Caterpillar NPR20K Lift Trucks Operation & Maintenance Manual - PDF DOWNLOAD

EN

Operation & Maintenance Manual NPR20K

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

1. Pallet truck ............................................................................ 3 2. Safety instructions ................................................................ 4 3. Operating environment ....................................................... 20 4. Operating devices ............................................................... 20 5. Driving instructions ............................................................. 20 6. Load handling ..................................................................... 20 7. Batteries ............................................................................. 20 8. Maintenance ....................................................................... 20 9. Transportation and storage ................................................ 20 10. Troubleshooting ................................................................ 20

1

2

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

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

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

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

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

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

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

3

MOTOR CONTROLLER FOR ELECTRONIC POWER STEERING

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

TABLE OF CONTENTS Content 1.

page

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

2.

Specifications

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

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

3.

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

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

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

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

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

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

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

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

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

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

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

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

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

1

2. SPECIFICATIONS 2.1

GENERAL Models

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

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

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

Part no

Motor type

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

FBW 4820 (48V battery voltage)

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

54Q020PB

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

54Q020NB / 54Q020RB / 54Q020QB

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

PM DC -motors

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

min. 0,5mH

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

4Q

Modulation

PWM (Puls Width Modulation)

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

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

2.2

FBW 2440 (24V battery voltage)

16kHz

BATTERY VOLTAGE Nominal

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

24VDC

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

48VDC

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

16-30VDC

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

33-58VDC

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

12VDC (Start level > 20V)

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

24VDC (Start level > 40V)

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

36VDC

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

72VDC

Tolerances: Continuous

Intermittent <50ms

<100µs

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

2

2.3

CURRENT CAPACITY Peak

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

40A

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

20A

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

25A

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

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

15A

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

2.4

At +55oC environmental temperature

50-100% of peak current.

Adjustable in 4 steps with dipswitches

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

2.5

Progressive characteristic input, meaning increased sensitivity when faster rotation.

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

2.6

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

+24VDC via 50 Ohm PTC

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

24VDC

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

48VDC

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

3

2.7

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

2.8

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

The same input as internal supply

Logic 1/logic 0

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

Logic 0: no limiting Logic 1: limiting

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

Logic 0: no limiting Logic 1: limiting

SAFETY RELAY OUTPUT Safety relay

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

24VDC (closed): ok

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

48VDC (closed): ok

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

2.9

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

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

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

Adjustable in 4 levels with dipswitches

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

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

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

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

4

Tachometer circuit

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

Disconnections and short circuits are detected.

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

Motor output voltage above commanded values detected.

Motor circuit

Disconnections and short circuit are detected.

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

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

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

Linear reduction of current limit starting at 75oC .

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

At every start-up: checking that contactor is open

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

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

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

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

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

2.11 INDICATIONS LED-indications

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

Outputs indications

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

5

2.12 OPERATION ENVIRONMENT Temperature: Operation Storage

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

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

Humidity

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

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

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

Contact cooling to metal plate or frame

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

500VAC according to prEN 1175-1

2.14 EMC Immunity:

According to prEN50081-2

Emmission:

According to prEN50082-2

6

Common

Error signal 2

Error signal 1

Direction blocking

-

+

Potentiometer

Tachometer

-12V

Tachometer 0V

+12V

Start/Stopp Safety relay

9

12

3

5

11

10

6

7

13 4

8

1

+ +

-

Monitor puls

IR-sensitivity

R

C

Blocking and sensitivity Speed regulator

Sensors monitor

Current limit

DC

+

-

Current monitor

Voltage monitor

PWM

Voltage monitor

Logic circuits monitor

R

C

Current regulator

DC

Temperatur sensor

Bat.-

M2

M1

Bat. +

2.15 BLOCK DIAGRAM

7

2.16 MECHANICAL DIMENSIONS

64

152 139 125

145

210

6.5

10

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

8

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

Safety brake

Truck computer

Limit switches

Steering wheel tachometer

0 1

Key switch

Control fuse

9

12

10

3

5

11

6

4

13

8

1

Error indication no 2, low

Error indication no 2, high

Controller

LED

LED

Battery-

Motor-

Current limit adjust.

Motor+

LED

Error indication no 1, low

Tachometer input scaling

Battery +

IxR-comp. adjust.

LED

Error indication no 1,high

- Direction limiting

+ Direction limiting

Tachometer

0V Tachometer

+24V

Safety circuit relay

Start/Stop Internal supply

-

M2

M1

+

Steer motor

Supply contactor

Power fuse

B-

B+

3.INSTALLATION INSTRUCTIONS

3.1 CONNECTION

9

3.2

COMPONENTS REQUIRED

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

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

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

50A

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

25A

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

30A slow

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

15A slow

3.2.2 POWER FUSE Current

3.2.3 CONTROL FUSE Current

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

6-10A slow

3.2.4 BATTERY AND MOTOR CABLES Dimension

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

min. 4mm2

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

min. 2,5mm2

3.2.5 CONTROL WIRING Dimension

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

min. 1mm2

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

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

10

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

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

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

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

11

3.3

CONNECTORS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

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

Function

1 2 3

Input:

4 5 6 7 8 9 10 11 12

Input: Input: Input:

13

Output:

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

Input: Output:

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

Output:

Supply for limit switches

Output: Output:

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

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

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

Function Input: Input: Output: Output

Battery voltage+ Battery voltageMotor connection + Motor connection -

24,48 V 0V

12

3.4

ADJUSTMENTS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

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

4820

2440

10A 14A 17A 20A

20A 28A 34A 40A

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

No compensation 1/3 2/3 Max compensation

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

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

5+6+7+8 open:

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

13

3.5 INDICATIONS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

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

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

supply contactor closed or voltage on emergency brake coil *

Outputs:

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

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

supply contactor closed or voltage on emergency brake coil *

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

14

CAT

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

1/1

PARAMETERS

Rev. Date

Zapi SEM-1 RO 1.78

5 20.12.2002

SEM1 SEM1 MAIN MENU/ PARAMETER CHANGE: ACCELERATION DELAY 3 3 DECELERATION DELAY 5 5 RELEASE BRAKING 5 5 INVERSE BRAKING 5 5 SOFT BRAKING 0 0 QUICK INV. BRAKE 5 5 SOFT ACCELERATION 0 0 CUTBACK SPEED 1 5 5 CUTBACK SPEED 2 1 1 H&S CUTBACK 0 0 MAX. SPEED FORWARD 9 9 MAX. SPEED FW FINE 9 9 MAX. SPEED BACKWARD 9 9 MAX. SPEED BW FINE 9 9 COMPENSATION 0 0 MAXIMUM CURRENT 5 5 ARMA. NOM. CURRENT 0 0 WEAK DROPOUT 5 5 FIELD NOM. CURRENT 7 7 CREEP SPEED 0 0 BACKING TIME 9 9 BACKING SPEED 6 6 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 ON ON 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 300A 300A SET FIELD CURRENT 22A 22A

NPR20K

NO10SPF

NO20SP

NO20S

TRUCK TYPES: NOTE

SEM1 SEM1

3 5 5 5 0 5 0 5 1 0 9 9 9 9 0 5 0 5 7 0 9 6 0

3 5 5 5 0 5 0 5 1 0 7 5 7 5 0 5 0 5 7 0 9 6 0

RUN BEL BRA ON HAN ON NOR

RUN BEL BRA ON HAN OFF NOR

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

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

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-1C 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-1C 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-1C: 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 5.6 SEM-1C Traction Standard Wiring Diagrams ...................................... 25 5.7 Sequence for SEM-1C Traction Settings. ........................................... 26 6 SEM-1C 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-1C 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-1C family of Choppers are suitable for operating on DC voltages from 24 to 48V inclusive, with maximum armature current up to 300A. The choppers may be used to control DC Separately Excited Motors with power ratings from 1.0KW to 3.5 KW.

Page 4

2 GENERAL CHARACTERISTICS 2.1 TECHNICAL SPECIFICATION Chopper for Separately Excited DC motors ................................................... 1.0÷ 3.5kW Regenerative Braking.

Voltage Range ............................................................................................ 24-36-48VDC 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 FIeld resistance .......................................................................................... 0.3 ÷ 0.6 Ohm

VERSIONS

MAXIMUM CURRENT

BOOSTER CURRENT

VOLTAGE DROP IN FULL CONDUCTION

24V-36V

200A (3')

220A (10'')

0.23V a 100A, 25°C

24V-36V

300A (2')

330A (10")

0.23V a 100A, 25°C

48V

180A (3')

200A (10")

0.18V a 50A, 25°C

2.2 CONTROL UNITS 2.2.a Microswitches - Microswitches should have a contact resistance lower than 0.1Ω, 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 : 500Ω Maximum Potentiometer Resistance : 10kΩ 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-1C 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-1C modules. The filter capacitors contained in the SEM-1C 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-1C 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-1C 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 10Ω and 100Ω.

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-1C 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-1C 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-1C 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 SEM-1C choppers must be fitted with Eprom CK ULTRA. Page 15

4.3 DESCRIPTION OF STANDARD CONSOLE MENU

Page 16

5 SEM-1C: 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

4

5

6

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.

BATTERY CHECK -ON

Is controlled the battery charge. Whe the battery is discarged is displayed "BATTERY LOW"

-OFF

Is controlled the battery charge,but not displayed the alarms.

SEAT SWITCH -HANDLE

a tiller switch is present

-SEAT

a seat switch is present

BACKING INPUT -ON

The backing function is activated

-OFF

The backing function is deactivated

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.

20 BACKING TIUME = Activation time the backing function.

21 BACKING SPEED = Motor speed during the backing function.

Page 22

5.5 TABLE OF ADJUSTMENTS The following Table shows the different values that the SEM-1C 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.

PA R A M E TE R S

PRO G RAM M ED LEVEL U N IT

0

1

2

3

4

5

6

7

8

9

AC C. D E LAY

sec.

0.30

0.50

0.70

0.90

1.10

1.25

1.40

1.55

1.75

2.00

D E C. D E LAY

*

9

8

7

6

5

4

3

2

1

0

R E LE A S E B R A K IN G

*

0

1

2

3

4

5

6

7

8

9

IN V E R S B R A K IN G

*

0

1

2

3

4

5

6

7

8

9

S O F T B R A K IN G

** %

50

40

33

28

25

22

20

18

16

15

S O F T AC C E LE R AT IO N

*** %

50

40

33

28

25

22

20

18

16

15

C U T B AC K S P E E D 1

% AC C

30

38

45

51

57

64

72

80

90

10 0

C U T B AC K S P E E D 2

% AC C

30

38

45

51

57

64

72

80

90

10 0

H & S C U T B AC K

% AC C

30

38

45

51

57

64

72

80

90

10 0

M A X S P E E D F O RW.

% FCN

10 0

90

80

71

62

53

45

40

36

33

M A X S P F O RW. F IN E

**** % F C N

0

1

2

3

4

5

6

7

8

9

M A X . S P E E D B AC K .

% FCN

10 0

90

80

71

62

53

45

40

36

33

M A X S P B AC K . F IN E

**** % F C N

0

1

2

3

4

5

6

7

8

9

C O M P E N S AT IO N

***** % I A

0

5

10

16

22

27

33

38

44

78

M A X IM U M C U R R E N T

% IM a x

82

84

86

88

90

92

94

96

98

10 0

A R M A C U R . N O M . (AC N )

% IM a x

45

47

50

52

54

56

58

61

63

65

W EAK DROP OUT

% AC N

40

44

48

52

57

62

66

70

75

80

F IE L D C U R R . N O M . (F C N )

A

7.5

8.1

8.7

9.3

10

10 .6

11 .2

11 .8

12 .5

13 .1

CREEP SPEED

% V B a tt

4

5

6

7

8

9

10

11

12

13

B AC K IN G T IM E

sec.

1.6

1.9

2.1

2.4

2.7

3.0

3.2

3.5

3.8

4.1

B AC K IN G S P E E D

% m ax sp.

19 .6

23 .5

27 .4

31 .3

35 .3

39 .2

43 .1

47 .0

51 .0

55 .0

*=

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

5.6 SEM-1C TRACTION STANDARD WIRING DIAGRAMS

Page 25

5.7 SEQUENCE FOR SEM-1C 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-1C 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-1C

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1K1

1

A

0F1 10A

3F1 50A

1

2

1

2F1 200A

2

1

1F1 200A

2

C

4F1 10A

3

2.5 mm2

25 mm2

2

2.5 mm2

25 mm2

1.0 mm2

1

X3 2.5 mm2

X2

3/13

E

5F1 10A

G

6F1 10A

5

7

5L4 16 mm2

5L3 7/26

5/12

X1: B-

7/23

4L1

5L1

0M1

3M1

2M1

1M1

4M1

5M1

3/13

2/24

2/20

2/13

3/21

5/22

0M2

4M2

5M2

5/13

5/16

7/29

AUX. DEVICES

STEERING CIRCUITS

PUMP MOTOR

6L1

5/20

PUMP CIRCUITS

2/13

5L2

5/14

DRIVE MOTOR

1L1

2/20

STEERING MOTOR

-

2L1

2/24

BATT.DISCARGE IND.

24V

G1

3L1

3/15

MAIN CONTACTORS

+

0L1

4L2

DRIVE CIRCUITS

0L2

X1: B+

A

6.0 mm2

7/16

6M1

0M3

D

M2:D2

TS831002

5F2 10A

F

NPR20K POWER SUPPLIES 24V

8

6F2 10A

H

2.5 mm2

2.5 mm2

CIRCUIT DIAGRAM

4F2 10A

6

2.5 mm2

2.5 mm2

B

4

2.5 mm2

0F2 10A

16 mm2

2

16 mm2

6.0 mm2

2/28

25 mm2

11

1 / 10

REV

3-6724

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

3 3L1

J1

J2

1/20

1/18

3/16

3/16

1

1

1K2

5/24

7/28

2

1,0 mm2

SM2

2

t +50°C 2 (RL450441)

1

4,0 mm2

16 mm2

16 mm2

2

1

3K1

2K1

3/17

1,0 mm2

16 mm2

4,0 mm2

2L1

1/22

16 mm2

1L1

4,0 mm2

16 mm2

E1

M1 A1

E2 4,0 mm2 F2 16 mm2 VMN

SH

M1

X31: 1 A1

M2

M3 A2

D2

X31: 2 4,0 mm2 M2

16 mm2

X6: 1

X7: 1

RED

RED

M4 BLK

X6: 2

M5 BLK

X7: 2

4,0 mm2 B-

4,0 mm2

-BATT

SEM-1C

A1

FBW 2440

A3

1,0 mm2

A2

4,0 mm2 F1

4,0 mm2

A3 STEERING MOTOR CONTROLLER

+BATT

D1

X30

16 mm2

A1 SEM-TRACTION CONTROLLER

B+

16 mm2

11

1M1

2M1

3M1

0M3

1/22

1/20

1/18

1/15

DRIVE MOTOR

PUMP MOTOR

STEERING MOTOR

CIRCUIT DIAGRAM

TS831002

NPR20K POWER CIRCUITS

AUXILIARY FANS

2 / 10

REV

3-6724

3

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

0L1

J11

J12

1/15

4/15

4/26

WHT/ BRN BLK

GRN

ORA

WHT

X21: 1

X21: 7

6

+ C11 - 0.4uF 3K2

FW

BW

POT LOW

0-5 V

B+

22

B-

B1

S2

X21: 4

5

4

7/29

3

R11

3

1ohm

Z11 1N4007

43

S1

S1 KEY SWITCH

14

+

44

X20:12

X20:11

12

X20: 2

23

J2

DISPLAY AND CONTROL UNIT 10

J1

J2

2/28

2/29

21

J10

19

X11: 3

X12: 1

M1

A1

A4

MAIN CONTACTOR 2

Y1 A2

2/13

1K2

A2

4M1

A2 -

BACKING

1K1

FW/BW

A1

BW/FW

A1

1/24

3

A

2

3

C

1

2

4

6

B

8

PEMB

NEMB

H&S

FORW

100nF

REV

CPOT

1

SR1

7

SR2

COM

2

PMC

C

X10: 4

NMC

X10: 2

NPOT

1/16

X12: 2

X10: 3 +

MAIN CONTACTOR 1

-

X11: 2

U X10: 1

30

WHT/ BLK

21

13

29

X11: 1

ACCELERATOR NM3V

X20: 1

EMERG.STOP

28

MAGN.BRAKE

START-UP

KEY

11

4

5

A

A1 SEM-TRACTION CONTROLLER 0M1 1/15

SEM-1C

A1 CIRCUIT DIAGRAM

TS831002

NPR20K TRACTION CIRCUITS 1

3 / 10

REV

3-6724

1

NC

NO

S10

COM

16

17

18

7

19

19

20

24

13

21

22

23

24

25

26

27

28

29

30

DEAD MAN’S PEDAL

BRAKE SWITCH

J2

BRAKE RELAY

15

SUPPLY

14

DASHBOARD ORIENT

13

SUPPLY

12

MAGNETIC BRAKE INTERLOCK

11

J10 DISPLAY AND CONTROL UNIT

J41

J11

7/21

3/16

J12

A4

3/27

CIRCUIT DIAGRAM

TS831002

NPR20K TRACTION CIRCUITS 2

4 / 10

REV

3-6724

11

12

13

14

BATT.DISCH.IND.

15

16

POWER SUPPLY

17

18

19

20

21

22

SIGNAL HORN

HOUR METER

0L2

0M2

4L2

4M2

5L1

1/15

1/15

1/24

1/24

1/26

23

24

25

INITIAL LIFT

26

27

28

29

30

INITIAL LOWER

X20: 3

NO

S5

NO

S6

COM

NO

S7

COM

X20: 4

COM

X20: 5

X20: 6

NC

S8 LIFT LIMIT

COM

6

17

J2

12

14

15

18

J10 DISPLAY AND CONTROL UNIT

NM906-917

A4

8

9

20

V5 H1

2/20

2K1

2Y1

A2

A2

A2

NPC

1/26

PPC

X10: 6

5M1

21

A1

PEV

-

1N4005 220uF/63V

PHORN

A1

A1

+

NEV

C5 BASIC LIFT

STABILIZERS LOWER

CABIN LIFT

STABILIZERS LIFT

SUPPLY -

SUPPLY +24V

BATT-

BATT+

X10: 5

NHORN 2

3

4

J2

5

6

D A1 SEM-TRACTION CONTROLLER

h CD701-024

SEM-1C

A1

CIRCUIT DIAGRAM

TS831002

NPR20K LIFTING CIRCUITS 1

5 / 10

REV

3-6724

14

15

16

17

18

19

20

21

22

23

1

2

S14 3

1

25

26

27

28

29

30

LIFT/LOWER (STACKING MODELS)

INITIAL LIFT/LOWER BUTTOMS IN THE BACK REST (OPTION)

S13

24

5kOhm

2 3

1

2

3

4

5

6

7

R1

7

SEE PAGE 3-6691/5

6

5

4

3

2

1

8

1

J1 DISPLAY AND CONTROL UNIT

LOWER

J10 5

16

6

7

A4

CIRCUIT DIAGRAM

TS831002

NPR20K LIFTING CIRCUITS 2

LOWER START

LIFT START

LOWER REFER.

12

LOWER: 0-10V

11

LIFT REFER,

X15:10

LIFT: 0-10V

13

BASIC LIFT

12

SUPPLY

11

6 / 10

REV

3-6724

12

13

14

15

16

18

19

20

21

22

24

25

26

5L4

J41

5L2

5L3

1/26

4/14

1/26

1/26

STEERING LIMIT SWITCHES

27

28

29

30

BLK

X10: 9

X33: 2

NO

S31

NO

S32

NO

S33

7

10

18

13

J2

22

11

29

6

X10: 10

STEERING ERROR

COM

SENSOR B

COM

SENSOR A

COM

LAMP

3K2 MAGNETIC BRAKE INTERLOCK

X33: 1

23

B3

RED

+

STEERING WHEEL TACHO

17

SENSOR C

11

STEERING FAILSAFE RELAYS

1

X10: 7 DISPLAY AND CONTROL UNIT

20

P

9

J10

STOP

6

4

X32

STEERING LIMIT CCW

A1 SAFETY CIRCUIT

SUPPLY 24VDC

2/24

OPTION.

OPTION.

STEERING LIMIT CW

+

TACHOMETER 0V

TACHOMETER REF.

A4

+ 8

3K1

3K2

A2

3/26 7/23

- 1 -

X10: 8 11

5

1

8

12345678 OPEN CLOSED

A3 STEERING MOTOR CONTROLLER

FBW 2440

5M2

A3

1/26

CIRCUIT DIAGRAM

TS831002

NPR20K STEERING CIRCUITS

7 / 10

REV

3-6724

21

23

24

SM2:2

L100

3

4

5

6

7

8

C

D

E

F

G

H

X20

RL450102 24

RL210366 12

X21

L300

RL108288 9

30

A1:J10 RL450103 22

L100

L150

L150

L200

L200

L200

L100

SM2:1 L150

29

L500

L100

L100

L100

8

A1: A

L100

6

A1: D

3

A1: C

6

A1: B

L150

L150

1K1:2

L300

L150

L150

1K1:1

CIRCUIT DIAGRAM

H1:A1

TS831002

NPR20K WIRE HARNESS W5: RL450548

H1:A2

3K1:2

X10 X11 RL210025 RL210021

M2:D2

X31:2

X31:1

S10:NC

X 7 RL211074

S10:NO

2

S10:COM

L250

S33:NO

3

2Y1

L50

S33:COM

L100 L100

12 L700

L100

L200

L1400

X12 RL211074 2

L400

L300

L50

S32:COM

S32:NO

28

L100

L200

L250

L500

L250

S31:NO

27

RL450548

X30 X32 RL168565 RL168565 5 13

S31:COM

26

A1:J2

L500

X 6 RL211074 2

25

X33 RL210020 2

2

1

22

L250

20

6F1:

19

5F1:

18

4F1:

17

B

16

0F1: RL199085

15

1

14

A

13

S8:NC

12

S8:COM

11

9 / 10

REV

3-6724

1

OSALUETTELO TASOLLA:13 11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

L350

X20

L150

12

L250

RL210025 RL210029

29

30

S2:21

RL197678

S2:22

RL197678

S1:13

RL197678

S1:14

RL197678

S1:43

RL197678

S1:44

RL197678

RL450141 L130

S5:COM RL197237 S5:NO

RL197237

L100

S6:NO

RL197237

L100

S7:NO

RL197237

L70

CIRCUIT DIAGRAM

TS831002

L130

S7:COM RL197237

L130

S6:COM RL197237

NPR20K WIRE HARNESS W06: RL450141

10 / 10

REV

3-6724

1

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

REV

3-6969

E

c ROCLA OYJ 2006

11

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

2/2

REV

3-6969

E

2. Safety instructions Instructions for site supervisor • • •

Familiarise yourself with the operating instructions and its contents.

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

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

Occupational safety • • • • • • •

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

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

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

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

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

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

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

Truck operator Requirements: • • • • •

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

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

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

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

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

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

Overhead guard and load support Trucks driven sitting or standing and that are capable of lifting a load higher than 1.8 m must be equipped with an overhead guard. Modifications to the overhead guard that could possibly weaken its structure are not allowed.

If it is possible for objects to fall through the openings in the overhead guard, the size of the openings must be reduced.

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

4

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

Never use the truck: • • • • • • • •

To transport and lift people At premises with risk of fire At premises with risk of explosion At premises with insufficient floor load capacity If it is damaged As a mounting surface To tow another truck Under the influence of intoxicating substances

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

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

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

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

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

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

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

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

5

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

Type plate The truck's type plate is marked with: • • • • • • • • •

Manufacturer Type of truck Year of manufacture Serial number Truck's dead weight in operating condition, without battery or accessories Maximum and minimum battery weight Battery terminal voltage Truck's nominal lifting capacity CE mark

Capacity plate The capacity plate states the maximum lifting capacity at the maximum lifting height and the lifting height with the nominal lifting capacity. In addition, the plate states the centre of gravity distances for the relevant lifting capacity.

WARNING! Do not overload the truck.

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

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

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

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

Use the parking brake also for emergency braking. However, note that releasing the safety pedal makes the truck uncontrollable and can cause the drive wheel to wear unevenly.

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

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

2.

6

When changing direction When the truck is free-wheeling

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

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

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

Accelerator (2) Turn the accelerator handle forward or backward to the driving direction. A larger movement of the handle produces a higher speed. The accelerator returns automatically to the central position when it is released. You can brake smoothly by moving the accelerator to the direction opposite to the driving direction. You should anticipate the situation when you must brake and decrease the speed well ahead.

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

Steering wheel (3) The steering wheel turns the drive mechanism electrically 360°, see Section Electronic steering system in Chapter 5 Driving instructions .

Emergency stop button (4) Press the emergency stop button to switch off the power circuit of the battery. Use the button in the following cases: • •

A short-circuit or other electrical fault, for example, if the pump motor runs continuously In an accident

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Release the emergency stop button by turning it clockwise.

Horn button (5) Buttons for lifting and lowering the lift cabin and forks (6) Use the buttons on the control panel to lift or lower the forks.

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

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

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

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

Hour meter (4) The hour meter counts the time that the truck has been in active operation. It is always on when the electrical devices are operating.

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

Fault monitoring of the speed and pump controls Certain circuits of the truck have automatic fault monitoring, which gives a warning of faults in the drive speed and pump controls. If a fault occurs, the truck cannot be driven until the fault has been eliminated. If the truck does not begin to move and no obvious fault can be found, switch off the power, wait about 5 seconds, then

8

switch on the power again (in this case, do not touch the drive or load controls). If the fault continues, contact maintenance. If fault monitoring finds a fault during operation and stops the driving, stop the truck immediately.

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

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

• •

Disconnect the battery.

Disconnect the plugs of the electronic devices.

Adjusting the driving position Armrest Change the height and distance of the adjustable armrest by turning the locking screw counterclockwise and sliding the armrest to the desired height. Lock the armrest in place by turning the screw clockwise.

NOTE Lock the armrest carefully in place before using the truck.

9

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

• • • • • • • • • • •

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

Check all wheels for damage or wear.

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

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

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

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

Also check the operation of the other electrical functions.

Check that the batteries are charged and locked in place.

Check the operation of the horn.

Check that the safety pedal works .

Check that the emergency stop operates properly.

Before you start: • • • • •

Make sure that the daily maintenance has been carried out.

Switch on the power Check the driving direction from the indicator lights.

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

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

Driving • • • •

Press the safety pedal down to move the truck.

Turn the accelerator lightly in the driving direction.

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

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

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

The system consists of three main components: 1.

2.

3.

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Tachometer located in the steering wheel Control unit located in the motor compartment Steering motor, which is also in the motor compartment

The control unit processes the signal coming from the tachometer and directs the steering motor to turn the drive wheel in the desired direction. In addition, the control unit constantly monitors the status of the system and reacts immediately if there are any problems.

The drive wheel turns 180° or without limits. Turn the wheel 180° to change the driving direction to the opposite.

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

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

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

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

Wait for at least 3 seconds before you switch on the power again after it has been switched off by the system. If the red warning light does not go off after switching the power off and on again, there is a problem in the steering system and the truck cannot be driven.

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

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

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

• • • • • • •

Drive slowly at intersections and when turning.

Handle the truck responsibly and always keep it under control.

Avoid sudden starts and stops.

Steer and brake smoothly.

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

Take great care when driving on a slanted surface.

Do not drive over any loose objects on the floor.

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

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

Be especially careful: • • •

When there are other people or objects in the working area When the load reduces visibility When driving in narrow aisles make sure that there is enough space for the truck and the load

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

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

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

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

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

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

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

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

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

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

• • • • • • • • • • •

Always drive the truck with its forks lowered.

When the load is raised, steer and brake carefully.

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

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

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

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

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

Only handle undamaged loads.

Place the load correctly.

On slopes and ramps, place yourself above the load.

Do not overload.

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

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

Handling a load Lift and lower the load with the valve buttons. Place the load so that its weight is distributed evenly on the lifting forks.

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

13

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

• • • • •

•

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

Do not smoke when working with batteries.

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

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

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

A low battery charge status may damage the battery during long-time use.

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

1.

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 specific gravity of the battery cell Measure the specific gravity of the battery fluid according to the manufacturer's instructions. The specific gravity of a fully charged battery is 1.28 to 1.30 at +30°C. • • • •

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

Releasing the battery Release the battery latch by pulling it up and to the side with both hands. When the latch is locked to the top position, you can safely remove the battery.

NOTE Before using the truck, always make sure that the battery is properly locked in place.

Replacing the battery Replace the battery according to the manufacturer's instructions. When reinstalling batteries, use the appropriate tools for moving, connecting and fastening the battery securely. Do not keep the tools or other metal implements on top of uncovered batteries.

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

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

Acquiring a new battery When acquiring a battery for the truck, pay attention to the following sections of the standard EN 1175-1: • •

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

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

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

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

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

Safety instructions for maintenance • • • • • • • • •

Keep the service area clean; oil, grease, and water make the floor slippery.

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

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

Release the hydraulic pressure before opening the system.

Do not use your hands to check for oil leaks.

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

Only use clean oil in the hydraulic system.

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

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

WARNING!

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

Weekly maintenance • • • • • • • • •

Check and clean the battery cable fastenings.

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

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

Check that the hydraulic system has no leaks.

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

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

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

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

Clean the truck if necessary.

NOTE

Do not let water onto the electrical devices.

Quarterly maintenance (300 hours) Check and adjust or repair, if necessary: • • • • • • •

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Contactors, microswitches, and solenoids and their cables Brake air gap: correct dimension 0.3–0.8 mm Accelerator operation Lift cabin tolerances, and the slope and condition of the forks Torque of the drive wheel attachment nuts (torque 190 Nm) Lifting hydraulics operation Collectors, carbon brushes, and electric cables of the drive and pump motors

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

Drive and pump motors and, if included in the equipment, the collectors, carbon brushes, and electric cables of the steering motor or steering servo. Clean the carbon dust from the motors Operation of the hydraulics and pressure limit valves Drive wheel for wear. The wheels should be changed at the latest when 10 mm of the tread is left.

Wheel bearings: lubricate Oil filter Condition of the side castor wheels and load wheels

Annual maintenance (1200 hours) • •

Change the hydraulic oil and oil filter once a year.

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

Monthly hydraulics maintenance The truck's lubricating points should be lubricated once a month: • •

Turning bearings of the drive unit Steering tooth ring

Lubricant recommendation Filling hole for hydraulic oil (1) Hydraulic oil: Neste 32 Super In freezer warehouses: Neste SH 15 Fill the tank to ¾ volume.

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

Electronics panel Open the electronics panel to access the battery connector, recharging plug and fuses. A gas spring holds the panel up. When closing the panel, be careful not to squeeze your fingers.

Fuses 0F1–0F2 Main Contactor 1F1 Drive motor 2F1 Pump motor 3F1 Steering motor 4F1–4F2 Drive circuits 5F1–5F2 Pump circuits 6F1–6F2 Auxiliary devices

17

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 Amount of parts ordered

Items 1 and 2 are listed on the front page of the manual or on the identification plate of the truck. Items 3 and 4 are listed on the spare part pages of the manual supplied with the truck.

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

18

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

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

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

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

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

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

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

Otherwise normal daily maintenance and inspection are sufficient.

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10. Troubleshooting Troubleshooting Symptom

Fault

Action

Truck does not move

Battery connector is loose

Plug in the battery connector.

Battery is empty

Recharge the battery.

Battery has not been locked into place

Check the locking and the switch.

Emergency stop button is activated Release the emergency stop button.

Key switch is faulty

Replace the switch.

Drive motor fuse has blown

Check the connections and cables and replace the fuse.

Main power fuse has blown

Check the connections and cables and replace the fuse.

Microswitch for safety pedal is broken

Replace the microswitch.

Drive motor carbon brushes are worn Replace the carbon brushes. out

Lift pump does not run

Lifting functions improperly

Battery does not charge

Accelerator is faulty

Contact maintenance personnel.

Pump or control circuit fuse has blown

Check the connections and cables and replace the fuse.

Drive switch is broken

Replace the switch.

Pump motor’s carbon brushes are worn out

Replace the carbon brushes.

Overload

Decrease the load.

Battery is empty

Recharge the battery.

Not enough oil in tank

Add oil.

Oil leak

Check the joints and seals.

Pump is faulty

Replace the pump.

Dirt or wear in valves

Clean the valves, replace if necessary.

Charger is incorrectly connected

Check the connection.

Charger fuse has blown or main voltage is missing

Check the connections and cables and replace the fuse.

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

Steering does not work properly

20

Steering motor fuse has blown

Check the connections and cables and replace the fuse.

Steering is hindered when turning strongly to the limit

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