109
MBB PALFINGER Customer Service Training Class Hinz, Dec. 2010
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
KUZF / BDF
Tail lift program
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.
Characteristics of the K plus - line
Structure MBB standard tail lift
Overview with electric
1.4
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
Set up MBB standard tail lift
Mount frame
KTL coated
Power packs and control units on
passenger side Serial Tag and product number
always on left side
Valveblock and
hydraulic pipes
Set up MBB standard tail lift
Mount frame
Valveblock and
hydraulic pipes
Hole center to center on each
side indicates the arm length
Lift arm
KTL coated
Set up MBB standard tail lift
Pitch
1300 or 1310 mm
in most cases
Available (mm):
600
700
800
900
1000
1100
Depending on model
Cylinder
Lift cylinder Powered one way
Tilt cylinder Powered both ways
Set up MBB standard tail lift
Platform
Serial
Tag
Clevis
and Ground
roller
Platform
cable
and
Sensor
Roll stops
Foot control
Warning lights
Set up MBB standard tail lift
Pins, Bushings and restrictor valves
Pin diameter indicates lift capacity
Number on valve descripes the
fluidflow (l/min)
Set up MBB standard tail lift
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
Look for breather oil
cap before mounting
new lift.
Manual engaging of S5-Valve
Cylinder
- Design
- Restrictor valves
Set up Structure on a 4-Cylinder and retractable gate
Lift cylinder inside
Tilt cylinder outside
Lift frame
Cylinder
Lift cylinder – power one way
Tilt cylinder – power both ways
Cylinders
Cylinder
Liftcylinder – power one way
5.11
Restrictor Valve # Lift cylinder Lift cylinder
Restrictor Valve ( R1 & R2)
Cylinder
5.11
Tilt cylinder -
power both ways
Restrictor Valve # Tilt cylinder Tilt cylinder
Restrictor Valve
(R3 & R4)
Hydraulic
- Symbols
- Plans
- Routing
Hydraulik symbols in schematics
Motor with Pump
DBV Pressure relief
valve
Shuttle valve /
(Flow divider)
Restrictor valve
Pressure gauge
4/2 Valve S5
1.2
2/2 Valve single
locking
Open with Motor 3.2.1
Open with Motor
M+S3+S4
Blue:
Under pressure from
pump
Red:
Returning line
Open 3.2.2
Open
S3+S4
Lowering 3.2.3
Lowering
S1+S2+S5
Auto Ground tilt 3.2.4
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
Horizontal Levelling 3.2.5
Horizontal levelling
M+S5
Lift 3.2.6
Lift
M
Close 3.2.7
Close
M+S5
Hydraulic with stabilizer cylinder
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
/ S11
Out: M + S8
in: M + S7
Retractable KUZ
/ S11
Out: M + S8
in: M + S7
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
PC Board
K1-Plus
2015340
B16
Platform
2015796
B13 liftarm
K-Plus & K1-Plus
1332476
PC Board
K-Plus 2007193 Standard
programable
B15
Platform
1332485
(compared to K1-Plus)
Picture displays K-Plus setup
K1-Plus slightly different at J41
and has not all ports
K-Plus control board set up
Main Electric ports
Control Box J30 - 4 Control Power
- 5 lift
- 6 lower
-14 open
- 3 Close
- Ground
Platform cable J3 - 7 Signal f. Lights
- 5 lift
- 6 lower
- 4 Control power
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
Cab Switch J11 - 2 Permanent Hot
- 4 Control Power
- Ground
- 1 LED Signal
Sensor J41 - B13 -> Blue, Black, Brown
- B15 -> Brown, Blue, Black
Open function
Open (with Motor)
Only for 12V
Lowering function
Lowering (with Auto tilt)
Only for 12V
Lift function
Lift (with horizontal levelling)
Only for 12V
Close function
Close
Only for 12V
Sensor monitoring
Signal
Only for 12V
-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)
4.25
Slide out
4.26
Lower
4.27
Lowering with Ground tilt
4.25
Lift with Horizontal levelling
4.25
Slide in
-KUZF BDF
- most likely only in Germany
- Schematic from lowering on wheel as sample
(German)
S A M P L E D I A G R A M
-Basic Control
2 versions:
- with and without automatich ground tilt
- Openschematic as sample
B13
Liftarm
2014705
B16
Platform
2017442
K-Basic (with auto ground levelling)
Circuit board
K-Basic
2015213
Open (with Motor)
Lowering (with ground tilting)
Lift (with horizontal levelling)
Close
B13
Liftarm
70077183
Circuit Board
K-Basic
2015213
K-Basic (without auto ground levelling)
Open (with Motor)
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
Control systems in comparison
● Standard
○ Option
not available
Kontrollgerät / Cab Cut-Off Switch
Blau / Blue
Schwarz / Black
SW /Blk
Gelb/GrünYellow/Green
#2
#4
#1
-
Rot / Red
J11
SW /Blk
Blau / Blue
optional
Weiß / White
Setup MBB Cab-cut-off-switch
B13 switch belonging and setting
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.
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
~
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
Platform closed
Platform 15° open Lights on, LEDs In cab switch on
Platform tilted
downwards Max opening reached Motor shut off
GN BR GE WS
J41
GN BR GE WS
J41
GN BR GE WS
J41
+ - + +
+ - +
- +
Color Wires Control Part number
purple 4 K1 Plus 2015796
black 3 Athlet (old) 1404176
yellow 5 K-Basic 2017442
3 Types:
Wire
12 or 24V = 1
0V = 0
Ground = -
Blinksignal = 2
Bla
ck
Blu
e
Bro
wn
Yello
w
Wh
ite
Green
Bro
wn
Yello
w
Wh
ite
Green
Bro
wn
Grey
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 -
* only if signal forlift
B16
1 o
nly
wh
en
sw
itch
fo
r lif
t is
acti
vate
d
Yellow
Pla
tfo
rm
PurpleBlack
How all B16-Switch function
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
Quick diagnosis with service plug
6.12
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
-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
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
MBB Diagnosis-Software
User interface
Input:
Commands from
the operator
Outputs:
Shows what is
activated
Monitoring:
Cycle counters,
Software infos
Interface:
Communicating
and electrical
diagrams
Sensor control:
Reports defective
sensors or wrong
conditions
***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
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“
812345
* * * * * * * *
Spare parts via Serialnumber
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.
83305656 (Example)
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.
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
Enter the desired
quantity
List price as well as
your prices are shown
After selection move on to basket
Spare parts via Serialnumber
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)
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 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)
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
Lift cylinder
Tilt 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
