semi et remorques - chereau · 2016. 11. 17. · chereau sas zi le domaine – ducey – bp 700...

Maintenance manual

for isothermal rear roller shutter

Serial number:

To be kept in the truck's glove box

3

CHEREAU SAS

ZI le Domaine – DUCEY – BP 700

F-50307 AVRANCHES CEDEX

FRANCE

Phone: + 33 (0) 233 580 600

E-mail: [email protected]

www.chereau.com

Edition 2.0

All rights reserved. Any reproduction, translation or duplication, even partial, is prohibited without written consent.

mailto:[email protected]

http://www.chereau.com/

4

Contents Contents ........................................................................................................... 4 General ............................................................................................................. 5 Responsibilities ................................................................................................. 6 Product description........................................................................................... 7 Instructions for use ........................................................................................... 8 Protection in the event of an electrical breakdown ......................................... 12 Safety instructions .......................................................................................... 14 Hazardous areas ............................................................................................. 15 Maintenance Scheduling ................................................................................. 17 Special Operations .......................................................................................... 19

1) Checking the condition of the roller supports: .......................................... 19 2) Inspection and cleaning of slides: .............................................................. 20 3) Checking the presence of washers and spacers: ....................................... 21 4) Check on the level of the roller shutter assembly: .................................... 22 5) Checking that the panels are centred: ....................................................... 23 6) Check on the adjustment of the eccentrics: .............................................. 25 7) Check that all slide rivets and fixing screws are present: .......................... 26 8) Check the peripheral seals:........................................................................ 27 9) Check on the fixing of the handle and closure bolt: .................................. 28 10) Check on the balancer tension: ............................................................... 29 11) Checking the condition of the rear cap on an electric roller shutter

(frequency: 6 months): ................................................................................... 34 12) Inspection and cleaning of the rail control rod: ...................................... 37 13) Check on the state of the cable and spiral support:................................ 38 14) Checking the wear pads, pinions, bearings and Silentblocs: ................... 39 15) Checking the alignment of the drive connecting rods = motor slide /

shutter: ........................................................................................................... 43 16) Check on the air pressure: ...................................................................... 44 17) Check that the pneumatic circuit is completely sealed: .......................... 45 18) Replacing the seals on the pneumatic cylinder: ...................................... 47

Electrical Schematic ........................................................................................ 57 Trouble shooting assistance ............................................................................ 61 List of spare parts ........................................................................................... 65 List of emergency parts ................................................................................... 71 Appendices ..................................................................................................... 72 Notes ............................................................................................................ 73

5

General

The purpose of this manual is to familiarise you with the use of the isothermal rear roller shutter and explain its operation. Please read this manual carefully and in its entirety before using the product. It is essential that the operator knows how to manipulate and use the isothermal rear roller shutter correctly. Any conversion work on isothermal roller shutters supplied by us is prohibited. If, exceptionally, you wish to make modifications, never go ahead without first obtaining our prior written consent. Breakdowns are frequently caused by a lack of maintenance or incorrect use.

This manual must be permanently kept in the vehicle and must be read by every user or person working on the equipment.

When you order spare parts, we need the following information, which can be found on the body's front bulkhead:

Manufacturing number

Year of construction Repairs should only be made using original spare parts.

We reserve the right to make necessary modifications to any product without prior notice, as part of our continuous improvement policy.

Errors and omissions excepted. The information, diagrams and descriptions contained in this instruction manual do not provide any right of recourse.

We remind you that Chereau bodies are intended to be used by transport professionals, whose responsibility it is to ensure that conditions of use comply with current local legislation.

To maintain your isothermal roller shutter in good condition, it is essential that you comply with the maintenance instructions and frequencies given in this manual.

All maintenance operations must be carried out by qualified, authorised personnel.

If the shutter becomes difficult to use or stops working, it must be repaired immediately by a specialist.

6

Responsibilities

Chereau declines all liability in the event of damage caused by travelling with the isothermal roller shutter open.

Ensure that the roller shutter is properly closed before making any movement.

Moving while the door is open will cause serious damage to the various actuators (motors, rollers, etc.).

7

Product description

Bodies are available with a retractable roller shutter rear access which may be manually, electrically or pneumatically operated.

The shutter, comprising pultruded profile sections around an insulating polyurethane core, moves in two slides fitted to the inside face of the sides in a special rolling track.

The number of sections depends on the internal height.

There are three operating methods for the isothermal roller shutter:

"Manual", using a pre-calibrated cylindrical spring which balances the shutter, limiting the effort required to open and close it, with locking into a mortise via a handle in the lower section.

"Electro-pneumatic", assisted by a pneumatic cylinder in the roof of the body "pulling and pushing" the shutter, controlled by two controls fitted externally (under the body and on the rear frame post). Pneumatic pressure is provided by the truck or semi-trailer.

"Electrical", assisted by an electric motor in the roof of the body "pulling and pushing" the shutter, controlled by two controls fitted externally (under the body and on the rear frame post). The electrical motor may be disengaged for use in manual mode.

8

Instructions for use

The open and close controls are located by default in the rear overhang of the vehicle on the right, on the right of the rear frame and, as an option, inside the body. A minimum space must be left to allow the device to operate.

Electric isothermal roller shutters:

1- Ensure that the bolt is in the unlocked position.

Using the shutter in electrical mode with the bolt in the locked position could cause premature damage to the electrical and mechanical actuators. Any damage caused by a failure to follow this instruction will not be covered by warranty.

2- Provide electrical power to the product

3- Turn the key (1) to O?

4- Use buttons 2 and 3 to open and close the shutter.

5- The limit switch sensor indicators allow you to check that the limit switch sensors are operating correctly. In the event of a problem with one of the sensors, it is possible to actuate the shutter by simultaneously pressing on the maintenance plug (4) with the tip of a screwdriver and on the raise (2) and lower (3) buttons.

Figure 2: Unlocked position Figure 1: Locked position

9

Main control :

Control on rear frame post:

6- Movement is stopped by releasing the control. This function operates as a stop at the work station.

Before moving the vehicle, ensure that the isothermal roller shutter is completely closed.

Raise (2)

Lower (3)

Raise

Maintenance button (4)

Lower

Key (1)

Fuse (5)

Limit switch sensor indicators (6)

10

Pneumatic isothermal roller shutters:

1- Check the air pressure (minimum 7 bars) on the pressure gauge in the control box.

2- Provide electrical power to the product

3- Use buttons 2 et 3 to open or close the shutter:

→ Movements are made by maintaining pressure on one of the controls.

11

Control on the rear frame post and rear overhang on the right:

4- Movement is stopped by releasing the control. This function operates as a stop at the work station.

Before moving the vehicle, ensure that the isothermal roller shutter is completely closed.

Raise (2)

Lower (3)

12

Protection in the event of an electrical breakdown

Electric isothermal roller shutters:

Opening from the outside:

With the safety barrel unlocking key (3) supplied with the vehicle, you can uncouple the motor from the roller shutter, which can then be operated in manual mode.

Opening from inside the body:

1- Disengaging the shutter in manual mode: a- Raise the shutter to the top of its travel and open the black protection valve

on the motor:

Motor uncoupling barrel (7)

1

13

Push the clutch support from right to left, as shown in the photographs above (if you have difficulty releasing it, lower the shutter by a few mm to free it of any restriction).

b- Disengaging the motor

2- Switching to electrical mode:

Push the clutch support from left to right.

Position finale Initial position 2 3

14

Safety instructions

Careful !

Damage caused by a failure to follow these safety instructions will free the manufacturer from any liability.

To ensure the safety of the operator and any persons present, the shutter should only be used by qualified personnel, trained in its use, who are familiar with and understand the whole of this manual.

Any negligence could present a major threat to the safety of the operator and any third parties present.

Modifying the construction of the shutter or its safety devices in any way is prohibited.

The product manufacturer's liability and warranty will be void in the event of a failure to comply with the instructions for use and maintenance or if non-original spare parts or components are used to maintain or repair the shutter.

The operator must be at least 18 years of age.

The operator must wear suitable working clothing. He/she should, under no circumstances, wear loose clothing which could become caught in the shutter's moving parts.

He/she should wear safety shoes with steel toe caps and non-slip soles, and protective gloves.

Do not move the vehicle with the isothermal roller shutter open.

The shutter should not be used if the operator is intoxicated or his/her capacities are reduced in any way.

Protect the door from aggressive or paint stripping products.

Have inspection and maintenance work done in accordance with these instructions.

15

Hazardous areas

The operator should always retain a clear view of the shutter and the movement area.

Ensure that the door's movement area is always free of obstructions and that no one is in the way while the door is being operated.

The operator should always remain outside the movement area and clear of any moving parts. Always be aware of the potential risk of crushing or severing fingers, hands, feet and toes between the moving part and the sill.

DANGER !

Stay outside the shutter's movement area

Keep away from moving parts

Always pay attention to the risk of your hands, feet or head becoming trapped

DANGER:

Risk of damage

The shutter must not be used as an

anchor point.

DANGER:

Risk of crushing Do not put your

fingers between the final panel and the

sill.

DANGER:

Risk of falling If sliding or

jumping from the vehicle.

DANGER:

Risk of crushing

Stay outside the movement area.

16

The main danger area for the operator and any persons present is as follows:

Good operator positioning

Hazardous area

17

Maintenance Scheduling

The purpose of the following instructions is to assist you in carrying out the annual maintenance of isothermal roller shutters. Follow the step-by-step inspection points and mark them systematically.

- When doing any work, safety lock-out instructions must be followed:

o isolate (cut the electrical power) o lock out (make it impossible to accidentally re-apply power: labelling); o identify (cone off the work area);

o check that parts are not electrically live;

19

Close the shutter and inspect from the inside.

Check the condition of all roller supports.

Change them, if necessary.

280 Vérifier la planéité du plan de joint avec la custode

(Régler si pas plan)

Special Operations

1) Checking the condition of the roller supports:

Time required = 10 min. Tools required: None

Key:

: OK fitting, adjustment CORRECT

: NOK fitting, adjustment NOT CORRECT.

1

3 2

20

Open the shutter



1- Check all slides. If there has been an impact, straighten or change the slide (note: any damage to the slides will result in difficulties when opening or closing the shutter, which could cause serious damage to the drive system).

2- Clean the slides with a rag (do not use grease).

2) Inspection and cleaning of slides:

Time required = 15 min.

Tools required: None

1

1

2

21

- Open the shutter to carry out this inspection. 1

Check for the presence of spacer washers

3) Checking the presence of washers and spacers:



- For manual and electric shutters: 1- Check for the presence of spacer washers. 2- Check that the rollers are not binding. The rollers keep the shutter clear

of the slides.

1

3

2

22

Close the shutter to carry out this inspection.

Check for level between the last panel and the sill:

If they are parallel: OK

If they are not parallel: NOK. Check the adjustment on the balancer (see pages 20 to 24).

4) Check on the level of the roller shutter assembly:



1 1

3

2

23


Check that all the panels are centred in relation to the rear frame posts for their entire height:

- OK: between 0 and -5mm between the rear frame and the panel. - NOK if > 5mm between the rear frame and the panels.



5) Checking that the panels are centred:


Tools required: 1 Rule

1

1

3

2

24

- If NOK: check the rear frame (semi-trailer or rigid for level)

Take the dimensions below and send them to [email protected]

An impact may have caused distortion and that could cause major problems (rollers, Silentblocs, pinions, etc.).

3

mailto:[email protected]

25

Check on the adjustment of the eccentrics:

- The eccentrics allow the position of the rollers to be adjusted; their position is important for ensuring sufficient pressure by the panels on the peripheral seals, thus producing a perfect seal around the shutter.

1- Loosen the roller support fixing bolt. 2- Ensure that rollers rotate freely without binding and change them if necessary. 3- Position the eccentrics, ensuring that there is sufficient pressure from the panels on the

peripheral seals (too much pressure could make the shutter difficult to open). 4- Re-tighten the roller support fixing bolt.


6) Check on the adjustment of the eccentrics:


Tools required: 10 mm spanner

1

1

3 2

26

Open the shutter

1

1- Check that all assembly rivets on the vertical post and rail and on the left and right aluminium profiles are present. If a rivet is missing, fit a new one.

2- Check that all M6 x 25 screws are present.

7) Check that all slide rivets and fixing screws are present:



1

27

Open the shutter

The seal should not have come unstuck or be cut.

1- Check the condition of the lateral seals and the top and bottom seals on the shutter panels and change them, if necessary.

: The unit is only insulating if the seals are in good condition.

8) Check the peripheral seals:



1 1

3 2

28

Check that the closure handle and bolt are correctly fixed (secured by rivets).

Check that the pin is in place (for an electrical isothermal roller shutter only).

9) Check on the fixing of the handle and closure bolt:



Failure to comply with this instruction could result in serious losses.

1

1

2

29

10) Check on the balancer tension:


Check the position of the cables with the shutter closed:

Incorrect tension could result in difficulties when opening or closing the shutter.

Adjustment of the balancer (where the tension is not correct):

1- Open the shutter

2- This check must be done when the vehicle is level. Do at least two

complete open/close cycles.

3- Mechanically lock the door in the open position

4- Check the position of the socket head cap screws on part no. 1 below:

ADJUSTMENT OK

Check the position of the cables

The cables must form a V, so as not to overlap during rolling.

30

If the skt. hd. cap screws are accessible, go to point 6.

5- Take two 21 mm spanners.

6- Remove bracket no. 2 (13 mm spanner) and hold the shaft (see photograph no. 2) with two 21 mm spanners (be careful, danger).

Turn the shaft to access the skt. hd. cap screws:

Bracket no. 2 to be removed

Skt. hd. cap screws Part no. 1

Photograph no. 1

31

7- Adjusting the position of the drums

a- Loosen the two skt. hd. cap screws on part 1 below and, above

all, hold the spring with a 10 mm diameter rod.

Note: The rod must be pushed to the bottom of hole in the middle. If the rod is not positioned on the bottom of the stop, the spring could fly out (= danger).

b- Push part no. 1 a few cm to the right with a hammer.

Skt. hd. cap screw to loosen

Enfoncer une tige de maintien du

ressort

Part no. 1

Photograph no. 2

Enfoncer une tige de maintien du

ressort

Push in a rod to hold the

spring.

32

c- Re-tighten the two socket head cap screws and remove the rod

holding the spring.

d- If you removed the bracket: Replace the shaft in its original position and re-fit the bracket.

e- Close the door and open it again.

Door open: You should see that the cable is perpendicular to the door. If this is not the case, go back to point 6.a

View with door open

NOK OK

33

8- Do the same operation for the other cable.

This picture shows the cable poorly adjusted.

34

Check that the rear cap is present and correct.

Close the shutter.

11) Checking the condition of the rear cap on an electric roller shutter (frequency: 6 months):


Tools required: Cross-head screwdriver, 13mm spanner and Allen key.

- If NOK: Follow the adjustment instructions below:

Deterioration of the black cap may be the cause of excessive motor travel.

1

3

2

2

1

2

35

Instructions: 5- Move the lower limit

switch sensor 1cm towards

the front of the vehicle.

1- Close the shutter. 2- Check and adjust the alignment of the connecting rod.

3- Remove the black front cap on the rail slide.

4- Take the black rod and pull it out one metre.

1cm minimum

Control criterion:

a- Re-fit the shutter and lower it completely:

Check that the head of the nut is positioned 1cm from the black rear support.

If this is not the case, move the position of the sensor by a few mm.

The operation consists of adjusting the motor / shutter drive strip and moving the lower position limit sensor.

36

6- Re-fit the rod and the front rail support:

37

Close the shutter

Inspect and clean the rail control rod (do not use grease).

The control rod must be replaced if any of its teeth are broken or missing.

12) Inspection and cleaning of the rail control rod:

Time required = 15 min. Tools required: None

2

1

1

38

Open the shutter

Check the condition of the spiral support; the cable must be replaced if it is cut or damaged.

13) Check on the state of the cable and spiral support:



1

1

3 2

39

Open the shutter and chock it in the open position.

Manually disengage the motor to release the cable stop.

Désaccoupler mécaniquement l’ensemble (goupille + axe) et le câble de débrayage.

14) Checking the wear pads, pinions, bearings and Silentblocs:

Time required = 30 min. (if no longitudinal partition) and 2 hr. (with longitudinal partition)

Tools required: Screwdriver and long nose pliers

1

1

3 2

40

Open the electrical connector cover. Remove the guide rail closure cap.

Remove the electrical connector. Take care with the spiral support's recoil force; support the sensor until it there is no longer any tension.Débrancher la prise électrique. Attention à l’effort de rappel du spiralé accompagner le capteur jusqu’à la position neutre.

Remove the motor assembly by pushing it forward.

Mechanically de-couple the assembly (pin and shaft) and the clutch cable.

4 5

6

7

8

9

41

Check the condition of the four wearing spacers (correct thickness = 12 to 13mm) and clean them.

If it is not that thick or there is visible damage, change it.

Check the two drive pinions.

If either of the two pinions is damaged, the motor must be replaced.

Check the condition of the pinions (teeth, external appearance), rollers and bearing.

Change them, if necessary.

10 11

12

42

13

43

Check the condition of the Silentblocs:

Change it/them if there is any evidence of cracking or cutting.




15) Checking the alignment of the drive connecting rods = motor slide / shutter:


Tools required: 1 Tape measure.

1

1

3

2

115

44



Open the shutter's electrical control box and check the air pressure on the gauge.

The pressure measured must be 7 bars.

16) Check on the air pressure:


Tools required: Screwdriver.

The operating pressure of an electro-pneumatic roller shutter must be at least 7 bars If the pressure measured is less than 7 bars, the shutter must not be used until repairs are carried out.

1

1

2 3

45

17) Check that the pneumatic circuit is completely sealed:


Tools required: 1 CH13.417 leak detector :

Check all pneumatic connectors (circuit under the chassis, solenoid valve connector box and on the cylinder):

1

Figure 3: Air reservoir on semi-trailer

46

Figure 4: Pneumatic control enclosure and dryer

Figure 4: Pneumatic cylinder; in the event of a leak, refer to the following page and dismantle the scraper seal.

Figure 5: Control circuit (from November 2013)

Figure 6: cylinder entry and exit

47

18) Replacing the seals on the pneumatic cylinder:

Time required = 30 min. Necessary parts:

- 1x 16653 kit:

- 1x 10041 kit : + 2 connectors + 2 olives (pneumatic connector)

Cylinder head

48

- 1x 19129 seal kit (6 seals -> piston: 2 lip seals + 1 segment, rear cylinder head nose seal, damper seal (rear cylinder head, front cylinder head damper seal)

- 1x 19128 scraper seal kit

Lubricants:

- Non-detergent oil, with no aggressive additive.

- Class VG32 (ISO3448)

- Viscosity 29 to 35 cSt (mm²/s) at 40°c

The use of silicone-based lubricants is prohibited.

Parts lists:

Reference Description

1 2 rod seals

2 2 damping seals

3 2 lip seals

4 1 segment

49

Instructions :

The work should be carried out in

a clean, dust-free area.

1- Open the isothermal roller shutter.

2- Disconnect the electrical and pneumatic power (disconnect

the air circuit at the exit from the solenoid valve or use the sectional valve).

Mechanically chock the door in the open position using props or locking pliers in the guide rails or use a small spreader bar. 3- Separate the cylinder from the shutter by removing the circlip::

4- Remove the swivel joint and the nut.

5- First disconnect the air pipe from the rear cylinder head.

If it is a quick connector, slide the ring. If it is an olive connector, undo the nut.

6- Remove the cylinder from the roof: Make a mark to identify the vertical position of the cylinder in relation to the front and rear cylinder head.

50

a- Remove the four stainless steel M10 x 30 skt. hd. cap screws from the front cylinder head.

Check the condition of the cylinder rod (scratches, pitting, etc.). Any damaged could necessitate the replacement of the entire cylinder. b- Remove the four stainless steel M10 x

30 skt. hd. cap screws from the front cylinder head.

c- Lower the cylinder from the roof and carry out the following operations.

7- Extract the scraper from the rear cylinder head by loosening the cone point set screws.

Check the condition of the scraper seal (ovalisation, distortion, deterioration) - replace it, if necessary (code 19128)

8- Remove the four screws from the rear cylinder head and then pull it out, taking care not to damage the seals (do not rotate it while removing it).)

9- Remove the four screws from the front cylinder head and then pull it out, taking care not to damage the seals (do not rotate it while removing it).

51

Replace the rear cylinder head seal:

Extract the aluminium ring from the inside, taking care not to rotate it (remove the O-ring shown below).

Check the condition of the bearing which guides the cylinder rod into the cylinder head (ovalisation, cracks and scratches). If there is wear, change the entire kit for cylinder head (article code = 16653) check the condition of the cylinder head (cracks, etc.).

Extract the damper seal from the aluminium ring using a small screwdriver and replace it with the new seal from the kit.

Remove the two O-rings, taking care not to damage them (seals not included in the repair kit).

Completely clean the cylinder head and aluminium ring of grease and any other residues (do not use corrosive products or solvents)

Extract the lip seal from the nose of the cylinder head using a small screwdriver in the groove in the edge of the cylinder head nose.

52

Coat the seals with grease and re-fit them all (take care with their orientation).

Replacing the seal in the front cylinder head: Extract the aluminium ring from the inside, taking care not to rotate it (take care not to lose the O-ring shown below).

Extract the damper seal from the aluminium ring, and the O-rings.

Completely clean the cylinder head and aluminium ring of grease and any other residues (do not use corrosive products or solvents).

Replacing the piston seals:

Remove the piston-rod assembly from the cylinder tube. Carefully remove the two lip seals and the segment.

Clean the rod, piston and inside of the tube (do not use corrosive products or solvents).

Check the condition of the piston (scratches, marks, ovalisation, etc.). If there is no damage, move to the next stage "Re-fitting the cylinder".

53

Removing the piston (piston kit ref: 10041) Loosen the screw at the end of the rod. Remove the two aluminium sockets, piston, screw and washer from the rod.

Assemble the new sub-assembly on to the rod (torque on the screw = 33Nm)

Grease the outside of the two lip seals and the segment.

Replacing the lip seals on the piston Lightly coat the lip seals and piston ring grooves with grease. Assembling the first piston seal: Place the lip seal in the groove on one side of the piston (take care with the direction of fitting).

Fit the second lip seal, following the above procedure.

Re-fit the segment

Grease the grove.

Fit the segment.

54

Re-fitting the cylinder:

Lightly grease the inside of the cylinder barrel and the lip seals. Place the piston crosswise in the lower part of the cylinder bore (fig. E). Gradually work in the lip seal using a smooth, flat tool, working the rod with a circular motion (fig. F). Grease the piston around its middle (fig. G)..

Push the piston into the cylinder bore.

Re-fit the bases:

Grease the inside ends of the bore.

Check that the bases are firmly pushed into the tube to ensure alignment and tighten the eight screws in an alternate cross pattern (tightening torque: 24Nm ±15%).

Re-fit the scraper seal:

Tighten the four screws.

55

Re-fitting the fixing bracket to the roof on the cylinder Position the brackets, following the marks made at stage X. Tighten the screws in an alternate cross pattern to a torque of 24Nm ± 15%.

Re-fit the cylinder in the roof:

Re-fit the nut and swivel joint at the top of the rod:

Pneumatic connection

Before connecting the two pneumatic intakes to the cylinder, change the two sealing olives (cut the pneumatic pipe, retrieve the sleeve from inside the cut pneumatic pipe).

Figure 1: sleeve

56

Insert the sleeve in the part of the pipe to be crimped. Fit the olive and tighten the nut on to the connector.

Secure the cylinder to the shutter:

Re-connect all power supplies:

Imperative: before carrying out any operations, hold the shutter up button pushed for 10 seconds (to fill the cylinder chamber).

Ensure that the shutter moves up and down correctly; there should be no air leaks.

57

Electrical Schematic

Att

ach

a r

ese

rve

fuse

to

th

e b

atte

ries

.

24

V S

UP

PLY

ELE

CTR

ICA

L SH

UTT

ER

58

Att

ach

a r

ese

rve

fuse

to

th

e b

atte

ries

.

24

V S

UP

PLY

ELE

CTR

ICA

L SH

UTT

ER

59

Dry

er: t

he

dry

er o

per

ates

as

the

shu

tter

is lo

wer

ed.

Ch

assi

s co

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ol

Elec

tric

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irin

g sc

hem

atic

FIT

elec

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-pn

eum

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sh

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Rea

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24

V t

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term

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61

Trouble shooting assistance

The Roller Shutter does not move or moves very slowly:

No authorisation to operate the shutter: o Turn the key in the control panel that allows the shutter to

operate.

The power on indicator flashes: o The output voltage from the battery is too low: Recharge the

battery.

The power on indicator is off: o Check the output power fuse on the battery, refrigeration unit or

tailgate. o Check the supply voltage (12V DC or 24V DC) on the electronic

board (the two 10 mm² wires) o Check the condition of the key contact. The contact should

normally be closed, as soon as the key is turned. o Check the 24V DC supply voltage on the motor terminal block o Resistance value on the motor connection terminal block (red and

black wire): ~2 ohm o Check the auto-transformer: Input voltage = 12-24V DC, Output =

32V DC o If incorrect: change the auto-transformer.Si incorrect: changer

l'autotransformateur

Wrong position of motor clutch: o Check the clutch position on the complete motor part; the motor

is in the disengaged position. o Check the position of the control rod.

No raise or lower control signal:

o Check the top and bottom limit contacts: o If the upper limit switch indicator is on, pressing the up button

will have no effect. o Check the condition of the limit switch contacts if the limit switch

indicator is lit when the roller shutter is not in position: o The limit switch electrical contact is open when it does not detect

62

the presence of the shutter. o If the electrical contact is closed when there is no end of travel

detected, change the limit switch contact. o Check the control switches: o While pressing the red button, measure the continuity from the

electrical contact on the button to the electronic board. o While pressing the green button, measure the continuity from the

electrical contact on the button to the electronic board.

Mechanical motor problem:

o Check the motor pinions: o If a pinion is broken, change it and ensure that the source of the

problem is resolved (roller problem, incorrect adjustment of the balancer etc.).

Mechanical problem: o Check that there is nothing in the way, blocking the raising or

lowering of the shutter. o Check the condition of the panels. If any of the panels is slightly

damaged, change it. o Check the condition of the guide arm. o Check the adjustment of the balancer. o Check that all rivets are in place. o Check the centring of the panel assembly in relation to the rear

frame posts. Check the condition of the rollers. Change them, if necessary.

Free up the slides.

Insufficient air pressure: o Check the pressure on the gauge:

If the pressure = 0 bar: check the air pressure on the tractor.

If the pressure is > 0 bar but < 7 bar: recharge the cylinders on the tractor by running its engine.

Leak in the air system: o Check the integrity of the air system.

63

Air leak at the cylinder: o Check the pneumatic connectors on the cylinder and the seals on

the cylinder head.

Water in the air circuit: o Check the dryer on the tractor; there should be no water in the

shutter's compressed air circuit. Electrical failure:

o Check the supply voltage on terminals 30 and 85 on the raise and lower relay in the pneumatic control box:

If the voltage measured is 12V DC or 24V DC:

Test the relay and change it if necessary.

If the voltage measured is not 12V DC or 24V DC:

Check the battery output power supply fuse.

o Check the distributor coils: 24V DC version:

The supply voltage must be 24V DC:

if there is 24V dc present but no movement:

Change the distributor coil

if there is no 24V dc supply present:

Test the up and down relay (self-maintaining contact), change the relay, if necessary.

12V DC version: (stand-alone version, supplied from the refrigeration unit):

The supply voltage must be 12V DC:

if there is 24V dc present but no movement:

Change the distributor coil

if there is no 24V dc supply present:

Test the up and down relay (self-maintaining contact), change the relay, if necessary.

64

The shutter becomes stuck:

Incorrect adjustment of the balancer: o Check the adjustment of the balancer; the shutter should move

freely. o Loosen the spring by one turn.

Distortion in the slides: o Visually check the condition of the slides: o If there is distortion, change the slide(s).

Problem with the engine Silentbloc: o Check the condition of the engine Silentblocs.

Problem with the rollers: o Check that the rollers turn freely: o If not: readjust the eccentrics and change the roller(s), if

necessary.

The shutter lowers without a button being pressed:

Electrical control problem: o Check the interior and exterior electrical controls. Change them, if

necessary.

Leak in the air system: o Check that the pneumatic circuit is completely sealed o Check the sealing on the cylinder:

After removing the cylinder, check the cylinder shaft seal and change it, if necessary.

65

List of spare parts

- View of mechanical spare parts for roller shutter:

67

- View of spare parts for electrical roller shutter:

69

- View of spare parts for electro-pneumatic roller shutter:

Rea

r fr

ame

con

tro

l

Ch

assi

s co

ntr

ol

71

List of emergency parts

72

Appendices

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Notes

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75

Our aim is to supply you with user instructions that match your needs as closely

as possible.

With this in mind, we ask you to send us comments and suggestions which could help us to improve the quality of this document.

CHEREAU Refrigerated vehicles

52, Boulevard du Luxembourg

F 50307 Avranches Cedex

Fax : (33) 0.233.893.837

E mail: [email protected]

semi et remorques - chereau · 2016. 11. 17. · chereau sas zi le domaine – ducey – bp 700...

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