resignation an the Motar Designation at the conductors At A2 D1 D2 Rotor winding Rotor winding Field winding Field winding (Issue: 02/99 (Replaces Issue 7 vee ek12 [As )may be roprodied in ay form, sopygnt Copyright potted. No prt of his manual ae az =71 wae / ( Chapter A Removing the Drive Motor Id.Nr. W8 002 874 Caution: After the motor has been removed, the brakes will not work! To prevent the vehicle from moving, secure it with wedges before removing the motor or the brakes. Removing the drive motor: ~ Pull the battery plug Fold down the electrical switchboard (1) Mark the motor supply lead. Release the 4 motor leads at the motor. Loosen 6 pan-head bolts M 8 x 30 (pos. 1) and remove motor upward, shaking it lightly. Note: When removing the electric motor, the gear box opening is revealed. It must be closed to prevent dirt from entering into the gear box. Travel drive | q Issue: 02/09 Workshop Replaces Issue: Manual Sheetno. A A )(Chapter A Travel drive ) Removing the Gear Box Td.Nr, W8 421 771 Removing the gear box: - Pull the battery plug. i i eee ah iM i {| | i i - Raise the vehicle until the bottom of the wheel is 4 inches off the ground. Remove the bumper (1). - Tum gear box 90°, 7 = Loosen the 6 pan-head bolts M8x30 (pos. 2). To remove the gear box, the drive motor must 3 Z be loosened, but can remain in the vehicle. - Raise the drive motor. To prevent it from sliding down, secure it by shimming with flat steel. - Slack steering chain and open chain end link at chain anchor. The chain can now be removed. - Position pallet jack below drive wheel (clearance between forks approx. 220 mm). Copyright protected. No part of his manual - Raise pallet jack until a slight pressure on the drive wheel is achieved. - Loosen the 6 bolts IM12x60 (pos. 3) and slowly lower the pallet jack. jt ti ~ The gear box now rests on the pallet jack and 2 can be pulled out. 1 iS Note: The gear box must be propped up to prevent it from tipping over. MY 2 Toone 00188 Workshop Sheet. Fepaces Issue: wana” EK 12 A5 )oprogieed in sy for. cone reserved Copyright protected. No part ofthis manual may ae az 1 cS MY Be e soe eee eee ( Chapter A Travel drive Commissioning the travel drive system (after exchanging) The following oil viscosities must be used: Standard oil SAE 60/90 Ambient temperature: 0°C Ww 40°C Low-temperature oi SAE 75 W Ambient temperatu to -40°C For special requirements, we recommend contacting the manufacturer. Oil quantity: appr. 3,51 Remark: The specified oil quantity is a guideline value. The correct oil quantity is ascertained by filing the tank up to the lower edge of the filling hole (1). Itis important to avoid overtilling, as otherwise the seals are damaged and it is possible that the operating temperature will not be adhered to. Lubrication of the slewing ring bearing: The slewing ring bearing should be relubricated twice a year using the two lubricating nipples (2), in particular after cleaning the gearbox (using a steam jet). Grease type: All-purpose grease Replaces Issue: Manual | (ne: oa worst EK 12 [>A GE )may be reprocicedin any Toon. copyaght Copyright protected. No part ofthis manual! reseed MY Bros ( Chapter A Travel drive ) Oil change gearbox The first oil change should take place after around 200 operating hours. All subsequent oil changes should be carried out at intervals of 2000 operating hours or once a year, Remark: The gear oil must be drained when at service temperature. ‘The maximum permissible service temperature is 80°C. Changing the oil: = Place an oil catchment vessel under the oil drainage screw (1) (capacity at least 3.5 litres) ~ Unscrew the filler cap (2). = Unscrew the oil drainage screw and drain off the oil, Caution: — The oil temperature can be as high as 80°C | = Replace the oil drainage screw, at the same time replacing the sealing ring, - Fill up with new gear oil to the lower edge of the threaded hole for the oil filler cap. - Replace the oil filler cap, at the same time using anew sealing ring Sealing ring: Id. Nr. W8 006 172 (ie 02/99 ‘Workshop Replaces Issue: Manual EK 12 |S" 4 7 )maybe reprodiced inary fom oopraght Copyright protected No part ofthis manual reserved Sri WAGNER \ { Chapter A tenance Drive motor, m: General Maintenance work between major overhauls should consist of the following: - Cleaning - General visual inspection - Exchanging damaged parts - Checking the brush unit and commutator - Exchanging the carbon brushes (if necessary) This work should be carried out at least every 500 operating hours or once a quarter. We recommend having major motor overhauls carried out by a specially equipped ‘workshop, as special tools and specalized knowledge are required. Caution: Before carrying out any work on the motor, always first pull out the battery plug to avoid short circuits or injury. Cleaning: ~ Remove the sealing tape and take out the brushes, = Clean the motor thoroughly using compressed air (taking care not to breathe in any dust). = Clean soiled commutators and brush unit using a clean cloth (not cotton wool) moistened with benzene and dry well. Remark: Do not lft the brush springs more than is necessary and do not bend them to the side. Travel drive } Issue: 02/99 Replaces Issue: Workshop Manual EK 12 Sheet no. Ag(Chapter A Travel drive ) Drive motor, maintenance (contd.) Visual inspection, exchanging damaged parts: - Straighten or exchange dented sealing tapes - Check fan impellers for damage. Damaged fans (imbalance, reduced output) must be exchanged. = Clean the ventilation channels at the gear (1). To do this remove the drive motor and clean the channels using a vacuum cleaner (do not blow out dust). Soiling will serve to reduce air circulation, leading to increased temperatures in the motor and to possible destruction, ~ Check windings of the field and armature for signs of overloading (overheating): Dark coloration, brittle or bumed insulation, unsoldered commutators. Motors bearing this kind of damage must be ‘exchanged without delay. Ifyou discover oil or grease in the motor (usually an oil paste, oil vapour mixed with dust and carbon abrasions), investigate the cause immediately and remedy. The motor must be cleaned extremely thoroughly. 3 H BB a reserved Remark: Rapid carbon brush or commutator wear is generally due to the effect of oil. The oil/grease bums in the brush sparks, leaving a sharpedged oil ash which has an abrasive effect. This can tend to lead to inadmissibly high levels of carbon brush wear before the scheduled maintenance dates. Tesue: 02708 Wrkshoo Sheet no, Manual” EK 12 Ag) Replaces Issue:{ Chapter A Travel drive } Drive motor, maintenance (Contd.) Checking the brush unit, changing the carbon brushes: After cleaning the brush unit, it should be possible lo easily move the brushes in their guides when the Carbon brushes spring is lifted. Id Nr. W8 400 688 If one or more of the brushes jain, they must not be sanded down with emery paper. Length new: 40 mm Exchange at length 20 mm, In this case, the entire brush unit must be exchanged, as itis possible that the brushes have been thermally overloaded. The brushes must also not be broken or bent at the running edges. Remarks: - Always exchange the entire brush set, basing your assessment on the shortest brush. tmay'be reprocieed in sy form, copyright reserved Copyright protected. No pat of his manual Only use original epare carbone (observe spare parts list!) - Do not allow the brushes to drop onto the springs when mounting. - Ifthe minimum length has not quite been reached, exchange anyway, as the remaining running time is probably shorter than the next maintenance interval. # re is - Amaximum of 3 consecutive brush sets should be exchanged before carrying out a general overhaul of the motor (by a specialized workshop). issue: 02199 Workshop ‘Sheet no. places Issue: Manual” EK 12 A10 )fom, copyeght s Copytight potted. No pert ofthis manual reproseesdin MY inden (Chapter A Travel drive | Drive motor, maintenance (Contd.) Commutator: The running surface of the commutator should be ‘even and smooth with a grey-black appearance. The commutator must not be worn, fluted or out of round. Should one of the above phenomena occur, the commutator must be reworked (major overhaul). Never attempt to achieve the necessary finish using afile, emery paper or similar. Bearing: The ball bearings need not be relubricated. The grease filling is sufficent for the maintenance periods between major overhauls. The bearings must be renewed: = onevery major overhaul, ~ after a maximum running period of 2000 h ~ with minimal use, after five yeare at the latest. Only use the bearings stipulated in the spare parts lists. Remark on the danger of overloading with ‘discharged batteries: If the motor speed drops noticeably, interrupt work immediately and check the battery. Recharge if necessary. Never drive at insufficient voltage! iso @2 tage EK 12 [Att ) Replaces Issue: Manual‘may be eproded in ay form soph Copyright protected. No pat ofthis manual reserved. MY indica ( Chapter A Specifications, drive motor Id. Nr. W8 002 874 Travel drive } Type GF 116-14/4.8 Motor type Series-wound motor Voltage W) 48 Current (A) 108 Max.current input (A) travel 275 Output (KW) 42 Speed (min “!) 2000 Protection class P24 Insulation class BF Issue: 02/89 Replaces Issue: Manual Workshon EK 49 | Sheet. A 4D ){| Chapter B __ Steering system ) Inhalt ‘Sheet no. Block diagram of electrical steering system ( W96 ) B2 Block diagram electronic steering controller W986. Description of steering controller .. Pin assignment for steering controller/steering output stage... Main current connections for steering controller/steering output stage Service switch for steering controller/steering output stage W96.... Adjusting steering controller W95/W96... Setpoint generator with steering button (1 gear) . Setpoint generator with steering wheel (5 gear) Actual value potentiometer... Servo unit Steering chain. MY xSten oF Workshop Sheet no, Fopices sue: ign EK12 B1 »)Chapter B Steering system ) Block diagram of electrical steering system Option Wheel position display “~s 0000} EKB1 C \ ‘YO 2 Fy ks Psi nc Ui OAS Operating console aene Copyright protected, No part ofthis manual sey oerephctin eyo Cop MY iranian Main cortacior-K1 Steering motor pontacior “3k eaaran f] Steering eror relay *) -3ks Servo unit EKBI 48 oe Actual value e] | «Ke G Brake relay ¥ a nome Issue: 02/99 Workshop Sheet no, ~) Replaces Issue: Manual Ek12 B2‘maybe reproduced inary form, Copyright Copyright protected. No part offs manual reserved, MY ancien {| Chapter B Block diagram of electronic steering controller W 96 Type 1 Id.Nr.: W8 407 261 Steering system ) poner ib ak {eee oe ee chee feel agin ys “Gast 1°} peagage or snot See ie [see 5° Output 8 Steering error control current Output +424 V steering OK Steering system } 9 Safety relay enable Output 10 2+24V Input 11 Option (signal carbon 24V) Output 12 Actual value > 2° right Output 13 Actual value » 2° fot Output 14 7.5 V reference Test output Terminal X2 1 Actual val. +15 V (w/o load) Output Actual val, =12.2 V (w. load) (Power supply) 2 Actual value 7.5V+2.7V Input 3 Aetual value OV (We load) Output Actual val. =1.3 V (with load)(Power supply) 4 Ovolts Screening Terminal X3 1 Setpoint +15 V (w/o load) Output “14.4 (mit Last) (Power supply) 2 Setpoint (ca. 1.1-10.6V) Input 3 Setpoint 0 V (w/o load) Output = 0.6 V (with load) (Power supply) 4 5 Ovolts Screening 8 Steenng straight on Output Continued on sheet no. B8 issue 09780 Workshon Sheet [_ Replaces issue: Manual EK12 B7‘ray be reproduced in ny form. Copyright aoned. ‘opyriht protected. No pat of his manual ae dz srr Wac! / ( Chapter B Steering system ) Continued from sheet no. B7 Steering output stage for inductive automatic steering (LR 80 ) Steering output stage W96 Type 3, Id. no. W9 407 259 Steering output stage W95 Type 6 -1, Id. no. Wo 406 498 Pin assignment Remark: Occupied only with inductive automatic steering ( LR 80 ) or with signal carbon. Terminal X4 (only LR 80 or with signal carbon) 1 7.5 V reference Test output 2 Pulse (LR 80) inverted Input 3. Right (LR 80) inverted Input 4 left (LR 80) inverted Input 5 Transm. enable (LR 80) inv. Input 6 Transm. output Output 7 Signal carbon brush 1 + Input 8 Signal carbon brush 2 + Input Issue: 02/08 Workshop Feplaces Issue: Manual EK12at # te is a ( Chapter B Steering system } Steering controller / output stage W96 Type 1 Id. no.: 407 261 Type 3 (LR 80) Id. no.: 407 259 Main current connections (1) 24-48 volt supply via contactor 34 2) Steering motor field connection (left) 8) Steering motor field connection (right) (4) O volts Issue: 02/99 Replaces Issue: Workshop Manual EK12 Sheet no. Bg )recucedin any form. Copyright Copyright potted. No part of his manual reserved mayor Jt az MY xe (Chapter B _ Steering controller W96 Type 1 Steering output stage W96 Type 3 Adjusting the service switch The service switch (1) can be used to limit the maximum power of the steering controller (the steering speed) by reducing the current. As a result of this power reduction, sudden approach to the mechanical end stop is prevented (could cause chain to break!) in the event that an error ocours in the steering system or there is an incorrect setting (reverse voltage at the setpoint potentiometer or the steering controlier). This service switch must be used during commissioning and adjustment work. (see table below). Note: The service switch is not a continuous switch and can only be switched between positions 0 to F and back again. Forcing the switch over tho stop between F and 0 will damage it! The switch positions for normal operation and commissioning work are different for different vehicle models. For this reason, itis important to follow the information in the appropriate tables. Service switch positions: Steering system } Steering | Steering wheel | button Setpoint potentiom. | S-gear_| I-gear_| Current Normal operation 1 5 max. Reduction 8 c 30% Reduction 9 D___| 40% Reduction A E 50% Reduction B F 60% Aller commissioning or adjustinent work the normal ‘operating position must be set again. Issue: 02/99 Replaces Issue: Workshop Manual EK12(Chapter B Steering system ) Steering controller W96 Adjustment 1. Tum off the vehicle (key-operated switch / ‘emergency-off), jack it up safely (drive wheel free) and secure it to prevent it from rolling away. 2. Check all the connections at the potentiometers for actual value and setpoint. 3. Check alll the connections at the steering motor and steering controller. 4, Check the steering mechanism and chain tension. 5. Service switch (4) - adjustment: ‘Steering button (centre detent): F (limited to 60 %) Steering wheel (no deten’): _B (limited to 60 %) . Tum the trimmers for the setpoint (actual value offset (1/2) into the centre position. For this purpose: Turn the potentiometer clockwise until it reaches ‘a stop (clicking is the stop), Than turn the potentiometer anti-clockwise unti it reaches a stop. Count the number of turns. Tum back clockwise for half this number of tus. If you cannot hear a click, turn the trimmer 20 times in any direction. For the centre position, turn the trimmer 10 tums back in the opposite direction. z i & gi maybe roprocucedin sry 2 reserved. Tum the trimmer for steering angle limitation (3) clockwise until it reaches a stop. Issue: 02/99 Worksho ‘Sheet no, Fee iia” EK12 Bit)(Chapter B Steering system } Steering controller W96 Adjustment Continued 7. Check the basic setting of the steering button setpoint potentiometer with centre detent (see sheet no. B15,16,17). 8. Check the basic setting of the steering wheel setpoint potentiometer (see sheet no. B19). 9. Check the basic setting of the actual value potentiometer (see sheet no. B20, B21) ae 2% — 10. Actuate the straight-on input X1.4 (1) with 24 V B or actuate the rail switch. ef 32 11. Switch on the vehicle and actuate the dead- i man's switch, 55, Remark: Ifthe drive wheel moves automatically on as far as the mechanical end stop, the 828 connections at the steering motor, steering controller or actual value potentiometer are wrongly connected. Check! 12, Tum the steering wheel until the steering looks. ue 2-handed operation is necessary. The steering = head must be in the detent and the steering = wheel must be in the electrical centre kg (see sheet no. B16). e Tesue: 02/09 Workshop EKi2 |" B42 ) Replaces Issue: Manual(Chapter B Electronic steering controller Adjustment Continued Steering system ) 13. B ee Bo 14, SE Br aH 1s 16. . Actuate the deadman's switch. The drive wheel Ifthe drive wheel is not now in the straight-on position, the actual value potentiometer must be adjusted. To do this, loosen the straps slightly and tum the potentiometer carefully until the drive wheel reaches the straight-on position and the green light goes on on the operating console. Secure the potentiometer mechanically again. The drive wheel moves during this adjustment work! Note: Check that the steering button or wheel is in the straight-on position. Setpoint specification 7.5V measured at test point X3:2 (3) against OV battery. Release the deadman's switch Remove 24 V from the straight-on input. ‘must not move. If it does, tum the "Setpoint offset" trimmer (2) until the drive wheel stops moving when the signal is removed from the straight-on input. Check the straight-on position of the drive wheel again. To do this, connect 24 V to the straight-on input (rail switch X1.4) and actuate the steering lock by tuming the steering wheel. If the drive wheel is not now in the straight-on position, the "Actual value offset trimmer (1) can be used to move the drive wheel into the straight-on position, Replaces Issue: o2ine Workshop Manual EK12 Sheet no. B13 )ey eo obroswesd in any torn. Copyright opytiht protected: No part of ia manual ened Je az 1 SNE! MY xe { Chapter B Electronic steering controller Adjustment Continued 17. Move the service switch (1) into the operating position: (see sheet nos. 810) 18. Actuate the deadman's switch and tum it carefully to move the drive wheel to the maximum steering angle. This must be 90° to both sides. The drive wheel must not hit the mechanical steering stop. 19. The "Steering angle" trimmer (2) (see sheet B3) can now be used for fine adjustment of the 90° steering angle (turning it clockwise makes the steering angle smaller) This must be carried out with both steering angles (right/eft) Do not set the steering angle too large! The drive must not hit the mechanical end stop. 20. To test the maximum steering angle, make a steering movement from max. right to max. left and back again. The drive must not hit the me- chanical end stop. 21. Finally check the entire steering function again and readjust with the trimmers if necessary. Note: Itis particularly important to ensure that straight-on travel with simulated rail travel (connect 24 V to straight-on input) is correct There should only be a minimal deviation (appr. 0.5 m) from straight-on travel over an extended stretch (approx. 10m) . If necessary, adjust with the “actual valve offset" trimmer (3). Tssue: 02/00 Workshop Replaces Issue: Manual Steering system ) i) i x [ey "8 ooo [EEE 8 EKi2 |" B14)maybe reproduced inary form. Copan Copyright prctected. No prt of his manual reserved MY Doren {| Chapter B Steering system Steering button setpoint generator {centre detent and 1-gear potentiometer) Id. no. W8 346 727 Basic setting Basic setting is necessary when the mechanical connection between the potentiometer (2) and the steering head shaft (1) has been disconnected, e.g to replace the potentiometer. Note: Pull out the battery plug Remove connector X3 of the setpoint potentiometer from the steering controller. 1. Remove the operating console, 2. Move the steering button (4) to the centre detent and adjust the centre position of the setpoint potentiometer (2) as follows. 3, Unscrew the threaded pin (1, AF 1.5) of the coupling, turn the potentiometer shaft (3) (with pointed pliers), until the specified measured values are reached. -—-@)--5 i i Test points | t — | ei | Total resistance approx. 5k2 1-3 | I Partial resist. approx. 2.5kQ. 1-2 an r a Partial resist. approx. 2.5k@2 2-3 @ e Nach Anziehen des Gewindestifts ist mit ange- schlossenem @-Meter zu priifen, ob sich der Wi- derstandswert von der Mitte aus nach links und. se nach rechts gleichmaBig um ca. 2k andert. 4. The trimmers | und Il (5) must be set symetrically ~~] to 1,2kQ. Test points Trimmer! approx. 1,2kQ X3.3-1 Trimmer Il approx. 1,2kQ 3-X3.1 issue: Workshop ‘Sheet no, Raplaces issue Manual EK12 B15 ){| Chapter B Steering system } Steering button setpoint generator (Centre detent and 1-gear potentiometer) Id. no. W8 346 727 Basic setting, live The basic setting described on sheet no. B15 can also be carried out live. Note: When carrying out work with the system live, ensure that you do not cause a short-circuit with a test prod or screwdriver. B ae 26 i] aco was So Hi ov 1 af Eby es z Test points Resistance Voltage an Setpoint potentiometer 13 ca. 5.0kQ | ca. 10.6V Trimmer | * 3.3 1 ca. 1.2kQ | ca. 1.75 V Trimmer I = 334 ca. 1.2kQ | ca. 1.75V Setpoint potentiometer 33° 3.2 ca. 3.7kQ| ca. 7.1V centre position (3.2) 8.1) (ca. 3.7 ki) | (ca._/.1.V) ‘Setpoint potentiometer 33° 3.2 ca. 23V de |Lofttun az ‘Setpoint potentiometer 33 32 ca. 1,9V Bo Right tun. ne ‘Setpoint lift 33 32 ca. 24.8V Replaces Issue: Manual (am 03/98 ‘Workshop EKi2 [= B46 )ht protected. No pat of i reprodotin sty om Cony MY ainda ( Chapter B Steering system ) Steering button setpoint generator (Centre detent and 1-gear potentiometer) Id. no. W8 346 727 Basic setting, mechanical 1. Adjusting retaining force of the centre detent ‘Screw the spring pressure piece (1) in or out and secure with the lock nut (2). The retaining force is set correctly when a precise centre position is maintained by the spring-loaded ball (3) but no pressure is. ee exerted on the shaft. Remark: To ease the movement, squeeze a little grease into the threaded hole. 2. Adjusting the steering resistance The adjusting screw (4) presses with disc springs (5) on a plastic bush (6) which sur- rounds the steering button shaft. This causes a slight steering resistance which is intended to prevent the steering button moving by itself Turning clockwise increases the pressure. The screw does not have to be secured. 3. Checking the maximum deflection The turning movement is limited mechanically by adjustable stops. The stops do not usually need to be adjusted. If, however, the maximum steering angles which can be reached (approx. 270°) at the gear are not adequate, despite adjustment at the steering controller and adjustment of the trimmers in the operating console, it may be necessary to alter the mechanical stops. Tes 00190 Workshop Replaces Issue Manual EKi2 Sheet. 47 ){ Chapter B Steering system } Setpoint generator with centre detent Id, no. W8 346 727 Removal Note: Pull out the battery plug 1. Remove the operating console. 2. Pullup the rotary handle (6) and unscrew the 3 hexagon socket screws (7, SW 3) 3. Pull off the 3 board connectors (8) and remove the Setpoint generator. pyro Removing the setpoint potentiometer Id. no. W8 002 858 1. Unsolder the potentiometer connections (9). For assignment see the relevant wiring diagram for the vehicle. Release the threaded pin (10, hexagon socket screw AF 1.5) the coupling and the nut (11, AF 12) on the potentiometer (12). 5 3 ‘eeved np 3. Remove the potentiometer. Installation To install the potentiometer, follow the above instructions for removal in reverse order. Remark: The setpoint potentiometer must be set to "Centre" after installation (see sheel nus. B15-17). Tseue: 02/00 Workshop hhh Replaces Issue: Manual‘may be reproduced inary form. Copyeght Copyright prosacted. No pat of his manual ‘ecorved MY Dixons { Chapter B Setpoint generator with steering wheel (5 gear ) Id. no. W8 373 585 Basic setting Remark: A steering wheel can be installed as an optional extra (potentiometer with 5 revo lutions). The table on pages B10 for switching the service switch must be observed. This setpoint generator covers a range of approx. 1800° from end stop to end stops (safety slipping coupling, 5). ‘No mechanical adjustment is required, since there is no centre detent! Installation and removal are carried out by the same method as for the setpoint generator with a centre detent. Steering wheel 100 mm diameter (1) Id. no. W8 413 150 Adjusting spring (2) Id. no. W8 005 904 Steering wheel 160 mm diameter (3) Id. no. W8 414 947, Handle (4) Id. no. W8 411 352 Safety slipping coupling (5) _ Id. no. W8 001 802 Potentiometer (6) Id. no. W8 002 831 (6 gear) Potentiometer (7) Id. no. W8 406 814 (7 gear) Remark: Before the steering controller is set the setpoint generator must be set to the electrical centre Steering system } x g SH < Issue: 02/89 Workshop Replaces Issue: ‘Manual EK12Sr WAGNER { Chapter B : Actual value potentiometers Id. no. W8 005 127 Basic setting The steering transmission (1) gears down (i = 4.17) the revolutions of the steering motor (2). As a result, the turing angle of the actual value potentiometers (3) Is approximately the same as the turning angle of the steered wheel (drive). The voltage signal influenced by the actual value potentiometer is sent to the steering controller X2:2 as a response from the the steering angle (see sheet nos. B2,3). In order to prevent the drive hitting the end stop during subsequent adjustment of the steering controller (the chain might break), a basic setting of the actual value potentiometer is carried out: 1. Jack the vehicle up safely on both sides 2. Move the travel drive to the straight-on position and pull out the battery plug. Check the installation position of the actual value potentiometer (3, Fig. 2). The connections should be made as shown in Fig. 2 (4), centrally between the straps (6). 4. Pull the block connector X2 off the steering controller. Connect an ohmmeter at block connectors X2.1 and X2.3, measure and note the total resistance Root Measured value = Ro, (total resistance) (see Fig. 3). 6. Connect an ohmmeter at block connectors X 2.1 and X 2.2 (see Fig. 3). The resistance value should be half the total resistance. If this is not the case, carry out point 7. Steering system } allan FS Rt Re Steering controller Fig. 3 Riot = R1+R2+RS. Riot = 1.5K. 1,50 +1040. Mot ~ 68: 19K0, Ngggl2 = c0. 6.5K Issue: 02/99 Workshop Replaces Issue: Manual EK12 |" B90 ){ Chapter B Steering system ) Actual value potentiometer Id. no. W8 005 127 Basic setting Continued 7. Release the hexagon sorew (6, SW 7). The toothed wheels (7) and (8) can now be rotated and therefore the actual value potentiometer (3) adjusted. 8. Turn the toothed wheel (8) until half the total resistance is measured at the actual value potentiometer. 9. Tighten the hexagon screw (6), ensuring that the actual value potentiometer is in the centre position (display on measuring device). 10. Lower the vehicle, insert the battery plug and check that the steering functions correctly, adjust if necessary. coveted No part this manual rocucedin any om Copyrat Copyright ‘carved MY isn Replaces Issue: Manual (ee 02/99 ‘Workshop EK12 |S" B94 ){| Chapter B Actual value potentiometer gear Id, Nr. W8 361 719 Removal Caution: Pull out the battery plug 1. Fold back and pull out the angled joint lock (1) (wire spring). 2. _ Lift the ball cup (2) (you will feel a slight Steering system ) resistance). 3. Unscrew the bolt (3) (AF 19) on the ee atmature shaft of the servo unit 28 Ae HZ 4. Remove the actual value potentiometer Pein = coat 5 | Installation 3. F $38 §2)) To install the actual value potentiometer gear, | follow the removal nsttuctons in reverse O1der Th Note: Ater installation, the steering lock and the straight-on position must be reset - EKi2 |= B20 ) Issue: 02/99 Workshop Replaces Issue: ‘Manual(Chapter B Steering system ) Actual value potentiometer gear 1=4.17 Id. Nr. W8 361 719 Dismantling Toothed belt: Id. no. W8 003 140 Potentiometer: Id. no. W8 005 127 Protective stopper: Id. no. We 413 702 Toothed wheel (6): Id. no. W8 410 148 8 1. Unscew the toothed belt tensioning screw (1) and remove the tensioning roll (2). 3g R 2. Release both threaded pins (3). ge 3. Remove the hexagon screw (4, SW 7) and PS remove both toothed wheels (5, 6) with was- a her (7) and toothed belt (8). u Note: The toothed wheel (6) may "stick". a Do not try to remove them by force, aS otherwise the toothed wheels may 8H be damaged. 3.1 Remove the circlip (9). 3.2. Push the bolt (10) down and out with the ball bearing (11). de JZ 3.3. Clamp the bolt (10) in a vice and pull off the 10 fe toothed wheel (6). < M3 3.4 Replace the toothed wheel (6). | Id. no. W8 410 148 8 Issue: 02/99 ‘Workshop EKi2 [SB og Reoplaces issue: Manualtrayloe reproduced in any form, Copyright Copyright reacted. No part this manual reserved Jt az MY Bix {| Chapter B Actual value poteniometer gear 1=4.17 Id. Ne. W8 361 719 Continued Dismantling 4, Remove the circlip (1) and pull off the ball bearing (2) with a puller device. 5. Release the 2 screws (3) and remove the potentiometer (4) by pressing on the axle (5) from below. 6. Release the 2 threaded pins (6) and remove the potentiometer (4) 7. Remove the circlip (7) and push out the ball bearing (8). Assembly To assemble the actual value potentiometer gear, follow the dismantling instructions in reverse order. Remark: — When tightening the fastening screw of the toothed belt tensioning roll (9) ensure that the roll can stil be turned easily. Secure the screw and threaded pins with Loctite. Steering system } > amp Issue: 02/99 Workshop Replaces Issue: Manual EK12 Sheetre. BOA )‘may be proceed inary form Copyright reserved Copyright protected. No part ofthis manual MY Grane {| Chapter B Servo unit Id. Nr. W8 413 804 General The servo unit consists of: = @48V direct current motor (1) with two separate series field windings (split field motor) - therefore it is possible to reverse the polarity for clockwise and anti-clockwise rotation. = a flange-mounted gear (2) Remark: The gearis maintenance-free. The servo unit is controlled by the electronic steering controller / steering output stage. Note: Series-wound motors must never be left without a load for an extended peri- od of time, i.e. they must not be run wi- thout gears ete. If they are lett in this way, their speed increases independently until they become irrepairably damaged. Adjusting spring ce 1 & @ | _ monitor 6-4 | oes. | oga ‘Signal carbon oa Issue: 02/99 ‘Workshop Replaces Issue: Manual EK12 Sheet no. oa B25.){ Chapter B Steering system } Servo unit Id. Nr. W8 413 804 Terminal board Designation at the motor AI “Armature winding D1/Dr Field winding right b2/DI Field winding left Technical data for servo unit Copyright protected. No part ofthis manual ‘may be reprodsced in rh tonh Copyright Model designation Circuit diagram Excitation type Series circuit Temperature Signal carbon Voltage 48V monitor brush E Current 11A ol Dr © Rated output 150 W Direction of rotation rechts/links Protection / insulation class JP 20/F Gear 18:1 {k 02/99 Workshop ‘Sheet rane | NenaggeEK 12/6 |e) 26 Replaces Issue:Chapter B Steering system } Servo unit Id. no. W8 416 142 Removal Caution: Pull out the battery plug The following is necessary to remove the servo unit Remove the steering chain (1) (see sheet B29). Remove the actual value potentiometer gear (2) (see sheet B24). 3. Pull off the chain wheel (3). Chain wheel Id. no. W8 416 761 Check the adjusting spring (4) is securely seated on the armature shaft for reinstallation, Adjusting spring Id. no. W8 003 675 Disconnect the motor connection cable (5), check the labelling and mark if necessary. 5. Unscrew the 4 fastening screws (6, hexagon socket screw, key size 5) of the servo unit and remove from the bottom. 6. Lift the servo unit (7) up and off. ae dz Be 8 \ Installation To reinstall the servo unit, following the removal instructions in reverse order. 1 \ Ray 2 ae 7 3 a er 6 Note: After installation, the steering lock and the straight-on position must be reset. Issue: 02/99 Workshop Replaces Issue: Manual EK12 Srestn. B 27 |( Chapter B Servo unit Id. Nr. W8 413 804 Replacing the carbon brushes Detailed information on this subject is provided in the instruction for the travel motor. 2 carbon brushes are to be built into the servo unit. 2 Stok. (1): Id. Nr. W8 402.302 Length of a new carbon brush: 22 mm #8 Change when residual length is: 11 mm ee £5 Brush spring (2) Id. Nr. We 407 178 38 38 tension spring is used to fix the perforated u tensioning belt. EE Tension spring (4) Id. Nr. W8 417 155 bay SEE Steering system } Issue: 02/99 Workshop Replaces Issue: Manual EK12 Shesino. BOB)( Chapter B ; Steering system ) Steering chain Id. Nr. W8 345 562 Removal 1. Turn the gear to 90° by steering anti-clockwise 90° (chain tensioner (5) of the steering chain at front). Caution: Pull out the battery plug 2. Release the lock nut (1) and unscrew the ten- sioning screw (2). » Ramave the steering chain (3). Remove the tensioning pin (4) with a suitable tool (e.g. screw M5, lever out the washer with a lever rod) and mark the position. = eprossosd in ay fo. Copyight B 3 Note: ‘When removing, try to avoid exerting pressure on the chain. Copyright protected. No par ofthe manual ‘Remark: —_ Tensioning pin is used again when the chain is reinstalled! 5. Fold out the chain tensioner (5) and remove it from above. The chain tensioner is inserted about 10m deep in the chain guide band (7) on the gear with a pin (6). Remark: MY Gixdwen Issue: 02/99) Workshop EKi2 |S" B99 ) Replaces Issue:(Chapter B Steering system ) Steering chain Id. Nr. W8 345 562 Installation To install the chain, follow the removal instructions in reverse order. Note: Check the steering lock and straight- on position and readjust if necessary. Adjust the tension of the steering chain (3) with the tensioning screw (2) Remark: as 0 that the chain can be depressed eS about 1 cm at its longest point when gs slight pressure is exerted with the as z thumb. Be Secure with the lock nut (1). Ft u a SEs est 4 2 Py JEN Ds ZZ Jt az net re ins (ea 02/99 Workshop EKi2 |" B39 ) Replaces Issue:( Chapter C Contents Electromagnetic brake Removing the Brakes. Setting brake clearance Setting the brake delay... Copyright protected. No pat ofthis manual traybdvoprogucedin ay foam pyeght reserved MY Grows Braking System ) Issue: 02/99 Replaces Issue: EK12 |S" 4le az is 1 iS MT (Chapter C Braking System _) Electromagnetic brake Id. Nr. W8 416 416 Function The two-stage electromagnetic brake consists of two independent electromagnetic circuits. This is necessary to be able to adapt the braking force to the requirements of the vehicle. If the mast is extended, for example, the braking force has to be reduced so that deceleration is adapted to the reduced driving speed of the truck. Brake applied: In a de-energized state, the sets of springs of the primary stage (7) and secondary braking stage (8) press onto the anchor plate (1). This in turn, presses on the friction lining (2), which is now pressed between the motor housing (3) and the anchor plate (1), so blocking the drive system. Brake released: If current is passed through the two magnetic coils, these are magnetized and pull the anchor plate (1 ) and the bell (4) against the spring force of the primary and secondary brake stages. This releases the brake disc (2), and the motor can turn. If the braking force is reduced, part of the spring power is "switched off". This is achieved by switching off the brake booster 1U2 using limit switch 1823 (is activated when the cabin is over 8 mettes high). The secondary brake stage 1y3 is continuously energized and so its brake supporting action is cancelled. (Hibben ser” EK 12 c2 )may be roprod.oedin ary form Sopyrant Copyright protected. No part of his manual reserved MY Dorn ( Chapter C Braking System ) Removing the Brakes Id. Nr. W8 416 416 Removing the brakes - Turn the vehicle off. - Remove cable of the first and second magnet coil at the terminal. - Secure vehicle with blocks against moving. - Unscrew 3 mounting bolts (1) and remove the whole braking unit. The brake lining (2) can now be removed. Caution: The brakes will not work if the braking unit is removed. On uneven ground the vehicle could start moving. To prevent this from happening, secure the drive wheel with blocks before starting to remove the brakes. Brake lining: Id.no. W8 414 655 oe Lining thickness, new: = 13mm Replace when lining is 7mm thick. Replaces Issue: Manual Issue: 02/99) | Workshe ‘Sheet no. issue: | jorshon EK 42. C3 )(Chapter C Braking System ) Setting brake clearance Brake not energized (in braked state) Loosen the three fillister-head screws (1) (do not unscrew), ‘J Using the fork wrench, pull the adjusting sleeves (2) far enough in or out to create a clearance of 0.3 mm using the sensor gauge between the magnet element (3) and the an- chor plate (4). Thighten the three tilister-head screws (1) and measure the clearance again, adjust if n 22 necessary gs eE Note: Be 2 [fone of the three adjusting sleeves is adju- 3% sted, itis necessay to also adjust the others 42 soas to ensure that the distance between the base plate and the magnet element is even in every position. Setting the brake delay The brake delay for both braking stages is firmly prescribed and cannot be allered. re z Fe ns Replaces Issue: Manual (ee 02/99 Workshop EK 42 | Sheet". GQ Aprodced in sry fon, Copyright 2 a Copyright protected. No part ofthis manual ‘may oe MY Dens (Chapter M Electrical system ) Content Control board 1... Enable relay -1K35 .. Interface PCB -A8.... Fuses, terminals. Contactors Pulse control, general . Thyristors... Thyristor power block.... Diode: Capacitors. Strom-Istwert-Geber 1U1..... Drive pulse control, Control current circuit, Circuit board. Circuit board, Adjustment, Platine EKB 1. Hydrauliksteuerung Issue: 02/99 Workshop Sheet no. Replaces Issue: Manual EK12 M1Copyright prctcted. No prt of his manual Preduces inary form. Copyright ‘served may oe re MY ote Chapter M Electrical system } Control board A1 Id. Nr. We 402 903 'oNr “Fea | Joom.connt +40V, 108, W8.401 895 19 | |cont.curen. 2448 V, 3 A, W8 401 692 F4_| | Batery discharge incicatort0 Foe] [A tH24V, 3A W8401 892 es. Ih ie ; : | snl Fo Fl Fane ff HE? Aad Components 000s, 1. -1U12 Steverplatine —id.Nr. we004910 - F10 O\\or 2. -1C1 Kondensator Id.Nr. W8002 895 Fyg__| 7 3. Ladewandler Id.Nr. W8403 883 8 4. Luftspule Id.Nr. W8403 681 FS 5. -N_ Zentral-Minus Id.Nr. W8400 480 6. -1U1 Istwert-Geber Id.Nr. W8402 555 -1L2. 7. -AV1 Hauptthyristor Id.Nr. W8004 514 8. -1V4 Lésch- und Umiadetnyristor —Id.\r. We403 S67 9. -1K5 Freigaberelais Id.Nr. W8403 680 10. Feldfreilaufdiode Id.Nr. W8403 574 11. -1V5S. Ankerfrellaufdiode Id.Nr. W8403.353 yy 12. -K32 Hauptschitz Id.Nr. W8403 884 ee 43. “2K8 Pumpenschatz ld. Nr, W403 684 44. “TK11 Fahrrichtungs- schitz rickwarts —Id.Nr. W8403 884 -4K5—_| 15. -1K9_ Fahrtrichtungs- schiitz vorwarts Id.Nr. W8403 884 16. -F15 Sicherung Hydrau- A8—| likpumpe 200 A Id.Nr. W8006 386 17, -F10_Sicherung Lenkpumpe 35 A Id.Nr. W8006 418 48. -F5.Sicherung Fahrmotor 160 A Id.Nr. W8006 406 19. -A8 — Anpassungsplatine Fahrgeschwindigk. Id.Nr. W8405 212 20. -1K18 Freigabe Fahrmotor Id.Nr. W8403 884 om wro181 21. -3K4 Freigabe Lenkmotor Id.Nr. W8004 174 Ka] [D7 Issue; 02/09 Workshop Replaces Issue: tonal” EKI2 |" M2)Copyright protected. No pat ofthis manual ‘may be reprodiced in ary ont, Copy a az 1 (GNE! MBX (Chapter M Enable relay -1K5 Id.Nr. W8 403 680 Funktion Das Freigaberelais schaltet 2+24V auf das Schiitz 1K 18 ( Freigabe Fahrmotor ) bei ein- wandfreier Funktion der internen Sicherheits- schaltung auf der Fahrimpuls-Steuerplatine und Anwahl einer Fahrtrichtung. If the relay is defective or has not been triggered, the drive function is disabled. Terminals 8 ET z 8680 a Ohmic resistance: R = 2902 Remark: If the circuit is functioning correctly, the control board “drive switches a minus potential, i.e. the relay 1 KS must pick up. The relay 1K18 enable drive mo- tor must pick up too. Electrical system ) (Issue: 02/99 Replaces Issue’ Workshop Manual EK12_ | Steno M3‘Copyright protected. No pat ofthis manual ‘may be reprodiced inary for, Copy reserved. MY Drones (Chapter M Elect trical system ) Interface PCB A8 Id, Nr. W8 405 212 Functions 2 4.2m ‘Schalter Freigabe | schalter Fahren Sohionen Option ints Travel speed reduction The following four travel speeds can be addjusted at the trimmer. ee RS 2 Interface PCP a0 A 18 9 + Maximum speed (Vina,) ~ Half maximum speed (Vinay 1/2) LR80 speed (6.5 kph) = Positioning speed (2.5 kph) Precise setting of the speed takes place at trimmers RI - R4 (see sheet no. M6). The LED under the trimmer to be adjusted lights up. Voltage reduction for contactors The coil voltage of the main and steering contactor is reduced from 24 V to the holding voltage of appr. 16 V. This prevents excessive heating of the cotactor coil, which serves to increase its service life. is8 168178148 AUI2 [____Farimputssteverung Al as A2 C Issue: 02/99 Workshop Replaces Issue: Manual EK12 Shooto NA 43 5 é MY anes od tray'beroprocsesdin any fom. Copy Copyright protected. No part { Chapter M Electrical system Interface PCB A8 —_— Block diagram Sahar Setiogen Shame Rae ise tenia of sora 7 —{ | ~ Prete 8 180) Fahrsteuerung Interface PCB -A8& Pin assignment Y PIN 1 ov PIN 10 39-11 V Analogue output reduced 2 Input “Contactor steering pump ON™ 11 24V Voltage supply, PCB 3 ov 12 0Vor26V input AS, 4 Output "Contactor steering pump ON" with 0 V drive fock 5 ov 13 0Vor24V input AO 6 ov 4 — 7 Output "Main contactor EIN" 18 Or appr. 8.5 V input with extemal 8 10V reference voltage input travel speed reduction. Only with @ 0Vor26V input At ‘ucks pre dolivery date 5/93 Issue: 02/09 ‘Workshop Sheet no. Replaces Issue Manual” EK12 MSrocesdin ay fom. Copyaght to op ned ‘Copytight protected. No part his mara! we az 1 IGNE! MYX (Chapter M | Electrical system ) Interface PCB A8 Truth table for PLC bit pattern : 2 Uan cy Aero paageanry s} Travel inhibit 11 aula 5 aye aaa eaa'a Travel reductiont| of o| 1 |7,.4-10v Caagaine sete === 3 Travel reduction2} of] 1] 1/3,9-10v ie 8 fl aentes Travel reduction 3} 1 oO 1 | 3,9-10V z aS BEEES sassaseaa Travel reduction 4| 1] 14] 1 (a.9-74v Por O=0Vol, 1=+24 Volt waiig pa SEE Gea a fe Travel reduction 1 for 2.5 kph; Adjustable » | SeHeDg Fe using trimmer R1 ramen fe Lo tpesee GE eco Travel reduction 2 for Vmavo! Adjustable using trimmer R2. & 8 Travel reduction 3 for 6.5 kph; Adjustable 5 3 using trimmer R3. griine LED FEE i. [_|s Travel reduction 4 for Vinay. adjustment; ry fe Adjustable using trimmer R4. 7 If the trimmers are turned clockwise, the 7 speed increases, i.e. the voltage is reduced. s Meaning of LEDS : 23. Voltage supply for the main contactor - V25 Travel reduction 1 active culpa rate sok: V26 Travel reduction 2 active 'V24 Minus for the main contactor is es Yes Travel oaucton ase 32. Output transistor for the steering ravel reduction contactor is triggered. 29 Signal AQ available \V33_ Voltage supply for the steering 30. Signal A1 available contactor - output transistor OK. V31 Signal RS available 34 Minus for the steering contactor is disconnected. issue 02199 Workshop Sheet no. Scns ae tage? EK12 Mé )Copyright protected. No pat ofthis manual tray'bdreprocucedin sy form Copyeaht reserved MY andwen (Baugruppe M Electrical system } Interface PCB A& Setting the DIP switches DIP switch Meaning Switch position 1 AO Signal internal OFF 2 A1 Signal internal OFF 3 RS Signal internal OFF 4 Travel reduction ON 5 Travel reduction OFF 6 ‘Steering pump run-on ‘ON 7 Steering contactor coils - voltage 24/48 V OFF 8 Main contactor coils - voltage 24/48 V OFF ° ° Gen BEE Begesoe seesfes inne 0s omer Ac SS ON 7 a |e or ELLE ES aaa 12345678 I gee Pin assigment see M5 Issue: 02/99 Workshop: ‘Sheet no. Replaces Issue: Manel” EK12 M7 )ht protected. No pat! his manual procucod in ay for. Copyright e dl MY den { Chapter M Electrical system Electrical system Fuses, terminals Using the main current fuses, the following functions are safeguarded: 85 A steering motor Id. Nr. WB 006 418 200 AA hydraulic pump Id. Nr. WB 006 386 160 A drive motor Id. Nr. W8 006 406 Checking the fuses: If there is any uncertainty about the condition of a ileal fuse, it must be removed and tested with a conti- nuity tester or an ohmmeter. Continuity or 1-10 Ohm means: Fuse in order. nce in the mega-ohm, No continuity or res range meat Fuse defective, Tesusi 02/09 Workshop Sheet no, Replaces Issue Manual Eki2 Msnay be reproduced in any form. Copyright Copyright protected. No part his manual roeerved. MY etek ( Chapter M Electrical system } Contactors Id. no. W8 403 884 Components The housing (1) is made of impact-resistant plastic. The upper half of the housing accommodates 4 M8 studs embedded in the plastic. The two lower studs serve as terminals for the contact bridges of the armature by means of flexible links. ‘The contact screws are screwed into the upper studs with a tightening torque of 10 Nm, The lower half contains 4 boreholes: 2 holes for connection with the coil frame (2) and 2 holes for fixture of the contactor on the contol panel. Coil assembly The armature assembly, the flexible part of the contactor, consists of the core, the magnetic coil, the carrier plate and circuitry. The circuitry is made up of: Diode 1 N 4005 resistor 49 © (24 V). The cir cuitry serves to reduce induction voltage on switch-off Remark: Due to the permanently built-in diode (4), the terminals for plus and minus are defined, Incorrect polation will ead to a short circuit. Issuer 09/09 Replaces Issue: Workshop Manual EKi2 |" 1M)Copyright prosctad No prt this manu maybe reproducstin ay fom. Copyright reserved, we az MX { Chapter M Electrical system } Contd. Contactors Armature assembly The armature assembly, the flexible part of the contactor, is mounted between the contactor housing and the coil assembly. The armature assembly is made up of: - Plastic carrier - Armature plate - Contact bridges with contact screws - Flexible links - Contact springs + Tension springs The contact screws of the contactor housing and the armature assembly are identical. Tightening torque 10 Nm. Contactor clearance If correctly assembled, there must be a distance of between 1.8 and 3.2 mm between the contact bridge and the support arm when the contactor is energized, Contact pressure Contact pressure of the contactor when fully actuated: Setpoint 11-14 N per contact, relative to centre contact. Remar! The contact spring exercises a certain friction. The contact is therefore correctly adjusted if, when subjected to a load of 12 - 13 N, the contact does not close when moved slowly, but touches and remains closed if moved quickly. 18-3,2mm Issue: 02/99 Replaces Issue: Workshop Manual EK12 seniroM10_—+)‘may oo eprodicedin sry form, copmight ‘eared ‘Copysoht protected. No pat ol his manual MY Geen ( Chapter uM Electrical system Electrical system Contactors, rating plate The contactor rating plate is a label located on the coil f contactors have to be replaced complete, check the rated voltage of the spare part. Blowout magnets The blowout magnets are used in accordance with the current flow direction. ee The arrangement of blowout magnets must be adhered to without fail. -2K8 aKa |[ Ki Flow direction A - B = red Flow direction B - A = blue Issue: 02/99 ‘Workshop ‘Sheet no. Replaces ue: woisno> EK12 M11 )proictad, No par otis manual produced inary form, cop MY axdten ( Chapter M Pulse control, general The pulse control is a device for low-loss, infinite adjustment of battery-run industrial trucks. Functional characteristics: A thyristor (HT) is connected in the main circuit of the drive motor. If the thyristor receives an ignition pulse from the control board, it is energized and the motor circuit is closed. The motor starts running, The main thyristor is then turned off. This interrupts the circuit again and switches off the motor. The curront mako/broak operation happens at an extremely fast rate which does not allow the current to ever die down ‘completely. The motor output is influenced by altering the make/break time of the main thyristor. Cycle ratio and current profile The ratio of make to break time is called the cycle ratio. A short cycle ratio results in short make times and long break times. Electrical system } Travel direction contactor § pce JUL © o Maketbrak proton the main hy Current profs nthe motor te Ia i | ‘The ascertained current profile curve indicates the motor output. ive Workshop Sheet (enlces sue anal” EK12 M12 ){ Chapter M i Electrical system } Contd. Pulse control, general Setpoint value current, frequency characteristic With increasing setpoint value, the cycle ratio is altered from approximately zero to approximately one Cycle ratio ee ca, 0.97 B A g8 38 3 af BE U (Volt) ig ca. 0.08 Set value at BB eee nts dive switch z8 00 Hl a With increasing setpoint value, the pulse frequency is varied in accordance with the ae graphs below. dz = oe k q 250 uns . Frequency q (He) U (Volt) a Sel value at 45 6 7 8 8 chive switch Issue: 02/99 Workshop ‘Sheet no. ( ima EK12 M13) Replaces issue:nay be reproded in ay form, copyright Copyright rotated. No pat of his manual MY een { Chapter M | Electrical system ) Contd. Pulse control, general ‘cuit Primary current Functional principle Ignition process: 1. At the boginning of the ignition process, the capacitor K22 must be charged. This happens as a result of ignition of the gate turn-off thyristor n22. Current path: MS, m2, K22, n22, m23 2. The main thyristor n20 can now be ignited = the motor starts up. Atthe same time, the transload thyristor 1136 must be ignited, to permit the + charge of the K22 to flow to the other side. This transcharge process is supported by the charge transformer m28 (induction, transformer principle), The capacitor is now charged with the correct polarity (+ at anode n22). Transcharge path: K22, m22, n20, n36, m23. 8. Turm-off of the main thyristor n20 is effected by triggering the gate tum-off thyristor n22. The parallel connection of the main thyristor and the capacitor is now closed - the capacitor charge can now flow to the main thyristor, permitting turn-off In addition, the motor current is now redirected via the now briefly discharged capacitor K22, (No current flows for a short time via main thyristor n20). Issue: 02/09 Workshon EK 49 | Sheet no M14 ) Replaces issue: Manual( Chapter M Electrical system } Continued Pulse control, general Main current circuit Connections for travel pulse control 1U12 and adapter board A8 1V1: Main thyristor 140: Diodes for 1K5 32: Main contactor 1V2: Deletion thyristor 1LI1: Current actual value transducer 4KS: Enable relay 48: Recharging thyristor 1K9: Travel direction contactor, forwards 1V4: Freewheel diode 1K11 Travel direction contactor, reverse 1V5: Brake diode 2K8: Pump contactor Selpoint Travel enable & deceleration ‘may be roprod.eedin ary form Sopygnt I g i i & = s ig, 1012 Tal pus cont 3410 V travel setpoint 10V Reet. for |AB Adapter board potentiometer Foc fies? EKI2 [""M15_ )(Chapter M wcopyraht tray'be reprocusedin sy fom. Copyright protest, No roeenved at az MY ie Thyristors Function of drive and lift pulse control / thyristors Symbol: le Thyristors are semi-conductor components, and have two stable operating statuses: a high-resistance and low-resistance status. They possess the characteristics of switches. Switchover from high-resistance to low- resistance status can be controlled by a gate. A kK [le G= Gate (Stoueranschiua) Mode of operation A thyristor polarized in the triggered direction pulls out on the arrival of a sufficiently large and long-lasting control pulee to the low- resistance (conductive) status. Triggered direction of a thyristor: I-@ anr2 In the low-resistance status, the gate becomes ineffective, The normal thyristor cannot be switched back to the high-resistance (disabled) status with the aid of the gate. It remains in the low- resistance status until the current lax has dropped below a certain minimum value. This minimum current value is called the holding current ly. Remark: A thyristor which is in the low- resistance status remains low-resistance until there is a drop below the holding current. Electrical system } ©) ain thyristor Oo XY Transch thyistor fo) Gate tumn-off thyriator FI = Travel pulse control issue: 02/09 Workshop Replaces issue: Manual EK12 ("M16in any fom copyright CCopysoht protested. No part of i manual t a = at az MY { Chapter M | Electrical system } Contd. Thyristors a) Thyristor installation K. Disc-type thyristors are used as main thyristors and gate turn-off thyristors. 7 The drawing shows the three most commonly used a variants. a) Ceramic housing (BBC) b) Ceramic/metal housing (AEG) ¢) Plastic housing (AEG) The installation instructions apply to all types, as only when an even level of pressure is applied through the tension cap is reliable function achieved under full load. Installation instructions: - The contact surfaces of the cooling arrangement must be level in the areas where components meet, as well as free of foreign bodies or dust. - Contact surfaces must be painted with heat transfer paste. = Observe the installation direction. See the switch symbol on the cell (anode to heat sink). - The screws must be tightened alternately. - Tighten screws until the tension cap makes contact with the heat sink. Flexible link, cup spring and tension cap are riveted together and provided with each thyristor. = The transcharge thyristor n36 must be hand- tightened (4 Nm). The thread must be painted with heat transfer paste. Note Ali heat sinks are insulated by a ‘common hostafan foil and screwed onto the base plate. Under the gate tum-off thyristor cooling plate is an additional hostafan foil. To improve heat conduction, the heat sink and the cooling plate must be coated with a thin layer of heat transfer aaa paste before installation. (ee 02/99 Workshop EKi2 |S"°M 47 ) Replaces issue:tected No part ofthis manual coda arty form copyright MY een (Chapter M [_ Electrical system ) Thyristor power block Id, Nr. W8 403 567 General The thyristor power block is used on the control panel A1 with adapter card A8, and incorporates the gate turn-off and transcharge thyristor (n22 and n36). Remark: No conducting connection should exist between the individual terminal and the cooling surface (resistance measurement, Fig. 1). Terminals AK -K: Transcharge thyristor n36 AK-A: Tum-off thyristor n22 AK kK A 1 Gate transcharge thyristor a 2 Gate turn-off thyristor 1 ° ‘ssue: 02/88 a Workshop Sheet no. Foplaces issue: Manual” EK12 M18Copyright protected. No part ofthis mary ‘nay be proceed inary form cop ‘eeerved MY Gdn Chapter M Diodes Id. no. W8 403 353 Lift pulse control + Drive pulse control with AB Functional characteristics When the vehicle rolls without the driver activating the drive lever (e.g. braking, reversing, coasting), the motor is no longer driven by the vehicle control system, but by the kinetic energy of the vehicle, The drive motor now works as a generator which is generating an inductive voltage. This inductive voltage is opposed to the applied current, and so leads to uncontrolled deceleration of the vehicle. Diode blocks 1VS short circuit the induction voltage. This prevents the induction voltage from generating any further deceleration moment, and the motor coasts to rest freely. The “field free-wheeling diode" n24 additionally supports the reversing operation. Layout, installation The two power diodes Diodeblocks 1V5 are identical in design. Electrical system } 1V5 A Bocas ° -1V5, They must both be installed with a rated “V4 tightening torque of 15 Nm. In addition, paint the thread with heat transfer paste. ovens Remark: When installing a power diode on the heat sink, ansuira that the contact surfaces of the diode are coated with heat transfer paste. _ Workshop Sheet no. Manual EK12 M19 Issuer 02/89 Replaces issue: