MBB PALFINGER Customer Service

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
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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
Serial Tag and product number
always on left side
Power packs and control units on
passenger 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
1300 or 1310 mm
in most cases
Available (mm):
600
700
800
900
1000
1100
Depending on model
Set up MBB standard tail lift
Cylinder
Lift cylinder
Tilt cylinder
Powered one way
Powered both ways
Set up MBB standard tail lift
Platform
Roll stops
Warning lights
Serial
Tag
Platform
cable
and
Sensor
Foot control
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.
2.
3.
4.
5.
6.
7.
8.
9.
Motor 12/24 V
Plastic tank
Hydraulic pump
Connector
S5 shiftvalve
Pressure relief valve
Shuttle valve
Restrictor valve R5
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 #
5.11
Lift cylinder
Cylinder
Tilt cylinder power both ways
Restrictor Valve
(R3 & R4)
Tilt cylinder
Restrictor Valve #
5.11
Tilt cylinder
Hydraulic
- Symbols
- Plans
- Routing
Hydraulik symbols in schematics
4/2 Valve S5
Motor with Pump
Pressure gauge
DBV Pressure relief
valve
2/2 Valve single
locking
Shuttle valve /
(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 liftand 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
2015796
B15
Platform
1332485
PC Board
K-Plus
2007193 Standard
programable
B13 liftarm
K-Plus & K1-Plus
1332476
PC Board
K1-Plus
2015340
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
-4
-1
- B13 -> Blue, Black, Brown
- B15 -> Brown, Blue, Black
-7
-5
-6
-4
Permanent Hot
Control Power
Ground
LED Signal
Signal f. Lights
lift
lower
Control power
Control Box J30
Valves J4
- 14 Tilt cylinder
- 15 Lift cylinder
Main Power J1
- 27 Power for processor
- 2 Permanent Hot
Ground
- 3 Motor Solenoid
- E Special input
- 12 Shift Valve
- E Special input
- 4 Control Power
- 5 lift
- 6 lower
-14 open
- 3 Close
- Ground
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
Liftarm
2014705
B16
Platform
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.
1 Control board in protected cap
2 CE Conformity
3
Foot control
4
Warning lights
5
Hand control
6
Wireless remote
7
Vorrangschaltung
8
Standard Control Box
9
Background light
10
Standard Cab switch
11
VEHH Code A
12
VEHH Code B (+ and - cable)
13
Batterie protection 12V/24V connector
14
Board programable
15
Diagnosis function
16
Aux lighting incl. activation
17
Load security (Software)
18
12V extra lead
20
Automatic ground tilt function
K basic ("Export control")
●
○
○ only withPos.2
○
○
○
●
●
○ only withPos.2
○ only withPos.2
○
○
○
Board can be delivered fully
sealed / protected
Notes
● Standard
○ Option
not available
K1 plus ("Compact control")
●
●
○
○
○
○
●
●
●
●
○
○
○
●
●
○
●
K plus ("Sensor control")
●
●
○
○
○
○
●
●
●
●
○
○
○
●
●
●
○
○
●
max 100W
Setup MBB Cab-cut-off-switch
optional
u
Bla
lue
B
/
Rot / Red
#2 Schwarz / Black
Blau / Blue
#4 SW /Blk
Yellow/Green
- Gelb/Grün
Weiß / White
Kontrollgerät / Cab Cut-Off Switch
#1 SW /Blk
J11
B13 switch belonging and setting
Color
Wires
Control
Part number
blue
2
H
70077183
green
3
H
1313006
red
3
K+H1
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.
~
same as purple
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
Lights on, LEDs
In cab switch on
GN
BR
+
-
GE WS
+
3 Types:
J41
Platform tilted
downwards
Max opening reached
Motor shut off
GN
BR
-
GE WS
+
Color
Wires
Control
Part number
purple
4
K1 Plus
2015796
black
3
Athlet (old)
1404176
yellow
5
K-Basic
2017442
How all B16-Switch function
B16
Purple
Brown
Yellow
White
Green
Brown
Yellow
White
Green
Brown
Closed
90°
1
1
1
1
1
1
-
0
1
0
-
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
-
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
-
0V
Ground
Platform
Blinksignal
* only if signal for
lift
Grey
Blue
Wire
1
=0
= =2
=
Black
12 or 24V
Yellow
1 only when switch for lift is activated
Black
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:
Commands from
the operator
Monitoring:
Cycle counters,
Software infos
Outputs:
Shows what is
activated
Sensor control:
Reports defective
sensors or wrong
conditions
Interface:
Communicating
and electrical
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
Fax
Online
standard
2% Fax rebate
3% eETK rebate
New customer
Registers online or via Fax formular
Order process
Create Job
(Service)
Packing List
(Warehouse)
Shipping List
(Shipping Dept)
Invoice
(Controlling)
Claim
Spare parts
shipment
Inhouse testing
Result
Inform Customer
Via telephone
Via formular
Invoice on hold
Warranty claim form
Return of claimed parts
Customer service
Quality control dept.
Accepted
Declined
Warranty Claim
Service Center
Availability:
Monday to Thursday
Freitag
7:30 am to 5:00 pm
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)
Dennis Meyer (Asst.)
Thomas Bröer
Sven Cronjäger
Andreas Kutzner
Andreas Lange
Andreas Löscher
Jesus Otero
Heike Schröder
Frank Tingelhoff
Marcel Kutzner
Tel +49 (0) 4221 853 355
Fax
+49 (0) 4221 87536
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