Caterpillar NPP13M Lift Trucks Service Manual – PDF DOWNLOAD

EN

Operation & Maintenance Manual NPP13M NPP16M NPP20M NPP20MR

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

SWHPU - 00011

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

SWHPU - 00011

492495

EN 07/2009

1. Truck .................................................................................... 3 2. Safety instructions ............................................................... 4 3. Operating environment ........................................................ 7 4. Operating devices ................................................................ 9 5. Driving instructions ............................................................ 11 6. Load handling .................................................................... 14 7. Batteries ............................................................................ 17 8. Maintenance ...................................................................... 20 9. Service ............................................................................... 22 10. Transportation and storage ................................................ 26 11. Troubleshooting and alarms .............................................. 27 12. Technical specifications ..................................................... 29

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

The truck conforms to the EN 1726-1 standard, ensuring its safety according to the EU machine directive 2006/42/EC. 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 country.

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

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

Electromagnetic compatibility The truck conforms to the EN 12895 standard, ensuring its safety according to the EMC directive 2004/108/EC. 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 expressed permission. Modifications to electric devices may affect the electromagnetic compatibility and, therefore, reduce operational safety.

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

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2. Safety instructions Instructions for site supervision • • •

Familiarise yourself with the operating instructions and their contents Train the operator on the use, safety and maintenance aspects of the truck Control that the operating and maintenance instructions, and safety regulations are observed

Occupational safety • • • • • • •

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

If you notice any faults or deficiencies that may effect the safe operation of the truck, take the truck out of operation until the faults or deficiencies have been remedied In the event of a malfunction, switch off the power and notify the site supervision.

Do not repair anything on the truck without the permission from the site supervision 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 The truck can only be used for purposes corresponding with its equipment. Intended use, see Chapter 4.

Truck operator Requirements: • • • • •

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

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

In case of fire, press the emergency stop button, disconnect the recharging plug and warn others.

Noise The average noise level (LpA) to which the driver may be subjected has been measured at the driver’s ear as per standards EN 12053:2001 and EN ISO 4871. The measured values are listed in Chapter 12, Technical Specifications, section 8.4 in this manual.

NOTE Higher sound pressure levels may occur during the truck’s operation, caused by different method of operation, environmental effects and other sources of noise.

Vibration The level of vibration to which the driver is subjected (aw,z ) has been measured as per standard EN 13059:2002.

The measured values are listed in Chapter 12, Technical Specifications, section 8.4 in this manual.

Work at dangerous premises A standard truck may not be used in an explosive atmosphere. There are specially manufactured trucks for such premises. Contact your truck dealer for a specially designed and equipped trucks for hazardous conditions.

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Repairs and structural modifications Do not modify the truck without the manufacturer's express 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.

NOTE Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided, however, that the user shall: • • • •

arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety; maintain a permanent record of the design, test(s) and implementation of the modification or alteration; approve and make appropriate changes to the capacity plate(s), decals, tags and instruction handbook; affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name and address of the organization that accomplished the tasks.

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

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Legend for warning symbols attached to the truck and used in this manual Note! A truck may cause serious accidents unless you are sufficiently familiar with its operation and unless you know its operating and maintenance instructions.

For more information, see the truck manual.

Familiarise yourself with the truck manual and its contents before operating or servicing the truck.

Do not touch moving parts.

Do not use the truck to lift persons.

Do not walk or stand underneath the truck's raised forks.

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3. Operating environment General Information Use the truck in dry, indoor facilities with substantially firm, smooth, level and prepared surfaces according to standard DIN 15185-1. The truck may be continuously operated at a temperature of +5...+25°C and for short periods at a temperature of 0...+45°C. The recommended humidity is 30...95% (non-condensing). If the operating temperatures differ from those mentioned above, contact your truck dealer and acquire a truck specifically designed for cold and freezing or extremely high temperatures. A special machine for freezing conditions can be used in temperatures down to -35°C. A special machine for hot conditions can be continuously used in temperatures up to + 45 °C. This truck conforms to the requirements of the EU machine safety directive (2006/42/EC) and thus has the CE marking.

Never use the truck: • • • • • • • • •

To transport or lift people At premises with risk of fire (ATEX premises) In explosive atmospheres At premises with insufficient floor load capacity If it is damaged As a mounting surface As an access board or a ladder To tow another truck Under the influence of intoxicating substances.

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

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

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

Using elevators You need 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 enter the elevator while driving the truck in or out. The parking brake of the truck must be engaged and power switched off before the elevator starts moving.

Driving on ramps You need a permission from the site supervision to drive on a slope or ramp. The inclination of the ramp should not exceed the measured values listed in Chapter 12, Technical Specifications, section 5.7 in this manual. We recommend using warning signs in places where this is exceeded.

NOTE All truck types are not suitable for driving on ramps. Make sure that the truck you are using is suitable for this purpose.

WARNING!

Driving trucks with a gradeability of 0% is forbidden on the ramp. RISK OF OVERTURNING!

Observe extreme caution when driving on a ramp. When the truck is loaded, travel with the load pointing uphill.

To ensure steerability and braking, the grip of the ramp must be equivalent to a standard floor.

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

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Driving 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 Control panel

Connector of the inbuilt charger (1) The battery can be charged using an inbuilt charger, see section "Recharging the battery" in chapter 7, "Batteries".

After charging, the charger connector must be connected to its own socket outlet, otherwise the truck cannot be used.

Main switch (key + emergency stop) (2) The main switch connects the truck's electrical equipment to the battery circuit.

• • • •

Power is on when the switch is pulled up.

Power is off when the switch is pushed down (power can still be connected to certain electronic devices).

The switch also functions as an emergency stop (the switch pushed down). In case of an emergency, the truck can be completely disconnected from the power source by unplugging the battery connector.

The key can be removed by first pushing it down and then turning it counterclockwise.

NOTE

Before carrying out electrical welding on the truck, disconnect the battery.

"Power on" indicator light (3) The green light indicates that the power is on. It also indicates possible faults in the truck. If the light blinks in a series of four flashes, the battery charge status is low, and you cannot raise the fork. If it blinks in any other way, contact the maintenance department.

Truck display (4) The device displays level of battery charge, indication of operational hours and system alarm codes. It always functions when some of the electric devices are on.

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Tiller arm

Safety button (1) The safety button prevents you from getting squeezed between the truck and an obstacle.

When you push the safety button, the truck reverses its travelling direction and stops when the button is released, if the speed control is also released at the same time.

NOTE Never use the safety button for normal driving. The safety button is disabled when driving on the platform.

Check the operation of the safety button daily before you start working with the forklift truck.

Push buttons for lifting and lowering (2) Horn (3) Steering (4) The tiller arm turns ± 100 degrees.

Accelerator (5) The accelerator is used for controlling the driving speed and for braking. Handle the accelerator gently!

Brake release / slow speed button (6)

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5. Driving instructions Daily checks before operation Carry out the daily maintenance check before using the truck. Neglecting daily maintenance may decrease the safety and reliability of the truck. Notify the site supervisor 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. (Does not apply to maintenance-free batteries.)

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

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

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

Also check the operation of the other electrical functions.

Check that the batteries are charged and locked in place.

Check the operation of the horn.

Check that the emergency stop operates properly.

Check that the safety button works.

Make sure that the tiller arm returns to the up position and the parking brake functions properly.

Check the fastenings of the lifting chain (does not apply to pallet trucks).

Before you start •

Make sure that the daily maintenance has been carried out.

Driving • • • •

Tilt the tiller arm to the driving position (tiller arm in position 1, see the picture in "Stopping the truck").

Turn the accelerator lightly in the driving direction.

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

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

NOTE

Due to safety reasons, the truck may be adjusted to travel slower to the direction of the forks.

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

• • • • • • •

Drive slowly at intersections and when turning.

Handle the truck responsibly and always keep it under control.

Avoid sudden starts and stops.

Steer and brake smoothly.

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

Take great care when driving on a slanted surface.

Do not drive over any loose objects on the floor.

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

This does not apply to trucks designed to be driven with the load raised.

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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 driving a pedestrian truck in the direction of the forks, stand behind the truck and keep both your hands on the tiller arm. When driving in the opposite direction, walk beside the truck and keep one hand on the tiller arm.

Platform for driving

A pallet truck equipped with a platform can be driven either standing on the platform or walking behind the truck.

The maximum driving speed is the same for both methods.

When you wish to drive a pallet truck standing on the platform, lower the platform to the horizontal position (1) and step on the platform. When you step off the platform, it automatically rises up.

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

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

Stopping the truck Brake the truck smoothly by turning the accelerator against the direction of travel (tiller arm in position 1).

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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, steer and brake carefully.

If the truck has side stabilizers, use them when loading and unloading. 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.

When driving the truck on slopes and ramps, • observe extreme caution.

• Keep the forks and load down.

• Drive straight with the load pointing uphill.

• Drive at a low speed and anticipate other traffic.

•

Do not overload.

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

WARNING! Do not exceed the truck's maximum loading capacity under any circumstances, because there is always a risk of overturning.

Pallet handling (pallet trucks) To load: • • •

Drive towards the pallet with the forks lowered.

Move forward until the forks are completely under the pallet.

Raise the pallet so that it is clearly above the floor level.

To unload: • • •

Stop the truck.

Lower the forks so that they disengage.

Reverse from the unloading location.

Two-pallet handling (double stackers) To load: • • • • • •

Drive towards the first pallet with the forks and fork arms lowered.

Move forward until the forks are completely under the pallet.

Raise the pallet so that it is clearly above the second pallet.

Drive towards the second pallet with the fork arms lowered.

Move forward until the fork arms are completely under the pallet.

Raise the pallet so that it is clearly above the floor level.

To unload: • •

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Stop the truck.

Lower the fork arms so that they disengage.

• • •

Reverse from the unloading location.

Lower the forks so that they disengage.

Reverse from the unloading location.

NOTE

Double stackers can be used for moving one or two pallets. Maximum capacity for moving only one pallet is 1600 kg. Maximum capacity for moving two pallets is 1000 kg on forks and 1000 kg on fork arms.

WARNING!

Do not overload under any circumstances!

WARNING!

Observe extreme caution when handling two pallets.

WARNING!

Do not drive fast speed or long distances with a pallet on the raised forks.

Stacking and unloading (stackers) To stack: • • • • • •

Drive towards the shelf or stacking level with the load lowered.

Lower the side stabilizers (if available).

Raise the load so that it is clearly above the stacking height or shelf level. Note the height of the upper horizontal beam of the shelf.

Move forward until the forks and load are on top of the shelf.

Lower the forks so that they disengage, and then reverse from the stacking location. Make sure that the forks are clear of both the stacking level and the pallet. Lower them to the driving position.

Raise the side stabilizers (if available).

To unload: • • • • • • •

Drive towards the shelf or stacking level with the forks lowered.

Lower the side stabilizers (if available).

Raise the forks high enough so that they can freely go underneath the pallet when you drive forward.

Move forward until the pallet is completely on top of the forks.

Raise the load so that it is clearly above the stacking height or shelf level. Note the height of the upper horizontal beam of the shelf.

Reverse from the stacking location so that the load can be freely lowered. Lower the forks.

Raise the side stabilizers (if available).

NOTE

The maximum lifting height has been limited to 1800 mm when driving the truck on the platform with the side guards unfolded. To lift above the limit, fold the side guards to the rest position.

Stacking and unloading (reach trucks) To stack: • • • • •

Drive towards the shelf or stacking level with the load lowered and the forks tilted upwards.

Straighten the forks to a level position.

Raise the load so that it is clearly above the stacking height or shelf level. Note the height of the upper horizontal beam of the shelf.

Move the mast forward until the forks and load are on top of the shelf.

Lower the forks so that they disengage, and then pull in the mast and reverse from the stacking location.

Make sure that the forks are clear of both the stacking level and the pallet. Tilt the forks upwards and lower them to the driving position.

To unload: • • • •

Drive towards the shelf or stacking level with the forks lowered and the forks tilted upwards.

Straighten the forks to a level position.

Raise the forks high enough so that they can freely go underneath the pallet when you drive forward.

Move the mast forward until the pallet is completely on top of the forks.

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• •

Raise the load so that it is clearly above the stacking height or shelf level. Note the height of the upper horizontal beam of the shelf.

Pull in the mast and reverse from the stacking location so that the load can be freely lowered. After lowering the forks, tilt them upwards.

NOTE

Tilt and reach functions are available in reach trucks only.

Collecting (order picker trucks) • •

Use the lifting and lowering lever to set a suitable collecting height.

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

WARNING!

Observe extreme caution when collecting items.

Handling of broken pallets

WARNING!

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

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

• • • • •

• • •

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

Do not smoke when working with batteries.

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

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

Battery fluid is a corrosive acid solution; avoid getting it on your skin or in your eyes. The battery fluid develops 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.

1600 and 2000 kg capacity trucks 2 V/cell.

1300 kg capacity trucks 10.5 V/battery (1.75 V/cell).

Recharging the battery Make sure that the charger is the appropriate model and that the battery has sufficient ventilation.

1.

2.

3.

4.

5.

Park the truck in a reserved recharging place.

Switch off the power from the key switch.

Make sure that the charger has been switched off.

Disconnect the battery connector and connect it to the charger.

Switch on the charger.

After recharging 1.

2.

3.

Switch off the charger.

Disconnect the battery connector from the charger. Grab the plugs; do not pull the cables.

Check the battery according to the battery manufacturer's maintenance instructions.

Measuring the battery's specific gravity

Measure the specific gravity 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. The gravity is • • • •

1.24 when the battery is 3/4 charged.

1.20 when the battery is 1/2 charged.

1.16 when the battery is 1/4 charged.

1.15 when the battery is 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 securely. Do not keep the tools or other metal implements on top of uncovered batteries.

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

When you use a lifting device for lifting the battery, place a 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 the standard EN 1175-1: • •

5.1 Traction batteries (includes the requirements for the protective cover of the battery case, ventilation and interior surface treatment) 7.4 Minimum markings (includes the requirements specified on the truck battery plate).

The battery plate should provide at least the following information: • • • • • •

Manufacturer Type Serial number Nominal voltage Capacity (Ah / 5h) Service weight.

Battery charging with an inbuilt charger You can access the plug (3) for the power supply of the integrated charger from the outside of the truck. To activate the charger, extract the plug for the power supply from the safety socket (4) on the machine and insert it into the correct outlet (230 V ±10% / 50 Hz).

During charging the main switch (1) must be pushed down so that the power is switched off. After activating the charger, charging starts automatically.

The charging phase is indicated with a three-colour indicator light (2): • • • • •

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Red (empty battery) Flashing red (charging has begun) Yellow (80% charged) Green (fully charged, the charger plug (3) can be unplugged and connected to the safety socket of the truck (4) Flashing red, yellow, and green indicates a fault in the system and charging is stopped automatically.

The charger will stop automatically after the charging is complete and you can unplug the charger plug and connect it to the safety socket of the truck.

NOTE If the plug is not connected to the safety socket, all electrical functions will remain switched off and the truck cannot be used.

WARNING!

No inflammable materials are allowed within two meters of the truck under charge or the charger.

Fastening batteries

1300 kg capacity trucks 1.

2.

3.

Connect the batteries (2 pcs.) according to the picture.

Fasten the battery (3) with belts (1) as shown in the picture.

Make sure that the belts are tight, and secure them with their own locking mechanism (2).

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8. Maintenance Only adequately trained truck operators and servicemen are allowed to carry out the daily and weekly check-up.

The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones.

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. If a metal object gets into contact with an electrically conductive part, a short-circuit or burn may result.

Switch off the truck's power before opening the cover of the motor or the electrical system.

Release the hydraulic pressure before opening the system.

Dismount the seat for the duration of service work (applies only to sit-on trucks).

Do not use your hands to check for oil leaks.

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

Only use clean oil in the hydraulic system.

When welding, always disconnect the battery and the electronic devices. Remove paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding.

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

WARNING!

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

Daily checks • • • • • • • • • • • • •

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. (Does not apply to maintenance-free batteries.)

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

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

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

Check also 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 emergency stop operates properly.

Check that the safety button works.

Check that the operating brake and the parking brake functions properly.

Check the fastenings of the lifting chain (does not apply to pallet trucks).

Weekly maintenance • • • • • • • •

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Check and clean the battery cable fastenings.

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

Clean the batteries with a dry rag.

Check that the hydraulic system has no leaks.

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

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

Check that the fastening bolts of the driving wheel are tight.

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

• • •

Clean the truck if necessary.

Check the length of the lifting chains. When the carriages are level with the mast, the chains should be slightly loose. Adjust if necessary. (Does not apply to pallet trucks.)

Apply a thin layer of lubrication on the mast's guide surfaces.

NOTE

Do not let water onto the electrical devices.

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

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

Semi-annual inspection service (or 600 h) Check and, if necessary, adjust or repair: • • • • • • • •

Connections of the drive motor and pump motor.

Operation of the accelerator.

Operation of the microswitches or inductive sensors.

Operation of the contactors and solenoids.

Cables.

Tiller arm gas spring.

Function of the lift cylinder.

Play of the fork carriage, and the slope of the forks and their condition.

2000 kg capacity truck • •

Air gap in the brake: 0.2 mm when new, maximum gap 0.55 mm.

Brake pad thickness: 8.5 mm when new, minimum thickness 5.5 mm.

1300 and 1600 kg capacity trucks • •

Air gap in the brake cannot be modified.

Brake pad thickness: 7.6 mm when new, minimum thickness 7.4 mm.

Opening the covers

Open the mounting screws (1) to remove the covers on both sides of the truck.

Monthly lubrication The following lubricating points of the truck should be lubricated once a month: •

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Turning bearings of the drive unit (2000 kg capacity trucks).

Lubricant recommendation

Filling hole for hydraulic oil (1) • • •

Hydraulic oil: ISO 11158 HM/HV/HR - VG 32.

In freezer warehouses: ISO 11158 HM/HV/HR - VG 15.

Fill the tank to the volume of ¾.

Transmission lubricant recommendation for 2000 kg capacity trucks • • •

Transmission oil: EP 80/90.

In freezer warehouses: NLGI No. 1 or No. 0.

Fill to the volume of 0.6 l. The oil level must reach the lower edge of the checking hole.

NOTE

Use grease as the transmission lubricant in 1300 and 1600 kg capacity trucks. You do not need to change it at all during the truck's useful lifetime.

Filling hole for transmission oil (1) Opening to check the oil level (2) Oil outlet (3)

Additional maintenance work for service personnel •

Change the hydraulic oil once a year (or 1200 h).

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• • • • • • •

Change the transmission oil once a year (or 1200 h), 2000 kg capacity truck.

Clean the oil filter.

Check the operation of the hydraulics and the pressure relief valves.

Check the fastening of the gearbox and the amount of transmission oil ( 2000 kg capacity truck); add if necessary.

Check the fastening of the tiller arm.

Check the condition of the side castor wheels and load wheels.

Check the wear of the drive wheel: • Drive wheel diameter is 230 mm when new • Drive wheel has to be replaced when its diameter is 218 mm.

Location of fuses in el-panel

1F1

10A

Line contactor fuse

2F1

10A

Control circuit fuse

3F1

10A

Aux. device circuit fuse

4F1

200A

Drive motor fuse

5F1

100A

Pump motor fuse

NOTE

The tightening momentum of the fuse (1) terminals is 4.5 ±1 Nm.

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

To ensure that you receive the correct parts, include the following information in the order: 1.

2.

3.

4.

5.

Truck type Serial number of the truck Order number of the part Name of the part Number of parts ordered.

The truck's type and serial number are listed on the front page of the manual or on the identification plate of the truck. The order number and name of the parts are listed on the spare part pages of the manual supplied with the truck.

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Hazardous waste and disposal Hydraulic and transmission oil, as well as batteries are hazardous waste that must be disposed of accordingly.

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

25

489467

10. Transportation and storage Transportation Lifting the truck.

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

NOTE If the truck has more than one lifting position, all of the positions must be used during lifting the truck.

Towing the truck.

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

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

Charge the battery well, and recharge it every 2 or 3 months to prevent damage during storage. At the same time, check the fluid level and add more if necessary.

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

If the machine is not used for more than a week, support the truck in such a way that the load exerted on the drive wheel becomes lighter.

Returning the truck to operation. If the truck has been stored for several months, it must undergo maintenance as per 600 operational hours. Otherwise normal daily maintenance and inspection are sufficient.

26

You should anticipate a situation when you must brake and decrease the speed well ahead. When you release the tiller arm to the up position or press it to the down position, the driving circuit breaks and the brake is engaged (tiller arm in position 2).

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

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

Traffic rules Maintain good visibility in the driving direction and keep sufficient safety distances. Follow the traffic regulations and speed limits.

Do not drive the truck outside a private area without an order or permission from the site supervisor. Outside a private area, the truck is subject to general traffic rules and regulations.

If a door opening is so narrow that two trucks cannot possibly pass through it at the same time, drive in the middle of the opening. When two trucks meet in a narrow or cross aisle, the loaded truck has the right of way.

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

13

CONNECTORS AND ERROR CODES NPP13M,NPP16M,NPP20M,NPP20MR dACi-TA 120GB/150GB/180GC

Rev. Pvm.

CAT

Connector X3

Connector X4

Connector X5

Connector X6

1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10/A 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10/A 11/B 12/C

x

x x

x

x x x

x x x x x x x

x

Pin description

Status shown in BPK

x x

Key Input +24V +24V Option input 1 Option output 1 0V (B-) Option input 2 +24V +24V Horn Lower Lift Safety Socket Lift limit 0V (B-) 0V (B-) Lift enabled +24V Temp sensor Encoder A Encoder B Brake control Temp sensor +24V +24V Tiller NO LED 0V (B-) Tiller NC +24V FWD BWD Belly Brake release 0-5V 0V (B-) Lift Lower Horn +10V speed reduction / platform present

Error description

Connector X2

13 2.7.2008

85_10449 Pin number

software version:

Connector X1

1/1

Error code (nr.of pulses)

ROCLA OYJ RD Technical Specifications

2

New Software version Runtime monitoring

3

Overcurrent Runtime monitoring

4

Low Voltage Battery Runtime monitoring

5

Over Voltage Battery Runtime monitoring

6

Over Temperature Motor Runtime monitoring

7

Over Temperature Inverter Runtime monitoring

8

Drive Switch Monitoring Input active in start-up

9

Sensor Bearing Monitoring Runtime monitoring

10

Belly Switch Input active in start-up

11

Tiller Switch Input active in start-up

12

Set Value Monitoring In start-up

13

error in platform switch (at power-on)

14

EEPROM Fault Runtime monitoring

15

Internal Parameter fault Runtime monitoring

16

Internal Parameter fault Runtime monitoring

Connectors and Errorcodes

17

Tiller Switch Runtime monitoring

18

Option speed reduction Input active in start-up

19

Brake release Input active in start-up

20

Safety Socket Input active in start-up

22

multiple error (at power-on) (tiller, safety socket, platform, forward…)

dACi-TA B2/C3 Traction system for induction motor

User Manual

Type: dACi-TA 24/120 GB and dACi-TA 24/180 GC Valid for software: 59_101(49)

1/1

Contents 1

TYPE DESCRIPTION .......................................................................................................................... 4

2

INSTALLATION ................................................................................................................................... 5

3

CONNECTIONS ................................................................................................................................... 7 3.1

Power Stage .............................................................................................................................................. 7

3.2

Control stage............................................................................................................................................. 7

4

USER INSTRUCTIONS ..................................................................................................................... 11

5

SETUP................................................................................................................................................ 12 5.1

Setup using the hand held terminal, type BPK.................................................................................... 12

6

PARAMETERS................................................................................................................................... 18

7

FAULT AND STATE REPORTS........................................................................................................ 22

8

TECHNICAL DATA............................................................................................................................ 26

2/2

NOTE WARNING: For the installation and use of the inverter this manual and other instructions for additional components must be followed.

WARNING: To avoid any hazard situation always disconnect the battery before working on the inverter or other additional components.

WARNING: Work on the traction motors must only be carried out when the power connection between battery and inverter is disconnected.

WARNING: It is assumed that only trained people who hold the necessary know-how carry out the installation and settings of parameters.

WARNING: All existing safety regulations both electric and mechanical must be followed.

3/3

1

Type description

The dACi-TA inverter is used to control a traction system for battery-powered vehicles, forklift trucks and other working machines using three-phase induction motors.

The electronic consists of a three-phase inverter and a control device.

The dACi-TA traction inverter provides a proportional drive control (speed control mode) where the vehicle speed is proportional to the position of the command handle. This offers a smooth driving performance and prevents the vehicle from uncommanded acceleration during downhill operation. The speed control mode is the common control concept for traction drive systems.

The characteristic of the command handle as well as the parameter for the acceleration and deceleration ramps can be adjusted individually.

4/4

2

Installation

The inverter has to be mounted on a flat base plate to provide for a sufficient cooling. The surface size of the base plate should be minimum four times the footprint of the inverter and at least 10mm thick. The preferred mounting position of the inverter is with the cooling fins vertically orientated for optimal airflow.

60

10

140 ø 6,5

X7 X4

X6

198

210

X3

X1 X5

+

U

V

W

-

128 Figure 1a: Outline B2

5/5

M8

70,0

ø 9,0

W X1 X2 -

X3

200,0

X4

182,0

V X5 + X6

X7

U

9,5 9,0

138,0

155,0 Figure 1b: Outline C3

6/6

3

Connections

3.1

Power Stage

Important:

The minus-connection always has to be connected first.

When disconnecting the system the minus has to be the last one to be disconnected.

Terminal + and The power supply (battery voltage) is connected to these terminals. The power cables have to be protected by a fuse (see ‘Technical data’ for fuse size). The diameter of the power cables has to be determined according to the dimension of the fuse.

Note: A polarity inversion will damage the inverter.

Terminal U,V,W The motor is connected to these terminals.

Basically the motor has to be connected to the inverter as Umotor to Uinverter and so on also for V and W.

3.2

Control stage

The dimension of the control wires is specified to 0,5mm2 (i.e. all plug-able connections). Bigger diameters can be used alternatively to improve the mechanical stiffness. The MOLEX connector is specified for wire dimensions between 0,24 and 0,82mm2.

The following schematic gives an example for the numbering of a 6- and 10-pin connector:

10

9

8

7

6

6

5

4

5

4

3

2

1

3

2

1

Figure 3: Numbering of connector viewed in direction to the inverter

7/7

3.2.1 X1, Key-switch X1.1

Key-switch Battery voltage has to be supplied to this input in order to power on the inverter. The inverter does not work without the key-switch being connected to the supply voltage – in that moment the current consumption on the main terminals is less than 10mA. A 5A fuse that can be reached from outside the housing protects this input. This input provides the supply voltage for other external components connected to the controller.

X1.2

Not in use. Do not connect!

X1.4

Not in use. Do not connect!

X1.3

Not in use. Do not connect!

3.2.2 X2, optional inputs and output (only C3) X2.1,2 Protected key switch voltage On these pins the fuse protected key-switch voltage is available for supply to other components in the system. Not in use. Do not connect!

X2.3

Optional digital input. Not in use. Do not connect!

X2.4

Optional digital output. Not in use. Do not connect!

X2.5

Battery minus, internally connected

X2.6

Optional digital input. Not in use. Do not connect!

3.2.3 X3, valve, contactor, switches and horn X3.1,2 Protected key switch voltage On these pins the fuse protected key-switch voltage is available for supply to other components in the system.

X3.3

Positive supply voltage for the horn, coming from X6.10

X3.4

Positive supply voltage for the lowering valve coming from X6.9

X3.5

Positive supply voltage for the contactor that switches on the pump-motor, coming from X6.8

X3.6

Input safety socket The drive can only be activated if this input is high (+24V), i.e safety socket should be mounted on the holder.

X3.7

Input lift limit If the max. hight is exceeded this input has to go low to switch off the contactor.

X3.8

B- for the horn, internally connected

X3.9

B- for the lowering valve, internally connected

X3.10

Digital output for the contactor that switches on the pump-motor Open-drain output; switching to 0V, freewheeling diode to X3.5

8/8

3.2.4 X4, Connections for the motor (thermistor and encoder) X4.1

Supply voltage for the brake Fuse-protected key switch voltage.

X4.2,

Temperature sensor (motor), Not in use. Do not connect!

X4.3

Encoder signal A (open collector or push-pull)

X4.4

Encoder signal B (open collector or push-pull)

X4.5

Digital output for the brake Open-drain output; switching to 0V, freewheeling diode to X4.1

X4.6

Temperature sensor (motor), Not in use. Do not connect!

X4.7

+15V Power supply for encoder

X4.8

0V connection for encoder The speed of the traction motor is when setup as “Speed Control” always be monitored and controlled. An incremental encoder suitable for 15V supply must be connected at the terminals mentioned above. The encoder must deliver two 90° phase shifted signals (A and B).

Phase sequence of encoder signals: Phase sequence of encoder signals and phase sequence of motor currents have to fit together.

When the shaft of the motor turns right (right sequence U,V,W), the inverter expects signal A before signal B. Signal A before signal B is calculated as positive speed.

3.2.5 X5, tiller and status LED X5.1,2 Protected key switch voltage On these pins the fuse protected key-switch voltage is available for supply to other components in the system.

X5.3

Digital input, tiller switch n.o In the upright position of the tiller this input has to be low, under working condition it has to be high.

X5.4

Digital output 1 Open-drain output; switching to 0V, freewheeling diode to X5.1 (key-switch input), see ‘Technical data’ for max current. The configuration of the digital output can be set by parameter #70.

X5.5

Battery minus, internally connected

X5.6

Digital input, tiller switch n.c.

If a tiller switch with complementary signals is used, then the second channel has to be connected here.

Parameter 223 has to be 1 to activate the supervision of the two inputs.

If only X5.3 is used, then parameter 223 has to be 0.

9/9

3.2.6 X6, analogue and digital inputs X6.1

Protected key switch voltage On this pin the fuse protected key-switch voltage is available for supply of switches and electrinic components in the tiller head.

X6.2

Digital input: Forward

X6.3

Digital input: Backward

X6.4

Digital input: Belly switch In normal operating condition this input has to be high.

X6.5

Digital input: Brake release If the tiller switch has stopped the vehicle (upright position), this input can be activated for driving with reduced speed.

X6.7

Battery minus for the tiller head, internally connected

X6.8

Input: Lift brings voltage to X3.5

X6.9

Input: Lower brings voltage to X3.4

X6.10

Input: Horn brings voltage to X3.3

X6.6

Speed reference input Control voltage (0..10V)

X6.11

Output 10V to supply a potentiometer, max 100mA, internally protected

X6.12

Digital input: Speed reduction Not in use. Do not connect!

3.2.7 X7, RS485 interface X7.1

+15V A 15V supply is available for an external interface converter or external display.

X7.2

0V The RS485 do not necessary need a 0V connection. To avoid floating potential it is recommended to use it anyway.

It is necessary for the handheld console or for the external display.

X7.3

RS485, A signal

X7.4

RS485, B signal

10 / 10

4

User Instructions

General information: The performance of the traction system is to a high degree adjustable to the actual application. By parameters it is possible to influence almost all actions of the system, inputs, outputs and limitations etc. can be defined.

The parameter list shows the setting as set by the factory.

If a parameter needs to be changed afterwards (by the OEM or user) the change has to be made by using the serial interface (RS485).

Potentiometer The Drive system needs an analog speed reference signal.

In the tiller head a potentiometer or an electronic sensor produces a signal between 0V and max. 10V. Encoder signal The encoder pulse number is set by parameter 168. At a right turning motor flux from U,V,W the encoder signal A must be come before the signal B with a phase shift of 90°.

A

B

Figure 4: incremental encoder signals Acceleration and deceleration ramps: Basically the slope of the speed demand signal determines the acceleration of a traction system. A ramp function is controlling the slope of the speed demand, and is always activated a speed reference signal and a release of the traction system. The setting of the speed ramp slope is done by parameter 133.

Deceleration (brake) can be performed different ways.

• By removing or lowering the speed reference signal or by removing the drive direction signal the inverter will always use the deceleration ramp set by parameter 134.

• A steeper deceleration ramp can be set for use by reversing the drive direction, parameter 139.

• If the vehicle drives into the tiller-direction and the belly-switch gets pushed, the speed will be reduced very fast (parameter 142) and then the vehicle will drive into the opposite direction for a max. time (parameter 122) with an adjustable speed (parameter 121) Speed: The speed input is at pin X6.6 (Plus) and X6.7 (Minus).

Temperature: The inverter will monitor the temperature of the heat sink in the region close to the power transistors.

Actions by faults: The inverter is constantly monitoring fault situations. If a fault occurs the attached motor is instantaneously disconnected from power.

The type of fault can easily be observed either from the integrated LED or through the PC service software (BPS).

The flash sequence LED will indicate the fault code that can be seen from the fault table in paragraph 6, parameters.

11 / 11

5

Setup

5.1

Setup using the hand held terminal, type BPK

The hand held terminal is used for: • Setting of parameters • Check of parameters • Monitor the actual drive condition • Fault display • Monitoring of inputs and outputs • Display time counter • Save and load total parameter sets Figure 5

Connection The BPK unit is connected to plug X7 on the inverter. The connection of the terminal can take place at any time, also when the inverter is in operation.

First display First the terminal will show its own software version, and then look for any attached inverter.

If an inverter is found it will show the serial number and the software version of the attached inverter.

Example:

SN.: Version:

594200006 10149

Keys ↑ ↓ By activating the keys it is possible to scroll up and down through the parameter list. Only the released parameters can be displayed and changed.

Information parameters are only for display.

First activation of the key ↓: Shortly the message „Searching next parameter“ will show up. In this period the unit will search for the next released parameter on the list.

When the first parameter is found the first display will show the parameter text and in the second line the parameter number.

Displayed shortly:

serial number 7

Shortly hereafter the displayed parameter number will be replaced with the parameter value: Display of Serial Number:

serial number

12 / 12

594200006 List of succeeding displayable parameters: text software version serial number operating hours actual speed speed set value temp. inverter operating state value speed pot. temp. inverter battery voltage connector X1 connector X2 connector X3 connector X4 connector X5 connector X6

parameter number 0 7 9 10 11 17 25 30 32 33 46 47 48 49 50 51

Description of the parameters: Serial number: Explicit number identifying each individual unit Operating hours: Actual counted time in which the motor has been operated.

Actual speed: The actual measured speed of the controlled motor.

Speed set value: The actual speed demand of the controlled motor.

Operating state: 0= Fault, 1= Ready, 2= Power stage active (current in motor) Speed potentiom.: Displays the analog voltage on input pin X6.6 in the range of 0..1023.

This input is the speed reference coming from the tiller head.

Battery voltage: Displayed in % of the nominal voltage (e.g. 24V, 48V or 80V)

State display for connectors X1 - X6: Example 1: Connector X1

connector X1 2

This display shows that the pin 2 on connector X1 is active, meaning that the internal transistor connects pin 2 to battery minus.

Pin 1: Key Switch (Battery voltage) Pin 2: Digital output 2 Pin 3: Analogue output minus Pin 4: Analogue output

Example 2: Connector X3

connector X3 67 A

This display shows that the inputs pin 6, pin 7 and pin 10 (A=10) are activated.

Pin 1: Pin 2: Pin 3: Pin 4: Pin 5: Pin 6:

Protected key switch voltag Protected key switch voltag Supply voltage for the horn Supply voltage for the lowering valve Supply voltage for the contactor that switches on the pump-motor Input safety socket

13 / 13

Pin 7: Pin 8: Pin 9: Pin 10:

Input lift limit Battery minus for the horn Battery minus for the lowering valve Digital output for the contactor that switches on the pump-motor

Example 3: Connector X4

connector X4 345

This display shows that pin 3,4 and 5 are active at this time.

Pin 3 and 4 shows the actual state of two encoder inputs A and B. When the motor runs the inputs will shift according the pulse sequence of the encoder. The display cannot follow the switching frequency at higher motor speeds. When the motor is spinning slowly it is possible to observe the pulse sequence. Depending on direction of rotation the display could be: 3 4 ; 3 _ ; __ ; _ 4.

Active pin 5 means that the belonging internal transistor is active, connection pin 5 to battery minus. If an electro magnetic brake is connected to pin 1 and 5 a current will flow and the brake activated (released) Pin 1: Pin 2: Pin 3: Pin 4: Pin 5: Pin 6: Pin 7: Pin 8:

Battery plus for brake Connection for motor temperature sensor Signal A from encoder Signal B from encoder Switched negative pole for brake Connection for motor temperature sensor 15V supply for encoder 0V supply for encoder

Example 4: Connector X5

connector X5 34

This display shows that pins 3 and 4 are active. The meaning is: There is an input voltage at pin 3. The transistor at pin 4 is on.

Pin 1: Protected key switch voltage Pin 2: Protected key switch voltage Pin 3: Digital input, tiller switch n.o.

Pin 4: Digital output 1 Pin 5: Battery minus, internally connected Pin 6: Digital input, tiller switch n.c.

Example 5: Connector X6

connector X6 2 4 C

This display shows that pin 2, 4 and 12 are active (C means 12).

Pin 1: Pin 2: Pin 3: Pin 4: Pin 5: Pin 6: Pin 7: Pin 8: Pin 9: Pin 10: Pin 11: Pin 12:

Protected key switch voltage Digital input: Forward Digital input: Backward Digital input: Belly switch Digital input: Brake release Speed reference input Battery minus for the tiller head Input: Lift Input: Lower Input: Horn Output 10V Digital input: Speed reduction

14 / 14

The following parameters will have a direct influence on the performance and behavior of the vehicle: english text stop mode tiller warn.temp.invert rev.speed belly max.time belly acceleration deceleration smoothing curve progress. curve reverse braking dec. belly.tiller min.batt.voltage max.batt.voltage value low batt. vred.low.battery vmax forward vmax backward vred. X6-12 vred.brake rel. tiller type error message teach-in speed

parameter-number 98 107 121 122 133 134 137 138 139 142 173 174 175 176 211 216 221 222 223 249 251

15 / 15

Keys ← → In order to make a parameter ready for change one of these keys must be pressed.

The last (right) digit of the parameter value will flash and can now be changed by using the keys ↑ or ↓.

The key ← can select digits to the right; herby total number change is possible.

Example: The right end digit is underlined and flashing: Change to the max speed

vmax. forward 5.00Km/h

By pressing key ← again the digit 2 is flashing: Change to the max speed

vmax. forward 5.00 Km/h

By pressing key ↑ once the digit is changed from 5 to 6, setting the value to 1460 rpm.

Change to the max speed

vmax. forward 6.00 Km/h

After 1 sec of no key activations the new value is active and the new value can be used.

As long as a digit is flashing it is not activated and can be reset by the Esc-key.

By activating the key ↵ all changes are made active, and at this point the parameters is saved.

Teach-In procedure for the speed input (potentiometer): Teach-in speed 0 Using one of the keys ← or → the digit zero is underlined and begins to flash.

Teach-in speed 0 Now the digit is changed to 1 by using key ↑.

Teach-in speed 1 By pressing the ↵ key the Teach-in procedure is started.

Within 15 sec the accelerator switch must be slowly moved to the max. forward value. At this point the pedal is kept for about 1 sec, then to the negative value and hereafter brought back the neutral position. After 15 sec the digit will turn back to zero, indicating that the Teach-in procedure is done.

The inverter is during the Teach-in blocked and will not turn the motor.

Pressing keys ← and → at the same time This will bring the display to extended menues like: List of errors (Fault history) Write (BPK->dACi) (Load parameters from the hand held terminal (BPK) to the inverter) Read (dACi->BPK) (Retrieve parameters from the inverter to the hand held terminal (BPK)) Search device (Search for inverter addresses) 16 / 16

Select address Select language Back to main menu

(Select an inverter address) (Select language for the hand held terminal (BPK)) (Return to the parameter setting menu)

The menues can be selected by pressing the keys → or ↓ to go down, and the keys ← or ↑ to go up the list.

The function is activated by the key ↵.

List of errors (Fault history) Displays in timely order the faults that have occurred in the system. A total number of 8 different faults can be displayed. Repeating failures of the same kind will only be shown once.

Write (BPK->dACi) (Load parameters from the hand held terminal (BPK) to the inverter)) Read (dACi->BPK) (Load parameters from the inverter to the hand held terminal (BPK))) The “Read” function will store a copy the actual parameters within the connected inverter on the hand held terminal (BPK). For this purpose 8 memories are available on the BPK, and can be selected using the arrow keys.

Using the “Write” function it is possible to select from 8 stored parameters sets on the BPK to be loaded down to the connected inverter.

Search device (Search for inverter addresses) Basically the and held terminal (BPK) can communicate with more inverters on the some communication bus therefore the actual unit address must be known. If the address is not know it is possible to make a search to obtain the addresses of the units connected.

If only one unit is connected this function is not used.

Select address (Select an inverter address) If more units are connected to the BPK the address of the unit to address is selected here.

If only one unit is connected this function is not used.

Select language (Select language for the hand held terminal (BPK)) Two languages are available, English and German.

17 / 17

6

Parameters

(Valid only for pre-series trucks, sw-version 10149 for NPP13M and NPP16M and 11020 for NPP20M) Parameters NPP13/16M Software version

Parameters NPP20M -

Format/ Scale

Unit

Description

Remark

-

Factory Default 10149

x.xxyy

Indicates Software version number

h rpm rpm °C

11020 -

0,1,2

-

Hz AD-units 0…1023 AD-units 0…1023 %

-

Indicates Software version number Serialnumber of the controller Operating hours of the controller Actual motor speed in rpm’s Set speed value from the accelerator Temperature measured from the heat sink of the controller The operating state of the controller: 0 = Error 1 = Ready 2 = Limit Active Indicates the voltage coming from accelerator. 0...5V ~ 0...511 AD-Units Temperature measured from the heat sink of the controller Indicates battery voltage. 24V is nominal (=100%)

Valid sw for pre-series NPP13M and NPP16M Valid sw for pre-series NPP20M

Serial Number Operating hours Actual Speed Speed set value Temp. Inverter

Software version Serial Number Time meter Actual Speed Desired Speed -

x.xxyy PPGGLLLLL 0,001 0,25 0,25 1

Operating state

-

Value speed pot.

Actual slip Speed pot.

1,0 1

Temp. Inverter

-

1

Battery voltage

Battery voltage

18 / 18

-

Parameters NPP13/16M Connector X1

Parameters NPP20M Connector X1

Format/ Scale

Unit

Factory Default

Connector X2

Connector X3

-

Connector X4

Connector X4

Connector X5

-

Connector X6

Connector X6

Stop mode tiller

-

1,2,3

2

warn.temp.invert

-

550

Rev. speed belly

-

0,25

AD-units 0…1023 rpm

-1500

Max. time belly

-

1.0

s

5.0

19 / 19

Description

Remark

Indicates the status of the inputs and outputs of the current connector. See description in manual Indicates the status of the inputs and outputs of the current connector. See description in manual Indicates the status of the inputs and outputs of the current connector. See description in manual Indicates the status of the inputs and outputs of the current connector. See description in manual Indicates the status of the inputs and outputs of the current connector. See description in manual Indicates the status of the inputs and outputs of the current connector. See description in manual Set a stop mode when tiller is activated: 1 = motor current off and brake voltage off 2 = deceleration ramp at first then brake voltage off 3 = deceleration ramp and brake voltage off Warning level for the high temperature of the controller.

Set’s a speed for the truck (backward 1500rpm ~1,8km/h direction) when belly is activated Timer setting for belly function. Truck will drive backwards up to “max .time belly” with a speed of “Rev.Speed belly”. When time is elapsed, truck stops.

If set to 0, truck will drive as long as belly is activated.

Parameters NPP13/16M Acceleration

Parameters NPP20M Acceleration

Format/ Scale

Unit

Description

Remark

rpm/s

Factory Default 3000

0,4883

Acceleration ramp setting

0,4883

rpm/s

3000

Deceleration ramp setting

Recommended setting from 1500…4000rpm/s Recommended setting from 1500…4000rpm/s

Deceleration

Deceleration

Smoothing curve

-

0 = keine Verrundung 0 = keine Progression

0...9

5

Adjustment for the curve smoothing

Progress. Curve

Progression

0...100

75

Adjustment for the curve progression

Reverse braking

Dec. change dir.

0,4883

rpm/s

4000

Dec.belly..tiller

-

0,4883

rpm/s

4000

Min.batt.voltage Max.batt.voltage Value low.batt

-

1 1 1

% % %

50 120 70

Deceleration ramp when using reverse braking function Deceleration ramp when activating belly or tiller function % value of nominal batt voltage (24V) % value of nominal batt voltage (24V) % value of nominal batt voltage (24V).

Indicates the level of low battery.

Vred.low.battery

-

1

%

50

Vmax. Forward

Max speed forw.

0,25

rpm

4987

Vmax. Backward

Max speed backw.

0,25

Rpm

4987

Max. Speed backward direction. Value in motor rpm.

Vred. X6-12 Vred. Brake rel.

-

1 1

% %

50 50

Speed reduction when using option Speed reduction when using Brake releasefunction. % of Vmax. speed setting

-

Speed red. 1 Speed red. 2 Picking speed

Rpm Rpm Rpm

4166 4166 -750

20 / 20

Speed reduction when battery low level is reached % of Vmax. speed setting Max. Speed forward direction. Value in motor rpm

Low batt level is reached when battery voltage level is less than “Value low.batt” more than 3 seconds.

4987rpm = 6,0km/h 4572rpm = 5,5km/h 4156rpm = 5,0km/h 3740rpm = 4,5km/h 4987rpm = 6,0km/h 4572rpm = 5,5km/h 4156rpm = 5,0km/h 3740rpm = 4,5km/h % of Vmax. speed setting

Only for NPP20M. Do not change!

Only for NPP20M. Do not change!

Only for NPP20M. Do not change!

Parameters NPP13/16M Tiller type

Parameters NPP20M

Error message Teach-in speed

Error message Teach-in speed

Format/ Scale

Unit 0,1

Factory Default 1

0,1

-

xx

21 / 21

Description Changes the type of tiller switch.

0 = use only NO contacts 1 = use NO/NC contacts Take a look at fault code below 1 activates the teach in for speed accelerator.

Remark

7

Fault and state reports

No. -

Type of fault or state report Watchdog

-

RAM-fault

-

FLASH-fault

2

New Software version Over current from power stage

3

Flash code LED

Remarks

Possible cause

Possible action

Pulse duty cycle 1:1 (f = 1,25 Hz) Pulse duty cycle 1:3 (f = 2,1 Hz) Pulse duty cycle 3:1 (f = 2,1 Hz) 2 pulses...pause

drive disabled, digital outputs switched off

Internal fault. Can not be reset by user

Replace the inverter

Will only appear when loading a new software version 1.The inverter was loaded at the limit for a long time. This fault will not appear as long as the motor speed is measured correct.

Reload the software exactly following the instruction Ad 1: Monitor the signals on connector X4 at very low motor speed. Check the encoder sequence. The digits 3 and 4 must appear in a uniform pattern. If the sequence is not right; check the cable and the connections or if necessary change the encoder.

3 pulses...pause

drive disabled, digital outputs switched off

drive disabled, digital outputs switched off

drive disabled, digital outputs switched off (Reset through parameter150) drive disabled

2. A parameter has been changed that is influencing the current or the over current shout down level

Ad 2: Using PC: Return to a previous setting of parameters, e.g. by loading a saved parameter set.

4

Low voltage, Battery

4 pulses...pause

If the battery voltage drops below the threshold value set in parameter 175 for more then 3 sec the max motor speed will drop the value specified in parameter 176.

If battery voltage drops below the value set in parameter 173 for more then 3 sec, the inverter will shot down.

Only switching off and on the supply to the inverter can reset this fault.

22 / 22

The battery voltage was below the value specified in parameter 173 for more than 3 sec. The battery could be close to discharged or there might be to high voltage drops in the supply cables to the inverter.

Check the charge condition of the battery.

Check the cable connection for the supply to the inverter.

No. 5

Type of fault or state report Over voltage, Battery

Flash code LED

Remarks

Possible cause

Possible action

5 pulses...pause

(Depending on the setting of parameter 174)

1. The battery voltage measured by the inverter has exceed the value set in parameter 174 for more than 3 sec, or the value has been exceeding 150% of the nominal voltage. If the battery is intact and the connections to the inverter are good this fault should not occur. (Assuming that parameter 174 is set correctly)

Ad 1: Check the settings of parameter 174.

Check that the connections from battery to inverter are OK Ad 2: Replace the inverter.

2. The power stage could be damaged.

6

7

Over temperature, Motor

Over temperature, inverter

6 pulses...pause

7 pulses...pause

(Depending on the setting of parameters 110 and 111) If the temperature shot down threshold (110) is exceeded the inverter will stay shot down.

If the measured value is below the value of parameter 111 the inverter interprets a short circuit sensor.

1. The temperature sensor connected to X4 has detected a too high temperature in the motor. The motor could have been overloaded for a too long time.

(Depending on the setting of parameters 106 and 108) If the temperature shot down threshold (108) is exceeded the inverter will stay shot down.

1. The inverter has been overloaded for a too long time.

2. If the motor is not equipped with a temperature sensor pin 2 and 6 on X4 must be short circuit.

Ad 1: Check if the traction system is operating sluggish or is defect. Check eventually the motor current. The continuously motor current must not exceed the motor nominal current.

Ad 2: Check the connection on X4.

Ad.3: Remove short circuit or set parameter 3. Parameter 111 is adjusted >0 and there is 111 to 0. a short circuit at the sensor.

2. There is a fault in the temperature measurement of the inverter.

Ad 1: Check that the inverter is mounted according to the directions regarding in order to be able to emit the heat. Check eventually the output current. The continuously current must not exceed the nominal current of the unit.

Ad 2: Replace the inverter

23 / 23

No. 8

9 10 11

12 13 14 15

16

17

18 19

Type of fault or state report Drive switch monitoring

Flash code LED

Remarks

Possible cause

Possible action

8 pulses...pause

The power stage is not activated (reset through drive switch)

Check using the service tools BPS, that the drive signals are working (connector X6).

Read out parameter 51 and observe that the signal is present. When activating the drive signals, the digits 2 for forward and 3 for backward should be seen.

10 Pulses... pause The power stage is not activated

After power-on the inverter wants to see definite start conditions: Drive signals off, speed reduction on, brake release off, tiller switch (n.o.) off, belly switch on, safety input on, set value near zero.

Fault at the sensor bearing or broken connection between sensor and controller. see above (8)

11 Pulses... pause The power stage is not activated

see above (8)

Check the signal on X5.3

12 Pulses... pause The power stage is not activated

see above (8)

Check the signal on X6.6

14 pulses...pause 15 pulses...pause

Internal fault. Can not be reset by user Parameters set does not make sense for the V/f characteristic of a motor.

Replace the inverter Using BPS service tool to return to a previous setting of parameters, e.g. by loading a saved parameter set.

Sensor bearing monitoring Belly-switch monitoring Tiller switch monitoring after power on Set value monitoring not used EEPROM fault Unrealistic setting of the U/f relationship

9 pulses...pause

Unrealistic parameter settings for speed input transfer function Tiller switch monitoring while system is running Speed reduction monitoring Brake release

16 pulses...pause

(Depending on the setting of parameters 212...220)

Parameters set using the PC tool that does not make sense for the speed input transfer function

Using BPS service tool to return to a previous setting of parameters, e.g. by loading a saved parameter set.

17 pulses...pause

(Depending on the setting of parameter 223)

The n.o. and the n.c. contact of the tiller switch are not comlementary to each other.

Check the signals on X5.3 and X5.6

18 pulses...pause

The power stage is not activated

see above

Check the signal on X6.12

19 pulses...pause

The power stage is not activated

see above

Check the signal on X6.5

(Depending on the setting of parameters 189...194)

24 / 24

Check the signal on X4.3 and X4.4.

Check the signal on X6.4.

No. 20

Type of fault or state report Battery charge switch (safety socket) monitoring

Flash code LED

Remarks

20 Pulses... Pause The power stage is not activated

25 / 25

Possible cause

Possible action

see above

Check the signal on X3.6.

8

Technical Data

Power Data Type:

dACi-TA-

24/120 GB

Unit size Nominal battery voltage [V] Voltage range [V] Continuously Short term (<30s) Rated current [A] 1) Maximum current [A] 2) Output voltage [V] 3) Dimensions [mm] BxHxT Power connections 1) Depending on cooling conditions 2) Time depending on cooling conditions 3) At nominal battery voltage Interface Type: Digital Inputs B2: X6.2, .3, .4, .5, .12; C3: X6.2, .3, .4, .5, .12;

dACi-TAX5.3, .6; X5.3, .6;

X3.6, .7 X3.6, .7;

Logic Number Impedance [Ω] Signal Low [V] max Signal High [V] min Analog Input Resolution Impedance [Ω] Voltage range [V] Digital Outputs Output for pump contactor Rated current [A] Maximum current [A] Operating mode Output Brake Rated current [A] Maximum current [A] Operation mode Optional output Rated current [A] Maximum current [A] Programmable outputs 1 and 2 Rated current [A] Maximum current [A]

24/180GC

B2

C3 24 17...30 17...35

60 120

90 180 3x 0...16

140 x 210 x 60 Screw M5

155 x 200 x 70 Bolt M8

24/120 GB

24/180GC

X2.3, .6

High-active 9

11 2,2k 2 12

(X6.6)

10 bit 86k 0...10 (X3.10)

(X4.5)

(X2.4; C3 only)

(X1.2, X5.4)

Low-side switching with freewheeling diode and z-diode 2,0 3,0 1sec 100% then 60% duty cycle Low-side switching with freewheeling diode 2,0 3,0 1sec 100% then 60% duty cycle Low-side switching with freewheeling diode 2,0 3,0 Low-side switching with freewheeling diode 1,0 1,5

26 / 26

Analog Output Voltage range [V] Impedance [Ω]

(X1.4)

Encoder input 1 Voltage level [V] Supply Temperature sensor, Motor Type

(X4.3, .4, .7, .8)

Serial interface Type Supply for converter

Additional information Switch frequency, power stage Efficiency Output frequency range Temperature range Relative humidity Operation indications Connectors Enclosure

0...10 100

0 / 15 A,B (e.g. sensor bearing) 15V, max 100mA (X4.2-6)

PTC (X7)

RS485 15V, max 100mA

16kHz Standard; selectable 4, 8, 12, 16, 20 kHz 95% at rated load 0...300 Hz -40°C ... 50°C (At mounting plate) Max. 90%, not condensing Integrated LED Molex Mini-Fit, Jr. IP40

* Optional

27 / 27

CAT RD Technical Specifications

Adjustment instructions NPP13M,NPP16M,NPP20M,NPP20MR dACi-TA 120GB/150GB/180GC

1/2

CAT

Rev. Pvm.

software version:

15 20/02/2009

85_10449

Parameter Valid in BPK number

NPP13M 35Ah AGM

NPP13M 48Ah GEL

NPP16M

dACiTA120GB

dACiTA120GB

dACiTA120GB

NPP20M

NPP20MR

D=Diagnostics

NPP13/16M kordel

dACidACidACiTA180GC/TA150GB TA180GC/TA150GB TA180GC/TA150GB

Range/value

NOTE

Software version Password service Operating hours Serial Number Actual Speed Speed set value Temp. Controller Battery Level Throttle value Battery voltage Connector X1 Connector X2 Connector X3 Connector X4 Connector X5 Connector X6 Wheel diameter Gear ratio

0 2 4 7 10 11 17 18 30 33 46 47 48 49 50 51 60 61

x x x x x x x x x x x x x x x x x x

D D D D D D D D D D D D D D D D 230 36.04

D D D D D D D D D D D D D D D D 230 36.04

D D D D D D D D D D D D D D D D 230 36.04

D D D D D D D D D D D D D D D D 230 30.1

D D D D D D D D D D D D D D D D 230 30.1

D D D D D D D D D D D D D D D D 230 26.6

BDI Curve

67

x

9

5

3

3

3

3

0…10

BDI algorithm selection

BDI reset

68

x

25.08

25.08

25.08

25.08

25.08

25.08

V

BDI timer

69

x

150.00

150.00

240.00

240.00

240.00

150 / 240

BDI reset voltage Use only factory defaults!

10049 0

Not valid!

x.xxxh 5942xxxxx km/h km/h °C 1…10 0…10V x.xV 0 0 0 0 0 0 mm i=

0,00s…655,36s

Lift cut-off

81

x

1

1

1

1

1

1

0= disabled, 1= enabled

Function selection for dig. input X6-12

82

x

0

0

0

0

1

1

0= X6-12 = speed reduction, 1= X6-12 = platform present

Disable belly switch with platform (NPP20MR).

CAT RD Technical Specifications

Adjustment instructions NPP13M,NPP16M,NPP20M,NPP20MR dACi-TA 120GB/150GB/180GC

Parameter Valid in BPK number

NPP13M 35Ah AGM

NPP13M 48Ah GEL

NPP16M

dACiTA120GB

dACiTA120GB

dACiTA120GB

NPP20M

NPP20MR

2/2

D=Diagnostics

NPP13/16M kordel

dACidACidACiTA180GC/TA150GB TA180GC/TA150GB TA180GC/TA150GB

Range/value

NOTE

Stop mode tiller

98

x

2

2

2

2

2

2

1= motor current off and brake voltage off at the same time, 2= deceleration ramp at first then brake voltage off, 3= deceleration ramp and brake voltage off at the same time.

Warn.temp.Contr.

107

x

70

70

70

70

70

70

50°C…79°C

Acceleration Deceleration Smoothing Curve Progress. Curve Reverse Braking Dec.Belly&Tiller

133 134 137 138 139 142

x x x x x x

2.80 2.80 5 75 4.80 9.00

2.80 2.80 5 75 4.80 9.00

3.60 3.60 5 75 4.80 9.00

3.60 3.60 5 75 4.80 9.00

3.60 3.60 5 75 4.80 9.00

2,8 / 3,6 2,8 / 3,6 5 75 4.80 9.00

0,50kmh/s…6,00kmh/s

Level low batt.

175

x

2

2

1

1

1

1

1…5

Low Batt.Speed Min. voltage to reactivate the brake PWM Max.Speed FWD Max.Speed BWD Opt.Speedlimit1 Brake Rel.Speed

176 178 211 216 221 222

x

33 16.1 5.80 5.80 100 33

33 16.1 6.00 6.00 100 33

33 16.1 6.00 6.00 100 33

33 16.1 6.00 6.00 100 33

33 16.1 5,8 / 6 5,8 / 6 100 33

10%…100%

x x x x

33 16.1 5.80 5.80 100 33

Tiller Type

223

x

0

0

0

0

0

0

0=with NO contact (SICK) 1=with NO+NC contact (telemecanique)

Start Up Delay

224

0

1.5

1.5

1.5

1.5

1.5

1.5

1.5

0-10 s

Error message Program throttle

249 251

x x

D 0

D 0

D 0

D 0

D 0

D 0

0

Error number

Level of high temp.warning

0,50kmh/s…6,00kmh/s 0…9 0…100 0,50kmh/s…6,00kmh/s 0,50kmh/s…9,00kmh/s

Level for lift cut-off activation % of Max.Speed

0,50km/h…6,00km/h 0,50km/h…6,00km/h 10%…100% 10%…100%

1=program throttle

% of Max.Speed % of Max.Speed

ADJUSTMENT INSTRUCTIONS ZAPI SEM

CAT

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

1/1

Rev. Date

NPP / NSP / NSV NPV / NSD Zapi SEM-0 Zapi SEM-1 RO 1.76 RO 1.78

16 27.10.2004

SEM0 SEM0 MAIN MENU/ PARAMETER CHANGE: ACCELERATION DELAY 2 2 DECELERATION DELAY 5 5 RELEASE BRAKING 1 1 INVERSE BRAKING 8 8 SOFT BRAKING 0 0 QUICK INV. BRAKE 5 5 SOFT ACCELERATION 0 0 CUTBACK SPEED 1 0 0 CUTBACK SPEED 2 0 0 H&S CUTBACK 0 0 MAX. SPEED FORWARD 8 6 MAX. SPEED FW FINE 5 5 MAX. SPEED BACKWARD 8 6 MAX. SPEED BW FINE 5 5 COMPENSATION 0 0 MAXIMUM CURRENT 5 9 ARMA. NOM. CURRENT 0 0 WEAK DROPOUT 1 1 FIELD NOM. CURRENT 2 2 CREEP SPEED 0 0 BACKING TIME 0 0 BACKING SPEED 0 0 AUXILIARY TIME 0 0 CONFIG MENU/ SET OPTIONS: HOUR COUNTER RUN RUN QUICK INVERSION BEL BEL AUX OUTPUT #1 BRA BRA BATTERY CHECK ON ON SEAT SWITCH HAN HAN BACKING INPUT OFF OFF INVERSION MODE NOR NOR ADJUSTMENTS: ADJUST BATTERY Ubat Ubat SET BATTERY TYPE 24V 24V SET CONT. TYPE 24V 24V THROTTLE 0 ZONE 1 1 THROTTLE X POINT 3 3 THROTTLE Y POINT 1 1 MAIN MENU/ ALARMS/ SPECIAL MENU: HARDWARE SETTINGS: LOAD HM FROM MDI OFF OFF CHECK UP DONE OFF OFF CHECK UP TYPE 0 0 ADJUSTMENT #02 4 4 ADJUSTMENT #01 4 4 SET CURRENT 150A 150A SET FIELD CURRENT 14A 14A

NSD16K

NSV12K (C)

NSV12K/12Ki

NSP12K/12Ki

NO20T NO25T

NPV30K

NPV25K

NPV22K

NPV20K

NPP25K

NPP16K/20K

TRUCK TYPES:

NOTE

SEM1 SEM1 SEM1 SEM1 SEM1 SEM0 SEM0 SEM1 SEM1

2 5 1 6 0 5 0 5 9 0 8 6 8 6 0 5 0 1 4 0 0 0 0

3 3 1 5 8 5 0 2 9 4 5 5 5 5 0 5 0 1 9 0 0 0 0

2 5 1 6 0 5 0 4 8 0 3 0 3 0 0 5 0 1 2 0 0 0 0

3 6 4 6 0 5 0 5 9 0 4 2 4 2 0 5 0 1 4 0 0 0 0

2 5 1 6 0 5 0 0 1 0 9 9 9 9 0 5 0 1 1 0 0 0 0

2 5 1 8 0 5 0 0 0 0 8 5 8 5 0 5 0 1 2 0 0 0 0

2 5 1 8 0 5 0 9 0 0 9 9 9 9 0 5 0 1 1 0 0 0 0

2 5 1 6 0 5 0 5 5 0 8 0 8 0 0 5 0 1 9 0 0 0 0

2 5 1 6 0 5 0 5 9 0 8 6 8 6 0 5 0 1 3 0 0 0 0

RUN BEL BRA ON HAN OFF OP2

RUN BEL BRA ON HAN OFF NOR

RUN BEL BRA ON HAN OFF OP2

RUN BEL BRA ON HAN OFF OP2

RUN BEL BRA ON HAN OFF OP1

RUN BEL BRA ON HAN OFF NOR

RUN BEL BRA ON HAN OFF NOR

RUN BEL BRA ON HAN OFF OP2

RUN BEL BRA ON HAN OFF OP1

Ubat Ubat Ubat Ubat Ubat Ubat Ubat Ubat Ubat 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 1 1 1 1 1 1 1 1 1 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 150A 14A

OFF OFF 0 4 4 150A 14A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

optional optional NPV20K pedestrian mode NPV20K without side guards optional

do not change do not change do not change do not change do not change not used not used not used

do not change do not change do not change do not change do not change not used optional do not change volts volts

not used not used not used do not change do not change do not change do not change

INDEX Page LEGEND 3 COLOUR CODES (Single Colours) ...................................................................... 3 1 Introduction to the ZAPI-MOS family .......................................................... 4 2 General characteristics ................................................................................. 5 2.1 Technical Specification.......................................................................... 5 2.2 Control Units.......................................................................................... 5 2.2.a Microswitches ............................................................................... 5 2.2.b Potentiometer ............................................................................... 6 2.3 Safety & Protection Features ................................................................ 7 2.4 Direction Orientation ............................................................................. 7 2.5 Operational Features ............................................................................ 8 2.6 SEM-Zero chopper diagnosis ................................................................ 9 2.7 Thermal Considerations ........................................................................ 9 2.8 General Instructions and Precautions ................................................. 10 3 Installation ................................................................................................... 11 3.1 Connection Cables .............................................................................. 11 3.2 Contactors ........................................................................................... 11 3.3 Fuses .................................................................................................. 11 3.4 Description of SEM-Zero Connectors.................................................. 12 3.5 Description of Power Connections ...................................................... 13 3.6 Mechanical Drawing & Dimensions ..................................................... 14 4 Programming & Adjustments using Digital Console ............................... 15 4.1 Adjustments via Console ..................................................................... 15 4.2 Description of Console & Connection .................................................. 15 4.3 Description of Standard Console Menu............................................... 16 5 SEM-Zero: cabling and configuration ....................................................... 17 5.1 Power diagram .................................................................................... 17 5.2 Connections ........................................................................................ 18 5.3 Description of Programmable Functions (Options). ............................ 19 5.4 Description of Parameters that may be Programmed ......................... 21 5.5 Table of Adjustments........................................................................... 23 5.4 SEM-Zero Traction Standard Wiring Diagrams ................................... 25 5.5 Sequence for SEM-Zero Traction Settings.......................................... 26 6 SEM-Zero Diagnostics ................................................................................ 27 6.1 Analysis of Alarms displayed on the Console ..................................... 28 6.2 Tester Description of the Functions .................................................... 31 6.3 Description of the Console SAVE Function ......................................... 33 6.4 Description of Console RESTORE Function. ...................................... 34 6.5 Description of Alarms Menu. ............................................................... 35 6.6 Description of Console PROGRAM VACC function. ........................... 36

Page 1

LEGEND B SW CM CPOT EMB EV FORW SW H&S HORN HORN SW LIFT SW LOW SW MC NEMB NEV NHORN NMC NPC NPOT PC PEMB PEV PHORN PMC PPC PPOT REV SW SR1 SR2 T SW

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

Belly Switch Common Microswitches Wiper Potemtiometer Electromechanical Brake Lowering Valve Forward Switch Hard & Soft Horn Horn Switch Lifting Switch Lowering Switch Main Contactor Negative Electromechanical Brake Negative Lowering Valve Negative Horn Negative Main Contactor Negative Pump Contactor Negative Potentiometer Pump Contactor Positive Electromechanical Brake Positive Lowering Valve Positive Horn Positive Main Contactor Positive Pump Contactor Positive Potentiometer Reverse Switch Speed Reduction 1 Speed Reduction 2 Tiller Switch

COLOUR CODES (SINGLE COLOURS) The following Codes represent the colours of individual wires used by Zapi (unless specified otherwise).

A

- Orange

M

-

Brown

B

- White

N

-

Black

BB - Blue

R

-

Pink

C

RR -

Red

G - Yellow

V

-

Green

GG - Grey

VV

-

Purple

- Sky Blue

Page 3

1 INTRODUCTION TO THE ZAPI-MOS FAMILY The ZAPIMOS chopper family represents ZAPI’s answer to the needs of the 90’s.

To ensure that products remain on the market, without running the risk of becoming technically obsolescent, the ZAPIMOS family offers the following features: - Advanced technology.

- Economical costs.

- Maximum safety.

- Maximum flexibility.

- Open to future technical innovations.

- Optimum level of protection.

The design has been derived from: - High Frequency Mos Technology .

- Real time control over the internal and external components that influence the behaviour of the machine, with self diagnosis of the checking circuits themselves.

- Stored Program Machine (SPC), where the hardware is completely separate from the functions to be configured. The programme is parametric and can easily be modified by the end user.

- Various chopper configurations can be selected by the user, without the need for hardware modifications.

- Future technological updates are made easy for the user.

The communication protocol will continue to evolve, thereby offering increasing possibilities of interaction and expansion. For this reason, the Zapimos family offers a standard dialogue mode with external systems. This allows interfacing with commercially available machines. Zapi can offer a range of individually designed Console Software with various features and prices.

- SEM-Zero meets the requirements of (IP54). This provides excellent protection against spray (water, acid.), and against the ingress of dust or small foreign particles.

Access to the control logic is very simple, and allows simple substitution or replacement.

- The SEM-Zero family of Choppers are suitable for operating on DC voltages from 24 to 36V inclusive, with maximum armature current up to 200A. The choppers may be used to control DC Separately Excited Motors with power ratings up to 2.0kW.

Page 4

2 GENERAL CHARACTERISTICS 2.1 TECHNICAL SPECIFICATION Chopper for Separately Excited DC motors ...................................................0.5 ÷ 2.0kW Regenerative Braking.

Voltage Range ................................................................................................. 24-36VDC Maximum Field Current (all the versions) ................................................................. 35 A Armature Switching Frequency ............................................................................... 16kHz Field Switching Frequency ........................................................................................ 1kHz Maximum Ambient temperature ............................................................................. + 40°C Minimum Ambient temperature ................................................................................ -30°C Maximum temperature of Chopper ........................................................................ + 80°C

VERSIONS

MAXIMUM CURRENT

BOOSTER CURRENT

VOLTAGE DROP IN FULL CONDUCTION

24 / 36V

150A (3')

180A (10'')

0.23V at 50A, 25°C

24 / 36V

200A (2')

230A (10")

0.23V at 50A, 25°C

2.2 CONTROL UNITS 2.2.a Microswitches - Microswitches should have a contact resistance lower than 0.1W , and a leakage current lower than 100 µA. - When full load current is being drawn, the voltage drop across the Key Switch con tact must be lower than 0.1V. - If an Electromagnetic Brake is used, the Handle Microswitch must be able to operate the Brake Coil.

- The Microswitches send a voltage signal to the microprocessor when an operating request (running) is made.

Page 5

2.2.b Potentiometer The Potentiometer should be wired in the 3 - Wire Configuration.

CPOT (B1) signal ranges from 0 to 10V. Minimum Potentiometer Resistance : 500W Maximum Potentiometer Resistance : 10kW Faults can occur if the potentiometer is out of this range.

The Procedure for automatic potentiometer signal aquisition is carried out using the Console. This enables adjustment of the minimum and maximum useful signal level (PROGRAM VACC function), in either direction. This function is unique when it is necessary to compensate for asymmetry with the machanical elements associated with the potentiometer, especially relating to the minimum level.

The two graphs show the output voltage from a non-calibrated potentiometer with respect to the mechanical “zero” of the control lever. MI and MA indicate the point where the direction switches close. 0 represents the mechanical zero of the rotation.

The Left Hand graph shows the relationship of the motor voltage without signal aquisition being made. The Right Hand Graph shows the same relationship after signal aquisition of the potentiometer.

Page 6

2.3 SAFETY & PROTECTION FEATURES - Connection Errors : All Inputs are protected against connection errors.

- Thermal Protection : If the chopper temperature exceeds 70°C, the maximum current reduces in proportion to the thermal increase. The temperature can never exceed 80°C (below -10°C, the current is reduced to 80%).

- Low Battery Charge : When the battery charge is low, the maximum current is reduced proportionally to the battery discharge.

- Protection against accidental Start up : A precise sequence of operations are necessary before the machine will start.

Operation cannot commence if these operations are not carried out correctly.

Requests for drive, must be made after closing the key Switch.

- Protection against uncontrolled movements : The Line Contactor will not close if : - The Power Unit is not functioning - The Logic is not functioning perfectly.

- Main / Line Contactor : Should be fitted to give protection to the chopper against reverse battery polarity, and safety.

- External Agents : The chopper is protected against dust and the spray of liquid to a degree of protection meeting IP54.

2.4 DIRECTION ORIENTATION Machines fitted with Tillers, Belly Switches, and Pulse Control Systems providing rapid reversal should conform to the requirements of Directive prEN 1175. This Directive requires that Direction Orientation should match the following drawing:

Page 7

2.5 OPERATIONAL FEATURES - Speed Control .

- Optimum sensitivity at low speeds.

- Speed Reductions in both the directions. Levels can be set using Console.

- Regenerative Braking based on deceleration ramps, in every condition.

- Three different modes of Braking : Release Braking, Inversion Braking, Speed Limit Braking.

- Speed Control during descent : the motor speed follows the accelerator. The chopper automatically brakes if the motor speed overcomes the accelerator set point.

This provides optimum performance on a gradient.

- Starts on a Ramp without roll back, even without an electric brake.

- Programmable Anti Roll Back : When the Key Switch is closed, if the motor is rotating, the chopper controls the speed and automatically brakes and keeps the motor at a very low speed during descent on a gradient. This is a very useful safety feature and is not driver dependent.

- Output for Hourmeter - The main contactor is open after 45 seconds of stand-by condition.

- Self Diagnosis with indication of fault shown via flashing Red Led. (In addition to Console Display).

- Modification of the parameters via Digital Console. See the specific description.

- Internal Hour Meter that is displayed on the Console.

- Memory of the last 5 Alarms, with relative Hour meter count and chopper temperature all displayed on the Console.

- Test Function within Console for checking main parameters. See the specific Description.

- High motor and battery efficiency due to High Frequency Switching.

Page 8

2.6 SEM-ZERO 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: the Watch Dog Circuits, the current sensor, VMN point, Contactor Drivers, the switch sequence for operation is correct, and the output of the accelerator or tiller is correct.

2) Standby Diagnosis at rest that checks: VMN Point, Contactor Drivers, and Current Sensor.

3) Diagnosis during operation that checks: Watchdog, VMN Point, Current, Contactor(s), and VMN when in full conduction.

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

Diagnosis is provided in 2 ways. The Red Led connected to Connector A will flash a certain number of times for a given Alarm (See Listings), or the Digital Console may be used. A permanent Alarm will be displayed on the Console immediately and the RED LED will flash. An intermittent Alarm will be recorded in the Alarm library, but the RED LED will only flash at the time of the Alarm.

2.7 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 9

2.8 GENERAL INSTRUCTIONS AND PRECAUTIONS - Never combine SCR low frequency choppers with SEM-Zero modules. The filter capacitors contained in the SEM-Zero module will change the SCR chopper operation and subject it to excessive workload. If it is necessary to use two or more control units (eg. Lift + traction), the choppers must 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, and a lower voltage may prevent the logic operating.

- During battery recharge, the SEM-Zero must be completely disconnected from the battery. As well as altering the charge current read by the battery charger, the module can be damaged by higher than normal voltages supplied via the charger.

- The SEM-Zero module should only be supplied by a traction battery. Do not use the outputs of converters or power supplies. For special applications please contact the nearest Zapi service centre.

- Start the machine the first time with the drive wheel(s) raised from the floor to ensure that any installation errors 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 10

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

Apply a 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 connector 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.

Verify that the wiring of the cable terminals and connectors has been carried out correctly. Ensure that suppression devices are fitted to the coils not protected by the SEM-Zero itself.

3.1 CONNECTION CABLES For the auxiliary circuits use cables better or equal to 0.5mm² section.

For power connections to the motor armature and battery use cable of 16mm² section.

For the Field connections use cable of 4mm² section.

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

3.2 CONTACTORS A Line 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 3A. Suppression for this contactor coil is within the chopper. Do not use external suppression. For any Contactor using external suppression, ensure that connections are made respecting correct polarity.

3.3 FUSES - Use a 6.3A Fuse for protection of the auxiliary circuits.

- For protection of the power unit, refer to diagrams.. The Fuse value shown is the maximum allowable. For special applications or requirements these values can be reduced.

- For Safety reasons, we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow.

Page 11

3.4 DESCRIPTION OF SEM-ZERO CONNECTORS.

PIN REFERENCE DESCRIPTION A1

HOURMETER Output hourmeter; it controls a load to -BATT. Maximum output current 200mA.

A2

KEY

B+ Supply into logic downstream of 10A fuse & key switch.

A3

NMC

Negative main contactor coil.

A4

NEMB

Negative electro-brake.

A5

TILLER

Tiller micro-switch.

A6

-BATT

-BATT.

A7

PMC

Positive main contactor coil and common positive supply for REV, FORW, B SW, HORN, LIFT, LOW microswitches.

A8

H&S

Hard & Soft function input. It should be connected to A7 through the H&S switch. Active high (+VB).

B1

CPOT

Accelerator's potentiometer wiper, or output of inductive device.

B2

NPOT

Provides a negative supply to accelerator's potentiometer.

B3

PPOT

Provides a positive supply to accelerator's potentiometer.

B4

REV

Reverse direction input, it should be connected to A7 by a microswitch. Active HIGH (+VB).

B5

B SW

Quick inversion input, it should be connected to belly button.

Active HIGH (+VB).

B6

FORW

Forward direction input. It should be connected to A7 by a microswitch, active HIGH (+VB).

Page 12

PIN REFERENCE DESCRIPTION C1

CM

Common positive supply for micro-switch SR1, SR2, (+BATT).

C2

SR1

Input for 1st speed reduction. It should be connected to C1 by micro-switch, active LOW.

C3

SR2

Input for 2nd speed reduction. . It should be connected to C1 by micro-switch, active LOW.

D1

REG SIGNAL Regenerative braking status.

Normally high, low while regenerating.

D2

PHORN

Positive horn, it should be connected to A7 by the horn micro-switch.

D3

NHORN

Negative horn, it is -BATT.

D4

PPC

Positive pump contactor; it should be connected to A7 by lifting micro-switch LIFT which provides the positive supply to the pump contactor's coil.

D5

NPC-NEV

Negative supply for pump contactor.

D6

PEV

Positive electro-valve for lowering.

E1

PCLRXD

Positive serial reception.

E2

NCLRXD

Negative serial reception.

E3

PCLTXD

Positive serial transmission.

E4

NCLTXD

Negative serial transmission.

E5

GND

Negative console power supply.

E6

+VL

Positive console power supply.

E7

---

Free.

E8

---

Free.

3.5 DESCRIPTION OF POWER CONNECTIONS +BATT

=

Positive Supply from Battery.

-BATT

=

Negative Supply from Battery.

VMN

=

Negative Supply (via chopper) to Motor.

F1, F2

=

Connections to Drive Motor Field Winding.

Page 13

3.6 MECHANICAL DRAWING & DIMENSIONS

Page 14

4 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 4.1 ADJUSTMENTS VIA CONSOLE Adjustment of Parameters and changes to the chopper’s configuration are made using the Digital Console. The Console is connected to the “E” connector of the SEM-Zero Chopper.

Pay attention to the polarity of the Console Connector when connecting to the chopper. The bevel on the connector should be uppermost.

4.2 DESCRIPTION OF CONSOLE & CONNECTION

Digital Consoles used to communicate with SEM2 choppers must be fitted with Eprom CK ULTRA.

Page 15

4.3 DESCRIPTION OF STANDARD CONSOLE MENU

Page 16

5 SEM-ZERO: CABLING AND CONFIGURATION 5.1 POWER DIAGRAM

Page 17

5.2 CONNECTIONS

Page 18

5.3 DESCRIPTION OF PROGRAMMABLE FUNCTIONS (OPTIONS).

Using the CONFIG MENU of the console, it is possible to select from the following options: SUBMENU “SET OPTIONS”: 1

HOUR COUNTER: - RUNNING:

The counter registers travel time only.

- KEY ON:

The counter registers when the key switch is Closed.

The A1 output for external hourmeter operates according to internal hourmeter. If the pump contactor is connected (D4), hourmeter output (A1) is activated during lifting as well.

2

3

QUICK INVERSION - BELLY:

Quick inversion is activated while the Belly Button is pressed.

- TIMED:

Quick inversion is activated, while the Belly Button is pressed, maximum for 2 second.

AUX OUTPUT #1: -FREE:

A4 output is not used: the controller carry out monitor function as described at the paragraph 2.5.

-BRAKE:

A4 output drives an electromechanical brake. The controller does not carry out monitor function, but locks the brake while in rest or alarm status.

Page 19

Flow Chart showing how to make changes to Configuration Menu using Digital Console. (Standard Eprom CK ULTRA fitted).

1) Opening Zapi Menu.

2) Press Top Left & Top Right Buttons simultaneously to enter the Config.Menu.

3) The Display will show : 4) Press ROLL UP (Top Left Button) until SET OPTIONS appears.

5) The Display will show : 6) Press ENTER to go into this part of the menu.

7) The first “Option” of the menu appears on the Display.

8) Press either ROLL UP or ROLL DOWN to bring up the next the Option.

9) A new Option appears on the Display.

10) When the desired Option is displayed, press PARAM (Top Right) or SET (Bottom Right) button to change the configuration 11) The new Configuration for the selected Option appears on the Display.

12) Press OUT to exit the Menu.

13) Press ENTER to accept the changes, or Press OUT if you do not accept the changes and wish to make further modifications to the particular Option.

14) The Display now shows: 15) Press OUT again. Display now shows the Opening Zapi Menu.

Page 20

5.4 DESCRIPTION OF PARAMETERS THAT MAY BE PROGRAMMED In addition to the Configuration, Parameter settings may be made by Zapi using standard default settings, settings to Customer Specifications, or the customer may make changes according to the application, using a Digital Console.

During the setting up procedure on the machine, the Console can remain connected to the chopper during travel. The Parameters can be modified in real time, during operation.

Pay attention to the polarity of the Console Connector. Refer to Page 15 of this Manual for connection details.

THE PROGRAMMING CONSOLE MUST BE PLUGGED ONLY WHEN THE KEY-SWITCH IS OFF. The following Parameters can be modified : 1 2

ACC. DELAY = Determines the acceleration ramp.

DECELER DELAY = Determines the deceleration ramp according to the accelerator pedal position.

3 RELEASE BRAKING = Determines the deceleration ramp when the travel request is released.

4 INVERSION BRAKING = Determines the deceleration ramp the the Direction Switch is inverted during travel.

5 SOFT BRAKING = Determines how much the brakings are reduced when the H&S function is active.

6 SOFT ACCEL. = Determines how much the acceleration ramps are reduced when the H&S function is active.

7 CUTBACK SPEED 1 = First speed reduction.

8 CUTBACK SPEED 2 = Second speed reduction.

9 H&S CUTBACK = Speed reduction active when the H&S function is active.

10 MAX SPEED FORW = Maximum Forward Speed, obtained by weakening the Field Current after it has reached 100% conduction of the Armature. With the Parameter set at level 0, the armature is in total conduction but the field current does not decrease below the Nominal value (low speed).

11 MAX SP FORW FINE = Maximum forward speed.Fine adjustement.

12 MAX SPEED BACK = Maximum Reverse Speed, obtained by weakening the Field Current after it has reached 100% conduction of the Armature. With the Parameter set at level 0, the armature is in total conduction but the field current does not decrease below the Nominal value (low speed).

13 MAX SP BACK FINE = Maximum reverse speed. Fine adjustement.

14 COMPENSATION = Speed compensation when load is present. It reduces the difference between maximum speed laden and unladen.

15 MAXIMUM CURRENT = Maximum controller current.

16 ARMA NOM.CURR. = 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.

Page 21

17 WEAK DROPOUT = This Parameter fixes a limit on the Armature Current above which the Field Current is increased linearly up to the Nominal Field Current (in proportion to the armature current).

18 FIELD NOM. CURR. = Nominal Field Current. This parameter fixes the minimum Field Current when the potentiometer is between 0% and 60% without total conduction of the Armature. Adjustment should be made with reference to the Data on the Motor Label. (The indication of Nominal Field Current).

19 CREEP SPEED = Minimum Speed. This Parameter sets the minimum voltage applied to the motor at the start of travel.

Page 22

5.5 TABLE OF ADJUSTMENTS The following Table shows the different values that the SEM2 Parameters may be adjusted to. A suitable acceleration performance assumes: FIELD CURR. NOM is set to level 5, and MAX SPEED (Fwd or Rev) is set to level 9.

PROGRAMMED LEVEL PARAMETERS UNIT

0

1

2

3

4

5

6

7

8

9

ACC. DELAY

sec.

0.30 0.50 0.70 0.90 1.10 1.25 1.40 1.55 1.75 2.00

DEC. DELAY

*

9

8

7

6

5

4

3

2

1

0

RELEASE BRAKING

*

0

1

2

3

4

5

6

7

8

9

INVERS BRAKING

*

0

1

2

3

4

5

6

7

8

9

SOFT BRAKING

** %

50

40

33

28

25

22

20

18

16

15

SOFT ACCELERATION

*** %

50

40

33

28

25

22

20

18

16

15

CUTBACK SPEED 1

%ACC

30

38

45

51

57

64

72

80

90

100

CUTBACK SPEED 2

%ACC

30

38

45

51

57

64

72

80

90

100

H&S CUTBACK

%ACC

30

38

45

51

57

64

72

80

90

100

MAX SPEED FORW.

%FCN

100

90

80

71

62

53

45

40

36

33

MAX SP FORW. FINE

**** %FCN

0

1

2

3

4

5

6

7

8

9

MAX. SPEED BACK.

%FCN

100

90

80

71

62

53

45

40

36

33

MAX SP BACK. FINE

**** %FCN

0

1

2

3

4

5

6

7

8

9

COMPENSATION

***** %IA

0

5

10

16

22

27

33

38

44

78

MAXIMUM CURRENT

%IMax

82

84

86

88

90

92

94

96

98

100

ARMA CUR. NOM. (ACN)

%IMax

45

47

50

52

54

56

58

61

63

65

WEAK DROP OUT

%ACN

40

44

48

52

57

62

66

70

75

80

FIELD CURR. NOM. (FCN)

A

7.5

8.1

8.7

9.3

10

CREEP SPEED

%VBatt

4

5

6

7

8

10.6 11.2 11.8 12.5 9

10

11

12

13.1 13

*=

If the current inclines to raise, then also the braking time raises in order to obtain a smooth braking action. Therefore, the duration of the braking depends on the type of motor and the operating conditions (laden, unladen, on plane, on gradient).

**=

The values in the table indicate how much the brakings (release, inversion, deceleration) are reduced while H&S function is active.

***=

The values in the table indicate how much the acceleration is reduced while H&S function is active.

****= Is a percentage of the field current which is subtracted to the value defined by the parameters MAX SPEED FORW and MAX SPEED BACK. *****= Indicates the percentage of the armature current (while the machine is at constant maximum speed) that is subtracted to the field current.

Page 23

Flow Chart showing how to make Programme changes using Digital Console fitted with Eprom CK ULTRA. 1) Opening Zapi Display.

2) Press ENTER to go into the General Menu.

3) The Display will show : 4) Press ENTER to go into the Parameter Change facility.

5) The Display will show the first Parameter.

6) Press either ROLL UP or ROLL DOWN to display the next parameter.

7) The names of the Parameters appear on the Display.

8) When the desired Parameter appears, the Display will show a Level Number that will be between 0 and 9. press either PARAM (Top Right) or SET (Bottom Right) buttons to change the Level value.

9) The Display will show the New Level.

10) When you are satisfied with the results of the changes you have made, Press OUT. 11) The Display asks “ ARE YOU SURE ?

12) Press ENTER to accept the changes, or Press OUT if you do not wish to accept the changes and wish to make further modifications to the parameters.

13) The Display will show :

Page 24

5.4 SEM-ZERO TRACTION STANDARD WIRING DIAGRAMS

Page 25

5.5 SEQUENCE FOR SEM-ZERO TRACTION SETTINGS. When the Key Switch is Closed, if no Alarms or Errors are present, the Console Display will be showing the Standard Zapi Opening Display.

If the chopper is not Configured to your requirements, follow the Sequence detailed on Page 20. Remember to re-cycle the Key Switch if you make any changes to the chopper’s Configuration. Otherwise follow the sequence detailed below : 1) Select the options required (Chapter 5.3).

2) Select and set the Battery Voltage.

3) Confirm correct installation of all wires. Use the Console’s TESTER function to assist.

4) Perform the accelerator signal acquisition procedure using the Console “PROGRAM VACC”.

5) Set the TRACTION IMAX Current, taking into account any Boost requirements. Use Table on Chapter 5.5.

6) Set the Acceleration Delay requirements for the machine. Test the parameters in both directions.

7) Set the CREEP level starting from level 0. The machine should just move when the accelerator microswitch is closed. Increase the Level accordingly.

8) Set the Speed Reductions as required. Make adjustments to CUTBACK SP.1, 2.

Check the performance with the accelerator pedal totally depressed. If the machine is a forklift, check the performance with and without load.

9) RELEASE BRAKING. Operate the machine at full speed. Release the accelerator pedal. Adjust the level to your requirements. If the machine is a forklift, check the performance with and without load.

10) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst traveling INVERT the Direction Switch. Set a soft Level of Inversion Braking. When satisfactory, operate the machine at Full Speed and repeat. If the machine is a Forklift, repeat the tests and make adjustments with and without load. The unladen full speed condition should be the most representative condition.

11) Set MAX SPEED FORW. 12) Set MAX SPEED BACK (Reverse).

13) Set ARMA CURR. NOM., NOM. FIELD CURR. e WEAK DROPOUT Check the parameters meaning on Chapter 5.4.

Page 26

6 SEM-ZERO DIAGNOSTICS The following list shows likely problems associated with the flashing RED LED. N° FLASHES MESSAGE 1 Logic failure #1:

NOTES Problem with Logic or Line Contactor.

1

Watch-dog:

Logic board and/or software failure.

1

EEPROM KO:

Problem with EEPROM or Logic.

2

INCORRECT STARTS:

Starting sequence for travel not correct.

2

FORW + BACK:

Double running requests.

3

CAPACITOR CHARGE

Problem in Power Block.

3

VMN NOT OK

Problem with Chopper.

3

VFIELD NOT OK

Problem with Field Voltage

4

VACC NOT OK

Potentiometer Wiper.

4

PEDAL WIRE KO

Pedal wire not OK.

5

NO FIELD CUR.

Field wiring not OK or field current sensor not OK.

5

HIGH FIELD CUR.

Field wiring not OK or field current sensor not OK.

5

STBY I HIGH

High current at the stand-by sensor of armature current not OK.

5

I= 0 EVER

No current: sensor of armature current not OK.

6

CONTACTOR DRIVER

Contactor Driver not OK.

6

COIL SHORTED

Coil contactor shorted.

6

CONTACTOR CLOSED

Line Contactor contact not OK.

7

TH. PROTECTION

Temperature too much high (>70°C) or low (<10°C).

32

BATTERY LOW

Battery too low.

Page 27

6.1 ANALYSIS OF ALARMS DISPLAYED ON THE CONSOLE 1

LOGIC FAILURE #1 This test is carried out at the start-up.

Possible cause: failure of the logic board

2

WATCH DOG The test is executed at the key turn-on, at the stand-by and on running. Possible causes: a) Watch-dog hardware circuit not OK; b) Software not OK.

3

EEPROM OK Fault in the area of memory where the adjustment parameters are stored. This Alarm inhibits machine operation. If the fault continues when the Key Switch is recycled, replace the logic. If the fault disappears, the previously stored Parameters will have been replaced by the default parameters.

4

INCORRECT START Alarm generated by an incorrect Starting Sequence. Possible causes: a) The ENABLE microswitch has welded or failed. b) Error in the starting sequence from the operator. c) Error in the wiring.

5

FORW + BACK This check is made continually. The alarm is generated when forward and reverse direction are requested simultaneously. Possible causes: a) Error in Wiring. b) Welding or Failure of a direction switch. c) Error in the starting sequence from the operator.

6

CAPACITOR CHARGE This check is made during the initial diagnosis. This Alarm is generated if the Capacitors are not charged within 500ms after the Key Switch is closed. Probable cause is failure inside the power block.

7

VMN NOT OK This test is performed at rest, with the general Contactor Closed, and also during operation. At rest if VMN is lower than battery voltage this Alarm is generated.

During operation this Alarm is generated if VMN doesn’t follow the duty-cycle of the chopper. Possible causes: a) Incorrect Motor connection. b) Short circuit motor windings to chassis. c) Defect in the power unit.

Page 28

8

VFIELD NOT OK This test is made at standby with the Line Contactor open. In this condition the voltages on both the connections of field must be to around ½ VBatt. This alarm is generated if the field voltage is different from this value. Possible causes: d) Frame fault on the motor to chassis; e) Incorrect connection of the field winding to the controller; f) Failure of the controller in the section relative to the field.

9

VACC NOT OK This Alarm is generated if the accelerator output voltage differs more than 2V from the acquired minimum during the PROGRAM VACC. Possible causes: 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 in PROGRAM VACC routine have not remained or made correctly.

10 PEDAL WIRE KO This Alarm is generated if potentiometer or wiring fault is detected. (NPOT or PPOT are open circuit).

11 STBY I HIGH This test is made during the initial diagnosis and at standby. The test verifies that the current is zero. This Alarm disables the machine. Possible causes: a) defective current sensor. b) logic failure. First replace the logic. If fault remains replace the power unit.

12 I = 0 EVER This check is made during travel. 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. Check the motor armature (brush connections).

13 HIGH FIELD CUR, NO FILD CUR 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.

14 CONTACTOR DRIVER, COIL SHORTED, DRIVER SHORTED These Alarms are generated if there is a problem with the General or Line Contactor. Possible causes: a) The coil of the contactor is either short-circuit, open circuit, or not connected. b) The Contactor Coil Driver is short-circuit. c) Defect in the wiring to the contactor, or logic failure.

Page 29

15 CONTACTOR CLOSED This check is made during the initial diagnosis. With the coil of the line contactor deenergized, the capacitors should not be charged, unless there is divert resistor across the power poles. Possible causes: a) The line contactor power poles are welded. b) This alarm could be generated even if the line contactor has opened, but there is a problem with either the field circuit, or a problem detected by the safety microprocessor.

16 TH. PROTECTION If the temperature of the chopper rises higher than 70°C, this alarm is generated.

The chopper current is reduced in proportion to the increase in temperature. At 80°C the chopper totally stops. If the temperature of the chopper is <- 10°C, this Alarm is also generated and the current is reduced by 80 %. If this alarm is displayed when the chopper is temperature is the same as ambient or better than zero degrees: a) Check the connection of the temperature sensor. b) The temperature sensor may be defective. c) The logic may be defective.

17 BATTERY LOW This Alarm is generated when the battery becomes 50% discharged from the nominal value.

Page 30

6.2 TESTER DESCRIPTION OF THE FUNCTIONS 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. The following definition listing shows the relative measurements : 1) BATTERY VOLTAGE: level of battery voltage measured at the input to the key switch.

2) MOTOR VOLTAGE: the voltage appearing across the drive motor. It is measured between B+ and VMN. 3) MOTOR CURRENT: the current flowing in the drive motor armature.

4) FIELD CURRENT: the current flowing in the drive motor field winding.

5) VMN: the voltage effectively dropped across the MOS. It is measured between Band VMN. 6) TEMPERATURE: the temperature measured on the aluminum heat sink holding the MOSFET devices.

7) ACCELERATOR: the voltage of the accelerator potentiometer wiper (CPOT).

The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side.

8) FORWARD SWITCH: the level of the Forward direction digital entry MA (pin B6).

ON /+ VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

9) BACKWARD SWITCH: the level of the Reverse direction digital entry MI (pin B4).

ON /+ VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

10) HANDLE/SEAT SWITCH: the level of the Handle/Seat Microswitch digital entry (pin A5).

ON / + VB = active entry of closed seat switch.

OFF / GND = non active entry of open seat switch.

11) QUICK INVERSION: the level of the digital entry from Belly Button microswitch (pin B5).

ON /+ VB = active entry, B SW closed.

OFF / GND = non active entry, B SW open.

12) CUTBACK SWITCH 1: the level of the Speed Reduction 1 Microswitch SR1.

ON / GND = active entry of speed reduction microswitch.

OFF / + VB = non active entry of microswitch.

13) CUTBACK SWITCH 2: the level of the Speed Reduction 2 Microswitch SR2.

ON / GND= active entry of speed reduction microswitch.

OFF / +VB = non active entry of microswitch.

Page 31

Flow Chart showing how to use the TESTER function of the Digital Console.

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

3) The Display will show : 4) Press either ROLL UP or ROLL DOWN button until TESTER MENU appear on the display.

5) The Display shows : 6) Press ENTER to go into the TESTER function.

7) The first variable to be tested is shown on the Display.

8) Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appears on the Display.

9) Next variable is shown.

10) When you have finished, Press OUT. 11) The Display shows : 12) Press either ROLL UP or ROLL DOWN button to show other MENU or press OUT to finish.

Remember it is not possible to make any changes using TESTER. All you can do is measure as if you were using a pre-connected multimeter.

Page 32

6.3 DESCRIPTION OF THE CONSOLE SAVE FUNCTION The SAVE PARAM function allows the operator to transmit the Parameter values and Configuration data of the chopper into the Console memory. It is possible to load 64 different programmes.

The information saved in the Console memory can then be reloaded into another chopper using the RESTORE function.

The data that is available via the SAVE function is as follows: - All Parameter Values (PARAMETER CHANGE).

- Options (SET. OPTIONS).

- The Level of the Battery (ADJUST BATTERY).

Flow Chart showing how to use the SAVE function of the Digital Console.

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

3) The Display will show : 4) Press either ROLL UP or ROLL DOWN button until SAVE PARAM. is shown.

5) The Display will show : 6) Press ENTER to go into the SAVE function.

7) If this facility has been used before the type of chopper data stored appears on the top line with a 2 digit reference.

8) Keep pressing either ROLL UP or ROLL DOWN keys until the second line indicates a FREE storage facility.

9) Press ENTER to commence SAVE routine.

10) You can see the items that are being stored whilst the SAVE routine is happening.

11) When finished, the Console shows : 12) Press OUT to return to the Opening Zapi Display.

Page 33

6.4 DESCRIPTION OF CONSOLE RESTORE FUNCTION. The RESTORE PARAM function allows transfer of the Console’s stored data into the memory of the chopper. This is achieved in a fast and easy way using the method previously used with the SAVE PARAM. function.

The data that are available via the RESTORE PARAM. function are as follows : - All Parameter Values (PARAMETER CHANGE).

- Options (SET OPTIONS) - The level of the Battery (ADJUST BATTERY) ATTENTION: When the RESTORE operation is made, all data in the chopper memory will be writtten over and replace with data being restored.

Flow Chart showing how to use the RESTORE function of the Digital Console.

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

3) The Display will show : 4) Press either ROLL UP or ROLL DOWN button until RESTORE PARAM. appears on the display.

5) The Display will show : 6) Press ENTER to go into the RESTORE PARAM. function.

7) The Display shows the type of Model stored, with a Code Number.

8) Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display.

9) The model is shown 10) Press ENTER to commence the Restore operation.

11) The Display will ask “ARE YOU SURE”.

Press ENTER for YES, or OUT for No. 12) Press ENTER to confirm (OUT to not confirm) 13) You can see the items that are being stored in the chopper memory whilst the RESTORE routine is happening.

14) When finished the Console displays : 15) Press OUT to return to the Opening Zapi Display .

Page 34

6.5 DESCRIPTION OF ALARMS MENU. The microprocessor in the chopper remembers the last five Alarms that have occurred.

Items remembered relative to each Alarm are : the code of the alarm, the number of times the particular Alarm occurred, the Hour Meter count, and the chopper temperature.

This function permits a deeper diagnosis of problems as the recent history can now be accessed.

Flow Chart showing how to use the ALARMS function via the Digital Console.

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

3) The Display will show : 4) Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display.

5) The Display will show: 6) Press ENTER to go into the ALARMS function.

7) The Display will show the most recent Alarm.

8) Each press of the ROLL UP button brings up following Alarms.

Pressing ROLL DOWN returns to the most recent.

9) If an Alarm has not occurred, the Display will show: ALARM NULL. 10) When you have finished looking at the Alarms, press OUT to exit the ALARMS menu.

11) The Display will ask CLEAR LOGBOOK ?

12) Press ENTER for yes, or OUT for NO. 13) Press OUT to return to the Opening Zapi Display.

Page 35

6.6 DESCRIPTION OF CONSOLE PROGRAM VACC FUNCTION. This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal. It enables compensation for non symmetry of the mechanical system between directions.

The operation is performed by operating the pedal after entering the PROGRAM VACC function.

Flow Chart showing how to use the PROGRAM VACC function of the Digital Console.

1) Opening Zapi Display.

2) Press ENTER to go into the General Menu.

3) The Display will show : 4) Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display.

5) Tthe Display will show : 6) Press ENTER to go into the PROGRAM VACC routine.

7) The Display will show the minimum and maximum values of potentiometer wiper output. Both directions can be shown.

8) Press ENTER to clear these values.

9) Display will show 0.0.

10) Select Forward Direction, close any interlock switches that may be in the system. Slowly depress the accelerator pedal (or tiller butterfly) to its maximum value. The new minimum and maximum voltages will be displayed on the Console plus an arrow indicating the direction.

11) Select the Reverse Direction and repeat Item 10.

12) When finished , press OUT. 13) The Display will ask : ARE YOU SURE ?.

14) Press ENTER for yes, or OUT for NO. 15) Press OUT again to return to the Opening Zapi Menu.

Page 36

INSTALLATION AND USER MANUAL CHOPPER SEM-ZERO-ONE

492501

11. Troubleshooting and alarms Troubleshooting Symptom

Fault

Action

Truck does not move

Battery connector is unplugged.

Plug in the battery connector.

Battery is empty.

Recharge the battery.

Incorrect start (Alarm 79).

Release the tiller arm and recycle the key switch.

Emergency stop button is activated. Release the emergency stop button.

Lift pump does not run

Lifting functions improperly

Battery does not charge

Key switch is faulty.

Replace the switch.

Contact maintenance personnel.

Drive motor fuse has blown.

Check the connections and cables and replace the fuse.

Contact maintenance personnel.

Control circuit fuse has blown.

Check the connections and cables and replace the fuse.

Contact maintenance personnel.

Accelerator is faulty.

Contact maintenance personnel.

Pump motor fuse has blown.

Check the connections and cables and replace the fuse.

Contact maintenance personnel.

Load handling switch is faulty.

Replace the switch.

Contact maintenance personnel.

Control unit is faulty.

Contact maintenance personnel.

Overload.

Reduce the load.

Battery is empty.

Recharge the battery.

Not enough oil in tank.

Add oil.

Oil leak.

Check the joints and seals.

Contact maintenance personnel.

Pump is faulty.

Contact maintenance personnel.

Dirt or wear in valves.

Contact maintenance personnel.

Charger is incorrectly connected.

Check the connection.

Charger fuse has blown or main voltage is missing.

Check the connections and cables and replace the fuse.

Contact maintenance personnel

Battery cell’s water level or specific gravity is low.

Check the cell voltages and specific gravity. Add water and/or acid when necessary. See section "Recharging the Battery" in chapter 7.

27

Alarms In addition to the charging phase, the three-colour indicator light of the integrated charger also indicates possible faults related to charging. In the event of an alarm, the battery charger stops charging automatically.

Condition

Alarm type

Description (Action)

Flashing GREEN

Timeout

The duration of the main charging time exceeds the given maximum.

Verify the battery capacity.

Flashing RED-YELLOW

Battery current

Loss of output current control (failure of the control logic).

Replace the charger.

Flashing RED-GREEN

Battery voltage

Loss of output voltage control (failure of the control logic).

Replace the charger.

Flashing RED-YELLOW-GREEN

Thermal

The charger is overheated.

Verify the fan operation.

Flashing YELLOW-GREEN

Selection

An unavailable configuration has been selected. Verify the selector's position.

28

492503

12. Technical specifications 1

IDENTIFICATION

1.2 Model

1300 kg

1600 kg

2000 kg

2000 kg (p)

1.3 Power source

[kg]

Battery

Battery

Battery

Battery

1.4 Operating mode

Pedestrian

Pedestrian

Pedestrian

Pedestrian / stand-on

1300

1600

2000

2000

1.5 Nominal capacity/load

Q [kg]

1.6 Load center (COG)

c [mm] 600

600

600

600

1.8 Load wheel axle to fork face (forks lowered)

x [mm] 959

959

963

963

1.9 Wheelbase (forks lowered)

y [mm] 1173

1294

1370

1370

2

WEIGHTS

2.1 Truck weight (with nominal load [kg] and battery) (see 6.5)

1500

1950

2475

2505

2.2 Axle loadings (with load and battery), drive/load side

943/557

1245/705

1600/875

1600/905

40/160

100/250

115/360

115/390

P/P

Vul/Vul

Vul/Vul

Vul/Vul

[kg]

2.3 Axle loadings (without load/with [kg] battery), drive/load side 3

WHEELS AND TYRES

3.1 Tyres, material (R=rubber/Vul=Vulkollan) drive/load side 3.2 Load wheel dimensions

[mm]

85x90

85x90

85x75

85x75

3.3 Drive wheel dimensions

[mm]

230x70

230x70

230x70

230x70

3.4 Castor wheel dimensions

[mm]

100x40

100x40

100x40

100x40

2/1x+2

2/1x+2

4/1x+2

4/1x+2

3.5 Number of the wheels (x=driven) drive/load side 3.6 Track width (centre of tyres), load side

b10 [mm]

503

503

552

552

3.7 Track width (centre of tyres), drive side

b11 [mm]

370

390

375

375

4.4 Lift

h3 [mm]

115

115

115

115

4.8 Platform height

[mm]

-

-

-

145

4.9 Height of the tiller arm in travel position (min./max.)

h14 [mm]

861/1305

861/1305

921/1355

889/1207

4.15 Fork height, fully lowered

h13 [mm]

85

85

85

85

4

DIMENSIONS

29

4.19 Overall length, platform up / down

1627

1750

1855/2305

4.20 Powerhead length (to fork face), l2 [mm] 356 platform up/down

477

600

705/1155

4.21 Chassis (overall width)

b1/b2 [mm]

700

700

700

706

4.22 Fork dimensions (thickness/width/length)

s/e/l [mm]

50/150/1150

50/150/1150

50/165/1150

50/165/1150

4.25 Outside width over forks

b5 [mm]

520

540

540

540

4.32 Ground clearance, center of wheelbase (forks lowered)

m2 [mm]

35

35

35

35

4.33 Working aisle width Ast3, pallet Ast3 1000x1200, load crosswise, [mm] platform up/down

1591

1704

1801

1906/2356

4.34 Working aisle width Ast, pallet 1000x1200, load crosswise, platform up/down

Ast [mm]

2151

2264

2365

2470/2920

4.35 Working aisle width Ast3, pallet Ast3 800x1200, load lengthwise, [mm] platform up/down

1791

1904

2001

2106/2556

4.36 Working aisle width Ast, pallet 800x1200, load lengthwise, platform up/down

Ast [mm]

2017

2130

2229

2334/2784

4.37 Turning radius (forks lowered), platform up/down

Wa [mm]

1350

1463

1564

1669/2119

5.1 Travel speed, laden/unladen *

[km/h]

5.8/6.0 *

5.8/6.0 *

5.8/6.0 *

5.8/6.0 *

5.2 Lifting speed, laden/unladen

5

l1 [mm] 1506

PERFORMANCE

[m/s]

0.039/0.052

0.03/0.046

0.03/0.046

0.03/0.046

5.3 Lowering speed, laden/unladen [m/s]

0.070/0.022

0.065/0.022

0.065/0.022

0.065/0.022

5.7 Gradeability, laden/unladen

10.0/20.0

8.0/20.0

10.0/20.0

10.0/20.0

Magn. brake

Magn. brake

Magn. brake

Magn. brake

[%]

5.10 Service brake 6

MOTORS

6.1 Drive motor S2 60 min

[kW]

0.6

0.6

0.8

0.8

6.2 Lift motor S3 15%

[kW]

1.0

1.0

1.0

1.0

6.4 Battery voltage/capacity (min.-max.)

[V/Ah]

2 x 12/35-48

24/120-160

24/165-240

24/165-240

6.5 Battery weight (min.)

[kg]

30

122-145

170-200

170-200

Stepless

Stepless

Stepless

Stepless

61

61

61

8

MISCELLANEOUS

8.1 Speed control type 8.4 Sound level at the driver's ear ** according to EN 12 053:2001 and EN ISO 4871, work

30

[dB (A)] 61

sequence LpA Sound level at the driver's ear [dB (A)] 62/69/0 according to EN 12 053:2001 and EN ISO 4871, driving / lifting / engine idle LpA

62/69/0

62/69/0

62/69/0

2

-

-

-

1,15

2

< 2,5

< 2,6

< 2,6

< 2,6

Whole body vibration according [m/s ] to EN 13 059:2002 Hand-arm vibration according to [m/s ] EN 059:2002

Manufacturer reserves the right to make technical changes. * Travel speed to the direction of the forks may be adjusted slower than announced ** Uncertainty of 4 dB(A) in section 8.4. (p) = platform

31

1300 kg Fork width

Fork length

b50 [mm]

l [mm]

520

1150

Options

Options

min. 480

950

max. 660

1020

Working aisle width (mm) Pallet size

Handling

AST 3

800x1200

Lengthwise

1791

1000x1200

Crosswise

1591

Working aisle width (mm) Pallet size

Handling

AST

800x1200

Lengthwise

2017

1000x1200

Crosswise

2151

32

1600 kg Fork width

Fork length

b50 [mm]

l [mm]

540

1150

Options

Options

min. 480

950

max. 660

1020 1450

Working aisle width (mm) Pallet size

Handling

AST 3

800x1200

Lengthwise

1904

1000x1200

Crosswise

1704

Working aisle width (mm) Pallet size

Handling

AST

800x1200

Lengthwise

2130

1000x1200

Crosswise

2264

33

2000 kg Fork width

Fork length

b50 [mm]

l [mm]

540

1150

Options

Options

min. 520

950

max. 660

1020 1450 2350

Working aisle width (mm) Pallet size

Handling

AST 3

800x1200

Lengthwise

2001

1000x1200

Crosswise

1801

Pallet size

Handling

AST

800x1200

Lengthwise

2229

1000x1200

Crosswise

2365

Working aisle width (mm)

34

2000 kg (p) Fork width

Fork length

b50 [mm]

l [mm]

540

1150

Options

Options

min. 520

950

max. 660

1000 1020 1450 2350

Working aisle width (mm) Pallet size

Handling

AST 3

800x1200

Lengthwise

2106/2556

1000x1200

Crosswise

1906/2356

Pallet size

Handling

AST

800x1200

Lengthwise

2334/2784

1000x1200

Crosswise

2470/2920

Working aisle width (mm)

35

36

37

38

3

EDU .* EDU .* EDU .*

),//,1*

0

+<'5$8/,& ',$*5$0 NPP13 M NPP20MR

NPV20K N NO20NT

7+

12

13

14

15

16

17

18

KEY SWITCH 3

19

20

21

22

23

24

BELLY SWITCH

TILLER HEAD

26

BRAKE RELEASE

27

28

29

HORN

LIFT

LOWER

COM

COM

COM

30

4

S1

COM

X4: 2

GRN

S3

COM

S4

S8

B1 ACCELERATOR NO

OPTION

NO

S5

S6

NO

NO

NO

B+

S2 TILLER SWITCH

X4: 1 X1: B+

25

FW

BW

POT LOW

0-5V

B-

2

1

1

1K1

28

2

20

X5:7

WHT/ BLK BRN GRY

X5:6

X5:4

X5:3

X5:2

C5

A2

2K1

COM

+

2

1

1F1 160A

S2

ORA

R5

KEY

2F1 160A

10A

X5:1

1

2

WHT/ BLK WHT

NC

-

1

A:B+

RED/ GRN

X5:5

3F1

X5:8

11

2

C1 C2 C3

SUPPLY SLOW2 SLOW1

A7

PMC

NC

D1

16 mm2

A1

+BATT

1K1

24V

A2 4,0 mm2 A2

M2 A2

F1

E1

M1 A1

E2 4,0 mm2

F2

TRACTION MOTOR: 0,8kW-24VDC (SEM-MOTOR)

VMN 16 mm2

X1: BX1 BATTERY CONNECTOR, EMERGENCY ISOLATION

COM

A3 D6 D4 A8 A5

NMC PEV PPC H&S PEMB

B4 B6 B2 B1 B5

FORW SW REV SW POT.LOW NPOT 0-5V INPUT CPOT B SW

VALVE PUMP SOFT BRAKE

X10: 1

F10

G1

LIFT LIMIT

S7

A1

1Y1 A2 X10: 2

A6

-BATT

A4

NEMB

BRAKE LOW

D3 D5

NHORN NPC

HORN LOW COILS LOW

A1

+ -

V6

A2

A1

A1

H1 2K1

2Y1

A2

A2

C6

-BATT

A1 SEM-0 150A

CIRCUIT DIAGRAM

TS780699

NPP16K/NPP20K STANDARD EQUIPMENTS

1/5

REV

3-6714

A

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

KEY SWITCH 3

SAFETY SOCKET LED DISPLAY

X1:B+

1

GRN

A2 DISPLAY MDI

CONTACT IS CLOSED WHEN MAINS SOCKET IS PLUGGED TO THE SAFETY SOCKET.

S0 X4: 1

3F1 A:B+

4

S1

X4: 2

MAINS SOCKET

2

10A

YEL 1

WHT BLU RED

1F1 160A

2

KEY

A3:1 2 3 1

1K1 1/20

A2

11

2

~230VAC RED

G1 BLK

16 mm2

+BATT

E1

PCLRXD

WHT

E2

NCLRXD

PUR

E3

PCLTXD

GRN

E4

NCLTXD

YEL

E5

GND

BLK

E6

+12V

RED

24V

+24VDC F1

A3 CHARGER 24V30A

F2

VMN 16 mm2

E7 E8

-BATT

X1:B-

A1 SEM-0 150A

X1 BATTERY CONNECTOR, EMERGENCY ISOLATION

CIRCUIT DIAGRAM

TS780699

NPP16K/NPP20K ACCESSORIES

2/5

REV

3-6714

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

A4 DRIVE (-) B+ KEY SW LIFT SWITCH (+) K3 LIFT

B-

1K1:A2 S1: 4 2K1:A1 2K1:A1

A1:-BATT

R-2 0.75mm2 (1300mm)

1

R-2 0.75mm2 ( 300mm)

2

R-2 0.75mm2 (1300mm)

3 +

R-2 0.75mm2 (1300mm)

4

R-2 0.75mm2 (1300mm)

6

R-2 0.75mm2 (1300mm)

SA4

h

SA4 LIFT CUT-OFF WHEN THE STATE OF DISCHARGE OF THE BATTERY IS LOW. (NOTE THE POLARITY!)

-

8 7 6 5 4 3 2 1

5

N M L K

O P R S T U

DISCHARGE

B+ 24 V

A1: B+

R-2 0.75mm2 (1300mm)

7 CONNECTIONS & ADJUSTMENT

ADAPTER HARNESS (RL462855)

CIRCUIT DIAGRAM

BDI (RL197674)

TS780699

NPP16K/NPP20K ACCESSORIES 2

3/5

REV

3-6714

11

12

13

14

15

16

17

18

19

20

21

22

23

24

X4:1 L700

27

28

29

30

L150

S1:3

L300

3F1:2

2K1:A2

S1:4

1K1:A2

1K1:A1

S2:NC

2K1:A1

L650

26

X4:2 L50

S2:COM

25

X 5 RL108288

9

3

A1: C

6

A1: B

6

A1: D

8

A1: A

00 L1

L100 L950

L100

L100

L1

S5:COM

L850

L250

L600

L150

S5:NO

L800

L250

S4:COM

L250

S4:NO

00

L250

L150

S6:COM

S8:NO

CIRCUIT DIAGRAM

H1:A2

L250

H1:A1

S8:COM

2Y2:A2

L150

2Y2:A1

S7:COM

S6:NO

S7:NC

L250

TS780699

X10 RL211074

2

NPP16K/NPP20K WIRE HARNESS W5:RL450339

4/5

REV

3-6714

11

12

13

14

15

16

17

18

19

20

21

22

23

24

L75

25

26

27

28

29

30

S5:COM

S5:NO

L75 S5:COM

S5:NO

L50

S6:COM

S6:NO

L50 L50

S6:COM S6:NO

L50 L75

S6:COM

S6:NO

L75

S5:COM

S5:NO

CIRCUIT DIAGRAM

TS780699

NPP16K/NPP20K WIRE HARNESS W5.1:RL461407

5/5

REV

3-6714

16

17

18

KEY SWITCH

TILLER SWITCH HEATER

3 1

20

R51

S50 S2 TILLER SWITCH

10A

1

2

20

A2

28

HORN

28

29

LIFT

30

LOWER

COM

S8

B1 ACCELERATOR

COM

S4 NO

COM

S5

COM

S6

NO

NO

NO

B+ FW

BW

POT LOW

0-5V

B-

2 WHT/ WHT BLK

NC

COM

C5

1K1

2K1

GRN

S3

NO

R50

S2

2

1

OPTION.

27

ORA

BLK WHT/ GRY BRN

X5:8

2

+

2

RED/ GRN

1

1F1 160A

26

R5

KEY

2F1 160A

25

100R

X5:1

1

COM

X5:7

A:B+

t

2 1

3F1 1

t=+40C

1

1M1 15

24

4

X4: 1

100R 2

23

BELLY SWITCH

X4: 2

1

22

TILLER HEAD

S1

t

t=+40C 2

X1: B+

21

X5:6

S51

19

X5:5

15

X5:4

14

X5:3

13

X5:2

12

-

11

2

C1 C2 C3

SUPPLY SLOW2 SLOW1

A7

PMC

NC

D1

16 mm2

A1

+BATT

1K1

24V

A2 4,0 mm2 A2

M2

F1

E1

M1

A2

A1

E2 4,0 mm2 TRACTION MOTOR: 0,8kW-24VDC (SEPARATELY EXITED)

F2

VMN

16 mm2

A3 D6 D4 A8 A5

NMC PEV PPC H&S PEMB

B4 B6 B2 B1 B5

FORW SW REV SW NPOT POT.LOW CPOT 0-5V INPUT B SW

VALVE PUMP SOFT BRAKE

A6

-BATT

A4

NEMB

BRAKE LOW

D3 D5

NHORN NPC

HORN LOW COILS LOW

U

X10:1 A1

1Y1 A2 X10:2

A1

+ -

V6

A2

A1

A1

H1 2K1

2Y1

A2

A2

C6

-BATT

X1: B1M1 X1 BATTERY CONNECTOR, EMERGENCY ISOLATION

COM

VDR-S14 K60

G1

LIFT LIMIT

S7

15

A1 SEM-Zero 150A

CIRCUIT DIAGRAM

TS871201

NPP16K/NPP20K COLD STORE STANDARD EQUIPMENTS

1/2

REV

3-6744

1

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

KEY SWITCH 3

SAFETY SOCKET LED DISPLAY

X1: B+

1

GRN

A2 DISPLAY MDI

CONTACT IS CLOSED WHEN MAINS SOCKET IS PLUGGED TO THE SAFETY SOCKET.

S0 X4: 1

3F1

A:B+

4

S1

X4: 2

MAINS SOCKET

2

10A

YEL 1

WHT BLU RED

1F1 160A

2 KEY

A3:1 2 3 1

1K1 1/20

A2

11

2

~230VAC RED

G1 BLK

16 mm2

+BATT

E1

PCLRXD

WHT

E2

NCLRXD

PUR

E3

PCLTXD

GRN

E4

NCLTXD

YEL

E5

GND

BLK

E6

+12V

RED

24V

+24VDC F1

A3 CHARGER 24V30A

F2

VMN 16 mm2

E7 E8

-BATT

X1: B-

A1 SEM-Zero 150A

X1 BATTERY CONNECTOR, EMERGENCY ISOLATION

CIRCUIT DIAGRAM

TS871201

NPP16K/NPP20K COLD STORE ACCESSORIES

2/2

REV

3-6744

12

13

14

SAFETY SWITCH (BELLY)

15

16

19

BW

POT LOW

FW

20

21

22

23

TILLER SWITCH

B2

0-5V B-

B+

com

COLD STORAGE

25

26

27

28

29

30

HORN

BRAKE RELEASE

LIFT / INITIAL LIFT

LOWER / INITIAL LOWER

R2

-

no

COM

S6

R1 WH/

NC

24

R1 + R2 for stacker trucks R1 for pallet trucks.

ACCELERATOR

NO

S3

COM

S4

NO COM

S5

NO COM

COM NO

COM S2.2

XB1/8

3

WH 4

OR 5

BK 6

BN 7

RED/ GRN 1

BN 2

XB2/1

BK 2

X20

BU 3

XT3/

2

1

XT5/

3

4

2

12

11

10

DATE: 2008-09-29

XB4.1/ 2

4

X21 6

5

1

XB4.1/ 1

WH/ BK

XB4.1/ 5

NC GRY

NAME: IR

CHANGE: TILLER SWITCH CONNECTIONS

18

RD B1

S2.1

17

XB4.1/ 3

c ROCLA OYJ 2006

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.

REV E

X22

XT1/7

6

5

4

3

2

1

9

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ DESIGN. 2006-09-14 FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

8

15

NAME: JL

14

13

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1150908

XT2/2

NEW TILLER LAVANSIIRTÄJÄT JA PINOAJAT PALLET AND STACKER TRUCKS

3

1

1/2

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12

13

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15

16

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18

19

20

21

22

23

24

25

26

27

28

29

30

1 SPEED LIFT / 2 SPEED LOWER OR PROPORTIONAL LIFT / LOWER, NOT BOTH IN SAME TRUCK B4

B3 1 SPEED LIFT, 2 SPEED LOWER

2 SPEED LOWER

1 SPEED LOWER

LIFT

B-

LIFT/LOWER

B+

0-2.5-5V B-

B+

BK OR WH/ BK

WH

WH/ BR

GR

XB4/ 5

4

3

2

1

XT4/5

4

3

2

1

GR

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: 2006-09-14

NAME:

CHANGE:

GRY

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2006-09-14 DESIGN. FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: JL

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1150908

NEW TILLER PINOAJAT STACKER TRUCKS

2/2

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3-6969

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22

23

1F1

K21

3 16 2 KEY SWITCH/ EMERGENCY STOP

CHANGE: K21 added.

2

S1

1

K1

8

K21

23

1

2

6 2 3 5

2

1

1

4 DIAG. INDICATOR 1 1 1Y1 2

12V

-

SENSOR BEARING

G1

XG1/+

+

G1 +

G2

-

B3:

WH BU RD BK

3 4 7 8 2 6

M2

+24V

A B +15V 0V TEMP. SENSOR

-

U

M1 3

V

BK(Mu)

U

WH(Va)

V

W

W BL(Si) NOTE: Colour codes only in NPP13/16M

27

BELLY BWD FWD 0-5V B+24V BRAKE RELEASE LIFT LOWER HORN OPTION +10V

+24V +24V HORN LOWER LIFT

S2 4 2 3 6

29

30

7 1

HORN XT1/12

LOWER

1

t +20°C

2

X42

X40

5 8 9 10 12 11

1 2 3

XS12/1

XS12/1

XS12/2

XS12/2

COM

S12

NO PLATFORM SENSOR FOR NPP20MR

LINK FOR THE OTHER VERSIONS

4 5 A1

DOUT BBDINP DINP

28

XT2/ 3

XT1/14

B-

0-5V

FW

BW

XA1X6/

XA1X3/

XG1/-

DOUT

5

24V

12V

+24V

XA1X4/

+

+

NC +24V NO 0V

XA1X5/

H1

1

NAME: IR DATE: 2009-08-19

X43

XT1/ 4

TILLER SWITCH XT1/15 XT1/ 9 XT1/ 8

XT1/ 2

2

2F1 1

XT1/ 3

X11.1/1

XT1/ 5

1

XA1X1/

XT1/ 7

2

1 2 3 4

XT1/ 6

BELLY

A1F1 5A

X11: 6 K21 added when if pin code device is used. 3/23 K21 installed paraller to tiller switch.

REV G

26

A1 +

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

Kts. myös uuden aisan piirikaavio 3-6969/TS115 See also the new tiller circuit diagram 3-6969/TS115.

CONTROLLER NPP13/16M:dACi-TA 24/120GB NPP20M:dACi-TA 24/150GB

LINK: A1:+ <-> X1:1 NPP20M:dACi-TA 24/150GB

24

LIFT

21

XT2/ 2

20

BRAKE REL.

19

XT1/11

PUMP FUSE 2F1 NPP13/16M:70A NPP20M:100A

18

COLD STOR. +

17

XT1/13

16

XT2/ 1

c ROCLA OYJ

TRACTION FUSE 1F1 NPP13/16M:70A NPP20M:100A

15

XT1/10

14

B+

13

XT1/ 1

12

COLD STOR. -

11

K1 10 9 8 7 6

A2

A1

2Y1 A2

RD

H2 BK

COM

S7

COM

S8 NC

NC

NPP13M BATTERY

NPP16/20M BATTERY

XB- TERM (RL450541)

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ DESIGN. 2007-01-11 FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

MOTOR CABLES 6mm2 for NPP13/16M 16mm2 for NPP20M NAME: IR

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

PUMP CONTACTOR

TS1220909

LOWER VALVE

HORN

LIFT LIMIT

SAFETY SOCKET

NPP13M/16M/20M/20MR PÄÄPIIRI dACi-TA 24/120GB/180GC MAIN CIRC.dACi-TA 24/120GB/180GC

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24

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29

30

STARTER BATTERY/ KEY SWITCH/ LORRY SIDE SIGNAL

MAINS SOCKET

DISPLAY UNIT 1 2 3 4

7 8 1

A3: XA3X1/

+

G1 24V

BK

2

OG

A2 230VAC

-

+

DC/DC BOOSTER

24VDC -

+ 1

S1 1

AUXILIARY FUNCTIONS

+24V +24V INP.1 OUT 1 BINP.2

+

24VDC

OUTPUT: 28,2V 8A

X2:

A201/

-

FA201A: 20A 2 BK

1 2 3 4 5 6

XA201/ 2

RD

1 SPIRAL CABLE RL469105

RL468311 TRUCK CONNECTOR

XTC/ RL468312

-(N) +(L) 1 FA201B/ 2 20A

XB- TERM

XBTERM

ONBOARD CHARGER

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ DESIGN. 2003-02-26 FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: HL

RL468921

1 2 3 4

INPUT: 25,8...29VDC

24VDC

RL469112

X7:

HANDHELD CONSOLE

RL468920

RS485 INTERFACE

VALID ONLY FOR dACi-TA 24/180GC

DATE: 2007-05-31

NAME: IR

CHANGE: CURTIS BDI ADAPTER REMOVED

X7/

REV D

16

CONTROLLER

RS485 INTERFACE

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.

15

S1 1

COMPLETE CHARGER KIT RL469111

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1220909

NPP13M/16M/20M/20MR OPTIOT/LISÄTOIMINNOT OPTIONS/ADD.FUNCTIONS

2/4

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c ROCLA OYJ

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14

15

STARTER BATTERY/ LORRY SIDE

16

17

18

19

20

SWITCH/ SIGNAL

21

22

23

24

25

26

27

28

29

30

PIN-CODE ENTRY (OPTIONAL) S1:2

XB-

X11.1:1

1/13

1/15

1/18

S1:2

XB-

1/13

1/15

+

STARTER BATTERY

CHANGE: RELAY ADDED TO PIN CODE OPTION

24V

-

3

1

XA201.1/2

XA201.1/ 1

K20 8

4

-(N)

REMA 80A 75306-00

XTC.1/

TRUCK CONNECTOR

NAME: IR

X11

1,0k 1W

R5 MUST ADDED IF PIN CODE DEVICE IS USED

+

4

2

6

5

1

3

4

2

6

5

1

3

4

2

6

5

1/19

1/18

X11:

1

BK

BRN

FA201A: 2 20A

GRN

+

OUTPUT: 28,2V 8A

BLU

DC/DC BOOSTER

BLK

24VDC

WHT

KEY

RED

REV F

24VDC

-

3

X43

X11

-

RL468921

INPUT: 25,8...29VDC

1

XA1X1:1

OG

BK DATE: 2008-10-16

22

R5

SPIRAL CABLE RL469105

+(L)

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.

K20

RD

B+

COM

NO

B-

XB-: S1: TERM 1

COMPLETE CHARGER KIT TO BE INSTALLED INTO THE TRUCK

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ DESIGN. 2004-07-02 FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

DRIVER PRESENT

NC

PIN-CODE LOCK NAME: HL

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1220909

NPP13M/16M/20M/20MR OPTIOT/LISÄTOIMINNOT 2 OPTIONS/ADD.FUNCTIONS 2

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15

NPP13 / 16M HEATING FOR LIFT LIMIT RL484149

16

17

18

20

21

22

23

24

25

26

27

28

29

30

NPP20M HEATING FOR LIFT LIMIT RL484170

2F1 2

2F1 2

1

5F1

19

1 5A (RL191658)

6F1

5A (RL191658) 2

COM t +40oC (RL198267) NC

COM t +40oC (RL198267) NC

DATE: 2007-11-02

NAME:

CHANGE: PAGE ADDED

2

S51

1

R51

1

R52 2

33R / 25W (RL147118)

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 E

2

100R / 25W (RL196800)

S52

XB-TERM

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ DESIGN. 2007-01-11 FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

XB-TERM

NAME: IR

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1220909

NPP13M/16M/20M/20MR NOSTON YLÄRAJAN LÄMMITYS HEATING FOR LIFT LIMIT

4/4

REV

3-6984

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13

14

SAFETY SWITCH (BELLY)

15

16

19

BW

POT LOW

FW

20

21

22

23

TILLER SWITCH

B2

0-5V B-

B+

com

COLD STORAGE

25

26

27

28

29

30

HORN

BRAKE RELEASE

LIFT / INITIAL LIFT

LOWER / INITIAL LOWER

R2

-

no

COM

S6

R1 WH/

NC

24

R1 + R2 for stacker trucks R1 for pallet trucks.

ACCELERATOR

NO

S3

COM

S4

NO COM

S5

NO COM

COM NO

COM S2.2

XB1/8

3

WH 4

OR 5

BK 6

BN 7

RED/ GRN 1

BN 2

XB2/1

2

X20

BU

BK 3

XT3/

2

1

XT5/

3

4

2

12

11

10

DATE: 2008-09-29

XB4.1/ 2

4

X21 6

5

1

XB4.1/ 1

WH/ BK

XB4.1/ 5

NC GRY

NAME: IR

CHANGE: TILLER SWITCH CONNECTIONS

18

RD B1

S2.1

17

XB4.1/ 3

c ROCLA OYJ 2006

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.

REV E

X22

XT1/7

6

5

4

3

2

1

9

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ DESIGN. 2006-09-14 FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

8

15

NAME: JL

14

13

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1150908

XT2/2

NEW TILLER LAVANSIIRTÄJÄT JA PINOAJAT PALLET AND STACKER TRUCKS

3

1

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12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1 SPEED LIFT / 2 SPEED LOWER OR PROPORTIONAL LIFT / LOWER, NOT BOTH IN SAME TRUCK B4

B3 1 SPEED LIFT, 2 SPEED LOWER

2 SPEED LOWER

1 SPEED LOWER

LIFT

B-

LIFT/LOWER

B+

0-2.5-5V B-

B+

BK OR WH/ BK

WH

WH/ BR

GR

XB4/ 5

4

3

2

1

XT4/5

4

3

2

1

GR

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: 2006-09-14

NAME:

CHANGE:

GRY

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2006-09-14 DESIGN. FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: JL

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1150908

NEW TILLER PINOAJAT STACKER TRUCKS

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EN

Operation & Maintenance Manual NPP16K NPP20K

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

-1-

PALLET TRUCK Type:

__________________________________

Manufacturing year and number: _____________________

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

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

-2-

Table Of Contents FOREWORD ............................................................................................................................................ 3 INSTRUCTIONS ON OPERATING THE TRUCK ................................................................................ 3 OCCUPATIONAL SAFETY...................................................................................................................... 5 LOAD HANDLING .................................................................................................................................. 6 DRIVING .................................................................................................................................................. 7 PARKING ................................................................................................................................................. 7 OTHER WORKING INSTRUCTIONS .................................................................................................. 8 RECHARGING AND REPLACING THE BATTERY ............................................................................ 8 HAZARDOUS WASTE AND DISPOSAL ............................................................................................. 10 ORDERING SPARE PARTS .................................................................................................................. 10 USE OF THE TRUCK ............................................................................................................................ 11 THE OPERATOR’S NORMAL DRIVING POSITION ....................................................................... 11 NOISE ..................................................................................................................................................... 11 CONTROLS AND THEIR DISPLAYS .................................................................................................. 12 OPERATION .......................................................................................................................................... 14 HANDLING A LOAD ............................................................................................................................. 15 EMERGENCY PROCEDURES ............................................................................................................. 15 INSPECTIONS, SERVICE, AND REPAIRS ......................................................................................... 15 TROUBLESHOOTING .......................................................................................................................... 19

-3-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Otherwise normal daily maintenance and inspection are sufficient.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The truck must always be driven with its forks lowered.

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

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

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

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

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

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

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

-7-

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

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

Sudden starts and stops should be avoided.

Steering and braking movements should be made smoothly.

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

Take great care when driving on a slanted surface.

Do not drive over any loose objects on the floor.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Connecting the battery to a charger: 1.

2.

3.

4.

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

Disconnect the battery connector and connect it to the charger.

Connect the current to the charger.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- 11 -

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

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

The truck is intended to be used in dry indoor spaces, on even and level floors. The temperature range, in which the truck can operate continuously is +25 - +5°C, and for short periods +45 - +25°C. If the operating conditions differ from those temperatures, contact your truck dealer, because in cold and freezing temperatures a separate machine intended for such conditions is needed. A special machine for freezing conditions can be used in temperatures down to -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 • on premises with fire risk • on premises with explosion risk • on premises with insufficient floor load capacity • if damaged • as a mounting surface • to tow another truck • under the influence of intoxicating substances.

THE OPERATOR’S NORMAL DRIVING POSITION The normal drive position of the driver when driving in the direction of the forks is behind the truck, with both hands on the tiller arm. When driving in the opposite direction, the driver walks beside the truck with one hand on the tiller arm.

NOISE The maximum noise level the driver may be subjected to is 76 dB (A). This noise level can be reached when raising classified load.

- 12 -

CONTROLS AND THEIR DISPLAYS KEY SWITCH (1) The key switch connects the truck’s electrical equipment to the battery circuit.

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

BATTERY CONNECTOR / MAIN CURRENT SWITCH (2) The battery connector is the main current switch of the forklift truck, and it also serves the purpose of emergency switch.

For further information on charging the battery via the battery connector, please see section on charging the battery.

NOTE !

• When welding with electrical welding equipment, the battery must be disconnected.

• In case of an emergency the forklifttruck can be disconnected from the power source by unplugging the battery connector HOUR METER AND BATTERY DISCHARGE INDICATOR (3) The hour meter counts the time that the truck has been in active operation. It is always on, when the electrical devices are operating.

The discharge indicator shows the level of the battery charge and stops the lift function, if the battery charge is too low. However, the battery should be recharged, before the charge level drops too much.

- 13 STEERING (4) The tiller arm turns ± 90 degrees. The movement limiter allows for an approximately 5 degree dampened increase in the total movement.

HORN BUTTON (5) SPEED CONTROL (6) The speed control is used for controlling driving speed and for braking the truck.

• Handle the speed control gently !

VALVE PUSH-BUTTONS (7) The truck has push-buttons for raising and lowering.

• Familiarize yourself with the operation of the push-buttons.

IDENTIFICATION PLATE (8) The identification plate gives the following information: • manufacturer • truck type • serial number • unloaded mass of the truck in working order without a battery and removable attachments • permitted maximum and minimum battery weight • terminal voltage • rated load capacity • CE- label SAFETY REVERSER (9) The safety reverser prevents the driver from getting squeezed between the truck and an obstacle. By pushing it the truck reverses the direction of travel, and stops when the button is released, if the manual control is released.

• Never use the safety reverser for normal driving.

• Check the operation of the safety reverser daily before you start working with the forklift truck.

- 14 CHARGE OF BATTERY WITH THE INTEGRATED CHARGER DEVICE The plug for the power supply of the integrated charger is accessible from the outside of the truck.

• Two LED’s (Yellow - Green) on the cover of the truck indicate the operating status of the charger: • The green LED indicates the presence of main power; • The yellow LED indicates the status of the charge cycle.

To activate the charger extract plug for the power supply from the safety socket on the machine and insert it into the correct outlet (230V ± 10% - 50 Hz). After connecting the power to the charger, the two LED’s will start blinking for some seconds simultaneously. Next the yellow LED will show the status of the charge cycle: • LED is On during phase 1; • LED is flashing quickly during phase 2 • LED is flashing slowly during phase 3 • LED is flashing irregularly during phase 4 • LED is Off when the charge cycle is completed or when the charger no longer powered As long as the charger is connected to the main power, the green LED will be on.

In case of a problem on charge duration, the green LED will start to flash. This may happen if a battery element failed (short-circuit) or when the ambient temperature is too high.

NOTE: • Do not disconnect the battery connector during the charge cycle!

• If the charger remains connected to the power after completing the charge cycle, the charger will automatically restart the charge cycle 48 hours after the end of the last charge to compensate the autodischarge of the battery.

• The power to the charger can be disconnected before the charge cycle has been completed since the charger will memorise its last charge. Repetitive short charge sessions may reduce the lifetime of the battery.

• After charging the battery the main power plug has to be inserted into the safety socket, otherwise all the electric functions of the truck are disconnected.

• DANGER! No inflammable materials are allowed within 2 meters either from the truck under charge or from the charger.

OPERATION DRIVING Before start, make sure that the daily maintenance has been carried out. See ”The Operator’s Daily Routines before Work”.

Switch on the power of the truck and tilt the tiller arm to the driving position. Turn the speed control gently to in the desired direction of travel. To brake or stop the truck, turn the speed control against the truck’s direction of travel so that the motor does the braking.

Steer the truck smoothly because abrupt movements of the tiller arm may cause a dangerous situation, especially when driving at high speed.

• Practice steering and controlling the truck.

• Drive slowly at intersections and when turning.

- 15 STOPPING As a rule you should brake the truck smoothly by turning the speed control against the truck’s direction of travel (tiller arm in position 1).

You should anticipate a situation when you must brake and decrease the speed well ahead. When you release the tiller arm to the up position or press it to the down position, the driving circuit breaks and the brake is switched on (tiller arm in position 2).

HANDLING A LOAD Lift and lower a load with the push-buttons on the tiller arm. Place the load so that its weight is distributed evenly on the lifting forks. The maximum lifting capacity of the truck is given on the identification plate.

Do not overload.

• Handle only undamaged loads.

• Place the load correctly.

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

WARNING: Do not transport badly piled or bound loads. Do not exceed the truck capacity.

EMERGENCY PROCEDURES If the truck or a load falls over or down in a ramp, release your grip from the tiller and warn everybody near you. If the truck behaves unexpectedly, release the tiller arm to the up position, or push it down completely.

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

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

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

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

• Release the hydraulic pressure, before opening the system, by lowering down the forks.

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

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

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

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

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

- 16 DRIVER’S DAILY ROUTINES BEFORE OPERATION • As an operator, you are responsible for the daily checking and maintenance of the truck.

• Carry out the daily maintenance according to the list below before the start of a working day or shift, before the truck is used.

• Neglecting the daily maintenance may decrease the safety and reliability of the truck.

• Notify the site supervision immediately if you notice any error or deficiency during the check.

• Check the truck externally to see that no oil leaks can be observed.

• Check all wheels for damage or outer 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.

• 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 by driving slowly forward and backward. Also check the operation of the other electrical functions.

• Make sure that the tiller arm returns to the up position and that the parking brake functions properly.

• Test the sound signal.

• Check the operation of the safety reverser DRIVER’S WEEKLY MAINTENANCE PROGRAM • Check and clean the fastenings of the battery cables.

• Make sure that the air holes of the battery cell plugs are not plugged up.

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

• Check the amount of hydraulic oil in the oil tank, when the forks are in lowered position. Add if necessary.

• Make sure that screws, nuts and pipe connectors are tight.

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

• Clean the truck if necessary.

- 17 NOTE:

DO NOT LET WATER IN THE ELECTRICAL DEVICES, especially if the power is on !

The truck’s lubricating points should be lubricated about once a month: • the turning bearings of the load wheels • the bearings of the side castor wheels • the suspension rail of the drive unit • the turning bearings of the drive unit

OIL RECOMMENDATIONS • Hydraulic oil (11): ISO VG 32 • In freezer warehouses: ISO VG 15 • Fill 3/4 of the tank’s volume.

• Gearbox oil (12): SAE 80W/OP,API:GL4 • Fill to the volume of 0.6 l • Checking the oil level (13) • Lubricating grease (3): NLGI No. 2. containing molybdenum disulphide •In freezer warehouses: NLGI No. 1 or No. 0.

QUARTERLY INSPECTION SERVICE (300 H) It is most economical to make an inspection and regular interval service agreement with your truck dealer.

Only professional service will ensure trouble-free truck operation. Service programme monitoring is facilitated by entering the service dates in a service logbook.

Besides the weekly programme, also the following points need to be inspected and, if necessary adjusted or repaired: • the collectors, carbon brushes and connections of the drive motor and of the pump motor. Clean the carbon dust from the motors • the operation of the speed control • the operation of the speed limiter • the operation of the lifting hydraulics • the microswitches • the contactors and solenoids • the cables • the air gap in the brake • the torque of the drive wheel mounting nuts • the tiller arm gas spring • the function of the lift cylinder • the play of the fork carriage, and the slope of the forks and their condition

- 18 SEMIANNUAL SCHEDULED MAINTENANCE (600 H) In addition to the quarterly and weekly procedures, the following points need to be carried out: • change the hydraulic oil once a year (1200 h) • change the gearbox oil once a year (1200 h) • clean the oil filter • check the operation of the hydraulics and the pressure-limiting valves • check the fastening of the gearbox and the amount of gearbox oil (see 17.4) • check the fastening of the tiller arm • check the condition of the side castor wheels and load wheels • check the wear of the drive wheel

LOCATION OF THE FUSES IN THE SPEED CONTROL UNIT Steering circuit fuses Drive current fuse Lift motor fuses

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

- 19 -

TROUBLESHOOTING

SYMPTOM:

FAULT:

PROCEDURE:

Truck does not move

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

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

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

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

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

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

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

• • • • • •

Battery does not charge

• Check the connection • Replace the fuse

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

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

• Check the cells current and specific gravity. Add water and / or acid when necessary. See Section "Recharging the battery"

Service Manual AC Power Pallet

22.07.2005

Revision Level:3

Table of Contents 1. Introduction ........................................................................................ 1 1.1. Purpose and target users ............................................................ 1 1.2. Structure ...................................................................................... 1 1.3. Acquiring spare parts .................................................................. 2 1.4. Waste disposal ............................................................................ 2 1.5. Further information ...................................................................... 2 2. Operating the truck ............................................................................ 5 2.1. Safety guidelines for use ............................................................. 5 2.2. Operating environment ................................................................ 7 2.3. Control devices ............................................................................ 9 2.4. Driving the truck ........................................................................ 13 2.5. Load handling ............................................................................ 16 2.6. Charging the batteries ............................................................... 16 2.7. Transportation and storage ........................................................ 18 3. Regular maintenance ...................................................................... 21 3.1. Safety guidelines and preparation ............................................. 21 3.2. Maintenance guidelines ............................................................. 23 3.3. Periodic maintenance procedures ............................................. 25 3.4. Daily maintenance ..................................................................... 27 3.5. Weekly maintenance ................................................................. 37 3.6. Monthly maintenance ................................................................ 41 3.7. Semi-annual maintenance (after 600 hours of operation) ......... 42 3.8. Annual maintenance (after 1,200 hours of operation) ............... 54 3.9. Lubricant and fluid recommendations ....................................... 61 4. Electrical operation and maintenance ............................................. 63 4.1. Electrical operation .................................................................... 63 4.2. Console ..................................................................................... 71 4.3. Traction controller ...................................................................... 74 4.4. Electrical maintenance and repairs ........................................... 95 5. Hydraulic operation and maintenance ........................................... 105 5.1. Hydraulic operation .................................................................. 105 5.2. Hydraulic maintenance and repairs ......................................... 108 6. Mechanical maintenance ............................................................... 113 6.1. Replacing wheels .................................................................... 113 6.2. Replacing the tiller arm gas spring .......................................... 116 6.3. Lever system maintenance ...................................................... 117

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i

1. Introduction This service manual provides information on maintaining and repairing the 1,300, 1,600 and 2,000 kg capacity models of the pedestrian power pallet truck. The manual aims to provide information necessary for keeping the truck fully operational for its entire service life.

1.1. Purpose and target users This service manual is intended as a reference source for the professionals responsible for maintaining these trucks. The maintenance and repair instructions in this manual are presented with the assumption that the reader is familiar with the operation and maintenance of powered trucks. Do not attempt any procedure described in this manual or elsewhere unless you have the authority, expertise and qualifications for the task.

Always adhere to all local regulations that apply to the work being done.

The information in this manual covers the common procedures necessary for keeping a truck in working order. The manual does not cover nor does it attempt to cover every eventuality that may arise when servicing trucks. Every effort has been made to ensure that the information given in this manual is correct and current. The information can, however, be incorrect, outdated or otherwise not suitable to the truck model or task. Make sure that you have all the latest information regarding the truck model and the maintenance task. This includes, but is not limited to, the most up-to-date schematic diagrams and special procedure instructions. Contact your supplier or technical support for information on obtaining the latest documentation.

1.2. Structure This manual is divided into five main chapters. Chapter 2 Operating the truck is based on the user’s manual. The chapter is intended as a reference source for the maintenance professional to study the use of the truck model being serviced.

Chapter 3 Regular maintenance presents the regular maintenance procedures of the truck. This chapter also gives the general guidelines for safety and maintenance.

1

Chapter 4 Electrical operation and maintenance examines the electrical aspects of the truck. It covers the electrical operation of the truck, and gives information on using the console to troubleshoot problems and to modify controller parameters. It also gives information on irregular electrical maintenance tasks.

Chapter 5 Hydraulic operation and maintenance examines the hydraulic operation of the truck and provides instructions for hydraulic maintenance tasks.

Chapter 6 Mechanical maintenance provides instructions for common mechanical maintenance procedures.

1.3. Acquiring spare parts When you need spare parts, contact your supplier. Always use original manufacturer-approved spare parts. To ensure that you receive the correct items, have the following information ready when ordering spare parts: 1.

Truck type

2.

Serial number of the truck

3.

Ordering numbers for the spare parts

4.

Spare part product names

5.

Required quantity of parts

1.4. Waste disposal When performing maintenance tasks with or on trucks, adhere to all local regulations governing the proper disposal of produced waste. Be especially careful when handling and disposing of hazardous waste, such as hydraulic and transmission fluids, lubricants and batteries. Reuse and recycle materials when possible.

1.5. Further information Contact your supplier or technical support when you require information on using, maintaining and repairing the truck. Before attempting any maintenance procedure, make sure that you have

2

the correct and most current version of all the necessary documentation.

3

2. Operating the truck This chapter presents instructions on operating the truck. The content is based on the user’s manual. The chapter does not contain the entire material of the user’s manual and should not be used as such. It is intended as a reference source for maintenance personnel, so that a separate user’s manual is not required. The chapter covers, among other topics, usage safety, the recommended usage environment, the truck’s controls, handling loads and charging the batteries.

2.1. Safety guidelines for use This section presents safety guidelines for operating the truck in normal circumstances. Please refer to Section 3.1 Safety guidelines and preparation and Section 3.2 Maintenance guidelines for information on safety and preparation for maintenance tasks.

The trucks have been designed and built to operate in an indoor environment. They are intended for handling and transporting goods and materials preferably on pallets. Do not use the truck for any other than the intended purpose. Follow the operating instructions in this section or in the user’s manual. A truck may cause danger to persons or materials if operated incorrectly. Do not attempt to use a truck before you have familiarised yourself with its operating instructions.

The trucks covered in this manual conform to the EN 1726-1 standard, which ensures their safety according to the EU machine directive 98/37/EC. The trucks also conform to the EN 12895 standard, ensuring their safety according to the electromagnetic compatibility (EMC) directive 89/336/EEG. The trucks are designed for light and heavy industry use (EN 50081-1 and EN 50082-2).

The most important safety guidelines are mentioned in this manual. Regulations vary from country to country, and you are expected to be familiar with the regulations and standards valid in your area.

2.1.1. Instructions for site supervision •

Familiarise yourself with the truck’s operating instructions.

5

•

Train the truck’s operators in the use, safety and regular maintenance of the truck.

•

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

2.1.2. Occupational safety •

Keep the truck clean and in good working order. Carry out the daily and weekly maintenance checks according to the maintenance schedule and instructions to avoid faults and operational errors.

•

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

•

Do not repair the truck without permission from the site supervisor.

•

In the event of a malfunction, switch off the truck’s power and notify the site supervisor.

•

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

•

Immediately notify the site supervisor of an accident or injury.

In such a case, leave the truck at the location of the accident.

•

Do not use the truck for a purpose or in an environment for which it is not intended. The truck must be specifically equipped for use in a cold environment.

2.1.3. Requirements for the truck operator

6

•

At least 18 years old.

•

Sufficient physical (e.g. good hearing and sight) and mental abilities for operating the truck without risks.

•

Appropriately trained, and familiar with the appropriate operating, safety and maintenance instructions.

•

Has permission from the site supervisor to operate the truck.

•

Knows and masters the driving and operational features of the truck.

2.1.4. Emergency procedures If the truck or a load falls over or down on a ramp, release your grip from the tiller and warn people near you. If the truck malfunctions, release the tiller arm to the upright position or push it down completely. This disables the driving circuitry. In case of a malfunction, always power down the truck either normally or by pressing the emergency stop button on the main panel, if possible.

2.1.5. Noise During use, the truck may subject the user to a noise level of 76 dB (A).

2.1.6. Work in dangerous environments Trucks used for working in areas susceptible to fire, explosion or other hazards must be specially equipped. A standard truck is not suitable for work in hazardous environments. Contact your supplier for specially designed and equipped trucks suitable for hazardous environments.

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

2.2. Operating environment Use the truck in dry, indoor facilities with hard, even and level floors. You can operate the truck continuously in temperatures between +5°C and +25°C, and for short periods in temperatures between 0°C and +45°C. If you require a truck to operate in temperatures below 0°C, contact your supplier to obtain a truck outfitted with optional cold store equipment. Such a truck can be used in temperatures down to –35°C.

7

Never use the truck: •

To transport or lift people

•

In environments with a fire hazard

•

In environments with an explosion hazard

•

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

2.2.1. Free space

NOTE

Make sure that the truck has sufficient moving space with respect to overhead structures and other obstructions. Before driving through aisles or door openings, ensure that there is enough space for the truck, the load and yourself. Reduce your driving speed in confined spaces.

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

2.2.2. 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 or driving surface.

2.2.3. Using elevators Obtain permission from the site supervisor to use an elevator to transport the truck between floors. Make sure that the combined weight of the truck, the load and any persons present 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.

8

NOTE

Make sure that there are no people in the elevator when driving the truck in or out. The parking brake of the truck must be on before the elevator moves. Release the tiller arm to the upright position to deactivate the drive and engage the parking brake.

2.2.4. Working on ramps

NOTE

Obtain permission from the site supervisor to drive the truck on a slope or ramp. When the truck is loaded, travel with the load pointing uphill. Without a load, you can travel with the forks pointing downhill.

Do not turn the tiller arm abruptly on a ramp, as the truck might overturn.

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

2.3. Control devices The truck has control devices in two locations: the main control panel and the tiller arm head assembly. The main panel houses the main key switch, the charging safety socket and plug, and different operational indicators. The tiller arm head assembly houses the controls needed to drive and use the truck.

2.3.1. Main control panel The main control panel is located on top of the main truck chassis.

9

Figure 2.1. Main control panel

2.3.1.1. Charger plug and safety socket (1) The charger plug is used to charge the truck’s battery from a normal electrical mains supply with the internal charger. During normal operation, the charger plug is in the safety socket. The truck cannot be driven if the plug is removed from the socket.

Refer to Section 2.6 Charging the batteries for more information on charging the truck’s battery.

2.3.1.2. Main key switch and emergency stop button (2) The main key switch is used to control power from the battery to the truck’s electrical system. The switch is equipped with a key that can be removed to prevent unauthorised use. To remove the key, press it down, turn it counterclockwise and pull it out.

When the key is in place, the truck’s power can be turned on by lifting the key to the up position. Press the key to the down position to turn off the truck’s power.

The key switch also functions as an emergency stop button. In an emergency, press the key downwards to remove electrical power from the truck.

2.3.1.3. Status LED (3) The status LED gives an indication of the current state of the truck. When the truck is powered up, normally the status LED is constantly illuminated. If the status LED flashes, this may indicate an internal fault.

10

The status LED indicates the possible fault with a distinct repeating flashing sequence. For example, four flashes and a pause indicates a low battery. The error indication may also be due to incorrect operation. Switch off the truck's power and turn it back on with the tiller arm in the upright position and without giving the truck any commands through its controls while it starts up. If the status LED continues to flash, power down the truck and contact local maintenance staff.

2.3.1.4. Display unit (4) The display unit shows the accumulated operating time of the truck in hours. It also displays the battery charge level. If an internal fault has occurred, the display unit also shows the error code.

2.3.2. Tiller arm head controls The tiller arm head assembly contains the controls used for driving the truck and controlling the forks.

Figure 2.2. Tiller arm controls

2.3.2.1. Safety button (1) The safety button is located at the far end of the tiller arm. Its purpose is to prevent the operator from being crushed between the truck and an object. The safety button is functional when the

11

truck is being driven in the direction of the tiller arm. It is inactive in the other direction.

When the safety button is pressed while the truck is being driven in the direction of the forks, the truck immediately stops and reverses its movement for a short period. The intensity of this function depends on the speed of the truck.

WARNING! The operation of the safety button is verified as part of the daily maintenance checks, which must be performed each day before using the truck. Never use a truck with a faulty safety button. Never use the safety button to manoeuvre the truck.

2.3.2.2. Lifting and lowering controls (2) Use these controls to lift and lower the truck’s fork carriage. You can use the controls on either side of the tiller arm.

2.3.2.3. Horn button (3) Press this button to activate the truck’s horn.

2.3.2.4. Steering (4) The truck is steered by moving the tiller arm from side to side.

The drive wheel is directly connected to the tiller arm and turns with it. The tiller arm can be turned 100 degrees in both directions from the centre position.

The vertical position of the tiller arm affects driving: The truck can only be driven when the tiller arm is in the driving position, which is the area between the two extremes. The truck’s traction is disabled when the arm is in the upright or the bottom position.

The restriction can be removed by pressing the brake release button.

2.3.2.5. Accelerator controls (5) The two winged rotating wheels control the direction and acceleration of the truck. The movement direction is determined by the direction in which the controls are displaced from the neutral position. The amount of displacement determines the truck’s speed in the given direction. The accelerator control is also used to reduce the truck’s speed by either releasing it to the neutral position or by turning it in the opposite direction to movement.

12

2.3.2.6. Brake release button (option) The brake release button is located on the top of the tiller arm head. The brake release can be used to remove the driving restriction when the tiller arm is in the upright or the bottom position. This can be useful in confined spaces. The brake release is intended to be used in special situations and should not be used constantly.

2.4. Driving the truck Before attempting to drive a truck, make sure that the daily maintenance checks have been carried out.

To power up the truck: •

Ensure that the charging plug is in the safety socket.

•

Ensure that the tiller arm is in the upright position.

•

Ensure that no controls or buttons are depressed.

•

If the key is not in place, insert it into the key switch and turn it clockwise.

•

Lift the key upwards to turn on the main power of the truck.

If, after the above procedure, the status LED is constantly illuminated, the truck is powered up and ready to be used. If the truck is equipped with a display unit, it activates and shows the accumulated operating time in hours and the charge level of the battery. Before starting to use the truck, check that the battery level is sufficient.

2.4.1. Driving instructions Always use care when driving a truck. Even without a load, the truck is heavy and can cause damage or injury if driven carelessly. Adjust your driving speed to the conditions. Reduce speed when operating in confined spaces or when transporting heavy or unstable loads.

To start driving the truck: •

Power up the truck, check that the status LED is constantly illuminated and that the battery charge level is sufficient.

13

•

Take hold of the tiller arm handles and lower the tiller arm to the driving position.

•

Ensure that there are no obstructions.

•

Turn the accelerator carefully in the desired direction.

The truck should start to slowly move in the selected direction.

Turn the accelerator further to increase the truck’s speed. Reduce the deflection to reduce the speed and release the accelerator to the neutral position to stop.

If you wish to reduce speed more rapidly, turn the accelerator control to request movement in the opposite direction. If you keep the accelerator held after the truck has stopped, it begins to move in the requested direction at the set speed.

Use the tiller arm to steer the truck. When driving the truck in the direction of the tiller arm, walk beside it and hold the tiller arm handle with one hand. When driving in the opposite direction, walk behind the truck and keep both hands on the tiller arm handles.

2.4.2. Safety guidelines for driving Before operating the truck, ensure that you have the appropriate training and skills. If you have little prior experience with this type of truck, take time to practise driving and operating it in a safe environment before actually using the truck.

Keep the following guidelines in mind when driving a truck:

14

•

Always adjust your driving speed to the situation. Consider the load, visibility, the environment, other persons and any obstructions.

•

Reduce your speed in confined spaces, near edges, at intersections, on ramps, on rough or slippery surfaces and when driving near other persons.

•

Accelerate and decelerate smoothly to avoid the load slipping or tipping.

•

Use smooth motions while steering the truck, especially when it is loaded to reduce the risk of the load or truck overturning.

•

When possible, keep both hands on the tiller arm handles.

•

Be especially careful when driving on slanted or uneven surfaces.

•

Do not drive over objects.

•

Be careful when driving with a load that reduces your visibility.

Use an assistant if necessary.

•

Always drive at a speed that enables you to stop the truck safely.

2.4.3. Stopping and parking the truck The speed of the truck is electrically controlled through the motor.

In addition to acceleration, the motor is used to reduce the truck’s speed.

To slow down the speed of the truck while it is being driven, reduce the deflection of the accelerator by moving it back towards the neutral position. The truck's speed decreases until it travels at the speed that corresponds to the accelerator’s deflection.

Return the accelerator control to the neutral position to decelerate completely and bring the truck to a standstill. To reduce the speed more rapidly, turn the accelerator against the direction of movement to request traction in the opposite direction.

When you wish to park the truck or otherwise leave it stationary, stop it first and then release the tiller arm to the upright resting position.The truck has an electrical parking brake, which engages automatically when the truck comes to a standstill and when the accelerator is not deflected. Releasing the tiller arm to the upright position also disables the drive.

The electrical parking brake remains engaged when the truck’s power is turned off. You should always turn off the truck’s power when leaving the truck standing or unattended for any length of time.

When the truck is not being used, it should be parked in a reserved parking place. Lower the fork carriage and release the tiller arm to the upright position. Turn off the truck by pressing down the key switch. For additional security, remove the key from the key switch. Ensure that the truck cannot move by itself or be accessed by unauthorised persons.

15

NOTE

Never park the truck or leave materials in front of fire exits, fire extinguishers, etc. Do not park on a slanted surface.

2.5. Load handling The truck has been designed for transporting materials on pallets.

When transporting a load, keep in mind the following guidelines: •

Always secure a load before transporting it.

•

Always drive the truck with the forks as low as possible.

•

Accelerate, decelerate and steer carefully.

•

Never place any part of your body between the structures of the truck and the fork carriage.

•

Be especially careful when transporting a load that is wider than the truck.

•

Only handle undamaged loads.

•

Place the load so that its weight rests as evenly as possible on the forks.

•

On slopes and ramps, place yourself above the load.

•

Do not overload the truck.

•

Verify the truck’s lifting capacity from the identification plate, which is fixed to the underside of the tiller arm.

WARNING!

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

2.6. Charging the batteries The truck is equipped with rechargeable batteries that should be fully recharged before the truck is taken into use each day.

Charging the batteries should be the responsibility of a trained professional. Lead-acid batteries contain a corrosive acid solution and can contain a considerable amount of stored electrical energy. Therefore, the responsible person or persons should be qualified and take appropriate precautions. See Section 3.1 Safety guidelines and preparation and Section 3.2 Maintenance guidelines for information on safety and preparation for maintenance tasks. See Chapter 3 Regular maintenance for

16

information on regular battery maintenance procedures and Section 4.4.1 Battery maintenance for more information on battery maintenance.

Adhere to the following guidelines when working with batteries: •

Do not handle a naked flame or smoke near batteries, as batteries can emit explosive gases.

•

Do not place conductive tools or other objects on top of the batteries to avoid short-circuiting.

•

Before charging wet lead-acid batteries, make sure that the cell caps are firmly fastened to prevent the corrosive battery solution from splashing.

•

Wear protective gear appropriate for handling batteries, which contain a corrosive acid solution.

•

Make sure that the area where batteries are charged is well ventilated to rapidly dissipate any produced explosive gases.

•

Always charge a battery before storing it or if it is not used for a long period. Storing a battery in a low-charge state can permanently damage it.

The battery can be charged either with an external or an internal battery charger. If an external battery charger is used, follow the instructions given by the manufacturer or supplier of the charging device. When using an external battery charger, ensure that it is suitable for the battery type.

A truck with an internal charger can be charged from a normal wall socket. To charge a truck with an internal battery charger: 1.

Park the truck in a reserved charging place.

2.

Turn off the truck’s power from the main key switch.

3.

Unplug the charging plug from the safety socket.

4.

Connect the plug to a suitable mains socket.

The charging indicator on the truck’s control panel indicates the progress of charging. The indicator flashes red at the beginning of charging. It changes to yellow to indicate 80% battery charge.

17

When the indicator turns to green, the truck’s batteries are fully charged and the charger can be unplugged. Even if the charger is not unplugged after charging is completed, it stops charging automatically.

A fault in the internal charger is indicated by the charging indicator as follows: •

Flashing green: Timeout alarm The charging duration exceeds the preset maximum value.

Verify that the battery has the correct capacity.

•

Flashing between red and yellow: Battery current alarm Loss of output power control. Indicates a fault in the control logic.

•

Flashing between red and green: Battery voltage alarm Loss of output power control. Indicates a fault in the control logic.

•

Flashing red, yellow and green in sequence: Temperature alarm Internal components have overheated. Verify fan operation.

•

Flashing between yellow and green: Configuration alarm An unavailable configuration has been selected. Verify selector position.

2.7. Transportation and storage Lift the truck only from a marked lifting point. Make sure that the capacity of the lifting device is sufficient. Only tow the truck with the drive wheel lifted from the surface.

18

Figure 2.3. Lifting point label If the truck is not used for a long period, it should be stored in a cool (above 0°C) and dry place. Make sure that the storage surface is even and support the truck so that weight is taken off the drive wheel. Fully charge the truck’s battery before storage and recharge it every 2 to 3 months of storage to prevent damage. Also check the level of battery fluid regularly and add fluid if necessary. If the truck is stored for over a year, change its hydraulic fluid annually.

If the truck has been stored for several months, perform the procedures described for semi-annual maintenance (Section 3.7 Semi-annual maintenance (after 600 hours of operation)) before returning it to use. For shorter storage periods, normal daily maintenance checks are sufficient before returning the truck to use.

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3. Regular maintenance Regular maintenance is the best way of keeping a truck fully operational and safe for the users. The procedures described in this chapter should be carried out according to the schedule outlined in Section 3.3 Periodic maintenance procedures.

Even though daily maintenance checks can be carried out without special training, this manual assumes that the reader is a professional trained in the service of trucks. Therefore, the presented maintenance and repair instructions should be followed only by professional service personnel.

3.1. Safety guidelines and preparation Do not attempt any maintenance or repair procedure unless you are authorised and qualified to carry it out. To service trucks you must be qualified to work on both electrical and hydraulic systems. Before planning maintenance actions on a truck, ensure that you are sufficiently familiar with the operation and use of the truck type and model. Make sure that you have the most current version of this service manual, as well as all the necessary and most current versions of schematic diagrams, charts and any other information needed for the maintenance tasks.

Perform maintenance and repair tasks only in a suitable environment. The service area must be safe for the servicing personnel, as well as for any other persons in its vicinity. The area must also be safe and suitable for performing electrical, hydraulic and mechanical maintenance procedures. The area must be kept clean. Any fluid stains, waste and unnecessary equipment must be cleared from the service area before and during maintenance. Make sure that the service area is well ventilated.

To uphold personal working safety, make sure that you are appropriately prepared to perform servicing. Ensure that you have the appropriate clothing for the tasks. This includes protective clothing, footwear and gloves, as well as other protective equipment required by the task, such as eyewear, a mask and hearing protection. Take the appropriate precautions when handling harmful, corrosive or toxic chemicals. Never use bare hands or other parts of your body to test for leaks etc.

Remove personal jewellery to reduce the risk of causing short

21

circuits. When working on trucks with any panels open, adhere to all regulations governing electrical and hydraulic maintenance.

When performing maintenance procedures on or near batteries, take special care to protect yourself and your environment. The battery fluid in battery cells is a corrosive acid solution, which will burn if it comes into contact with bare skin or eyes. Never handle a naked flame or smoke a cigarette near batteries. Be careful with conductive tools near batteries, especially if any battery contacts are exposed. Always disconnect the battery from the truck before removing it.

Do not attempt a maintenance procedure unless you have all the necessary tools and equipment required by the task. Use only spare parts approved by the manufacturer. Use only the correct fluids and lubricants. Refer to Section 3.9 Lubricant and fluid recommendations for the recommended lubricants and fluids.

Use jacks of suitable design and sufficient capacity to lift the truck. Remember balance when lifting with a jack: position the jack so that the truck’s weight rests evenly on the supports and there is no risk of it overturning. Always secure the truck after lifting it with a jack. Do not work underneath a truck that is supported only by jacks.

Always turn off the main power of the truck and release hydraulic pressure before opening any covers. If any cover is open, turn on the main power or use the hydraulic system only if it is necessary for accomplishing the maintenance task. Disconnect the main battery connector unless electrical power is required.

Take extreme care when working near electrical components.

Even if the main power is switched off, there may be considerable electrical charges in truck components, such as in the batteries and in power capacitors.

Note that some components become hot during operation. Allow the truck to cool down after use before opening any covers.

Especially the components of the electrical and the hydraulic system can heat up considerably during operation.

When larger repairs are involved, for example, when welding, the battery should be disconnected or removed. When welding is necessary, remove any paint or other finishing over a radius

22

of at least 100 mm from the welding point to reduce the possibility of toxic gases being produced.

Adhere to all local (national and site-specific) regulations and recommendations governing the working area and the maintenance procedures that you are performing. This includes regulations on personnel safety, the handling of materials, environmental safety and disposal of waste.

Do not perform a maintenance procedure, if you are uncertain of how it should be carried out. Do not modify the truck in any way that might reduce its structural integrity or affect its safe use.

If you have doubts or concerns about a procedure described in this manual, contact the local product representative or the manufacturer’s technical support.

Return a truck to normal use only after all regular and other necessary maintenance procedures have been completely carried out and the truck is deemed to be in full working order.

3.2. Maintenance guidelines Reserve a sufficiently large area for servicing the truck. The area should be large enough for you to be able to test all of the truck’s normal operating functions, such as driving and lifting.

Determine the model of the truck under maintenance from the identification plate that is located on the underside of the tiller arm (when viewed from the driving position). The identification plate should be easily readable when the tiller arm is in the upright position. The three truck models covered by this manual are distinguished by their nominal lifting capacity. The identification plate indicates the capacity of the truck as 1,300, 1,600 or 2,000 kg. The truck models differ slightly in both regular and irregular maintenance and repair procedures. Most of the regular maintenance is identical for the three models, and the differences are indicated where necessary.

23

Figure 3.1. Identification plate All the truck models have two main covers that can be opened: the main cover and the top cover. In addition, the 1,600 and 2,000 kg capacity trucks have a separate battery compartment cover on top of the truck between the top cover and the forks.

This battery compartment cover is hinged and can be opened by lifting it. The main and top panels are held in place by screws on both sides of the truck chassis. The two topmost screws on either side hold the top cover, while the two lower screws on either side hold the main cover in place.

Figure 3.2. Main cover fixing screws To open the main or the top cover on any truck model, loosen the fixing screws enough for the cover to be removed, but do not remove the screws entirely. The screws move a fixing bracket, which holds the cover in place.

24

All of the covers on a truck should be closed when its functions are tested. Open the covers only when it is necessary for accomplishing the maintenance or repair task.

Some maintenance and repair tasks require the truck to be lifted.

Only suitable lifting equipment should be used to lift a truck. Use only marked lifting points. When this is not possible, make sure that you choose lifting points that can securely support the weight of the truck without being damaged. Remember to secure a lifted truck so that it does not pose a risk to personnel safety.

3.3. Periodic maintenance procedures The periodic maintenance procedures are grouped based on the intervals after which they must be performed. This section lists the procedures for your convenience. If faults or damage are encountered during any of the periodic maintenance procedures, the maintenance process should be halted and the fault or damage fixed. After the truck has been repaired, the maintenance process should be restarted from the beginning. Always begin with the daily maintenance checks before using the truck after any repairs or modifications.

The regular maintenance schedule: Daily maintenance •

Check the operation of the main key switch and the emergency stop.

•

Check that the battery is charged.

•

Visually check the truck for any apparent damage.

•

Check the condition of the wheels.

•

Check the fastening of the two batteries on 1,300 kg capacity trucks and that the battery is securely in place on 1,600 and 2,000 kg capacity trucks.

•

Check the level of battery fluid in each battery cell (does not apply to 1,300 kg capacity trucks).

•

Check the transmission for leaks.

•

Visually check the condition of hydraulic tubing and couplings.

25

•

Test the operation and condition of the tiller arm.

•

Test the operation of the safety button.

•

Test the driving functions: controlling direction and speed, steering, the tiller arm position sensors, and the horn.

•

Test the operation of the parking brake.

•

Test the operation of the lifting hydraulics and controls.

Weekly maintenance •

Check that all fixing hardware and tube couplings are secure.

•

Check and clean the batteries and battery cabling.

•

Check the amount of fluid in the hydraulic system.

•

Check the condition of identification plates and labelling.

•

Clean the truck if necessary.

Monthly maintenance •

Lubricate the drive unit bearings on 2,000 kg capacity trucks (does not apply to 1,300 or 1,600 kg capacity trucks).

Semi-annual maintenance (after 600 hours of operation) •

Complete all the daily and weekly maintenance tasks.

•

Check the electrical connections and cabling.

•

Check the angle and condition of the forks.

•

Check the wear of the brake pad.

•

Check the fastening of the transmission and the drive unit on 2,000 kg capacity trucks (does not apply to 1,300 or 1,600 kg capacity trucks).

•

Check the amount of transmission fluid on 2,000 kg capacity trucks (does not apply to 1,300 or 1,600 kg capacity trucks).

Annual maintenance (after 1,200 hours of operation) •

26

Change the hydraulic fluid.

•

Change the transmission fluid on 2,000 kg capacity trucks (does not apply to 1,300 or 1,600 kg capacity trucks).

3.4. Daily maintenance The daily maintenance procedures are vital for keeping a truck fully operational. They should always be carried out thoroughly each day before using the truck. Daily truck maintenance can be the responsibility of a person that does not have professional training. In this manual, it is assumed that the daily maintenance procedures presented below are carried out by a maintenance professional.

If any damage or other problems that affect the use or safety of the truck are encountered during daily maintenance, the truck must not be used until it is fully operational.

3.4.1. Checking the operation of the main key switch and the emergency stop Before starting any other maintenance tasks, check that the main key switch and the emergency stop button operate properly. If the key switch is faulty or the emergency stop function does not operate, remove the truck from use use immediately. Return the truck to use only after it is fully operational. Refer to Chapter 2 Operating the truck for information on the truck’s controls.

Begin by turning the main key switch on. The truck should power up and indicate standby mode by illuminating the indicator LED. If the truck is equipped with an hour meter, the meter should activate and indicate the accumulated operating hours and the level of battery charge. Turn the main key switch off to test that the truck shuts down.

27

Figure 3.3. Control panel The emergency stop button is integrated into the main key switch.

To test the emergency stop button, first switch the truck on normally. With the truck active press the emergency stop button to check that it deactivates the truck immediately. To reactivate the truck, lift the button into the operating position.

3.4.2. Checking the battery charge It is assumed that the truck’s battery is fully charged each day before daily maintenance and use. The battery can be charged with an external or internal charger. If an external charger is used, you should follow the instructions issued by the manufacturer or supplier of the charger.

If the internal battery charger is used, follow the instructions in Section 2.6 Charging the batteries. An internal charger is equipped with a charging progress indicator on the truck’s control panel. Ensure that the indicator indicates a fully charged battery before taking the truck into use.

If the truck is equipped with an hour meter, the meter shows the approximate level of battery charge when the truck’s main power is switched on. After charging, this indicator should read full battery charge.

If the battery does not seem to charge properly, does not hold a charge or presents other problems, refer to the battery

28

maintenance section in Chapter 4 Electrical operation and maintenance for more information.

3.4.3. Checking the truck for external damage Visually check the truck for any apparent problems or external damage. If damage is apparent, its extent should be checked and any necessary repairs made before continuing with regular maintenance. If the damage in any way affects the use or safety of the truck, the truck must be taken out of use until it is fully operational.

3.4.4. Checking the condition of the wheels The truck has three wheel types: drive, load and castor. The drive wheel is located immediately under the tiller arm anchoring point and supports a considerable portion of the truck’s weight.

It is attached to the drive motor via the transmission to propel the truck, and it is turned with the tiller arm to steer the truck.

Figure 3.4. Drive wheel The load wheels are located near the ends of the forks. Their main purpose is to support the weight of the load. Depending on

29

the truck model, there is either a single or a double load wheel in each fork.

Figure 3.5. Load wheels The side-supporting castor wheels are located under the main chassis on either side of the drive wheel. They support the truck when it is driven and prevent it from tilting, as there is only one drive wheel. The castor wheels turn automatically to follow the direction of travel. They are equipped with suspension springs.

30

Figure 3.6. Castor wheel Remove the main cover to gain better access to the wheels.

Check all the wheels on a truck for damage and wear.The wheels should wear evenly, and there should be no flats or holes in the wear surface. The wheels should also turn smoothly on their axles and there should not be play in the bearings. Even wear can be tested by driving the truck on a smooth surface to test that all the wheels turn and the truck rides smoothly. If a wheel or a bearing has sustained damage that affects use or if its surface has worn completely, it should be replaced. Refer to Chapter 6 Mechanical maintenance for information on replacing and servicing wheels.

3.4.5. Checking that the batteries are securely fastened The fastening of the batteries depends on the truck model. The 1,300 kg capacity truck does not have a separate battery compartment. Its two service-free batteries are located within the main chassis, on both sides. These batteries are held in place by straps. Open the main cover to perform this check. Check that the straps are tight and that both batteries are securely held in place.

31

Figure 3.7. Battery arrangement on 1,300 kg capacity trucks Trucks with a capacity of 1,600 and 2,000 kg have a separate battery compartment between the main chassis and the forks.

On the 1,600 kg capacity truck, the battery assembly sits in its well and is kept in place by its own weight. The implementation is similar on the 2,000 kg capacity truck, but the battery assembly is also held in place with a fixing bracket. Open the battery compartment cover to check the battery assembly. In both cases, check that the battery assembly sits evenly at the bottom of the battery well. Check that the bracket is securely fixed on the 2,000 kg capacity truck.

32

Figure 3.8. Battery arrangement on 1,600 and 2,000 kg capacity trucks

3.4.6. Checking the level of battery fluid in each cell NOTE

This check applies only to the 1,600 and 2,000 kg capacity trucks with wet batteries. The 1,300 kg capacity truck has service-free batteries. Make sure that the battery is fully charged before checking the level of battery fluid.

Take appropriate precautions when handling batteries and battery fluid. Battery fluid is a corrosive acid solution and can cause burns if it comes into direct contact with bare skin. Use only approved fluid to fill the battery cells. Refer to Section 3.9 Lubricant and fluid recommendations for fluid recommendations.

Open the battery compartment cover to access the battery cells.

Follow the instructions issued by the battery or battery cell manufacturer for maintaining battery cells in good condition. Use care not to contaminate the solution with impurities. Do not overfill the cells and close the caps firmly to avoid leakage.

33

3.4.7. Checking the transmission for leaks Visually check that there are no apparent fluid leaks in the transmission assembly. Open the main cover to perform this check. The transmission of 1,300 and 1,600 kg capacity trucks is service free and has been filled with grease to last its entire operating life. The transmission of 2,000 kg capacity trucks is fluid-filled and serviceable. It has a filling cap at the top, a checking cap on its side and a draining cap on the underside.

Check that these caps are firmly fastened. Never use your hands to check for leaks. The amount of transmission fluid is checked during semi-annual maintenance (see Section 3.7.6 Checking the amount of transmission fluid (2,000 kg capacity trucks only)).

3.4.8. Checking the condition of hydraulic tubing and couplings Visually check the condition of all accessible hydraulic lines and couplings. Open the main cover to perform this check. The location of hydraulic components differs between truck models, but you should check that all the accessible couplings and tubing in the hydraulic system are in good condition. There should be no evidence of leaks or damage. Follow the hydraulic system from the tank and pump assembly to all couplings.

The operation of the hydraulic system is tested during daily maintenance (see Section 3.4.13 Testing the lifting hydraulics and controls). The amount of hydraulic fluid in the system is checked during weekly maintenance (see Section 3.5.3 Checking the amount of hydraulic fluid). The hydraulic fluid in the system is changed annually (see Section 3.8.1 Changing the hydraulic fluid). If you find any problems or damage in the hydraulic system, the truck must be taken out of use until it is fully operational.

Refer to Chapter 5 Hydraulic operation and maintenance for information on hydraulic maintenance.

3.4.9. Testing the operation and condition of the tiller arm When the truck is not being used, the tiller arm must rest in the upright position. Check that the arm moves smoothly between the top and bottom positions. Check that the gas spring in the tiller arm returns the arm from any position to the upright position.

Check that the tiller arm is securely fastened at its base. Check for any unwanted play in the moving parts. Note that the position of the tiller arm affects driving (see Section 3.4.11 Testing the

34

speed control unit, steering and the horn). If the tiller arm does not function properly or if it has sustained damage, the truck must be taken out of use until it is fully operational. Refer to Chapter 6 Mechanical maintenance for information on mechanical maintenance.

3.4.10. Testing the safety button WARNING!

Never use a truck with a faulty safety button!

Check the operation of the safety button immediately after the main power switch is turned on. Test the operation of the safety button before continuing with the other operational tests.

Close all the covers before you switch on the main power. For the remaining daily maintenance tests, you have to switch on the truck’s main power. Refer to Chapter 2 Operating the truck for information on the truck’s controls.

The safety button is located at the far end of the tiller arm. Its purpose is to prevent the user from being crushed between the truck and a solid object. The safety button works only when moving in the direction of the tiller arm. If the button is pressed while moving, the truck should stop immediately and reverse its direction for a short time. The intensity of the reversing action is proportional to the movement speed.

Figure 3.9. Safety button

35

Check the operation of the safety button by pressing it while driving the truck slowly in the direction of the tiller arm. If the safety button does not function properly, halt the maintenance process immediately and take the truck out of use until the safety button is fully operational.

3.4.11.Testing the speed control unit, steering and the horn Continue with this test only if the safety button of the truck is operational. Refer to Chapter 2 Operating the truck for information on the truck’s controls and driving.

36

1.

Begin by taking hold of the tiller arm and lowering it from the upright position to the driving position. Do not lower it to the bottom position.

2.

Use the accelerator on either side of the tiller arm to test the speed control. Move the accelerator gently in the forward direction. The truck should accelerate smoothly while the controller is moved. Reduce the speed from the accelerator and the truck should respond smoothly.

3.

Test the reverse direction similarly. Accelerate in the forward direction once again and test reverse braking by moving the accelerator opposite to the direction of the movement. The truck should first decelerate and then begin to move in the opposite direction until the accelerator is released.

4.

Test that the position sensor of the tiller arm operates by attempting to drive when the arm is in the upright and in the bottom position. The truck should not respond to the accelerator when the tiller arm is in these extreme positions.

5.

Repeat the test by moving the tiller arm to the driving position, driving the truck slowly and both pressing the arm down to the bottom position and releasing it to the upright position. In both cases, the truck should stop.

6.

Drive the truck both forward and backward, and test the steering by moving the tiller arm from side to side. Steering should be smooth throughout the available arc in both directions.

7.

Test the horn by pressing the horn button on the tiller arm.

If any problems are encountered during this test, take the truck out of use until it is fully operational.

3.4.12. Testing the parking brake The trucks are equipped with an automatic parking brake. The brake should be active when the main power is off and also when the main power is on unless the accelerator is moved to issue a driving command. Test the parking brake by trying to move the truck. When the brake is active, the truck should not move forward or backward. The parking brake only affects the drive wheel so that the other wheels are still free to turn. The tiller arm can also be freely moved from side to side while the parking brake is active.

3.4.13. Testing the lifting hydraulics and controls Test the operation of the lifting hydraulics by lifting and lowering the forks. Refer to Chapter 2 Operating the truck for information on the truck’s controls. The forks should rise smoothly from the lowest position to the highest position. The forks should stop smoothly when reaching the upper position. If the forks hit the upper position at full speed, there may be a problem in the system. Refer to Chapter 6 Mechanical maintenance for information on mechanical maintenance.

3.5. Weekly maintenance Like daily maintenance, weekly maintenance is important for keeping the truck in full working order. Weekly maintenance should be scheduled for a certain day of the week, so that the maintenance interval does not fluctuate. When weekly maintenance is due, complete all of the daily maintenance procedures first before continuing with the weekly maintenance procedures.

Before beginning, ensure that the main power of the truck is turned off. Open the main and top covers of the truck before commencing with the weekly maintenance procedures. Refer to Section 3.2 Maintenance guidelines for information on how to open the truck’s covers.

Should the weekly maintenance procedures reveal anything that affects the use or safety of the truck, the truck must immediately be taken out of use until it is restored to full working order.

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3.5.1. Checking that fixing hardware and tube couplings are secure Check that all accessible fixing hardware is securely fastened, and that there is no play between parts that should be firmly fixed. Check that all the couplings in the hydraulic system are tight.

3.5.2. Checking and cleaning the batteries and battery cabling The batteries of the 1,300 kg capacity truck are located in the main chassis, so you have to open the main cover to access them. The batteries of the 1,600 and 2,000 kg capacity trucks are located in the battery compartment between the main chassis and the forks. Open the battery compartment cover to access the batteries.

Visually check the condition of the two batteries on 1,300 kg capacity trucks. Visually check the condition of the battery cells on 1,600 and 2,000 kg capacity trucks. Check that all the battery cabling (both to the main poles and between cells) is securely fixed and in good condition, with all the insulators intact.

Over time, grime accumulates onto the batteries. Clean batteries weekly with a non-conductive and non-abrasive dry cloth. Never use water or any other cleaning agent when cleaning batteries or battery cells. Take precautions for handling lead-acid batteries, which contain a corrosive acid solution. Take care to not short-circuit a battery or cell connection.

3.5.3. Checking the amount of hydraulic fluid Check the amount of fluid in the hydraulic system. Before checking the amount, ensure that there is no pressure in the system, that is, that the forks are resting in the lowest position.

The location of the hydraulic tank differs between truck models, but it is visible when the main cover is open. On 1,300 kg capacity truck models, the tank is installed horizontally, and it should be half full.

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Figure 3.10. Hydraulic tank location (1,300 kg capacity truck model) On 1,600 kg and 2,000 kg capacity truck models, the tank is installed vertically, and it should be filled to three-quarters (¾) of the capacity when measured from the bottom of the tank to the bottom edge of the filling tube.

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Figure 3.11. Hydraulic tank location (1,600 and 2,000 kg capacity truck models) If the level of fluid in the tank is below the above amounts, you must add hydraulic fluid to the system. Refer to Section 3.9 Lubricant and fluid recommendations for fluid recommendations.

When adding hydraulic fluid to the system, use only new and clean fluid, and uphold cleanliness during the operation so that contaminants are not introduced into the hydraulic system. Take appropriate precautions when handling hydraulic fluid, as it is harmful.

3.5.4. Checking the condition of identification plates and labelling The main identification plate of the truck is located on the underside of the tiller arm. Check that it is firmly in place, undamaged and fully legible. If the plate is missing or cannot be read, a new one must be fitted. In addition to the identification plate, check that other labelling and markings, such as lifting points or any warnings, are in place and intact.

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3.5.5. Cleaning the truck Clean the truck at least once a week. Keeping the truck clean upholds safety and helps to maintain it in good working condition.

If the truck is kept clean, it is also easier to notice possible damage or wear.

When cleaning the truck, take care not to let water or other fluids enter the main chassis or battery compartment. Never use a pressure washer to clean the truck. Use a dry and clean cloth when possible and use solvents only when necessary. If solvents are necessary, make sure that the chemicals will not harm the surface or component that is being cleaned.

3.6. Monthly maintenance There is only one monthly maintenance procedure, which affects 2,000 kg capacity trucks.

3.6.1. Lubricating the drive unit bearings (2,000 kg capacity trucks only) The bearings of the drive unit must be lubricated monthly. Open the main cover of the truck to gain access to the bearing. The bearing assembly to be lubricated sits above the drive motor and transmission assembly. The lubrication nipple should be used to lubricate the bearings.

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Figure 3.12. Lubrication nipple location Use a grease gun to press the lubricant into the bearing assembly. Refer to Section 3.9 Lubricant and fluid recommendations for lubricant recommendations. After lubrication, move the tiller arm from side to side to distribute the lubricant evenly in the bearing assembly.

3.7. Semi-annual maintenance (after 600 hours of operation) Semi-annual maintenance should be carried out either after half a year or after 600 hours of use, whichever is sooner. If the truck is equipped with an operating time meter, semi-annual maintenance is easy to schedule. If not, the operating time can be read using the console (refer to Chapter 4 Electrical operation and maintenance for more information on using the console).

The semi-annual maintenance procedures should be carried out only by a trained professional.

3.7.1. Daily and weekly maintenance procedures Before beginning the semi-annual maintenance procedures, both the daily and weekly maintenance procedures must be carried out as explained above.

Before continuing to the semi-annual maintenance procedures, ensure that the power to the truck is turned off. The procedures

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described below require that you first remove the main and top covers of the truck.

3.7.2. Checking the electrical connections and cabling Visually check that all the main electrical connections and cabling of the truck from the battery to the drive and pump motors are in good working order. Take appropriate precautions for performing electrical maintenance.

1.

Begin by checking that the main battery connection is firmly in place.

Figure 3.13. Main battery connection (1,300 kg capacity truck model)

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Figure 3.14. Main battery connection (1,600 and 2,000 kg capacity truck models)

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2.

Follow the main cabling from the battery connection to the main fuses. Visually check the condition of the cabling for any damage. One fuse routes power to the drive motor while the other routes power to the pump motor.

3.

Check that all the connections to and from the fuses are secure and that the cable ends are in good working order.

Figure 3.15. Main fuses 4.

Follow the power cable to the traction controller. Visually check that the cable is in good working order.

5.

Check that all the traction controller connections are secure and that the cable ends are in good working order.

Figure 3.16. Traction controller

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6.

Follow the three phases cables from the traction controller to the drive motor while checking the condition of the cables.

Figure 3.17. Traction motor connections

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7.

Return to the main fuses and follow the power cable to the pump contactor. Visually check that the cable is in good working order.

8.

Check that the contactor connections are secure and in good working order.

Figure 3.18. Pump contactor 9.

Follow the cabling from the pump contactor to the pump motor and check the condition of the cables.

Figure 3.19. Pump motor connection 10. Check the security and condition of the main minus connection and all the cabling attached to it.

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Figure 3.20. Universal minus connection After these main connections have been checked, continue by visually checking the condition of the remaining accessible electrical cabling and connections. Pay special attention to binding points and eyelets, as well as other locations where cables or cable groups are or may come under stress during use.

3.7.3. Checking the angle and condition of the forks As the forks are the working part of a truck, they wear and may become damaged during use. It is necessary to monitor their condition regularly. Ordinary wear, such as that of the paint or surface, is acceptable, but any actual damage or deformation of the forks must be fixed before the truck is returned to use.

Verify that the forks are straight and parallel to each other. Check that they do not droop, and that they are at right angles to the main chassis both vertically and horizontally. Also check that they do not hang between the supporting points, that is, the main chassis and the load wheels. A hang of up to 10 mm is acceptable.

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Figure 3.21. Checking the forks

3.7.4. Checking, cleaning and adjusting the brake Check the brake for wear and clean it. The brake on 1,300 and 1,600 kg capacity trucks cannot be adjusted, and the brake pad must be replaced when it has worn. The air gap in the brake of the 2,000 kg capacity truck can be adjusted to compensate for the wear of the brake pad.

Open the main cover to perform these maintenance procedures.

Turn the tiller arm so that you can access the brake. Remember to uphold a clean working environment when working with the brake so that you do not inadvertently introduce dirt into the brake mechanism.

3.7.4.1. 1,300 and 1,600 kg capacity trucks Check the wear of the brake pad and clean the brake. Perform the following procedure to service the brake.

1.

Open the three screws that fix the brake to the drive unit.

Use a 7 mm wrench.

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Figure 3.22. Brake fixing screws 2.

Detach the brake unit carefully.

3.

Detach the brake pad and measure its thickness. The thickness of a new brake pad is 7.6 mm. Replace the pad when it has worn to a thickness of under 7.4 mm.

Figure 3.23. Checking the brake pad thickness

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4.

After checking/replacing the brake pad, clean the brake unit from any accumulated dust with pressurised air. Follow work safety procedures when using pressurised air and use a low pressure.

5.

After the above procedures, reattach the brake unit to the drive unit.

3.7.4.2. 2,000 kg capacity trucks Check the wear of the brake pad by measuring the air gap. If the air gap is within acceptable limits, only cleaning the brake with pressurised air is necessary.

To service the brake: 1.

Remove the rubber gasket over the brake air gap.

Figure 3.24. Removing the rubber gasket 2.

Use a feeler gauge to measure the air gap of the brake.

Measure the air gap at three points near each fixing screw.

The air gap should be between 0.2 and 0.55 mm and equal at each point.The air gap increases as the brake pad wears.

If the air gap is within limits and equal at each point, continue directly to Step 5. Otherwise, continue to Step 3.

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3.

To adjust the air gap, loosen the three fixing screws with a 7 mm wrench and adjust the gap with the adjustment nuts in the brake. Retighten the fixing screws and measure that the air gap is within limits and equal at each point. Repeat this procedure if necessary to set the air gap as near 0.2 mm as possible to allow for wear. If the adjustment is successful, continue directly to Step 5, otherwise continue to Step 4.

Figure 3.25. Adjusting the air gap

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4.

If the brake pad has worn so much that the air gap can no longer be adjusted, the pad should be replaced. If the pad must be replaced, open the brake completely, remove the old brake pad and replace it with a new brake pad. The thickness of a new brake pad should be 8.5 mm.

Reassemble the brake after replacing the brake pad and return to Step 3.

5.

After the brake has been checked and possibly serviced, it must be cleaned. Use pressurised air to remove any accumulated dust from the brake. Follow work safety procedures when using pressurised air and always use a low pressure.

6.

After the above steps, reattach the rubber gasket. Carefully position the gasket so that its skirt falls into the grooves on both sides to seal the enclosure.

3.7.5. Checking the fastening of the transmission and the drive unit (2,000 kg capacity trucks only) Check that the drive unit fixing bolts and the main transmission bolts are securely fastened.

Figure 3.26. Main transmission bolts

Figure 3.27. Drive unit fixing bolts

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3.7.6. Checking the amount of transmission fluid (2,000 kg capacity trucks only) For this check, access the checking hole on the side of the transmission unit. If you need to lift the truck to perform the check, make sure that it remains level while performing this check.

Remember cleanliness and follow fluid safety procedures.

To check the fluid level, open the cap of the checking hole with a 5 mm Allen key. If the fluid level is clearly lower than the edge of the checking hole, you must add transmission fluid. For more information on adding transmission fluid, refer to Section 3.8.2 Changing the transmission fluid (2,000 kg capacity trucks only).

Refer to Section 3.9 Lubricant and fluid recommendations for fluid recommendations.

Figure 3.28. Location of the checking hole

3.8. Annual maintenance (after 1,200 hours of operation) Annual maintenance should be carried out either after a year or after 1,200 hours of use, whichever is sooner. If the truck is equipped with an operating time meter, annual maintenance is easy to schedule. If not, the operating time can be read using the console. Refer to Chapter 4 Electrical operation and maintenance for more information on using the console. The

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annual maintenance procedures should be carried out only by a trained professional.

3.8.1. Changing the hydraulic fluid The hydraulic fluid must be changed once a year on all truck models. The location of the hydraulic system components differs between truck models. Follow the given instructions based on the truck model. Note that the filling cap functions as a breather for the tank, so do not overtighten it or overfill the tank to avoid leakage. Refer to Section 3.9 Lubricant and fluid recommendations for fluid recommendations. Remember cleanliness and follow the precautions for handling harmful fluids.

3.8.1.1. 1,300 kg capacity trucks Remove the main and top covers of the truck. The hydraulic pump and tank assembly is located in the upper left part of the main chassis when viewed from the front. The assembly is installed horizontally.

To drain the fluid from the tank, use a draining apparatus. Make sure that all the tools and tubing you use are clean so that no dirt is introduced into the hydraulic system. After draining the tank completely, fill it to half (½) its volume with new hydraulic fluid.

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Figure 3.29. Draining the hydraulic tank (1,300 kg capacity truck model)

3.8.1.2. 1,600 kg capacity trucks Remove the main and top covers of the truck. The hydraulic pump and tank assembly is installed vertically. The filling tube of the tank has a right angle, so the tank must be removed to drain the old fluid. Remove the hydraulic tank according to the following steps.

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1.

The hydraulic pump and tank assembly is fixed to a bracket, which is fixed to the bottom of the main chassis. Locate the bolts that fix the bracket to the chassis and open them.

2.

After opening the bolts, turn the assembly out of the chassis to gain access to it.

3.

Open the four screws that hold the entire assembly together using a 4 mm Allen key. Be careful when handling the assembly with the screws removed.

Figure 3.30. Removing the hydraulic tank (1,600 kg capacity truck model) 4.

Carefully remove the tank and pour out the old hydraulic fluid.

5.

Reattach the tank to the rest of the assembly and refix the four fixing screws.

6.

Reattach the entire assembly to the main chassis.

7.

Open the filling cap and fill the tank with new hydraulic fluid to three-quarters (¾) of its capacity when measured from the bottom of the tank to the filling tube.

3.8.1.3. 2,000 kg capacity trucks On 2,000 kg capacity trucks, you have to remove the battery pack to gain access to the fixing screws that hold the hydraulic pump and tank assembly. Except for the hydraulic pump and tank assembly being fixed directly to the back plate of the main chassis, the process is similar to the 1,600 kg capacity truck model.

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Take the utmost care and suitable precautions when lifting the battery assembly from the truck. Protect any unshielded contacts against short-circuiting. Use a non-conductive belt for hoisting the battery assembly. The battery assembly can be lifted with a crane or another truck.

Figure 3.31. Removing the battery pack (2,000 kg capacity truck model) After the battery assembly has been removed, you can access the fixing screws for the hydraulic pump and tank assembly.

Follow the procedure given for the 1,600 kg capacity truck for draining and refilling the tank. After the pump and tank assembly has been reattached, replace the battery assembly.

3.8.2. Changing the transmission fluid (2,000 kg capacity trucks only) Change the transmission fluid once a year on 2,000 kg capacity trucks. The transmission has three orifices: the filling hole (1) at the top, the checking hole (2) on the side, and the draining hole (3) on the underside.

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Figure 3.32. Location of filling (1), checking (2) and draining (3) orifices The filling cap is opened with a 12 mm wrench, while the checking and draining hole caps require a 5 mm Allen key. Take precautions for handling transmission fluid and keep the servicing area clean.

To change the transmission fluid: 1.

Lift the truck with a suitable jack or other safe method and secure it to a level position. Always secure the truck so that it is safe to work under.

Never work under a truck that is supported only by jacks.

2.

After the truck has been lifted and levelled, place a suitable container under the transmission draining hole. There is approximately 0.6 litres of fluid in the transmission.

3.

Open the draining hole cap using a 5 mm Allen key.

NOTE

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Figure 3.33. Opening the draining cap 4.

Open the filling hole cap using a 12 mm wrench and let the transmission fluid drain completely.

Figure 3.34. Opening the filling cap

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5.

Close the draining hole cap.

6.

Open the checking hole cap using a 5 mm Allen key.

Figure 3.35. Location of the checking hole 7.

Using a funnel, pour new transmission fluid carefully into the filling hole until it reaches the level of the checking hole.

Refer to Section 3.9 Lubricant and fluid recommendations for fluid recommendations.

8.

Close the checking and filling hole caps.

3.9. Lubricant and fluid recommendations Take the appropriate precautions when handling lubricants and fluids during maintenance. Many of the used fluids are harmful or even toxic, and some solutions are corrosive. Always use protective clothing, eyewear and gloves when handling harmful fluids. Refer and conform to all local safety guidelines governing these fluids and lubricants. Before use, always familiarise yourself with a substance by reading the instructions and precautions for use from the container or associated documentation. Never handle an open flame or smoke a cigarette in or near the area where these substances are handled.

3.9.1. General lubricant Use grease that conforms to NLGI grade No. 2 requirements as the general lubricant for moving parts in trucks. If the truck is used in cold environments, such as cold store applications, use NLGI No. 1 or No. 0.

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3.9.2. Battery fluid Use fluid intended for lead-acid batteries as the battery fluid for trucks with serviceable batteries. Never use any other fluid to fill the battery cells.

3.9.3. Hydraulic fluid Normally use fluid of the ISO VG 32 viscosity class as the hydraulic fluid. Use fluid of the ISO VG 15 viscosity class in cold environments.

3.9.4. Transmission fluid The transmissions of 1,300 and 1,600 kg capacity trucks are grease filled at the factory and do not require service. Use transmission fluid of grade EP 80 or 90 as the transmission fluid for 2,000 kg capacity trucks.

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4. Electrical operation and maintenance This chapter examines the electrical aspects of the truck. The chapter begins with a description of the truck's electrical operation. It continues by introducing the console and presents its use in reading and modifying controller parameters. The chapter concludes with electrical maintenance and repair instructions not covered in Chapter 3 Regular maintenance.

Refer to Section 3.1 Safety guidelines and preparation and Section 3.2 Maintenance guidelines for information on safety and preparation for maintenance tasks. Refer to Chapter 2 Operating the truck for operating instructions.

4.1. Electrical operation This section presents the truck's primary electrical functions.

Ensure that you have the correct version of the electrical schematics for the truck model under maintenance. Contact your supplier or technical support for information on obtaining up-to-date documentation for your truck.

The section assumes that you are using the standard model of the truck. This chapter only addresses the primary electrical functions. To troubleshoot a particular component, you need to locate it on the electrical schematic diagram to understand how it is connected to the entire system. Keep a copy of the electrical schematic diagram at hand while reading this chapter.

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4.1.1. Using the schematic diagram

Figure 4.1. A sample page from the electrical schematic diagram of the pedestrian power pallet truck (TS980803) NOTE

Always acquire the correct version of the electrical schematics before proceeding with electrical maintenance.

The electrical schematic diagram is divided into zones, which are presented along the top edge of each page. Use these zones

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as a navigating aid to locate components. For example, the text may refer to a component in a certain zone of a certain page of the schematics.

4.1.2. Power source The electrical power source differs between truck models. Trucks with a nominal lifting capacity of 1,300 kg use two 12-volt batteries. These batteries are either AGM type batteries with a maximum capacity of 35 Ah or GEL type batteries with a maximum capacity of 48 Ah. The batteries are presented in zone 11 of page 1 of the electrical schematic diagram. They are marked G1 and G2 and are connected in series to provide the system with the required 24 volts.

The more powerful truck models with nominal lifting capacities of 1,600 and 2,000 kg have wet lead-acid batteries, which consist of 12 cells and supply a nominal voltage of 24 volts. The batteries have a maximum capacity of 270 Ah on the 1,600 kg capacity truck model and 345 Ah on the 2,000 kg capacity truck model.

The batteries reside in a separate compartment and are connected to the system via the XG1 battery connector. The battery is presented as G1 in zone 13 on page 1 of the electrical schematic diagram.

4.1.3. Key switch The main key switch S1 controls the electrical power supply to the entire system. It also functions as the emergency stop button.

The main key switch is activated by pulling it up, which closes the switch. If the system needs to be powered down at any time, the key switch can be pressed. This opens the S1 switch connection. The switch is located in zone 13 on page 1 of the electrical schematic diagram.

When the main key switch closes the contact, electrical power is supplied to the system through the main fuses 1F1 and 2F1.

Fuse 1F1 supplies the battery positive voltage B+ to the traction controller. The fuse is rated at 70 A on 1,300 and 1,600 kg capacity trucks, and 100 A on 2,000 kg capacity trucks. Fuse 2F1 supplies B+ to the pump motor contactor K1. The fuse is rated at 70 A on all the truck models. Refer to the electrical schematic diagram for the location of the main fuses in zones 13 and 15 on page 1.

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After the main fuse 1F1, the B+ supply is fed to the main positive input terminal of the traction controller. The positive power feed is internally connected to the auxiliary fuse A1F1 in the traction controller. Fuse A1F1 is rated at 5 A. Refer to zone 20 on page 1 of the electrical schematic diagram. On 2,000 kg capacity trucks, the main positive electrical power feed is also connected to pin 1 of connector X1 of the traction controller. The battery negative pole B- is connected directly to the negative input terminal of the traction controller.

The pump motor contactor K1, which is fed through the main fuse 2F1, is controlled by the traction controller. In the schematic diagram, the K1 contacts are presented in zone 15 on page 1.

The coil controlling the K1 contacts is presented in zone 23 on page 1. The coil is connected to pins 5 and 10 of connector X3 of the traction controller. Pin X3:5 is the positive supply and pin X3:10 is the digital output for the pump motor contactor. The contactor coil is powered as long as the battery voltage is high enough. Lifting is disabled when the battery voltage drops under the level set with the Level low batt. parameter of the traction controller. Refer to Section 4.2 Console for information on reading and modifying the parameters of the traction controller.

4.1.4. Traction The movement of the truck is controlled by the traction controller.

Before the truck can be driven, the battery must be connected, the main key switch must be closed (in the up position) and the system must have passed the self-test procedure.

When the truck is powered on and in standby mode, it can be driven by moving the accelerator at the end of the tiller arm towards the forward or backward direction. The accelerator is presented in zones 23 to 26 on page 1 of the electrical schematic diagram. Refer to Chapter 2 Operating the truck for more information on driving the truck.

The accelerator unit receives its 24-volt electrical supply from pin 1 of connector X6. The negative connection is supplied through pin 7 of connector X6. As the accelerator is moved in either direction, it indicates the direction to the traction controller via pins 2 and 3 of connector X6. It also provides a varying voltage to pin 6 of connector X6. The voltage varies between approximately 0.3 and 5 V, and depends on the position of the

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NOTE

accelerator control. The voltage increases as the accelerator is moved to either extreme.

If the accelerator needs to be replaced for any reason, the sensor values should be reread using the console.

Refer to Section 4.3.2.38 Parameter 251: Program throttle for information on the Program throttle parameter.

When the voltage at pin 6 of connector X6 of the traction controller rises above 0.3 V, the controller first checks the directional inputs (pins 2 and 3 of connector X6) for a direction indication. The controller also checks for any internal errors.

Before the controller engages the traction motor, it releases the 1Y1 electrical parking brake.

The brake is controlled through pins 1 and 5 of connector X4.

The parking brake is active when it receives no power, that is, also when the truck is powered down. To release the brake, the traction controller applies 24 V to pin 1 of connector X4 for one second and then reduces the voltage to 60% to hold the brake open. Refer to zone 18 on page 1 of the electrical schematic diagram.

After the parking brake is released, the traction controller begins to feed the three-phase alternating current to drive the M1 traction motor. The AC traction motor is connected to the U, V and W outputs of the traction controller. Refer to zones 17 to 19 on page 1 of the electrical schematic diagram.

Figure 4.2. Traction motor connections

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The truck is powered by a DC battery. The direct current is converted in the traction controller to three-phase alternating current to drive the AC traction motor. This process is known as inverting. The three motor inputs are driven out of phase to create a voltage drop between the phases. The order of the phases, that is, which phase is leading and which phases follow, determines the rotating direction of the motor.

The rotating speed of the motor is relational to the width and frequency of the pulse. The greater the pulse width, the longer current flows through the motor. The actual current passing through the motor is more sinusoidal than pulsed due to the characteristics of an inductor. The pulse width varies depending on feedback from the traction speed encoder bearing B3. If the motor revolves faster than the speed reference, the pulse width is decreased and vice versa.

NOTE

Motor speed feedback allows the control system to maintain an exact speed, regardless of the load on the truck. The feedback process continues until the request to move ends. In other words, until you release the accelerator or an alarm occurs, which forces the traction controller to cease operation and to engage the brake.

If there are no alarms when the accelerator is released, the traction controller reverses the motor phasing to slow it down (by attempting to reverse its rotating direction). The parking brake is engaged once the motor has stopped revolving, which the traction controller senses via the traction speed encoder.

The maximum forward and backward travel speeds of the truck can be modified with the console. The maximum permitted speed of a pedestrian truck is 6 km/h. Refer to Section 4.2 Console for more information on using the console to adjust parameters.

The traction speed encoder is connected to the traction controller at pins 3, 4, 7 and 8 of connector X4. Pin 7 supplies the encoder with 15 volts while pin 8 supplies the negative connection. Pin 3 is encoder channel A and pin 4 is encoder channel B. The traction controller determines the rotating speed of the motor by counting the pulses produced by the encoder over a certain period.The faster the motor turns, the more pulses are generated during the monitoring period. The rotating direction of the traction motor is determined by comparing the signals of the two channels. The motor’s turning direction causes the signal of one channel to lead while the other lags.

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NOTE

The operation of the traction speed encoder can be tested using the console. Refer to Section 4.2 Console for more information on using the console.

4.1.5. Braking The truck is normally slowed down with the traction motor. When the truck is being driven in one direction, reducing the deflection of the accelerator control causes the system to reduce the speed reference to the traction motor, which actively reduces the speed.

The operator can slow down the truck more rapidly by turning the accelerator in the opposite direction to the movement. This causes the traction controller to instruct the traction motor to reverse its movement and therefore to rapidly reduce its turning speed. If the accelerator is held in this position after the truck has stopped, it begins to move in the given direction at the requested speed.

NOTE

In practice, when the accelerator is turned opposite to the direction of movement, the traction controller switches the order of the two of the three motor input phases (U, V and W). This action forces the traction motor to reverse its rotating direction.

This will initially slow down the motor and then begin to turn it in the opposite direction.

Braking characteristics can be adjusted with the Reverse braking parameter. Refer to Section 4.2 Console and Section 4.3.2 Parameters for more information on setting truck parameters with the console.

When the movement of the truck is slowed down with the motor, the motor acts as a generator and produces electrical power.

This power is used to recharge the truck’s battery. This is known as regenerative or inverse braking. In this situation, the motor produces AC voltage from each of its phases. This AC voltage is rectified to a direct positive and negative voltage. As long as the resultant DC voltage is higher than the battery voltage, the battery is charged.

The truck is equipped with an electrical brake, but this is normally not used to control the truck’s speed. The Stop mode tiller parameter controls the function of the electrical brake. In the default mode, the electrical brake is engaged only after the truck's movement has stopped. This reduces the wear on the electrical brake. The electrical brake can be used to slow down the truck, but this is not recommended.

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4.1.6. Safety button The truck is by regulations obligated to have a safety button to protect the operator. The safety button is situated at the far end of the tiller arm. Its purpose is to stop and reverse the direction of the truck’s movement to minimise the risk of the operator being crushed between the truck and an obstacle.

The safety button works only when the truck is driven in the direction of the tiller arm. When the button is pressed, the truck automatically stops and reverses its movement for a short period.

The sharpness of the response is controlled by parameter 142 and also by the original speed. The response is greater at faster driving speeds. Refer to Section 4.2 Console for more information on setting the truck’s parameters with the console.

The safety button S2 is located in zone 23 on page 1 of the electrical schematic diagram. When it is pressed, it opens the connection and removes the 24-volt electrical supply from pin 4 of connector X6.This causes the controller to connect the reverse direction. The reversing acceleration is set with parameter 142.

4.1.7. Lifting and lowering the forks The forks are lifted hydraulically. The operator requests lifting or lowering by using the micro switches in the tiller arm head. Lifting is requested with switch S4 and lowering with switch S5. Refer to zones 28 and 29 on page 1 of the electrical schematic diagram.

When the operator requests lifting, switch S4 is closed, which sends the 24-volt signal to pin 8 of connector X6 of the traction controller. Before the traction controller reacts to the request, the battery voltage must be above a designated level. The traction controller energises the K1 contactor coil through pin 5 of connector X3. K1 closes and feeds the battery voltage to the pump motor. The pump motor engages and turns the pump to draw hydraulic fluid from the tank and send it to the lifting cylinder.

The pump motor runs until the lifting request is removed or the forks reach the top position. When the top position is reached, the lifting limit switch (S7) opens, which deactivates the pump motor.

When the operator requests lowering, switch S5 is closed, which sends the 24-volt signal to pin 9 of connector X6. The traction controller then controls the magnetic valve through pin 4 of

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connector X3. Refer to Chapter 5 Hydraulic operation and maintenance for information on the hydraulic operation of the power pallet truck.

4.2. Console The handheld console provides a user interface to the controllers used in trucks. The console can be used to verify the operation of the truck, read and modify controller parameter values, monitor the inputs and outputs of a controller, and display the error code when a fault has occurred. The console used in conjunction with these trucks is the BPK part number (RL)469054. Contact your supplier for information on obtaining a handheld console.

Figure 4.3. Handheld console, model BPK ((RL)469054)

4.2.1. Connecting the console Before connecting the console, make sure that the truck’s main key switch is turned off. The console is connected to connector X7 of a controller. To access the connector, remove the main cover of the truck. Refer to Chapter 3 Regular maintenance for information on removing the truck’s covers. The connector may already be reserved by a peripheral device, such as a display unit. If so, simply disconnect the peripheral device to connect the console, and reconnect the peripheral device after disconnecting the console.

To connect the console:

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1.

Turn off the truck’s main key switch.

2.

Open the main cover and locate the controller.

3.

Disconnect a possible peripheral device (e.g. the display unit) from controller connector X7.

4.

Connect the connection cable of the handheld console to connector X7 on the controller.

4.2.2. Navigating the parameter list After the console is connected to the controller, the truck’s main key switch can be turned on. As the console goes through its start-up procedure, it first displays its own software version. After the start-up sequence, the console displays the serial number and software version of the controller to which it is connected.

The handheld console has six keys on its face: four arrow keys, an Esc key and an Enter key. Use the up and down arrows to scroll through the available parameters.

Press the down arrow from the first display to scroll to the first available parameter. The console displays “Searching next parameter” for a short period, then the name and number of the parameter, before displaying the name and value of the parameter.

Some controller parameters are diagnostic parameters and cannot be modified by the user. When you reach a modifiable parameter, press the left or right arrow key to enter editing mode.

After the cursor has appeared, move it to the correct position with the left and right arrow keys and modify the selected value with the up and down arrow keys.

When in editing mode, if a value is changed and no keys are pressed for one second, the new value is temporarily in use but has not been stored into the system. The Enter key must be pressed to store the value in the controller memory and to exit editing mode. If you wish to discard any changes and return to the previous stored value, press the Esc key to exit editing mode without storing the new value.

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4.2.3. Accessing additional functions The handheld console provides additional functions, which can be accessed by pressing the left and right arrow keys simultaneously.This opens a submenu with the following choices: List of errors This function displays a chronological list of the last eight controller faults that have occurred. The eight slots are reserved for different fault codes. If the same fault has occurred several times, it is displayed only once.

Write (BPK->dACi) and Read (dACi->BPK) These commands are used to upload and download parameter sets to a controller. This can be useful, for example, when the controller must be replaced and settings must be moved to the new controller, or when several controllers are to be programmed with the same parameter set.

The Read (dACi->BPK) command is used to read and store the parameter values of a connected controller into the BPK handheld console. The handheld console has memory space to store up to eight parameter sets. When using this command, you are asked to select one of the available storage locations.

The Write (BPK->dACi) command is used to overwrite the parameter set of a connected controller. Once this function is selected, the console asks you to select one of the eight possible parameter sets to be downloaded to the controller. Be careful with this command, as it overwrites the entire parameter set of the connected controller.

Search device When the connected controller is on a communication bus that contains other controllers, this function can be used to search for the device addresses of the controllers on the bus.

Select address When the connected controller is on a communication bus that contains other controllers, this function can be used to connect the console to a different controller on the same bus.

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Select language Use this function to select one of the two available console user interface languages: English or German.

4.3. Traction controller The traction controller is an important part of the truck’s electrical system. Depending on the truck model, it controls some or nearly all the electrical functions, such as driving, braking, lifting and lowering the forks, and the safety functions. The main task of the traction controller is to act as an inverter and convert the DC battery voltage to AC electrical power to drive the AC electrical motor.

4.3.1. Connections As the electrical schematic diagram shows, the traction controller is connected to several electrical components of the truck. The traction controller A1 is presented in zones 20 to 22 on page 1 of the electrical schematic diagram. There are different models of the controller for different truck models. They, however, all function similarly. If the controller has to be replaced, contact your supplier or technical support for information on obtaining up-to-date documentation and parts for your truck.

Figure 4.4. Traction controller

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NOTE

The traction controller has two main DC voltage inputs from the battery. It has three main AC voltage outputs to the three phases of the traction motor. In addition to these connections, the controller has several connectors for peripheral devices. The different connectors of the traction controller are listed below.

Refer to the given sections of the electrical schematic diagram to locate the connectors. The actual physical location of the connectors on the traction controller varies by model, but is marked on its casing.

The operation of the traction controller connections can be tested with the console. For more information, refer to Section 4.2 Console and Section 4.3.2 Parameters.

4.3.1.1. Connector X1 (zone 20, page 1) X1, pin 1: The battery voltage is applied to this input in order to power on the controller. The input is protected by a 5 A fuse, which can be reached from outside the controller housing. This input provides the voltage supply for the other peripheral components.

Pins 2, 3 and 4 of connector X1 are not in use. Do not connect.

4.3.1.2. Connector X2 (zone 12, page 2) This connector is not used in this application. Do not connect.

4.3.1.3. Connector X3 (zones 21-22, page 1) X3, pin 1: This pin supplies the 24-volt battery voltage to the safety socket switch S8 (zone 28, page 1). If the charging plug is removed from its socket, traction is disabled. Lifting is still permitted.

X3, pin 2: This pin supplies the 24-volt battery voltage to the lifting limit switch S7 (zone 27, page 1). When the lifting limit of the forks is reached, this switch opens and disables lifting.

X3, pin 3: The positive voltage supply for the H2 horn (zone 25, page 1). This output is controlled by input X6:10.

X3, pin 4: The positive voltage supply for the magnetic lowering valve 2Y1 (zone 24, page 1). This output is controlled by input X6:9.

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X3, pin 5: The positive voltage supply for the K1 pump motor contactor (zone 23, page 1). This output is controlled by input X6:8.

X3, pin 6: The digital input for the safety socket switch S8. See X3, pin 1.

X3, pin 7: The digital input for the lifting limit switch S7. See X3, pin 2.

X3, pin 8: The negative connection for the horn H2.

X3, pin 9: The negative connection for the magnetic lowering valve 2Y1.

X3, pin 10: The digital output for the K1 pump motor contactor.

4.3.1.4. Connector X4 (zone 20, page 1) X4, pin 1: The positive 24-volt supply for the 1Y1 electrical brake (zone 18, page 1).

X4, pins 2 and 6: Connection for the motor temperature sensor.

Not used in this application. Do not connect.

X4, pin 3: Channel A signal link from the B3 motor encoder (zone 17, page 1).

X4, pin 4: Channel B signal link from the B3 motor encoder.

X4, pin 5: Digital output for the 1Y1 electrical brake.

X4, pin 7: The 15-volt supply for the B3 motor encoder.

X4, pin 8: The 0-volt connection for the B3 motor encoder.

4.3.1.5. Connection X5 (zone 20, page 1) X5, pin 1: The positive 24-volt supply for the H1 status LED (zones 16-17, page 1).

X5, pin 2: The positive 24-volt supply for the B2 tiller arm position switch (zones 17-18, page 1).

X5, pin 3: Input from the tiller arm position switch. Indicates that the tiller arm is in the driving position.

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X5, pin 4: Digital output for the H1 status LED. X5, pin 5: The 0-volt connection for the B2 tiller arm position switch.

X5, pin 6: Input from the tiller arm position switch. Indicates that the tiller arm is either in the upright or in the bottom position. In these positions, traction is disabled unless the S3 brake release switch is closed.

4.3.1.6. Connector X6 (zones 21-22, page 1) X6, pin 1: The positive 24-volt supply for the B1 tiller arm head module (zones 23-30, page 1).

X6, pin 2: Digital input from the accelerator for the forward direction.

X6, pin 3: Digital input from the accelerator for the backward direction.

X6, pin 4: Digital input from the safety button (S2) (zone 23, page 1). Switch S2 is normally closed. If S2 is opened, the 24-volt supply is removed from this terminal and the traction controller acts accordingly.

X6, pin 5: Digital input from the brake release switch S3 (zone 28, page 1). By pressing this switch, the operator can drive the truck at reduced speed even when the tiller arm is in the upright or bottom position.

X6, pin 6: The speed reference input from the accelerator.

X6, pin 7: The battery negative connection for the B1 tiller arm head module.

X6, pin 8: Input for the lifting switch S4 (zone 28, page 1).

Controls the X3:5 output.

X6, pin 9: Input for the lowering switch S5 (zone 29, page 1).

Controls the X3:4 output.

X6, pin 10: Input for the horn switch S6 (zone 29, page 1).

Controls the X3:3 output.

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X6, pin 11: 10-volt output, 100 mA maximum current. Not connected.

X6, pin 12: Digital input for speed reduction. Not in use.

Connected directly to pin 1.

4.3.1.7. Connector X7 (zone 12, page 2) This is the controller’s RS485 interface connector. If the truck is equipped with a display unit, it is connected to connector X7.

The console connects to this connector. If a display unit is included, it must be disconnected before the console is connected. Refer to Section 4.2 Console for more information on using the console.

X7, pin 1: 15-volt supply.

X7, pin 2: 0-volt connection.

X7, pin 3: RS485, signal A. X7, pin 4: RS485, signal B.

4.3.2. Parameters There are two main parameter types in the controller: diagnostic and modifiable. The values of diagnostic parameters can be viewed but cannot be changed. The parameters available for the traction controller are presented below. Their order is determined by the parameter number, which controls the order in which they are listed on the handheld console.

NOTE

You may notice that not every parameter is available even for viewing. The console shows only those parameters that are meant to be user read or modified. Other parameters exist, but these are either not used in the current application or they have been preset by the manufacturer.

Do not alter the value of a parameter unless you are completely certain of the necessity of the change and aware of how it affects the truck’s operation.

4.3.2.1. Parameter 0: Software version (diagnostic) This parameter displays the version of the connected controller’s internal software.

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4.3.2.2. Parameter 4: Operating hours (diagnostic) This parameter displays the operating time of the connected controller. The time is displayed in hours and to an accuracy of three decimals.

4.3.2.3. Parameter 7: Serial number (diagnostic) This parameter displays the serial number of the connected controller.

4.3.2.4. Parameter 10: Actual speed (diagnostic) This parameter displays the actual current speed of the truck in km/h.

4.3.2.5. Parameter 11: Speed set value (diagnostic) This parameter displays the speed reference value from the accelerator in km/h.

4.3.2.6. Parameter 17: Temp. controller (diagnostic) This parameter displays the temperature measured from the traction controller heat sink. The temperature is displayed in degrees Celsius (°C) and to an accuracy of one degree.

4.3.2.7. Parameter 18: Battery level (diagnostic) This parameter displays the level of the battery charge. The level is displayed as a value between 1 and 10, with 1 indicating a level of 10% and 10 indicating 100%.

4.3.2.8. Parameter 30: Throttle value (diagnostic) This parameter displays the speed reference value from the accelerator. The value is displayed as a voltage between 0 and 5 V, and to an accuracy of one decimal. When the accelerator is in the neutral position, the value should be close to 0 V. When the accelerator is moved to either extreme, the value should increase linearly close to 5 V.

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4.3.2.9. Parameter 33: Battery voltage (diagnostic) This parameter displays the current measured battery voltage.

The nominal voltage in this application is 24 V. The reading decreases while the truck is operated, as electrical power is drawn from the battery.

4.3.2.10. Parameter 46: Connector X1 (diagnostic) This parameter displays the active pins of connector X1.

4.3.2.11. Parameter 47: Connector X2 (diagnostic) This parameter displays the active pins of connector X2.

Connector X2 is not used is this application.

4.3.2.12. Parameter 48: Connector X3 (diagnostic) This parameter displays the active pins of connector X3. In the standby state, the parameter displays pins 6, 7 and 10 (A=10).

Pin 6 is the digital input of the safety socket. If the plug is removed from the safety socket, pin 6 should disappear from the display. When the safety socket is removed, the truck cannot be driven, but the forks can still be lifted.

Pin 7 is the digital input of the lifting limit switch. When the forks are lifted to the top position, the lifting limit switch (S7) opens, and removes the 24-volt supply from digital input pin 7 of connector X3. In this situation, the 7 should disappear from the display. As the pump motor is disabled, the A (pin 10) should also disappear from the display. Pin 10 is the digital output for the pump motor contactor K1.

4.3.2.13. Parameter 49: Connector X4 (diagnostic) This parameter displays the active pins of connector X4. The possible displayed pins are 3, 4 and 5. Pin 3 is the channel A input signal from the motor encoder bearing and pin 4 is the channel B signal. Pin 5 is active when the electrical brake is released.

You can test the encoder by driving the truck very slowly to observe the signals from the two encoder channels. When you start driving, pin 5 should appear to indicate that the electrical brake has been released. Pin 5 should not be displayed when

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the truck is stationary, as the electrical brake should be engaged.

The sequence of pins 3 and 4 depends on the direction of travel.

They could, for example, indicate the following sequence: first pin 3, then both pin 3 and pin 4, then only pin 4, then neither, then pin 3 again, and so forth.

4.3.2.14. Parameter 50: Connector X5 (diagnostic) This parameter displays the active pins of connector X5. The possible displayed pins are 3, 4 and 6. Pin 3 indicates that the tiller arm is in the driving position. Pin 4 indicates that the status LED is illuminated. Pin 6 indicates that the tiller arm is either in the upright or in the bottom position.

When the truck is powered on and no faults have occurred, the status LED should be constantly illuminated, that is, pin 4 should be constantly displayed. If a fault has occurred, both the status LED and pin 4 flash in a pulse sequence that indicates the fault type. In other words, the error code can be counted from the sequence.

Move the tiller arm between the upright and bottom positions to check that the tiller switch works correctly. When the tiller arm is in the upright or bottom position, pin 6 should be displayed and the truck should not respond to driving commands, unless the brake release button is pressed.

4.3.2.15. Parameter 51: Connector X6 (diagnostic) This parameter displays the active pins of connector X6. The possible displayed pins are 2, 3, 4, 5 and 12 (C=12). Pin 2 indicates that the digital input for the forward driving direction is active. Pin 3 indicates that the digital input for the backward direction is active. Pin 4 indicates that the digital input of the safety switch is active. Pin 5 indicates that the digital input of the brake release button is active. Pin 12 indicates that the optional digital input is active.

When the truck is driven, pin 2 or 3 is displayed to indicate the driving direction. Pin 4 is normally displayed and disappears when the safety switch is pressed. Pin 5 appears when the brake release button is pressed to enable traction even when the tiller arm is in the upright or bottom position. Pin 12 (C) is displayed constantly, as it is an optional pin that has been hardwired to the 24-volt supply.

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4.3.2.16. Parameter 60: Wheel diameter This parameter is used to set the diameter of the drive wheel.

The value is displayed in millimetres.The nominal wheel diameter is 230 mm.

4.3.2.17. Parameter 61: Gear ratio This parameter is used to set the gear ratio of the truck’s transmission. The factor has been preset and should not be changed. The default value is 36.04 for 1,300 and 1,600 kg capacity trucks, and 30.1 for 2,000 kg capacity trucks.

4.3.2.18. Parameter 67: BDI curve This parameter is used to select the algorithm used for battery discharge monitoring. The selection depends on the battery type.

Use the following values: 9 for 1,300 kg capacity trucks with AGM batteries, 5 for 1,300 kg capacity trucks with GEL batteries, and 3 for 1,600 kg and 2,000 kg capacity trucks.

4.3.2.19. Parameter 68: BDI reset This parameter sets the voltage value at which the system displays full battery charge. The default value is 25.08 V.

4.3.2.20. Parameter 69: BDI timer This parameter determines a time period for battery discharge monitoring. Use the preset value. Do not change. The default values are 150.00 s for 1,300 kg capacity trucks, and 240.00 s for 1,600 kg and 2,000 kg capacity trucks.

4.3.2.21. Parameter 81: Lift cut-off This parameter controls the lift cut-off function. When it is active, that is, set to 1, lifting is disabled when the low battery warning is triggered. The low battery warning level is set with parameter 175.

4.3.2.22. Parameter 98: Stop mode tiller This parameter controls how the controller decelerates when the tiller arm is removed from the driving position. There are three choices, indicated by the number 1, 2 or 3. The default and

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recommended value is 2. Its advantage is that it reduces the wear of the electrical brake. The alternatives are: 1.

The motor’s power feed is cut and the brake is applied at the same time.

2.

The motor’s deceleration ramp is applied and the brake is engaged after the truck has come to a standstill.

3.

The motor’s deceleration ramp is applied and the brake engaged at the same time.

4.3.2.23. Parameter 107: Warn. temp. contr.

This parameter sets the temperature level for the controller’s high temperature warning. The value is entered in degrees Celsius (°C) and can be between 50 and 79. The default value is 70, which should not be changed.

4.3.2.24. Parameter 133: Acceleration This parameter controls the rate at which the truck accelerates when the accelerator is moved to request traction. Acceleration is given in km/h/s with an accuracy of two decimals and in the range from 0.50 to 6.00. The default value is 2.80 for 1,300 kg capacity trucks, and 3.60 for 1,600 and 2,000 kg capacity trucks.

4.3.2.25. Parameter 134: Deceleration This parameter controls the rate at which the truck decelerates when the accelerator is released to request stopping.

Deceleration is given in km/h/s with an accuracy of two decimals and in the range from 0.50 to 6.00. The default value is 2.80 for 1,300 kg capacity trucks, and 3.60 for 1,600 and 2,000 kg capacity trucks.

4.3.2.26. Parameter 137: Smoothing curve This parameter affects the smoothing of the motor control curves.

Its range is from 0 to 9, and the default setting is 5 for all truck models. This value should not be changed.

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4.3.2.27. Parameter 138: Progress. curve This parameter affects the progression of the motor control curves. Its range is from 0 to 100, and the default setting is 75 for all truck models. This value should not be changed.

4.3.2.28. Parameter 139: Reverse braking This parameter controls the rate at which the truck decelerates when the accelerator is moved to the opposite direction of movement, that is, when performing reverse braking. The deceleration is given in km/h/s with an accuracy of two decimals and in the range from 0.50 to 6.00. The default value is 4.80 for all truck models.

4.3.2.29. Parameter 142: Dec. belly & tiller This parameter controls the rate at which the truck decelerates when the truck is driven in the direction of the tiller arm and the safety button is pressed. The deceleration is given in km/h/s with an accuracy of two decimals and in the range from 0.50 to 9.00.

The default value is 9.00 for all truck models.

4.3.2.30. Parameter 175: Level low batt.

This parameter sets the battery discharge level at which the low battery warning is triggered. The warning is triggered, if the battery level is below the set level for over three seconds. The parameter also sets the level at which the lift cut-off function activates (parameter 81 controls the lift cut-off function). The value range is from 1 to 5. The default value is 2 for 1,300 kg capacity trucks, and 1 for 1,600 and 2,000 kg capacity trucks.

4.3.2.31. Parameter 176: Low batt. speed This parameter sets the speed reduction when the low battery warning is triggered. It sets the percentage of maximum speed (set by parameters 211 and 216) that is allowed when the low battery warning is triggered. The value range is from 10% to 100%, and the default value is 33 for all truck models.

4.3.2.32. Parameter 211: Max. speed FWD This parameter sets the maximum speed permitted in the forward direction. The value range is from 0.50 to 6.00 km/h. The default

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value is 5.80 km/h for 1,300 kg capacity trucks, and 6.00 km/h for 1,600 and 2,000 kg capacity trucks.

4.3.2.33. Parameter 216: Max. speed BWD This parameter sets the maximum speed permitted in the backward direction. The value range is from 0.50 to 6.00 km/h.

The default value is 5.80 km/h for 1,300 kg capacity trucks, and 6.00 km/h for 1,600 and 2,000 kg capacity trucks.

4.3.2.34. Parameter 221: Opt. speed limit 1 This parameter sets the optional speed reduction. It sets the percentage of the maximum speed permitted when using the option. The value range is from 10% to 100%, and the default value is 100%. The option is not used in this application.

4.3.2.35. Parameter 222: Brake rel. speed This parameter sets the speed reduction when using the brake release function. It sets the percentage of maximum speed (set by parameters 211 and 216) that is allowed when the low battery warning is active. The value range is from 10% to 100%, and the default value is 33 for all models.

4.3.2.36. Parameter 223: Tiller type This parameter sets the type of the installed tiller arm position switch. It has two values: “0” refers to an NO type switch and “1” refers to an NO/NC type switch. The default value is “1”. Do not change.

4.3.2.37. Parameter 249: Error message (diagnostic) This parameter displays the current error code, if any. Refer to Section 4.3.3 Fault codes for an explanation of the possible error codes.

4.3.2.38. Parameter 251: Program throttle This parameter is used to program the voltage range of the accelerator potentiometer into the controller.This procedure must be performed, if either the controller or the accelerator module in the tiller arm head is replaced. It can also be performed, if the truck does not seem to be responding correctly to the accelerator.

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To program the voltage range: 1.

Scroll to the Program throttle parameter. The console displays a value of “0”.

2.

Press either the left or the right arrow key to activate the cursor.

3.

Press the upward arrow key to change the value to “1”.

4.

Press the Enter key to initiate the programming procedure.

5.

During the 15-second programming period:

6.

NOTE

a.

Move the accelerator smoothly to the maximum forward value.

b.

Keep it held for one second.

c.

Move it to the maximum backward value.

d.

Keep it held for one second.

e.

Return it to the neutral value.

If the procedure was successfully completed, the parameter value returns to “0” automatically.

The traction motor is disabled while the programming procedure is carried out.

4.3.3. Fault codes When a fault occurs while the truck is operated, truck functions are disabled and the status LED flashes to indicate a fault. The status LED flashes in a particular sequence, depending on the fault. The error code can be determined from the sequence. If the truck is equipped with a display unit, it displays the numerical error code. The error code can also be read with the console by accessing the Error message parameter (249). This section presents the possible error codes with explanations.

4.3.3.1. Error: Watchdog This fault does not have a numerical error code. It can be determined from the status LED. When the Watchdog error is

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triggered, the status LED flashes with the following sequence: pulse duty cycle 1:1 and frequency 1.25 Hz. This error signifies an internal fault in the controller. When triggered, it disables the drive and digital outputs. The controller is faulty and must be replaced.

4.3.3.2. Error: RAM fault This fault does not have a numerical error code. It can be determined from the status LED. When the RAM fault error is triggered, the status LED flashes with the following sequence: pulse duty cycle 1:3 and frequency 2.1 Hz. This error signifies an internal fault in the controller. When triggered, it disables the drive and digital outputs. The controller is faulty and must be replaced.

4.3.3.3. Error: FLASH fault This fault does not have a numerical error code. It can be determined from the status LED. When the FLASH fault error is triggered, the status LED flashes with the following sequence: pulse duty cycle 3:1 and frequency 2.1 Hz. This error signifies an internal fault in the controller. When triggered, it disables the drive and digital outputs. The controller is faulty and must be replaced.

4.3.3.4. Error 2: New software version This fault has error code number 2. The status LED indicates this fault by repeating the following sequence: two pulses and a pause.

This error appears only when a new software version is being loaded into the controller. It disables the drive and digital outputs.

Reload the software as instructed.

4.3.3.5. Error 3: Overcurrent from power stage This fault has error code number 3. The status LED indicates this fault by repeating the following sequence: three pulses and a pause.

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When this error occurs, the drive is disabled. This error can occur if the controller was loaded for a long period at its current limit.

The fault should not appear as long as motor speed monitoring functions correctly. The error can also appear, if a parameter that influences the controller current or the overcurrent shutdown level was modified.

Check the signals from the encoder bearing while the traction motor operates. The signals of channels A and B (pins 3 and 4 of controller connector X4) should appear in the correct sequence. If the sequence is incorrect, check the encoder cable and connections, and change the encoder if necessary.

If the problem is due to altered parameters, it may be resolved by returning to a previous parameter set.

4.3.3.6. Error 4: Low battery voltage This fault has error code number 4. The status LED indicates this fault by repeating the following sequence: four pulses and a pause.

This error is triggered when the measured battery voltage drops below the level set with parameter 175 for more than three seconds. It causes the traction speed to be reduced to the level set with parameter 176. It also causes the lift cut-off function to activate, if it is enabled with parameter 81. If the battery voltage drops below the value set with parameter 173 (not accessible with the console) for more than three seconds, the controller is shut down.This fault can be reset only by switching the controller supply off and on.

This error can also be triggered, if there are too great voltage drops in the controller supply cables. Check the condition of the battery and the controller supply cabling.

4.3.3.7. Error 5: Battery overvoltage This fault has error code number 5. The status LED indicates this fault by repeating the following sequence: five pulses and a pause.

This error is triggered when the measured battery voltage exceeds the value set with parameter 174 (not accessible with the console) for more than three seconds. It is also triggered if

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the battery voltage exceeds 150% of the nominal voltage. This fault should not occur, if the battery and the connections to the controller are intact (assuming that parameter 174 is correctly set). This error could also result from a damaged power stage in the controller.

Check that the connections between the battery and the controller are in good condition. Check the value of parameter 174, if possible. If the cause cannot be found, change the controller.

4.3.3.8. Error 6: Motor overtemperature This fault has error code number 6. The status LED indicates this fault by repeating the following sequence: six pulses and a pause.

This error should not occur, as a motor temperature sensor is not used in this application.

4.3.3.9. Error 7: Controller overtemperature This fault has error code number 7. The status LED indicates this fault by repeating the following sequence: seven pulses and a pause.

This error is triggered if the controller has overheated during operation. This may result from the controller being overloaded for a long period. This error can also result from a fault in the controller’s temperature measurement function.

Check that the controller is mounted according to the instructions so that it is able to dissipate heat efficiently. Check the controller’s output current. It should not exceed the unit’s nominal current.

If the fault persists, the controller needs to be replaced.

4.3.3.10. Error 8: Drive signal monitoring This fault has error code number 8. The status LED indicates this fault by repeating the following sequence: eight pulses and a pause.

This error indicates a fault with the accelerator. The error can be due to an incorrect operating sequence. After the controller is powered up, the following conditions must be true: •

Drive signals (X6:2 and X6:3) must not be present.

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•

Speed reduction must be active.

•

The brake release switch (S3) must be open. ara>

•

The tiller switch (B2) must not indicate driving position.

•

The safety switch (S2) must be closed (i.e. not depressed).

•

The safety socket (S8) must be closed.

•

The speed reference signal (X6:6) must be near 0 V.

Check that the drive signals are working. Access parameter 51 with the console. Test that turning the accelerator in the forward direction provides the drive signal at pin 2 of connector X6 and that backward direction provides the drive signal at pin 3 of connector X6.

4.3.3.11. Error 9: Encoder bearing monitoring This fault has error code number 9. The status LED indicates this fault by repeating the following sequence: nine pulses and a pause.

This error could indicate a fault in the encoder bearing or a broken connection between the encoder and the controller.

Check the encoder signals from channels A and B at pins 3 and 4 of connector X4. Refer to Section 4.3.2.13 Parameter 49: Connector X4 (diagnostic).

4.3.3.12. Error 10: Safety switch monitoring This fault has error code number 10. The status LED indicates this fault by repeating the following sequence: ten pulses and a pause.

This error indicates a fault with the safety switch. The error can be due to an incorrect operating sequence. After the controller is powered up, the following conditions must be true:

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•

Drive signals (X6:2 and X6:3) must not be present.

•

Speed reduction must be active.

•

The brake release switch (S3) must be open.

•

The tiller switch (B2) must not indicate driving position.

•

The safety switch (S2) must be closed (i.e. not depressed).

•

The safety socket (S8) must be closed.

•

The speed reference signal (X6:6) must be near 0 V.

Use the console to check that there is a signal at pin 4 of connector X6. Refer to Section 4.3.2.15 Parameter 51: Connector X6 (diagnostic).

4.3.3.13. Error 11: Tiller switch monitoring after power-up This fault has error code number 11. The status LED indicates this fault by repeating the following sequence: eleven pulses and a pause.

This error indicates a fault with the tiller switch. The error can be due to an incorrect operating sequence. After the controller is powered up, the following conditions must be true: •

Drive signals (X6:2 and X6:3) must not be present.

•

Speed reduction must be active.

•

The brake release switch (S3) must be open.

•

The tiller switch (B2) must not indicate driving position.

•

The safety switch (S2) must be closed (i.e. not depressed).

•

The safety socket (S8) must be closed.

•

The speed reference signal (X6:6) must be near 0 V.

Use the console to check that there is a signal at pin 6 of connector X5. Refer to Section 4.3.2.14 Parameter 50: Connector X5 (diagnostic).

4.3.3.14. Error 12: Accelerator monitoring This fault has error code number 12. The status LED indicates this fault by repeating the following sequence: twelve pulses and a pause.

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This error indicates a fault with the accelerator. The error can be due to an incorrect operating sequence. After the controller is powered up, the following conditions must be true: •

Drive signals (X6:2 and X6:3) must not be present.

•

Speed reduction must be active.

•

The brake release switch (S3) must be open.

•

The tiller switch (B2) must not indicate driving position.

•

The safety switch (S2) must be closed (i.e. not depressed).

•

The safety socket (S8) must be closed.

•

The speed reference signal (X6:6) must be near 0 V.

Use the console to check that the voltage value from the accelerator to pin 6 of connector X6 is close to 0 V when the accelerator is in the neutral position. The value can be checked with parameter 30 (refer to Section 4.3.2.8 Parameter 30: Throttle value (diagnostic)).

4.3.3.15. Error 14: EEPROM fault This fault has error code number 14. The status LED indicates this fault by repeating the following sequence: fourteen pulses and a pause.

This error signifies an internal fault in the controller. The controller is faulty and must be replaced.

4.3.3.16. Error 15: Unrealistic U/f relationship This fault has error code number 15. The status LED indicates this fault by repeating the following sequence: fifteen pulses and a pause.

This error indicates that there is a problem with the parameters that control the U/f relationship of the drive.

The error can be resolved by returning to a previous parameter set.

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4.3.3.17. Error 16: Unrealistic speed input transfer function This fault has error code number 16. The status LED indicates this fault by repeating the following sequence: sixteen pulses and a pause.

This error indicates that there is a problem with the parameters that control the speed input transfer function.

The error can be resolved by returning to a previous parameter set.

4.3.3.18. Error 17: Tiller switch monitoring while system running This fault has error code number 17. The status LED indicates this fault by repeating the following sequence: seventeen pulses and a pause.

This error indicates that the two tiller switch signals are not complementary.

Use the console to check the operation of the tiller switch (signals X5:3 and X5:6). Refer to Section 4.3.2.14 Parameter 50: Connector X5 (diagnostic).

4.3.3.19. Error 18: Speed reduction monitoring This fault has error code number 18. The status LED indicates this fault by repeating the following sequence: eighteen pulses and a pause.

This error indicates a fault with the optional speed reduction function. The optional function is not used in this application. The option connection on connector X6 is bridged to the 24-volt supply.

The error can be due to an incorrect operating sequence. After the controller is powered up, the following conditions must be true: •

Drive signals (X6:2 and X6:3) must not be present.

•

Speed reduction must be active.

•

The brake release switch (S3) must be open.

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•

The tiller switch (B2) must not indicate driving position.

•

The safety switch (S2) must be closed (i.e. not depressed).

•

The safety socket (S8) must be closed.

•

The speed reference signal (X6:6) must be near 0 V.

Use the console to check that there is a signal at pin 12 (C) of connector X6. Refer to Section 4.3.2.15 Parameter 51: Connector X6 (diagnostic).

4.3.3.20. Error 19: Brake release monitoring This fault has error code number 19. The status LED indicates this fault by repeating the following sequence: nineteen pulses and a pause.

This error indicates a fault with the brake release function. The error can be due to an incorrect operating sequence. After the controller is powered up, the following conditions must be true: •

Drive signals (X6:2 and X6:3) must not be present.

•

Speed reduction must be active.

•

The brake release switch (S3) must be open.

•

The tiller switch (B2) must not indicate driving position.

•

The safety switch (S2) must be closed (i.e. not depressed).

•

The safety socket (S8) must be closed.

•

The speed reference signal (X6:6) must be near 0 V.

Use the console to check that pressing the brake release button provides a signal at pin 5 of connector X6. Refer to Section 4.3.2.15 Parameter 51: Connector X6 (diagnostic).

4.3.3.21. Error 20: Safety socket monitoring This fault has error code number 20. The status LED indicates this fault by repeating the following sequence: twenty pulses and a pause.

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This error indicates a fault with the safety socket. The error can be due to an incorrect operating sequence. After the controller is powered up, the following conditions must be true: •

Drive signals (X6:2 and X6:3) must not be present.

•

Speed reduction must be active.

•

The brake release switch (S3) must be open.

•

The tiller switch (B2) must not indicate driving position.

•

The safety switch (S2) must be closed (i.e. not depressed).

•

The safety socket (S8) must be closed.

•

The speed reference signal (X6:6) must be near 0 V.

Use the console to check that there is a signal at pin 6 of connector X3 when the safety socket is in place. Refer to Section 4.3.2.12 Parameter 48: Connector X3 (diagnostic).

4.4. Electrical maintenance and repairs This section provides instructions for specific maintenance procedures. These tasks are not part of the regular maintenance schedule.They are performed when needed. Refer to Section 3.1 Safety guidelines and preparation and Section 3.2 Maintenance guidelines for information on safety and preparation for maintenance tasks.

If other (than those examined below) electrical components fail, contact your supplier or local technical support for replacement parts and instructions. If you have a specific electrical maintenance problem that is not answered here or in another part of the manual, contact your supplier or technical support.

4.4.1. Battery maintenance Before performing battery maintenance, take safety precautions appropriate for handling lead-acid batteries and battery fluid. A truck battery carries a considerable amount of stored electrical energy. When handling a battery, battery assembly or battery cell, insulate all the electrical contacts to minimise the risk of a short circuit. Be careful with conductive tools and equipment when working near batteries. Lead-acid batteries contain a

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corrosive acid solution. Wear appropriate protective gear such as protective clothing, gauntlets and eyewear. Refer to Chapter 3 Regular maintenance for information on regular battery maintenance procedures. Contact technical support for current information on servicing truck batteries and acquiring a new battery or battery assembly.

There are three possible power source arrangements (see Section 4.1.2 Power source). The 1,300 kg capacity truck has two independent batteries. They are AGM or GEL type batteries, which are mounted in the main chassis of the truck. Both types are service free, and the entire battery must be replaced when it begins to age. Refer to the instructions provided by the battery manufacturer on using and maintaining AGM and GEL batteries.

When replacing the batteries, remember to replace them with batteries of equal weight so that the usage safety of the truck is not affected.

Figure 4.5. Power sources of the 1,300 kg capacity truck The 1,600 and 2,000 kg capacity truck models have a separate battery compartment, which holds a battery cell assembly. The battery assembly consists of 12 wet lead-acid battery cells and has a nominal voltage of 24 V. The truck models can accommodate power sources with varying capacities. The maximum battery capacity is 270 Ah for 1,600 kg capacity trucks and 345 Ah for 2,000 kg capacity trucks. The battery assembly is connected to the truck’s electrical system via connector XG1.

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Refer to Section 4.1 Electrical operation for more information on the electrical connections and operation of these trucks.

Figure 4.6. Power source of a 1,600 kg capacity truck

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Figure 4.7. Battery assembly When you suspect that a battery cell or the entire battery assembly is not functioning optimally, check the state of the cells in the assembly by measuring their specific gravity. This measurement provides more reliable information about the condition of a cell than, for example, measuring its voltage.

Always refer to the maintenance instructions issued by the manufacturer or supplier of the battery cell or battery assembly.

As a guideline, however, the specific gravity measurement of a fully-charged battery cell should be 1.28 to 1.30 at 30°C. A cell is about half-charged if it measures 1.20 and empty at 1.15 or below.

If a battery cell needs to be replaced, refer to the maintenance instructions issued by the cell manufacturer. Remember to use a cell that is identical to the original one in electrical characteristics, size and weight. In circumstances in which several cells are performing badly, it may be wise to replace the entire battery assembly. It is very important that all the characteristics, especially the weight of the new battery assembly is identical to the original one, so that the truck’s usage safety is not affected.The truck’s identification plate indicates the minimum weight of the battery.

Be careful when replacing the battery assembly, as it is very heavy. Use a sufficiently powerful crane or truck to lift the

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assembly from its marked lifting points. Never lift the assembly from any other points. When preparing the assembly for lifting, insulate the battery cell contacts to protect against short circuits.

4.4.2. Fuses The truck's fuses do not require regular checks. They need to be replaced only if they have blown. Never operate a truck with a blown fuse. Replace the fuse before continuing to use the truck.

When fuses need to be changed, always replace them with identical components. Never use a fuse of another rating than that recommended by the manufacturer.

The standard truck has two main fuses and an auxiliary fuse in the controller. To access the fuses, open the truck’s main cover.

Figure 4.8. Example of the two main fuses On the electrical schematic diagram, the main fuses are marked as 1F1 and 2F1 (zones 13 and 15 on page 1). Fuse 1F1 supplies the positive battery feed to the traction controller. It is rated at 70 A on the 1,300 and 1,600 kg capacity trucks, and 100 A on 2,000 kg capacity trucks. Fuse 2F1 supplies the positive battery feed to the K1 pump motor contactor. It is rated at 70 A on all truck models.

The auxiliary controller fuse is mounted in the controller, but can be accessed from the outside. The auxiliary fuse is marked as

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A1F1 in the electrical schematic diagram (zone 20 on page 1).

It is rated at 5 A.

Figure 4.9. Auxiliary controller fuse If the truck is fitted with optional cold store equipment, an additional heater fuse is present. The heater fuse is marked as F51 in the electrical schematic diagram (zone 14 on page 3). It is rated at 5 A.

4.4.3. Replacing a controller A controller in the truck may encounter an internal fault, which cannot be fixed from the outside. In this case, it is best to replace the entire controller. Contact your supplier or technical support for information on obtaining up-to-date documentation and parts for the truck. The truck cannot be used with a faulty controller.

Turn the main key switch off and disconnect the battery before attempting any maintenance procedures on the controller. When disconnecting the controller, remember to start by removing the positive supply connection first and the negative connection last.

When connecting a new controller, connect the negative supply connection first and finish with the positive connection. Pay attention to the polarity markings on the controller, as polarity inversion will damage it. Contact technical support for the latest information regarding controller replacement.

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NOTE

The parameters of the replacement controller must be reprogrammed for the application.

4.4.4. Replacing the accelerator module in the tiller arm head The accelerator module in the tiller arm head may require replacement during the truck’s operating life. The tiller arm head assembly contains the main control devices needed by the operator to use the truck. Its main component is the accelerator.

It also houses the lifting controls, the brake release button, the horn button and the safety button. Refer to Chapter 2 Operating the truck for more information on the truck’s control devices.

WARNING! Disconnect the battery connector before beginning.

To replace the accelerator module: 1.

Begin by locating the two fixing screws on the underside of the head assembly and the two screws on the topside of the assembly. Open the four screws using a 5 mm Allen key.

Figure 4.10. Main fixing screws at the back of the tiller arm head assembly

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Figure 4.11. Main fixing screws in front of the tiller arm head assembly 2.

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After removing the screws, lift the top section upwards from the edge containing the safety button. Be careful with the end closer to the arm, as lifting it might stress the internal wiring.

Figure 4.12. Opening the assembly 3.

Disconnect the connector from the accelerator module.

4.

Remove the accelerator controls from both sides of the assembly by unscrewing them from the axle. Take care not to lose the spring washers.

5.

Loosen the two fixing screws holding the accelerator module with a 4 mm Allen key. The screws do not have to be removed, loosening is sufficient.

6.

Remove the safety switch carefully by prying it with a flat-head screwdriver.

7.

Install the new accelerator module.

8.

Replace the safety switch.

9.

Tighten the accelerator module fixing screws.

10. Replace the accelerator controls to the assembly. Note the position of the controls: one of the three wings of both

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controls should point in the direction of the arm, that is, downwards when the arm rests in the upright position.

11. Connect the accelerator module connector.

12. Reposition the top section of the assembly on to the bottom section.

13. Tighten the four fixing screws.

Once the accelerator module has been replaced, it should be tested. Begin by programming the voltage range of the accelerator to the truck’s traction controller. For more information on this procedure, refer to Section 4.3.2.38 Parameter 251: Program throttle. After this procedure, thoroughly test the operation of the tiller arm head controls before returning the truck to normal use.

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5. Hydraulic operation and maintenance This chapter describes the hydraulic system of the truck. The chapter is divided into two main sections. The first section, Hydraulic operation, presents the hydraulic operation of the truck.

The second section, Hydraulic maintenance, provides information on maintenance and repair procedures not covered in Chapter 3 Regular maintenance.

Refer to Section 3.1 Safety guidelines and preparation and Section 3.2 Maintenance guidelines for information on safety and preparation for maintenance tasks. Refer to Chapter 2 Operating the truck for operating instructions.

5.1. Hydraulic operation This section presents the hydraulic operation of the truck. Please ensure that you have the appropriate version of the hydraulic schematics for the truck model under maintenance. Contact your supplier or technical support for information on obtaining up-to-date documentation for your truck model.

The hydraulic schematic diagram illustrates the operation of the hydraulic system. In the following procedures, different parts of the hydraulic system are numbered. These numbers refer to the figure below.

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Figure 5.1. Hydraulic system (TH50 1104) The principle of the hydraulic operation of the truck is as follows: Lifting:

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1.

The electrical motor (1) operates the hydraulic gear pump (2).

2.

The hydraulic fluid is pressurised.

3.

The fluid pressure is maintained using a relief valve (3), which opens at a certain pressure. In such cases, hydraulic fluid is returned to the fluid tank. The opening pressure of the relief valve is indicated in the hydraulic schematics.

4.

The pressurised hydraulic fluid flows through the no-return valve (5) to the lifting cylinder (6).

5.

The lifting cylinder piston lifts the forks.

Figure 5.2. Hydraulic fluid flow during lifting Lowering 1.

The solenoid valve (8) is opened with the lowering switch.

2.

Hydraulic fluid flows through a 300 µ sieve (7) back to the fluid tank.

3.

As the hydraulic pressure reduces, the lifting cylinder piston retracts and the forks are lowered.

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Figure 5.3. Hydraulic fluid flow during lowering Various truck models can have different configurations of the hydraulic system.

5.2. Hydraulic maintenance and repairs The following sections illustrate various hydraulic maintenance procedures not covered in Chapter 3 Regular maintenance.

5.2.1. Replacing gaskets NOTE

When the gasket of the hydraulic cylinder needs to be replaced, the wiper and guide strips are also replaced.

To replace gaskets:

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1.

Pull out the piston rod from the cylinder.

2.

Remove the wiper from the cylinder using suitable pliers.

3.

Pull the old gasket carefully out of the cylinder.

NOTE

Do not use sharp tools.

4.

NOTE

Squeeze the new gasket using round pointed pliers. The groove in the gasket goes inside the cylinder (towards the bottom of the cylinder).

Do not scratch the inside walls of the cylinder.

Figure 5.4. Squeezing the gasket 5.

Attach the new wiper to the cylinder. The wiper prevents dirt from entering the cylinder when the piston rod moves.

6.

Insert the piston rod into the cylinder.

5.2.2. Replacing the hydraulic pump The hydraulic pump and tank assembly is located in the left part of the main chassis when viewed from the front. Depending on the truck model, the assembly is installed either horizontally (1,300 kg capacity truck model) or vertically (1,600 and 2,000 kg capacity truck models).

To replace the hydraulic pump: 1.

Remove the main and top covers of the truck.

2.

The hydraulic pump and tank assembly is fixed to a bracket, which is fixed to the main chassis. Locate the bolts that fix the bracket to the chassis and open them.

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NOTE

On 2,000 kg capacity trucks, you have to remove the battery pack to gain access to the fixing screws that hold the hydraulic pump and tank assembly.

3.

After opening the bolts, turn the assembly out of the chassis to gain access to it.

4.

Open the four screws that hold the entire assembly together using a 4 mm Allen key. Be careful when handling the assembly with the screws removed.

Figure 5.5. Removing the hydraulic tank (1,600 kg capacity truck model)

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5.

Carefully remove the tank and drain out the old hydraulic fluid.

6.

Detach the hydraulic hoses from the hydraulic pump and tank assembly.

7.

Disconnect the electrical connections from the hydraulic pump motor.

8.

Replace the hydraulic pump motor.

9.

Connect the electrical connections to the new hydraulic pump motor.

10. Connect the hydraulic hoses to the hydraulic pump.

11. Attach the hydraulic tank to the hydraulic pump and fasten the four fixing screws.

12. Reattach the entire assembly to the main chassis.

13. On 2,000 kg capacity trucks, reattach the battery pack.

14. Open the filling cap and fill the tank with new hydraulic fluid to half (1,300 kg capacity truck model) or three-quarters (1,600 and 2,000 kg capacity truck models) of its capacity when measured from the bottom of the tank to the filling tube.

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6. Mechanical maintenance This chapter presents the mechanical maintenance procedures not covered in Chapter 3 Regular maintenance. Refer to Section 3.1 Safety guidelines and preparation and Section 3.2 Maintenance guidelines for information on safety and preparation for maintenance tasks. Refer to Chapter 2 Operating the truck for operating instructions.

6.1. Replacing wheels A truck has three wheel types: drive, load and castor wheels.

Check all the wheels on a truck for damage and wear.The wheels should wear evenly and there should be no flats or holes in the wear surface. The wheels should also turn smoothly on their axles and there should not be play in the bearings. Even wear can be checked by driving the truck on a smooth surface to test that all the wheels turn and the truck rides smoothly. If a wheel or a bearing has sustained damage that affects use or if its surface has worn completely, it should be replaced.

To replace a truck wheel, follow the instructions given below.

WARNING! Never work under the truck if it is supported only by a jack.

6.1.1. Replacing the drive wheel The drive wheel is located immediately under the tiller arm anchoring point and supports a considerable portion of the truck’s weight. The drive wheel is used to propel and steer the truck. It is attached to the drive motor via the transmission. The tiller arm is used to turn the drive wheel when steering the truck.

To replace the drive wheel: 1.

Open the main and the top covers of the truck by loosening the fixing screws enough for the cover to be removed, but do not remove the screws entirely. The screws move a fixing bracket, which holds the cover in place.

2.

If you are working on a 2,000 kg capacity truck, skip to step 4. On 1,300 and 1,600 kg capacity trucks: Open the four fixing screws of the bottom steel plate cover. Use a 5 mm Allen key.

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Figure 6.1. Removing the bottom plate fixing screws

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3.

Lift the bottom steel plate cover up over the tiller arm. Make sure that none of the control panel wires are damaged.

4.

Turn the drive wheel using the tiller arm so that the fixing screws of the wheel can be reached.

5.

On 2,000 kg capacity trucks, remove the five wheel fixing screws with a 19 mm wrench. On 1,300 and 1,600 kg capacity trucks, remove the ten wheel fixing screws with a 5 mm Allen key. Do not remove the two countersunk screws, as they hold the planet gear rim in place.

Figure 6.2. Removing the drive wheel fixing screws on 1,300 and 1,600 kg capacity trucks 6.

Lift the truck from under the chassis using a suitable jack so that the drive wheel is lifted off the supporting surface.

7.

Remove the old drive wheel.

8.

Attach the new drive wheel.

9.

Replace all truck covers and test the operation of the drive unit.

6.1.2. Replacing the load wheels The load wheels are located near the ends of the forks. Their main purpose is to support the weight of the load. Depending on the truck model, there is either a single or a double load wheel in each fork.

To replace single load wheels: 1.

Loosen the locking pin from the axle using a 5 mm pin punch.

The locking pin is located on the outside end of the axle.

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2.

Raise the forks and lift the truck slightly with a jack.

3.

Remove the locking pin from the axle.

4.

Remove the load wheel axle.

5.

Replace the load wheel and reattach the axle and the locking pin.

To replace double load wheels: 1.

Lift the truck using a jack. Place supporting brackets under the truck.

2.

Remove the axle bolt using a 8 mm Allen key on both ends of the bolt.

3.

Replace the load wheel and reattach the axle bolt.

6.1.3. Replacing the castor wheels The side-supporting castor wheels are located under the main chassis on either side of the drive wheel. They support the truck when it is driven and prevent it from tilting, as there is only one drive wheel. The castor wheels turn automatically to follow the direction of travel. They are equipped with suspension springs.

To replace the castor wheels: 1.

Lift the truck using a jack. Place supporting brackets under the truck.

2.

Remove the axle bolt using a 17/19 mm wrench on both ends of the bolt.

3.

Replace the castor wheel and reattach the axle bolt.

6.2. Replacing the tiller arm gas spring This section gives instructions on how to replace the gas spring of the tiller arm. The purpose of the gas spring is to return the tiller arm automatically to the upright resting position. It is a safety device, which must always be fully operational.

To replace the gas spring: 1.

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Remove the cover from the base of the tiller arm.

2.

Remove the ball joints from both ends of the gas spring using a 13 mm wrench.

3.

Replace the gas spring.

4.

Attach the ball joints to the tiller arm.

5.

Reattach the cover to the base of the tiller arm.

6.

Test the operation of the tiller arm.

Figure 6.3. Replacing the tiller arm gas spring

6.3. Lever system maintenance The lever system is present only on trucks with initial lifting functionality. The system is composed of levers and the initial lifting cylinder between the main chassis and the mast assembly, and push rods under the forks. They operate to lift the mast and fork assembly evenly when initial lifting is used. The following procedures provide instructions for disassembling the system for maintenance purposes.

The bushings in the initial lifting levers must be changed when play has developed in the system.

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WARNING!

These procedures require the truck to be lifted and supported. Take care to support the weight of the truck and the separated components. Take care especially when removing the levers between the main chassis and the mast assembly.

To remove the pushrods: 1.

Lift the truck.

2.

Remove the locking pins from both ends of the push rods using a 5 mm punch.

3.

Remove the shafts from both ends of the push rods.

The shafts at the cylinder ends of the push rods cannot be removed by hitting them with a punch. You have to use an inertia hammer to pull the shaft out from the push rod.

4.

Remove the push rods.

NOTE

To remove the wheel forks: 1.

Remove the load wheels from the wheel forks.

2.

Remove the locking pins and detach the wheel forks.

To remove the hydraulic cylinder lever: 1.

Remove the push rods.

2.

Remove the circlips from the cylinder axle ends.

3.

Remove the axle from the cylinder. There are two washers on each side of the cylinder attachment point.

4.

Remove the lever.

To remove the upper and lower levers:

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1.

Remove the locking pins with a 4 mm punch.

2.

Remove the axles. Depending on the lever end, gently hammer the axles out or remove them with an extractor.

3.

Remove the bushings from the axle and install new ones.