Caterpillar NOH08K Lift Trucks Operation & Maintenance Manual - PDF DOWNLOAD

EN

Operation & Maintenance Manual NOH08K NOH10KC NOH10K NOH10KH

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

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ORDER PICKER Type:

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Manufacturing year and number: _____________________

NB: Please read this manual before operating or performing maintenance on the forklift truck.

Following the instructions will improve safety and enable unnecessary danger situations and accidents to be avoided.

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Table of contents FOREWORD ............................................................................................................................................... 3 INSTRUCTIONS ON OPERATING THE TRUCK .................................................................................. 3 OCCUPATIONAL SAFETY ........................................................................................................................ 5 LOAD HANDLING ..................................................................................................................................... 6 DRIVING ..................................................................................................................................................... 7 PARKING ..................................................................................................................................................... 7 OTHER WORKING INSTRUCTIONS ..................................................................................................... 8 RECHARGING AND REPLACING THE BATTERY .............................................................................. 8 HAZARDOUS WASTE AND DISPOSAL ................................................................................................ 10 ORDERING SPARE PARTS .................................................................................................................... 10 USE OF THE TRUCK ............................................................................................................................... 11 DRIVER’S NORMAL DRIVING POSITION ........................................................................................ 11 NOISE LEVEL DATA ................................................................................................................................ 11 THE CONTROLS AND HOW TO USE THEM ..................................................................................... 12 OTHER EQUIPMENT ON THE TRUCK ............................................................................................... 16 OPERATION .............................................................................................................................................. 17 HANDLING LOADS ................................................................................................................................. 19 EMERGENCY PROCEDURE .................................................................................................................. 20 INSPECTIONS, SERVICE, AND REPAIRS ........................................................................................... 20 “FLY BY WIRE” ELECTRONIC STEERING ........................................................................................ 23 TROUBLESHOOTING ............................................................................................................................. 25

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FOREWORD Warehouse trucks are designed for the varying needs of customers to lift and transport objects in indoor premises. Familiarise yourself with this manual carefully in order to be able to use all the features offered by the truck for efficient working.

Important: ! After reading this manual, store it in a safe place for later use. ! Do not use the truck before you have read this manual.

The truck conforms to the EN 1726 standard, ensuring its safety according to the EU machine directive.

The most important regulations and guidelines are mentioned in these instructions. As regulations vary from country to country, we expect users to be aware of the regulations and standards valid in their local area.

In order to use the truck safely, users should find out about safety risks in advance. All the safety regulations in the manual must be followed. The truck operator should acquaint himself with the instructions of a new truck carefully, and practice driving and controlling the truck in a protected area.

We hope that you will put your truck to continuous economical and efficient use. In order to remain fully operational, the truck must be maintained competently, according to the maintenance instructions and schedule supplied by us. We offer to you economical and efficient maintenance and spare part service.

The most advantageous arrangement to ensure that the truck is operational at all times is to sign a maintenance agreement with your dealer.

For further information or training on trucks, please contact our sales organisation.

WARNING! A truck is a moving machine, which may cause serious accidents, unless its operator is sufficiently familiar with its operation and unless he knows its operating and maintenance instructions. To order more copies of instruction books, contact your dealer.

INSTRUCTIONS ON OPERATING THE TRUCK INSTRUCTIONS FOR SITE SUPERVISION The operator must be trained with the use, maintenance and safety aspects of the truck. The site supervision must control that the operator and maintenance instructions as well as safety regulations are observed. It is in everybody’s interest that the truck remains continuously operational and in productive use. ! It is the site supervision’s duty to advise the operator and control that the operator and maintenance instructions are observed. ! The site supervision must familiarise themselves with the operator instructions and their contents.

-4RECEIPT OF THE TRUCK Before shipping, each truck is inspected carefully to make sure that the truck you receive is in impeccable condition and equipped as per your order. We request, however, that immediately after receiving the truck you inspect it for any damages during shipping. This way your truck can be put to productive work without undue delay.

TRUCK STORAGE If the truck is not used for a lengthy period, it should be stored in a cool (above 0 C) and dry place on an even surface. Before storage, complete the following: BATTERY Charge the battery well, and while stored recharge it every 2 or 3 months to prevent damage. At the same time, check the fluid level and add if necessary.

HYDRAULIC SYSTEM If the machine is out of use for more than a year, change the hydraulic oil.

DRIVE UNIT If the machine is out of use for more than a week, support the truck in such a way that the load exerted on the drive wheel becomes lighter.

Returning the Truck to Operation If the truck has been stored for several months, it must undergo maintenance as per 600 operation hours.

Otherwise normal daily maintenance and inspection are sufficient.

MAINTENANCE AND REPAIR The operation of the truck requires that it is maintained regularly and competently. Daily and weekly maintenance is the work of the operator or an appointed individual, who must be supplied with adequate training and instruction for the task. It should also be borne in mind that the terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original spare parts.

Monitoring the maintenance instructions is easier if maintenance dates are entered in the maintenance record located on the last page of the Manual.

The most advantageous arrangement is to sign a maintenance agreement with your dealer, who can also supply you with any supplies and spare parts you may need. Contact our maintenance department or your truck dealer for good and efficient maintenance service for your truck. ! If maintenance is neglected, the truck may cause damage to property, and even personal injuries. ! Proper maintenance and care ensure that the truck can be used efficiently and without errors. ! Truck inspections, lubrication and maintenance must be made according to the maintenance schedule. ! Only a specially appointed and trained individual is allowed to repair and adjust the truck. ! If you are not sure of the symptom or the error, do not take any corrective action but contact your dealer. ! For troubleshooting chart, see Appendix.

-5TRUCK OPERATOR The truck operator must be at least 18 years of age, and he must have the physical (e.g. good hearing and sight) and psychological properties required for operating the truck without risks. Only an individual trained for the truck may operate it. In addition, he must have permission from the site supervision to operate the truck.

The operator must know and master the drive and operational properties of the truck as well as all the relevant safety and other regulations. He must be able to control the truck also in a situations of sudden danger. Familiarisation and drive practice with a new truck should be arranged in a protected area.

The operator is responsible to the site supervision for observing all the instructions and regulations in his daily work and for taking care of the truck. The operator must check the condition of the truck at the start of each work shift. In particular, he must check the operation of steering and brakes, the condition of the batteries, parking brake and signal horn.

The operator must familiarise himself carefully with the truck and its operator and maintenance instructions as well as safety regulations.

LIFTING THE TRUCK The truck may only be lifted from a marked position.

Make sure that the capacity of the lifting device is sufficient.

TOWING THE TRUCK The truck may only be towed with its drive wheel raised free of the floor.

ELECTROMAGNETIC COMPATIBILITY The truck conforms to the prEN... (Proposal 09.95) standard, ensuring its safety according to the EMC directive.

The truck is designed for use on premises of light and heavy industry (EN 50081-1 and prEN 50082-2).

WARNING Modifications to electric devices may affect the electromagnetic compatibility and, therefore, the safety of the truck.

No modifications may be made to the electric devices in the truck without permission from the manufacturer, as such modifications may put safety at risk.

OCCUPATIONAL SAFETY The truck must be kept clean and in good working order. The daily and weekly checks in accordance with the maintenance instruction must be carried out on time in order to avoid faults and operational errors.

If any faults or deficiencies risking safety are observed in the truck, the truck must be taken out of operation until the faults or deficiencies have been remedied.

-6! The operator may not make any repairs without permission from the site supervision. ! In case of malfunction disconnect the battery connector.

The operator must always promptly notify the site supervision of any accidents or injuries. In such a case the operator must leave the truck at the place of the accident. ! When using the truck, the operator is responsible for both his own and his environment’s safety. ! The truck may only be used for purposes corresponding to its outfit.

REPAIRS AND STRUCTURAL MODIFICATIONS The truck may not be modified without manufacturers permission: no parts may be added or removed, as the modifications could affect the operation of the truck and might weaken its construction. ! Do not weld or bend the truck’s forks.

WORK ON DANGEROUS PREMISES Trucks used for working on premises susceptible to fire or explosion or other hazards must be specially equipped. A standard truck is not suitable for such work.

OVERHEAD GUARD AND LOAD SUPPORT Trucks driven sitting or standing that are capable of lifting the load more than 1.8 m must be equipped with an overhead guard. No modifications to the overhead guard that weaken its structure are allowed. If it is possible that objects might fall through the slots in the overhead guard, the slots must be reduced.

Trucks used for transporting small objects or unstable loads must be equipped with a load support.

LOAD HANDLING The load must be handled without causing any risk of accident or damage to the load. The load can only be transported when it has been loaded safely. ! ! ! ! !

The truck must always be driven with its forks lowered.

If the truck has side supports, use them when you fetch or leave a load. Raise them when driving.

Do not let anyone, under any circumstances, walk or stand under the forks.

Never place any part of your body between the mast structures or any moving parts of the truck.

If driving a load that is larger than the outlines of the truck, take into account the extra space it requires.

LIFTING CAPACITY The operator must know the truck’s maximum lifting capacity and never exceed it under any circumstances.

Likewise, he must abide by the maximum values for load weight and load centre information printed on the capacity plate in the different loading situations.

Take into account the effect of any attachments to the lifting capacity.

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DRIVING The truck must always be driven from the actual operator’s seat. Keep your body completely within the outlines of the truck. Anticipate any dangers so that you can avoid all risks of accident or injury. ! ! ! ! ! !

The truck must at all times be under the operator’s control, and it must be handled responsibly.

Sudden starts and stops should be avoided.

Steering and braking movements should be made smoothly.

Decrease the speed if the floor is slippery, e.g. because of humidity.

Take great care when driving on a slanted surface.

Do not drive over any loose objects on the floor.

When driving, the load must be kept down and, if possible, tilted backwards. The load must not be lifted except when stacking. This does not apply to trucks designed to be driven with the load raised.

Be especially careful: ! when there are other people, or moving or fixed objects in the working area. ! when the load reduces visibility. When driving in narrow aisles, make sure that there is enough space for the truck and the load.

SPEED Speed must be chosen according to the situation. Things to take into consideration include load, visibility, people in the working area, as well as moving and fixed objects. Speed must be reduced at cross aisles and whenever vision is obstructed. If the visibility is inadequate, the operator should use an assistant.

Careless driving leads to risk situations: for example, uncontrolled acceleration or braking, excessive speed at turning points, as well as fast and sudden turning may overturn the load and cause an accident.

In all conditions, drive the truck at a speed which makes it possible to stop it safely. Keep sufficient distance to a preceding vehicle.

TRAFFIC RULES The general rule is that the truck should be driven on the right-hand side of the driving lane. The operator should keep good visibility in the direction of driving and mind the traffic and other people by keeping sufficient safety distances. It is not allowed to drive the truck outside a private area without an order or permission by the site supervision. Outside a private area, the truck is subject to general traffic rules and regulations. Traffic regulations and speed limits should also be observed in a private area.

If a door opening is so narrow that two vehicles cannot pass each other, drive in the middle. When two trucks meet in a narrow or cross aisle, the loaded truck has the right of way. ! When driving, the horn should sounded when necessary to warn others in the same area.

PARKING The truck can be parked without supervision only in a specially reserved parking place. When parking the truck, the forks must be lowered to the down position and the parking brake must be on. It must be ensured that the truck under no circumstances can move by itself or that an inexperienced person can start driving it.

-8! Never park or stack goods in front of fire doors, fire extinguishers, emergency exits and the like. ! Never park the truck on a slanted surface.

OTHER WORKING INSTRUCTIONS FREE SPACE ! The operator must make sure that the truck has sufficient moving space with respect to overhead structures. Before driving to aisles or door openings, it must be ensured that there is enough space for the truck, the load and the operator. ! Always drive at a safe distance from the edge of loading platforms or bridges.

BEARING CAPACITY OF THE FLOOR The operator must make sure that the combined weight of the truck and the load does not exceed the bearing capacity of the floor.

USE IN ELEVATORS An elevator can only be used to transport the truck between floors by permission of the site supervision.

When using an elevator, it must be ensured that the combined weight of the truck, the load and the operator does not exceed the maximum load capacity of the elevator. The truck should always be driven with the load in front to elevators, as well as any other narrow premises. ! Do not let any other people be in an elevator when driving the truck in or out. ! The parking brake of the truck must be on before the elevator starts.

WORKING ON RAMPS The operator must get permission from the site supervision to drive on a slope or ramp. When the truck is loaded, travel with the load uphill. Without a load, you can also travel with the forks downhill. ! Do not turn the steering wheel abruptly on a ramp. The truck might overturn.

WORKING ON LOADING BRIDGES Before starting with loading or unloading, always check the bearing capacity and the fastening of the bridge. If the truck is to be driven into another vehicle, it must be ensured that the vehicle cannot move during the work. Do not drive to the edges of a loading bridge, because there is always the risk of overturning.

RECHARGING AND REPLACING THE BATTERY Only appointed and trained personnel may replace and recharge batteries. Individuals maintaining batteries must have sufficient protective clothing. ! Do not handle naked flame in the vicinity of batteries because of a risk of explosion. ! Do not smoke when working with batteries. ! Do not leave tools or other metal implements on top of the battery. Sparking or a short circuit may cause the battery to explode.

-9! When the batteries are recharged, the cell plugs must be screwed tight to prevent battery fluid splashing. ! Battery fluid is a corrosive acid solution, so caution should be exercised to avoid it getting on the skin or in the eyes. Battery fluid develops an explosive gas at the end phase of recharging. Therefore, make sure that the battery has sufficient ventilation. ! A low battery charge status may damage the battery during long-time use.

RECHARGING THE BATTERY ! Make sure that the charger is the appropriate model for recharging the battery. ! Park the truck in a specially reserved recharging place. ! Make sure that the battery has sufficient ventilation.

Connecting the battery to a charger: 1.

2.

3.

4.

Switch off the truck current Make sure that the charger has been switched off.

Disconnect the battery connector and connect it to the charger.

Connect the current to the charger.

After charging, when beginning the work: 1. Switch off the charger.

2. Disconnect the battery connector from the charger. Grab the plugs. Do not pull the cables.

3. Check the battery according to the manufacturer’s and maintenance instructions.

Measuring the Cell Density of the Battery Measure the acid density of the battery fluid according to the manufacturer’s instructions. The acid density of a fully charged battery is 1.28 to 1.30 at + 30 °C. 1.24 1.20 1.16 1.15

3/4 charged 1/2 charged 1/4 charged Empty. The battery must be charged immediately.

REPLACING THE BATTERY The battery must be replaced according to the manufacturer’s instructions. When reinstalling batteries, use the appropriate tools for moving, connecting and fastening the battery solidly. Tools and other metal implements must not be kept on top of uncovered batteries.

When replacing the battery for an electric truck, use a battery with dimensions and weight that fit the truck so that the stability or braking properties of the truck are not weakened. The minimum weight of the battery is indicated on the identification plate of the truck.

When a lifting device is used for lifting the battery, place a non-conductive plate on top of the battery to avoid the risk of a short circuit. This is not necessary if the lifting device has sufficient insulation and is equipped with a distributor or if the pole shoes and cell combinations are fully protected.

- 10 ACQUIRING A NEW BATTERY When acquiring a battery for the truck, pay attention to the standard prEN 1175-1, section “Traction batteries”, which lays down the requirements on the protective cover of the battery case, ventilation and interior surface treatment, and section “Minimum markings”, which lays down the requirements on the truck battery plate.

The battery plate should give at least the following information: • manufacturer • type • serial number • rated voltage • capacity (Ah/5h) • service weight

HAZARDOUS WASTE AND DISPOSAL Hydraulic and gear oils as well as batteries are hazardous waste, which must be disposed of accordingly.

The truck itself is not hazardous waste, and can be recycled.

ORDERING SPARE PARTS When ordering spare parts, always turn to your dealer or maintenance centre. Use only original spare parts.

To make sure you receive the correct parts, include the following information in the order: • TYPE OF TRUCK • SERIAL NUMBER OF TRUCK • ORDER NUMBER OF PART • NAME OF PART • NUMBER OF PARTS ORDERED Of the above information, items 3 and 4 are listed on the spare part pages of the manual supplied with the truck, and items 1 and 2 on the front page of the manual or on the identification plate of the truck.

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USE OF THE TRUCK This product has been designed for the collection and transfer of goods from all levels in a warehouse.

The truck can be driven both in a guided aisle and using free steering.

The truck is intended to be used in dry indoor spaces, on even and level floors. The temperature range, in which the truck can operate continuously is +25 - 5oC, and for short periods +45 - 0oC. If the operating conditions differ from those temperatures, contact manufacturer, because in cold and freezing temperatures a separate machine intended for such conditions is needed. A special machine for freezing conditions can be used in temperatures down to -35oC. This device conforms to all the requirements of the EU machine safety directive and thus has a CE marking.

NEVER USE THE TRUCK: • to transport and lift people • on premises with fire risk • on premises with explosion risk • on premises with insufficient floor load capacity • if damaged • as a mounting surface • to tow another truck • under the influence of intoxicating substances.

DRIVER’S NORMAL DRIVING POSITION When moving forwards, the driver’s normal driving position is standing firmly, with one foot on the brake pedal. The left hand should be on the steering wheel and the right hand on the speed control support handle.

CAUTION! When driving, no part of the body should be outside the driver’s cab.

NOISE LEVEL DATA The greatest noise that the driver is subject to is 76 dB (A). This level is reached, when a classified load is being lifted.

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THE CONTROLS AND HOW TO USE THEM PLATES ON THE TRUCK Check that the plates are legible and securely attached.

Type plate The truck’s type plate is marked with: • the manufacturer • the type of truck • the year of manufacture • the series number • the truck’s deadweight in operating condition, without battery or accessories • the maximum and minimum battery weight • the battery terminal voltage • the truck’s nominal lifting capacity • the CE mark Capacity plate High-lift trucks have a capacity plate, which states the maximum lifting capacity at the maximum lifting height, and the lifting height with the nominal lifting capacity. If necessary, a lifting capacity between the heights referred to above is stated. In addition, the plate states the centre of gravity distances for the relevant lifting capacities.

WARNING! CHECK AND KNOW THE LOAD AND CENTRE OF GRAVITY DISTANCE IN EVERY SITUATION. IT IS DANGEROUS AND THEREFORE FORBIDDEN TO OVERLOAD THE TRUCK Capacity plate for accessories If detachable accessories are used with the truck, corresponding plates must be attached to the truck and changes in the lifting capacity due to them must be stated on a capacity plate marked with the type of accessory.

SAFETY PEDAL

When operating the truck, the pedal on the floor must be depressed with the foot to the drive position. If the pedal is in the upper position, all the truck’s operations are prevented and the brake is activated. (See also ‘Speed control’.)

- 13 BRAKES Operating and parking brakes The parking brake is a magnetic brake, which is always switched on when the driver leaves the truck (lifts their foot from the safety pedal). During normal driving, the counter-current (reversing) brake is used.

Charging braking (regenerative braking) The truck is equipped with a charging motor braking system. When braking, energy that would otherwise be wasted is collected in the battery. This increases the service life of the battery and saves the drive motor.

Motor braking charges the battery and slows the truck in the following cases: 1. When changing direction.

2. When the truck is freewheeling.

• Practise using the brake with a load before beginning work • The parking brake must always be used when the truck is not being driven • During normal operation, the counter-current (reversing) brake is used CAUTION The truck will stop suddenly, if the brake pedal is released.

CONTROL PANEL

Power lock (1) The power lock connects the truck’s electrical equipment to the battery circuit.

0 = Power off (power is still connected to certain electronic devices) 1 = Power on When power is switched on, an automatic warning light test takes place, so that the driver knows if the warning lights and flashers are working.

Horn button (2) Speed control

- 14 Monitoring of faults in the drive controls Certain circuits of the truck have automatic fault monitoring, which warns of faults in the drive speed controller. The truck can then not be driven until the fault has been eliminated. If the truck does not begin to move and no obvious fault can be found, switch off power with the power key, wait about 5 seconds, then switch on the power again (in this case, do not touch the drive or load controls). If the fault continues, contact maintenance. If fault monitoring finds a fault during operation and driving stops, stop the truck immediately using the brake pedal.

Speed control (3) The drive speed of the truck is controlled using the right-hand control handle on the control panel. The speed control is turned forwards or backwards to the desired drive direction. A larger movement of the handle produces a higher speed. The speed control automatically returns to the central position, when it is released.

The truck can be braked smoothly by moving the speed control to the direction opposite the drive direction.

Braking should be planned beforehand and speed reduced in good time.

When driving in a guided aisle, the left hand must be on the steering wheel knob, for the drive to operate.

This is a safety measure, to ensure that the driver’s hands are in a safe position.

Valve control levers Pump control fault monitoring Certain circuits of the truck have automatic fault monitoring, which sends a fault warning to the pump control. The truck can then not be operated until the fault has been eliminated. If the hydraulic system does not function, switch of power with the power switch, wait about 5 second, then turn the power on again (in this case, do not touch the drive or load controls). If the fault continues, contact maintenance.

Lifting and lowering the load cage (4) The load cage can be lifted/lowered using the lift lever on the control panel. Stopping of the lowering movement is hydraulically damped. Once the lift cage has reached the maximum lifting height, lifting stops automatically. The speed of the truck depends on the lifting height: see ‘drive speed limits’.

The left hand must always (even when driving outside a guided aisle) be on the steering wheel knob for the hydraulic operations to function (including extra lift). This is a safety measure, to ensure that the driver’s hands are in a safe position.

Extra lift (ergolift) (5) The ergolift is lifted/lowered using the button on the control panel. Using the ergolift makes it easier to use the truck to collect goods and place pallets on shelves.

Compulsory use of two hands Compulsory use of two hands through the steering wheel knobs, which must be pressed: • when the truck moves along a narrow guided aisle (both drive and hydraulics operations).

• also during hydraulics operations outside a guided aisle.

- 15 Steering wheel (6) The steering wheel turns the drive mechanism electrically ± 100o.

• ! Read carefully the section ‘Fly by Wire’ electrical steering.

Emergency stop button (7) Pressing the button switches off the power circuit from the battery. Use the button in such cases as: • a short circuit or other electrical fault, e.g. if the pump motor runs continuously.

• in an accident.

The switch is released by turning the button clockwise.

Chain tension sensing reset button (16) The tension of the truck’s chains is monitored electrically. If the lift cage chains slacken due to an obstacle, all the operations of the truck are automatically switched off.

To set the chains of the lift cage to a normal tension, the driver must first of all find the cause of their loosening. After that, press the reset button while simultaneously pressing the lift cage lift button, when the chain tension will return to normal.

Lifting height intermediate limit (optional) If the truck is equipped with a lifting height intermediate limit, the lifting height is limited electrically to a lower level than the maximum lifting height.

If you want to lift above this lifting height, press the reset button and continue lifting.

DISPLAY Drive direction indicator lamps (10) The drive direction of the truck in relation to its length is shown by indicator lamps.

Fault monitoring of the control electronics (11) A warning light operates in the case of a steering fault, a communications fault in the electronics, or of an incorrect starting procedure. ! When the light is on the magnetic brake comes on automatically! ! See the details in the section ‘Fly by Wire’ electrical steering.

- 16 Limited speed indicator light (13) This light comes on, if the drive speed of the truck is limited, for example, due to the lifting height.

Chain tension sensing indicator light (8) See ‘Chain tension sensing reset button’.

Lifting height intermediate limit light (12) See ‘Lifting height intermediate limit (optional)’.

Hour meter (14) The hour meter counts the time that the truck has been in active operation. It is always on, when the electrical devices are operating.

Battery guard (15) The battery guard shows the level of the battery charge and stops a lift, if the battery charge is too low.

However, the battery should be recharged, before the charge drops too much.

OTHER EQUIPMENT ON THE TRUCK RECHARGING PLUG The truck’s recharging plug has a handle and can be detached.

See the section ‘Recharging the battery’ for instructions on using the plug to recharge the battery.

CAUTION! WHEN CARRYING OUT ELECTRICAL WELDING ON THE TRUCK: • The battery must be disconnected.

• The plugs of the electronic devices must be disconnected.

OPERATING LIGHT SWITCH The cab light switch turns on the cab operating and general lights.

Emergency rope The truck has an emergency rope attached to the roof of the lift cage. Read carefully the instructions for the emergency rope (appendix).

Use the rope only in emergencies.

- 17 SEAT/BACKREST The height of the adjustable backrest can be altered but pulling the lower edge outwards slightly and sliding the rest to the desired height.

LOWERING THE LIFT CAGE IN EMERGENCIES

The valve is use, if the truck malfunctions with the lift cage raised. Press the spindle of the lowering valve in the machine compartment to lower the cage manually. A spike with a narrow point can be used to press the spindle.

OPERATION DRIVING Before moving off, ensure that daily maintenance has been carried out - see the section ‘Driver’s daily routine before beginning operation’.

Check the operation of the horn and brake by trying them. Check also that the valve levers and the pedals move properly.

Check that the batteries are charged and locked in place.

When you use the truck for the first time, read the operating instructions carefully before moving off.

Familiarize yourself with the control of the truck by practising driving carefully in a safe area.

Close the doors and switch on power to the truck. Check the drive direction from the indicator lights (appears, when the speed control is turned) and whether the truck is switched to automatic control or not.

Grip the steering wheel knob with your left hand and the speed control with your right. Take up a position so that only one foot is on the stop pedal and lean against the backrest or sit. The truck will move only when the pedal is pressed.

Move the speed control with your finger lightly forwards and back, in the desired drive direction. The truck is braked by moving the speed control against the drive direction.

- 18 PRECONDITIONS FOR STARTING: • The doors are closed • Your foot is on the safety pedal • Your left hand is on the steering wheel knob (when driving in a guided aisle) AND • Fault monitoring shows no faults • Practice driving and controlling the truck.

• Do not release the safety pedal at high speeds.

• Use smooth movements to control the truck.

• Plan braking in good time and brake softly.

• Drive slowly at crossing and when turning.

• Always drive with the lift cage lowered when not in a collection aisle.

• CAUTION! Sudden movements of the speed control or brake pedal may cause the truck or load to break away.

‘FLY BY WIRE’ ELECTRICAL STEERING The truck is equipped with full electrical steering. With electrical steering, the movement of the steering wheel is transmitted to the motor steering the wheel without a mechanical connection.

SAFETY When you switch on the power from the main power switch and the power key, the system automatically checks its operating condition. This check lasts for a maximum of 2 seconds, after which the truck is ready for operation.

When the power is switched on, the control unit continuously sends checking signals through the entire system, which the operator may hear as a ‘clicking’ noise. If there is a fault in the system, the control unit reacts by immediately lighting up the ‘STOP’ indicator light, switching off the drive operation, and switching on the magnetic brake.

An electronic communication fault is indicated either by flashing the STOP indicator light or by rapidly flashing the warning lights.

• ! There must by a gap of at least 2 seconds between switching off the power and switching it on again.

STEERING Familiarize yourself thoroughly with a new truck. You will notice that when the steering wheel reaches its extreme limit (± 100o), it can still be turned further with no mechanical stop.

CAUTION! The steering wheel must not be turned needlessly when the truck is stationary!

‘STOP’ indicator light: The ‘STOP’ indicator light goes on if there is a fault in the steering system. If the light does not go off after switching the power off and on again (remember the 2-second wait), there is a fault in the steering system and you must not go on driving.

CAUTION! NEVER ALTER THE SETTINGS OF THE CONTROL UNIT, THEY HAVE BEEN GIVEN THE CORRECT VALUES AT THE FACTORY DO NOT WET THE CONTROL UNIT WITH RUNNING WATER!

- 19 DRIVE SPEED LIMITS The truck has drive speed limits, which operate as follows: • Outside an aisle: lifting height drive speed 0 - 1200 mm 9 km/h 1201 2.5 km/h • In a guided aisle: lifting height 0 - 4500 mm 4501 -

drive speed 9 km/h 2.5 km/h

REMEMBER: • The truck’s drive speed will increase, when the lift cage drops below the speed limit range.

• Avoid using the safety pedal, if the lift cage is raised.

• Use counter-current braking.

HANDLING LOADS Place the load so that the weight is distributed as evenly as possible on the lifting forks. You can see the truck’s maximum lifting capacity on the type plate - this must never be exceeded.

WARNING: POORLY STACKED OR SECURED LOADS MUST NOT BE MOVED! NEVER EXCEED THE TRUCK’S CAPACITY!

COLLECTION • Approach the collection point at a sufficiently low speed, so that you can stop the truck precisely.

• CAUTION! Only collect with a stopped truck.

• If you must lean far into a shelf, switch off the power with the power lock.

• Use the ergolift to set a suitable collection height.

• Do not open the safety doors when working in the lift cage.

• Place the collected goods on the pallet so that the weight is distributed as evenly as possible.

• If there are no guides in the collection aisle, turning movements should be as gentle as possible.

STACKING AND UNLOADING A collection truck is not intended for continuous pallet stacking and unloading. In temporary stacking work, use the ergolift set to the stacking level.

Drive in front of the shelf or stack level with the load lowered.

Raise the load so that it freely clears the stacking height or shelf level. Then drive forward and approach the stacking or shelf level. When the load is in the correct position, lower it into the level.

Lower the forks, so that they disengage, then reverse out of the stacking location.

When taking a load from a stacking or shelf level, the operations are the same, but in the reverse order.

• When driving in or out of a level, ensure that the forks are clear of both the stacking level and the pallet.

• Ensure that the load is securely on the forks.

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Caution: • Always compare the weight of the load with the lifting capacity and height stated on the type plate.

• Always also watch the free space above the load.

• Always approach stacking shelves at right-angles and with the forks in the lowered position.

• When the load is raised, steering and braking must be careful and gentle.

• A broken pallet or an unstable load must never be left on a shelf or stack, but must always be removed.

EMERGENCY PROCEDURE If the truck falls over, hold onto the steering wheel and warn others. If the machine behaves strangely, lift your foot from the pedal and switch off power. The truck must not be used again, until a person appointed by the work supervisor has repaired the truck.

INSPECTIONS, SERVICE, AND REPAIRS SAFETY INSTRUCTIONS FOR SERVICE • Only persons trained in the service and repair of this type of truck may carry out service and repairs.

• The service area should be kept clean: oil, grease, and water will make the floor slippery.

• Short circuits and burns are possible when working with the truck’s electrical system, if a metal object touches a charged electrical connection. Therefore, rings, watches, and other metal jewellery must be removed.

• Switch of the truck’s power, before opening the cover of the drive unit or the electrical system.

• Release the hydraulic pressure, before opening the system.

• Do not use your hand to check for oil leaks.

• Remember that the surfaces of the hydraulic system and the motors may be hot.

• The hydraulic system may only be filled with clean oil.

• Always disconnect the battery when welding. Paint should be removed from an area 10 cm around a point being welded, to avoid noxious gases being formed during welding.

• The truck must always be supported on stands, if someone must work under it.

DRIVER’S DAILY ROUTINE BEFORE BEGINNING OPERATION • As the driver, you are responsible for the daily inspection and service of the truck.

• Carry out daily service according to the list below before the beginning of the work day or shift, before you begin to use the truck.

• Failure to carry out daily service may interfere with the truck’s safety and reduce its reliability.

• Notify the work supervisor immediately if you notice a fault or deficiency during the inspection.

• Check the truck externally and make sure there are no oil leaks.

• Check the attachment of the battery.

• Check all the wheels for damage or wear.

- 21 • Check the battery fluid in each cell. If necessary add only battery water. The level of the fluid should be about 15 mm above the plates.

• Check for leaks in the transmission. Check also the hydraulic pipes, hoses, and connectors. There must be no leaks or damage in them.

• Check that the lifting chain attachments have not loosened.

• Switch on power and check the operation of the lift hydraulics by lifting and lowering the lift cage and forks.

• Check the operation of the speed control by driving slowly forwards and back. Check also the operation of the other electrical devices.

• Check that the safety pedal works.

• Check that the steering works perfectly.

• Check the operation of the horn.

• Check that the emergency stop operates.

• Check the operation and attachment of the safety doors.

• Check that the speed limits function.

• Check that the hoses and cables run freely and are not damaged.

DRIVER’S WEEKLY SERVICE PROGRAMME (30 H) • Check and clean the battery cable attachments.

• Check that the air holes in the battery cell plugs are not blocked.

• Wipe the batteries with a dry rag. If necessary, the batteries can be washed with hot water or a weak soda solution, which will neutralize battery acid. After washing, the battery must be carefully dried, for example, using a water vacuum cleaner.

• Check the length of the lifting chains. When the lift cage is in the lower position and the forks are on the floor, all the chains should have a slight tension. Adjust if necessary.

• Lightly lubricate the mast and the lift cradle guides.

• Check that there are no leaks in the hydraulic system. The hoses and connectors must not leak or be damaged.

• Check that the lifting height limit switches are closed and function correctly. The limit switch attachment screws must be locked with a screw lock.

• Check the hydraulic oil level in the oil reservoir when the forks are in the lower position. Add oil if necessary. See the separate oil recommendations.

• Check that the attachment nuts of the drive wheel are tight.

• Check that all screws, nuts, and pipe connections are tight.

• Check that the machine plates and markings are secure and can be read easily.

• Clean the truck if necessary.

CAUTION: NEVER ALLOW WATER TO TOUCH THE ELECTRICAL DEVICES, PARTICULARLY IF THEY ARE LIVE! About once a month, lubricate the truck’s three lubrication points. These are: • the drive mechanism turning bearings (2 grease nipples) • the steering tooth ring.

OIL RECOMMENDATIONS Hydraulic oil: NESTE 32 Super Hydraulic oil for use in refrigerated stores: NESTE SH 15 Transmission oil: EP 80/90 Lubrication grease:NLGI No. 2, containing molybdenum sulphide, in refrigerated stores, NLGI No. 1 or No. 0.

- 22 QUARTERLY INSPECTION SERVICE (300 H) It is most economical to make an inspection and regular interval service agreement with a retailer. Only professional service will ensure trouble-free truck operation.

Service programme monitoring is facilitated by entering the service dates in a service logbook.

Besides the weekly programme, the service engineer will inspection and, if necessary, adjust or repair the following points: • contactors, micro switches, and solenoids and their cables • the brake air gap: correct dimension 0.3 - 0.8 mm • the operation of the speed control • attachment of the cylinders and the locking of the settings • lift cradle tolerances, the slope of the forks, and the attachment of the mast to the frame • the lateral tolerance of the mast. If necessary, the tolerance is adjusted by loosening the eccentric rollers, turning them, and retightening • the torque of the drive wheel attachment nuts (Torque 190 Nm) • the operation of the lifting hydraulics • the collectors, carbon brushes, and guides of the drive and pump motors

HALF-YEARLY INTERVAL SERVICE (600 H) In addition to the quarterly and weekly service programmes, the service engineer will: • Check the drive and pump motors, and, if included in the equipment: the collectors, carbon brushes, and guides of the steering motor or steering servo, and clean carbon dust from the motors.

• Change the hydraulic oil and the oil filter once a year (1200 h).

• Clean the oil filter.

• Check the operation of the hydraulic and pressure limit valves.

• Check the attachment of the transmission and change the transmission oil once a year (1200 h).

• Check the drive wheel for wear. The wheels should be changed at the latest when 10 mm of the tread is left.

• Check, clean, and lubricate the lifting chains.

• Check the condition of the extra lift.

• Check the wheels and chain guards of the lifting chains.

• Check the driver’s cab and its attachment.

• Check the condition of the battery rollers • Lubricate the wheel bearings.

FUSES

1F1, 2 Batt. discharge indicator 2F1, 2 Keyswitch 3F1 Drive- / pumpmotor 4F1 Steering motor 5F1, 2 Cabin 6F1, 2 Cabin

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7F1, 2 Drive- / pumpcircuit 8F1, 2 Steeringcircuit 9F1, 2 DC/DC-converter 24V 10F1, 2 Fans 21F1 PLC CPU 22F1 PLC I/O 23F1 Solenoidvalves 24F1 Warninglights

Fuses 101F1 102F1 103F1 105F1 106F1 107F1 121F1 122F1 123F1 124F1 321F1 322F1

/ Cabin DC/DC-converter 24V Signal horn Reserve DC/DC-converter 12, 24V Spotlight Reserve PLC CPU PLC I/O Display unit Cabinlight Radio 12V Computer equipm. 12V / 24V / 8A

WARNING NO ALTERATIONS OR REPAIRS MAY BE MADE TO THE DEVICE THAT MAY WEAKEN ITS STRUCTURE OR ENDANGER SAFETY.

“FLY BY WIRE” ELECTRONIC STEERING The truck is equipped with a new and completely electronic steering system. The steering wheel movement in electronic steering is transmitted without a mechanical connection to the motor that controls the drive wheels.

- 24 The system consists of three main components, a tachometer located in the steering wheel, a control unit located in the motor compartment, and a servo motor, which is also in the motor compartment. The control unit processes the signal coming from the tachometer and controls the servo motor to turn the drive wheel in the desired direction. In addition, the control unit constantly monitors how the system is functioning and its status. The control unit reacts immediately whenever something goes wrong.

The drive wheel turns ± 360° or ± 100°.

SAFETY When the power is turned on by the main switch and the ignition key, the system performs a diagnostic test which lasts no more than 0.3 seconds. After the test is done, the truck is fully operational and ready to use.

When the power is turned on, the system constantly performs a diagnostic check by sending a check signal throughout the system. This signal can be heard as the tapping noise emitting from the truck. In case something goes wrong, the control unit will react immediately to the situation by turning on the STEERING STOP indicator and applying the magnetic brake.

The truck immediately stops when a problem appears.

Wait for at least 2 seconds before you turn the power on again after it has switched off.

OPERATION Completely acquaint yourself with the truck and please note that when the turning wheel reaches the turning limit (± 90°), the steering wheel may continue turning as it has no mechanical stops to prevent it from doing so.

The “STEERING STOP” indicator The STEERING STOP light is lit when there is a fault in the control system or if the power is switched off and on too quickly (<2 seconds). The truck cannot be driven if the light is on.

NOTE ! Do not turn the steering wheel unnecessarly, when the truck is not moving!

MAINTENANCE The system has been designed to be as maintenance free as possible. The user only has a few simple maintenance tasks to take care of.

Quarterly maintenance check (300 hrs.)

• Fastening of the steering control unit terminals NOTE: • DO NOT under any circumstances adjust the control unit as it has been pre-set at the factory.

• DO NOT subject the control unit to running water.

An authorized serviceman can, when needed, tune the steering, e.g. the number of rotations for the steering wheel.

- 25 -

TROUBLESHOOTING

SYMPTOM:

FAULT:

PROCEDURE:

Truck does not move

• The battery connector is loose • The battery is empty • The battery has not been locked into its place • The emergency stop button is activated • The key switch is faulty • The microswitch for the tiller arm is broken • The drive motor fuse has blown

• Plug in the battery connector • Recharge the battery • Check the locking and micro switch

• Pump fuse has blown • Control current fuse has blown • Drive switch is broken

• Replace the fuse • Replace the fuse and check cables • Replace the switch

• Release the emergency stop button • Replace key switch • Replace the microswitch

• Check the connections and cables and replace the fuse • The main power fuse has blown • Check the connections and cables and replace the fuse • The drive motor carbon brushes are • Replace the carbon brushes worn out • The speed control is faulty • Contact your truck dealer The lift pump doesn't run

Lifting functions improperly • Overload • Battery is empty • Not enough oil in tank • Oil leak • Pump is faulty • Dirt in valve

• Decrease the load • Recharge the battery • Add oil • Check joints and seals • Replace the pump • Clean the valve, replace if necessary

Battery does not charge

• Check the connection • Replace the fuse

• Charger is connected incorrectly • Charge fuse has blown or mains voltage is missing • The battery cell's water level or specific gravity is low

The steering isn’t working • The control motor fuse has blown properly • The control power fuse has blown • A short voltage break (<2 sec.). It could be caused by switching the power on too soon.

• faulty servo controller (indicators are not lit)

• Check the cells current and specific gravity. Add water and / or acid when necessary. See Section "Recharging the battery" • Change the fuse (F12) • Change the fuse (F3/F6) • Switch the power off and wait more than 2 seconds. Turn the power on.

• Contact your truck dealer

The steering works poorly • The steering motor carbon brushes are • replace the carbon brushes worn out • The steering hits an obstacle when • the end line switches are faulty or strongly turning ääriasentoon misadjusted. Replace and adjust

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- 27 7F1, 2 Drive- / pumpcircuit 8F1, 2 Steeringcircuit 9F1, 2 DC/DC-converter 24V 10F1, 2 Fans 21F1 PLC CPU 22F1 PLC I/O 23F1 Solenoidvalves 24F1 Warninglights

Fuses / Cabin 101F1 DC/DC-converter 24V 102F1 Signal horn 103F1 Reserve 105F1 DC/DC-converter 12, 24V 106F1 Spotlight 107F1 Reserve 121F1 PLC CPU 122F1 PLC I/O 123F1 Display unit 124F1 Cabinlight 321F1 Radio 12V 322F1 Computer equipm. 12V / 24V / 8A

WARNING NO ALTERATIONS OR REPAIRS MAY BE MADE TO THE DEVICE THAT MAY WEAKEN ITS STRUCTURE OR ENDANGER SAFETY.

- 28 -

- 29 -

Index Pag. 1

4

5

6

General characteristics ................................................................................ 3 1.1 Technical specifications .......................................................................... 3 1.2 General scheme ..................................................................................... 3 1.3 Performance features ............................................................................ 4 1.4 Driving devices ....................................................................................... 5 1.5 The concept of compensation ................................................................ 6 1.6 Protection features ................................................................................. 6 1.7 General notes and warnings . .......................................................... 7 1.8 Main contactor and safety switch . ................................................... 8 1.9 Susceptibility and electromagnetic emission . ................................... 8 2 Installation ............................................................................................ 9 2.1 Positioning and thermal dispersion ......................................................... 9 2.2 Connection cables .................................................................................. 9 2.3 Contactors .............................................................................................. 9 2.4 Fuses ..................................................................................................... 9 2.5 Suppression ......................................................................................... 10 2.6 C1 controller mechanical drawing ........................................................ 11 3 C1 Combi connectors ........................................................................ 12 3.1 Connectors disposition ......................................................................... 12 3.2 C1 Combi power connectors description .............................................. 14 Programming and setting using the console ........................................... 15 4.1 Setting by console ................................................................................ 15 4.2 Ppogrammable console ........................................................................ 15 4.3 Map of the console function ................................................................. 16 4.4 Options: description and programming instructions ............................. 17 4.5 Adjustment: description and programming instructions........................ 20 4.6 Parameters: description and programming instructions ....................... 23 4.7 Tester: functions descriptions .............................................................. 27 4.8 Save parameters: description .............................................................. 30 4.9 Restore parameters: description .......................................................... 31 4.10 Alarms: menu description ..................................................................... 32 4.11 Program VACC: description ................................................................. 33 4.12 Instructions for making adjustments .................................................... 33 Diagnosis ..................................................................................................... 36 5.1 Traction led diagnosis........................................................................... 36 5.2 Deconding console displayed traction alarms ...................................... 37 5.3 Diagnosis pump control ........................................................................ 45 5.4 Decoding console displayed alarms ..................................................... 45 Wiring diagram ............................................................................................ 47 6.1 Diagram legend .................................................................................... 47 6.2 Decoding colours symbol ..................................................................... 47

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1 GENERAL CHARACTERISTIC 1.1 TECHNICAL SPECIFICATIONS Version Version 24 V 36V & 48V Traction maximum current (3’) ....................................... 400A ........................ 350A Traction booster current (3”) .......................................... 460A ........................ 400A Traction current 1 hour ................................................... 150A ........................ 120A Pump maximum current (3’) ........................................... 350A ........................ 350A Pump current 1 hour ...................................................... 150A ........................ 120A Traction motor maximum power..................................... 3 kW ................... 4 kW, 5kW Pump motor maximum power ........................................ 3 kW ................... 4 kW, 5kW Voltage drop (IM = 120A) ............................................. 280 mV .................... 400 mV Type of motors requested .................................... traction: DC series wound 4 terminals ............................................... pump: DC series wound Power switching device ................................................................ MOSFET Control unit ................................................................... 8 bit 12 MHz Microprocessor Maximum operating ambient temperature .................................... + 40 °C Minimum operating ambient temperature ......................................- 25 °C Relative Humidity ....................................................................... 20 % ÷ 95 % IP protection degree ........................................................................ IP 54 AC insulation ................................................................................ 550 VAC Weight (controller only) .................................................................. 4,9 kg 1.2 GENERAL SCHEME

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1.3 PERFORMANCE FEATURE – Two controllers included in a single unit, one for the traction motor with energy recovery and one for the pump motor.

– Optimum sensitivity to low speeds.

– High motor and battery efficiency due to high frequency commutation.

– Internal arc suppression of contactor coils.

– ARC less operation of contactors.

– Driving of a main contactor.

– Diagnosis with indication of the fault type via 2 LEDS. – Configuration by console.

– Modification of the parameters by console.

– Internal hour-meter with values that can be displayed on the console.

– Memory of the last five alarms with relative hour-meter value and temperature, displayed on the console.

– Tester by console for real time checking of the main parameters such as inputs, motor voltage, battery, etc..

– Programming of the traction and pump potentiometer stroke.

– Regenerative braking both in inversion and at release.

– Traction and pump speed reductions with compensation for the dropping voltage.

– Conforms to 86/663 rules referring to the point 9.7.3.5.5 and 9.7.3.1.7.

– Conforms to DRAFT PREN 1175 rules referring to the point 5.9.3,5.9.4,5.9.5,5.13,5.14,5.15.

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1.4 DRIVING DEVICES 1.4.1 Microswitches Microswitches send a voltage signal when the request for start-up or the desired function is made. Microswitches for forward, reverse are sized for carrying the current of one contactor (3A).

1.4.2 Pedal and lifting potentiometer If the 3 - wire configuration is implemented; the CPOT (G2) useful input signal goes from 0V to 10V, while at the input CPOTS (L2) the signal goes from 0V to 5V. The resistive value of the potentiometer must be between 500W and 10 kW . Lower values overload the power supply.

Relationship between the voltage signal at the pin G2 and the motor voltage.

The procedure for automatic potentiometer signal acquisition is carried out from the console. This makes it possible to adjust the minimum and maximum useful signal of the pedal stroke and of the lifting potentiometer.

The procedure is described at the paragraphs 4.11.

The acquisition procedure is invalidated by the controller if the difference between the minimum and the maximum value is less than 1 V.

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1.5 THE CONCEPT OF COMPENSATION Compensation means that the voltage on the pump motor does not depend only on the position of the potentiometer or the fixed value but also on the current drawn by the controlled pump motor. Through the parameter "COMPENSATION" it is possible to choose how much this effect influences the lifting speed, that means how much the current absorbed can affect the voltage on the pump motor. In this way the rotational speed of the pump become almost constant, even though the load on the forks changes, allowing a good control of the speed independently of the load.

1.6 PROTECTION FEATURES - Battery Inversions: Respect the connections indicated in the diagrams in order to avoid damage to the power unit. Protection against battery polarity inversion can be achieved by an external main contactor. In lifting versions, it can be connected a main contactor controlled by the logic against battery polarity inversion. The logic is internally protected.

- Connections errors: All the inputs are protected against connections errors.

Contactors do not accept loads greater than 3A and are protected against overloads and short circuits.

- Thermal Protection: If the temperature exceeds 80° C the maximum current is reduced in proportion to the thermal increase. The temperature may never exceed 85° C. - Low Battery charge: When the battery charge is too low all functions except steering are cut off.

This feature may be excluded by the Console.

- External Agents: The controller is protected against dust and splashes (IP 54) It is completely enclosed.

- Protections against accidental start-up: A precise sequence of operations is necessary for starting the machine.

If these operations are not carried out correctly the machine will not start.

The request for running must be activated after the key and seat microswitches.

The pump will not start if there is a speed request present when they key is closed.

The steering is always activated.

- Protection against uncontrolled movements: The contactors do not close if: - the power unit potentiometer has failed; - the accelerator does not go below the minimum value stored increased by 2 Volt; - the logic is not perfectly operational; - one running microswitch is closed.

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1.7 GENERAL NOTES AND WARNINGS - Never combine SCR low frequency choppers with C1 modules. The filter capacitors contained in the C1 module alter SCR chopper operation, subjecting it to excessive workloads.

If it is required to use two or more control units (e.g. lift + traction), they must all be of the high frequency ZAPIMOS family.

- Do not connect the chopper to a battery with a different nominal voltage than that indicated on the chopper identification plate. A higher battery voltage can cause MOS failure. A lower battery voltage prevents the module from operating.

- During battery recharge, the C1 module must be completely disconnected from the battery. In addition to altering the charge read by the battery charger, the module can be damaged by the higher voltage generated by the charger, and by the ripple current generated in the capacitors if the battery charger operates at low frequency.

- The C1 module must only be supplied with a traction battery. Do not use outputs of converters or power supplys. For special applications, please consult the nearest ZAPI service centre.

- Start the machine the first time with the wheels raised, to ensure that connection errors do not create safety risks.

- With the key off, the filter capacitors inside the module may remain charged for several minutes.

For safe operation, we recommend that after the battery has been disconnected, short circuit the power positive and negative on the chopper for a few seconds with a resistance of between 10W and 100W , min 2W. - Susceptibility and the Electromagnetic emission are considerably influenced by the installation. Take particular care with the length, of the electrical connections and of the braided wires.

ZAPI declines any responsibility for incorrect operation that can be attributed to the above mentioned circumstances, above all if the manufacturer of the machine doesn't carry out the tests required by the regulations in force (conducted emissions, irradiated emissions, IEC 801 - 2 (ESD), IEC 801 - 3 (irradiated susceptibility), IEC 801 - 4 (burst), IEC 801 - 5 (surge), IEC - 6 (conducted immunity)).

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1.8 MAIN CONTACTOR AND SAFETY SWITCH WARNINGS FOR THE CONNECTION - Emergency disconnection my be achieved using one at the following: - With mechanical Safety Switch (Power):

- With switch and general contactor:

- One of these circuits is necessary to prevent controller failure when the connection to the battery is opened during the phase of regenerative braking. The controller falls out automatically from braking if the battery voltage is exceed by 30% of the battery nominal voltage.

1.9 SUSCEPTIBILITY AND ELECTROMAGNETIC EMISSION Susceptibility and electromagnetic emission are considerably influenced by the installation. Take care with the length and the path of the electrical connections and to the braided wires.

Zapi declines any responsibilities for badrunning caused by the circumstances above mentioned, above all if the manufacturer of the machine doesn’t carry out the tests required by the regulations in force (EN50081-2).

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2 INSTALLATION 2.1 POSITIONING AND THERMAL DISSIPATION Install the chopper with the base-plate on a flat metallic surface that is clean and unpainted. Apply a light layer of thermo-conductive grease between the two surfaces to allow a good heat dissipation.

Despite the protection provided against external agents, the continuous presence of corrosive substances may cause the connector contacts to oxidise, thus jeopardising good operation.

Keep this in mind when choosing the installation position on the vehicle.

Use the special holes on the base-plate for fixing the chopper.

Ensure that the wiring of the cable terminals and connectors is carried out correctly.

Fit suppression devices to the horn, solenoid valves, and contactors not connected to the chopper such as those for activating the pump motor or steering motor, if the latter is not controlled by the chopper itself.

2.2 CONNECTION CABLES For the auxiliary circuits, use cables of 0,5 mm2.

For power connections to the motor and to the battery use cables of 35mm 2 - 50mm2.

For optimum controller performance, the cables to the battery should run side by side and be as short as possible.

2.3 CONTACTORS Choose the type of contactors with respect to the maximum operating current of the motor and the specific chopper configuration.

- The current drawn by the coil must not be greater than 3A. - The coil suppressors are inside the chopper. Do not use contactors with arc suppressors.

- For contactors with magnetic suppressors, ensure that the polarity indicated on the cap is respected.

- Protect the contacts against dust, dirt and, external agents which may jeopardise performance and good operation.

2.4 FUSES - Use a 10A fuse for auxiliary circuit protection.

- Use a 500A fuse for power unit protection.

The value shown is the maximum allowable. For special applications or requirements this value can be reduced.

For safety reasons, we recommend that protected fuses are used in order to prevent the spread of fused particles in the event of blowout.

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2.5 SUPPRESSION - Solenoid valves, contactors not controlled by chopper, horn and, any other kind of inductive loads shall have suppression devices connected in parallel.

Provided the arc suppresser consists of a diode, this is required to carry the same current as the coil.

- Examples: a) for pump contactor or relay.

R resistor value shall be about the same of coil resistance value; power level is to be computed as follows: V2 PW = 10R EXAMPLE: Calculate the correct value for an arc-suppresser of a contactor that has an 18W coil resistance, 24 V .

R Ω = 18Ω 24 2 576 = = 3.2W 10 ⋅18 10 ⋅ 18 therefore you will use a 18W /3W resistor.

PW =

b) Motor-horn: Combine a 10µF/100V capacitor in parallel to motor-horn contacts.

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2.6 C1 CONTROLLER MECHANICAL DRAWING

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3 C1 COMBI CONNECTORS 3.1 CONNECTORS DISPOSITION

pin A1 A2

function -LED +LED

B1 B2 B3 B4 B5 B6 B7 B8

PCLRXD NCLRXD PCLTXD NCLTXD GND +12 F.SELECT UP/DOWN

description Alarm LED negative: to be connected to the cathode Alarm LED positive: to be connected to the anode Output current 12mA, for standard type LED Serial reception positive Serial reception negative Serial transmission positive / pump alarm LED (anode) Serial transmission negative / pump alarm LED (cathode) Console supply negative Console supply positive Channel for mini - console Channel for mini - console

E1 E2 E3 E4 E5 E6 E7 E8 E9

+CH IN PT NTINDT NTIDR NTG NTI NTA PTFR NTFR

Input key that has to be connected to the feed return key.

Positive direction coil contactors.

Negative for weakening traction contactor Negative for hydrodrive contactor Negative for main contactor or state Negative for reverse contactor Negative for forward contactor Positive for braking contactor Negative for braking contactor

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F1 F2

MSED Seat microswitch input, active when high 4TH/RV1*/SLOW Carries out the same function of the input L9, it is connected with L9.

G1 G2

NPOTT CPOTT

G3 G4 G5

PPOTT ----CMM

G6 G7 G8

MF MI MA

Negative potentiometer is Battery negative Central potentiometer, it must be connected with the wiper of the accelerator potentiometer for the regulation of the traction motor speed.The useful signal goes form 0 Volt (minimum speed) to 10 Volt (maximum speed).

Positive potentiometer of the accelerator is 13V output.

Not used Common running microswitches, is a voltage output with battery potential (max 3A) Brake microswitch input is high level active (+VB) Reverse running microswitch input is high level active (+VB) Forward running microswitch input is high level active (+VB)

H1 H2 H3

----St. REC. PT AUX

Not used Output regenerative state for battery level indicator Positive for auxiliary load (max. 2A)

L1 L2 L3 L4 L5 L6 L7 L8 L9

NPOTS CPOTS -BATT PPOTS ABP 1ST 2ND 3RD/RV2*/HYD 4TH/RV1*/SLOW

Negative for lifting potentiometer Input for lifting potentiometer (range 0 ÷ 5V) Negative for common speed request micro Positive for lifting potentiometer (8,2V) Input for potentiometer enable request 1st pump speed 2nd pump speed 3rd pump speed / cutback speed n°2 / hydrodrive request 4th pump speed / cutback speed n° 1 associated to the braking in curve / pump speed reduction.

* = Connect these inputs to the normally closed contacts when they are used as (CUT BACK SPEED).

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3.2 C1 COMBI POWER CONNECTORS DESCRIPTION

+SH T - SH T +SH P - SH P

Input for traction motor current sensor Output for traction motor current sensor Input for pump motor current sensor Output for pump motor current sensor

VMN P +B -B VMN T

Power drive of pump motor Positive of the battery Negative of the battery Power drive of the traction motor

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4 PROGRAMMING AND SETTINGS USING A CONSOLE 4.1 SETTING BY CONSOLE Adjustments of the parameters and the configurations are to be carried out by the programmable Console. The Console is connected to the relative connector B. The connection is to be carried out with the key sw. open or the battery disconnected.

Pay attention to the connector polarity of the console when it is connected to the controller.

4.2 PROGRAMMABLE CONSOLE

The Console to be connected to the controller C1 is to be equipped with the EPROM CONSOLE starting from “release 2.00”.

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4.3 MAP OF THE CONSOLE FUNCTIONS

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4.4 OPTIONS: DESCRIPTIONS AND PROGRAMMING INSTRUCTIONS Configuration of the options (menu SET OPTIONS) allow selection of the operating mode of some inputs and outputs and the operating management as follows: BATTERY CHECK:

ANTIROLLBACK:

RELEASE BRAKING:

HOUR COUNTER:

ON=

The logic reading battery voltage and state of change is enabled.

When the charge is less than 10%, the traction maximum current is halved, the pump functions are disabled except the power steering.

OFF=

Management of the discharged battery alarm is disabled.

ON=

Antirollback management enabled.

OFF=

Antirollback management disabled.

ON=

Braking upon release of the running pedal (RELEASE BRAKING) is enabled.

OFF=

At the release of the running pedal the truck continues without release braking.

KEYON=

The hourmeter is always operational when the logic unit is supplied.

RUNNING= The hourmeter is activated only under the following conditions: traction running, braking, pump, power steering.

MAIN CONTACTOR:

CUTBACK INPUT #1:

PRESENT= The output E5 (NTG) is ready for the control of the main contactor. It needs to connect a resistance for the capacitors charge, see the following wiring diagrams.

NONE=

The output E5 (NTG) is disabled.

ON=

The input L9 is programmed as cutback speed request (RV1) of the traction adjustable with the parameter CUTBACK SPEED 1 (the cutback speed is activated when the microswitch is open).

OFF=

The input L9 is programmed as cutback speed request of the pump (4TH) adjustable with the parameter 4TH SPEED. The cutback speed is accepted when the microswitch is closed to battery negative.

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SLOW LIFT INPUT:

ON=

The input L9 is programmed as cutback speed of the pump set by the potentiometer, the speed is reduced to the value programmable with the parameter SLOW LIFT SPEED.

OFF=

The input L9 is accepted for working in the way defined by the option CUTBACK INPUT #1.

CUTBACK INPUT #2: ON=

HYDRO INPUT:

PUMP MODE:

OFF=

The input L8 is programmed as cutback speed request of the pump (3TH) adjustable with the parameter 3RD SPEED. The cutback speed is accepted when the microswitch is closed to battery negative.

ON=

The input L8 is programmed as power steering request from an external drive, the power steering function is activated only by this input when the microswitch is closed battery negative .

OFF=

The input L8 can work in the way defined by option CUTBACK INPUT #2.

STAND PUMP= Programme this way if there is a single motor for lifting and power steering.

PUMP+HYD=

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The input L8 is programmed as cutback speed request (RV2) of the traction adjustable with the parameter CUTBACK SPEED 2 (the cutback speed is activated when the microswitch is open).

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Programme this way when the power steering is activated by a third motor, so the power steering function works only on the output E4 (NTIDR) for activating a contactor.

Programming "options", using the console: 1) Opening Display 2) Press ROLL UP + SET UP to simultaneously enter the menu SET. 3) Headline of the menu SEL MODEL. 4) Press ROLL UP to select the menu SET OPTIONS.

5) Headline of the menu SEL OPTIONS. 6) Press ENTER to entering in the menu.

7) The first item of the menu appears.

8) Press ROLL UP or ROLL DOWN to scroll the different items.

9) A new item appears.

10) Press SET UP or SET DOWN to modify the configuration.

11) The new configuration appears.

12) Press OUT to come out of the menu.

13) Confirmation of the modification request appears.

14) Press ENTER to confirm the modifications or press OUT to cancel.

15) Headline of the menu SEL OPTIONS appears.

16) Press OUT to return back to the opening display.

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4.5 ADJUSTMENT: DESCRIPTION AND PROGRAMMING INSTRUCTIONS 4.5.1 Lifting potentiometer acquisition This function allows to carry out the acquisition of the minimum and maximum values of the lifting potentiometer output.

ADJUSTMENT operations with the console: 1) Opening display.

2) Press ROLL UP + SETUP to enter the menu CONFIG. 3) Headline of the menu SET MODEL (function not available) appears.

4) Press ROLL UP to select the menu ADJUSTMENT. 5) Headline of the menu ADJUSTMENT appears.

6) Press ENTER to enter in the menu.

7) The first item of the menu set LIFT MIN appears.

8) Press ENTER to enable the acquisition.

9) Push the lifting lever up to the closure of the microswitch (minimum voltage value).

10) While the lever is in this position press OUT. 11) Request for the confirmation appears.

12) Press ENTER to confirm the acquisition or OUT to cancel it.

13) Headline of the menu adjustments appears.

14) Press ROLL UP to select the next menu.

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15) SET LIFT MAX appears.

16) Press ENTER to enable the acquisition.

17) Push the lifting lever up to the end of its stroke (maximum voltage value).

18) While the lever is at the end-of-stroke, press OUT. 19) Request for the confirmation appears.

20) Press ENTER to confirm the acquisition or OUT to cancel it.

21) Headline of the menu.

22) Press OUT to return to the main menu.

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4.5.2 Set battery voltage This function allows fine settings of the internal measurement of the battery voltage if it is too high the voltage dropout to the key is disabled. This setting operation requires the same measurement values, read in the console to be the same as measured on the battery.

ADJUSTMENT operations with the console: 1) Opening display.

2) Press ROLL UP + SETUP to enter the menu CONFIG. 3) Headline of the menu SEL MODEL (function not available) appears.

4) Press ROLL UP to select the menu ADJUSTMENT. 5) Headline of the menu ADJUSTMENT appears.

6) Press ENTER to enter in the menu.

7) The first item of the menu (only ADJUSTMENT BATTERY is available) appears.

8) The button SETUP increases the value shown on the display, the button SET DOWN decreases it.

Set to the same value as measured on the battery with a multimeter.

9) Press OUT to come out from the menu.

10) Confirmation of the request for modifications appears.

11) Press ENTER to confirm the modifications or OUT to cancel them.

12) Headline of the menu ADJUSTMENTS appears.

13) Press OUT to return to the opening display.

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4.6 PARAMETERS: DESCRIPTION OF THE PROGRAMMING INSTRUCTIONS The Controllers adjustment parameter levels are carried out in the menu PARAMETERS CHANGE. For each parameter 10 adjustment levels are available (9 for the pump speeds).

The traction parameters are indicated with the symbol T. The pump parameters have the symbol P. 1)

ACCELER DELAY (t) = acceleration time, that is the minimum time during which the motor voltage comes from 0V to the maximum value.

9)

CUTBACK SP.1 (t) = speed reduction RV1 associated to the input L9 and F2. The accelerator is reduced and put on scale. The parameter can be activated if the option CUTBACK INPUT #1 is programmed ON.

3)

CUTBACK SP.2 (t) = speed reduction RV2 associated to the input L8. The parameter can be activated if the option CUTBACK INPUT #2 is programmed ON.

4)

BRAKE CUTBACK (t) = speed reduction level applied when the braking pedal is pressed and accelerator is not released.

5)

TRACTION IMAX (t) = defines the maximum current of the traction controller both during running and braking.

All the adjustments of current are defined in percentage of this value. The adjustment range is from 50% (level 0) to 100% (level 9).

6)

INVERSION BRAKING (t) = braking base current at running inversion.

Added to a value in response to the accelerator, plus a fixed increment each second.

7)

RELEASE BRAKING (t) = braking current at pedal or running release.

8)

PEDAL BRAKING (t) = braking current at running release with braking pedal pressed (pin G6 activated).

9)

HYDRO TIME (p) = delay time for the power steering drop out.

10) WEAK DROPOUT (t) = current threshold for the opening of the weakening contactor.

11) CREEP SPEED (t) = this defines the minimum voltage applied to the motor with the running request on. This allows a more prompt response when starting.

12) PLUG CURRENT (t) = braking current when the controller is braking in plugging mode (only for emergency brakings, when the regenerative braking does not trigger off).

13) BRAKING MODUL (t) = defines the entity of the accelerator for increasing of braking current during inversion.

Pressed completely, during inversion, the braking becomes as stronger when the accelerator is as the higher the value of the parameter.

14) COMPENSATION (t) = speed compensation (motor voltage) in association to the current when speed reductions are activated. It is activated only with the pedal pressed more than 80%.

15) PU. ACCELER DELAY (P) = pump motor acceleration time.

16) PU. DECELER DELAY (p) = deceleration time, for cancelling the voltage on the motor at release.

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17) PUMP IMAX (p) = defines the maximum current of the pump controller. All the adjustment of the pump are defined in percentage of this value. The adjustment range is from 50% (level 0) to 100% (level 9).

18) SLOW LIFT SPEED (p) = pump speed reduction set by the potentiometer, the speed is put on scale for the programmed coefficient. The function is activated only when the option SLOW LIFT OPTION is selected ON. 19) HYD SPEED COARSE (p) = coarse power steering speed (from 0% to 100% Vbatt on the motor). The parameter is activated if the option PUMP MODE is programmed STANDARD PUMP. 20) HYD SPEED FINE (p) = fine power steering speed (it is added a value from 0% to 10% Vbatt to the coarse speed). The parameter is activated if the option PUMP MODE is programmed STANDARD PUMP. 21) HYDRO COMPENS (p) = compensation for power steering. The parameter is activated if the option PUMP MODE is programmed STANDARD PUMP. 22) 4TH SPEED COARSE (p) = n° 4 pump speed coarse regulation. The parameter is activated if the option CUTBACK INPUT #1 is programmed OFF. 23) 4TH SPEED FINE (p) = n° 4 pump speed fine regulation. The parameter is activated if the option CUTBACK INPUT #1 is programmed OFF. 24) 4TH SPEED COMP. (p) = n° 4 pump speed compensation. The parameter is activated if the option CUTBACK INPUT #1 is programmed OFF. 25) 3RD SPEED COARSE (p) = n° 3 pump speed coarse regulation. The parameter is activated if the option CUTBACK INPUT #2 is programmed OFF. 26) 3RD SPEED FINE (p) = n° 3 pump speed fine regulation. The parameter is activated if the option CUTBACK INPUT #2 is programmed OFF. 27) 3RD SPEED COMP. (p) = n° 3 pump speed compensation. The parameter is activated if the option CUTBACK INPUT #2 is programmed OFF. 28) 2ND SPEED COARSE (p) = n° 2 pump speed coarse regulation.

29) 2ND SPEED FINE (p) = n° 2 pump speed fine regulation.

30) 2ND SPEED COMP. (p) = n° 2 pump speed compensation.

31) 1ST SPEED COARSE (p) = n° 1 pump speed coarse regulation.

32) 1ST SPEED FINE (p) = n° 1 pump speed fine regulation.

33) 1ST SPEED COMP. (p) = n° 1 pump speed compensation.

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4.6.1 C1 Adjustment chart

PARAMETERS

PROGRAMMED LEVEL UNIT

0

1

2

3

4

5

6

7

8

9

sec.

0.9

0.9

1

1.1

1.3

1.5

1.7

1.9

2.1

2.3

CUTBACK SPEED 1 E 2

%

20

28

36

45

53

62

69

78

86

100

BRAKE CUTBACK

%

20

28

36

45

53

62

67

78

86

100

TRACTION IMAX (24V)

Amp.

200

222

244

266

288

310

332

354

376

400

TRACTION IMAX (36 / 48V)

Amp.

175

194

213

233

252

271

290

310

329

350

INVERS. BRAKING

%IMax.

15

18

22

25

28

32

35

38

42

45

RELEASE BRAKING

%IMax.

15

19

23

27

31

36

38

42

46

50

PEDAL BRAKING

%IMax.

15

19

23

27

31

36

38

42

46

50

sec.

0

0.5

2

4

7

9

12

14

17

20

WEAK DROPOUT

%IMax.

10

20

30

40

50

60

70

80

90

100

CREEP SPEED

%VBatt

0

1.9

3.9

5.9

7.8

9.8

12

14

16

18

PLUG CURRENT

%IMax.

10

20

30

40

50

60

70

80

90

100

BRAKING MODUL

%IMax.

0

3

5

8

11

14

17

20

22

25

COMPENSATION

K (I)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

PU ACCELER DEL

sec.

0.15 0.24 0.39 0.50 0.63 0.74 0.86 0.97

1.1

1.2

PU. DECELER DEL

sec.

0.06 0.13 0.19 0.25

0.31 0.38 0.44 0.50 0.56 0.62

PUMP IMAX

Amp.

175

194

213

233

252

271

290

310

329

350

%

2

4

8

10

15

20

25

30

40

50

HYDRO 1/2/3/4 SPEED COARSE

%Vbatt

0

11

22

33

44

55

66

77

88

100

HYDRO 1/2/3/4 SPEED FINE

%VBatt

0

1.2

2.4

3.6

4.8

6

7.3

8.5

9.7

10.9

K (I)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

ACCELER. DELAY

HYDRO TIME

SLOW LIFT SPEED

HYDRO 1/2/3/4 SPEED COMP.

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How make the programming operations with the console: 1) Opening display.

2) Press ENTER to enter the main menu .

3) The headline of the first item, PARAMETER CHANGE appears.

4) Press ENTER to enter to the function PARAMETERS. 5) The first parameter of the list appears.

6) Scroll the list of the parameters with the buttons ROLL UP and ROLL DOWN. 7) The item of the parameters appear.

8) Change the programmed level with the buttons SET UP and SET DOWN. 9) The new value adjusted appears.

10) Press OUT when programming is finished.

11) The confirmation request appears.

12) Press ENTER to confirm the modifications or OUT to cancel.

13) The headline of the item PARAMETER CHANGE appears.

14) Press ROLL UP or ROLL DOWN for scrolling the other items, or press OUT for coming back to the opening display.

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4.7 TESTER: FUNCTIONS DESCRIPTION Some of the most important input/output signals can be measured in real time using the tester function of the console. Here are the hems and their meanings: TRACTION VMN:

Is the value of the voltage measured between B-'ve and the terminal VMNT; 3 voltage ranges are available: 0% = from 0% to 22% of the battery voltage; 50% = from 22% to 70% of the battery voltage; 100% = from 70% to 100% of the battery voltage.

PUMP VMN:

Is the value of the voltage measured between B-'ve and the terminal VMNP; 3 voltage ranges are available: 0% = from 0% to 22% of the battery voltage; 50% = from 22% to 70% of the battery voltage; 100% = from 70% to 100% of the battery voltage.

TR V. MOTOR PU:

Is the voltage applied to the motors measured between the terminals -SHT and VMNT for the traction and between the terminals -SHP and VMNP for the pump. The value TR is the traction motor voltage; the value PU is the pump motor voltage. All the values are in Volts.

TR I. MOTOR PU:

Is the current drawn by the motors measured between the terminals -SHT and VMNT for the traction and between the terminals -SHP and VMNP for the pump. The value TR is the traction motor current and the value PU is the pump motor current. All the values are in Amps.

BATTERY VOLTAGE:

Is the battery voltage on the input CH pin E1. Capacity = 60V; resolution = 0,3V; accuracy = ± 1,5%.

TEMPERATURE:

Is the temperature of the aluminium baseplate close to the MOSFET devices. Range = -27°C ÷ 100°C; resolution = 1°C; accuracy = ± 1°C.

ACCELERATOR:

Is the voltage of the traction accelerator signal on the input CPOT pin G2, range 0V ÷ 10V, resolution 0,04V, accuracy = ± 1%. The voltage value is on the left side of the display whilst on the right there is the percentage value of the signal relative to the function PROGRAM VACC.

LIFTING CONTROL:

Is the voltage of the pump accelerator signal on the input CPOTS pin L2.The voltage value is on the left side of the display whilst on the right there is the percentage value of the signal relative to the function PROGRAM VACC. Range 0V ÷ 5V, resolution 0,02V, accuracy = ± 1%.

FORWARD SWITCH:

Is the state of the forward running digital input, MA pin G8.ON ), input active, voltage on the connector. / +VB = ( ), input in stand-by, connector OFF / GND = ( free.

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BACKWARD SWITCH: Is the state of the reverse running digital input, MI pin G7. ON ), input active, voltage on the connector. / +VB = ( OFF / GND = ( ), input in stand-by, connector free.

CUT BACK SWITCH 1: Is the state of the cutback speed 1 digital input (RV1 pin L9).

The tester of the function is activated when the option CUTBACK INPUT #1 is programmed ON. ), input in stand-by, connector to OFF / GND = ( battery negative.

ON / +12 = ( ), input active, connector free.

CUT BACK SWITCH 2: Is the state of the cutback speed 2 digital input (RV2 pin L8).

The tester of the function is activated when the option CUTBACK INPUT #2 is programmed ON. OFF / GND = ( ), input in stand-by, connector to battery negative.

ON / +12 = ( ), input active, connector free.

BRAKE SWITCH:

Is the state of the braking pedal digital input, FR pin G6. ), input active, voltage on the conON / +VB = ( nector. OFF / GND = ( ), input in stand-by, connector free.

SEAT SWITCH:

Is the state of the digital input from the seat microswitch, MSED pin F1. ON / +VB = ( ), input active, voltage on the connector.

OFF / GND = ( ), input in stand-by, connector free.

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How to enter the TESTER function of the console: 1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select TESTER. 5) The selected item (TESTER) appears.

6) Press ENTER to enter the function TESTER. 7) The first signal tested appears.

8) Scroll the signals tested with the buttons ROLL UP and ROLL DOWN. 9) The following signal appears.

10) Press OUT to return to the item list.

11) The selected item appears.

12) Press ROLL UP and ROLL DOWN for scrolling the remaining items, or press OUT to return to the opening display.

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4.8 SAVE PARAMETERS: DESCRIPTION The function SAVE PARAM. allows loading on the console memory parameter values and the controller configuration data. It is possible to load max 64 configurations.

The data stored on the console memory can be loaded again on another controller by means of the function RESTORE (par. 4.9).

Data loaded with the function SAVE is: - all the parameters values (PARAMETERS CHANGE); - the settings of the options (SET. OPTION); - the setting of the battery (ADJUST BATTERY).

How to enter the SAVE function by the console: 1) Opening Display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select SAVE PARAM. 5) The selected item (SAVE PARAM.) appears.

6) Press ENTER to enter the SAVE function.

7) In the first line the model code selected, appears in the second line it appears FREE if the memory box is free or the name of the model if it is busy.

8) Select the model code with the buttons ROLL UP and ROLL DOWN. 9) The new model code selected and its condition (FREE/BUSY) appears.

10) Press ENTER to confirm the reading operation.

11) On the second line the items of the parameters stored scroll.

12) At the end of the operation it returns to the main menu SAVE PARAM.

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4.9 RESTORE PARAMETERS: DESCRIPTION The function RESTORE PARAM allows transfer of data stored in the console memory to the controller in the same way of the model loaded with the function SAVE PARAM. Data loaded in the controller by means of the function RESTORE PARAM. is: - all the parameters values (PARAMETERS CHANGE); - the settings of the option (SET. OPTION); - the setting of the battery (ADJUST BATTERY).

ATTENTION:

the function RESTORE overwrites all the data of the controller.

After this operation, old configuration data is cancelled.

How to enter in the RESTORE function by the console: 1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select RESTORE PARAM. 5) The selected item (RESTORE PARAM.) appears.

6) Press ENTER to enter the function RESTORE PARAM. 7) In the first line the model code selected appears and in the second line the type of controller stored in the memory appears.

8) Select the model code with the buttons ROLL UP and ROLL DOWN. 9) The model code selected and the type of controller stored appears.

10) Press ENTER to confirm the loading operation.

11) The confirmation request for the operation appears (ENTER = YES, OUT = NO).

12) Press ENTER to confirm the loading operation (OUT for cancelling).

13) The list of the parameter items during the loading phase appears.

14) At the end of the operation it returns to the main menu RESTORE PARAM.

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4.10 ALARMS: MENU DESCRIPTION The controllers stores the last five alarms, recording the following information: alarm code; how many times this is occurred; the temperature and the hourmeter value in the occurrence of the alarm. In the menu ALARMS of the console, it is possible to enter in this data memory.

This function allows a deeper diagnosis, knowing the sequence of the alarms occurred.

How to enter the menu ALARMS. 1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select ALARMS. 5) The selected item (ALARMS) appears.

6) Press ENTER to enter the function ALARMS. 7) The first alarm occurred with the number of times, hourmeter and temperature, appears.

8) The button ROLL UP scrolls the previous alarms, the button ROLL DOWN returns to the more recent.

9) If there were no other alarms, ALARM NULL appears.

10) Press OUT to leave the menu ALARMS. 11) The confirmation request for cancelling all the alarms stored, appears.

12) Press ENTER to confirm the operation (OUT for returning to the main menu).

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4.11 PROGRAM VACC: DESCRIPTION This function allows storing of the minimum and maximum values for the accelerator signal in each running direction. This is necessary to compensate for the asymmetry in the mechanical operation of the potentiometer.

This operation is made using the pedal. After entering the menu PROGRAM VACC, the following the operations are described below.

How to enter in the menu PROGRAM VACC and carry out the operations: 1) Opening display.

2) Press ENTER to enter in the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select PROGRAM VACC. 5) The selected item (PROGRAM VACC) appears.

6) Press ENTER to enter the function PROGRAM VACC. 7) The maximum current values matched to the forward and backward running appears.

8) Press ENTER. 9) The controller is now ready to record the minimum and the maximum value of the potentiometer signal.

10) Press the pedal. Move slowly at the start and complete the stroke.

N.B. : select the direction before pressing the pedal.

11) The new maximum and minimum values for each running direction appears.

The arrow indicates the direction selected.

12) Press OUT. 13) The confirmation request for storing new values appears.

14) Press ENTER to confirm or OUT to cancel.

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4.12 INSTRUCTIONS FOR MAKING ADJUSTMENTS With the machine switched off, connect the programming console and then switch on. If no errors are found, the display shows the manufacturer's name, program release, configuration, and hourmeter value.

4.12.1 Traction adjustment sequence 1) Select the desired options.

2) Select and set battery voltage.

3) Check the operation of all the wired inputs, including the potentiometer, by means of the tester functions on the console.

4) Carry out accelerator signal acquisition on the “PROGRAM VACC” menu.

5) Set the maximum current by selecting the level corresponding to the desired value shown on the table of modifications (point 5.1.4 and 5.2.4).

6) Set acceleration by moving the machine forward and backward.

7) Set the CREEP speed starting from level 0. With the machine stopped, press the pedal lightly in order to close the direction microswitch, leaving the potentiometer at the minimum value, and then raise the level of the CREEP until the machine begins to move.

8) To set the speed reductions, activate the desired reduction request microswitch, take the compensation level to 0, set the speed (CUTBACK SP.l, etc.) with machine in standby on a flat surface and the accelerator pedal pressed all the way down.

Then, apply a load on the machine or put it on a slope. In these conditions set the compensation level until you reach the desired speed.

9) RELEASE BRAKING is set by running the machine and then completely releasing the accelerator pedal without pressing other pedals.

10) For INVERSION BRAKING, first set the MODUL BRAKING level at 0, run the machine and invert the direction with the pedal pressed down, then regulate the braking level.

11) MODUL BRAKING with accelerator. A parameter that increases the inversion braking according to the level of the accelerator signal; set this by inverting the direction with the pedal pressed all the way down.

12) Release braking with brake pressed (PEDAL BRAKING). Set by pressing the brake pedal lightly during release.

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4.12.2 Pump adjustment sequence 1) Select and set battery voltage.

2) Check the operation of all the wired inputs, including the potentiometer, by means of the tester functions on the console.

3) Carry out accelerator signal acquisition on the “PROGRAM VACC” menu.

4) Set the maximum current by selecting the level corresponding to the desired value.

5) Set the speed of the respective functions with the machine in standby, and the level of compensation set at “0”. Apply a load and set the compensation until it reaches the desired speed.

The adjustment of speed and compensation are interdependent. Therefore further adjustments must be made before reaching the optimum condition.

6) Set the hydrodrive speed in the same way as the others. The only difference being that the speed is set with the steering in standby, while the compensation is set with the steering is under load.

7) Set acceleration, deceleration, and creep as necessary.

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5 DIAGNOSIS 5.1 TRACTION LED DIAGNOSIS Description of the alarms signalled by the diagnostic LED. The alarm code is shown in parentheses. A detailed description is given in the section “DECODING THE ALARMS DISPLAYED ON CONSOLE” on point 5.5.

1 FLASH = Logic Anomaly (EEPROM KO, WATCH DOG).

2 FLASHES

=

Running request on startup or error in handle/speeds sequence (INCORRECT START).

3 FLASHES

=

Error on VMNT test (NO FULL CONDUCTION, VMN LOW, CAPACITOR CHARGE).

4 FLASHES

=

Accelerator high in standby - this error inhibits operation (VACC NOT OK).

5 FLASHES

=

Error in reading current - this error inhibits operation (I HIGH AT STAND, I=0 EVER).

6 FLASHES

=

Malfunction of the contactor driver circuit (DRIVER SHORTED, COIL SHORTED).

7 FLASHES

=

Excessive temperature, greater than 80°C (TH. PROTECTION).

8 FLASHES

=

Contactors do not open or VMN high in standby (BRAKE CONT. OPEN, DIR CONT. OPEN, VMN HIGH).

9 FLASHES

=

Contactor failure (BRAKE CON CLOSED, DIR CONT CLOSED).

CONTINUOUS FLASHING (32 FLASHES) =

Low battery charge, battery with <10% of residual charge (BATTERY).

LED REMAINS ON = Double running request (FORW BACK).

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5.2 DECODING CONSOLE DISPLAYED TRACTION ALARMS 1)

BRAKE CON CLOSED Test carried out in the transition to running state or when starting the regenerative braking. When a direction contactor closes, if the VMNT is > 2/3 VBATT, an alarm is issued. Possible causes are: a) The normally open contact of the braking contactor has failed or welded. Free the contact and clean it: if it is damaged replace the contactor. b) The braking contactor remains closed to much, due to a detect in the logic board or because the NTFR wire is in shorted to b-'ve.

To understand if the defect is produced by one of these causes, select a direction, press the pedal without giving the seat or tiller request, if the operation of the braking contactor occours at the same time as the pedal (or selector) command verify what follows: disconnect the wire from the NTFR connector and repeat the test above. If the contactor remains disactivated replace the logic, otherwise if the contactor moves check that there is not a short circuit with some metallic part.

2) DIR. CONT. OPEN Test carried out at running request: direction contactor closure is verified by checking that the VMN signal is consistent. a) To find the causes follow the diagnosis procedure below: CONDITION UNDER WHICH FAULT IS DETECTED

TEST

ONLY AT FORWARD RUNNING REQUEST

YOU SEE FORWARD CONTACTOR (TA) CLOSING FOR 0.3sec. THEN OPENING?

ONLY AT BACKWARD RUNNING REQUEST

AT BOTH RUNNING REQUEST

YOU SEE BACKWARD CONTACTOR (TI) CLOSING FOR 0.3sec. THEN OPENING?

YOU SEE FORWARD OR BACKWARD CONTACTOR (TA OR TI) CLOSING FOR 0.3sec.

THEN OPENING

TEST

RESULT

FAULT DESCRIPTION AT POINT:

YES

→

→

A1

YES

B1

NO

WHEN REQUESTING FORWARD RUNNING YOU FIND ANY VOLTAGE AT COIL CONTACTS FOR 0.3 sec.?

NO

C1

→

A2

YES

B2

NO

C2

→

A3

YES

B3

NO

C3

RESULT

YES

→

NO

WHEN REQUESTING BACKWARD RUNNING YOU FIND ANY VOLTAGE AT COIL CONTACTS FOR 0.3sec.?

YES

→

NO

WHEN REQUESTING FORWARD RUNNING YOU FIND ANY VOLTAGE AT TA COIL'S CONTACTS (OR AT BACKWARD CONTACTOR COIL'S CONTACTS (BTI)) FOR 0.3sec.?

A1) There is not a good contact either on TA (=forward contactor) NA (normally open) or on TI (=backward contactor) NC (normally closed), due to dust, dirt or any particles which prevent a valid contact.

Clean contacts by means of compressed air; if necessary remove dirt applying a soft abrasive movement.

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It may be necessary to change both contactors.

A2) There is not a good contact either on TI NA or on TA NC, due to dust, dirt or any particles.

Clean contacts by means of compressed air; if necessary remove dirt applying a soft abrasive movement.

It may be necessary to change both contactors.

A3) The most likely reason is that the normally closed contact of the braking contactor doesn’t make good contact Battery Negative. This dust, may be due to dirt or because the contact doesn’t close completely due to an internal mechanical defect.

It may be necessary to replace the contactor.

Due to 1 of following causes: a) Open circuit brushes (fig.1). b) Burning of brush cables (fig.2). c) B-'ve missing on regen contactor (fig. 3) d) Open circuit motor or cables.

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B1) Forward contactor (TA) supplied with correct voltage but it does not close.

Possible causes: 1) Contactor coil is open circuit, verify its resistance using an ohmmeter.

2) Mechanical restriction.

3) Incorrect coil voltage.

B2) Reverse contactor (TI) is supplied with a correct voltage but it does not close; everything relative to point B1 for TA is valid here.

B3) Reverse and forward contactors are supplied with correct voltage but do not close; see point B1.

C1) Supply is not present on TA. Check cables and connections from TA coil to connectors E2 (PT) and E7 (NTA).

C2) Supply is not present on TI. Check cables and connections from TI coil to connectors E2 (PT) and E6 (NTI).

C3) Supply is not present on TA and TI. Check cables and connections from the coils to connectors E2 (PT), E6 (NTA) and E7 (NTI).

- For points C1, C2, C3 replacement controller of the may be necessary.

3)

BRAKE CONT. OPEN. (regenerative only) Test carried out during the passage to running state. After closure of the running contact, the braking contactor closes, verifying that the VMNT goes from < 1/3 to > 2/3. Not, an alarm is shown.

To find the cause follow the diagnosis procedure below:

TEST

RESULT

2° TEST

RESULT

3° TEST

YES

→

→

→

FAULT RESULT DESCRIPTION AT POINT A4 → A5 YES

AT RUNNING REQUEST THE TFR CLOSES FOR 0.3sec?

NO

WHEN THERE'S THE RUNNING REQUEST, IS THERE A VOLTAGE AT PIN BTFR FOR A TIME OF 0.3sec?

YES

CHECK WITH AN OHMMETER OF THE TFR COIL IS INTERRUPTED

B4 B5

NO B6

NO

→

Combi

→

C4

Page 39

A4) There is not good contact on the NA of TFR. Clean the contact, if it is damaged too much, replace the contactor.

A5) Positive is missing on the braking contactor.

B4) Replace the contactor coil or the complete contactor.

B5) Contactor mechanically locked, Rectify or replace.

B6) Contactor has incorrect coil fitted. Fit correct coil.

C4) Supply does not appear at the contactor coil. Check the cables and the connections from the coil to the connector E8 (PTFR) and E9 (NTFR). If there are no errors in the cables, there may be failures in the electronic board. In this case it is necessary to replace the logic.

4) DIR. CON. CLOSED The running contactor remains closed (locked).

Test carried out during the passage to standby or braking. Check that the running contactor opens by comparing the consistent status of the VMNT potential. Possible causes: a) Running contactor locked or slow to open; b) Logic failure.

5) VMN LOW. The test is carried out at standby and in running up to 80% of PWM. If the VMNT voltage is lower than 1/3 of the battery voltage, an alarm is shown.

To find the causes follow the diagnosis procedure following:

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CONDITIONS UNDER WHICH FAULTS IS DETECTED

1° TEST

AT THE KEY ON

DISCONNECT THE MOTOR CABLE CONNECTED TO THE BATTERY AND THEN VERIFY IF THE ALARM STILL PRESENT

RUNNING WITH CONTACTORS ON RUNNING POSITIONS

→

AS SOON AS THE ACCELERATOR IS IT PRESENT THE PEDAL IS BYPASS OR THE COMPLETLY WEAKENING RELEASED FOR CONTACTOR? DOING A RELEASE BRAKING

FAULT RESULT DESCRIPTION POINT:

RESULT

2° TEST

RESULT

3° TEST

YES

→

→

→

→

C5 B7

YES

NO

THE LOCKED CONTACTOR COIL IS SUPPLIED?

YES

A RUNNING CONTACTOR IS LOCKED IN WORKING POSITION

NO

B8 D1 D2 D3

NO

→

→

→

→

→

C5

YES

→

→

→

→

E1

NO

→

→

→

→

C5

B7) If the running contactor remains locked, verify: 1) if the wire going from NTA to NTI is sometimes shorted to a metallic part connected to the battery negative; 2) disconnecting the contactor wire always excited from board connector if the contactor is no longer excited, replace the logic board.

B8) A direction contactor is locked in the working position, unlock the contact. It may be necessary to replace the contactor.

D1) Incorrect connection of the motor cables. The stator and the armature are crossed.

D2)

There is a current leakage in the motor between the stator winding and the armature. Otherwise there are some electric parts of the windings that make contact inside the motor.

D3)

Check that there are no metallic parts inside the contactor board that cause a short toward negative in the points connected to -SHT and +SHT.

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C5)

The most likely reason is that the failure is inside the controller. Replace it.

E1)

If there is a bypass contactor check that it is not locked or it is too slow in opening. To verifying this possibility, disconnect the bypass and check if the failure disappears: if this happens, replace the logic.

ATTENTION: the contactors connected to the controller must not have arc suppressers fitted on the contactor coils. These are internally connected to the controller. Any external suppression will modify the contactor opening times.

6) VMN HIGH. Test carried out in standby. If the VMN voltage is greater than 2/3 VBATT, an alarm is shown. Possible causes: a) Short circuit between +BATT and VMN. Check if there are any metallic parts causing short circuit in the contactor board. b) The traction motor cable could have been crossed with a pump motor cable. c) Logic failure, probably the braking diode has failed. Replace the power block.

7) NO FULL COND. The test is carried out in full conduction. If, in this condition, the VMN is found to be greater than 1/3 VBATT, the diagnostic circuit is faulty, causing a safety risk, thus machine operation is inhibited. If the defect persists, replace the logic.

8) HIGH TEMPERATURE An indication that the controller temperature has exceeded 80° C. The maximum current is gradually reduced, reaching 0 at a temperature of 85° C. a) If the alarms occurs while cold, the most probably reason is the failure of the thermal circuit on the power, or on the logic board, replace as appropriate or replace the complete controller. b) If the alarm occurs after short time after the machine has been working, it is probably due to inadequate heat sink. Check the retaining fixing nuts and the correct installation.

9) BATTERY The battery charge is low.

The alarm is signalled only if the “battery check” option has been selected from the console (default). When this alarm occurs, the maximum current is reduced to 50%.

10) INCORRECT START An incorrect starting sequence.

The machine only starts if the following sequence is made: key-handle (or seat) running. Possible causes: a) Direction microswitch or handle microswitch failure. b) Error in sequence made by the operator, pedal pressed at the key on. c) Incorrect wiring. If there are no defects externally, it may be necessary to replace the logic.

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11) FORW - BACK The test is carried out continuously. An alarm is signalled when two requests for running are made simultaneously. Possible causes: a) Defective wiring. b) Running microswitch closed or failed. c) Incorrect manoeuvre. d) If there are no external defects, replace the logic.

12) VACC NOT OK The test is made in standby.

The alarm indicates that the accelerator voltage is greater than 1V with respect to the minimum value stored. Possible causes: a) A potentiometer wire is open circuit. b) The potentiometer is not correctly calibrated. c) The potentiometer is defective (interrupted).

13) STBY I HIGH Test carried out in standby. Checks that the current is zero.

If this is not verified, an alarm is signalled. This alarm inhibits machine operation.

Possible causes: a) Current sensor failure or logic failure.

First replace the logic. If the defect persists, replace the power unit.

14) I=0 EVER Test carried out in running.

Checks that the current during running is greater than a minimum value. If not, an alarm is signalled and the machine is shut down. Possible causes: a) The current sensor is faulty. Replace the power unit. b) Incorrect connection of the motor cables to the power bars -SHT and +SHT. 15) EEPROM KO Fault in the area of memory in which the adjustment parameters are stored. This alarm inhibits machine operation. If the defect persists when the key is switched off and on again, replace the logic.

16) WATCH - DOG The test is made in both running and standby.

It is a self-diagnosis test within the logic. If an alarm should occur, replace the logic.

17) COIL SHORTED An overload or a short circuit toward +BATT on the contactor negative driver outputs. Possible causes: a) The contactor coils are short circuit or draw more than 6 A continuous. b) Short circuit with +BATT of the wiring that comes from the contactor connector.

The alarm indicates an overload, not the breakdown of a chopper component. Once the external cause is removed, the chopper can be restarted.

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18) DRIVER SHORTED The test is carried out in standby, and checks that the voltage of the drivers that control the contactors is consistent with the preset value.

Possible causes: a) Logic failure. b) Driver breakdown caused by overvoltage in the contactor negative wiring.

Replace the logic after having removed the cause.

19) CAPACITOR CHARGE Test is carried out at the key on when the option MAIN CONTACTOR has been selected at the PRESENT mode. It verifies that the VMNT rises to a value > 1/3 Vbatt in less 1 sec.; if the VMNT overcomes 1 sec, there is a fault that stops the capacitors charging. An alarm appears and the main contactor does not close.

Possible causes: a) Power circuit failure. b) A short circuit or leakage between the motor and battery negative.

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5.3 DIAGNOSIS PUMP CONTROL Description of the alarms signalled by the diagnostic LED. The alarm code is shown in parentheses. A detailed description is given in the section “DECODING THE ALARMS DISPLAYED ON CONSOLE”.

1 FLASH = Logic Anomaly (EEPROM KO, WATCH DOG).

2 FLASHES = Running request at the startup (INCORRECT START).

3 FLASHES = Error on VMN test (PU NO FULL CONDUCTION, PUMP VMN LOW, CAPACITOR CHARGE).

4 FLASHES = Lift potentiometer not calibrated.

5 FLASHES = Error in reading current - this error inhibits operation (PUMP STBY I HIGH, PUMP I=0 EVER).

6 FLASHES = Malfunction of the contactor driver circuit (DRIVER SHORTED, COIL SHORTED).

7 FLASHES = Excessive temperature, greater than 80°C (HIGH TEMPERATURE).

CONTINUOUS FLASHING (32 FLASHES) = Low battery charge, battery with < 10% of residual charge (BATTERY).

5.4 DECODING CONSOLE DISPLAYED ALARMS 1)

PUMP VMN LOW. The test is carried out in standby. If the VMNP voltage is lower than 1/3 of the battery voltage, an alarm is signalled. Possible causes: a) Check the motor wiring. b) Chopper failure. Replace.

2)

PU NO FULL COND. The test is carried out in full conduction.

If, in this condition, the VMNP is found to be greater than 1/3 VBATT, the diagnostic circuit is faulty, causing a safety risk, and thus machine operation is inhibited. If the defect persists, replace the logic.

3)

INCORRECT START. A running request is present at the key start-up.

Possible causes: a) Operator error; b) Request microswitch closed. The presence a power steering only request at the key on does not cause an alarm.

4)

PUMP STBY I HIGH Test carried out in standby, checks that the current is zero.

If this is not verified, an alarm is signalled. This alarm shuts down the machine.

Possible causes: a) Current sensor failure and logic failure.

First replace the logic. If the defect persists, replace the power unit.

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5) PUMP I=0 EVER Test carried out in running.

Checks that the current during running is greater than a minimum value. If not, an alarm is signalled and the machine is shut down. Possible causes: a) The current sensor is faulty. Replace the power unit.

6) EEPROM KO See the description indicated at the par. 5.2, alarm n° 15 7) WATCH-DOG See the description indicated at the par. 5.2, alarm n° 16 8) HIGH TEMPERATURE See the description indicated at the par. 5.2, alarm n° 8 9) CAPACITOR CHARGE See the description indicated at the par. 5.2, alarm n° 19 10) COIL SHORTED See the description indicated at the par. 5.2, alarm n° 17 11) DRIVER SHORTED See the description indicated at the par. 5.2, alarm n° 18 12) BATTERY See the description indicated at the par. 5.2, alarm n° 9

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6 WIRING DIAGRAM 6.1 DIAGRAM LEGEND AP AUX AV BTA BTFR BTG BTI BTIDR BTIND CH EV IN MA MCL MD MF MI MS MSED MT MUM NT POT RV TA TFR TG TI TIDR TIND

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

Micro potentiometer Auxiliaries (load) Forward Forward direction contactor coil Braking contactor coil Main contactor coil Reverse direction contactor coil Hydrodrive contactor coil Weakening contactor coil Key Solenoid valve Reverse Forward running microswitch Horn microswitch Descent microswitch Mechanical brake pedal microswitch Reverse running microswitch Lifting microswitch Seat microswitch Tiller microswitch Dead man microswitch Negative of the contactor Potentiometer Speed reduction Forward direction contactor Braking contactor Main contactor Reverse direction contactor Hydrodrive contactor Weakening contactor 6.2 DECODING COLOURS SYMBOL

Colour coding of wires: A B BB C G GG

ORANGE WHITE BLUE CYAN YELLOW GREY

M N R RR V VV

BROWN BLACK PINK RED GREEN PURPLE

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Page 48

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ZAPIMOS

C1 COMBI

OPERA TING HANDBOOK AND ATING FUNCTIONAL DESCRIPTION

MOTOR CONTROLLER FOR ELECTRONIC POWER STEERING

FLY BY WIRE INSTALLATION/OPERATION MANUAL for FBW 4820 FBW 2440 Publication no 88Q020 Rev.C Date:2000-05-04 54Q020PB 54Q020NB 54Q020RB 54Q020QB

TABLE OF CONTENTS Content 1.

page

Overview ...................................................1

2.

Specifications

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16

General ..............................................2 Battery voltage ...................................2 Current capacity.................................3 Analog control inputs .........................3 Voltage outputs..................................3 Voltage input......................................3 Digital control inputs ..........................4 Safety relay output.............................4 Motor speed feedback .......................4 Safety system ....................................4 Indications..........................................5 Operating environment ......................6 Cooling and isolation .........................6 EMC...................................................6 Block diagram ....................................7 Mechanical dimensions .....................8

3.

3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.3 3.3.1 3.3.2 3.4 3.4.1 3.4.2 3.4.3 3.5 3.5.1 3.5.2

Installation instructions Connections...................................... 9 Components required .......................10 Main contactor..........................10 Power fuse ...............................10 Control fuse ..............................10 Battery and motor cables .........10 Control wiring............................10 Limit switches ...........................10 Battery power supply ................11 Steering wheel tachometer.......11 Servo motor and gear...............11 Connectors .......................................12 Control connector .....................12 Power connector ......................12 Adjustments ......................................13 Current limit ..............................13 IR-compensation ......................13 Tachometer input scaling .........13 Indications.........................................14 LED ..........................................14 Output.......................................14

1. OVERVIEW ELECTRONIC POWER STEERING FOR INDUSTRIAL BATTERY TRUCKS FLY BY WIRE is the name of a series of controllers for electronic power steerings, developed by Atlas Copco Controls in co-operation with manufacturers of industrial battery trucks.

A complete steering system includes: - electronic controller, FLY BY WIRE - reference sensor (tachometer) - DC-motor with gear - contactors, fuses and cables The electronic controller is designed to control a fully electric power steering system. There is no mechanical connection between the steering wheel and the traction wheel.

The FLY BY WIRE controller continuously monitors the entire steering system to prevent any hazards. Any faults in the sensor, the cables, the controller or the motor, will result in a fault condition and deenergized safety relay, diagnosed by LED and optoisolated outputs.

When using a fully electric steering system the vehicle has to be stopped automatically if any errors occurs.

This is achieved by connecting the safety relay, in the controller, to an electric brake in the vehicle.

The safety system meets the European: Safety of machinery - Industrial trucks prEN 1175-1 Part 1: Electrical requirements for battery powered trucks.

The power MOSFET transistors controlling the servo motor current provide high efficiency, high reliability and long lifetime. The PWM switching frequency of 16kHz reduces motor losses and provides silent operation.

The controller has current and speed regulators and armature feedback with compensation for motor voltage drop, I*R-compensation.

Cooling is achieved by mounting to a flat metal surface in the vehicle.

The right selection of sensors and servo motors is very important to guarantee reliable operation. Atlas Copco Controls will assit in this matter.

.......................................

1

2. SPECIFICATIONS 2.1

GENERAL Models

2440 .................

........................

4820 .................

Part no

Motor type

........................

FBW 4820 (48V battery voltage)

2440 .................

54Q020PB

4820 .................

54Q020NB / 54Q020RB / 54Q020QB

........................

PM DC -motors

Motor inductance....................

min. 0,5mH

No. of quadrants .....................

4Q

Modulation

PWM (Puls Width Modulation)

........................

Switching frequency...............

2.2

FBW 2440 (24V battery voltage)

16kHz

BATTERY VOLTAGE Nominal

2440 .................

24VDC

4820 .................

48VDC

2440 .................

16-30VDC

4820 .................

33-58VDC

2440 .................

12VDC (Start level > 20V)

4820 .................

24VDC (Start level > 40V)

2442 .................

36VDC

4820 .................

72VDC

Tolerances: Continuous

Intermittent <50ms

<100µs

........................

2

2.3

CURRENT CAPACITY Peak

2440 .................

40A

4820 .................

20A

Thermal average 2440 .................

25A

........................

4820 .................

15A

Adjustable current limits....... ........................

2.4

At +55oC environmental temperature

50-100% of peak current.

Adjustable in 4 steps with dipswitches

ANALOG CONTROL INPUTS From tachometer, put on the steering wheel: Reference value ..................... ........................ ........................ ........................ ........................ ........................

2.5

Progressive characteristic input, meaning increased sensitivity when faster rotation.

VOLTAGE OUTPUTS + .....................

2.6

+-1,3VDC up to +-5,9VDC Scaling adjustable in 16 steps with dipswitches.

+24VDC via 50 Ohm PTC

VOLTAGE INPUT Internal supply The same input as .................... start/stopp 2440 .................

24VDC

4820 .................

48VDC

........................

3

2.7

DIGITAL CONTROL INPUTS Logic "0"=<4VDC Logic "1"=>8VDC max 58VDC

2.8

Start/stop ........................

The same input as internal supply

Logic 1/logic 0

Positiv direction limiting ........ ........................

Logic 0: no limiting Logic 1: limiting

Negative direction limiting..... ........................

Logic 0: no limiting Logic 1: limiting

SAFETY RELAY OUTPUT Safety relay

2440 .................

24VDC (closed): ok

4820 .................

48VDC (closed): ok

........................ ........................ ........................ ........................

2.9

0VDC (open): error Relay data: max 48VDC, 3A

MOTOR SPEED FEEDBACK Armature feedback with I*R-compensation.

I*R-compensation ................... ........................

Adjustable in 4 levels with dipswitches

2.10 SAFETY SYSTEM When errors are detected the safety relay opens within 75ms and the controller blocks power output.According to prEN 1175-1 The control is achived by a current pulse which is generated by the safety system with frequency of 15Hz. The pulse passes through the sensor, power electronics and motor circuit. If the pulse disappears or changes shape beyond certain limits the safety system will indicate error.

At every start up the safety system is checked by an error simulation. It takes max 0,3 sec.

If the controller is stopped (turned off) it has to be >2 sec. before a new start up.

........................

4

Tachometer circuit

........................ ........................

Disconnections and short circuits are detected.

Electronic controller............... ........................

Motor output voltage above commanded values detected.

Motor circuit

Disconnections and short circuit are detected.

........................ ........................

Temperature protection ......... ........................ ........................

Short circuit protection .......... ........................

Linear reduction of current limit starting at 75oC .

Power supply contactor .........

At every start-up: checking that contactor is open

Emergency brake coil.............

At every start-up: checking there is no voltage on the coil

Direction limit switches .........

In direction limiting mode there is still possible to get max 20-40% of supply voltage on the motor output

- Motor output+ to motor output- Motor outputs to battery -

2.11 INDICATIONS LED-indications

- Controller active - Negative direction blocking active - Positive direction blocking active - Error in tacho sensor circuit - Error in controller or motor circuit - Error in controller - Supply contactor closed or voltage on emergency brake coil

Outputs indications

- Controller active - Error in sensor circuit - Error in controller or motor circuit - Error in controller - Supply contactor closed or voltage on emergency brake coil

5

2.12 OPERATION ENVIRONMENT Temperature: Operation Storage

........................ ........................

-35oC - +55oC -40oC - +70oC

Humidity

........................

100% condensing according to IEC 68-2-30, Db

2.13 COOLING External cooling ........

Contact cooling to metal plate or frame

Isolation .....................

500VAC according to prEN 1175-1

2.14 EMC Immunity:

According to prEN50081-2

Emmission:

According to prEN50082-2

6

Common

Error signal 2

Error signal 1

Direction blocking

-

+

Potentiometer

Tachometer

-12V

Tachometer 0V

+12V

Start/Stopp Safety relay

9

12

3

5

11

10

6

7

13 4

8

1

+ +

-

Monitor puls

IR-sensitivity

R

C

Blocking and sensitivity Speed regulator

Sensors monitor

Current limit

DC

+

-

Current monitor

Voltage monitor

PWM

Voltage monitor

Logic circuits monitor

R

C

Current regulator

DC

Temperatur sensor

Bat.-

M2

M1

Bat. +

2.15 BLOCK DIAGRAM

7

2.16 MECHANICAL DIMENSIONS

64

152 139 125

145

210

6.5

10

.......................

8

.......................

Safety brake

Truck computer

Limit switches

Steering wheel tachometer

0 1

Key switch

Control fuse

9

12

10

3

5

11

6

4

13

8

1

Error indication no 2, low

Error indication no 2, high

Controller

LED

LED

Battery-

Motor-

Current limit adjust.

Motor+

LED

Error indication no 1, low

Tachometer input scaling

Battery +

IxR-comp. adjust.

LED

Error indication no 1,high

- Direction limiting

+ Direction limiting

Tachometer

0V Tachometer

+24V

Safety circuit relay

Start/Stop Internal supply

-

M2

M1

+

Steer motor

Supply contactor

Power fuse

B-

B+

3.INSTALLATION INSTRUCTIONS

3.1 CONNECTION

9

3.2

COMPONENTS REQUIRED

3.2.1 POWER SUPPLY CONTACTOR It must be controlled directly from the safety relay as shown in the drawing.

Other connections may delay closing of main relay and cause error condition.

Switching current 2440 .............

50A

4820 ............

25A

2440 ............

30A slow

4820 ............

15A slow

3.2.2 POWER FUSE Current

3.2.3 CONTROL FUSE Current

...............

6-10A slow

3.2.4 BATTERY AND MOTOR CABLES Dimension

2440 ............

min. 4mm2

4820 ............

min. 2,5mm2

3.2.5 CONTROL WIRING Dimension

...............

min. 1mm2

3.2.6 LIMIT SWITCHES Normal open (NO) Operating at 5mA

...............

10

3.2.7 BATTERY POWER SUPPLY Other power switching units on the same power supply cables may affect the controllers internal capacitor. Please consult Atlas Copco Controls in this case.

3.2.8 STEERING WHEEL TACHOMETER Use only tachometers recommended by Atlas Copco Controls.

3.2.9 SERVO MOTOR AND GEAR Use only motors and gears recommended by Atlas Copco Controls.

.......................

11

3.3

CONNECTORS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

3.3.1 CONTROL CONNECTOR, 13-pin MIC, make: AMP Pin no

Function

1 2 3

Input:

4 5 6 7 8 9 10 11 12

Input: Input: Input:

13

Output:

Start/stop and internal supply Not connected Error indication no 1, high

Input: Output:

Tachometer Negative direction limiting Reference value from tachometer Not connected Safety circuit relay Error indication no 2, low Error indication no 1, low Positive direction limiting Error indication no 2, high

Output:

Supply for limit switches

Output: Output:

24,48 V max 24 V, 5mA (open collector) 0V 15-48 V +-[1,3-5,9] V 24,48 V

24,48 V max 24 V, 5mA (open collector) +24 V (max 20 mA)

3.3.2 POWER CONNECTOR 4-pin POSITIV LOCK (5-pin with center pin excluded), make: AMP Pin no. + M1 M2

Function Input: Input: Output: Output

Battery voltage+ Battery voltageMotor connection + Motor connection -

24,48 V 0V

12

3.4

ADJUSTMENTS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

3.4.1 CURRENT LIMIT Dipswitch no 1 and 2: Both switches open: Switch no. 2 closed: 1: 1+2:

4820

2440

10A 14A 17A 20A

20A 28A 34A 40A

3.4.2 IR-COMPENSATION Switch no 3 and 4: Both switches open: Switch no. 3 closed: 4: 3+4:

No compensation 1/3 2/3 Max compensation

3.4.3 TACHOMETER INPUT SCALING Switch no. 5, 6, 7 and 8: Switch no.

5+6+7+8 closed: 6+7+8: 5+7+8: 7+8: 5+6+8: 6+8: 5+8: 8: 5+6+7: 6+7: 5+7: 7: 5+6: 6: 5: Switch no.

5+6+7+8 open:

+-1,3V +-1,6V +-1,9V +-2,3V +-2,6V +-2,9V +-3,2V +-3,5V +-3,8V +-4,1V +-4,4V +-4,7V +-5,0V +-5,3V +-5,6V +-5,9V

13

3.5 INDICATIONS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

3.5.1 LED: LED 1 on (green): LED 2 on (red): LED 3 on: LED 4 on LED 5 off: LED 4 off LED 5 on: LED 4 on LED 5 on: LED 1 on LED 4 off LED 5 off, and controller is not starting up; no output from safety circuit relay, 8:

controller active negative direction limiting active positive direction limiting active error in sensor circuit error in controller or motor circuit error in controller

supply contactor closed or voltage on emergency brake coil *

Outputs:

Error indication: No 1 open no 2 open: No 1 active no 2 open: No 1 open no 2 active: No 1 active no 2 active: No 1 open no 2 open, and controller is not starting up; no output from safety circuit relay, 8:

controller active error in sensor circuit error in controller or motor circuit error in controller

supply contactor closed or voltage on emergency brake coil *

* It has to be > 2 sec between a controller stop (turned off) and a new start up. Otherwise this error may occur.

14

EA 1/4"

EA 1/4"

N 1/2"

M 1/4" Y11

Y14 Y13 Y12

P1 1/2"

T 1/2"

M

2005-06-10

1:1 HYDRAULIC DIAGRAM

TH48 0605 NOH

TH48 0605

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

K11 6/16

1

10A

2

2

1L1

2L1

3L1

4L1

12/28

6/12

4/14

4/21

E

10A

5

X21: 8

X121: 6

X121: 8

CABIN A

101F1

10A

BATT. DISCHARGE INDICATOR

X1:B-

E

3

G

10A

10F1 5

7

9L2 2/21

7L1

8L1

9L1

10L1

7/23

10/17

2/12

14/12

10A

G

106F1 7

3/26

105L1

106L1

3/12

13/13

3/21

13/25

SIGNAL HORN

DC/DC-CONVERTER 24V

STEERING MOTOR

DRIVE-/PUMPMOTOR

MAIN CONTACTORS

E

CABIN

102L1

101M1

102M1

3/12

13/13

105M1

106M1

3/21

13/25

105M2 3/26

2

1M1

2M1

3M1

4M1

12/29

6/16

4/14

4/21

2

4

10A

X121: 9

X21: 7

X21: 9

10A

K12 6/17

1

8 H

7M1

8M1

9M1

10M1

6/22

10/19

2/12

14/12

9M2 2/21

2

8

5F2 D

10A

106F2 F

D

6

2F2

6

105F2

X121: 7

4 10A

10A

102F2 B

B

10A

9F1

105L2

8/25

10A

10A

C

6/22

5

3

10A

8F1 1

101L1

101F2

1F2

10A

A

7L2

105F1

101L2

KEYSWITCH

G1: 48VDC

C

102F1 1

X1:B+

10A

7F1 7

X21: 6

10A

G

6F1

5F1

FANS

3

30A

4F1

DC/DC-CONVERTER 24V

1

1

3F1

STEERINGCIRCUIT

500A

C

2F1

1

2,5mm2

DRIVE-/PUMPCIRCUIT

10A

A

2,5mm2

SPOTLIGHT

10A

1F1

2

DC/DC-CONVERTER 12,24V

1

6F2 10A

F

7F2 10A

H

2,5mm2

4

8F2 B

10A

6

9F2 D

10A

8

10F2 F

10A

H

2,5mm2

1

2

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

1 / 20

POWER SUPPLY 48V

3-6869

2

11

12

13

14

15

16

17

18

19

20

+48V

21

22

23

24

25

26

27

28

29

30

+48V

9L1

9L2

1/28

1/28

5A

A

21F1

5A

C

22F1 1

5A

E

H

5A

24F1

23F1 3

5A

G

221F1 7

5

8

22L4 11/12

23L2

10/21

9/12

13/27

21L1

22L1

23L1

24L1

221L1

5/20

5/21

9/24

13/18

15/29

21M1

22M1

23M1

5/21

6/19

9/24

13/18

21M2

22M2 9/21 22M3

23M2

24M2

9/15

13/27

5/25

Vi+

WIREGUIDANCE

Go-

WARNING LIGHTS

SOLENOIDVALVES

Gi-

24V/8A

PLC I/O

G3 48V

24L2

Vo+

PLC CPU

Vi+

22L3 10/22 22L2

Vo+

G201 48V

24V/5A

Gi-

Go-

24M1

10/24

221M1 15/29

5A

2

5A

4

22F2

21F2 B

5A

6

23F2 D

F

9M1

9M2

1/28

1/28

NO:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

2 / 20

POWER SUPPLY 24 V BASE

3-6869

2

11

12

13

14

15

16

17

18

19

20

21

+48V

22

23

24

25

26

+48V

101L1

105L1

1/19

1/23

5A

A

121F1

5A

C

122F1 1

5A

D

123F1 3

5A

28

29

30

+48V 105L2 1/23

F

G

5A

124F1 4

27

6

H

8A

321F1

322F1 7

8

122L4 16/18 122L3 7/12

124L1

321L1

5/21

8/23

13/23

14/18

48V

Gi-

24V/8A

Go-

121M1

122M1

123M1

124M1

5/21

7/19

8/23

13/23

121M2

122M2

Vi+

Vo+

12V/5A

Gi-

16/19

5/25

Vi+

G301 48V

322L1

RADIO 12V

G101

PLC I/O

Vo+

PLC CPU

Vi+

CABINLIGHT

123L1

5/20

DISPLAY UNIT

121L1

122L2 7/13 122L1

5/24

Go-

ATK 12V / 24V / 8A COMPUTER EQUIPMENT

121L2

Vo+

G302 48V

Gi-

12V/24V/8A

Go-

322M1

321M1 14/18

5A

2

5A

5

123F2

121F2 B

E

101M1

105M1

105M2

1/19

1/23

1/23

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

3 / 20

POWER SUPPLY 24V CABIN

3-6869

2

12

13

14

15

16

17

18

19

20

21

4L1

3L1 1/17

1/18

1

1

K0

10/19

2

2

K3

27

28

29

30

BY-PASS CONNECTION ONLY IN WIRE GUIDANCE VERSION

H

4

4

K2 3

2

K1

A1

A2

M1 1

2

X12: M1

+SHP

K2 7/26

X13: 1

1 -SHP +SHT

D2 VMNT

-BATT

M2

M3

48V A2

X13: 2 VMNP

X12: M2

D1

ZAPI COMBI

-SHT

TRACTION/PUMP MOTOR CONTROLLER

48V D1

A1

A2

X12: BA1

A2

3M1

4M1

1/17

1/18

DRIVEMOTOR

PUMPMOTOR

ATLAS COPCO 4820

7/26

3 48V

7/25

26

3

1

K1 7/25

25

X12: B+

R1

+BATT

K3 7/27

3

24

2

X4: 3

7/27

23

K4

7/24

4

22

STEER MOTOR CONTROLLER

11

STEERINGMOTOR

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

4 / 20

MAINCIRCUITS

3-6869

2

11

12

13

14

15

16

17

18

19

20

21

121M1

+24V 121L1

3/15

22

23

24

+24V 122L1

+24V 121L2

3/16

3/15

26

27

28

29

30

121M2 3/15

X161:

X160:

3/15

25

L+ 8

3

X162:

M

1L+

1

1M

2L+

2M

DC OUTPUTS

1M

2M

DC INPUTS

A101.1 X115: A1 B1

X122: 1

1M

2M

RELAY DC INPUTS OUTPUTS

A101.2

+24V

21M1

+24V

2/15

21M2 2/15

22L1 2/16

21L1 2/15

X15: A1

M

PLC ( CABIN )

2

X22: 1

L+

X60:

X61:

2

X62:

B1 PLC SUPPLY L+ 8

3

M

1L+

1M

2L+

2M

1M

2M

L+

M

1M

2M

L+

M

1M

2M

1 DC OUTPUTS

DC INPUTS

A3.1

RELAY DC INPUTS OUTPUTS

A3.2

RELAY DC INPUTS OUTPUTS

A3.3 OPTION

PLC ( BASE ) Siemens S7-200

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

5 / 20

PLC SUPPLY

3-6869

2

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

7L2 1/26

A3.1 2L1 PLC

1/14

DC OUTPUTS 3

K22

0.0

19

X21: 1

X121: 2

1 7

X121: 3 K22 19

+ C11 -

6 9

X21: 10 K22

1

19

11

R11 2

X21: 2

X121: 1

X21: 3

X121: 10

X7: 1

X128: 1

X124: 1

A

V1 NO SAFETY PEDAL

14

S111 13

S121 X128: 2

COM

K

X7: 2 J1 7/24

X26: 1

KEYSWITCH

X121: 11 22

32

22

32

21

31

X46: 1

S1

S112 21

31

EM.STOP

X21: 11

EM.STOP

1

Y1

F104 4

X124: 2

X124: 3

2

M1

1 48V 2

K21 10/20

3

+ A1 48V A2

K11

K12

A1 48V A2

-

F103

F102

+

K22

2 24V 10

-

22M5

X46: 2

X26: 2

9/17

2M1

22M1

7M1

1/14

2/16

1/26

MAINCONTACTORS

BRAKERELAY

MAGN.BRAKE

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

6 / 20

DRIVECIRCUIT 1

3-6869

2

11

12

13

SAFETY PEDAL

14

STEERING WHEEL SW.

15

17

18

19

20

B111

122L3

122L2

122L11

3/16

3/16

8/15

122L7

122L5

11/15

15

21

22

23

24

25

26

28

29

30

A3.2

HANDACCELERATOR

2.2

X124: 6

27

PLC RELAY OUTPUTS

GRN

X128: 3

16

WHT/ BLK

X146:1

3

1L

WHT/ BRN

WHT

4

2.1

7

BLK

ORA

6

5

+48V

2.0

.2

2.4

.1

.0

2L

.4

J1 6/21

7L1 1/26

X24: 11 X126A:3 X126B:3 X144: 1

4

5

5

6

4

6

8

7

8

X44: 11

7

122L6

NO

S113

122M1 X122: 4 3/16 J102

122L5 4

13

J101 10/23

COM

X122: 3

21 RUN STOP

10/24

X22: 4

3

X44: 12 X24: 12

0,5-5V

X144: 2

X22: 3

R2 0V

S122

22

OPTION *S212

10/25

4,7k

X3: 5

X3: 7

MAGN. BRAKE

1

MOTOR BRAKE

BW

SLOW 2,5km/h

FW

2

X3: 6

X3: 4

X3: 8

X3: 9

X3: 10

X3: 11

X4: 5

X4: 9

BACKWARD

X124: 7 FORWARD

X128: 4

X3: 2

2

1

3

1

1 E

G ZAPI COMBI

5

6

7

F

8

1

8

G

L

E 2

5

7

6

9

8

TRACTION MOTOR CONTROLLER

0.3 0.3 PLC

0.2 0.2

0.0 0.0

0.1

A1 K0

0.1

A1 48V A2

K1

A1 48V A2

K2

A1 48V A2

K3

A1 48V A2

DC INPUTS

A101.1 No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

7 / 20

DRIVECIRCUIT 2

3-6869

2

LIFT

13

SERVICE LOWER

14

15

ERGONOMICAL LIFT

16

17

ERGONOMICAL LOWER

18

19

20

21

22

23

24

25

CABINLIFT/LOWER

22L5

122L11

122L12

123L1

101L2

10/21

7/14

11/20

3/17

1/19

2

3

4

5

6

7

14

S3

14

13

S115

4

13

S116

7

3

6

5

4

J1 J10 2

PLC

.6

3

2

12

1

14

DISPLAY-/CONTROL UNIT

1

15

J10 18

5

16

X126A: 10 X126B: 10

12

X4: 10

X4: 8

LOWER LASKU

14

13

14

X122: 5

X122: 6

0-5V

LIFT NOSTO

12

13

0V

X126A: 11 X126B: 11

X124: 9

X22: 5 R5 1k

X22: 6 2

R6 1

X4: 6

0.0

0.1

0.6 0.6

.5

X125: 13

1

0.1

30

RELAY OUTPUTS (2L) 2.6 2.5

A111

0.0

29

4

3

X124: 8

28

X126B:9 X126A:9

(RL450229)

S2

27

A3.2

R101

1

26

PUMP ANALOG CONTROL ENABLE

12

PUMP LOW SPEED (ERGO)

11

0.7 0.7

0.4 0.4

1k

2

X4: 7

0.5 0.5 2

3

6

5

L PLC DC INPUTS

PLC DC INPUTS

PUMP MOTOR CONTROLLER

123M1 A3.1

3/17

A101.1

A1

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

8 / 20

LIFTCIRCUIT 1

3-6869

2

11

12

13

14

15

A111

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

+24V

A3.1

23L1 PLC

J10 6

17

0.6

0.5

0.6

X125: 14

X125: 15

X122: 7

X122: 8

X22: 7

X22: 8

K23

8 24V - 1

2/17

DC OUTPUTS 0.7

0.5

K24

8 24V - 1

1.0

0.7

K25

8 24V - 1

1.1

1.0

1.1

4

K26

8 24V - 1

22M5

22M6

6/19

13/15

4

K24

4

K25

18

K26

19

3

20

3

3

X7: 3 1

R3 J2

22M4

20

20

2 4

K23 23L2

3,9k

X7: 4

7 5

K23

17

3

17

6

2/17

23M2 2/17

J2 13

X27: 1

2

X27: 3

X27: 4

X7: 5 1

X27: 2

R4 1k

X7: 6 1 +24V

3 C+

4 C-

1

2

X27: 5

2

+

2 0 V

A1 24V A2

-

X27: 9 +

Y13

A1 24V A2

-

Y14

A1 24V A2

-

14

X27: 6

A11 Y11

+

Y12 22M4

X27: 7

A1 24V A2

CABINLOWER VALVE

22M2

23M1

2/16

2/17

SERVICE LOWER CONTROL

X27: 8

CABINLIFT

ERGOLIFT

X27: 10

ERGOLOWER

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

REV

NOH10K: NEW FUSEBOX

9 / 20

LIFTCIRCUIT 2

3-6869

2

11

12

13

14

15

16

17

STEERING WHEEL TAKOMETER

18

19

20

21

+48V

22

PLC DC OUTPUTS

8L1

22L2

1/27

2/16

-

27

X166: 2

0.3

K21

NOTE 2 2

X56: 3

1

20

30

S12

S13

X220:9

BLU

2

3

BRN

X29: 1

BLK

BLU

2

3

22L6

22M7

12/13

12/14

1.0

0.6

1.0

0.7

0.6

0.7

PLC DC INPUTS

A221

A3.1 PLC DC OUTPUTS 0.1

0.0

J101

J102

122L6

7/17

7/18

7/15

0.2

0.1

0.5

0.2

0.5

X126B: 15

X3: 12 + F101

STEERING LIMIT CCW

STEERING LIMIT CW

3

2/16

X36: 4

X11:

2

22M3

A101.1

A1 48V (K41) A2

BLU

2/16

0.0

K4

X30: 1

BLK

22L3

1.1

X56: 4

NOTE 1

BRN

6

1.1

WGA SAFETY RELAY

X122: 10

X28: 1

BLK

OHJAUS OK STEERING OK

X220:5

X22: 10

29

STEERING SENSORS

BRN

0.4

5

X22: 9

28

8/12

0.4

X36: 3

X122: 9

26

22L5 0.3

X126A: 1 X126B: 2

25

S11

B112

X166: 1

24

+24V

A3.1 +

23

X125: 3

X125: 4

X125: 5

X125: 6

10

22

11

1

K21

8 48V - 1

A111-J2:

23

12

24

-

4

6

11

5

7

1

8

X3: 13 DISPLAY UNIT

STEER MOTOR CONTROLLER

8M1 1/27

A2

A111 STOP

NOTE 1:CONNECTED ONLY IN WGA VERSION NOTE 2:NOT CONNECTED IN WGA VERSION

STEERING FALESAFE RELAYS

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

NOH10K: NEW FUSEBOX STEERING CIRCUIT

10 / 20

REV

3-6869

2

11

12

13

14

15

(MAST ) CHAIN SENSORS

16

17

18

19

GATE SWITCHES

CHAIN SENSORS

20 SLACK CHAIN ACKNOWLEDGE

21

22

23

24

25

26

27

28

22L7

122L7

122L8

122L12

122L8

22L7

2/16

28

7/12

24

8/17

18

13

X24: 1

X24: 3

X129: 1

X44: 1

X44: 3

X129: 9

22

11

21

0.2 0.2

22

11

21

X129: 6

4

S117

S312

4

12

22

11

21

S127

3

22

S128

21

X129: 7

22

S311

21

22

X44: 7

X44: 9

X129: 4

X129: 2

1.0 1.0

1.1

S18

21

22

S211

22 21

21

X44: 6

X44: 8

X44: 10

X24: 6

X24: 8

X24: 10

22

X124: 10

X129: 8

1.1

22

S17

21

21

0.3

A3.1

S124

S126

0.3

PLC DC INPUTS

X44: 5

OPTIONAL HEIGHT

12

BOTTOM LIMIT

12

X24: 4

X24: 9

4500mm

21

X24: 2

X24: 7

TOP LIMIT

11

S123

OPTIONAL HEIGHT

22

X44: 4

X24: 5

21

12

X44: 2

X129: 13

22

3

S16

X129: 11

1200mm

S15

X129: 5

S125

30

HEIGHT LIMIT SWITCHES

OPTIONAL HEIGHT ACKNOWLEDGE

22L4

X129: 3

29

1.2 1.2

X129: 10

X124: 11

1.3 1.3

.0 2.0

X129: 12

1.4 1.4

X129: 14

1.5 1.5

.1

1.5

2.1

PLC DC INPUTS

1.5

.1

.0 2.0

2.1

PLC DC INPUTS

A101.2

A101.1

A101.1

A101.2

A3.1

A3.2

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

NOH10K: NEW FUSEBOX CONTROL CIRCUIT 1

11 / 20

REV

3-6869

2

11

12

13

14

15

OPTIONS: AISLE SENSORS LEFT SIDE

S21

16

17

18

19

20

21

22

23

24

25

26

0.7

1.0

27

28

29

30

OPTION RIGHT SIDE

S22

END

S212

A101.1 PLC DC OUTPUTS 0.6

RED

WHT

BRN

X31: 1

BLK

BLU

2

RED

3

WHT

BRN

BLK

X32: 1

BLU

2

3

RED

X33: 1

22L6

22M7

22L8

10/28

10/30

16/12

0.4

0.5

0.4 PLC

ORA

BLU

2

0.7

1.0

1/13

X21: 4

X21: 5

X121: 4

X121: 5

X125: 7

X125: 8

X125: 9

X125: 1

X125: 2

A111-J2: 14

2

3

6

17

h

DISPLAY UNIT

A3.2

A111

A NOTE: S21 AND S22 NOT USED IN WGA VERSION

SLACK CHAIN

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

1M1

1/13

2.2

DIGITAL IN

A3.1

1L1

3

.2

0.5

0.6

CIRCUIT DIAGRAM

TS721006

SLOW DRIVE

OPTIONAL HEIGHT

NOH10K: NEW FUSEBOX CONTROL CIRCUIT 2

HOUR METER

BATTERY INDICATOR

12 / 20

REV

3-6869

2

11

12

13

14

15

16

17

18

A3.1

102L1 1/20

PLC DC OUTPUTS

21

22

23

0.1

CABINLIGHTS +24V

25

27

28

29

OPTION

WORKING LIGHTS +48V

REVERSE VARNING-BUZZER/LIGHT +24V

124L1

106L1

24L2

3/18

1/24

2/18

30

X131: 9 X131: 10

K27 15

4

X151: 9

4

S321 S114

26

OPTION

2/18

3

0.2

24

24L1

0.2

0.1

X124: 4

20

WARNING LIGHTS +24V

SIGNAL HORN +48V

19

K28 16

3

14

4

13

X25: 3

X25: 1

X124: 5

X45: 3 X1

DATE: 2006-10-02

H11 LEFT

V101

X128: 5 K A

OPTION: Warning light

X1

24V X2 2x10W

H12 RIGHT

X45: 2

X45: 4

X25: 2

X25: 4

24V X2 2x10W

X1

H171

48V

X45: 5

X1

+

E311

24V X2

H211

X171: 7

X2

-

X1

2/ 4

LEFT

24V 1

H212

24V X2

X45: 6

X171: 8 X1

E312

24V X2

X25: 6

RIGHT

A1

H111

OPTION:Simultaneous function

A2

X128: 6

X25: 5 X171: 4

X45: 1

REV 2

X151: 13

X171: 1

E111

CHANGE: OPTIONS ADDED

3

K27

+ 5 24V - 1

K28

+ 8 24V - 1

X171: 2

X171: 3

X131: 11

X131: 12

102M1

22M6

24M1

124M1

106M1

24M2

1/20

9/20

2/18

3/18

1/24

2/18

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

NOH10K: NEW FUSEBOX SIGNAL-/LIGHTCIRCUIT

13 / 20

REV

3-6869

2

11

12 +48V

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

AUXILIARY FANS

10L1

321L1

1/29

3/24

RIGHT -

W211

X131: 1

B211 +

ANTENNA X151: 1

X54: 1

X74: 1

X94: 1 +

+12V RED

M11

48V

RED

M12

BLK

48V

BLK

RED

M13

48V

RIGHT SPEAKER

RADIO RECEIVER

BLK

LEFT + SPEAKER -

GND A211 X54: 2

X74: 2

X94: 2

X151: 2 X131: 2

+ B212 -

10M1

321M1

1/29

3/24

LEFT

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

NOH10K: NEW FUSEBOX FANS, AUX. DEVICES

14 / 20

REV

3-6869

2

11

12

13

14

15

16

17

18

STEERING MODE SWITCH

19

20

21

FRONT ANTENNA (ANT.1)

A222

22

23

24

25

REAR ANTENNA (ANT.2)

A223

26

27

28

STEERING FEEDBACK POT

SPEED/DIR. FEEDBACK

R221

B221

29

30

+24V

221L1 2/24

1

S331 X152: 1

14

22

13

21

3

+

-

X36:1

2

J331 X132: 1

X244: 1

16/19

122L15

X152: 2

X152: 3

X132: 2

X132: 3

2

3

4

5

X264: 1

7

2

3

4

5

X56:1

7

16/25

221L2

3

8

7

11 12

12

13

X263: 3

X243: 5

7

X36: 6

3.3

X36: 7

.3

X56: 6

X56: 7

X56: 8

X56: 9

X222: 16

20

21

19

18

BW

FBW

A221

X221: 11

X221: 6

X222: 2

X56: 10

X56: 11

X56: 12

X36: 9

X56: 5

FW

-15V

WIRE GUIDANCE UNIT

.2

X36: 8

+15V

+15V

X11: 9 WGA

WGA

X36: 10

X36: 11

X36: 12

3

12

10

X222: 3

4

WG REF-

13

15

X220: 6

X56: 2 K221

1

+ 8

WG REF+

1

WGA ERROR

3.2 .1

GND

WGA STOP

3.1 .0

+15V

OFF WIRE

3.0

+24V

6

RELAY OUTPUTS

1L

X36: 5

X224: 5

9

X220:1

2

GND

A3.3

6

X263: 2

X224: 1 PLC

X223: 5

X263: 1

DC INPUTS

2.7 FBW (MAN)

SEARCH

PLC

23

.7

LOCKED

A101.2

X243: 3

2.6 WGA

X243: 2

.6

X243: 1

+24V

K222

1

+ 8

K223

1

+ 8

K224

1

K225

+ 8

1

+ 8

X36: 2

AUTO

STEER MOTOR CONTROLLER

WIRE GUIDANCE UNIT

A221

A2

221L2

221M1

30

2/24

+24V

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

NOH10K: NEW FUSEBOX WIRE GUIDANCE CIRCUIT

15 / 20

REV

3-6869

2

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

A101.2 22L8 12/20

PLC

RELAY OUTPUTS 2.1

X37: 1

.1

1L

X57: 1

2.3

2.2

X132: 4

.2

X132: 5

2.4 .3

X132: 6

2.5 .4

X132: 7

.5

2L

X132: 8

122L14

122L15

25

15/12

122L4

X152: 4

3/16

X152: 5

X152: 6

X152: 7

122L14

X152: 8

18

J331 15/14

15/27

WGA STOP

WGA ERROR

3

OFF WIRE

3

X57: 2

X57: 3

X57: 4

X57: 5

X57: 6

X37: 2

X37: 3

X37: 4

X37: 5

X37: 6

WHT

X1

H332 X2

GRN

X1

H333 X2

YEL

X1

H334 X2

RED

X1

H335 X2

RED

X1

H336 X2

RED

X2

WGA ERROR

15/26

SEARCH

3

X1

S331

WGA STOP

15/25

LOCKED

3

4

K225

OFF WIRE

15/24

3

4

K224

SEARCH

15/23

4

K223

LOCKED

4

K222

WIRE GUIDANCE ON

4

K221

X152: 9 .1 3.1 PLC

.2 3.2

.3 3.3

.4 3.4

.5

X132: 9

3.5

DC INPUTS

122M2 3/16

A3.3

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

NOH10K: NEW FUSEBOX WIRE GUIDANCE CIRCUIT

16 / 20

REV

3-6869

2

X29

X30

X25

X26 X31

X32 X33

2004-04-21

L50

CIRCUIT DIAGRAM L150

DATE:

TS721006

8

7

6

H

G

F

E

D

10F2:

10F1:

9F2:

9F1:

8F2:

3 4 5 6 7 8

C D

E

F G H

3 4

5

6 7 8

22F2: 23F1:

23F2: 24F1:

D E F G H

22F1: C

26

6F2:

6F1:

5F2:

5

4

8F1:

25

5F1:

2F2:

C

21F2: B

L75

3

2

B

6

2

21F1: A

L100

7F2:

S3:14

B

S2:14

1

S3:13

A

S2:13

1

13

7F1:

24

2F1:

L150 A

L150

L100

L170

2

L50

5

RL199085

L120

1F2:

1

S1:32

23

1F1:

S1:31

22

RL199085

2

21

RL199085

S1:22

20

L50

S1:21 L75

L75

19

L50

15

18

K12:A2

K12:A1

L75

L150 L250

17

K12:2

K12:1

16

K11:2

K11:1

K21:3 K21:4 K21:5 K21:6 K22:9 K22:10 K22:11 K22:1 K22:2 K22:3 K23:3 K23:4 K24:3 K24:4 K25:3 K25:4 K26:3 K26:4 K27:3 K27:4 K28:3 K28:4

15

K11:A2

X27

L100

L50

14

K11:A1

X 7

0989506 0989551

1074184 0989506 RL210352

0989506 0989552

X36

X 4:

0899421 0899420

X 3:

RL211074 0864263 0864263 0864263

15

0899421 0989506 0899421 1074184

X24

19/23

X22

L50

J12

19/14

X21

X28

L200

J11

13 27

NOH10K: NEW FUSEBOX

WIRE HARNESS W10:RL472436

L100

L75

0864263 0864263 0864263

L100

12

L75

Box order from the front:

11 28 29

L50 RL168565

X13:1 RL210584

X13:2 RL210584 L300

L100

30

RL211074

X54:

RL168565

X12:

15 0989506

X27

X11: 6 1074184 RL210352

X 7

12 0899421 0899420

X36

3 0864263

X33

3 0864263

X32

3 0864263

X31

2 RL211074

X26

1074184

X25

12 0899421

X24

15 0989506

X22

L100

12 0899421

X21

3 0864263

X30

3 0864263

X29

3 0864263

X28

No:RL199084 NEW FUSEBOX

17 / 20 REV

3-6869

2

X94 RL211074

RL211074

L800

18

19

20

21

L75 L50

L70

L600

A3.2:OUT: .6 A3.2:OUT: .5 A3.2:OUT: .4 A3.2:OUT:2L

23

24

25

26

27

28

29

30

L150

A3.2:IN:2M

A3.2:OUT: .2 A3.2:OUT: .1 A3.2:OUT: .0 A3.2:OUT:1L

22

G201:Gi-

2

17

G201:Vi+

X75

16

L50

L250

A3.2:IN: .2 A3.2:IN: .1 A3.2:IN: .0 A3.2:IN:1M A3.2:OUT:L+ A3.2:OUT:M

L70

15

G3:Go-

2

14

G3:Vo+

13

G3:Gi-

12

G3:Vi+

11

A3.1:L+ A3.1:M

L50

X15:Cover X15:A2 X15:A1

L150

L15

L15

L15

K28:8+

K27:8+

K26:8+

K25:8+

K23:8+ K23:1K24:8+

K22:7 K22:6

L100

A3.1:IN:1.1 A3.1:IN:1.0 A3.1:IN:2M A3.1:IN:0.7 A3.1:IN:0.6 A3.1:IN:0.5 A3.1:IN:0.4 A3.1:IN:0.3 A3.1:IN:0.2 A3.1:IN:0.1 A3.1:IN:0.0 A3.1:IN:1M

L50

L15 L50

L50

K21:1K21:8+

A3.1:IN:1.5

L50

L100

A3.1:OUT:1.1 A3.1:OUT:1.0 A3.1:OUT:0.7 A3.1:OUT:0.6 A3.1:OUT:0.5 A3.1:OUT:2L+ A3.1:OUT:2M A3.1:OUT:0.4 A3.1:OUT:0.3 A3.1:OUT:0.2 A3.1:OUT:0.1 A3.1:OUT:0.0 A3.1:OUT:1L A3.1:OUT:1M

J11

J12

18/11

18/12

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

NOH10K: NEW FUSEBOX WIRE HARNESS W10:RL472436

18 / 20

REV

3-6869

2

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

S17:21 L550

L1150

S17:22

13

S18:22

12

S18:21

11

450558-1

12 L770

L450

X45 0899420

L150 6

X44

L320

S16:21

1

S16:11

S16:22

S16:12

H12:x2

L300 H12:x1

H11:x2

H11:x1

S15:21

S15:11

S15:22

S15:12

L320

L300

RL210352

No:RL199084 NEW FUSEBOX DATE: 2004-04-21

CIRCUIT DIAGRAM

TS721006

NOH10K: NEW FUSEBOX WIRE HARNESS W15: RL450588

19 / 20

REV

3-6869

2

2004-04-21

L50

L75 L50

L50

CIRCUIT DIAGRAM

DATE:

TS721006

6

105 F1:

105 F2:

8

H

6

F

7

5

E

G

4

D

122 F1: 123 F1: 123 F2: 124 F1: 321 F1: 322 F1:

C D E F G H

121 F2: B

L120

8

5

102 F2:

3

C

121 F1: A

G302:Vo+

X128 X129

106 F2:

4

102 F1:

2

B

24

7

3

101 F2:

1

A

G302:Gi-

G302:Vi+

23

106 F1:

2

L120

1

L75

22

101 F1:

199085 199085

A101.1:IN:.1M

21

A101.1:OUT:1M

L50

A101.1:IN:0.0

A101.1:IN:0.1

A101.1:IN:0.2

L75

20

A101.1:OUT:1L

A101.1:OUT:0.0

A101.1:OUT:0.1

A101.1:IN:0.3

G301:Vo+

G301:Go-

G301:Gi-

19

A101.1:OUT:0.2

A101.1:IN:0.4

A101.1:IN:0.5

L75

18

A101.1:OUT:2M

A102.1:IN:0.6

L70

A101.1:OUT:2L+

A101.1:IN:0.7

A101.1:IN:2M

A101.1:IN:1.0

A101.1:IN:1.1

L75

17

A101.1:OUT:0.5

A101.1:OUT:0.6

A101.1:OUT:0.7

A101.1:OUT:1.0

A101.1:IN:1.2

G301:Vi+ 16 25 26

X129

27

X131

X115:A1 X115:B1 X115: cover

NOH10K: NEW FUSEBOX WIRE HARNESS W101: RL472437

L75

A101.1:M

A101.1:IN:1.3

G101:Vo+

G101:Go-

15

L100

A101.1:L+

L75

14

A101.1:IN:1.4

L75

G101:Gi-

13

A101.1:IN:1.5

A101.2:OUT:M

A101.2:OUT:L+

A101.2:IN:1M

A101.2:IN:.0

A101.2:IN:.1

G101:Vi+

12

L75

A101.2:IN:2M

11 28 29

Free

L75 15

15

L150

15 15

L170

15

12

L75 15 6

30

Box order from the front: X121 X122 X124 X125 X126A

X126B

RL472437 0989506

X126A

0989506

X126B

0989506

X125

0989506

X124

0989506

X122

12 0899421

X121

0899421

X131

0989506

X129

1074184

X128

L400

No:RL199084 NEW FUSEBOX

20 / 20 REV

3-6869

2