Caterpillar NOM10K Lift Trucks Operation & Maintenance Manual - PDF DOWNLOAD

EN

Operation & Maintenance Manual NOM10K

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

1. Order picker .......................................................................... 5 2. Safety instructions ................................................................ 5 3. Operating environment ......................................................... 6 4. Operating devices ................................................................. 7 5. Driving instructions ............................................................. 11 6. Load handling ..................................................................... 13 7. Batteries .............................................................................. 14 8. Maintenance ....................................................................... 15 9. Transportation and storage ................................................. 17 10. Troubleshooting .............................................................. 18 Emergency rope instructions .................................................. 20

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

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

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

WARNING! 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 electric devices in the truck without the manufacturer's permission. Modifications to electric devices may affect the electromagnetic compatibility and, therefore, reduce safety.

Delivery Before shipping, each truck is inspected carefully to make sure that the truck you receive is in impeccable condition and equipped accordingly. Nevertheless, check the truck immediately after receiving it for any damages during shipping.

2. Safety instructions Instructions for site supervision • Familiarize yourself with the operating instructions and their contents • Train the operator on the use, maintenance and safety 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 checks in accordance with the maintenance instruction and on time to avoid faults and operational errors.

• If you notice any faults or deficiencies risking safety, take the truck out of operation until the faults or deficiencies have been remedied • Do not repair anything without the permission from the site supervision • In case of a malfunction, disconnect the battery connector • When using the truck, you are responsible for both your own and your environment's safety • Immediately notify the site supervision of any accidents or injuries. In such a case, leave the truck at the place of the accident.

Truck operator Requirements: • At least 18 years old • Sufficient physical (e.g. good hearing and sight) and psychological properties required for operating the truck without risks • Appropriately trained; familiar with operating, maintenance and safety instructions • Knows and masters the drive and operational properties of the truck

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

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

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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 above mentioned work.

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

Overhead guard and load support Trucks driven sitting or standing that are capable of lifting a load higher than 1.8 m must be equipped with an overhead guard. No modifications to the overhead guard that could possibly weaken its structure are allowed. If objects could fall through the slots in the overhead guard, the size of the slots must be reduced.

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

3. Operating environment The truck should be used in dry indoor spaces, on even and level floors. The temperature range in which the truck can continuously operate is +5 - +25°C, and for short periods +0 - 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 safety 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 to 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 a permission from the site supervision 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: Do not let other people be 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 a 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 also 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 the risk of overturning.

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4. Operating devices 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 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 press the pedal on the floor with foot to the drive position. The truck will move only when the pedal is 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. Use counter-current (reversing) brake during normal driving.

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

2. When the truck is free-wheeling.

Practise braking with a load in a safe area before you start working with the truck.

CAUTION! The truck will stop quickly if you release the safety pedal.

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Left-hand control panel Emergency stop button (1) 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, e.g. if the pump motor runs continuously.

• In an accident.

The switch is released by turning the button clockwise.

Power lock (2) The power lock connects the truck's electrical equipment to the battery circuit.

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

Steering wheel (3) The steering wheel turns the drive mechanism electrically 360º, see section Electrical steering.

Right-hand control panel Speed control (1) Turn the speed control forward or backward to the desired drive direction. A larger movement of the handle produces a higher speed. The speed control 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 drive direction. You should anticipate the situation when you must brake and decrease the speed well ahead. When driving in a guided aisle, keep your left hand on the steering wheel knob. This is a safety measure ensuring that your hands are in a safe position.

Horn button (2) Lifting and lowering the lift cage (3) Use the lift lever on the control panel to lift/lower the lift cage. Stopping of the lowering movement is hydraulically damped. Once the lift cage has reached the maximum lifting height, lifting stops automatically. The speed of the truck depends on the lifting height, see section Drive speed limits.

Keep your left hand always (even when driving outside a guided aisle) on the steering wheel knob when operating the hydraulics (including extra lift). This is a safety measure ensuring that your hands are in a safe position.

Chain tension sensing reset button (4) The tension of the truck's chains is monitored electrically. If the lift cage chains slacken due to an obstacle, all lifting and lowering operations of the truck are automatically switched off.

First, find the cause for loosening to set the chains of the lift cage to a normal tension. Then, press the reset button simultaneously with the lift cage lift button, and the chain tension will return to normal.

Extra lift (5) Press the button on the control panel to lift/lower extra lift. Using the extra lift makes it easier to use the truck to collect goods and place pallets from shelves.

Lifting height intermediate limit (optional) If the truck is equipped with a lifting height intermediate limit, the lifting height is limited electrically to a lower level than the maximum lifting height. If you want to lift above this lifting height, press the reset button and continue lifting.

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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 on, the magnetic brake comes on automatically.

Magnetic brake indicator light (2) Magnetic brake indicator light indicates that the brake is on.

Drive direction indicator lamps (3) The indicator lamps indicate the drive 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 guard (5) The battery guard 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. Hour meter/battery guard is located on the top of the battery.

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

Recharging plug The truck's recharging plug has a handle and can be detached. See section Recharging the battery 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.

Operating light switch The cab light switch turns on the cab operating and general lights.

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Emergency rope The truck has an emergency rope below the driver’s seat. In emergency situations the rope can be attached to the roof of the lift cage. Read the instructions for the emergency rope carefully, see Appendix. Use the rope only in cases of emergency!

Seat/backrest Change the height of the adjustable backrest by pulling the lower edge outwards slightly and sliding the rest to the desired height.

Lowering the lift cage in emergency The valve is used in case of a malfunction when the lift cage of the truck is raised. Turn the handle of the lowering valve in the machine compartment 90 º to lower the cage manually. The lowering speed of the cage is limited to 0,40 m/s.

Safety gates The safety gates must be closed for driving and lifting as follows:

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Lifting height

Safety gates

0 - 1200 mm

Open

Driving/lifting is possible when the gates are either open or closed.

1201 - mm

Closed

Driving/lifting is possible only when the gates are closed.

Note

5. Driving instructions Daily checks before operation Carry out the daily maintenance 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 current and test the operation of the lifting hydraulics by raising and lowering the forks.

• Check the operation of the speed control 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.

• Check that emergency stop operates.

• Check the operation of the truck’s safety doors.

• Check the operation of the speed limit function.

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

Before you start: • • • • • •

Close the truck gates (when the lift cage is raised over 3000mm).

Switch on the power.

Check the drive direction from the indicator lights.

Check whether the truck is switched to automatic control or not.

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

Take a position where only one foot is on the safety pedal and lean against the backrest or sit.

Driving • Press the pedal to move the truck.

• Turn the speed control lightly to the drive direction.

• To brake, turn the speed control to the opposite from the driving direction.

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

The system consists of three main components: 1. Tachometer located in the steering wheel 2. Control unit located in the motor compartment 3. Servomotor, which is also in the motor compartment.

The control unit processes the signal coming from the tachometer and directs the servomotor 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 problems.

The drive wheel turns around without limits. Turn the wheel 180º to change the drive direction of the truck to the opposite. Choose the driving direction again by using the acceleration switch to change the driving direction to the required direction.

Safety When the power is turned on from the main switch and the ignition key, the system performs a 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 by switching on the magnetic brake, and the truck will stop.

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

Wait for at least 3 seconds before you turn on the power again after it has been switched off by the system. If the STOP LED 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. Quarterly maintenance check (300 hrs.) includes fastening of the steering control unit terminals.

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

Speed limits The truck has drive speed limits, which operate as follows:

Lifting height

Speed limit

Note

0 - 1200 mm

9 km/h

1201 - 3000 mm

4 km/h

3001mm -

2,5 km/h

Lifting height

Speed limit

Note

0 - 3000 mm

9 km/h

When the steering wheel is turned 10 º or more from the direct drive position, and the cage is lifted higher than 1200 mm, the speed limit is 2,5 km/h.

3001 mm -

2,5 km/h

When the steering wheel is turned 10 º or more from the direct drive position, the speed limit is 2,5 km/h.

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 in your control.

• Avoid sudden starts and stops.

• Make the steering and braking movements smoothly.

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

• Take great care when driving on a slanted surface.

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

When driving, 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 brake pedal. The left hand should be on the steering wheel and the right hand on the speed control support handle.

If you drive the truck from the operator's platform, always keep your body completely within the outlines of the truck. Anticipate any dangers so that you can avoid risks of accident or injury.

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

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 at 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 traffic regulations and speed limits. Do not drive the truck outside a private area without an order or permission by the site supervision.

Outside a private area, the truck is subject to general traffic rules and regulations. If a door opening is so narrow that two vehicles cannot pass each other, drive in the middle. When two trucks meet in a narrow or cross aisle, the loaded truck has the right of way.

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

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

• Always drive the truck with its forks lowered.

• When the load is raised, steering and braking must be done carefully.

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

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

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

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

• Only handle undamaged loads.

• Place the load correctly.

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

• Do not overload.

Lifting capacity The maximum lifting capacity of the truck is given on the identification plate. Do not exceed the truck's maximum loading capacity under any circumstances. Obey the maximum values for load weight and load center information in the different loading situations. The values are printed on the capacity plate. Take into account the effect of any attachments on the lifting capacity.

Collection • • • •

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

Use the extra lift to set a suitable collection height.

Do not open the truck’s safety gates when working in the lift cage.

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

Stacking and unloading A collection truck is not intended for continuous pallet stacking and unloading. When stacking and unloading, use an extra lift set to the stacking level.

To stack: • Drive towards the shelf or stack level with the load lowered.

• Raise the load so that it is clearly above the stacking height or shelf level.

• Drive forward towards the stack.

• When the load is in the correct position, lower it to the stacking level.

• Lower the forks, so that they disengage, and reverse from the stacking location. Make sure that the forks are clear of both the stacking level and the pallet.

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

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

• Do not handle naked flame in the vicinity of batteries because of a risk of explosion.

• Do not smoke when working with batteries.

• Do not leave tools or other metal implements on top of the battery. Sparking or a short-circuit may cause the battery to explode.

• When batteries are recharged, the cell plugs must be screwed on tight to prevent battery fluid splashing.

• Battery fluid is a corrosive acid solution; avoid getting it on the skin or in the eyes. Battery fluid develops an explosive gas at the end phase of recharging. Therefore, make sure that the battery has sufficient ventilation (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 track current.

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

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

5. Connect the current to the charger.

After charging 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 and maintenance instructions.

Measuring battery cell density Measure the acid density of the battery fluid according to the manufacturer's instructions. The acid density of a fully charged battery is 1.28 to 1.30 at + 30 °c.

• 1.24 3/4 charged • 1.20 1/2 charged • 1.16 1/4 charged • 1.15 empty. Charge the battery immediately

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

Acquiring a new battery When acquiring a battery for the truck, pay attention to the following sections of standard prEN 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 on the truck battery plate) The battery plate should give at least the following information: • Manufacturer • Type • Serial number • Rated voltage • Capacity (ah/5h) • Service weight

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

It is recommended to sign a maintenance agreement with the truck dealer, who can also supply spare parts. Only professional service ensures 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 good 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 hand to check for oil leaks.

• Do not open the hydraulic accumulator.

• 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 toxic gases being formed during welding.

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

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 mild soda solution, which neutralizes the battery acid. Dry the battery carefully after the wash.

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

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

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

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• Lightly lubricate the mast and the lift cage 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.

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

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

• Clean the truck if necessary.

Note: Do not let water onto the electrical devices.

Quarterly maintenance (300h) Check and, if necessary, adjust or repair: • Contactors, micro switches, and solenoids and their cables • Brake air gap: correct dimension 0.3 - 0.8 mm • Speed control operation • Attachment of the cylinders and the locking of the settings • Lift cage 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.

• Torque of the drive wheel attachment nuts (Torque 190 Nm) • Lifting hydraulics operation • Collectors, carbon brushes and electric cables of the drive and pump motors

Semi-annual maintenance (600h) Check and, if necessary, adjust or repair: • Drive and pump motors, and, if included in the equipment: the collectors, carbon brushes, and electric cables of the steering motor or steering servo. Clean carbon dust from the motors.

• Operation of the hydraulic and pressure limit valves.

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

• Condition of the extra lift.

• Lifting chain wheels and chain guards.

• Driver's cabinet and its attachments.

• Battery rollers • Check, clean, and lubricate the lifting chains.

• Check and lubricate the wheel bearings.

• Clean the oil filter.

Annual maintenance • 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 mechanism • Steering tooth ring

Lubricant recommendation Hydraulic oil: Neste 32 super. In freezer warehouses: Neste SH 15. Fill ¾ of the tank's volume.

Transmission oil: EP80/90 Lubrication grease: NLGI No.2, containing molybdenum sulpide. In freezer warehouses: NLGI No.1 or 0.

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Fuses (1): 1F1 Main fuse (2): 3F1 Steering main fuse (3): 0F1 Main contactor 0F2 Main contactor 4F1 Control circuit 4F2 Control circuit 5F1 Lifting cage 5F2 Lifting cage 6F1 Option 6F2 Option

Ordering spare parts When ordering spare parts, always turn to your dealer or the maintenance centre. Only use original spare parts.

To ensure 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. Number 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 gear oils, and batteries are hazardous waste that must be disposed of accordingly. The truck itself is not hazardous waste, and can be recycled.

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

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

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

Battery has not been locked into place

Check the locking and the switch

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

Drive motor carbon brushes are worn out

Replace the carbon brushes

Speed control is faulty

Contact the truck dealer

Pump fuse has blown

Replace the fuse

Control current fuse has blown

Replace the fuse and check the cables

Drive switch is broken

Replace the switch

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 in valve

Clean the valve, replace if necessary

Charger is connected incorrectly

Check the connection

Charge fuse has blown or main voltage is missing

Replace the fuse

Battery cell’s water level or specific gravity is low

Check the cell’s current and specific gravity. Add water and/or acid when necessary. See section Recharging the battery.

Lift pump does not run

Lifting functions improperly

Battery does not charge

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Symptom

Fault

Action

Steering does not work properly

Control motor fuse has blown

Change the fuse (F12)

Control power fuse has blown

Change the fuse (F3/F6)

Short voltage break (<2 sec.) caused by e.g. switching of the power on too soon.

Switch off the power and wait more than 2 seconds. Turn the power back on.

Faulty servo controller (indicators are not lit)

Contact the truck dealer

Steering motor carbon brushes are worn out

Replace the carbon brushes

Steering is hindered when turning strongly to the limit

The end line switches are faulty or misadjusted. Replace and adjust.

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Emergency rope instructions Follow the operating instructions. The rope is for emergency use only. Keep it away from children.

Descending alone Caution! Person descending alone must weigh over 25 kg.

1. Attach the rope end securely to a solid object with the rope lock.

2. Tighten the harness under your arms.

3. Throw the loose end of the rope to the ground.

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4. Hold the rope with at least one hand. Keep your hands close to your sides as shown in the picture.

5. Lower yourself by gradually releasing your grip from the rope.

Descending an incapacitated person Before descending an incapacitated person, one person has to descend to the ground first.

1. Pull up the rope and attach the rope end, which is closer to the harness, securely to a solid object with the rope lock.

2. Throw the loose end to the ground.

3. Adjust the harness brake closer to the attached rope end to eliminate slack.

4. Tighten the harness under the incapacitated person’s arms.

5. Descend the person by controlling the speed of the descent from the ground.

21

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.

Page 11

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.

Page 12

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).

Page 13

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.

Page 14

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.

Page 17

4.2 DESCRIPTION OF STANDARD CONSOLE MENU

Page 18

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.

Page 19

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.

Page 21

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

Initial lift 2x D40

Ergo -lift 1x D50

Scale

1:1 HYDRAULIC DIAGRAM TH66 1103 NOM10K

Former

P006381

TH66 1103

1/4

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

4/4

12

13

14

15

16

17

18

19

20

21

22

23

24

25

A

3F1

28

4F1

29

30

2.5 mm2

6F1 5

7

2

4L2

0L1

1L1

4/13

3L1

3/12

3/21

4L4

10/19

11/13

4L1

4L3

12/22

4/18

X11: 4

X12: 1 NOSTOKORI CABIN

4

X103: 1

101L3

102L2

102L4

101L1

102L1

102L3

2/21

JÄNNITEMUUNTIMET DC/DC-CONVERTERS

MERKINANTO/VALOPIIRIT SIGNAL/LIGHT CIRCUITS

OHJAUSPIIRIT STEERING CIRCUITS

NOSTOPIIRIT LIFT CIRCUITS

AJOPIIRIT DRIVE CIRCUITS

OHJAUSMOOTTORI STEERING MOTOR

PUMPPUMOOTTORI PUMP MOTOR

AJOMOOTTORI DRIVE MOTOR

AKKUVARTIJA BATT.DISCARGE IND.

PÄÄKONTAKTORIT MAIN CONTACTORS

2/13

102M1

102M3

101M2

102M2

102M4

X101: 5

X102: 2

X103: 2

REV

2/13

4/21

0M1

1M1

4/13

3M1

3/12

3/21

0M2

4M1

4M3

12/27

14/16

4M2

13/13

4M10

14/21

17

29

X12: 2

B

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

4F2 10A

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

6

5F2 D

2.5 mm2

2.5 mm2

4

X13: 2

10A

TS961108

8

6F2 F

2.5 mm2

4.0 mm2

25 mm2

2.5 mm2

0F2 25 mm2

NOSTOKORI CABIN

5

14/19

3/27

2 10A

2/21

X11: 5

10/12

14/21

101M1 13/17

X1: B-

14/19

NOM10K JÄNNITESYÖTÖT 24V POWER SUPPLIES 24V

10A

H 2.5 mm2

CHANGE: DATE:

-

28

X102: 1

13/15

24V

16

X101: 4 10/29

G1

X13: 1

NOSTOKORI CABIN

0L2

13/12

+

G

10A

5F1 3

4L10

X1: B+

E

10A

LISÄLAITTEET AUX. DEVICES

1

C

10A 1

25A

2.5 mm2

2.5 mm2

2 4.0 mm2

1

25 mm2

1.0 mm2

25 mm2

0F1

NAME:

27

4/13

10A

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

26

0K1 25 mm2

c ROCLA OYJ 2003

11

1 / 26

REV

3-6877

2

c ROCLA OYJ 2003

11

12

13

14

15

16

17

18

19

20

21

22

LISÄLAITTEET OPTIONAL DEVICES

23

24

25

30

1/27

1

5A

1

3A

111F1

121F1 2

2

111L1

24V

Vo+

24V/5A 199151

24V

Vo+

12V/5A 211072

G102

Go-

Gi-

Go-

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV

Gi-

Vi+

PÄÄTE TERMINAL

Vi+

121L1

TULOSTIN PRINTER

CHANGE:

29

102L2

1/27

NAME:

28

+24V

102L1

DATE:

27

LISÄLAITTEET OPTIONAL DEVICES

+24V

G101

26

111M1

121M1

102M1

102M2

1/27

1/27

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K JÄNNITESYÖTÖT 12-24V POWER SUPPLIES 12-24V

2 / 26

REV

3-6877

2

12

13

14

15

16

17

18

1L1

19

20

21

22

23

24

25

26

27

3L1

0L3

1/19

1

1K1

SM1

3K1

4/17

30

4/16

2

t

12/25

2

29

1,0 mm2

BY-PASS CONNECTION ONLY IN WGA-VERSION 1

28

0L4

4/15

4,0 mm2

1/17

25 mm2

c ROCLA OYJ 2003

11

2

XA3A:

25 mm2

+B1

1 +50°C (RL450441)

B+

1 425A 16 mm2

XA3A:

16 mm2

+B2

4,0 mm2

D1

X6: 1

4,0 mm2 A2

E1

F1

A1

A1

M3 M2

E2 4,0 mm2

16 mm2

-T

SH

SH

BLK

XA3A:

16 mm2

-P

4,0 mm2

RED

M4

A2

D2

X7: 1

RED

F2

REV

X6: 2

M5 BLK

X7: 2

M2

25 mm2

XA3A:

25 mm2

-B TRACTION AND PUMP CONTROLLER

A1

1M1

A3

4M10

3M1

1/17

AJOMOOTTORI DRIVE MOTOR

BSTEERING MOTOR CONTROLLER

4,0 mm2

DATE:

M1

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

M1

1,0 mm2

NAME:

CHANGE:

1F1 2

1/21

1/19

PUMPPUMOOTTORI PUMP MOTOR DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

LAITETUULETTIMET AUXILIARY FANS

OHJAUSMOOTTORI STEERING MOTOR

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K PÄÄVIRTAPIIRIT POWER CIRCUITS

3 / 26

REV

3-6877

2

12

13

14

15

16

17

18

19

20

0L1

0L3

X11: 1

X12: 5

1/14

1

20

X101: 1

X102: 5

4L3

0L4

3/27

X111: 1

21

22

23

TURVAPOLJIN SAFETY PEDAL

PÄÄKONTAKTORIT MAIN CONTACTORS

24

25

26

27

28

29

30

RATTIKYTKIN STEERING WHEEL SW.

101L2

1/22

3/28

J1063

13/15

11/24

X106: 6 X144: 1

X122: 4

X111: 4

S122

22

S113

NO

4

S112 HÄTÄSEIS EMERG.STOP

21

COM

14

44

13

43

3

X122: 5

X144: 2

S111 VIRTALUKKO KEY SWITCH

X111: 2 X101: 2

X101: 3

2

3

X11: 2

X106: 7

X11: 3 32

21

31

6

X106: 3

V125 A K A K V124 +

12

13

NMC

-

PMC

3/12

A1 1K1 A2

B

8

+

8

+

8

6/18 7/13 14/14 6/19 K101 7/24 K102 x/xx K103

-

1

-

1

-

1

K101: ENABLE TRACTION K102: ENABLE LIFT/LOWER K103: WARNING LIGHTS

25

+ 8 K105 - 1

+BATT

+ KEY IN

1/16

5

NOTE: ->IN AISLES: S113 always required.

->OUTSIDE AISLES: S113 required for lift/lower & init.lift/lower but NOT for traction.

X105: 1

22

A1 0K1 A2

K105

AISLE DETECTION

S1 HÄTÄSEIS EMERG.STOP

7

28

X111: 3

F101

c ROCLA OYJ 2003

CHANGE: CHANGED TWO HAND PROTECTION NAME: HT DATE: 2004-03-08 REV 1 This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

11

LUKITUSRELEET INTERLOCK RELAYS 2

1

X105: 15

X105: 2 101M7 7/22

0M1 1/14

TRACTION AND PUMP CONTROLLER

101M3

A1 DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

14/12

NAME: ES ES HT

101M2 1/24

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

101M5

101M6

7/28

TS961108

7/28

NOM10K AJOPIIRIT 1 DRIVE CIRCUITS 1

4 / 26

REV

3-6877

2

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

30

TURVAPOLJIN SAFETY PEDAL

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

SERIAL TILLER INTERFACE

J101 13/25

X101: 13 5

3

2

4

C

X122: 3

1 13

RXD

A102

NO COM

X11: 13

X122: 1

X17: 13 X101: 9

X101: 10

X101: 11

X101: 12

X101: 14

X16: 9

CHANGE:

X101: 8

5

5

10/16 6

10/29 6

K13

9

10

11

K19

X11: 12

4

3K2

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

2

3

C

5

6

3

7

1

A

2

2

F

1

4

3

2

D

9

8

7

TILLER

NCLTXD

PCLTXD

NCLRXD

PCLRXD

-BATT

+12VDC

KEY OUT

BACK

BACK

CONNECTION FOR CONSOLE KEY OUT

KEY (+BATT)

-BATT

DRFT

TILLER SWITCH

BELLY SWITCH

12/27

+ -

KEY OUT

X11: 11

F105

DATE: REV

X11: 10

S121

X11: 14

X17: 12 X11: 9

X122: 2

14

X16: 3

X11: 8

NC

12

NAME:

8

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

29

MAGNETIC BRAKE INTERLOCK

c ROCLA OYJ 2003

11

4

C

8

TRACTION AND PUMP CONTROLLER

A1 DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K AJOPIIRIT 2 DRIVE CIRCUITS 2

5 / 26

REV

3-6877

2

14

17

18

19

WHT/ BRN

BLK

ORA

GRN

WHT

WHT/ BLK

20

21

22

23

24

26

27

28

29

30

X121: 6

X121: 5

X121: 1

FW

B+

BW

ACCELERATOR

X121: 7

X121: 4

X121: 3 X231: 6

X131: 8

CHANGE:

X131: 6

X231: 8

23

12

J2

DISPLAY AND CONTROL UNIT

DATE:

NAME:

21

X131: 7

X131: 9

X105: 3

X105: 5

REV

K101 3

A

8

3

X231: 7

7

B

X231: 9

5 4/21

6

ENABLE RELAY

3

FW/BW

X105: 6

BW/FW

X105: 4 +BATT

POT LOW

0-5 V

ENABLE RELAY

6

J10

K101

4/21

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

10

A101

4

-BATT

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

25

B101

POT LOW

7/18

16

0-5 V

13

J102

15

B-

12

B-

c ROCLA OYJ 2003

11

2

SERIAL TILLER INTERFACE

A102 DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K AJOPIIRIT 3 DRIVE CIRCUITS 3

6 / 26

REV

3-6877

2

16

17

18

19

20

22

NO

COM

COM 2

3

S2

4

7

5

6

30

3 3

2

4

K104

J102

28

6/12

MAINTENANCE

7

X105:10

6

5

K104 3

X103: 3

K102

2

X105:12

X13: 3

R102

28

MAINTENANCE

14

S3

14 13

LASKU LOWER

X13: 4

X13: 5

31

32

6

4/22

ENABLE RELAY

K

X103: 4

X103: 5

X106: 1

X106: 2

A

V122 K

X105:14

NAME:

30

4

1

X105: 8

DATE:

6

X105: 9

0-5VDC

X105: 13

X105: 11

-BATT

3

K102

REV

A

V123 101M7 4/28

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

6

1

5

7

A

9

12

B

13

+BATT

LIFT

LOWER

0-5VDC

+5VDC

LIFT

B

LOWER

V120 +BATT

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

2

29

28

NOSTO LIFT

5

X120: 4

+5VDC

X120: 1

I.LOWER

I.LIFT

+24VDC CHANGE:

X120: 11

27

13

5 4/22

26

5kOhm

X105: 7

ENABLE RELAY

25

HUOLTOMIEHEN NOSTO/LASKU MAINTENANCE LIFT/LOWER

R101 X120: 10

24

+24VDC

NO S116

1

X120: 9

23

NOSTO/LASKU LIFT/LOWER

LISÄNOSTO/LASKU INIT.LIFT/LOWER

S115

21

LOWER

15

LIFT

14

+24VDC

13

LIFT

12

LOWER

c ROCLA OYJ 2003

11

A K

V121

A K

+ 8 K104 - 1

14

20 21

101M6 4/28

SERIAL TILLER INTERFACE

101M5

A102

4/23

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K NOSTOPIIRIT 1 LIFT CIRCUITS 1

7 / 26

REV

3-6877

2

c ROCLA OYJ 2003

11

12

13

14

15

16

17

18

19

20

10

21

11

22

21

22

23

24

9

20

25

26

27

28

29

30

A1

B

NMF

17

PEV

NEV

6

NAME:

CHANGE:

PEB

16

NEB

5

PMF

TRACTION AND PUMP CONTROLLER

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV

DATE:

X10: 1 F103

A1

Y1

(210561)

U

X10: 3

M1

A2

A1

A1

A1

2Y1

2Y2

2Y3

A2

A2

A2

RED

M3 BLK

X10: 2

MAGN.JARRU MAGN.BRAKE

X10: 4

PROPOVENTTIILI PROPOVALVE

P.NOSTO/LASKU INIT.LIFT/LOWER

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

NOSTO/LASKU LIFT/LOWER

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TUULETIN MOTOR FAN

TS961108

NOM10K NOSTOPIIRIT 2 LIFT CIRCUITS 2

8 / 26

REV

3-6877

2

12

13

14

NOSTON RAJOITUS LIFT LIMIT

K20 CHANGE: K31/5 - K12/6 CONNECTION

LIFT LIMIT

20

21

22

23

10/23

SLACK CHAIN

GATES

4

26

27

28

29

30

AJOHIDASTUS 2 CUTBACK SPEED 2

4

K17

OPTION

10/26

3

SLACK CHAIN

2

K12 10/15

3

3000mm

11/17

3

K11

10/12

3

1200mm

4

2

K32 10 deg

4

K33 3

11/19

10 deg

5

K12 3

10/15

3000mm

4 11/26

AISLE

2

6

5

K31 3

4

K11 10/12

3

1200mm

5

K31 6

11/26

AISLE

6

4

K16

NAME: IR

25

3

4

SLACK CHAIN

24

AJOHIDASTUS 1 CUTBACK SPEED 1

K15

DATE: 2008-11-10

K18 10/27

3

SLACK CHAIN

3

4

K14

16

6

E

LIFT LIMIT

3

13 LOWER LIMIT

7

17

I.LIFT LIMIT from RO1.02->

9

19 SELECT MODE 2

10

20 SELECT MODE 1

11

1 CUTBACK SPEED 2

(4,0 km/h)

X15: 10 CUTBACK SWITCH

GATES

X15: 9

COM

X15: 6

COM (+24VDC)

S2

-BATT

X15: 5

-BATT

COM

X15: 4

S1

X15: 3

TOP MAST 2

X15: 2 LIFTING BLOCK

X15: 1

3

COM

10/17

UPPER LIMIT

COM

REV 2

19

4

10/24

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

18

K19

10/29

3

4 15/12

17

4

K13 1200mm

16

LASKUN RAJOITUS LOWER LIMIT

4 10/16

15

LOW LEVEL LIMIT

c ROCLA OYJ 2003

11

14

4 CUTBACK SPEED 1 (2,5 km/h)

TRACTION AND PUMP CONTROLLER

A1

1200mm LIFT STOPPED IF GATES OPEN

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ DESIGN. 2003-04-02 FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K VALVONTAPIIRIT 1 CONTROL CIRCUITS 1

9 / 26

REV

3-6877

2

c ROCLA OYJ 2003

11

12

13

14

15

16

17

18

19

20

21 S117: 0864265 0989649 0989654 0989651

KORKEUSANTURIT HEIGHT SENSORS

4L8

4L2

4L9

14/29

15/12

4L5

1/21

22

15/14

X15: 11

XCK-P118 (3C9944)

X44: 3

12

XCK-P118 (3C9944)

12

X44: 2

X14: 2

11

XCK-P118 (3C9944)

S13

S12

1200mm

SLACK CHAIN

12

S11 11

X44: 5

3000mm

11

X44: 4

NOSTON YLÄRAJA UPPER LIMIT

K18 6

27

SLACK CHAIN

X102: 9

X14: 6

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

14/12

X17: 1

9/23 9/28

+ 8 K12 - 1

+ 8 K13 - 1

9/13 5/25

+ 8 K14 - 1

9/13 x/xx

NO

S125

3

X46: 1

X120: 12

S15

COM

X46: 3

X108: 2

12

22

11

21

S126

S16

12

22

11

21

22

X12: 9

X12: 7

X15: 12

X15: 7

102M6 14/19

9/13 x/xx

X109: 1 NO

X102: 7

A K

+ 8 K11 - 1

X108: 1

X17: 3

S117

V20

9/23 9/28

PORTTIKYTKIMET GATE SWITCHES

101L4

4 YEL

30

1/24

19

SLACK CHAIN RESET

6

24

X44: 6

X14: 4

b

X123: 2

K17

7

29

28

101L3

5L1

H117

X44: 1

27

KETJUN TUNNISTUS (MASTO) CHAIN SENSORS (MAST)

101L5

a 7

26

26

15/17

X123: 1

CHANGE: ADDED SLACK CHAIN SIGNAL LAMP NAME: HT

KETJUJEN KUITTAUS SLACK CHAIN RESET

REV 1

DATE: 2004-03-08

X14: 5

25

101L6

26

X14: 3

24

14/13

5L1

X14: 1

23

+ 8 K15 - 1

V21

X46: 2

X46: 4

X16: 2

X16: 4

A K

+ 8 K16 - 1

V22 K V23 K 9/13 x/xx

COM

X109: 2 X102: 8 23

X12: 8 A

X15: 8

A 9/16 19

+ 8 K17 - 1

+ 8 K18 9/16 20 - 1

+ 8 K19 - 1

9/14 5/26

X15: 14 4M5

4M2 5508402

15/12

1/21

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K VALVONTAPIIRIT 2 CONTROL CIRCUITS 2

10 / 26

REV

3-6877

2

c ROCLA OYJ 2003

11

12

13

14

15

16

17

18

19

20

21

22

23

24

OHJAUKSEN RAJAKYTKIMET STEERING LIMIT SWITCHES

25

26

27

29

28

30

KÄYTÄVÄN TUNNISTIMET AISLE SENSORS

4L4

J1063

1/22

4/28

4L11 15/12

4L12 15/27

S31

S32

COM NO

S33

COM NO

COM

X21: 1

NO BRN

X12: 10

X12: 11

25

X15: 13

X15: 15

X102: 6

27

CHANGE:

9/26

8

21

+ 8 9/27 K33 - 1

K32 - 1

MOTOR

X102: 10

X102: 11

X102: 12 4M8

X131: 11

29

X21: 2

X12: 6

(C) B

X131: 12

X17: 14

X231: 12

SENSOR A 0...180 deg 180...360 deg

X16: 10

XA101J2:11

XA101J2:22

X231: 11

SENSOR B 0...10 deg

S3-R-C50 (RL211645)

BLU

X22: 1

BRN

BLK

X231: 10

PNP

X21: 3

WHT

S22

XA101J2:10

REV This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

LEFT

RED

A

DATE:

X131: 10

4M9

26

WHT

S21 BLK

26 +

NAME:

X12: 12

X22: 2

+ 8 K31 - 1

RIGHT

RED PNP

S3-R-C50 (RL211645)

BLU

X22: 3

9/24 9/29

SENSOR C 0...10 deg

4M8

TRAVEL DIRECTION INDICATORS

17

DISPLAY AND CONTROL UNIT

4M7

A101

14/14

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

4M11 15/24

NOM10K OHJAUSPIIRIT 1 STEERING CIRCUITS 1

4M9 19

11 / 26

REV

3-6877

2

12

13

14

16

17

18

20

21

22

23

24

25

26

27

28

29

30

DATE:

X12: 4

STEERING ERROR

A101J2:01

A101J10:09

X30: 3 NOTE 2 X31: 3 X220:5 WGA SAFETY RELAY

X131: 15

X220:9

X101: 15

X31: 4

15

X30: 4

X11: 15

REV

A11

B+

19

X12: 3

A101J10:20

BLK TACHO 0V

X102: 4

NAME:

18

1/21

X231: 15

STEERING LIMIT CCW

X102: 3

A101

X133: 2

TACHO REF.

X133: 1

4L1

DISPLAY AND CONTROL UNIT -

RED

+

NOTE 1

X17:10

X16: 7

OPTION: 2

K22 X17: 11

XA3B:8

6

XA3B:7

27

XA3B:1

3K2 XA3B:5

XA3B:11

XA3B:4

7

XA3B:6

A1 3/21

+

X16: 8

3

15/24

+ 8

3K1

3K2

A2

18 5/25

- 1

-

F102

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

19

OHJAUSPYÖRÄN TAKOMETRI STEERING WHEEL TACHO

B103

CHANGE:

15

STEERING LIMIT CW

c ROCLA OYJ 2003

11

12345678 OPEN CLOSED

STEERING MOTOR CONTROLLER

A3

4M1 1/21

NOTE 1:CONNECTED ONLY IN WGA VERSION NOTE 2:NOT CONNECTED IN WGA VERSION DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

OHJAUKSEN VIKAVALVONTARELEET STEERING FAILSAFE RELAYS

NOM10K OHJAUSPIIRIT 2 STEERING CIRCUITS 2

12 / 26

REV

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2

c ROCLA OYJ 2003

11

12

13

14

15

16

AKKUVARTIJA BATT.DISCH.IND.

0L2

18

19

20

21

22

23

24

25

26

27

28

29

30

SYÖTTÖJÄNNITE POWER SUPPLY

0M2

1/14

17

101L1

1/14

101M1

1/24

J101

1/24

5/30

101L2

X131: 13

X231: 1

X231: 2

X231: 3

X231: 4

X231: 5

X231: 13

BATTERY SENSE+

SUPPLY +24V

SUPPLY GND

SLOW SPEED

SLACK CHAIN

XA101J2: 3

XA101J2: 17 BATTERY SENSE-

OPTIONAL HEIGHT

XA101J2:18

X131: 5

XA101J2: 14

X131: 4

XA101J2: 2

X131: 3

XA101J10:18

X131: 2

XA101J10:15

X131: 1

XA101J10:14

X101: 7

XA101J10:12

X101: 6

BRAKE ON

XA101J2:24

7

XA101J10:13

6

XA101J2:13

X11: 7

MAGNETIC BRAKE INTERLOCK

X11: 6

XA101J2: 6

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV 1

DATE: 2004-03-08

NAME: HT

CHANGE: REMOVED RELAYS CONTACTS K17 AND K18

4/21

DASHBOARD ORIENT.

DISPLAY AND CONTROL UNIT

A101 DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K MERKINANTO/VALOPIIRIT 1 SIGNAL/LIGHT CIRCUITS 1

13 / 26

REV

3-6877

2

13

ÄÄNIMERKKI SIGNAL HORN

101L4 10/29

101L5 10/23

14

15

VAROITUSVALOT WARNING LIGHTS

102L8

16

17

18

VAROITUSVALOT WARNING LIGHTS

1/28

4L7

NO

X110: 3

X210: 1 X25: 1

S321

CHANGE:

H11

33

VAS. LEFT

X13: 6

X46: 6

3

5

2

E113

X46: 7 X1

E311 VAS. LEFT -

X46: 8

X1

V5 C5

H111

+ -

A1 A2

X17: 4

11

X1

+12V

OIK. RIGHT

RIGHT SPEAKER

RADIOVASTAANOTIN RADIO RECEIVER

X2

-

+

GND

LEFT + SPEAKER -

X46: 9 2/ 4

H201

X1 24V

1

X46: 10

X2

H202

X17: 6 X210: 2

X110: 6

X210: 4

Go-

Gi211072

X110: 2 102M6

X110: 4 102M5

102M3

102M4

10/21

11/26

15/17

14

X17: 5

4M7

4/20

K25

X210: 6

2 K25 10

4M6

9

A211

1N4005 100uF 63V

101M3

W211 ANTENNI ANTENNA

X25: 3

E312 X2

4L8

X210: 5

+

24V H12 24V X2 2x10W OIK. X2 2x10W RIGHT

30

16

Vo+

X17: 2 X16: 1

+

X110: 5

6

E114

X46: 5 X1

DATE:

NAME:

+

X120: 8

-

B211

X210: 3

X25: 2

29

28

10/12

COM

REV This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

RIGHT

14

S114

X103: 6

27

4L7

19

V1+

3

X106: 5

26

1

K103 4/23

25

OPTION. PERUUTUSSUMMERI/VALO REVERSE WARNING BUZZER/LIGHT

4

X120: 7

24

102L8

X110: 1

K25

23

102L5

1/28

23

3

22

OPTION. TYÖVALOT WORKING LIGHTS

102L5

29

14

21

102L3

102L4

15/16

X106: 4

20

OHJAAMOVALOT CABIN LIGHTS

4L6

23

19

12V/5A

12

24V

c ROCLA OYJ 2003

11

4M3

4M4

1/22

29

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

1/28

NAME: ES ES HT

G301 B212

+ -

23

1/28

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

102M5

LEFT

21

TS961108

4M4 17

NOM10K MERKINANTO/VALOPIIRIT 2 SIGNAL/LIGHT CIRCUITS 2

14 / 26

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2

c ROCLA OYJ 2003

11

12

13

14

4L5

4L9

10/17

15

16

101L7 24

4L11 11/26

S118

4

CHANGE: NAME: DATE:

22

23

a

24

17

H118

S118

NOSTON VÄLIRAJA

K21 17

27

28

29

30

2

a

H118

4L12 11/26

YEL 1

b

X120: 14

X120: 15

X103: 7

X103: 9

X103: 8

X103: 9

36

35

36

X13: 9

X13: 8

X13: 9

X17: 9

X17: 8

X17: 9

X16: 6

X16: 5

X16: 6

5

K21 3

26

OPTION: AUTOMAATTIJARRUTUS KÄYTÄVÄN PÄÄSSÄ AUTOMATIC BRAKING AT THE END OF AISLES

X120: 15

17

X13: 7

6

X14: 10

X17: 7

14

S14

7

+ 8 12/29 K22 - 1

K20

NOSTON VÄLIRAJA

12

13

6

X44: 9

X50: 2

X14: 9 + 8 9/13 K20 - 1

25

101L7

b

34 4

XCK-P118 (3C9944)

X14: 8

21

X120: 13

X44: 10

REV This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

XCK-P118 (3C9944)

S14

X44: 8

RESET

3

X44: 7

11

20

YEL

X14: 7

12

19

(0864265) (0989649) (0989654) (0989651)

10/23

14/16

18

OPTION: NOSTONRAJOITUS/ KUITTAUS

101L6

4L6

10/20

17

14 15

X50: 1

4 1

+ 8 K21 - 1

(RL210330) (RL470799)3

S50: TUNNISTIN DETECTOR

X50: 3 4M5 10/29

4M11

4M6

11/27

14/14

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K OPTION: LISÄLAITTEET OPTION: AUX. DEVICES

15 / 26

REV

3-6877

2

S1:21

S1:22 3K1:A2

25

3K1:A1

24

26

27

29

28

SM1:2 L100

L150

L150

X30 210025 12 0899420 0899421 12 210366

15 L100

SM1:1

L250

2

20

L550

L200

L50

L100

463201-2 L200

L50

L250

S33:COM L350

L50

L250

L250

L150 L250

M3:A2

2

X10 RL211074 211074

A1: C

22

A1: B RL450938 450938

2

A1: A RL450934 450934

L100 L50

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K PM10 ROCLA JOHTOSARJA W9: 463201 WIRE WIRE HARNESS HARNESSW9: W9:RL463201 463201

3K2: 8

3K2: 1

3K2: 4

3K2: 3

3K2: 7

1K1:A2

XA3B: RL168565 168565

1K1:A1

XA3A: RL168565 168565

0K1:A2

13

0K1:A1

S32:NO

S32:COM

5

3K2: 6

S33:NO

S31:NO

L100

M3:A1

L100

9

L100 8

L200

A1: E

RL450935 450935

L300

X13 6R5761 108288

L250

12

A1: F RL450934 450934

RL450664 450664

L200 X12 0899421 210366

30

A1:B-

0K1:2

0K1:1

3K1:2 L250

L250

L400

6F2: 8 H

6F1: 7 G

5F2: 6 F

5F1: 5 E

4F2: 4 D

4F1: 3 C

0F2: 2

0F1:

L200

B

15

1

15

L250 X11

23

A

L550

L700

RL210028 210028

L800

S31:COM

CHANGE: PÄIVITYS PIIRIKAAVIOLLE NAME: ES DATE: 2004-03-23 REV 2 This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

2

X17

RL210026 210026

RL199085 199085

L150

L250

0989506 210028

22

L100

X15 X6 RL211074 211074

21

S1:12

3

20

S1:11

3

19

S2:14

3

18

S2:13

17

S3:14

16

S3:13

2

RL211074 211074

15

2Y3 RL509985 509985

14

2Y2 RL509985 509985

X7

13

2Y1 RL509985 509985

12

L1300

c ROCLA OYJ 2003

11

17 / 26

REV

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2

c ROCLA OYJ 2003

CHANGE: X16: MUUTOS / X16: CHANGE

12

13

X14 12 RL210025

X16 12 RL210025

DATE: 2003-08-12

X17 15 RL210026

X25 6 RL210352

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

14

15

16

17

18

19

20

21

22

23

L100

24

25

26

27

28

29

30

465174-1

L100

12

X44 RL210366

15

X46 RL210028

L100

L4300

1

REV 1

NAME: ES

11

L100

L100

L100

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K JOHTOSARJA W11: 465174 WIRE HARNESS W11: RL465174

18 / 26

REV

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c ROCLA OYJ 2003

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

X44 X46 RL210025 RL210026 12 15

465175 L500

L300

H12:x1

L150

S15:12

H12:x2

S16:12 S16:11 S16:22

S15:21

S16:21

L300

S15:22 L750

L250

S14:12 S14:11 S14:14 L250

DATE: REV

L350

H11:x2

S15:11

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

L300

L150

NAME:

CHANGE:

H11:x1

S14:13

S11:12 S11:11 S12:12 S12:11 S13:12 S13:11

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K JOHTOSARJA W12: 465175 WIRE HARNESS W12: RL465175

19 / 26

REV

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c ROCLA OYJ 2003

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

X108 2 RL211074

G301:Gi-

L700

29

L2100

L100

L100 L300

L200

G301:Vo+

9 X110 RL108288

L300

6

4

X111 RL211075

2

X133 RL210020

2

X144 RL211074

X122 RL210352

L300

L100

L1000

463203-2 L300 15

L100 15

X120 RL210028 210028

9

X121 6R5761 108288

2

X123 RL211074 211074

L2100 L100 12

10

L100

L100

14

6 L100

X109 2 RL211074

X105 X106 Rl210026 210026 RL210025 210025

A102:A RL450936 450936

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

A102:B RL450937 450937

NAME: ES ES HT

A102:C RL450661 450661

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

30

H111:A1

G301:Go-

X131 15 RL210028

28

L700

G301:Vi+

27

L100

H111:A2

L700

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV 2

DATE: 2004-03-22

NAME: ES

CHANGE: X123:LISÄYS / X123:EXTRA

X101 X102 X103 RL210028 210028 RL210366 210366 6R5761 15 12 9

26

2 TS961108

NOM10K JOHTOSARJA W101: 463203 WIRE HARNESS W101: RL463203

20 / 26

REV

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2

c ROCLA OYJ 2003

CHANGE: MITOITUS / DESIGN NAME: ES

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1

463204-1 X131 15 RL210026

15

L2800

X231 RL210028

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV 1

DATE: 2004-02-24

11

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K JOHTOSARJA W102: 463204 WIRE HARNESS W102: RL463204

21 / 26

REV

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2

c ROCLA OYJ 2003

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

OSALUETTELO TASOLLA:13

NAME:

CHANGE:

11

L100

DATE:

RL467659

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV

L50 X111

L150

4

S112:22

RL197678

S112:21

RL197678

S111:14

RL197678

S111:13

RL197678

S111:44

RL197678

S111:43

RL197678

L50

RL210045 RL210029

L50

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K JOHTOSARJA W103: 467659 WIRE HARNESS W103: RL467659

22 / 26

REV

3-6877

2

c ROCLA OYJ 2003

12

NAME: ES DATE: 2004-03-12 REV 1 This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

29

28

30

OSALUETTELO TASOLLA:13

CHANGE: LISÄYS/MUUTOS / EXTRA/CHANGE

11

L100

R101 RL199215 RL199216

7

S114:NO

RL197237

S114:COM RL197237 S115:NO

RL467660-1

S115:COM RL197237 S116:NO

X120

RL197237

S116:COM RL197237

15

RL210026 RL210029 X123

RL197237

L150

L50

2

RL210020 RL210029

1

S117: 4

RL197237

S117: 3

RL197237

H117: a

RL197237

H117: b

RL197237

S118: 4

RL197237

S118: 3

RL197237

S118: 1

RL197237

S118: 2

RL197237

H118: a

RL197237

H118: b

RL197237

1 DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K JOHTOSARJA W104: 467660 WIRE HARNESS W104: RL467660

23 / 26

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c ROCLA OYJ 2003

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

OSALUETTELO TASOLLA:13

L3000

X110 9 RL210044 RL210029

9

X210 6R5761 RL210030

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV

DATE:

NAME:

CHANGE:

467664

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K JOHTOSARJA W110: 467664 WIRE HARNESS W110: RL467664

24 / 26

REV

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15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

E312:x2

L1200

E311:x1

E312:x1

14

E311:x2

13

A211:GND

12

A211:+12V

c ROCLA OYJ 2003

11

L500

RL210044 RL210029

E114:B+

L650

L200

E114:B-

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: ES ES HT

S321:6

S321:5

S321:3

S321:2

E113:B-

E113:B+

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

L200 L650

L250

9

REV

DATE:

NAME:

X210

L200

CHANGE:

RL467682

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

NOM10K JOHTOSARJA W111: 467682 WIRE HARNESS W111: RL467682

25 / 26

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c ROCLA OYJ 2003

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

X231 15 RL210026

REV This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

A101:J10 RL450103

24

A101:J2

29

30

L700

L150

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2003-04-02 DESIGN. FINLAND CHECK. 2004-03-23 Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

28

22

RL471242

DATE:

NAME:

CHANGE:

L150

27

NAME: ES ES HT

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS961108

RL450102

NOM10K JOHTOSARJA W112: 471242 WIRE HARNESS W112: RL471242

26 / 26

REV

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2