Caterpillar NOL10KF Lift Trucks Operation & Maintenance Manual - PDF DOWNLOAD

EN

Operation & Maintenance Manual NOL10K NOL10KF NOL10KV

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

1. Order picker ........................................................................... 4 2. Safety instructions ................................................................. 5 3. Operating environment .......................................................... 6 4. Operating devices .................................................................. 7 5. Driving instructions .............................................................. 10 6. Load handling ...................................................................... 12 7. Batteries ............................................................................... 13 8. Maintenance ........................................................................ 15 9. Transportation and storage .................................................. 18 10. Troubleshooting .................................................................. 19

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1. Order picker Warehouse trucks are designed and manufactured to lift and transport materials indoors. Please read this manual before operating or performing maintenance on the truck. After reading this manual, store it in a safe, dry place for later use.

The truck conforms to the EN 1726-1 standard, ensuring its safety according to the EU machine directive 98/37/EC. The most important regulations and guidelines are mentioned in these instructions. As regulations vary from country to country, we expect you to familiarise yourself with the regulations and standards valid in your country.

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

A truck may cause serious accidents unless you are sufficiently familiar with its operation and unless you know its operating and maintenance instructions. To order more copies of instruction books, contact your dealer.

Electromagnetic compatibility The truck conforms to the EN 12895 standard, ensuring its safety according to the EMC directive 89/336/EEG. The truck is designed for light and heavy industry use (EN 50081-1 and EN 50082-2).

WARNING! Do not make any modifications to the electrical devices in the truck without the manufacturer's expressed permission. Modifications to electrical devices may affect the electromagnetic compatibility and, therefore, reduce operational safety.

Delivery Before shipping, each truck is inspected carefully to make sure that the truck you receive is flawless and fully equipped. Nevertheless, check the truck immediately after receiving it for any damages that may have occurred during shipping.

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2. Safety instructions Instructions for site supervisor • Familiarise yourself with the operating instructions and its contents.

• Train the operator on the use, safety, and maintenance aspects of the truck.

• Control that the operating and maintenance instructions, and safety regulations are observed.

Occupational safety • Keep the truck clean and in good working order. Carry out the daily and weekly maintenance checks in accordance with the maintenance schedule and instructions to avoid faults and operational errors.

• If you notice any faults or deficiencies that may effect the safe operation of the truck, take the truck out of operation until the faults or deficiencies have been remedied.

• Do not repair anything on the truck without permission from the site supervisor.

• In the event of a malfunction, switch off the power and notify the site supervisor.

• When using the truck, you are responsible for both your own safety and the safety of your environment.

• Immediately notify the site supervision of any accidents or injuries. In such a case, leave the truck at the place of the accident.

• The truck can only be used for purposes corresponding with its equipment.

Truck operator Requirements: • At least 18 years old • Sufficient physical (e.g. good hearing and sight) and mental abilities for operating the truck without risks • Appropriately trained; familiar with operating, safety and maintenance instructions • Has permission from the site supervision to operate the truck • Knows and masters the drive and operational features of the truck

Emergency procedures If the truck falls over, hold onto the steering wheel and warn others. If the machine malfunctions, brake and switch off the power. The truck must not be used again until a person appointed by the work supervisor has repaired the truck.

Noise The maximum noise level that the driver may be subjected to is 76 dB (A).

Work at dangerous premises Trucks used for working at premises susceptible to fire or explosion or other hazards must be specially equipped.

A standard truck is not suitable for the above-mentioned work. Contact your truck dealer for specially designed and equipped trucks for hazardous conditions.

Repairs and structural modifications Do not modify the truck without the manufacturer's express permission. Do not add, remove, weld, or bend any parts, as the modifications could affect the operation of the truck and weaken its construction.

Overhead guard and load support Trucks driven sitting or standing and that are capable of lifting a load higher than 1.8 m must be equipped with an overhead guard. Modifications to the overhead guard that could possibly weaken its structure are not allowed. If it is possible for objects to fall through the openings in the overhead guard, the size of the openings must be reduced.

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

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3. Operating environment Use the truck in dry, indoor facilities with hard, even and level floors. The temperature range in which the truck can continuously operate is +5 to +25°C, and for short periods +0 to +45°C. If the operating temperatures differ from the above mentioned, contact your truck dealer to obtain a separate machine designed for cold and freezing temperatures. A special machine for freezing conditions can be used in temperatures down to -35°C. This truck conforms to all the relevant requirements of the EU machine directive and thus has a CE marking.

Never use the truck: • To transport and lift people • At premises with risk of fire • At premises with risk of explosion • At premises with insufficient floor load capacity • If it is damaged • As a mounting surface • To tow another truck • Under the influence of intoxicating substances

Free space Make sure that the truck has sufficient moving space with respect to overhead structures. Before driving through aisles or door openings, ensure that there is enough space for the truck, the load and yourself.

NOTE: Always drive at a safe distance from the edge of loading platforms or bridges.

Bearing capacity of the floor Make sure that the combined weight of the truck and the load does not exceed the bearing capacity of the floor.

Using elevators You need permission from the site supervisor to use an elevator to transport the truck between floors. Make sure that the combined weight of the truck, the load and yourself does not exceed the maximum load capacity of the elevator. Always drive the truck into elevators and any other narrow spaces with the load in front.

NOTE: Make sure that there are no people in the elevator when driving the truck in or out. The parking brake of the truck must be on before the elevator moves.

Working on ramps You need permission from the site supervision to drive on a slope or ramp. When the truck is loaded, travel with the load pointing uphill. Without a load, you can travel with the forks pointing downhill.

NOTE: Do not turn the steering wheel abruptly on a ramp; the truck might overturn.

Working on loading bridges Always check the bearing capacity and the fastening of the bridge before loading or unloading. If you need to drive the truck onto another vehicle, ensure that the vehicle cannot move during this procedure. Do not drive to the edges of a loading bridge because there is always a risk of overturning.

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4. Operating devices Identification plates on the truck Check that the plates are legible and securely attached.

Type plate The truck's type plate is marked with: • Manufacturer • Type of truck • Year of manufacture • Serial number • Truck's dead weight in operating condition, without battery or accessories • Maximum and minimum battery weight • Battery terminal voltage • Truck's nominal lifting capacity • CE mark Capacity plate The capacity plate states the maximum lifting capacity at the maximum lifting height and the lifting height with the nominal lifting capacity. In addition, the plate states the centre of gravity distances for the relevant lifting capacity.

WARNING! Do not overload the truck.

Capacity plate for accessories Detachable accessories affect the truck’s lifting capacity. If the truck is used with detachable accessories, corresponding capacity plates must be attached to the truck.

Safety pedal To operate the truck, first press the safety pedal on the floor with your foot down to the drive position. The truck will not move if the pedal is not pressed.

Brakes Operating and parking brakes The parking brake is a magnetic brake which switches on automatically when you lift your foot from the safety pedal.

CAUTION! The truck will stop abruptly if you release the safety pedal during high travelling speed.

Use the accelerator to brake during normal driving. Remember to handle the accelerator gently.

Motor braking charges the battery and slows the truck in the following cases: 1. When changing direction 2. When the truck is free-wheeling Practice braking with a load in a safe area before you start working with the truck.

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Control panel Key switch (1) The key switch connects the truck's electrical equipment to the battery circuit.

0 = Power off (the power is still connected to certain electronic devices) 1 = Power on When the power is switched on, an automatic warning light test takes place ensuring that the warning lights and flashers work properly.

Accelerator (2) Turn the accelerator handle forward or backward to the driving direction. A larger movement of the handle produces a higher speed. The accelerator returns automatically to the central position when it is released.

You can brake smoothly by moving the speed control to the direction opposite to the driving direction. You should anticipate the situation when you must brake and decrease the speed well ahead.

You can also use the lever on the side of the truck to move the truck slowly forwards or backwards. First you need to straighten the drive wheel.

Horn button (3) Steering wheel (4) The steering wheel turns the drive mechanism electrically 360°, see Section "Electronic steering system" in Chapter 5.

Emergency stop button (5) Press the emergency stop button to switch off the power circuit of the battery. Use the button in the following cases: • A short-circuit or other electrical fault, for example, if the pump motor runs continuously • In an accident Release the emergency stop button by turning it clockwise.

Lever for lifting and lowering the lift cabin and forks (6) Use the lever on the control panel to lift or lower the lift cabin and forks. You can also use the lever on the side of the truck.

Lowering of the lift cabin and forks is automatically stopped when their height is 200 mm. To lower the lift cabin and forks all the way down, first lower them to 200 mm and release the lever. Then use the lever again and lower the lift cabin and forks to the lowest position.

Controls on the side of the truck Lever for moving the truck forwards and backwards Use the lever on the side of the truck to move the truck forwards and backwards when you are not standing on the platform. Make sure that drive wheel is straight before operating the truck from the side.

Lever for lifting and lowering the forks You can lift and lower the forks also with a lever on the side of the truck when you are not standing on the platform.

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Display Fault monitoring of the control electronics (1) A warning light is lit when a steering fault, a communications fault in the electronics, or an incorrect starting procedure occurs.

NOTE: When the light is lit, the magnetic brake goes on automatically.

Parking brake indicator light (2) The parking brake indicator light indicates that the brake is on.

Drive direction indicator lights (3) The indicator lights indicate the driving direction of the truck.

Hour meter (4) 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 discharge indicator (5) The battery discharge indicator shows the level of the battery charge and stops the lift if the battery charge is too low. However, you should recharge the battery before the charge drops too much. For instructions, see Section "Recharging the battery" in Chapter 7.

Fault monitoring of the speed and pump controls Certain circuits of the truck have automatic fault monitoring, which gives a warning of faults in the drive speed and pump controls. If a fault occurs, the truck cannot 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 the power, 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 stops the driving, stop the truck immediately.

Recharging plug The truck's recharging plug has a handle and can be detached. See Section "Recharging the battery" in Chapter 7 for instructions on using the plug to recharge the battery.

CAUTION! Before carrying out electrical welding on the truck: • Disconnect the battery.

• Disconnect the plugs of the electronic devices.

Lowering the lift cabin in an emergency The lowering valve is used in the event of a malfunction when the lift cabin is raised. Press the spindle of the lowering valve with a sharp object to lower the cabin manually.

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5. Driving instructions Daily checks before operation Carry out the daily maintenance check before using the truck. Neglecting daily maintenance may decrease the safety and reliability of the truck. Notify the site supervision immediately if you notice an error or deficiency during the check.

• Check the truck externally to see that there are no oil leaks.

• Check all wheels for damage or wear.

• Check the battery fluid in each battery cell. Top up with battery water if needed. The fluid surface should be about 15 mm above the plates (this does not apply to maintenance-free batteries).

• Check the gearbox for leaks. Also check the hydraulic pipes, hoses, and connectors. No leaks or damage should be found.

• Switch on the power and test the operation of the lifting hydraulics by raising and lowering the forks.

• Check the operation of the accelerator and steering by driving slowly forward and backward.

• Also check the operation of the other electrical functions.

• Check that the batteries are charged and locked in place.

• Check the operation of the horn.

• Check that the safety pedal works and that the parking brake functions properly.

• Check that the emergency stop operates properly.

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

Before you start: • • • • •

Make sure that the daily maintenance has been carried out.

Switch on the power.

Check the driving direction from the indicator lights.

Grip the steering wheel knob with your left hand and the accelerator with your right hand.

Take a position where only one foot is on the safety pedal.

Driving • • • •

Press the safety pedal down to move the truck.

Turn the accelerator lightly in the driving direction.

To brake, turn the accelerator in the opposite direction to the driving direction.

Steer the truck smoothly because abrupt movements may cause a dangerous situation, especially when driving at high speeds.

• Always drive with the lift cabin lowered when not in the collection aisles.

Electronic steering system The truck is equipped with a fully electronic steering system. The steering wheel movement is transmitted without a mechanical connection to the steering motor that controls the drive wheel.

The system consists of three main components: 1. Tachometer located in the steering wheel 2. Control unit located in the motor compartment 3. Steering motor, which is also in the motor compartment The control unit processes the signal coming from the tachometer and directs the steering motor to turn the drive wheel in the desired direction. In addition, the control unit constantly monitors the status of the system and reacts immediately if there are any problems.

NOTE: Do not turn the steering wheel unnecessarily when the truck is not moving.

Safety When the power is turned on from the key switch, the system performs a self-diagnostic test. The test lasts for less than a second, after which the truck is ready for operation.

When the power is on, the control unit sends continuous diagnostic check signals throughout the system. This signal can be heard as a tapping noise emitting from the truck. In case of a system malfunction, the control unit will react immediately to the situation by switching off the drive operation and turning on the magnetic brake, and the truck will stop.

Problems in electronic steering or in the control system are indicated by the red STOP warning light. The truck does not drive if the light is on.

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Wait for at least 2 seconds before you switch on the power again after it has been switched off by the system. If the red warning light does not go off after switching the power off and on again, there is a problem in the steering system and the truck cannot be driven.

Maintenance of the electronic steering system The system has been designed to be as maintenance free as possible. The quarterly maintenance check (300 hours) includes the fastening of the steering control unit terminals.

NOTE: The control unit is configured at the factory. Do not attempt to adjust it. An authorised service person can tune the steering, e.g. the number of rotations for the steering wheel, if necessary.

General driving instructions Practice steering and controlling the truck carefully in a safe area.

• Drive slowly at intersections and when turning.

• Handle the truck responsibly and always keep it under control.

• Avoid sudden starts and stops.

• Steer and brake smoothly.

• Decrease the speed if the floor is slippery, for example, because of humidity.

• Take great care when driving on a slanted surface.

• Do not drive over any loose objects on the floor.

When driving, keep the load lowered and, if possible, tilted backwards. Do not lift the load 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 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

Driving position When moving forwards, stand firmly with one foot on the safety pedal. Keep your left hand on the steering wheel and your right hand on the accelerator handle.

When driving, always keep your body completely within the outlines of the truck. Anticipate any dangers so that you can avoid risks of accident or injury.

Speed Control the speed according to the situation. Take into consideration the load, visibility, and people in the working area and the working environment. Slow down at cross aisles and whenever the vision is obstructed. If the visibility is inadequate, use an assistant to help guide you.

Uncontrolled acceleration or braking, excessive speed at turning points, and fast and sudden turning may overturn the load and cause an accident. In all conditions, drive the truck at a speed that enables you to stop it safely.

Parking Park the truck in a reserved parking place. When parking the truck, the forks must be lowered and the parking brake must be on. Ensure that the truck cannot move by itself or that an inexperienced person cannot start driving it under any circumstances.

NOTE: Never park or stack goods in front of fire doors, fire extinguishers, emergency exits and the like. Do not park on a slanted surface.

Traffic rules Maintain good visibility in the driving direction and keep sufficient safety distances. Follow the traffic regulations and speed limits. Do not drive the truck outside a private area without an order or permission from the site supervisor. Outside a private area, the truck is subject to general traffic rules and regulations. If a door opening is so narrow that two trucks cannot possibly pass through it at the same time, drive in the middle of the opening.

When two trucks meet in a narrow or cross aisle, the loaded truck has the right of way.

NOTE: When driving, you should sound the horn when necessary to warn others in the same area.

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6. Load handling Only transport a load when it has been safely loaded.

• Always drive the truck with its forks lowered.

• When the load is raised, steer and brake carefully.

• If the truck has side stabilisers, 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.

• When carrying a load larger than the outlines of the truck, take into account the extra space it requires.

• Before stacking, always lower the initial lift to the down position.

• Only handle undamaged loads.

• Place the load correctly.

• On slopes and ramps, place yourself above the load.

• Do not overload.

Lifting capacity The lifting capacity of the truck is printed on the capacity plate. Obey the maximum values for load weight and load center information in different loading situations. Take into account the effect of any attachments on the lifting capacity.

WARNING! Do not exceed the truck's maximum loading capacity under any circumstances.

Collection • Use the lifting and lowering lever to set a suitable collection height.

• If you need to lean far over a shelf, first switch off the power with the key switch.

• Place the load so that its weight is distributed evenly on the lifting forks.

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

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7. Batteries Only appointed and trained personnel may replace and recharge batteries. Individuals maintaining batteries must have sufficient protective clothing and eye gear.

• Do not handle a 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.

• When batteries are recharged, the cell plugs must be closed firmly to prevent splashing of battery fluid.

• The battery fluid is a corrosive acid solution; avoid getting it on your skin or in your eyes. The battery fluid develops an explosive gas at the end phase of recharging. Therefore, make sure that the battery has sufficient ventilation (this does not apply to maintenance-free batteries).

• 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 and that the battery has sufficient ventilation.

1. Park the truck in a reserved recharging place.

2. Switch off the power from the key switch.

3. Make sure that the charger has been switched off.

4. Disconnect the battery connector and connect it to the charger.

5. Switch on the charger.

After recharging 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 battery manufacturer's maintenance instructions.

Measuring the specific gravity of the battery cell Measure the specific gravity of the battery fluid according to the manufacturer's instructions. The specific gravity of a fully charged battery is 1.28 to 1.30 at +30°C. • 1.24 3/4 charged • 1.20 1/2 charged • 1.16 1/4 charged • 1.15 empty. Charge the battery immediately.

Replacing the battery Replace the battery according to the manufacturer's instructions.

When reinstalling batteries, use the appropriate tools for moving, connecting and fastening the battery securely. Do not keep the tools or other metal implements on top of uncovered batteries.

When replacing the battery, use one with similar dimensions and weight 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 you use a lifting device for lifting the battery, place a nonconductive 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.

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Acquiring a new battery When acquiring a battery for the truck, pay attention to the following sections of the standard EN 1175-1: • 5.1 Traction batteries (includes the requirements for the protective cover of the battery case, ventilation and interior surface treatment) • 7.4 Minimum markings (includes the requirements specified on the truck battery plate) The battery plate should provide at least the following information: • Manufacturer • Type • Serial number • Rated voltage • Capacity (Ah/5 h) • Service weight

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8. Maintenance Only adequately trained people are allowed to carry out daily and weekly maintenance. The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones.

It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our maintenance department or your truck dealer for qualified, authorised and efficient maintenance service.

Safety instructions for maintenance • Keep the service area clean; oil, grease, and water make the floor slippery.

• Remove all rings, watches and other metal jewellery. Short-circuits and burns may occur if a metal object touches a charged electrical connection when working with the truck's electrical system.

• Switch off 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 hands to check for oil leaks.

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

• Only use clean oil in the hydraulic system.

• Always disconnect the battery when welding. Remove paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding.

• The truck must always be supported on jacks if someone needs to work underneath it.

WARNING! Do not make any alterations or repairs that can weaken the truck’s structure or endanger safety.

Weekly maintenance • Check and clean the battery cable fastenings.

• Ensure that the air holes of the battery cell plugs are not plugged up (this does not apply to maintenance-free batteries).

• Clean the batteries with a dry rag. If necessary, you can wash the batteries with warm water or a mild soda solution, which neutralises the battery acid. Dry the battery carefully after the wash.

• Check that the hydraulic system has no leaks.

• Check the hydraulic oil in the oil tank. Add if necessary.

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

• Check that the fastening bolts of the drive wheel are tight.

• Check that the machine plates and labels are securely fastened and fully legible.

• Clean the truck if necessary.

• Lubricate lightly the mast and the lift cabin guides.

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

NOTE: Do not let water onto the electrical devices.

Quarterly maintenance (300 hours) Check and adjust or repair, if necessary: • Contactors, microswitches, and solenoids and their cables • Brake air gap: correct dimension 0.3–0.8 mm • Accelerator operation • Attachment of the cylinders and the locking of the settings • lift cabin tolerances, the slope of the forks, and the attachment of the mast to the frame • Lateral tolerance of the mast. If necessary, the tolerance is adjusted by loosening the eccentric rollers, turning them, and retightening them.

• Torque of the drive wheel attachment nuts • Lifting hydraulics operation • Collectors, carbon brushes, and electric cables of the drive and pump motors

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Semi-annual maintenance (600 hours) Check and adjust or repair, if necessary: • • • • • • •

Driving, steering, and pump motors: clean away the dust Operation of the hydraulics and pressure limit valves Drive wheel for wear. The wheels should be changed at the latest when 10 mm of the tread is left Battery rollers Wheel bearings: lubricate Oil filter Fastening of the gearbox

Annual maintenance (1200 hours) • Change the hydraulic oil and oil filter once a year.

• Check the attachment of the transmission and change the transmission oil.

Monthly hydraulics maintenance The truck's lubricating points should be lubricated once a month: • Turning bearings of the drive unit

Lubricant recommendation Filling hole for hydraulic oil Hydraulic oil: Neste 32 Super In freezer warehouses: Neste SH 15 Fill the tank to ¾ volume.

Transmission oil: EP80/90 Lubricating grease: NLGI No.2, containing molybdenumdisulphide In freezer warehouses: NLGI No.1 or No. 0

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Fuses 0F1, 0F2 1F1 3F1 4F1, 4F2 5F1, 5F2

Main contactor Drive motor, pump motor Steering motor Drive circuit Pump circuit, steering circuit

6F1, 6F2

Auxiliary devices

Ordering spare parts When ordering spare parts, always contact your dealer or the maintenance centre. Only use original spare parts. To ensure that you receive the correct parts, include the following information in the order: 1. Truck type 2. Serial number of the truck 3. Order number of the part 4. Name of the part 5. Amount of parts ordered Items 1 and 2 are listed on the front page of the manual or on the identification plate of the truck. Items 3 and 4 are listed on the spare part pages of the manual supplied with the truck.

Hazardous waste and disposal Hydraulic and transmission oils, and batteries are hazardous waste that must be disposed of accordingly. The truck itself is not hazardous waste, and can be recycled.

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9. Transportation and storage Transportation Lifting the truck The truck can only be lifted from a marked position. Make sure that the capacity of the lifting device is sufficient.

Towing the truck The truck can only be towed with its drive wheel raised from the floor.

Storage If the truck is not used for a lengthy period of time, it should be stored in a cool (above 0°C) and dry place on an even surface. Before storage, complete the following: • 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 more if necessary.

• Change the hydraulic oil if the machine is not used for more than a year.

• If the machine is not used 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 operational hours.

Otherwise normal daily maintenance and inspection are sufficient.

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10. Troubleshooting

Symptom

Fault

Action

Truck does not move

Battery connector is loose

Plug in the battery connector.

Battery is empty

Recharge the battery.

Emergency stop button is activated

Release the emergency stop button.

Key switch is faulty

Replace the switch.

Drive motor fuse has blown

Check the connections and cables and replace the fuse.

Control circuit fuse has blown

Check the connections and cables and replace the fuse.

Microswitch for safety pedal is broken

Replace the microswitch.

Drive motor carbon brushes are worn out

Replace the carbon brushes.

Speed controller is faulty

Contact maintenance personnel.

Pump or control circuit fuse has blown

Check the connections and cables and replace the fuse.

Pump motor’s carbon brushes are worn out

Replace the carbon brushes.

Pump motor controller is faulty

Contact maintenance personnel.

Overload

Decrease the load.

Battery is empty

Recharge the battery.

Not enough oil in tank

Add oil.

Oil leak

Check the joints and seals.

Pump is faulty

Replace the pump.

Dirt or wear in valves

Clean the valves, replace if necessary.

Charger is incorrectly connected

Check the connection.

Charger fuse has blown or main voltage is missing

Check the connections and cables and replace the fuse.

Battery cell’s water level or specific gravity is low

Check the cell’s voltage and specific gravity. Add water and/or acid when necessary. See Section "Recharging the battery" in Chapter 7.

Lift pump does not run

Lifting functions improperly

Battery does not charge

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Symptom

Fault

Action

Steering does not work properly

Steering motor fuse has blown

Check the connections and cables and replace the fuse.

Steering motor carbon brushes are worn out

Replace the carbon brushes.

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RO-B RO-B RO-C RO-C RO-B RO-D RO-D RO-D RO-D MAIN MENU/ PARAMETER CHANGE: ACCELERATION DELAY 3 3 5 1 1 1 FLD ACCELERATION 5 5 5 2 2 2 DECELERATION DELAY 5 5 5 3 3 3 RELEASE BRAKING 3 3 9 7 7 7 INVERSE BRAKING 5 5 9 5 5 5 CURVE BRAKING (RO-D) 5 5 5 5 5 5 CUTBACK SPEED 1 (LOW) 4 0 1 0 9 9 9 CUTBACK SPEED 2 (MIDDLE) 1 1 1 4 4 4 MAX. SPEED FORWARD 9 9 5 7 7 7 MAX. SPEED BACKWARD 9 9 5 7 7 7 TRACTION IMAX 9 9 9 9 9 9 ARMA. NOM. CURRENT 0 3 0 0 0 0 WEAK DROPOUT 0 5 0 0 0 0 FIELD CURRENT MAX. 9 9 9 6 6 6 FIELD NOM. CURRENT 1 3 4 5 6 6 6 CREEP SPEED 1 1 0 3 3 3 BACKING TIME 9 9 9 9 9 9 BACKING SPEED 0 0 0 0 0 0 AUXILIARY TIME 0 0 0 0 0 0 PUMP ACCELER.DELAY 5 5 0 5 5 5 PUMP DECELER.DELAY 5 5 0 0 0 0 PUMP CREEP 0 0 5 5 5 5 1ST SPEED COARSE 9 9 9 9 9 9 SLOW LIFT SPEED 5 5 9 5 5 5 FORK LIFT SPEED 3 5 9 6 6 6 2ND SPEED COARSE 0 0 0 4 4 4 3RD SPEED COARSE 0 0 0 4 4 4 MIN. VALVE VOLT 0 8 0 6 1 1 1 MAX. VALVE VOLT 6 0 3 9 2 2 2 SLOW LOW SPEED 7 5 9 9 9 9 FORK DOWN SPEED 7 7 9 4 4 4 EV.ACCELER.DELAY 9 3 0 9 9 9 EV.DECELER.DELAY 7 7 0 0 0 0 2ND EV.DECELER.DELAY 2 0 0 2 2 2 BRAKE DELAY 2 2 2 4 4 4 CONFIG MENU/ SET OPTIONS: HOUR COUNTER RUN RUN RUN RUN RUN RUN BATTERY CHECK ON ON OFF ON ON ON AUX FUNCTION #2 PRE PRE PRE PRE PRE PRE LIFTING POT PRE PRE PRE PRE PRE PRE QUICK INVERSION BEL BEL BEL BEL BEL BEL I-LIFT FUNCTION OFF ON ON OFF OFF OFF OFF ON AUX INPUT #1 1 1 1 1 1 1 GATE MODE OFF OFF OFF OFF OFF OFF INVERSION MODE OFF OFF OFF OFF OFF OFF AUX CURRENT #1 OFF OFF OFF OFF OFF OFF SAFETY SWITCH ON ON ON OFF OFF OFF OFF AUX OUTPUT #1 0 0 0 0 0 0 BRAKING MODULATION ON ON ON ON ON ON AUX FUNCTION #3 OFF OFF OFF OFF OFF OFF ADJUSTMENTS: ADJUST BATTERY Ubat Ubat Ubat Ubat Ubat Ubat ADJUSTMENT #01 4 4 4 4 4 4 ADJUSTMENT #02 4 4 4 4 4 4 MAIN MENU/ ALARMS/ SPECIAL MENU: HARDWARE SETTINGS: SET CURRENT 300A 300A 300A 300A 300A 300A SET FIELD CURRENT 20A 20A 20A 20A 20A 20A FIELD CURRENT MIN. 3 3 3 3 3 3 AUX FUNCTION #1 OFF OFF OFF OFF OFF OFF CHECK UP DONE OFF OFF OFF OFF OFF OFF CHECK UP TYPE NON NON NON NON NON NON

NSR12..20K side stab.

Rev. Date

NSR12..20K initial lift

NSR20K

NSR16K

NSR12K

NOM10K

NOL10KF

NOL10K / NOL10KF / NOM10K / NSR12/16/20K Zapi CombiSEM 24V 300A+300A COMBI RO 1.23-1.25

NOL10K

CAT Controller: Program version: Zapi's serial number from:

ADJUSTMENT INSTRUCTIONS ZAPI COMBISEM

NSR12..20K lift limit

CAT RD Technical Specifications

31 25/03/2008

NOTE

curve braking NSR12/16/20K: do not change NSR12/16/20K: do not change

do not change do not change do not change do not change do not change

lift speed adjustment on/off-lift speed adjustment sidestabilizers down sidestabilizers up propor.lower speed adjustment on/off-lower speed adjustment lower acceleration ramp lower deceleration ramp init.lift lower deceleration ramp magn.brake apply delay

3

4

measurement type lift lock-out proportional lowering variable lifting speed not used initial lift option additional initial lift buttons side guard option belly switch option 800W motor setting (NSP16K) hydr.functions after tiller sw. programmable output normal motor braking at slow speed parallel functions blocked exact battery voltage discharge ind. 100%-level discharge ind. 10%-level

do not change do not change do not change Load HM from MDI not used not used

CAT RD Technical Specifications CAT Controller: Program version: Zapi's serial number from:

ADJUSTMENT INSTRUCTIONS ZAPI COMBISEM NOL10K / NOL10KF / NOM10K / NSR12/16/20K Zapi CombiSEM 24V 300A+300A COMBI RO 1.23-1.25

Calibration instructions for accelerator and lift/lower potentiometer: 1. Program all the parameters and options of CombiSEM controller.

2. Check that SLOW LIFT is not activated (Zapi Console/Main Menu/Tester/).

3. Check that SLOW LOW is not activated (Zapi Console/Main Menu/Tester/).

4. Turn key switch off.

5. Locate connector J1 in Zapi Serial Tiller Card and close it with jumper.

6. Turn key switch on.

7. Rotate accelerator slowly fully forward.

8. Wait 2 seconds.

9. Release accelerator slowly to the neutral position.

10. Wait 2 seconds.

11. Rotate accelerator slowly fully backward.

12. Wait 2 seconds.

13. Release accelerator slowly to the neutral position.

14. Wait 2 seconds.

15. Push lift lever slowly fully forward.

16. Wait 2 seconds.

17. Release lever slowly to the neutral position.

18. Wait 2 seconds.

19. Pull lift lever slowly fully backward.

20. Wait 2 seconds.

21. Release lever slowly to the neutral position.

22. Wait 2 seconds.

23. Open J1.

24. Wait 5...10 seconds.

25. Turn key switch off.

26. Turn key switch on.

27. Check acceleration forward and backward.

28. Check lifting and lowering.

2/4

Rev. Date

31 25.3.2008

CAT RD Technical Specifications CAT Controller: Program version:

ADJUSTMENT INSTRUCTIONS ZAPI COMBISEM NOL10K / NOL10KF / NOM10K / NSR12/16/20K Zapi CombiSEM 24V 300A+300A COMBI RO 1.23-1.25

3/4

Rev. Date

SERTIL RO 1.00

Calibration instructions for traction and lift/lower potentiometer: 1. Program all the parameters and options of CombiSEM controller.

2. Check that SLOW LIFT is not activated (Zapi Console/Main Menu/Tester/).

3. Check that SLOW LOW is not activated (Zapi Console/Main Menu/Tester/).

4. Turn key switch off.

5. Locate connector J1 in Zapi Serial Tiller Card and close it with jumper.

6. Turn key switch on.

7. Move traction potentiometer fully backward slowly (from 2.5V to 5V).

8. Wait 2 seconds.

9. Release potentiometer to the neutral position.

10. Wait 2 seconds.

11. Move traction potentiometer fully forward slowly (from 2.5V to 0V).

12. Wait 2 seconds.

13. Release potentiometer to the neutral position.

14. Wait 2 seconds.

15. Move lifting potentiometer fully upward (from 2.5V to 5V).

16. Wait 2 seconds.

17. Release potentiometer to the neutral position.

18. Wait 2 seconds.

19. Move lifting potentiometer fully downward (from 2.5V to 0V).

20. Wait 2 seconds.

21. Release potentiometer to the neutral position.

22. Wait 2 seconds.

23. Open J1.

24. Wait 5...10 seconds.

25. Turn key switch off.

26. Turn key switch on.

27. Check acceleration forward and backward.

28. Check lifting and lowering.

AUX INPUT #1 programming in NSR12/16/20K trucks: CombiSEM1 RO-D 1.05 AUX INPUT #1 can be programmed in 4 different ways: > OPTION #1: no sidestabilizers, reset lift limit by closing E3-E13 (CombiSEM) > OPTION #2: no sidestabilizers, reset lift limit by closing E3-E13 (CombiSEM) or A5-B6 (SERTIL) > OPTION #3: sidestabilizers, reset lift limit by closing E3-E13 (CombiSEM) > OPTION #4: sidestabilizers, reset lift limit by closing E3-E13 (CombiSEM) or A5-B6 (SERTIL) NOTE: After changing AUX INPUT #1 parameter press OUT and save changes.

Turn power off and on again in order to activate the selected option.

1.) Closing E3-E13 is handled though pressure switch.

2.) Closing A5-B6 is handled though joystickin reset button or separate reset button in control panel.

3.) If lift limit acts as a top lift limit, E3-E13 (CombiSEM) and A5-B6 (SERTIL) shall be left unconnected.

AUX OUTPUT #1 programming in NSR12/16/20K trucks: CombiSEM1 RO 1.08 -> 1. Programmable warning light/buzzer output

31 25.3.2008

CAT RD Technical Specifications

ADJUSTMENT INSTRUCTIONS ZAPI COMBISEM

Parameter name: AUX.OUTPUT #1 Parameter values: 0-9 CombiSEM1 output: B9-B20 Signal (from the tiller card) that activates the output: 0 - disabled 1 - forward 2 - backward 3 - forward/backward 4 - lift 5 - lower 6 - lift/lower 7 - all above 8 - horn 9 - fan

2. Programmable safety switch request CombiSEM1 RO 1.09 -> Parameter name: SAFETY SWITCH Parameter values: OFF (default), ON OFF = tiller/safety pedal required only for traction ON = tiller/safety pedal required for both traction and pump

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Index 1

Page General characteristics ................................................................................. 3 1.1 Technical specifications ........................................................................ 3 1.2 General description ............................................................................... 3 1.3 Main features ........................................................................................ 3 1.4 Safety & protection features .................................................................. 4 1.5 Thermal considerations ......................................................................... 4 1.6 Combi Sem-1 chopper diagnosis .......................................................... 5 1.7

2

3

4

5

Main Contactor and safety button

.................................................. 5

1.8 General instructions and precautions ............................................ 6 Installation ..................................................................................................... 7 2.1 Connection cables ................................................................................. 7 2.2 Contactors ............................................................................................. 7 2.3 Fuses .................................................................................................... 7 2.4 Combi Sem-1 controller mechanical drawing ........................................ 8 2.5 Serial tiller mechanical drawing ............................................................. 9 Connection .................................................................................................. 10 3.1 Combi Sem-1 connection drawing ...................................................... 10 3.2 Serial tiller connection drawing............................................................ 11 3.3 Description of combi sem-1 connectors .............................................. 12 3.3.1 Connector "A" description .......................................................... 12 3.3.2 Connector "B" description .......................................................... 12 3.3.3 Connector "C" description .......................................................... 13 3.3.4 Connector "D" description .......................................................... 14 3.3.5 Connector "E" description .......................................................... 14 3.3.6 Connector "F" description .......................................................... 16 3.4 Combi Sem-1 power connection ......................................................... 16 Regulation .................................................................................................... 17 4.1 Zapi Programming handly console ...................................................... 17 4.2 Description of standard console menu ................................................ 18 4.3 "Parameter Change" menu ................................................................. 19 4.4 "Tester" menu ..................................................................................... 21 4.5 "Adjustment" menu .............................................................................. 21 4.6 "Set Option" menu ............................................................................... 21 Alarms .......................................................................................................... 23

Page 1

1 GENERAL CHARACTERISTICS 1.1 TECHNICAL SPECIFICATIONS

Motor Types (Traction): .............................................................................. DC SEM Motor Types (Pump): ............................................................................ DC SERIES Power ratings (Traction): ........................................................................... 1 to 2 kW Supply Voltage: ......................................................................................... 24V / 48V Armature Switching frequency: ..................................................................... 16 kHz Field Switching frequency: ............................................................................ 800 Hz Temperature range: ....................................................................... -30 °C to +40 °C Maximum controller temperature: ................................................................... 75 °C Version

Maximum Traction current

Maximum Pump current

200+250

200 A

250 A

300+300

300 A

300 A

400+250

400 A

250 A

1.2 GENERAL DESCRIPTION ZAPI COMBI SEM-1 controller performs all the electric functions that are usually presents in transpallet, stacker, low order picker etc.

The controller can perform the following functions: - Traction controller for SEM motor; full-bridge on the field, half-bridge on the armature.

-

Lifting controller for series excited motors.

-

Drivers for ON/OFF electrovalves and for one proportional valve (electrodistributor)

-

Interface for serial tiller head

-

MDI interface (Multifunction Digital Instrument) battery discharge indicator, hourmeter, alarms, programmed maintenance.

1.3 MAIN FEATURES

-

High frequency MOSFET controller (high efficency, silent, etc.).

-

Speed control with regenerative braking (controls the truck also on the slope)

-

Idraulic functions control with different programmable speeds and ramps, It is possible to use proportional functions.

-

Lowering speed control through proportional valve.

-

All the parameters are programmable by means of the ZAPI console.

-

Complete diagnosis through console or MDI.

-

High temperature protection with current reduction.

-

Drivers real time diagnosis (electro-brake, general contactor and proportional valve.

-

Electrobrake and general contactor are controlled with a PWM.

-

Drivers protected against short-circuits.

Page 3

1.4 SAFETY & PROTECTION FEATURES - Reverse Battery Polarity.

Electrical Circuit diagrams must be followed in order to avoid damage to the power unit. A Main contactor, controlled by the logic unit, is necessary to protect the system against reverse battery polarity.

- Connection errors All inputs are protected against connections errors. Contactor drivers are suitable for loads up to 2 Amps, and are protected against overload.

- Thermal protection If the controller temperature exceeds 77°C, the maximum current will be reduced proportionaly to the thermal increase. The temperature can never exceed 90°C. - Low Battery charge When the battery charge is low, the maximum current is reduced.

- External Agents The chopper is protected against dust and spray of liquid to a degree of protection meeting IP64.

- Protection against accidental Start Up A precise sequence of operations is necessary before the machine starts. If these operations are not carried out correctly the machine stops. Driving requests must be made after closing the Key Switch.

- Protection against uncontrolled movements.

The Main Contactor will not close if: - The Power Unit is not operating correctly - The Logic Unit is not operating correctly - The Serial Tiller is not operating correctly 1.5 THERMAL CONSIDERATIONS - The heat generated by the power block must be dissipated. For this to be possible, the compartment must be ventilated and the heat sink materials ample.

- The heat sink material and system should be sized on the performance requirement of the machine. Abnormal ambient air temperatures should be considered. In situations where either ventilation is poor, or heat exchange is difficult, forced air ventilation should be used.

- The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle.

Page 4

1.6 COMBI SEM-1 CHOPPER DIAGNOSIS The microprocessor continually monitors the chopper and carries out diagnostic procedures on the main functions.

The diagnosis is made in 4 points: 1) Diagnosis on key switch closing that checks: watch-dog, Current Sensors, VMN point, contactor drivers, presence of a start requirement, and connection with the Serial Tiller ok.

2) Standby Diagnosis that checks: watch-dog, VMN Point, Contactor Drivers, Current Sensors.

3) Driving diagnosis that checks: Watchdog, VMN Point, Current, Contactor(s).

4) Continuos Diagnosis that checks: Chopper temperature, Battery Voltage.

1.7 MAIN CONTACTOR AND SAFETY BUTTON - Battery disconnection should be made according to the Diagram below.

- In order to avoid damage to the controller during the regenerative phase, the supply to the Key Switch must be cut off at the same time.

Wiring with cut off in series to positive supply.

- An internal protection is activated when the voltage on B12 connector is greater than 30% of battery voltage, or when the key switch is opened before the battery is opened.

Page 5

1.8 GENERAL INSTRUCTIONS AND PRECAUTIONS - Never combine SCR low frequency choppers with COMBI SEM-1 modules. The filter capacitors contained in the COMBI SEM-1 module would change the SCR chopper operation and subject it to excessive workload. If it is necessary to use two or more control units, the choppers should both be of the High Frequency Zapi family.

- Do not connect the chopper to a battery with a different nominal voltage to the value indicated on the chopper. A higher battery voltage may cause MOS failure. A lower voltage may prevent the logic operating.

- During battery recharge, the COMBI SEM-1 must be completely disconnected from the battery. Beside changing the charging current seen by the battery charger, the module can be damaged by higher than normal voltages supplied via the charger.

- The COMBI SEM-1 module should only be connected to a traction battery. Do not use converters outputs or power supplies. For special applications please contact the nearest Zapi Service Centre.

- In the first instance, start the machine with the drive wheels raised from the floor to ensure that any installation error do not compromise safety.

- After operation, even with the Key Switch open, the internal capacitors may remain charged for some time. For safe operation, we recommend that the battery is disconnected, and a short circuit is made between Battery Positive and Battery Negative power terminals of the chopper using a Resistor between 10W and 100W. Minimum 5 W. - The susceptibility and electromagnetic emmission levels are seriously influenced by installation conditions. Take particular care with the length of cables and wires, types of electrical connections, and braided/screened wires. Zapi declines any responsibility for incorrect or bad operation that can be attributed to the above circumstances. Above all, the manufacturer of the machine must ensure that the requirements of EN 50081-2 are met.

Page 6

2 INSTALLATION Install the chopper baseplate onto a flat metallic surface that is clean and unpainted.

Apply a very thin layer of thermo-conductive grease between the two surfaces to permit better heat dissipation.

Despite the protection provided against external agents, the continuous attack of corrosive elements and substances may cause oxidization of contacts, resulting in bad operation. Remember this point when deciding the installation position on the vehicle.

Fix the chopper using the special holes located on the baseplate (maximum screwing torque: 3 Nm for M5 and 4Nm for M8 screws).

Verify that the wiring of the cable terminals and connectors has been carried out correctly.

2.1 CONNECTION CABLES For the auxiliary circuits use cables bigger or equal to 0.5mm2 section.

For power connections to the motor (pump and traction rotor) and to the battery use cables of 16÷25 mm2 section. The cables from chopper to battery should be run side by side and be as short as possible.

2.2 CONTACTORS A Main Contactor, designed for Continuous Operation should be installed. This contactor should be fitted with a coil corresponding to the battery voltage. The current absorbed by the coil must not be greater than 2A. Suppression for this contactor coil is inside the chopper logic. Do not use any additional external suppression.

2.3 FUSES - Use a 10A fuse for protection of the auxiliary circuits.

- The power fuse is alrady installed on the chopper by Zapi. For special applications or requirements this value can be reduced.

Page 7

2.4 COMBI SEM-1 CONTROLLER MECHANICAL DRAWING

Page 8

2.5 SERIAL TILLER MECHANICAL DRAWING

Page 9

3 CONNECTION

3.1 COMBI SEM-1 CONNECTION DRAWING

Page 10

3.2 SERIAL TILLER CONNECTION DRAWING The folllowing drawing is an example of typical tiller head functions.

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3.3 DESCRIPTION OF COMBI SEM-1 CONNECTORS

3.3.1 Connector "A" description The "A" connector is connected by Zapi.

A1

KEY OUT

This pin is connected to the pin1 of the F connector; is a key signal.

A2

BACKING

This pin is connected to the pin2 of the F connector; is a backing signal.

3.3.2 Connector "B" description The "B" connector managed the main contactor, the brake and the electrovalves coils.

B1

+ BATT

Positive after the main contactor; is the electrovalves positive.

B2

NMC

Negative of the main contactor

B3

-BATT

Negative free for the customer.

B4

-BATT

Negative free for the customer.

B5

NEB

Negative of the electromechanical brake.

B6

NEVP

Negative of the proportional electrovalve.

B7

NEV2-NHO Negative of the electrovalve 2; (option: negative of the horn).

B8

NEV1

Negative of the electrovalve 1.

B9

NEV4

Negative of the electrovalve 4.

B10 NEV3

Negative of the electrovalve 3.

B11 NEV5

Negative of the electrovalve 5.

B12 KEY IN

Input of the Key switch signal.

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B13 PMC

Positive of the main contactor.

B14 KEY OUT

Output of the Key switch signal.

B15 NOT USED Free.

B16 PEB

Positive of the electromechanical brake.

B17 PEVP

Positive of the proportional electrovalve.

B18 PEV2

Positive of the electrovalve 2.

B19 PEV1

Positive of the electrovalve 1.

B20 PEV4

Positive of the electrovalve 4.

B21 PEV3

Positive of the electrovalve 3.

B22 PEV5

Positive of the electrovalve 5.

Note: Proportional valve can be programmed by console as proportional or ON/OFF: if proportional the valve has an acceleration and deceleration ramp and its current is controlled by the lifting potentiometer.

If ON/OFF the valve is completely opened/closed without ramps.

The positive supply to the main contactor is provided from the key (pin 12) trough a diode against polarity inversion. The positive supply for the electrobrake is available in the pin 16 only if the tiller switch is closed.

The positive for the brake and all the other ON/OFF valves comes from the main contactor, so these loads do not affect the key input but only the auxiliary fuse.

3.3.3 Connector "C" description The "C" connector manages the serial link of the tiller card.

C1

-BATT

Negative free for the customer.

C2

BELLY

Quick inversion microswitch input. This signal is directly connected with the Combi for safety reason.

C3

SNAIL + T

Snail microswitch input. It is necessary that the tiller microswitch is cabled in the serial tiller card; in this case it is possible to run the truck also with the handle released at a slow speed.

C4

TILLER

Tiller microswitch input. In this case the tiller is directly connected with the Combi.

C5

DRFT

Data from the serial tiller

C6

-BATT

Negative for the serial tiller card.

C7

KEY OUT

Positive for the serial tiller card (is a key switch signal).

C8

KEY OUT

Positive for the tiller microswitch (is a key switch signal).

Note: The tiller microswitch can be cabled in the serial tiller (see serial tiller drawing) or directly in the controller (PIN 4 and 8 for the key in the serial tiller).

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3.3.4 Connector "D" description The "D" connector manages the MDI instrument or a Zapi console.

D1

NOT USED Free.

D2

PCLRXD

Positive of the reception from the console or the MDI instrument.

D3

-BATT

Negative of the console or the MDI instrument.

D4

+12

Positive of the console or the MDI instrument.

D5

NOT USED Free.

D6

NOT USED Free.

D7

NCLTXD

Negative of the transmission to the console or the MDI instrument.

D8

PCLTXD

Positive of the transmission to the console or the MDI instrument.

D9

NCLRXD

Negative of the reception from the console or the MDI instrument.

D10 NOT USED Free.

Note: The console must be connected to "D" at the place of MDI by means of an adaptor (follow the table for the right connections).

3.3.5 Connector "E" description The "E" connector manages the inputs from the chassis of the truck.

E1

INPUT 1

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E2

-BATT

Negative free for the customer.

E3

CM

Positive for the "Input 2"; is a key switch signal interrupted by a diode for safety reason.

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E4

INPUT 3

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E5

-BATT

Negative free for the customer.

E6

INPUT 4

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E7

CM

Positive for the "Input 5"; is a key switch signal interrupted by a diode for safety reason.

E8

CM

Positive for the "Input 6"; is a key switch signal interrupted by a diode for safety reason.

E9

SELECT 1

This is a digital input for model configuration.

E10 SELECT 2

This is a digital input for model configuration.

E11 CM

Positive for the "Input 1"; is a key switch signal interrupted by a diode for safety reason.

E12 -BATT

Negative free for the customer.

E13 INPUT 2

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E14 CM

Positive for the "Input 3"; is a key switch signal interrupted by a diode for safety reason.

E15 -BATT

Negative free for the customer.

E16 CM

Positive for the "Input 4"; is a key switch signal interrupted by a diode for safety reason.

E17 INPUT 5

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E18 INPUT 6

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E19 -BATT

Negative of the "Select 1" input.

E20 -BATT

Negative of the "Select 2" input.

Note: For the inputs is acceptable a PNP sensor with a 24V output. The maximum load for single inputs is less than 5mA.

Page 15

3.3.6 Connector "F" description The "F" connector is connected by Zapi.

F1

KEY OUT

This pin is connected to the pin1 of the A connector; is a key signal.

F2

BACKING

This pin is connected to the pin2 of the A connector; is a backing signal.

3.4 COMBI SEM-1 POWER CONNECTION

+BATT before FUSE +BATT after FUSE -BATT F1, F2 VMNT VMNP

Page 16

Positive of the battery after the main contactor Positive of the battery after the main cont. and after the fuse.

Negative of the battery.

Field connections for traction motor.

Traction motor current sensor input.

Pump motor input (without the current sensor).

4 REGULATION

4.1 ZAPI PROGRAMMING HANDLY CONSOLE In Combi Sem-1 controller is possible to program several functions through the console.

In this way is possible to modify the performances of the truck following the customer needings.

The console can remain connected to the controller while running and the parameters can be changed in real time. In this case it is important to go in stand by condition before switch off the controller in order to give the possibility to store the new values in the Eeprom.

This section describes the ZAPI console functions.

Six buttons provide the capability of changing or reading the parameter of the Combi: 1

Roll-Up

push to scroll up the submenu and to select a parameter;

2

Roll-Down

push to scroll down the submenu and to select a parameter;

3

Enter

push to have access to the selected submenu or to confirm a changement;

4

Out

push to exit the selected menu or to refuse a changement;

5

Set-Up

push to increase a parameter;

6

Set-Down

push to decrease a parameter;

Note: After a modify, memoriz the new value pushing the "4" (Out) button and the "3" (Enter) button. Double pushing of the "4" (Out) button doesn't save the value.

Numbers inside the triangles in the following map correspond to the same number on the console keyboard buttons shown in the figure below. The orientation of the triangle indicates the way to the next function.

Important CONNECT AND DISCONNECT THE CONSOLE ONLY WITH THE CONTROLLER SWITCHED OFF.

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4.2 DESCRIPTION OF STANDARD CONSOLE MENU

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4.3 "PARAMETER CHANGE" MENU The following parameters are an example of a typical Parameter Change menu; some of this parameters could be changed from customer requests.

The parameters with (p) symbol are related to the pump, those with (t) are related to the traction motor.

1) ACCELERATION DELAY (t) = Sets the acceleration ramp.

2) FLD ACCELERATION (t) = Field acceleration ramp: is the time needed to lower the field till to the weakened value, is a function of "Acceler. delay".

3) DECELERATION DELAY (t) = Sets the deceleration ramp according to the accelerator potentiometer position.

4) RELEASE BRAKING (t) = Sets the deceleration ramp when the driving request is released.

5) INVERS BRAKING (t) = Sets the deceleration ramp when is inverted the driving direction.

6) CUTBACK SPEED 1 (t) = Speed reduction 1.

7) CUTBACK SPEED 2 (t) = Speed reduction 2.

8) MAX. SPEED FORW. (t) = Maximum Forward speed, obtained by weakening the field current after reaching 100% conduction on the armature. With the parameter set at level 0, the armature is in full conduction but the field current does not decrease below the nominal value (low speed).

9) MAX SPEED BACK (t) = Maximum Reverse speed, obtained by weakening the field current after reaching 100% conduction on the armature. With the parameter set at level 0, the armature is in full conduction but the field current does not decrease below the nominal value (low speed).

10) TRACTION I MAX (t) = Sets the maximum current of the Chopper (Armature).

11) ARMA NOM. CURR (t) = Nominal armature current. This parameter fixes a limit for the armature current above which the field current is at least the nominal value (FIELD NOM. CURR.), regardless of accelerator position.

12) WEAK DROPOUT (t)= This parameter fixes a limit on the armature current above which the field current is increased linearly up to the nominal field current (proportionally to the armature current).

13) FIELD CURR. MAX. (t) = Maximum field current. This parameter fixes the maximum field current when the armature reaches the maximum value.

14) FIELD NOM. CURR. (t)= Nominal field current. This parameter fixes the minimum field current when the accelerator is between 0% and 60% without full conduction on the armature. Adjustment should be made with reference to the data on the motor label. (The indication of Nominal Field Current).

15) CREEP SPEED (t)= Minimum speed. This parameter sets the minimum start voltage applied to the motor.

16) SOFT WORKING (t) = Sets the entity of the acceleration and deceleration curves with the Snail (H&S) function selected.

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17) PUMP ACC DELAY (p) = Pump motor acceleration time:during this time the voltage on the pump motor goes to the desired value.

18) PUMP DEC DELAY (p) = Pump motor deceleration time:during this time the voltage on the pump motor decreases to the desired value..

19) PUMP CREEP (p) = This parameter sets the minimum voltage applied to the pump motor.

20) 1ST SPEED COARSE (p) = Main lift maximum speed.

21) FORK LIFT SPEED (p) = Forks lift maximum speed.

22) FORK DOWN SPEED (p) = Forks down maximum speed.

23) R - SHIFT SPEED (p) = Right shift maximum speed.

24) L - SHIFT SPEED (p) = Left shift maximum speed.

25) MIN EVP COARSE (p) = Sets the minimum voltage applied to the EVP. This is a big regulation.

26) MAX EVP COARSE (p) = Sets the maximum voltage applied to the EVP. This is a big regulation.

27) MIN EVP FINE (p) = Sets the minimum voltage applied to the EVP. This is a fine regulation.

28) MAX EVP FINE (p) = Sets the maximum voltage applied to the EVP. This is a fine regulation.

29) EVP ACC. DELAY (p) = Sets the acceleration time of the EVP. 30) EVP DEC. DELAY (p) = Sets the deceleration time of the EVP. 31) BACKING SPEED (t) = Sets the maximum backing (inching) speed.

32) BACKING TIME (t) = Sets the duration of the backing function.

Page 20

4.4 "TESTER" MENU The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage, current and temperature.

4.5 "ADJUSTMENT" MENU 1) ADJUST BATTERY = Battery voltage reading adjustment according with the real battery voltage.

2) ADJUSTEMENT #01 = Sets the maximum value of the battery discarge curve.

3) ADJUSTEMENT #02 = Sets the minimum value of the battery discarge curve.

4.6 "SET OPTION" MENU 1)

2)

3)

4)

5)

HOUR COUNTER Keyon

hourmeter always updated.

Running

hourmeter updated only if traction, lifting or hydraulics functions are activated.

BATTERY CHECK On

the battery discarge level check is carried on; when the battery level reaches 10%, an alarm is signaled and the maximum current is reduced to the half of the programmed value.

Off

the battery discarge level check is carried on but no alarm is signaled.

AUX FUNCTION 2 Present

Proportional electrovalve present.

Absent

Proportional electrovalve not present. Will be driven like an On/Off electrovalve.

QUICK INVERSION Belly

the truck goes backward direction (at 50% of maximum speed) till the belly button is pressed.

Timed

the truck goes backward direction (at 50% of maximum speed) only for some seconds.

SHIFT FUNCTION Present

The Shift function is enabled.

Absent

The Shift function is not used. In this case the output for the shift left valve can be used to drive an external horn. The Combi buzzer will be driven in parallel with the horn.

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6)

7)

8)

AUX FUNCTION #1 On

the Combi hour-meter is immediately over-written by that of MDI instrument.

Off

In this configuration the alarm "AL98" will be displayed on the MDI for 1 minute. If during this minute the user doesn't set ON the "Aux function #1", the MDI hour-meter will be over-written by that of the controller.

CHECK UP ENABLE On

This function sets an alarm (AL99, Check Up Needed) after 300 hours which informs the operator that it is necessary to make assistance service on the machine.

Off

This function is disabled.

CHECK UP DONE On

This option enables to reset the check-up hour-meter and the alarm "Check Up Needed".

Off

This function is disabled.

Page 22

5 ALARMS "ZAPI CONSOLE" 1) POWER FAILURE #1

"MDI" 73

Short-circuit on the ON/OFF valves, or in the main contactor coil, or in the electrobrake coil.

2) EEPROM KO

13

Fault in the area of memory where the parameters are stored. This alarm inhibits machine operation. If the fault continues when the Key switch is turned off and on again, replace the logic. If the fault disappears, the previously stored parameters will be replaced by the default parameters.

3) INCORRECT START

79 (Traction), 95 (Pump)

Alarm generated by an incorrect starting sequence. Possible reasons: a) The Enable microswitch has welded or failed. b) Error in the starting sequence from the operator. c) Error in the wiring. d) Lifting operation awaiting when the key is turned on.

4) CAPACITOR CHARGE

60

This check is made during the initial diagnosis. This Alarm is generated if the capacitors are not charged within 500 mSec after the Key switch on. Probable cause is a failure within the power block.

5) VMN NOT OK

32

This test is performed at rest, with the Main Contactor closed, and also during operation. This Alarm is generated if the VMN is lower than battery voltage in standby. This alarm is generated if VMN does not follow the duty-cycle of the chopper while driving. Possible causes: a) Incorrect motor connection. b) Frame fault of motor to chassis. c) Defect in the power unit.

6) VACC NOT OK

78

This Alarm is generated if the accelerator output voltage from the serial tiller is higher than 1V. Possible causes to be checked on the serial tiller: a) the track of the potentiometer has become open. b) the potentiometer is not wired correctly. c) the potentiometer itself is defective. d) the values set during the acquisition procedure are wrong.

Page 23

7) VFIELD NOT OK

3

This test is made in standby with the Main Contactor open. In this condition the voltage on both the connections of field must be around ½ VBatt. This alarm is generated if the field voltage is different from this value. Possible causes: a) Frame fault on the motor to chassis. b) Incorrect connection of the field winding to the chopper. c) Failure of the chopper in the section relative to the field.

8) PUMP VACC NOT OK

4

This alarm is generated if the lifting potentiometer output voltage from the serial tiller is higher than 1V. Possible causes to be checked on the serial tiller: a) the track of the potentiometer has become open. b) the potentiometer is not wired correctly. c) the potentiometer itself is defective. d) the values set during the acquisition procedure are wrong.

9) I = 0 EVER

49

This check is made while driving. If the current is not higher than a preset minimum value, this alarm is generated and the machine disabled. Possible causes: see "STBY I HIGH" alarm.

10) HIGH FIELD CURRENT

57

Problem detected with the field current sensor. Possible causes: a) Failure of the field current sensor. b) Failure of the field power unit.

11) NO FIELD CURRENT

58

Problem detected with the field winding current. Possible causes: a) Failure of the field current sensor. b) Field cables not connected or incorrectly connected. c) Failure of the field power unit.

12) DRIVER SHORTED

74

The test is carried out with Main Contactor open. The logic unit verifies that the coil of the Main Contactor is not shorted. Possible causes: a) Driver shorted. b) Problems in the feed back circuit of the Main Contactor coil. c) Wiring error. d) Fault in the protection circuit.

Page 24

13) COIL SHORTED

76

When the key is turned on, the microprocessor tests the overloads protection circuit of the contactor driver. If a problem is detected, this alarm is generated. Possible causes: a) Failure within the contactor coil. b) Incorrect wiring. c) Failure of the protection circuit.

14) CONTACTOR DRIVER

75

This alarm is generated if there is a problem with the Main Contactor. Possible causes: a) The Main Contactor coil driver is open-circuit. c) Defect in the Main Contactor coil voltage feed back circuit.

15) CONTACTOR CLOSED

37

This check is made before closing Main Contactor. It checks that the driver is not open. Possible causes: a) the contactor s power poles are not welded. b) This alarm could be generated if the line contactor is opened, but there is a problem within the field circuit.

16) FORW + BACK

80

This check is made continuosly. The Alarm is generated when forward and reverse directions are requested simultaneously. Possible causes: a) Incorrect Wiring. b) Welding or failure of a direction switch. c) Incorrect operation from the operator.

17) BATTERY LOW

66

This Alarm is generated when the battery becomes 90% discharged from the nominal value. If there is the alarm and the battery is not discharged, check the battery value in the Tester menu of the console; if it is incorrect, re-adjust via the Adjustment menu.

18) STBY I HIGH

53

This test is made during the initial diagnosis and in standby. The test verifies that the currents are zero. This alarm disables the machine. Possible causes: a) Defective current sensor. b) Feed back circuit failure or logic failure or power unit failure.

19) BRAKE DRIVER KO

2

The alarm is present when there is a problem on the electrobrake driver. Possible causes: a) driver in short-circuit b) driver broken, cannot drive the brake; c) current feedback circuit for the brake coil faulted Page 25

20) EVP NOT OK

1

At stand: proportional valve opened. Running: the proportional valve doesn t follow the applied PWM. 21) SERIAL ERROR #1

6

Wrong message or no message from serial tiller 22) INPUT ERROR #1

99

No belly switch on the tiller card 23) INPUT ERROR #2

98

Clearing hour meter.

24) THERMAL PROTECTION

67

This alarm is generated if the chopper temperature rises above 77°C, . If this alarm is displayed when the chopper s temperature is the same as ambient: a) check the connection of the temperature sensor. b) the temperature sensor may be defective. c) the logic may be defective.

25) WATCHDOG

8

The test is executed at key on, in stand-by and on running. Possible causes: a) Watch-dog hardware circuit not OK; b) Software not OK. 26) CHARGING BATTERY Battery charger connected

Page 26

68

COMBI SEM-1 OPERATING AND USER MANUAL

COMBI SEM1 FAULT CODES MDI

CONSOLE

DESCRIPTION

1 5 8 13 15 18 32 33 37 49 53 57 58 60 62 66 70 73 74 75 78 79 80 85 94 95 98 99

EVP NOT OK SERIAL ERROR #1 WATCHDOG EEPROM KO VFIELD NOT OK EB DRIVER KO VMN NOT OK LIFTING BLOCK CONTACTOR CLOSED I = 0 EVER STBY I HIGH HIGH FIELD CURR NO FIELD CUR CAPACITOR CHARGE TH.PROTECTION BATTERY LOW PUMP VACC NOT OK POWER FAILURE #1 DRIVER SHORTED CONTACTOR DRIVER VACC NOT OK INCORRECT START FORW+BACK STEER HAZARD INPUT ERROR #2 INPUT ERROR #1

Wrong evp voltage Problems in serial comunication with serial tiller Watchdog hardware error or program loop without exit problems in eeprom Field voltage not at VMN/2 with no traction Wrong EB voltage Without traction : VMN not at VBATT, with traction: VMN doesn't follow pwm Lifting stop Contactor closed at keyon No armature current during traction High armature current without traction High field current without traction No field current during traction Capacitors don0t charge at keyon Chopper temperature too high ( > 75°C) Battery charge <= 20% Pump set point from tiller card high without lift/low request short circuit on ON/OFFvalves or on TG or on EB main contactor driver shorted main contactor driver doesn't close Traction set point from tiller card high without forw/reverse request Tiller input ON or lift/low/forw/reverse request ON at keyon or wrong start sequence Forward and reverse request together Steer hazard input open : blocks traction (D model) Tiller card belly input different from chopper belly input: chopper input is OFF Tiller card belly input different from chopper belly input: tiller input is OFF Mdi hour meter and chopper hour meter ar different (only on MDI) Maintanence needed

CHECK UP NEEDED

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

HYDRAULIC DIAGRAM NOL10K, NOL10KV TH58 0800

HYDRAULIC DIAGRAM NOL10KF

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

0K1 2

A

10A

1

25A

2

25 mm2

4.0 mm2

1

0L3 2/28

0L2 5/13

X1: B-

5

7

4L2

5L2

6L2

5/15

7/26

5/26

3L1

4L1

5L1

6L1

2/13

2/24

4/14

7/16

5/21

AUX. DEVICES

PUMP CIRCUITS

STEERING MOTOR

PUMP MOTOR

STEERING CIRCUITS

1L1

DRIVE MOTOR

-

6F1

4/13

BATT.DISCARGE IND.

24V

G1

3

G

10A

0L1

MAIN CONTACTORS

+

E

10A

5F1

DRIVE CIRCUITS

X1: B+

4F1

3F1

0F1

C

10A

2.5 mm2

1

2.5 mm2

25 mm2

1.0 mm2

25 mm2

2.5 mm2

4/13

0M1

1M1

3M1

4M1

5M1

6M1

4/13

2/13

2/24

6/16

4/28

5/21

4M2

5M2

6M2

5/17

7/29

5/26

0M2 5/14

0M3

2.5 mm2

2.5 mm2

CIRCUIT DIAGRAM

TS891201

6F2

5F2 D

10A

F

10A

8

NOL10K/NOL10KF POWER SUPPLIES 24V

H

10A

2.5 mm2

B

4F2

6

2.5 mm2

0F2

4

2.5 mm2

25 mm2

2 10A

4.0 mm2

2/28

25 mm2

11

1/8

REV

3-6766

2

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

3L1

0L3

1/18

1/21

1/15

4,0 mm2

25 mm2 1

29

30

1,0 mm2

1L1

1

3K1

1K1

7/28

2 4,0 mm2

25 mm2 +B:1 1 300A

4,0 mm2

1F1

B+

2

16 mm2 4,0 mm2

16 mm2

E1

4,0 mm2 F1

M1 A1

E2 4,0 mm2 F2

D1

A1

M3 M2

A2

D2

16 mm2

4,0 mm2

16 mm2 -T

SH

SH

M2

-P

X7: 1

X6: 1 RED

M4 BLK

X6: 2

M5 BLK

X7: 2

4,0 mm2

25 mm2

B-

4,0 mm2

-B

CombiSEM

A1

FBW 2440

A3

1M1

3M1

0M3

1/18

1/21

1/15

DRIVE MOTOR

RED

1,0 mm2

A2

M1

A1 SPEED CONTROLLER

+B:2

A3 STEERING MOTOR CONTROLLER

25 mm2

2

X30

4/19

25 mm2

11

PUMP MOTOR

CIRCUIT DIAGRAM

STEERING MOTOR

TS891201

NOL10K/NOL10KF POWER CIRCUITS

AUXILIARY FANS

2/8

REV

3-6766

18

19

20

21

22

J2

30

6

7 +24VDC

5

LOWER

-BATT

4

4/26

X111: 7

J10

A101

3

2

6

3

B

9

2

4

C

X111: 8

X111: 9

1

5

7

A

9

12

B

+BATT

J204

4/12

13 14

1

RXD

A102

X111: 6

J10

2

2

F

1

1

2

3

4

C

X11: 5

X11: 6

6

5

CONNECTION FOR CONSOLE BRAKE SWITCH

X11: 1

7

8

4

3

2

D

9

NCLTXD

X11: 4

TILLER

X11: 3

8/14

PCLTXD

X11: 2

-BATT

BACK

BACK

A

KEY OUT

8/23

NCLRXD

J11

X111: 5

PCLRXD

X111: 4

-BATT

X111: 3

+12VDC

X111: 2

KEY OUT

3

R101

21

5

1

2

LOWER

J203

SERIAL TILLER INTERFACE

A 2-pin B 22-pin C 8-pin D 10-pin E 20-pin F 2-pin

29

23

FW/BW

+BATT 7

BW/FW

POT LOW

0-5 V

-BATT

3

8

28

5kOhm

X121: 3

10

A

8/29

X110: 4

FW

X121: 4

27

COM

DISPLAY AND CONTROL UNIT

6

J22

8/28

+24VDC

X121: 1

12

A 10-pin B 14-pin C 6-pin D 2-pin

J21

8/27

1

X121: 5

26

LIFT

WHT

J20

HORN

X121: 6

WHT/ BLK

+BATT

X121: 7

GRN

25

NO

S103

BW

B-

0-5 V

B101

ORA POT LOW

BLK

B+

WHT/ BRN

24

INIT.LIFT/LOWER CABIN LIFT/LOWER

SIGNAL HORN

ACCELERATOR NM3V

23

LIFT

17

0-5VDC

16

0-5VDC

15

+5VDC

14

+5VDC

13

LOWER

12

LIFT

11

8

7

KEY OUT

SPEED CONTROLLER CombiSEM

A1 CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF CONTROL DEVICES 1

3/8

REV

3-6766

29

0L1

4L1

1/15

1/24

A1

X10: 1

START-UP

MAIN CONTACTOR

MAGN.BRAKE

PROPOVALVE

30

SIGNALHORN

INIT.LIFT/LOWER LIFT/LOWER

CombiSEM

A1 SPEED CONTROLLER B 1

12

2

13

5

16

6

17

10

21

11

22

9

20

14

PHO

NHO

PEV

NEV

PEB

NEB

PMC

NMC

KEY IN

+BATT

X110: 1

S101 13 KEY SWITCH

J204 3/21

22

S102 21

X10: 15

EMERG.STOP

X110: 2 A1

V5

H1

-

A2

X10: 2

X12: 1 A1

1/16

0K1 A2

+

A1

F101

2/13

0K1: MAIN CONTACTOR 1

A1

F103

Y1

1K1 A2

M1

U

A2

+ C5

1N4005 100uF 63V A1

A1

2Y1 A2

*)

2Y2 A2

A1 *)

2Y3 A2

X12: 2

1K1: MAIN CONTACTOR 2

J203

0M1

5M1

3/20

1/15

1/26

*) APPLIED ONLY TO TRUCKS WITH INITIAL LIFT

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF CONTROL DEVICES 2

4/8

REV

3-6766

12

13

14

15

BATT.DISCH.IND.

16

17

POWER SUPPLY

18

19

HOUR METER

20

21

22

+24V

23

24

OPTIONAL DEVICES

25

26

27

28

29

0M2

4L2

4M2

6L1

6L2

1/15

1/15

1/24

1/24

1/28

1/28

1

5A

1

3A

21F1

22F1 2

X10: 6

X10: 7

2

X10: 8 21L1

22L1

X11: 12

24V

J2

NM906-917

15

18

BASIC LIFT

14

STABILIZERS LOWER

12

CABIN LIFT

G2 STABILIZERS LIFT

17

X110: 8

SUPPLY -

6

X110: 7

SUPPLY +24V

X110: 6

BATT-

X110: 5

8

9

20

21

J10

J2

DISPLAY AND CONTROL UNIT

h CD701-024

Vo+

Vi+

PRINTER

Vi+

X11: 14

24V/5A

Gi-

24V

G3

Go-

Vo+

12V/3A

Gi-

X11: 13

TERMINAL

X10: 5

30

+24V

0L2

BATT+

11

Go-

X11: 15

21M1

22M1

6M1

6M2

1/28

1/28

A101

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF DISPLAY DEVICES 1

5/8

REV

3-6766

14

15

16

17

X14: 4

XS1M18PA370 (199213)

BRN

19

20

TOP LIMIT/LOW LIMIT

SLOW LIFT/LOWER

X14: 1

18

22

23

24

25

26

27

X15: 1

B13

PNP

PNP BLU

PNP

BLK

BLU

BLK

BLU 550mm

X14: 3

X14: 2

X15: 3

X15: 2

X14: 6

X14: 5

30

19

J10

A101 BLK

29

DISPLAY AND CONTROL UNIT

XS1M18PA370 (199213)

BRN

B11

28

BACKING

CUTBACK SPEED

XS1M18PA370 (199213)

BRN

B12

21

BACKING

13

X110: 9

16

1

11 CUTBACK SPEED 2

3

13

14

CUTBACK SPEED 2

E

4

9

CUTBACK SPEED 1

19 SELECT MODE 2

10

20

18

COM

-BATT

S2

S1

SR

FLOOR

COM

COM

GATES 6

COM (+24VDC)

1/24

-BATT

4M1

ENABLE BACKING

X10: 9

TOP MAST

12

COM

11

8

SELECT MODE 1

A1 SPEED CONTROLLER CombiSEM

A1 1100mm 1140mm 200mm 160mm

SLOW LIFT SPEED ACTIVATED LIFT STOPPED LOW LIMIT SLOW LOW SPEED ACTIVATED

400mm SLOW TRACTION SPEED ACTIVATED

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF DISPLAY DEVICES 2

6/8

REV

3-6766

A

13

14

STEERING WHEEL TACHO

15

16

17

18

19

20

21

+

26

5L2

8/24

1/26

STEERING LIMIT SWITCHES

NO

S32

COM

NO

S33

COM

COM

X10: 14

X110: 12

X110: 13

X110: 14

SENSOR B

X10: 13

SENSOR A

X10: 12

10

J2

22

28

29

30

3K2 29

6

X10: 3

X110: 15

X110: 3

18

11

27

7

LAMP

NO

S31

SENSOR C

BLK

RED

25

J12

-

X110: 11

24

1/26

X133: 2

X110: 10

23

5L1

B103

X133: 1

22

STEERING ERROR

12

MAGNETIC BRAKE INTERLOCK

11

13

1

STEERING FAILSAFE RELAYS

DISPLAY AND CONTROL UNIT

X10: 11

20

P

9

J10

STOP

X32

11

STEERING LIMIT CCW

OPTION.

2/24

5

SAFETY CIRCUIT

4

A1

SUPPLY 24VDC

6

OPTION.

STEERING LIMIT CW

+

TACHOMETER 0V

TACHOMETER REF.

A101

1

8

+ 8

3K1

3K2

A2

23 8/23

- 1

-

F102

X10: 10

12345678 OPEN CLOSED

A3 STEERING MOTOR CONTROLLER

FBW 2440

5M2

A3

1/26

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF STEERING CIRCUITS

7/8

REV

3-6766

17

18

19

20

21

22

23

24

X115: 1

X115: 2

4

6

X115: 4

S113 6

X115: 5

1

X115: 6

NO COM DEAD MAN’S PEDAL

S115

NC

S110 BRAKE SWITCH

13

J10

J2

30

S114

3

1

2 3

NO

S116

COM

COM

I.LIFT

I.LOWER

+ -

X115: 11

X115: 12

BRAKE

DISPLAY AND CONTROL UNIT

J10 3/24

3

0.4 uF

3K2

1 ohm

SUPPLY

4 7/29

24

2

X115: 10

X10: 4

DASHBOARD ORIENT

BW

FW

X111: 11

19

29

ONLY NOL10KF

NO

7

28

LOWER

5

S112

SUPPLY

4

X115: 3

X111: 10

27

BRAKE

FW

3

5

BRAKE

1

S111

BW

3

2

SUPPLY

S112

SUPPLY

1

2

26

INIT.LIFT/LOWER BUTTOMS IN THE CABIN

PEDESTRIAN DRIVE BUTTOMS IN THE LIFT CABIN

S111

25

LOWER

16

LIFT

15

LIFT

14

SUPPLY +24VDC

13

MAGNETIC BRAKE INTERLOCK

12

SUPPLY

11

A101 CIRCUIT DIAGRAM

J11

J12

J20

J21

J22

3/20

7/21

3/22

3/23

3/24

TS891201

NOL10K/NOL10KF TRACTION CIRCUITS 2

8/8

REV

3-6766

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

S110:COM S110:NC

L2200

S110:NO

X115 RL210366

L300

12

X110 15 L300 RL210028

15

X10 RL210026

15

X11 RL210028

L2620

X111 RL210026

15 L300

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF WIRE HARNESS W5: RL450925

10 / 8

REV

3-6766

S103:COM

L300

19

20

A102:C

18

6

7

17

A102:B

R101 RL199215

16

14

15

A102:A

14

10

13

21

22

23

24

25

26

27

28

29

30

L250

S103:NO

X121 RL108288

22 L150

9

L150

A101:J10 RL450103

15

L150

X110 RL210026 L450

X133 RL210020

2

L250 15

X111 RL210028

24 L150

S102:21

L350 S102:22

S101:13

A101:J2 RL450102

L250

12

S101:14

11

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF WIRE HARNESS W6: RL450926

11 / 8

REV

3-6766

7

8

G

H

L150 L100

L100 L100

M3:A2

M3:A1

L200

L50

L250

S33:COM

L50

L50

L250

L250

L200

L250

L150

L150

X12 RL211074

L350

2

L1000

2

A1: F

20

A1: E

8

A1: C

22

A1: B

2

A1: A

L100

L50

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF WIRE HARNESS W9: RL450927

3K2: 8

3K2: 1

3K2: 4

3K2: 3

3K2: 7

1K1:A2

1K1:A1

X30 X32 RL199085 RL199085

0K1:A2

13

0K1:A1

S32:NO

S32:COM

5

3K2: 6

S33:NO

S31:NO

X11 15 RL210026

L200

L300

30

0K1:2

0K1:1

X10 15 L150 RL210028 L250

29

A1:B-

6 F

28

L250

5 E

27

L250

L250

4 D

26

3K1:A2

H1:A1

3 C

L300

6F1:

4F1: 2 B

25

3K1:2

24

3K1:A1

23

H1:A2

22

L300

L1500

X15 3 RL210022

0F1: L500

2

S31:COM

X14 6 RL210353

L150

21

L200

X6 RL211074

2Y1:A2

2Y1:A1 2

20

L400

X7 RL211074

19

5F1:

18

1

17

A

16

2Y3:A2

15

2Y3:A1

14

L500

13

2Y2:A2

12

2Y2:A1

11

12 / 8

REV

3-6766

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

WIRE HARNESS: NOL10K/NO20S

8

S113 RL199098

L850 8 6

S111 RL199098

X115 12 RL210025 8

S112 RL199098

L850 8

S114 RL199098

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF WIRE HARNESS W7: RL450142

13 / 8

REV

3-6766

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

EXTRA LIFTING WIRE HARNESS: NOL10KF

L100

S115:NO S115:COM

L3000

L100

S116:COM L100

S116:NO

8

S113 RL199098

L850 8 6

S111 RL199098

X15 12 RL210025

8

S112 RL199098

L850 8

S114 RL199098

CIRCUIT DIAGRAM

TS891201

NOL10K/NOL10KF WIRE HARNESS W8: RL461434

14 / 8

REV

3-6766