Caterpillar NR14XE Lift Trucks Operation & Maintenance Manual - PDF DOWNLOAD

EN

Operation & Maintenance Manual NR14K NR14KE NR14XE NR16K NR16KN NR20K NR25KH

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

1. Reach 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 organization.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

WARNING! Do not overload the truck.

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

Pedals Accelerator (1) Use the accelerator with your right foot. The lower you press the pedal, the higher the speed. Handle the accelerator gently.

Brake (2) Press the brake pedal to slow the driving speed. The truck is equipped with a regenerative motor braking system, which recharges the battery and decelerates the truck in the following cases: • When you press the brake pedal • When you change the driving direction • When the truck is free-wheeling NOTE: Practice using the brake with and without a load.

Safety pedal (3) To operate the truck, first press the safety pedal down to the drive position. The truck will not move if the pedal is not pressed.

Right-hand controls Driving direction switch (1) Use the driving direction switch to choose the direction of travel.

Parking brake (2) The parking brake is a magnetic brake. Switch on the parking brake every time you leave the truck. If you forget to switch it on, the parking brake will be engaged automatically after a certain time.

Emergency stop button (3) Press the emergency stop button to switch off the power circuit of the battery. Use the button in the following cases: • A short-circuit or other electrical fault, e.g. if the pump motor runs continuously 7

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

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

• Check all wheels for damage or wear.

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

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

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

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

• Also check the operation of the other electrical functions.

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

• Check the operation of the horn.

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

• Check that the emergency stop operates properly.

• Check the fastenings of the lifting chain.

Before you start: • • • • •

Make sure that the daily maintenance has been carried out.

Switch on the power.

Release the parking brake.

Grip the steering wheel knob with your left hand and use the valve levers with your right hand.

Take a position where your left foot is on the safety pedal and your right foot is on the accelerator.

Driving • • • •

Press the safety pedal down to move the truck.

Press the accelerator pedal lightly.

To brake, press the brake pedal.

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. Tachometer located in the steering wheel 2. Control unit located in the motor compartment 3. Steering motor, which is also in the motor compartment.

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

Notice that when the drive wheel reaches its maximum position (± 90°), the steering wheel can still turn without a mechanical stop.

NOTE: Do no 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 switching on the magnetic brake, and the truck will stop.

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Problems in electronic steering or in the control system are indicated by the “S” indicator on the Problem monitoring display. The “S” indicator also shows if the power is switched off and on again too quickly. The truck does not drive if the indicator is on.

NOTE: Wait for at least 3 seconds before you switch on the power again after it has been switched off.

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

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

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

• Drive slowly at intersections and when turning.

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

• Avoid sudden starts and stops.

• Steer and brake smoothly.

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

• Take great care when driving on a slanted surface.

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

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

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

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

Driving position Drive the truck always from the operator’s seat, left foot on the safety pedal and the right on the accelerator. Keep your left hand on the steering wheel and the right on the valve levers. 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.

• 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.

Stacking and unloading To stack: • Drive towards the shelf or stacking level with the load lowered and the mast tilted backwards.

• Straighten the mast.

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

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

• Lower the forks, so that they disengage, and then pull in the mast and reverse from the stacking location. Make sure that the forks are clear of both the stacking level and the pallet. Tilt the mast backwards and lower the forks to the driving position.

To unload: • • • • • •

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

Straighten the mast.

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

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

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

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

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

Display of lifting height The display of lifting height has been preset, and normally you do not need to change the default settings. However, you may need to change the settings during maintenance.

• Press the Exit key when you switch on the power.

• Lift the forks slightly over the free lifting range, so that the indicator light of the sensor in the mast goes off.

• Press Enter to go to the Main menu.

• Select “Program offset” using the arrow keys and press Enter.

• Measure the distance from the floor to the forks, and set this value with the arrow keys and press Enter.

• To exit the menu, press Exit twice.

Height selector The height selector is an optional feature. With the height selector you can program different stacking and 13

unloading heights to ease the operation. During the automatic sequence, you can exit to normal operation in any phase by pressing the Exit key.

NOTE:The height selector operates only above the free lifting range.

To stack with the height selector: • Press Exit in the basic display to get to the Preselection menu.

• Make sure that the mast is all the way in.

• Select the correct height with the arrow keys and press Enter.

• Lift the forks until they stop automatically.

• Check that the fork height is correct and move the mast all the way forward.

• When the load is in the correct position over the shelf, lower the forks.

• Pull the mast all the way in to end the stacking sequence, and then lower the forks.

To unload with the height selector: • Press Exit in the basic display to get to the Preselection menu.

• Make sure that the mast is all the way in.

• Select the correct unloading level with the arrow keys and press Enter.

• Lift the forks until they stop automatically.

• Check that the fork height is correct and move the mast all the way forward.

• When the load is completely on the forks, lift the load.

• Pull the mast all the way in to end the stacking sequence, and then lower the forks.

Programming the height selector • Check that the forks are down and you are in the basic display.

• Go to the Main menu by pressing Enter.

• Select “Autoteaching” with the arrow keys and press Enter.

• Select the height number to be programmed with the arrow keys and press Enter.

• Lift the forks slowly to the correct level and press Enter.

• Lower the forks and program other levels, or exit the menu by pressing Exit twice.

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

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

• Do not smoke when working with batteries.

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

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

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

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

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

1. Park the truck in a reserved recharging place.

2. Switch off the power from the key switch.

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

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

5. Switch on the charger.

After recharging 1. Switch off the charger.

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

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

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

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

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

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

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

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

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

It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts.

Only professional service ensures long-term, trouble-free truck operation. Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our maintenance department or your truck dealer for qualified, authorised and efficient maintenance service.

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

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

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

• Release the hydraulic pressure before opening the system.

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

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

• Only use clean oil in the hydraulic system.

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

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

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

Weekly maintenance • Check and clean the battery cable fastenings.

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

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

• Check that the hydraulic system has no leaks.

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

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

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

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

• Clean the truck if necessary.

• Check the length of the lifting chains. When the mast is upright and the top of the mast bars is on the same level with the mast, the chains should be a little loose. Adjust if necessary.

• Lightly lubricate the grooves of the mast, reach carriage, and the lift carriage.

NOTE: Do not let water onto the electrical devices.

Quarterly maintenance (300 h) Check and adjust or repair, if necessary: • Contactors, microswitches, and solenoids and their cables • Accelerator operation • Operation of the hydraulic valve • The amount of brake fluid • The brake pipes and tubes: press the pedal hard to check for leaks • Condition of the forks • Connection of the mast to the body • Lifting chain: lubricate and check for stretch • Horizontal and vertical play of the reach carriage. Adjust the play by loosening the tension screws and turning the adjustment screw • Attachment of the cylinders and the locking of the settings

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

Driving, steering, and pump motors: clean the dust Operation of the hydraulics and pressure limit valves Drive wheel for wear. The wheels should be changed at the latest when 10 mm of the tread is left Lifting chain wheels and chain guards Driver's cabinet Battery locking mechanism Lifting chains: clean and lubricate Oil filter Fastening of the gearbox Opening covers Open the covers by pressing the button.

Annual maintenance (1200 h) •Change the hydraulic oil once a year.

•Change the transmission oil once a year.

•Lubricate the motor’s bearings once a year.

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

Lubricant recommendation Hydraulic oil: ISO VG 32 In freezer warehouses: ISO VG 15 Transmission oil: SAE 80W/90, API: GL-4 Fill to the volume of 4.5 l.

Lubricating grease: NLGI No. 2, containing molybdenumdisulphide In freezer warehouses: NLGI No. 1 or No. 0

Fuses 1F1 3F1 5F1 10F1, 10F2 11F1, 11F2 12F1, 12F2

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Key switch circuit fuses Drive and pump motor fuses Traction motor fuse Drive circuit fuses Lift circuit fuses Accessory fuses

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

To ensure that you receive the correct parts, include the following information in the order: 1. Truck type 2. Serial number of the truck 3. Order number of the part 4. Name of the part 5. Amount of parts ordered Items 1 and 2 are listed on the front page of the manual or on the identification plate of the truck. Items 3 and 4 are listed on the spare part pages of the manual supplied with the truck.

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

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

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

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

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

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

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

Otherwise normal daily maintenance and inspection are sufficient.

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10. Troubleshooting

Symptom

Fault

Action

Truck does not move

Battery connector is loose

Plug in the battery connector.

Battery is empty

Recharge the battery.

Emergency stop button is activated

Release the emergency stop button.

Key switch is faulty

Replace the switch.

Drive motor fuse has blown

Check the connections and cables and replace the fuse.

Main power fuse has blown

Check the connections and cables and replace the fuse.

Microswitch for safety pedal is broken

Replace the microswitch.

Speed controller is faulty

Contact maintenance personnel.

Leak in the brake system

Check the connections and change the sealing.

Movement of the pedal is too wide

Adjust the brake heads.

Friction surface of the pedal is worn out

Change the brake heads.

Microswitch for brake pedal is broken

Replace the microswitch.

Speed controller is faulty or settings have changed

Contact maintenance personnel.

Pump or control circuit fuse has blown

Check the connections and cables, and replace the fuse.

Pump motor controller is faulty

Contact maintenance personnel.

Overload

Decrease the load.

Battery is empty

Recharge the battery.

Not enough oil in tank

Add oil.

Oil leak

Check the joints and seals.

Pump is faulty

Replace the pump.

Dirt or wear in valves

Clean the valves, replace if necessary.

Brake does not work properly

Lift pump does not run

Lifting functions improperly

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Symptom

Fault

Action

Battery does not charge

Charger is incorrectly connected

Check the connection.

Charger fuse has blown or main voltage is missing

Check the connections and cables, and replace the fuse.

Battery cell’s water level or specific gravity is low

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

Steering motor fuse has blown

Check the connections and cables, and replace the fuse.

Control circuit fuse has blown

Check the connections and cables, and replace the fuse.

Short voltage break (<5 seconds) caused by e.g. switching of the power on too soon.

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

Faulty steering controller (indicators are not lit)

Contact maintenance personnel.

Steering is hindered when turning strongly to the limit

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

Steering does not work properly

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• In an accident Release the emergency stop button by turning it clockwise.

Control panel Steering wheel (1) The truck is equipped with an electronic steering system; see Section "Electronic steering system" in Chapter 5.

Display (2) Key switch (3) 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 Valve levers (4) Keypad (5) Horn button (6) Fork adjustment switch (7) The fork adjustment device is an optional feature.

Valve levers Reach trucks usually have 4 valve levers for: • Lifting and lowering the forks (1) • Moving the mast forwards and backwards (2) • Tilting the mast or carriage (3) • Side-shifting the carriage or forks (4) Familiarise yourself with the operation of the levers.

Display When you switch on the power, the display will show you the operation hours of the truck for a few seconds, and then the charge level of the battery (1). Whenever you are driving, the speed is displayed in the same place. If the truck is equipped with a lifting height display, the lifting height is also displayed in the centre.

Steering system fault indicator (2) Faults in the steering system are displayed with an “S” indicator. When the indicator is lit, the truck stops automatically. For more information, see Section "Electronic steering system" in Chapter 5.

Parking brake indicator (3) When you switch on the parking brake, the parking brake indicator is lit.

Speed control fault indicator (4) Faults in the speed control are displayed with a “T” indicator and an explanation in the Message field (9). The truck cannot be driven before the problem is corrected. When the fault indicator is lit, switch off the power from the key switch. Then wait at least 5 seconds and switch the power on again. If the fault is not corrected, contact maintenance personnel.

The indicator is also lit if you do not press the safety pedal down before pressing the accelerator. In that case lift your feet from the pedals, wait a few seconds, and then press the pedals in the correct order.

Pump control fault indicator (5) Faults in the pump speed control are displayed with a “P” indicator and an explanation in the Message field (9).

The truck cannot be driven before the problem is corrected. When the fault indicator is lit, switch off the power from the key switch. Then wait at least 5 seconds and switch the power on again. If the fault is not corrected, contact maintenance personnel.

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Drive mode indicator (6) The drive mode indicator displays the drive mode you have selected: slow, normal, or fast.

Battery low indicator (7) The battery low indicator displays when you need to recharge the battery.

Travel direction indicators (8) The travel direction arrows display the driving direction.

Message field (9) The message field displays explanations of faults or incorrect use of the truck.

The fault explanation field also gives an alarm if the truck is overheated. If you get the alarm, drive the truck slowly to a safe location and let the truck cool down. Before you start driving the truck again, find out the cause to overheating.

Height selector display (10) The truck can be equipped with a height selector display. Stacking is displayed with forks with a load, and unloading with forks without a load. For more information, see Section "Height selector" in Chapter 6.

Keypad With the keypad you can move in different menus and select functions.

• Enter (1): Press Enter to go to the Main menu from the basic display, and to confirm your selections.

• Exit (2): Press Exit to leave menus. If the truck is equipped with a height selector, you can activate it by pressing Exit.

• Arrows down and up (3, 4): With the arrow keys you can select different options or set values. In the basic display, you can change the drive mode with the arrow keys.

Recharging plug The truck’s recharging plug has a handle and can be detached.

See Section "Recharging the battery" in Chapter 7 for instructions on using the plug to recharge the battery.

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

• Disconnect the plugs of the electronic devices.

Adjusting the driving position Seat You can adjust the seat spring tension according to your weight (1). You can also adjust the distance to the pedals (2) and tilt the backrest of the seat (3).

9

Control panel You can adjust the angle of the control panel with a screw behind the panel.

10

CAT RD Technical Specifications

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

Adjustment Instructions Zapi AC-2 Pump

ZAPI AC-2 PUMP INVERTER 48V 350A ACRO0.16

CONNECTION TYPE: 5

ADJUSTMENTS: SET BATTERY TYPE ADJUST BATTERY THROTTLE 0 ZONE THROTTLE X POINT THROTTLE Y POINT ADJUSTMENT #04 ADJUSTMENT #03 ALARM/ZAPI MENU/ HARDWARE SETTING: SAT FREQUENCY BRAKING MODUL BOOST CORNER FREQ MAXSLIP LOW FREQ

Rev. Date

11 15.02.2005

NR14K

NR16KC/KN

NR16K

NR20K

NR25KH

DEFAULT

TRUCK TYPES: NR14XE

MAIN MENU/ PARAMETER CHANGE: ACCELER. DELAY DECELER. DELAY MAX SPEED UP MIN SPEED UP MAXIMUM CURRENT CONFIG MENU/ SET OPTIONS: HOUR COUNTER SET TEMPERATURE

1/3 DOC00000954

0 0 110 0 9

0 0 110 0 9

0 0 110 0 9

0 0 110 0 9

0 0 95 0 9

0 0 95 0 9

0 0 110 0 9

RUN RUN RUN RUN RUN RUN ANA ANA ANA ANA ANA ANA

RUN ANA

48 BV 11 63 36 120 55

48 BV 11 63 36 120 55

48 BV 11 63 36 120 55

48 BV 11 63 36 120 55

48 BV 11 63 36 120 55

70 70 70 3,5

70 70 70 3,5

70 70 70 3,5

70 70 70 3,5

48 BV 11 63 36 120 55

48 BV 11 63 36 120 55

10kW 10kW 10kW 10kW 14kW 14kW

NOTE

CAT RD Technical Specifications

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

Adjustment Instructions Zapi AC-2 Pump

Rev. Date

ZAPI AC-2 PUMP INVERTER 48V 350A ACRO0.16

CONFIG MENU SET MODEL SET OPTIONS HOUR COUNTER

11 15.02.05

NOT AVAILABLE RUNNING

BATTERY CHECK

OFF

SET TEMPERATURE

ANALOG

ADJUSTMENTS SET BATTERY TYPE

2/3 DOC00000954

V

48

ADJUST BATTERY

V

BATTERY VOLTAGE

THROTTLE 0 ZONE

%

11

THROTTLE X POINT

%

63

THROTTLE Y POINT

%

36

ADJUSTMENT #04

°

120

ADJUSTMENT #03

°

55

MAIN MENU PARAMETER CHANGE ACCELER. DELAY

0

1

2

3

4

5

6

7

8

9

DECELER. DELAY

0

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

MAX SPEED UP

Hz

110

MIN SPEED UP

Hz

0

MAXIMUM CURRENT

0

CAT RD Technical Specifications TESTER MOTOR VOLTAGE FREQUENCY ENCODER SLIP VALUE CURRENT RMS TEMPERATURE MOTOR TEMPERAT. ACCELERATOR LIFTING SWITCH 1ST SPEED SWITCH 2ND SPEED SWITCH 3RD SPEED SWITCH 4TH SPEED SWITCH HYDROSP REQ CUTBACK SWITCH VOLTAGE BOOSTER BATTERY VOLTAGE COS FI BATTERY CURRENT BATTERY CHARGE SAVE PARAM. RESTORE PARAM ALARMS ZAPI MENU SPECIAL MENU SET CURRENT SET TEMPERATURE AUX OUTPUT#1 AUX OUTPUT#2 HARDWARE SETTING COMPENSATION SLIP CONTROL DC-LINK COMPENS SAT FREQUENCY BRAKING MODUL. HYDRO SAT. FREQ MINIMUM VOLTAGE BOOST AT LO FREQ BOOST AT HI FREQ BOOST CORNER FRE BRAKING BOOSTER MOTOR RESISTANCE SLIP COEFFICIENT SLIP RESET MAX SL.LOW FREQ INCREMENT MAX SL MAXSLIP FREQ MAXSLIP FREQ INC OPTION 07 OPTION 08 OPTION 06 PROGRAM VACC MOTOR DATA

Adjustment Instructions Zapi AC-2 Pump

% Hz Hz Hz A °C °C V

% V A %

A °C

2,3 0,30 0,00 0,30 6 23 50 0,3 OFF GND OFF +VB OFF +VB OFF GND OFF GND OFF +VB OFF GND 0,0 48,4 0,26 6 0

350 5 8

Hz Hz Hz % % % Hz %

Hz Hz Hz Hz Hz

ON ON ON 65 65 110 5 19 19 65 100 0 0 0,6 4,0 1,0 50 50 1 1 6

3/3 DOC00000954

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

Adjustment Instructions Zapi AC-2 Traction

ZAPI AC-2 TRACTION INVERTER 48V 350A AC2RO0.16

CONNECTION TYPE: 2

9 15.02.2005

NR16KC/KN

NR16K

NR20K

NR25KH

DEFAULT

TRUCK TYPES: NR14K

CONFIG MENU/ SET OPTIONS: HOUR COUNTER BATTERY CHECK CUTBACK MODE HYDRO KEY ON STOP ON RAMP AUX OUTPUT#1 PEDAL BRAKING SET TEMPERATURE ADJUSTMENTS: SET BATTERY TYPE ADJUST BATTERY THROTTLE 0 ZONE THROTTLE X POINT THROTTLE Y POINT ADJUSTMENT #04 ADJUSTMENT #03 ADJUSTMENT #02 ADJUSTMENT #01 ALARM/ZAPI MENU/ HARDWARE SETTING: SAT FREQUENCY BRAKING MODUL MAXSLIP LOW FREQ

Rev. Date

NR14XE

MAIN MENU/ PARAMETER CHANGE: ACCELER. DELAY I ACCELER. DELAY II ACCELER. DELAY III RELEASE BRAKING I RELEASE BRAKING II RELEASE BRAKING III INVERSE BRAKING I INVERSE BRAKING II INVERSE BRAKING III PEDAL BRAKING I PEDAL BRAKING II PEDAL BRAKING III SPEED LIMIT BRK. MAX SPEED FORW I MAX SPEED FORW II MAX SPEED FORW III MAX SPEED BACK I MAX SPEED BACK II MAX SPEED BACK III FREQUENCY CREEP MAXIMUM CURRENT I MAXIMUM CURRENT II MAXIMUM CURRENT III AUXILIARY TIME

1/4 DOC00000952

2 2 1 5 5 6 6 6 7 8 8 8 0 70 90 100 70 90 100 0,3 9 9 9 2

2 2 1 5 5 6 6 6 7 8 8 8 0 70 90 100 70 90 100 0,3 9 9 9 2

2 2 1 5 5 6 6 6 7 8 8 8 0 70 90 100 70 90 100 0,3 9 9 9 2

2 2 1 5 5 6 6 6 7 8 8 8 0 70 90 100 70 90 100 0,3 9 9 9 2

2 2 1 5 5 6 6 6 7 8 8 8 0 70 90 100 70 90 100 0,3 9 9 9 2

2 2 1 5 5 6 6 6 7 8 8 8 0 70 90 100 70 90 100 0,3 9 9 9 2

2 2 1 5 5 6 6 6 7 8 8 8 0 70 90 100 70 90 100 0,3 9 9 9 2

RUN ON ABS OFF OFF BRA DIG ANA

RUN ON ABS OFF OFF BRA DIG ANA

RUN ON ABS OFF OFF BRA DIG ANA

RUN ON ABS OFF OFF BRA DIG ANA

RUN ON ABS OFF OFF BRA DIG ANA

RUN ON ABS OFF OFF BRA DIG ANA

RUN ON ABS OFF OFF BRA DIG ANA

48 BV 7 63 36 120 35 6 6

48 BV 7 63 36 120 35 6 6

48 BV 7 63 36 120 35 6 6

48 BV 7 63 36 120 35 6 6

48 BV 7 63 36 120 35 6 6

48 BV 7 63 36 120 35 6 6

48 BV 7 63 36 120 35 3 3

60 80 3,5

60 80 3,5

60 80 3,5

60 80 3,5

75 85 3

75 85 3

60 80 3,5

NOTE

set measured battery voltage

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

Adjustment Instructions Zapi AC-2 Traction

2/4 DOC00000952

Rev. ZAPI AC-2 TRACTION INVERTER 48V 350A Date AC2RO0.16

CONFIG MENU SET MODEL CONNECTION

1 SICOS

SET OPTIONS HOUR COUNTER

2

TR

6 EPS

9 RIO

RUNNING

BATTERY CHECK

ON

CUTBACK MODE

ABSENT

HYDRO KEY ON

OFF

STOP ON RAMP

OFF

AUX OUTPUT #1

BRAKE

PEDAL BRAKING

DIGITAL

SET TEMPERATURE

ANALOG

ADJUSTMENTS SET BATTERY TYPE

5 PU

9 15.02.05

V

48

ADJUST BATTERY

V

BATTERY VOLTAGE

THROTTLE 0 ZONE

%

7

THROTTLE X POINT

%

63

THROTTLE Y POINT

%

36

ADJUSTMENT #04

°

120

ADJUSTMENT #03

°

35

ADJUSTMENT #02

3

ADJUSTMENT #01

3

MAIN MENU PARAMETER CHANGE ACCELER. DELAY I

0

1

2

3

4

5

6

7

8

9

ACCELER. DELAY II

0

1

2

3

4

5

6

7

8

9

ACCELER. DELAY III

0

1

2

3

4

5

6

7

8

9

RELEASE BRAKING I

0

1

2

3

4

5

6

7

8

9

RELEASE BRAKING II

0

1

2

3

4

5

6

7

8

9

CAT RD Technical Specifications

Adjustment Instructions Zapi AC-2 Traction

3/4 DOC00000952

RELEASE BRAKING III

0

1

2

3

4

5

6

7

8

9

INVERSE BRAKING I

0

1

2

3

4

5

6

7

8

9

INVERSE BRAKING II

0

1

2

3

4

5

6

7

8

9

INVERSE BRAKING III

0

1

2

3

4

5

6

7

8

9

PEDAL BRAKING I

0

1

2

3

4

5

6

7

8

9

PEDAL BRAKING II

0

1

2

3

4

5

6

7

8

9

PEDAL BRAKING III

0

1

2

3

4

5

6

7

8

9

SPEED LIMIT BRK.

0

1

2

3

4

5

6

7

8

9

30

40

50

60

70

40

50

60

70

30

40

50

60

70

30

40

50

60

70

30

40

50

60

70

30

40

50

60

70

90 10 90 10 90 10 90 10 90 10 90 10

100 11 100 11 100 11 100 11 100 11 100 11

110 12 110 12 110 12 110 12 110 12 110 12

120

30

80 9 80 9 80 9 80 9 80 9 80 9

0,2

0,4

0,8

1

1,5

2

3

4

5

MAX SPEED FORW I MAX SPEED FORW II MAX SPEED FORW III MAX SPEED BACK I MAX SPEED BACK II MAX SPEED BACK III FREQUENCY CREEP

Hz km/h Hz km/h Hz km/h Hz km/h Hz km/h Hz km/h Hz

9

MAXIMUM CURRENT II

9

MAXIMUM CURRENT III

9

AUXILIARY TIME

0

BRAKE % Hz Hz Hz A % V °C °C V

%

120 120 120 120

0,3

MAXIMUM CURRENT I

TESTER MOTOR VOLTAGE FREQUENCY ENCODER SLIP VALUE CURRENT RMS VOLTAGE BOOSTER BATTERY VOLTAGE TEMPERATURE MOTOR TEMPERAT. ACCELERATOR FORWARD SWITCH BACKWARD SWITCH ENABLE SWITCH BACKING F. BACKING B. CUTBACK SWITCH BRAKE SWITCH BRAKEPEDAL POT. SEAT SWITCH

120

2,3 0,30 0,00 0,30 6 0,0 48,4 23 50 0,3 OFF GND ON +VB ON +VB OFF GND OFF GND OFF +VB OFF GND 0 ON +VB

CAT RD Technical Specifications EXCLUSIVE HYDRO HANDBRAKE COS FI BATTERY CURRENT BATTERY CHARGE SAVE PARAM. RESTORE PARAM ALARMS ZAPI MENU SPECIAL ADJUST. SET CURRENT SET TEMPERATURE AUX OUTPUT#1 AUX OUTPUT#2 HARWARE SETTING COMPENSATION SLIP CONTROL DC-LINK COMPENS SAT FREQUENCY BRAKING MODUL MINIMUM VOLTAGE BOOST AT LO FREQ BOOST AT HI FREQ BOOST CORNER FRE BRAKING BOOSTER MOTOR RESISTANCE SLIP COEFFICIENT MAXSLIP RESET MAXSLIP LOW FREQ MAXSLIP INC MAXSLIP FREQ MAXSLIP FREQ INC OPTION 07 OPTION 08 OPTION 06 READ RAM READ EPROM CLEAR EEPROM CLEAR CONSOLE PROGRAM VACC MOTOR DATA

Adjustment Instructions Zapi AC-2 Traction

A %

A °C

4/4 DOC00000952

OFF GND OFF +VB 0,26 6 0

350 5 8 ON ON ON

Hz Hz % % % Hz %

Hz Hz Hz Hz Hz

60 (5,5kW) 80 (5,5kW) 1 19 23 80 0 0 0 0,6 3,5 (5,5kW) 1,0 12 48 1 1 6

75 (7.5kW) 85 (7.5kW)

3 (7,5kW)

CAT RD Technical Specifications

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

Adjustment Instructions Zapi EPS AC

Zero feedback pot.allignment: SET MODEL: SYSTEM CONFIG = 1

6 15.02.2005

NR14K

NR16KC/KN

NR16K

NR20K

NR25KH

DEFAULT

TRUCK TYPES: NR14XE

MAIN MENU/ PARAMETER CHANGE: SPEED LIMIT AUX FUNCTION 3 SENSIBILITY AUX FUNCTION 2 CREEP SPEED COMPENSATION AUXILIARY TIME ANTIROLLBACK CONFIG MENU/ SET OPTIONS: HOUR COUNTER MICRO CHECK ENCODER CONTROL FEEDBACK DEVICE LIMIT DEVICE DIRECTION GAUGE AUTO INPUT ACTIV AUX FUNCTION 1 ADJUSTMENTS: ADJUSTMENT #01 SET CURRENT ADJUSTMENT #02 ADJUSTMENT #03 ADJUSTMENT #04 SET BATTERY TYPE SET SAT. FREQ. OVERSAT FREQ. MAXIMUM SLIP ZERO SP POT SET STEER 0-POS. SET MIN FB POT SET MAX FB POT AUX VOLTAGE #1 AUX VOLTAGE #2

Rev. Date

ZAPI EPS AC 48V 40A (50A) EPS AC ST RO 1.02-1.03

CONNECTION TYPE: 6

1/3 DOC00000955

6 4 1 4 0 2 7 40

6 4 1 4 0 2 7 40

6 4 1 4 0 2 7 40

6 4 1 4 0 2 7 40

6 4 1 4 0 2 7 40

6 4 1 4 0 2 7 40

6 4 1 4 0 2 7 40

RUN PRE OFF OP1 OFF OP1 1 0

RUN PRE OFF OP1 OFF OP1 1 0

RUN PRE OFF OP1 OFF OP1 1 0

RUN PRE OFF OP1 OFF OP1 1 0

RUN PRE OFF OP1 OFF OP1 1 0

RUN PRE OFF OP1 OFF OP1 1 0

RUN PRE OFF OP1 OFF OP1 1 0

0 0 0 0 0 0 0 0 0 0 0 0 100 100 100 100 100 100 107 107 107 107 107 107 113 113 113 113 113 113 48 48 48 48 48 48 100 100 100 100 100 100 1 1 1 1 1 1 5 5 5 5 5 5 2,5 2,5 2,5 2,5 2,5 2,5 2500 2500 2500 2500 2500 2500 0,4 0,4 0,4 0,4 0,4 0,4 4,4 4,4 4,4 4,4 4,4 4,4

NOTE

0 0 100 107 FACTORY SET 113 FACTORY SET 48 100 1 5 NOT USED 2,5 NOT USED 2500 NOT USED 0,4 NOT USED 4,4 FACTORY SET FACTORY SET

CAT RD Technical Specifications

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

Adjustment Instructions Zapi EPS AC

ZAPI EPS AC 48V 40A (50A) EPS AC ST RO 1.02-1.03

CONFIG MENU SET MODEL CONNECTED TO

(6)

SYSTEM CONFIG

0

SET OPTIONS HOUR COUNTER

2/3 DOC00000955

Rev. Date

6 15.02.05

RUNNING

MICRO CHECK

PRESENT

ENCODER CONTROL

OFF

FEEDBACK DEVICE

OPTION #1

LIMIT DEVICE

OFF

DIRECTION GAUGE

OPTION #1

AUTO INPUT ACTIV

1

AUX FUNCTION

0

ADJUSTMENTS ADJUSTMENT #01

0

SET CURRENT

0

ADJUSTMENT #02

100,0

ADJUSTMENT #03

%

(106,6)

FACTORY ADJUSTED

ADJUSTMENT #04

%

(113,3)

FACTORY ADJUSTED

SET BATTERY TYPE

V

48

SET SAT. FREQ.

Hz

100,0

OVERSAT FREQ.

Hz

1

MAXIMUM SLIP

Hz

5,00

ZERO SP POT

V

2,5

SET STEER 0-POS.

mV

SET MIN FB POT

V

0,4

SET MAX FB POT

V

4,4

AUX VOLTAGE #1

mV

2500

2500

AUTO ADJUSTED

CAT RD Technical Specifications AUX VOLTAGE #2

Adjustment Instructions Zapi EPS AC mV

MAIN MENU PARAMETER CHANGE SPEED LIMIT

2500

6

AUX FUNCTION 3

4

SENSIBILITY

1

AUX FUNCTION 2

4

CREEP SPEED

0

COMPENSATION

2

AUXILIARY TIME

2

ANTIROLLBACK TESTER DT SET POINT POT FEEDBACK POT TEMPERATURE FREQUENCY MOTOR VOLTAGE ENC ENC SPEED ENDSTROKE CW ENDSTROKE ACW CW LIMIT LEVEL ACW LIMIT LEVEL BACKING F. BACKING B. CUTBACK SWITCH BRAKE SWITCH AUTOMATIC REQ. MM ALARM SWITCH SM ALARM SWITCH SAVE PARAM. RESTORE PARAM ALARMS ZAPI MENU SPECIAL ADJUSTMENT SET TEMPERATURE HARDWARE SETTING MAXIMUM CURRENT CAN BUS PROGRAM VACC MOTOR DATA

%

40

V V V °C Hz % % Hz

0,01 0,00 4,96 23 0,00 0 0 1,85 OFF +12V OFF +12V OFF +12V OFF +12V OFF GND OFF GND OFF +VB OFF GND OFF GND OFF +12V OFF +12V

A

40 PRESENT

AUTO ADJUSTED

3/3 DOC00000955

Indice Page Introduction .......................................................................................................... 3 1 System components ..................................................................................... 4 1.1 Steering servo motor control unit .......................................................... 4 1.2 Steer angle position potentiometer ....................................................... 5 1.3 Operator console ................................................................................... 5 1.4 AC steering servo motor ....................................................................... 5 1.5 Steering handle ..................................................................................... 5 1.6 Motor shaft encoder .............................................................................. 6 2 Electrical specifications ............................................................................... 7 2.1 Battery voltage range ............................................................................ 7 2.2 Steer motor current range ..................................................................... 7 2.3 Command device specifications ............................................................ 7 2.3.1 Tacho generator or stepper motor ............................................... 7 2.3.2 Automatic centering potentiometer .............................................. 8 3 Mechanical specifications ............................................................................ 9 4 System description ..................................................................................... 10 4.1 Manual steering with tacho-generator or stepper motor ..................... 10 4.2 Automatic centering............................................................................. 10 5 Jumpers description ................................................................................... 11 6 Power connection diagram ........................................................................ 13 6.1 Electrical drawing ................................................................................ 14 6.1.1 Tacho-generator steering ........................................................... 14 6.1.2 Stepper motor steering ............................................................... 15 6.1.3 Tacho-generator steering with automatic centering ................... 16 6.1.4 Stepper motor steering with automatic centering ....................... 17 6.1.5 Interface description ................................................................... 18 7 One shot installation procedure ................................................................ 20 8 Description of connectors .......................................................................... 21 8.1 CNB connector .................................................................................... 21 8.2 CNA connector .................................................................................... 23 9 Setting the steering ..................................................................................... 25 9.1 Tacho-generator or stepper motor controlled steering ........................ 25 9.2 Automatic centering............................................................................. 25 9.3 Steer angle indicator gauge ................................................................ 26 10 Zapi hand set description ........................................................................... 27 10.1 Manual mode steering option - hand set function map ....................... 28 10.2 Manual mode steering option and automatic centering hand set function map ......................................................................... 29 10.3 Main menu "Parameters list" ............................................................... 30 10.4 Parameters in set model 0 (tacho-generator or stepper motor only) .. 30 10.5 Parameters in set model 1 (tacho-generator or stepper motor and automatic centering) ............................................................................ 32 10.6 Main menu: "Tester" functions list ....................................................... 33 10.7 Config menu: "Set options" functions list ............................................. 35 2=CA

10.8 Config menu: "Adjustments" functions list ........................................... 37 10.9 Config menu: "Set model" ................................................................... 40 10.10 Maximum current adjustment .............................................................. 40 11 EPS-AC alarm list ........................................................................................ 41 11.1 Analysis of alarms displayed on console ............................................. 41 11.1.1 One blink alarms ...................................................................... 41 11.1.2 Two blinks alarms .................................................................... 44 11.1.3 Three blinks alarms .................................................................. 45 11.1.4 Four blinks alarms .................................................................... 46 11.1.5 Five blinks alarms .................................................................... 46 11.1.6 Six blinks alarms ...................................................................... 47 12 Safety controls and their use ..................................................................... 49 12.1 Safety controls in tacho-generator and automatic centering steering . 49 12.2 Safety on motor wires broken ............................................................. 49 12.3 Safety on failure of the steering tacho-generator ................................ 49 12.3.1 Safety on failures of the steering stepper motor ...................... 49 12.4 Safety on the presence of current when the steering motor is at rest . 49 12.5 Safety on the presence of phase voltage when the steering motor is at rest .................................................................................... 50 12.6 Safety on pot wires broken (for automatic centering operation) .......... 50 12.7 Cross diagnosis between master and supervisor microcontroller ....... 50

Publications N°: ADCZP0AA Edition: July 2000

INTRODUCTION This equipment enables manually controlled power steering and automatic centering. Manually controlled steering may use either a tacho-generator or, in a later version, an inexpensive stepper motor fixed to the steering wheel. The automatic centering operation requires a potentiometer mechanically fixed on the MDU (Motor Drive Unit).

The MDU uses an inexpensive, robust and maintenance free three phases AC induction motor.

Also, our patented system makes optional the adoption of an encoder mounted on the steering motor shaft.

The on board CAN interface makes the communication exchange between our EPS and other controllers placed on the truck rapid and simple, so potentially extending the steering performance to steer equalization for traction speed, CAN management of a wire guidance application and so on.

Configuration options, steering adjustment, measurement functions, and toubleshooting operations are integrally supported by the ZAPI hand held controller equipped with Eprom release number CKULTRA ZP3.01 or later.

Improved safety and operation are provided by having two microprocessor: the first of them performs operations and a second one executes supervisor functions.

The microprocessors combined with the ZAPI hand held controller make servicing easy and direct, reducing adjustment and troubleshooting time. Increased steering motor performance and reduced noise levels are achieved by using MOSFET technology.

2=CA !

1 SYSTEM COMPONENTS The EPS_AC equipment consists of the following parts: 1.1 STEERING SERVO MOTOR CONTROL UNIT It consists of a control unit using the logic marked ADCZPA0D which operates the AC motor for both manual and automatic centering steering. There are three different control units available: 1) A 24/36Vbatt unit provides a maximum current of 70Amps.

2) A 48Vbatt unit provides a maximum current of 70Amps.

3) A 48/80Vbatt unit provides a maximum current of 50Amps.

2=CA "

1.2 STEER ANGLE POSITION POTENTIOMETER To execute an automatic centering operation, a multiturn 5K potentiometer must be mounted directly on the end of the output shaft of the steering gear reduction box. This potentiometer measures the angle of the MDU directly. The full range of possible output is approximately 0÷5Vdc. This potentiometer also provides information for the steer angle indicator gauge mounted on the operator console.

1.3 OPERATOR CONSOLE The control unit can support the following devices typically fixed on the operator console.

1) Key switch 2) Manual/automatic centering selection switch (AUTOSEL).

3) A status device (BUZZER).

4) A steer angle indicator gauge.

1.4 AC STEERING SERVO MOTOR The steering system includes a three phase AC induction motor with a maximum rated power of: 1) 40A current rating (Imax=70A) if the battery voltage is 36Vdc or less. (about 1KW rated power motor at Vbatt=36V).

2) 30A current rating (Imax=70A) if the battery voltage is 48Vdc. (about 1KW rated power motor).

3) 22A current rating (Imax=50A) if the battery voltage is greater than 48Vdc. (about 1.2KW rated power motor at Vbatt=80V).

The gear box should be chosen so that the complete 180° MDU rotation takes 3 to 6 seconds at the maximum steer speed.

1.5 STEERING HANDLE This is a multi-turn steering handle or wheel attacched to a command device. There are two option: 1) tacho-generator. This solution requires just a two wire connection. The recommended tacho-generator is AIRPAX Part N° 24Vdc - 9904 -120 - 16206.

2) stepper motor. This solution requires either a six wire connection or an optional three wire connection. The recommended stepper motor model is Minebea type code AA23KM-K227-T20V. This last device requires a frictional linkage because there is no gear box.

Mounting the command device to eliminate axial or radial loading on the input shaft is important for reliable operation.

Note: the logic card for the tacho-generator and for the stepper motor applications are different. So a different order code must be specified.

2=CA #

1.6 MOTOR SHAFT ENCODER This device is optional (not necessary). The Eps-Ac can receive an encoder (CNA #6, #16, #17 and #7) directly connected to the steering motor shaft. This is an option for a special application. E.g. fine steering speed control, safety improvement etc. A typical manual controlled steering with automatic centering does not require an encoder; it just requires a feedback pot.

2=CA $

2 ELECTRICAL SPECIFICATIONS 2.1 BATTERY VOLTAGE RANGE

Battery voltage input ranges for different releases of the control unit: 24/36 24-36 Vdc 48

48 Vdc

48/80

48-80 Vdc 2.2 STEER MOTOR CURRENT RANGE

24/36

Imax ≤70Aac. Adjustable with the hand held controller (HARDWARE SETTING)

48

Imax ≤70Aac. Adjustable with the hand held controller (HARDWARE SETTING)

48/80

Imax ≤50Aac. Adjustable with the hand held controller (HARDWARE SETTING)

2.3 COMMAND DEVICE SPECIFICATIONS 2.3.1 Tacho generator or stepper motor We supply two command device solutions: Tacho-generator and Stepper motor.

Tacho-generator is to be AIRPAX 24VDC - part No. 9904-120-16206. Use of any other device may provide non-optimum performance.

Stepper motor is to be Minebea type code AA23KM-K227-T20V. Use of any other device may provide non-optimum performance.

Stepper motor - mechanical specification

2=CA %

Tacho generator - mechanical specification

2.3.2 Automatic centering potentiometer The potentiometer fixed on the steering gear box output shaft should be a 5K conductive plastic potentiometer. A multi-turn potentiometer is suggested to ensure negligible mechanical play.

The feedback angle potentiometer should rotate approximately ensure 80% of its total travel, corresponding to 180 degrees of steering angle. The greater the travel, the better the resolution and accuracy.

2=CA &

3 MECHANICAL SPECIFICATIONS

2=CA '

4 SYSTEM DESCRIPTION

4.1 MANUAL STEERING WITH TACHO-GENERATOR OR STEPPER MOTOR This option uses a tacho-generator (or a stepper motor) attached to the steering wheel to convert the steering wheel rotation into an electrical signal. The control logic sets the steer servo-motor in motion at a speed that increases with the speed of the steering wheel. Steering sensitivity and maximum speed are adjustable by using the ZAPI hand held controller.

4.2 AUTOMATIC CENTERING Through the AUTOSEL input request it is possible to turn the steering state from manual mode to automatic centering. The automatic centering request should be edge or level conditioned (see option AUT INP ACTIVE 10.7.7). As soon as an automatic centering request is recognized, the steering control will start to automatically rotate the MDU until it is straight ahead.

2=CA

5 JUMPERS DESCRIPTION Three are three jumpers it is possible to configure.

J7: This jumper selects the active level on the travel demand inputs. Travel demands are connected in the CNA #5 and CNA #15 positions. They are used in the automatic centering to restart steering always when the truck is moving. When J7 is closed between pins No. 1 and 2, travel demands are expected active low (fig. 5.1); when closed between pins No. 2 and 3, travel demands are expected active high (fig. 5.2).

2=CA

J8: This jumper selects the optional encoder supply voltage. When J8 is closed between pins No. 1 and 2, the encoder supply is 16Vdc; when closed between pins No. 2 and 3, the encoder supply is 5Vdc. J2: This is a two pin jumper. When closed the safety contact is internally grounded.

When open the safety contact is floating and should be externally polarized (see 8.1).

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6 POWER CONNECTION DIAGRAM

Note: Reversing Battery positive and negative will damage the unit.

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6.1 ELECTRICAL DRAWING 6.1.1 Tacho-generator steering

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6.1.2 Stepper motor steering

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6.1.3 Tacho-generator steering with automatic centering

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6.1.4 Stepper motor steering with automatic centering

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6.1.5 Interface description a) The 5K steer angle feedback potentiometer should be rigidly mounted to the steering linkage with no play. The pot wiper is connected to Pin #11 of CNA connector. The ends of the pot are connected to Pins #1 and #2 of CNA connector.

This feedback pot is necessary when either a direction gauge or the automatic centering operation is required. b) Pin 5 on connector CNA is connected to the FWD (drive unit side) travel demand.

Pin 15 on connector CNA is connected to REV (load wheels side) travel demand.

Travel demands may be active high (plus battery) or low (minus battery). Specify the mode you want by configuring the Jumper J7 (see 5).

The travel demands are only required to maintain the steering control active after alignment when the truck is moving. c) The status device is an optional extra (12Vdc max 40mA Buzzer or Lamp) supplying an audible or visible warning when a steering alarm occurs. It should be connected between connector CNB Pin #2 (16Vdc supply) and CNB Pin #8 (device driver collector). d) The Eps-Ac provides an internal safety contact accessible through connector CNB pin #7 and CNB pin # 1. It should be used to stop the traction and to enable an electromechanical brake when a steering alarm occurs. This safety contact is closed when the key switch is turned on. The contact opens where there is a steering alarm.This safety contact is floating, that means it's possible to connect it either to the plus battery or to the minus battery. Ensure that the pin #7 is connected to an equal or higher voltage than pin #1.

For safety two cascaded safety switches are internally connected between pin # 7 and pin #1. The first is managed by the Main processor, the second is managed by the supervisor processor.

Note: If the safety switch is connected in series with external switches (seat switch, tiller switch or similar) it's recommended that the steering safety switch should be directly connected to the supply source (plus battery or minus battery) with no interposed switches. (it should be the first the chain: see fig.

6.1.5.1).

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e) The automatic centering request must have an NPN open collector output (see fig.

6.1.5.2). So it should assume the model of an open or closed switch with respect to GND. External pull-up is not required. The automatic centering request may be level or edge triggered depending on the AUT INP ACTIVE setting (see 10.7.7).

An edge is detected if the level before or after the edge remains for at least 30msec.

f)

Pin #18 of CNA connector provides 0 to 4.5Vdc output to control the steering angle indicator gauge Leds. Pin # 8 of CNA connector provides negative to the steering indicator.

g) Pin # 12 of CNA connector (centering acknowledgment) provides a max 2Amps NPN open collector driver normally GND connected that opens when an automatic centering operation is finished. h) The CAN connections are provided on the Pin #3 and Pin#4 CNA connector for the High reference and on Pin #13 and Pin #14 for the Low reference. They are two because our CAN should be externally loaded with a 120 ohms resistance to terminate the transmission line. i)

The Eps_ac provides an encoder interface. It was foreseen for special applications like accurate speed control or safety improvement. Normally it's not required. The encoder channels are connected on Pin #16 and Pin #17 of connector CNA. The encoder supply is provided through the Pin #6 of connector CNA (choose the supply you want through the jumper J8-see 5) and a Gnd reference on the Pin #7 of connector CNA (see fig. 6.1.5.3).

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7 ONE SHOT INSTALLATION PROCEDURE This section of the manual describes the connection procedure for the tacho-generator, the potentiometer and the motor.

Step 1 - STEERING WHEEL (COMMAND) DEVICE CONNECTIONS Connect the two wires from the tacho-generator (or the two stepper motor lines) so that clockwise rotation of the steering wheel produces an increasing (higher positive) command value. This may be measured in two ways. Using the ZAPI hand held controller see the TESTER MENU' (see 10.6.1). The second way, (valid only for a tacho-generator application) is to use a DC voltmeter on the +DT (Pin #9 of CNB connector) and the minus terminal on the battery.

Step 2 - STEERING ANGLE FEEDBACK POT. CONNECTION a) The steer angle feedback pot. has 3 wires: two end wires and a wiper wire. If the truck has a not leading MDU (Motor Drive Unit - see figure 7.1)* connect the two end wires to Pin #1 and #2 of connector CNA so when the Drive Unit is turned CounterClockwise (Clockwise for a truck with a leading MDU) the value on the wiper is increasing. This value may be measured in two ways. Use the Zapi hand held controller through the TESTER MENU' (see 10.6.3). The second way is to use a DC voltmeter connected to the steering angle feedback pot. wiper and battery negative. The wiper should be connected to Pin # 11 of connector CNA.

*

Not leading MDU : means the steering-traction wheel is opposite to the driving seat.

When the steering handle is turned clockwise, the MDU turns counterclockwise.

Leading MDU : means the steering traction wheel is on the same side of the driving seat. When the steering handle is turned clockwise, the MDU turns clockwise too.

b) Physically adjust the steering angle feedback potentiometer so with the Drive Unit straight ahead, the wiper voltage is 2.5Vdc. The Zero Point for the steering angle feedback pot. can be adjusted using the ZAPI hand held controller. See the CONFIG MENU' (see. 10.8.1).

Step 3 - STEER MOTOR CONNECTIONS Connect the three steering motor wires so that a Clockwise steering wheel movement causes a Counter-Clockwise steer movement, for a not leading MDU truck, or a Clockwise steer movement, for a leading MDU truck. If this operation is carried out correctly, the truck will turn Clockwise when the steering wheel is moved Clockwise while the truck is travelling in frontal direction (with respect to the driving seat).

Step 4 - LIMIT SWITCHES CONNECTION After completing Steps 1 - 3, check that the limit switch connected to Pin #12 of connector CNB stops steering in the handwheel clockwise direction. Then, check that the limit switch connected to Pin # 6 stops steering in the Counter_Clockwise direction.

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8 DESCRIPTION OF CONNECTORS 8.1 CNB CONNECTOR

1

NK1

This is the second (lower potential) safety switch connection.The first connection is on Pin #7. If jumper J2 is closed, the Pin # 1 is ground referenced and NK1 is at ground (GND) potential. If jumper J2 is open, NK1 is floating. (It assumes an externally applied potential).

NK1 must be connected to an equal or lower potential than K1 (Pin #7 of CNB).

2

+16

Output for internally provided +16Vdc stabilized supply. It may be used for the status device supply. The maximum rated output is 40mAmps. Warning: do not short circuit this pin because it is common with the Electric Power Steering card supply.

3

DT-/DL

For the tacho-generator application this is a tacho-generator connection. It is internally connected to battery negative (GND). For the stepper motor application this is a stepper motor line (called D line).

4

GND

This is internally connected to ground (battery minus) reference. It may be used for the GND reference of the Automatic Centering request switch and for the stepper motor GND connection.

5

GND

This is internally connected to ground (battery minus) reference. It may be used for the GND reference of the limit switches.

6

LLS

Left (CCW) Limit Switch. It's possible to stop steering in the direction that causes negative signal from the tacho-generator by closing the connection between LLS (Pin #6) and negative (GND Pin#5).

Therefore, connection of a normally open switch between Pin #6 and Pin #5 acts as a Counter-Clockwise steering limit switch.

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7

K1

This is the first (higher potential) safety switch connection.The second connection is on Pin #1. This normally open contact is closed by switching on the key. When the key switch is On, the contact opens in case of steering alarm. If Jumper J2 is closed, ground is provided on pin 7 whenever the key switch is on and there is no alarm. If jumper J2 is open, the safety contact between NK1 and K1 is floating and may be referenced either to the plus battery (connecting K1 to a plus battery voltage reference) or to the minus battery (connecting NK1 to a minus battery voltage reference).

8

BUZZ

This connection provides a ground line to switch on the status device (it could be a 12Vdc buzzer device). It can sink up to 40mAmps. This status device encodes steering alarm conditions.

9

DT+/QL

This is a tacho-generator connection or a stepper motor line (called Q line).

10

AUT

This is the automatic request input. It can be either an active level or edge detection depending by the AUTO INP ACTIVE setting (see 10.7.7). When the selected event happens an automatic centering request will immediately start. This input pin may be connected to: 1. An external ground through a switch.

2. An internal ground (Pin #4) through a switch.

3. An external open collector transistor (For example an output of a photocell circuit).

To recognize an automatic request each level should remain for at least 30msec.

11

KEY

This is the key switch voltage input.

12

RLS

Right (CW) Limit Switch. It's possible to stop steering in the direction that causes positive signal from the tacho-generator by closing the connection between RLS (Pin #12) and negative (GND Pin#5).

Therefore, connection of a normally open switch between Pin #12 and Pin #5 acts as a Clockwise steering limit switch.

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8.2 CNA CONNECTOR

1

NPOT

This is the lower voltage connection for the steer feedback potentiometer. It's internally connected to GND through a 470 Ohms resistance.

2

PPOT

This is the higher voltage connection for the steer feedback potentiometer. It's internally connected to a 5Vdc reference through a 470 Ohms resistance .

3

CANH

This is the high reference of the CAN interface.

4

CANH

Same of pin #3. Pin #3 and #4 are internally connected together.

5

FWD

A request to travel in the Drive Unit direction must provide a signal on this input, either at battery positive or battery negative. Either level may be selected configuring Jumper J2.

6

VCC

Optional encoder supply. When an encoder is used it may be supplied through this pin. The output voltage is selected through the jumper J8 (see. 5).

7

GND

This is internally connected to ground (battery minus) reference. It may be used for the GND reference of the optional encoder or for the stepper motor (manual command device).

8

GND

This is internally connected to ground (battery minus) reference. It may be used for the GND reference of the steer angle direction Led gauge.

9

PPOC

Not Used. This is the higher voltage connection for a handwheel set point potentiometer. This steering option requires modifications on the logic card and cannot be carried out when a tachogenerator or a stepper motor card is chosen. This pin is internally connected to a 5Vdc reference through a 470 Ohms resistance.

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10

QLS

The stepper motor has four channels DL, QL, DLS, QLS. DL and QL are already assigned on the connector CNB. DLS and QLS are the stepper motor channels for the Supervisor microprocessor. This pin is the QLS input.

11

CPOT

This is the wiper connection for the steer feedback potentiometer.

12

K3

Pin # 12 of CNA connector provides a max 2Amps NPN open collector driver. GND is applied by switching on the key and GND is removed when an automatic centering operation is finished.

13

CANL

This is the low reference of the CAN interface.

14

CANL

Same of pin #13. Pin #13 and #14 are internally connected together.

15

REV

A request to travel in the Load Wheels direction must provide a signal on this input, either at battery positive or battery negative.

Either level may be selected by configuring Jumper J2.

16

CHA

This is the first channel input for the optional encoder.

17

CHB

This is the second channel input for the optional encoder.

18

INDIC

Outputs a scaled and converted 0 to 4.5Vdc steer angle feedback potentiometer position for the steer angle indicator gauge LEDs. 0Vdc corresponds to the steer angle feedback pot voltage that was memorized using the ZAPI hand control for SET MAX FB POT. 4.5Vdc corresponds to the steer angle feedback pot voltage that was memorized using the ZAPI hand control for SET MIN FB POT . See 10.7.6 to reverse the turning direction displayed.

19

PPOC2

Not Used. This is the higher voltage connection for a second handwheel set point potentiometer. To improve the safety a second optional command pot is foreseen. While the first set point pot is Master microprocessor processed, this second set point pot is Supervisor microprocessor processed. The wiper of this second set point pot should be connected to the Pin #9 of CNB connector. The lower voltage end should be connected to the Pin #3 of CNB connector. This steering option requires modifications on the logic card and cannot be used when a tacho-generator or a stepper motor card is chosen. This pin is internally connected to a 5Vdc reference through a 470 Ohms resistance.

20

DLS

The stepper motor has four channels DL, QL, DLS, QLS. DL and QL are already assigned on the connector CNB. DLS and QLS are the stepper motor channels for the Supervisor microprocessor. DLS enters in this connection.

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9 SETTING THE STEERING Use the ZAPI hand set to adjust the manual steering settings.

9.1 TACHO-GENERATOR OR STEPPER MOTOR CONTROLLED STEERING The following procedure should be used only after "One Shot Installation Procedure" in Section 7 is completed. Carry out the procedure in the following sequence.

1) Use the hand set to specify the steering is tacho-generator type using the SET MODEL setting (see 10.9).

2) Adjust SET BATTERY TYPE to the battery voltage in the truck using the hand set (see 10.8.6).

3) Regulate the maximum frequency to the motor rated frequency. Use the hand set adjustment SET SATURATION FREQ (see 10.8.7).

4) Regulate the SPEED LIMIT for steering on the hand set. Higher values cause the MDU to turn faster (see 10.4.1).

5) Adjust the slow steering responce using the SENSIBILITY setting on the hand set. A higher value causes faster responce (see 10.4.2).

Note: Low settings of the SPEED LIMIT result in almost no steering responce when turning the steering wheel al low speed. To avoid this problem increase the SENSIBILITY setting.

9.2 AUTOMATIC CENTERING 1) For automatic centering operation it is necessary to adjust SET MODEL to level 1.

When an automatic centering request on the input Pin #10 of CNB connector is recognized an automatic MDU alignment will start.

2) Adjust the steer angle centering precision using KP and POSITION ACCURACY parameters on the hand set. The first is for coarse regulation, the second is for fine regulation. Higher value of these parameters increase the precision, but make steering "busy" with dither.

3) Use the hand set SET STEER 0-POS (see 10.8.11) to adjust the steer angle feedback pot for straight steering MDU.The setting may be adjusted up and down in 5mV increments from the 2.5V default voltage. Test the results by driving the truck forward and reverse with a centered MDU. Watch for straight travel.

4) Use PURSUIT RAMP on the hand set to adjust the automatic centering speed (see 10.5.3).

5) Use DESENSIBILIZAT on the hand set to adjust the automatic centering speed closely the straight ahead MDU position (see 10.5.4).

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9.3 STEER ANGLE INDICATOR GAUGE If a steer angle indicator gauge with Leds is applied then you will also need to perform the following steps for the gauge to respond correctly: 1) Use SET MIN FB POT on the hand set to memorize the steer angle feedback pot voltage for maximum Clockwise rotation of the Drive Unit (see 10.8.12).

2) Use SET MAX FB POT on the hand set to memorize the steer angle feedback pot voltage for maximum Counter-Clockwise rotation of the Drive Unit (see 10.8.13).

3) Use the hand set SET STEER 0-POS (see 10.8.11) to adjust the steer angle feedback pot for straight steering MDU.The setting may be adjusted up and down in 5mV increments from the 2.5V default voltage. Test the results by driving the truck forward and reverse with a centered MDU. Watch for straight travel.

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10 ZAPI HAND SET DESCRIPTION This section describes the ZAPI hand set functions. Numbers inside the triangles correspond to the same number on the hand set keyboard buttons shown in the figure below. The orientation of the triangle indicates the way to the next function.

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10.1 MANUAL MODE STEERING OPTION - HAND SET FUNCTION MAP

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10.2 MANUAL MODE STEERING OPTION AND AUTOMATIC CENTERING - HAND SET FUNCTION MAP

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10.3 MAIN MENU "PARAMETERS LIST" The parameters are slightly different between tacho-generator, tacho-generator with automatic centering and pot steering option. (the stepper motor application has the same hand set map as the tacho-generator configuration) After modifyng a parameter, memorize it with the hand set by pushing the "4" (OUT) button and the "3" (IN) button. Double pushing the OUT button exits without saving the modifications.

10.4 PARAMETERS IN SET MODEL 0 (TACHO-GENERATOR OR STEPPER MOTOR ONLY)

1) SPEED LIMIT Regulates the MDU maximum turning speed.

- Level 0 is for slow turning.

- Level 9 is for fast turning.

Intermediate levels are for proportionally increasing speed settings. Maximum MDU speed has to be regulated after SET BATTERY TYPE is done (see JJ) 2) SENSIBILITY It provides a non-linear relationship between MDU steering speed and tachgenerator voltage when low. This parameter produces increasing steering sensitivity with small changes in steering input.

- Level 0 is for steering response that is less sensitive to small steering wheel movements.

- Level 9 is for steering response that is very sensitive to small steering wheel movements.

Intermediate levels are for proportionally increasing speed setting. This parameter does not influence the maximum MDU steering rate.

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3) CREEP SPEED Provides an increased torque for slow turning steering wheel. It's used to compensate the drop in V/f (flux) when the frequency applied to the motor is low.

- Level 0 is for no torque compensation - Level 9 is for a very strong torque compensation Intermediate levels are for proportionally increasing torque setting. This parameter is useful in two ways. First of all it guarantees a large torque for very slowly turned handwheel. Secondly this large torque allows it to neutralize the elastic tire effect when the handwheel is close to being released it.

4) COMPENSATION Provides stator flux compensation. The ideal motor control provides constant flux value for each working frequency. While CREEP SPEED provides low frequency feedforward flux compensation effect, COMPENSATION produces a feedback flux compensation effect. This is a very important setting for an application without the shaft encoder be cause by turning compensation to a different value than zero gets the motor flux (and torque) indipendent from the battery voltage. So torque is guaranteed when the battery is low: - Level 0 means no compensation but a flux degradation when current is too high - Level 1 compensate the drop on power mosfets and cables - Level 2 compensate the drop on power mosfets, cables and stator resistance - Level 3 means no compensation.

This should normally be set to Level 2 as a strong compensation reduces the slip (difference between the speed and the frequency applied to the motor). An exception can be a smaller motor (small torque required) in which a strong flux (and a greater magnetization current) is not necessary (Level 0).

5) ANTIROLLBACK Adjusts the stand still torque value with a released handwheel. This setting is a percentage of Imax. The stand still torque is used to neutralize the elastic tire effect which would move the MDU an angle back in the direction it was coming from. This parameter is specified as a percentage of the maximum current.

6) AUXILIARY TIME Defines the time, after the handwheel is released, for which the stand still torque is applied.

- Level 0 is for no stand still torque - Level 1 is for a short application of a stand still torque (about 6sec) - Level 9 is for a long application of a stand still torque (about 90sec) Intermediate levels are for proportionally increasing auxiliary time.

7) AUX FUNCTION 3 Through the Can comunication, the traction chopper supplies the truck speed information to the EPS-AC. The EPS-AC can reduce the steering motor speed as the truck speed increase. Aux function 3 make it possible to alter the amount of the max steering speed reduction with increasing truck speed.

- level 0 no effect - level 9 maximum steering speed reduction

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8) AUX FUNCTION 4 Has the same purpose as the previous parameter. The only difference is the aux function 4 varies the value of the steering speed when the hand-wheel is turning slowly.

10.5 PARAMETERS IN SET MODEL 1 (TACHO-GENERATOR OR STEPPER MOTOR AND AUTOMATIC CENTERING) All the parameters in the section 10.3 are adopted also for the tacho-generator (or stepper motor) and automatic centering model. To this previous list here we have to add the following parameters: 1) KP Used for the automatic centering set up. It modifies the static precision of the position control loop. To obtain precise centering increase the KP value. If overshoot becomes evident, try to lower the KP value.

- Level 0 is for less precise centering.

- Level 9 is for very precise steering (but "busy").

Intermediate levels are for proportionally increasing centering precision.

2) POS. ACCURACY Used for automatic centering set up. It has the same KP function but it was introduced to increase the resolution of the static precision. To obtain precise centering increase the POS. ACCURACY value. If overshoot becomes evident, try to lower the POS. ACCURACY value.

- Level 0 is for less precise centering.

- Level 9 is for very precise centering (but "busy").

Intermediate levels are for proportionally increasing centering precision.

3) PURSUIT RAMP Used for automatic centering set up. It decreases the amount of time it takes to complete an automatic centering operation.

- Level 0 is for an automatic centering carried out with a motor frequency of SAT.FREQ/5.

- Level 9 is for an automatic centering carried out with a motor frequency of SAT.FREQ. Intermediate levels are for proportional frequency changes.

4) DESENSIBILIZAT Used for automatic centering set up. It slows down the MDU in the region close to the straight ahead position.

- Level 0 is for a large slowing down quasi-centered MDU. - Level 9 is for a no slowing down quasi-centered MDU. Intermediate levels are for proportionally slowing down changes. The close to straight position slowing down should reduce the MDU overshoot in an automatic centering operation.

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10.6 MAIN MENU: "TESTER" FUNCTIONS LIST The TESTER functions list is common for applications with or without the automatic centering model. Each TESTER function provides the measurement, executed by the software, of the specified parameter. Descriptions of each TESTER function are given below.

1) DT Provides the value of the tacho-generator (or stepper motor) input from the steering wheel with its sign in real time. The value is scaled for the CPU A/D converter (range 0±5Vdc). The value measured directly on the tacho-generator output is sometimes higher than measured on the hand set.

2) SET POINT POT Not used. Pot steering only. It provides the steering handle command potentiometer voltage in real time (i.e. the voltage on the Pin #20 of CNA connector)(for two pots closed loop position control only).

3) FEEDBACK POT Provides the MDU steer angle feedback potentiometer voltage in real time. A steer angle straight ahead corresponds to about 2.5Vdc. 4) TEMPERATURE Provides in real time the control unit plate temperature in celsius degrees. An alarm occurs when the temperature is above 76 degrees Celsius.

5) FREQUENCY Provides in real time the frequency applied to the steering motor with its sign.

6) MOTOR VOLTAGE Provides in real time the voltage applied to the steering motor as a percentage of the battery voltage.

7) MOTOR CURRENT Provides in real time the phase motor current (Rms).

8) ENC Not used. It's for the optional encoder.

9) ENC SPEED Not used. It's for the optional encoder. This reading (and the previous) was introduced to read the optional encoder speed and position. At present it's not managed.

10) ENDSTROKE CW Provides in real time the active state (ON) or not of the Clockwise (Right) limit switch.

11) ENDSTROKE ACW it provides in real time the active state (ON) or not of the Anti_Clockwise (Left) limit switch.

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12) CW LIMIT LEVEL Provides in real time the information that the steer angle feedback potentiometer has overcome the SET MAX FB POT value (see 10.8.13).

13) ACW LIMIT LEVEL Provides in real time the information that the steer angle feedback potentiometer has overcome the SET MIN FB POT value (see 10.8.12).

14) AUTOMATIC REQ. Provides in real time the steering state: manual or automatic. Note: this reading is not the AUTOSEL (Pin #10 of CNB connector) level but the steering state the SW is recognizing. This information coincides with the AUTOSEL input level when this input is level triggered.

15) DIRECTION INPUTS Provides in real time the information of an active travel demand. It turns ON when either a FWD or a REV travel demand is present.

16) MM ALARM SWITCH Provides in real time the state (closed or not) of the Master Microprocessor controlled safety switch.

17) SM ALARM SWITCH Provides in real time the state (closed or not) of the Slave Microprocessor controlled safety switch.

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10.7 CONFIG MENU: "SET OPTIONS" FUNCTIONS LIST The SET OPTIONS functions list is used for all the steering options. These options modify the system configuration on user request. A description of each option follows in the list below.

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1) HOUR COUNTER There are two possible value options for what will appear in the root menu hand set display.

- RUNNING = Run time when the steering is enabled.

- KEYON = Time counted continously when the logic is supplied.

2) MICRO CHECK This feature is to support the debugging activity option. It is used to inhibit the Supervisor microprocessor operation and allow the system to run with just the Main microprocessor support. This operating mode does not allow the supervisor controlled safety switch to close. Therefore, traction is disabled.

- NONE = Inhibit supervisor functions.

- PRESENT = Enable diagnostic interaction between Main and Supervisor microprocessors.

3) ENCODER CONTROL Not used. This setting will turn the optional encoder control ON. 4) FEEDBACK DEVICE Not used. The only feedback device expected is the steer angle feedback pot. This option (and the previous too) was to cater for an application using the FB encoder as a FB potentiometer replacement. This choice makes it possible to use the encoder also for the motor control: it could be a valid support to make steering control easier in a closed loop application (steering position control).

5) LIMIT DEVICE When this option is set ON the steer angle feedback pot will be adopted instead of the limit switches. As soon as the feedback pot voltage overcomes either the SET MIN FB POT or the SET MAX FB POT adjustment, the steer will be disabled.

6) DIRECTION GAUGE There are two options for trucks equipped with a steer angle direction gauge. This setting permits the indicated turning direction displayed on the gauge to be reversed.

7) AUTO INP ACTIVE Sets the active logic level (or edge) for the automatic centering mode request (AUTOSEL).

- Level 0 = External automatic request is active High (i.e. the AUTOSEL switch is open) - Level 1 = External automatic request is active Low (i.e. the AUTOSEL switch is closed) - Level 2 = External automatic request is active on the rising edge of every odd number (i.e. the first rising edge is for automatic, the second returns to manual, the third is for automatic, etc.)

- Level 3 = External automatic request is active on the falling edge of every odd number (i.e. the first falling edge is for automatic, the second is return to manual, the third is for automatic, etc.)

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8) AUX FUNCTION #1 Sets the steering mode after the feedback pot has reached the final position (it is for only the two pots steering and the automatic centering options).

- Level 0 = The steering motor is turned on when a travel demand is active.

- Level 1 = The steering motor is alternatively turned off (for 15sec.) and on (for 3sec.) disregarding the travel demand state.

- Level 2 = The steering motor is alternatively turned off (for 15sec.) and on (for 3sec.) but only when a travel demand is active.

The off state is counted starting from the expiration of the antirollback time. It duration depends on the AUXILIARY TIME setting. So, in reality, the off state duration is the sum of the AUXILIARY TIME and the fixed 15sec. delay.

10.8 CONFIG MENU: "ADJUSTMENTS" FUNCTIONS LIST The ADJUSTMENT functions list is common for both tacho-generator and tachogenerator plus automatic centering model.

1) ADJUSTMENT #1 This adjustment supports the acquisition of the stator motor resistance and of the current amplifiers gain (factory adjusted). When Level=1 is set, a stator resistance acquisition procedure is enabled. The stator resistance is used for the flux compensation when the COMPENSATION parameter is Level=2 (see 10.4.4).

When Level=2 is set both stator resistance and current gain amplifiers acquisition procedure is enabled. As soon as this adjustment is turned to a Level different from 0 a DATA ACQUISITION alarm will immediately occurs.

2) SET CURRENT After the ADJUSTMENT #1 is changed from 0, the operator should connect a DC ammeter in series with the motor phase U or W. Next push the N° 5 (right side top) button on the hand set until the motor current is increased to a DC current level equal to the half Imax value. Then Roll back to ADJUSTMENT #1 and turn to 0 the selected level. Then execute a save operation pushing OUT and ENTER button.

After switching the key off and on the SW will acquire the parameter (stator resistance or gains) you want.

Pay attention. The current amplifier gains are factory adjusted while the stator resistance must be adjusted by the user.

3) ADJUSTMENT #2 Provides the mOhms stator resistance value. It can be acquired (as above explained) or hand adjusted in 5mOhms step pushing the right side buttons. The stator resistance value is used for stator resistance drop compensation when COMPENSATION parameter is level 2. The motor resistance can be measured between two motor connections. This measured value can be replayed in the hand set "Adjustment #2" by rolling up or down the right side buttons.

4) ADJUSTMENT #3 Provides the first phase current gain: it can be acquired or hand adjusted pushing the right side buttons (factory adjusted).

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5) ADJUSTMENT #4 Provides the second phase current gain: it can be acquired or hand adjusted pushing the right side buttons (factory adjusted).

6) SET BATTERY TYPE Specify the battery you have through this option. This setting is used for the flux compensation when the COMPENSATION parameter is set to Level 1 or 2. Note: it is important that the battery setting must be compatible with the Eps_ac version you have.

7) SET SAT FREQ it specifies the limit frequency for the constant flux control law. There are two control regions. The first works with a constant V/f (flux) value from zero to saturation frequency. The second works with a constant voltage (Vbatt) for higher than saturation frequency values (weakening region) .

8) OVERSAT FREQ The limit frequency for the constant voltage control law (degraded flux and torque) is set through this adjustment. It provides the increment over saturation frequency for the constant voltage region (weakening region).

In our open loop steer we suggest that you adjust oversat freq to level 1. A motor used as power steering infact does not need to work in the weakening region. We advise against oversat freq = 0 because with this setting the sinusoidal wave shape at the maximum frequency becomes a square wave increasing the noise.

9) MAXIMUM SLIP Provides the maximum slip when an optional encoder control is adopted. It is used also to set the lowest limit to the frequency in a max current limit with a blocked rotor. (Typical value is 5Hz).

2=CA !&

10) ZERO SP POT Is only for a two pots steering application. It is used to capture the zero setting of the steer handle pot for manual mode steering.

11) SET STEER 0-POS Is used to set the voltage the steer angle feedback pot wiper will assume at the end of an automatic centering operation. Adjust this setting by Entering SET STEER 0POS. The default value is 2500.0 mV. You may roll the value up and down using the (5) and (6) keys in 5mV increments until the truck will move straight ahead after centering.

12) SET MIN FB POT it is used to adjust the scaling of the counterclockwise 90 degrees rotation of the MDU for use with the LEDs steer angle indicator and to stop steering when this value is surpassed and LIMIT DEVICE setting is ON. Adjust this setting with guidance in manual mode (tacho or stepper motor controlled steering). Turn the handle-wheel counterclockwise until the maximum 90 degrees angle is obtained.

With the SET MIN FB POT in the ZAPI hand set display, push the ENTER (3) button. The display changes to the present feedback pot value. Push the OUT (4) and the ENTER (3) button to save this new reading.

13) SET MAX FB POT Is used to adjust the scaling of the clockwise 90 degrees rotation of the MDU for use with the LEDs steer angle indicator and to stop steering when this value is surpassed and LIMIT DEVICE setting is ON. Adjust this setting with guidance in manual mode (tacho or stepper motor controlled steering). Turn the handle-wheel clockwise until the maximum 90 degrees angle is optained. With the SET MAX FB POT in the ZAPI hand set display, push the ENTER (3) button. The display changes to the present feedback pot value. Push the OUT (4) and the ENTER (3) button to save this new reading.

14) AUX VOLTAGE #1 Is for the stepper motor application only. This voltage is auto acquired the first time the EPS-AC is switched on and corresponds to the voltage level in the D line (CNB3) when the stepper motor is standing. Typical 2.5V. 15) AUX VOLTAGE #2 Is for the stepper motor application only. This voltage is auto acquired the first time the EPS-AC is switched on and corresponds to the voltage level in the Q line (CNB9) when the stepper motor is standing. Typical 2.5V.

2=CA !'

10.9 CONFIG MENU: "SET MODEL" This adjustment selects the steering configuration. For a tacho-generator (or a stepper motor) controlled steering the only permissable settings are 0 and 1: - Level 0: tacho-generator (or stepper motor) steering - Level 1: tacho-generator (or stepper motor) steering plus automatic centering - Level 2: two pots manual steering (logic modification required) - Level 3: two pots manual steering plus automatic centering (logic modification required) Note: a new SET MODEL value will be acquired only after the key is switched off.

10.10 MAXIMUM CURRENT ADJUSTMENT With the hand set is possible to modify the maximum current setting. In order to modify it Enter the ALARM CONFIG MENU. Push at the same time the two right side buttons.

This sequence will enter the hidden ZAPI MENU. Roll up and down (buttons 1 and 2) until the "HARDWARE SETTING" appears on the hand set display. Enter it and change with the right side buttons the maximum current setting. Save the new setting before exiting. Switch off and on the key to acquire the new setting. It is important that the new maximum current value is compatible with the Eps_ac version you have.

2=CA "

11 EPS-AC ALARM LIST

11.1 ANALYSIS OF ALARMS DISPLAYED ON CONSOLE Here is the alarm list 11.1.1 One blink alarms 1)

2)

3)

4)

5)

MICRO SLAVE KO Cause:

When no number is specified it means the Master Microprocessor (MM) has detected a status signal coming from the supervisor (SM) that dos't agree with the present comand values. In fact in real time MM and SM compare the command (tacho-generator, stepper motor, limit switches, automatic request) they are reading. When MM is reading a command value different from the one the SM is reading, this alarm occur.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

MICRO SLAVE #1 Cause:

Means the SM has detected a lacking synchronisation pulse. MM generates a continuous a synchronisation pulse (every 16msec) to run an interrupt service routine reading the command on the SM. When this synchronisation pulse is missing for more than 100msec this alarm occur.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

MICRO SLAVE #2 Cause:

Means the SM has detected the safety contacts closed prior to being commanded.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

MICRO SLAVE #3 Cause:

Means the SM has detected an analog status signal coming from the MM -and replying the SP POT- frozen while the SP POT is changing.

(Only for two pots steering).

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

MICRO SLAVE #4 Cause:

means the SM has detected the motor turning direction is opposite to the present command. (Command and action disagree. Only for two pots steering and automatic centering).

Remedy:

If the alarm occurs systematically, it is necessary a logic substition.

2=CA "

6)

7)

8)

9)

MICRO SLAVE #5 Cause:

Means the SM has detected the motor is standing while the command is not at rest.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

MICRO SLAVE #6 Cause:

Means the SM has detected the motor turning direction is opposite to the tacho command. (Command and action disagree. Only for a tacho or stepper motor controlled steering).

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

MICRO SLAVE #7 Cause:

Means the SM has opened its safety contact but has not specified the reason on the local status bus. For example it occurs when the SM is absent or broken.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

KM CLOSED Cause:

It occurs when the MM has detected its safety contact closed prior to being commanded.

Remedy:

The alarm can be due to a wrong installation. As figure 11.1.1.1 shows two cascaded safety switches are internally connected. They have three diagnostic points; low voltage, mid point and high voltage end that are read by software. When the switches are open, the three diagnostic points expect to be at different potential values thank to the resistances. If the outside interface connected on pin #1 and pin #7 of connector CNB gets one end equal to the midpoint, it looks like the switch is closed before it is driven and this unwanted alarm occurs. So we recommend the safety switch should be directly connected to the supply source (plus battery or minus battery) with no interposed switches.

2=CA "

If the alarm does not occur due to wrong wiring, it is necessary to substitute the logic. The failure could be in a mechanical relay defect or in a fault of the relay driver.

10) KS CLOSED Cause:

It occurs when the MM has detected the SM safety contact closed before it's commanded.

Remedy:

The alarm can be due to a wrong installation. As figure 11.1.1.1 shows two cascaded safety switches are internally connected. They have three diagnostic points; low voltage, mid point and high voltage end that are read by software. When the switches are open, the three diagnostic points expect to be at different potential values thank to the resistances. If the outside interface connected on pin #1 and pin #7 of connector CNB gets one end equal to the midpoint, it looks like the switch is closed before it is driven and this unwanted alarm occurs. So we recommend the safety switch should be directly connected to the supply source (plus battery or minus battery) with no interposed switches.

If the alarm does not occur for the wrong wiring, it is necessary a logic substition. The failure could be in a mechanical relay defect or in a fault of the relay driver.

11) KM OPEN Cause:

It occurs when the MM has detected its safety contact open after being commanded.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic. The failure could be in a mechanical relay defect or in a fault of the relay driver.

12) KS OPEN Cause:

It occurs when the MM has detected the SM safety contact open after being commanded.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic. The failure could be in a mechanical relay defect or in a fault of the relay driver.

13) DATA ACQUISITION Cause:

This alarm only occurs when the operator turns to level 1 the "Adjustment #1"

Remedy:

switching off and on the key will automatically remove the alarm.

2=CA "!

11.1.2 Two blinks alarms 1)

2)

3)

4)

5)

6)

7)

POWER FAILURE #1 o #2 o #3" Cause:

They occur when respectively phases U, V and W of the motor are broken. This alarm occurs when at least one of the phase currents is less than 6Aac while the applied frequency is different from zero.

Remedy:

Verify the motor cables and motor windings continuity.

LOGIC FAILURE #1 Cause:

It occurs when the real voltage between phase U and V is different fom the desired.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

LOGIC FAILURE #2 Cause:

It occurs when the real voltage between phase U and W is different fom the desidered.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

HIGH CURRENT Cause:

It occurs when the output current amplifiers signal result higher than Imax level (not controllable) for more than about 1 sec.

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

MAIN CONT. OPEN Cause:

It occurs during init by Can-Bus synchronisation with traction module if main contactor doesn't close.

Remedy:

Probable traction controller alarm.

KEY OFF Cause:

It's a warning that occurs if the Sicos module gives a key-off command via Can-Bus.

Remedy:

This warning disappears if the Sicos module switches off the command.

CAN-BUS Cause:

It's a warning that occurs if the traction module is not connected or if there is some problems on the Can-Bus line.

Remedy:

Check the Can-Bus lines. If you want the EPS-AC working without Can-Bus comunication turn to "Absent" the hardware setting "CanBus" with the hand set.

To do it enter in the alarm config menu. Push at in the same time the two right side buttons. This sequence will enter the hidden Zapi menu. Roll up and down (buttons 1 and 2) until the "Hardware setting " appears on the handset display. Enter it and roll with the left side button until the "Can-Bus" text appears. Turn it to "Absent" with the right side buttons.

2=CA ""

11.1.3 Three blinks alarms 1)

2)

3)

4)

STEER SENSOR KO Cause:

It occurs when the tacho-generator is open or short circuited.

Remedy:

Check the tacho-generator wires and measure the tacho-generator resistance (should be close to 22 Ohms). If the problem is not due to wiring, replace the tacho-generator.

D LINE SENSOR KO Cause:

It occurs when the stepper motor channel on the CNB pin #3 is open.

Remedy:

Check the stepper motor wires and measure the stepper motor line D resistance (should be close to 30 Ohms between pin #3 CNB and GND). If the problem is not due to wiring, replace the stepper motor.

Q LINE SENSOR KO Cause:

It occurs when the stepper motor channel on CNB pin #9 is open.

Remedy:

check the stepper motor wires and measure the stepper motor line Q resistance (should be close to 30 Ohms between pin #9 CNB and GND). If the problem is not due to wiring, replace the stepper motor

F.B OUT OF RANGE Cause:

It occurs when the angle steering feedback pot has a broken connection that means its wiper is higher than 4.7Vdc or smaller than 0.3Vdc.

Remedy:

Check the steer angle feedback pot connections. If the problem is not due to wiring, replace feedback pot. Below is the feedback pot internal interface: when a connection is broken the pot wiper is stuck at 0Vdc o 5Vdc.

2=CA "#

5)

SP OUT OF RANGE Cause:

For a two pots closed control loop only. This alarm is the same as the previous but for the command pot.

Remedy:

Check the set point pots connections.

11.1.4 Four blinks alarms 1)

EEPROM KO Cause:

It occurs due to a hardware or software defect of the non-volatile onboard memory parameters.

Remedy:

Execute a CLEAR EEPROM operation. To do it Enter the ALARM CONFIG MENU. Push at the same time the two right side buttons.

This sequence will enter the hidden ZAPI MENU. Roll up and down (buttons 1 and 2) until the "CLEAR EEPROM" appears on the hand set display. Push twice the Enter button. If the alarm occurs permanently, it is necessary to substitute the logic.

Note: each time the Eprom release is changed this alarm could occur. So we suggest doing a CLEAR EEPROM before changing the Eprom.

2)

GAIN EEPROM KO Cause:

It occurs at startup if some reserved EEprom cells are damaged, or when substituting an old software (prior than 0.67) with a new one.

Remedy:

It is necessary to modify the contents of EEprom address 0 x 63 and then to clear the EEprom. Ask for Zapi technicians support.

11.1.5 Five blinks alarms 1)

HIGH TEMPERATURE Cause:

It occurs if the power base exceeds 76°C.

Remedy:

Let the unit cool down. If the alarm occurs after, it is necessary to improve the unit's heat dissipation capability.

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11.1.6 Six blinks alarms 1)

2)

3)

STBY I HIGH Cause:

It occurs if the rest state current signals (measured on the phases U and W) are not in the window 2.5±0.3Vdc after switching on the key and 2.5±0.15Vdc when in the steady state. These voltage are measured between D46 and D45 anodes and gnd.

Remedy:

The 2.5Vdc rest state values should be TM3 (for D46) and TM2 (for D45) factory adjusted. If the problem is not due to TM3 or TM2 settings, to try a logic substitution.

VMN NOT OK Cause:

It occurs when in the initial rest state at least one of the phases of the motor voltage is high: that means the voltage between D47 and D48 anodes and gnd are not in the window 2.5±0.3Vdc (see Fig. 11.1.6.2).

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

LOGIC FAILURE #3 Cause:

It occurs when in the rest state the Vv-Vu phase motor voltage is high: that means the voltage between D47 anode and gnd is not in the window (Vv-Vu)0±0.25Vdc (see Fig. 11.1.6.2).

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

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4)

LOGIC FAILURE #4 Cause:

It occurs when in the rest state the Vu-Vw phase motor voltage is high: that means the voltage between D48 anode and gnd is not in the window (Vu-Vw)0±0.25Vdc (see Fig. 11.1.6.2).

Remedy:

If the alarm occurs permanently, it is necessary to substitute the logic.

2=CA "&

12 SAFETY CONTROLS AND THEIR USE

12.1 SAFETY CONTROLS IN TACHO-GENERATOR AND AUTOMATIC CENTERING STEERING The following malfunctioning conditions are tested on electrical manual steering: 1) Safety on motor wires broken.

2) Safety on failures of the steering wheel tacho-generator or stepper motor.

3) Safety on the presence of current when the steering motor is at rest.

4) Safety on the presence of phase voltage when the steering motor is at rest.

5) Safety on pot wires broken (for automatic centering operation).

6) Cross diagnosis between Master and Supervisor microcontroller.

All of these alarm conditions cause a relay to open that will remove the enabling drive.

Here is a detailed look at them.

12.2 SAFETY ON MOTOR WIRES BROKEN If the current on at least one of the motor phases is detected as less than 6Aac when the motor frequency is other than 0Hz an alarm will occur. The delay for alarm occuring decreases as the motor frequency increases. For a motor frequency higher than 50Hz this alarm will occur with a 100msec delay. If the steady state motor current is less than 6Aac this alarm could unwillingly occur.

12.3 SAFETY ON FAILURE OF THE STEERING TACHO-GENERATOR The safety on tacho-generator failure detects the presence on the line of the tachgenerator impedance (22 ohms resistance and 6 mH inductance). This is possible by using it as a load for an astable oscillator. It is therefore possible to detect defects due to disconnection and short circuiting the tacho-generator. The tacho-generator impedance is about 40 ohms. So when an impedance lower than 15 ohms and higher than 300 ohms is detected, an alarm occurs in less than 100msec.

12.3.1 Safety on failures of the steering stepper motor The safety on stepper motor failures detects the presence of the stepper motor phases resistance (30 ohms). A biasing current is injected in both the D (CNB pin #3) and Q (CNB pin#9) lines for testing. When at least one of these currents is broken off an alarm occurs in less than 100msec.

12.4 SAFETY ON THE PRESENCE OF CURRENT WHEN THE STEERING MOTOR IS AT REST The microprrocessor logic continuously tests the current amplifiers output at rest and if they are other than 2.5Vdc±0.15Vdc, causes an alarm. These voltage are measured between D46 and D45 anodes and gnd (see figure 11.1.6.1).

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12.5 SAFETY ON THE PRESENCE OF PHASE VOLTAGE WHEN THE STEERING MOTOR IS AT REST The microprrocessor logic continuously tests the phase voltage amplifiers output at rest and if they are other than 2.5Vdc±0.25Vdc, causes an alarm. These voltage are measured between D47 and D48 anodes and gnd (see Fig 11.1.6.2).

12.6 SAFETY ON POT WIRES BROKEN (FOR AUTOMATIC CENTERING OPERATION) The safety on pot broken operates by looking for either higher than 4.7Vdc or less than 0.3Vdc on the wiper pin of the steer angle feedback pot. In fact, the 5K pot is connected with two resistances that confine its center point inside the two limits specified above if the pot is correctly connected (see Fig 11.1.3.1).

12.7 CROSS DIAGNOSIS BETWEEN MASTER AND SUPERVISOR MICROCONTROLLER Each microcontroller independently reads the command input (tacho-generator or pot) and calculates a consequent controlling action. While the action generated by the Master becomes the executive, the supervisor's is just for a matching comparision. As each microcontroller receives both its own and the other microcontroller's value, if they are mismatched each microcontroller may open its own alarm switch.

2=CA #

EPS-AC OPERATING AND USER MANUAL

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

Rev. Date

ZAPI MHYRIO 48V MHYRIO RO 1.07 Valve:

CONNECTION TYPE: 9

11 15.02.2005

Buchholz

NR14K

NR16KC/KN

NR16K

NR20K

NR25KH

DEFAULT

TRUCK TYPES: NR14XE

CONFIG MENU/ SET OPTIONS: LIFT TYPE LOWER TYPE REACH FWD TYPE REACH BWD TYPE TILT UP TYPE TILT DW TYPE SHIFT RGT TYPE SHIFT LFT TYPE MAIN MENU/ PARAMETER CHANGE: MIN LIFT MIN LOWER MIN REACH FWD MIN REACH BWD MIN TILT UP MIN TILT DW MIN SHIFT RGT MIN SHIFT LFT MAX LIFT MAX LOWER MAX REACH FWD MAX REACH BWD MAX TILT UP MAX TILT DW MAX SHIFT RGT MAX SHIFT LFT LIFT/LOWER ACC DEL REACH ACC DEL TI/SH ACC DEL LIFT/LOWER DEC DEL REACH DEC DEL TI/SH DEC DEL

1/3 DOC00002012

Adjustment Instructions Zapi MHYRIO Valvecontroller

OP1 OP2 OP1 OP1 OP1 OP1 OP1 OP1

OP1 OP2 OP1 OP1 OP1 OP1 OP1 OP1

OP1 OP2 OP1 OP1 OP1 OP1 OP1 OP1

OP1 OP2 OP1 OP1 OP1 OP1 OP1 OP1

OP1 OP2 OP1 OP1 OP1 OP1 OP1 OP1

OP1 OP2 OP1 OP1 OP1 OP1 OP1 OP1

OP1 OP2 OP1 OP1 OP1 OP1 OP1 OP1

30 30 30 30 30 30 30 30 160 103 160 160 160 160 160 160 4 2 2 0 3 3

30 30 30 30 30 30 30 30 160 103 160 160 160 160 160 160 0 3 3 0 3 3

30 30 30 30 30 30 30 30 160 103 160 160 160 160 160 160 0 3 3 0 3 3

30 30 30 30 30 30 30 30 160 103 160 160 160 160 160 160 0 3 3 0 3 3

30 30 30 30 30 30 30 30 160 103 160 160 160 160 160 160 0 3 3 0 3 3

30 30 30 30 30 30 30 30 160 103 160 160 160 160 160 160 0 3 3 0 3 3

30 5 30 30 30 30 30 30 160 105 160 160 160 160 160 160 0 3 3 3 3 3

NOTE

CAT RD Technical Specifications

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

2/3 DOC00002012

Adjustment Instructions Zapi MHYRIO Valvecontroller Rev. Date

ZAPI MHYRIO 48V MHYRIO RO 1.07

11 02.15.05

Buchholz

CONFIG MENU SET MODEL SET OPTIONS LIFT TYPE

OPTION #2

LOWER TYPE

OPTION #2

REACH FWD TYPE

OPTION #2

REACH BWD TYPE

OPTION #2

TILT UP TYPE

OPTION #2

TILT DW TYPE

OPTION #2

SHIFT RGT TYPE

OPTION #2

SHIFT LFT TYPE

OPTION #2

ADJUSTMENTS MAIN MENU PARAMETER CHANGE MIN LIFT

30

255 255

MIN REACH FWD

33 0,15 30

MIN REACH BWD

30

255

MIN TILT UP

30

255

MIN TILT DW

30

255

MIN SHIFT RGT

30

255

MIN SHIFT LFT

30

255

160

255

MIN LOWER A

MAX LIFT

255

A MAX LOWER

120 0,61

MAX REACH FWD

150 0,77 160

MAX REACH BWD

160

255

MAX TILT UP

160

255

MAX TILT DW

160

255

A

Defaults

190 0,99

255 255

CAT RD Technical Specifications

3/3 DOC00002012

Adjustment Instructions Zapi MHYRIO Valvecontroller

MAX SHIFT RGT

160

255

MAX SHIFT LFT

160

255

LIFT/LOWER ACC DEL

2

3

4

5

6

7

8

9

REACH ACC DEL

2

3

4

5

6

7

8

9

TI/SH ACC DEL

2

3

4

5

6

7

8

9

LIFT/LOWER DEC DEL

2

3

4

5

6

7

8

9

REACH DEC DEL

2

3

4

5

6

7

8

9

TI/SH DEC DEL

2

3

4

5

6

7

8

9

TESTER DIGITAL INPUT #1 DIGITAL INPUT #2 DIGITAL INPUT #3 DIGITAL INPUT #4 DIGITAL INPUT #5 DIGITAL INPUT #6 DIGITAL INPUT #7 DIGITAL INPUT #8 ANALOG INPUT #1 ANALOG INPUT #2

V V

SAVE PARAM. RESTORE PARAM ALARMS PROGRAM VACC MOTOR DATA

Defaults

SICOS OPERATING AND USER MANUAL

Index 1

2

3

4

Page Sicos description .......................................................................................... 2 1.1 General features........................................................................................ 2 1.2 Graphical display description .................................................................... 3 1.2.a Direction indication ....................................................................... 3 1.2.b Battery indication.......................................................................... 3 1.2.c Hourmeter indication .................................................................... 4 1.2.d Truck speed indication ................................................................. 4 1.2.e Height indication .......................................................................... 4 1.2.f Alarm indication ............................................................................. 4 1.2.g Symbol bar ................................................................................... 5 1.2.h Preselector or Customer Logo ..................................................... 5 Display menu Description ............................................................................ 6 2.1 Selection buttons control ........................................................................... 6 2.2 Main menu ................................................................................................. 6 2.3 Submenu ................................................................................................... 7 2.3.a Tester Master ............................................................................... 7 2.3.b Tester Slave ................................................................................. 8 2.3.c Autoteaching ................................................................................ 9 2.3.d Alarms ........................................................................................ 10 2.3.e Lift Limit ...................................................................................... 11 2.3.f Program Offset ............................................................................ 11 Console description .................................................................................... 12 3.1 Sicos "Tester" menu ................................................................................ 12 3.2 Sicos "Parameter Change" menu ............................................................ 13 3.3 Sicos "Set Model" menu .......................................................................... 13 3.4 Sicos "Set Option" menu ......................................................................... 14 3.5 Sicos "Adjustment" menu ........................................................................ 15 3.6 Console map ........................................................................................... 16 Alarms .......................................................................................................... 17 =

The informations included into the marked paragraphs by this symbol are essential for the safety.

Page 1

1 SICOS DESCRIPTION IMPORTANT: The following descriptions are about a typical application of SICOS display. The features of the Sicos depends on the customer software installed.

1.1 GENERAL FEATURES The SICOS is a can-bus device that provide the following functions: - Sicos display is an intelligent dashboard connected to the truck system by CAN-BUS line. This dashboard provides the diagnostic of the whole truck system: SICOS itself, Traction controller, Pump controller, Mhyrio, EPS AC and, eventually, other modules connected on the CAN-BUS net. If Traction, Pump or Mhyrio are not present in the CAN-BUS, an alarm "CAN BUS KO" is provided on the SICOS display, the alarm locks the truck. SICOS communicate also with the EPS AC; if EPS AC is not present on the CAN BUS net no alarm is displayed on the SICOS. - Furthermore, by connecting the console to the SICOS is possible to read and modify the setting of all the modules present on the CAN-BUS net.

- Sicos is also the node of the CAN-BUS line which provides the access to an external diagnostic device, handy console or PC console.

- Sicos provides the conversion between CAN messages and serial link messages so providing the complete visibility of the truck system by a PC. Thank to this Sicos capability, an external tool (handy console or PC console) can have direct access to the diagnostic and set up of the modules connected in the CAN-BUS net.

- The Sicos console has a graphical display with 4 selection buttons control, a main page and some menu that will be explained in the following chapters.

Page 2

1.2 GRAPHICAL DISPLAY DESCRIPTION The display is composed by a main page and a menu tree.

In the heading is displayed:

1.2.a Direction indication Depends from the selected direction (FWD or BWD) and from the status of three input that give the steering wheel position. On the display are drawn 6 white arrows; by selecting a driving direction, one arrow become black according to the steering wheel direction.

1.2.b Battery indication It is displayed the battery charge coming from the traction inverter in percentage and a figure with a bar every 20% of charge. If the battery is low (<= 20%), then appears also a battery symbol with an exclamation mark in the higher part of the display. The battery charge is displayed after the key on and every time the truck is in stand by condition.

Page 3

1.2.c Hourmeter indication A sand-glass is displayed with the functioning hours every time that the truck is switched-on and every time when coming back to the main page. The hourmeter is displayed for some seconds, after that the battery is displayed again.

1.2.d Truck speed indication When the truck is running the truck speed is displayed. The speed sensor is the traction encoder. It is possible to select to display the speed in Km/h or mph by an option. If a speed reduction is selected, a turtle is shown behind the speed.

1.2.e Height indication It is displayed when the lifting or lowering function is executed; and only activating an option through an option is possible to select meter or feet. In the displayed height value is considered also a programmable offset that is the height at which is placed the encoder zero sensor. If the Sicos module receives an height value higher than zero without receiving his zero encoder signal than the display shows 22,22m+offset.

1.2.f Alarm indication The name of the alarm and the module in which the alarm happened is displayed in a square in the bottom of the page with the following code: MOD #1 -> SICOS MOD #2 -> TRACTION MOD #5 -> PUMP MOD #9 -> MHYRIO MOD #6-> EPS AC

Page 4

1.2.g Symbol bar 1) Steering sensor problem 2) Hand brake activated 3) Traction alarm 4) Pump alarm 5) Driving mode; it is selectable through an option or using the up and down buttons on the main page. Three driving modes are possible. Each mode has its own parameter table 6) Discharged battery

1.2.h Preselector or Customer Logo Through the activation of an option is possible to show the customer logo on the display. If the option is not activated a white space is shown. If the height preselector function is active in the logo place are displayed 4 floors, 2 for the loaded forks and 2 for the unloaded ones.

To enter the floor selection area is necessary to press the OUT button: in the main page a black cursor appears that can be moved between the floors with UP/DOWN. It is possible to select till to 50 floors. If UP or DOWN are pressed for some seconds, the fast scrolling function is activated. The ENTER button selects the desired floor (signed with a black circle); the OUT button exits the height pre-selector menu and the selection is erased.

Page 5

2 DISPLAY MENU DESCRIPTION 2.1 SELECTION BUTTONS CONTROL 4 buttons provides the capability of changing or reading the parameters of the SICOS display and of the controllers connected to the Can-Bus net: Enter:

push to have access to the selected menu or to confirm a change;

Out:

push to exit the selected menu or not to accept a change;

Up:

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

Down:

push to scroll down the submenu and to select or increase a parameter; 2.2 MAIN MENU

By pressing Enter the MAIN display MENU is showed: with Up and Down is possible to move an arrow that point the sub-menus, the menu is selected by pressing Enter; Out returns to the main menu.

The main menu has 6 submenu: -

TESTER MASTER TESTER SLAVE AUTOTEACHING ALARMS LIFT LIMIT PROGRAM OFFSET

Page 6

: SICOS inputs status tester : main PUMP and TRACTION inputs status tester. : floors heights setting. : alarms logbook : lifting block height setting : encoder zero reference switch height

2.3 SUBMENU 2.3.a Tester Master This is the tester menu of the display. It shows the status of the display inputs; it is composed by two pages.

Page 1

where: I1 = forward switch I2 = backward switch I3 = pedal switch I4 = seat switch I5 = dead man switch I6 = brake switch I7 = pressure switch I8 = speed reduction switch I9 = hand brake switch I10 = lifting/lowering request I11 = reach request I12 = tilting request I13 = shift request I14 = auxiliary 1 hydraulic function 1 I15 = auxiliary 2 hydraulic function 2 I16 = CREEPER function I17 = steering sensor A I18 = steering sensor B I19 = steering sensor C I20 = overcoming height block switch the meaning of the inputs could be changed in order to customer request.

Page 7

Page 2 For having access to the "Page 2" is necessary to press the Enter button while is displayed the "Page 1".

where: TRACTION ACCELERAT. POTENTIOMETER #1 PU POTENTIOMETER #2 PU POTENTIOMETER #3 PU POTENTIOMETER #4 PU

= traction potentiometer = lifting/lowering potentiometer = reach potentiometer = tilting potentiometer = side shift potentiometer

2.3.b Tester Slave This is the tester menu of the Traction and Pump modules connected with the Sicos by the Can-Bus net. It shows the status of the inputs; it is composed by two pages.

Page 1

where: CURRENT TRACTION = Traction inverter current (Arms) VOLTAGE TRACTION = Traction inverter voltage (%) FREQUENCY TRAC. = Traction inverter frequency (Hz) TEMPERATURE TR.= Traction inverter temperature (°C)

Page 8

Page 2 For having access to the "Page 2" is necessary to press the Up or Down button while is displayed the "Page 1".

where: CURRENT PUMP VOLTAGE PUMP FREQUENCY PUMP TEMPERATURE PU.

= Pump inverter current (Arms) = Pump inverter voltage (%) = Pump inverter frequency (Hz) = Pump inverter temperature (°C)

2.3.c Autoteaching This is a menu who managed floors heights setting; it is composed by one page.

Through Up or Down is possible to select the desired floor; By pressing Enter is possible to store in the selected floor the height read from the encoder.

where: LEVEL NUMBER = floor selection HEIGHT VALUE = programmed height for the selected floor ENCODER VALUE = encoder height

Page 9

2.3.d Alarms In this menu are displayed the last 5 alarms happened in every module connected to the CanBus net; it is composed by one page.

By pressing Out the question "Clear Alarms?" is displayed. By pressing Enter is possible to clear the logbook instead by pressing Out the alarms stored in the logbook will be not cleared.

where: HOURS NUM NTC MOD

Page 10

= hour counter when the alarm happens = number of times for the same alarm = display temperature at the moment of the alarm = module number on which the alarm happened 1 = SICOS 2 = TRACTION 5 = PUMP 9 = MHYRIO 6 = EPS

2.3.e Lift Limit This menu is accessible only if the Out button is pressed during the key switch on.

In this menu is possible to program the encoder level corresponding to the stop lifting height; it is composed by one page.

Through Up or Down is possible to select the desired height; By pressing Enter is possible to store in the selected height the value read from the encoder.

where: HEIGHT VALUE = lifting block height ENCODER VALUE = height read from the encoder 2.3.f Program Offset This menu is accessible only if the Out button is pressed during the key switch on.

In this menu is possible to program the "0" level of the encoder; it is composed by one page.

Through Up or Down is possible to select the desired value (the value is express in millimeters); By pressing Enter is possible to store the value.

where: OFFSET VALUE = zero encoder height in mm. By pressing UP and DOWN, the height is changed.

Page 11

3 CONSOLE DESCRIPTION By connecting the console on the SICOS, it is possible to communicate with the other modules connected to the CanBus net.

In this way is possible to modify or read the parameter of the module connected.

To select the module it is necessary to enter in the "SET MODEL" menu and select the "CONNECTED TO" parameter.

Five options are available: 1 -> Sicos connection 2 -> Traction connection 5 -> Pump connection 9 -> Mhyrio connection 6 -> EPS-AC connection If the option is saved while exiting the menu, by switching off and on the key or by pressing the three lower buttons on the console, the selected module is connected.

In case of CAN BUS problems the console switches automatically on the SICOS. 3.1 SICOS "TESTER" MENU 1) ACCELERATOR = traction potentiometer 2) ANALOG INPUT #1 = lifting pot 3) ANALOG INPUT #2 = reach pot 4) ANALOG INPUT #3 = tilt pot 5) ANALOG INPUT #4 = side shift pot 6) BRAKEPEDAL POT. = brake pot 7) FORWARD SWITCH = forward direction switch 8) BACKWARD SWITCH = backward direction switch 9) ENABLE SWITCH = pedal switch 10) SEAT SWITCH = seat switch 11) DEADMAN SWITCH = dead man switch 12) BRAKE SWITCH = brake switch 13) PRESSURE SWITCH = pressure switch 14) CUTBACK SWITCH = speed reduction switch 15) HANDBRAKE = handbrake switch 16) 1ST SPEED SWITCH = lifting/lowering enable switch 17) 2ND SPEED SWITCH = reach enable switch 18) 3RD SPEED SWITCH = tilt enable switch 19) 4TH SPEED SWITCH = side shift enable switch 20) DIGITAL INPUT #1 = auxiliary function 1 switch 21) DIGITAL INPUT #2 = auxiliary function 2 switch 22) CREEPER FUNCTION = CREEPER function status 23) STATUS #1 = steering sensor A input status Page 12

24) STATUS #2 = steering sensor B input status 25) STATUS #3 = steering sensor C input status 26) DIGITAL INPUT #3 = lifting unlock input 3.2 SICOS "PARAMETER CHANGE" MENU 1) CUTBACK SPEED 1 = Traction speed reduction 2) CUTBACK SPEED 2 = Traction speed reduction with CREEPER function 3) 1ST SPEED COARSE = Lifting max speed 4) 5TH SPEED COARSE = Lowering max speed 5) 2ND SPEED COARSE = Reach max speed 6) 3RD SPEED COARSE = Tilt max speed 7) 4TH SPEED COARSE = Side shift max speed 8) PUMP CREEP #1 = Minimum pump speed while lifting 9) PUMP CREEP #2 = Minimum pump speed while reaching 10) PUMP CREEP #3 = Minimum pump speed while tilting 11) PUMP CREEP #4 = Minimum pump speed while shifting 12) SPEED 2 CUTBACK = Reach speed reduction 13) AUX SPEED #1 = pump speed while AUX 1 input active 14) AUX SPEED #2 = pump speed while AUX 2 input active 15) PUMP STOP DELAY = delay between pump stop and valve closing 16) LIFT CUTBACK = lifting speed reduction (with pre-height selector) 17) LOW CUTBACK = lowering speed reduction (with pre-height selector) 18) ADJUSTMENT #01 = changes slow lift height (with pre-height selector) 19) ADJUSTMENT #02 = changes slow low height (with pre-height selector) 20) ADJUSTMENT #03 = changes the distance between block height and load height (with pre-height selector) 21) ADJUSTMENT #04 = changes the distance between block height and unload height.

22) AUXILIARY TIME = delay between lifting-lowering stop and auxiliary valve opening.

3.3 SICOS "SET MODEL" MENU 1) CONNECTED TO Selects the CAN BUS module to which connect the console.

1 -> Sicos connection 2 -> Traction connection 5 -> Pump connection 9 -> Mhyrio connection 6 -> EPS-AC connection Page 13

3.4 SICOS "SET OPTION" MENU 1) CHECK UP TYPE Through this parameter is possible to program the maintenance type selection 0

no programmed maintenance

1

alarm after 300 hours ("Check up needed")

2

alarm after 300 hours, traction speed reduction after 340 hours

3

alarm after 300 hours, traction speed reduction after 340 hours, traction block after 380 hours

2) PERFORMANCE TYPE 0...1...2

Through this parameter is possible to program the truck performance type; on the SICOS this parameter modifies the pump lifting and lowering max speeds, then is passed to the traction that modifies other parameters; can assume the values 0-1-2. It is possible to modify the truck performance by pressing the Up and Down button from the main page of the display too.

3) HEIGHT DISPLAY ON

the height is shown on the display.

OFF

the height is not shown on the display.

4) HOUR COUNTER Through this parameter is possible to program the hourmeter mode KEYON

hourmeter always active with key on

RUNNING

hourmeter active only with traction, pump, valves ON.

5) BATTERY CHECK ON

lifting block active when the battery is low.

OFF

lifting block not active when the battery is low.

6) PRE-HEIGHT SEL. ON

height preselector present

OFF

height preselector not present

Page 14

7) CHECK UP DONE ON

resets the hours for the programmed maintenance.

OFF

function disable.

8) SEAT SWITCH ON

seat switch present

OFF

seat switch not present

9) LOGO DISPLAY ON

the customer logo will be displayed

OFF

the customer logo will be not displayed

10) MEASURE SYS TYPE Selects the measurement system: OPTION #1

metric decimal system

OPTION #2

anglo-Saxon system 3.5 SICOS "ADJUSTMENT" MENU

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20)

MIN ACC LIFT = lifting pot minimum value MAX ACC LIFT = lifting pot maximum value MIN ACC LOW = lowering pot minimum value MAX ACC LOW = lowering pot maximum value MIN REACH BACK = reach pot minimum value (BWD) MAX REACH BACK = reach pot maximum value (BWD) MIN REACH FORW = reach pot minimum value (FWD) MAX REACH FORW = reach pot maximum value (FWD) MIN TILT UP = tilt pot minimum value (lifting dir.)

MAX TILT UP = tilt pot maximum value (lifting dir.)

MIN TILT DOWN = tilt pot minimum value (lowering dir.)

MAX TILT DOWN = tilt pot maximum value (lowering dir.)

MIN SHIFT RIGHT = side shift pot minimum value (right dir.)

MAX SHIFT RIGHT = side shift pot maximum value (right dir.)

MIN SHIFT LEFT = side shift pot minimum value (left dir.)

MAX SHIFT LEFT = side shift pot maximum value (left dir.)

MIN POT. BRAKE = brake pot minimum value MAX POT. BRAKE = brake pot maximum value LEVEL NUMBER = floor number to program LEVEL HEIGHT = corresponding height to the selected level

Page 15

3.6 CONSOLE MAP

Page 16

4 ALARMS 1) VACC NOT OK = accelerator high at stand or not correctly programmed 2) POT #1 NOT OK = lifting pot high at stand or not correctly programmed 3) POT #2 NOT OK = reach pot high at stand or not correctly programmed 4) POT #3 NOT OK = tilting pot high at stand or not correctly programmed 5) POT #4 NOT OK = side shift pot high at stand or not correctly programmed 6) CAN BUS KO = one of the modules connected to the sicos through CAN BUS don’t communicate correctly 7) CHECK UP NEEDED = programmed maintenance request 8) EEPROM KO = EEprom parameters managing error 9) CLEARING EEPROM = appears when pressing the buttons UP+DOWN+ENTER at key switch on for at least 10 seconds. The EEPROM is in the re-programming phase. Turning off the key before 10 sec. will not clear EEPROM 10) BATTERY LOW = discharged battery (<= 20%) 11) FORW+BACK = forward and backward switch closed in the same time 12) INCORRECT START = pump or traction enable request at key switch on or wrong starting sequence 13) POWER FAILURE #1 = short circuit on one of the SICOS digital outputs (three auxiliary outputs) 14) STEER SENSOR KO = wrong configuration of the steering switches on the steering wheel

Page 17

CAT RD Technical Specifications

Rev. Date

17 31.3.2006

NR16KC/KN

NR16K

NR20K

NR25KH

0 0 6 8 9 9 9 9 4 3 3 5 0 0 0 0 0 8 6 6 5 9 7 5 5 0 0 0

0 0 6 8 9 9 9 9 4 3 3 5 0 0 0 0 0 8 6 6 5 9 7 5 5 0 0 0

0 0 6 8 9 9 9 9 4 3 3 5 0 0 0 0 0 8 6 6 5 9 7 5 5 0 0 0

0 0 6 8 9 9 9 9 4 4 4 5 0 0 0 0 0 9 6 6 5 9 7 5 5 0 0 0

0 0 6 8 9 9 9 9 4 4 4 5 0 0 0 0 0 9 6 6 5 9 7 5 5 0 0 0

0 0 6 8 9 9 9 9 6 3 3 0 0 0 0 0 0 8 6 6 5 9 7 5 5 0 0 0

1

1

1

1

1

1

1

0 2 0 OFF RUN ON OFF OFF OFF OFF OP1 OFF ON ON OFF OFF

0 2 0 OFF RUN ON OFF OFF OFF OFF OP1 OFF ON OFF OFF OFF

0 2 0 OFF RUN ON OFF OFF OFF OFF OP1 OFF ON OFF OFF OFF

0 2 0 OFF RUN ON OFF OFF OFF OFF OP1 OFF ON OFF OFF OFF

0 2 0 OFF RUN ON OFF OFF OFF OFF OP1 OFF ON OFF OFF OFF

0 2 0 OFF RUN ON OFF OFF OFF OFF OP1 OFF ON OFF OFF OFF

0 2 0 OFF RUN ON OFF OFF OFF OFF OP1 OFF ON OFF OFF ON

2,7 4,3 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4

2,7 4,3 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4

2,7 4,3 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4

2,7 4,3 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4

2,7 4,3 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4

2,7 4,3 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4

CAT Settings

ON

ON ON

DEFAULT

NR14K

0 0 6 8 9 9 9 9 5 3 2 5 0 0 0 0 0 8 6 6 5 9 7 5 5 0 0 0

OPTIONAL: HEIGHT SELECTOR

NR14XE

OPTIONAL: SEAT SWITCH

TRUCK TYPES:

CONNECTION TYPE: 1

MAIN MENU/ PARAMETER CHANGE: CUTBACK SPEED 1 CUTBACK SPEED 2 1ST SPEED COARSE I 1ST SPEED COARSE II 1ST SPEED COARSE III 5TH SPEED COARSE I 5TH SPEED COARSE II 5TH SPEED COARSE III 2ND SPEED COARSE 3RD SPEED COARSE 4TH SPEED COARSE MAX SPEED PU #5 PUMP CREEP #1 PUMP CREEP #2 PUMP CREEP #3 PUMP CREEP #4 PUMP CREEP #5 SPEED 2 CUTBACK AUX SPEED #1 AUX SPEED #2 PUMP STOP DELAY LIFT CUTBACK LOW CUTBACK ADJUSTMENT #01 ADJUSTMENT #02 ADJUSTMENT #03 ADJUSTMENT #04 AUXILIARY TIME CONFIG MENU/ SET MODEL: CONNECTION TYPE SET OPTIONS: CHECK UP TYPE PERFORMANCE TYPE AUX.OUTPUT #1 HEIGHT DISPLAY HOUR COUNTER BATTERY CHECK PRE-HEIGHT SEL. CHECK UP DONE SEAT SWITCH LOGO DISPLAY MEASURE SYS.TYPE AUX.FUNCTION #1 AUX.FUNCTION #2 AUX.FUNCTION #3 LIFT-LOWER STOP 5TH FUNCTION SIDESHIFT MODE ADJUSTMENTS: MIN ACC LIFT MAX ACC LIFT MIN ACC LOW MAX ACC LOW MIN REACH BACK MAX REACH BACK MIN REACH FORW MAX REACH FORW MIN TILT UP MAX TILT UP MIN TILT DOWN MAX TILT DOWN MIN SHIFT RIGHT MAX SHIFT RIGHT MIN SHIFT LEFT MAX SHIFT LEFT MIN 5TH FORWARD MAX 5TH FORWARD MIN 5TH BACKWARD MAX 5TH BACKWARD

1/4

ZAPI SICOS SICOS RO 1.04-1.08

OPTIONAL: HEIGHT DISPLAY

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

ADJUSTMENT INSTRUCTIONS ZAPI SICOS DISPLAY

2,7 4,3 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4 2,7 4,5 2,1 0,4

NOTE

creeper-speed, slow speed Lift I Lift II Lift III Lower I Lower II Lower III Reach Tilt Side shift Clamp-option

Clamp-option Reach slow Auxiliary device Auxiliary device Lift speed reduction level Lowering speed reduction level Height for lift speed reduction Height for lowering speed reduction Height for retrieve level Height for leave level

Warning light output driver

Disable lifting at low discharge

OP1=metric, OP2=anglo Short height select cycle Enable height programming ON=lift top limit (i-mast) ON=lift cage sensor enabled ON=clamp-option SICOSK 0.05

Clamp-option Clamp-option Clamp-option Clamp-option

CAT RD Technical Specifications

ADJUSTMENT INSTRUCTIONS ZAPI SICOS DISPLAY

CAT Controller: ZAPI SICOS Program version: SICOS RO 1.04-1.08 Zapi's serial number from:

Rev. Date

2/ 4 17 31.3.2006

CONFIG MENU SET MODEL CONNECTION TYPE

1 SICOS

SET OPTIONS CHECK UP TYPE

2 TR

5 PU

1

2

9 RIO

0

PERFORMANCE TYPE

0 0

1

2

3

4

5

6

7

disabled

fw

bw

fw/bw

lift

low

lift/low

all

AUX.OUTPUT #1 Warning light output driver HEIGHT DISPLAY

OFF

HOUR COUNTER

RUNNING

BATTERY CHECK

OFF

ON

PRE-HEIGHT SEL.

OFF

ON

CHECK UP DONE

OFF

ON

SEAT SWITCH

OFF

ON

LOGO DISPLAY

OFF

ON

MEASURE SYS.TYPE

OPT1

AUX.FUNCTION #1 Short height select cycle AUX.FUNCTION #2 Enable height programming

OFF

ON

OFF

ON

ADJUSTMENTS MIN ACC LIFT MAX ACC LIFT MIN ACC LOW MAX ACC LOW MIN REACH BACK MAX REACH BACK MIN REACH FORW MAX REACH FORW MIN TILT UP MAX TILT UP MIN TILT DOWN MAX TILT DOWN MIN SHIFT RIGHT MAX SHIFT RIGHT MIN SHIFT LEFT MAX SHIFT LEFT

6 EPS

V V V V V V V V V V V V V V V V

ON

OPT2

2,7…2,8 4,2…4,3 2,0…2,1 0,4…0,5 2,7…2,8 4,4…4,5 2,0…2,1 0,4…0,5 2,7…2,8 4,4…4,5 2,0…2,1 0,4…0,5 2,7…2,8 4,4…4,5 2,0…2,1 0,4…0,5

CAT Defaults

CAT RD Technical Specifications

ADJUSTMENT INSTRUCTIONS ZAPI SICOS DISPLAY

3/ 4

MAIN MENU PARAMETER CHANGE CUTBACK SPEED 1

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

9 100 9 100 9 100 9 100 9 100 9 100 9 100 9 100 9 100 9 100 9

PUMP CREEP #2

0

1

2

3

4

5

6

7

8

9

PUMP CREEP #3

0

1

2

3

4

5

6

7

8

9

PUMP CREEP #4

0

1

2

3

4

5

6

7

8

9

SPEED 2 CUTBACK

0

1

2

3

4

5

6

7

8

9

AUX SPEED #1 Spread AUX SPEED #2 Spread PUMP STOP DELAY

0

1

2

3

4

5

6

7

8

9

0

1

2

3

4

5

6

7

8

9

0

1

2

3

4

5

6

7

8

9

LIFT CUTBACK 0 1 2 3 Lift speed reduction before reaching the programmed height.

LOW CUTBACK 0 1 2 3 Lower speed reduction before reaching the programmed height.

ADJUSTMENT #01 0 1 2 3 Height where starts the lifting speed reduction.

ADJUSTMENT #02 0 1 2 3 Height where starts the lowering speed reduction.

ADJUSTMENT #03 0 1 2 3

4

5

6

7

8

9

4

5

6

7

8

9

4

5

6

7

8

9

4

5

6

7

8

9

4

5

6

7

8

9

6

7

8

9

7

8

9

CUTBACK SPEED 2 Creep (dir.sw.)

1ST SPEED COARSE I Lift 1ST SPEED COARSE II Lift 1ST SPEED COARSE III Lift 5TH SPEED COARSE I Lower 5TH SPEED COARSE II Lower 5TH SPEED COARSE III Lower 2ND SPEED COARSE Reach 3RD SPEED COARSE Tilt 4TH SPEED COARSE Sideshift PUMP CREEP #1

0

%

0 (1,8km/h) 0

% % % % % % % % %

Distance between the stop level and the level at which you have to lift to take the load.

ADJUSTMENT #04

0

1

2

3

4

5

Distance between the stop level and the level at which you have to lower to leave the load.

AUXILIARY TIME (Pressure adj.valve delay)

0

1

2

3

CAT Defaults

4

5

6

CAT RD Technical Specifications TESTER ACCELERATOR ANALOG INPUT #1 ANALOG INPUT #2 ANALOG INPUT #3 ANALOG INPUT #4 BRAKE PEDAL POT FORWARD SWITCH BACKWARD SWITCH SEAT SWITCH ENABLE SWITCH DEAD MAN SWITCH BRAKE SWITCH PRESSURE SWITCH CUTBACK SWITCH HANDBRAKE 1ST SPEED SWITCH 2ND SPEED SWITCH 3RD SPEED SWITCH 4TH SPEED SWITCH DIGITAL INPUT #1 DIGITAL INPUT #2 CREEPER FUNCTION SAVE PARAM. RESTORE PARAM ALARMS PROGRAM VACC VACC SETTINGS MOTOR DATA

V V V V V V

ADJUSTMENT INSTRUCTIONS ZAPI SICOS DISPLAY

0,00 0,00 0,00 0,00 0,00 0,00 OFF GND OFF GND

LIFT/LOWER REACH TILT SIDESHIFT

LIFT/LOWER REACH TILT SIDESHIFT

V

0,1 5,0 NOT AVAILABLE

CAT Defaults

4/ 4

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

K11 4/12

+48V 1 8A

2

K12 4/13

A

1F1

1

1

C

8A

10F1

2

8A

11F1 3

1

500A

25A

B

12F1 5

7

35mm2

10L5

11L3

6/22

11/27

10L4

11L2

12L2

4/17

11/26

2/19

5L1

10L1

11L1

12L1

3/16

3/20

11/12

11/19

2/12

X1: -

LIFTCIRCUIT

DRIVECIRCUIT

STEERING MOTOR

48V

MAIN CONTACTORS

KEYSWITCH

G1

AUX. DEVICES

3L1

4/12

DRIVE- AND PUMPMOTOR

1L1

X1: +

G

11/23

2

2

8A

10L6

5F1

3F1

E

3M1

5M1

10M1

11M1

12M1

4/12

3/16

3/20

11/12

11/28

2/12

35mm2

1M1

10M3

12M2

6/24

2/19

4

10F2 8A

6

11F2 D

8A

8

12F2 F

8A

H

0V

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN POWER SUPPLY 48 V

1 / 23

REV

3-6777

11

12

13

14

15

16

17

18

+48V

19

20

21

22

23

24

25

+48V

26

27

28

29

30

+48V

12L3

12L2

12L4

12L3

1/26

25

1/26

12/23

18

X51:1

12L1

21L1

31L1

41L1

Vo+

48V

Gi-

12V/5A

Vo+

G3

RADIO

G2

Vi+

48V

Go-

12V/8A 24V/8A

Gi-

Vo+

G4

48V

24V/5A

Gi-

31M1

13/19

Go-

41M1

X51:2

21M1

Go-

Vi+

CAMERA/MONITOR

Vi+

13/25

AUX. DEVICES

13/19

13/26

12M1

12M3

12M2

12M4

12M3

1/26

25

1/26

12/18

18

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN POWERSUPPLY 12/24V

2 / 23

REV

3-6777

11

12

13

14

15

16

17

18

19

20

3L2

3L1

5L1

16

1/17

1/19

21

22

23

24

25

26

27

28

29

30

3L2 12

B+

B+

U

U

U

V W

V

M2

3

W

W

B-

V

V

3

V

V W

W

B-

A1

M3

W

B-

A2

STEER MOTOR CONTROLLER

U

TRACTION MOTOR CONTROLLER

3

U

PUMP MOTOR CONTROLLER

U

M1

B+

A3

3M2 12

3M2

3M1

5M1

16

1/17

1/19

DRIVEMOTOR

PUMPMOTOR

STEERINGMOTOR

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN MAINCIRCUITS

3 / 23

REV

3-6777

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

OPTION HANDBRAKE SWITCH

BRAKE PEDAL

1L1

1L2

10L4

1/13

12/13

1/24

SEAT SWITCH

STEERING MOTOR CONTROLLER

A3 XA3B:1

13

S11

S23

X23:1

X12: 1

X21:9

XA3B:7

S14

COM

3

NO

14

S28

2

S22.2

S12

X21:10

COM

P BRAKE PEDAL

22 EM.STOP

NC

12/13

X13:12 XA4B: 18

1M2

X13:11

-

48V

(I9)

48V

(I4)

48V

X34: 2

XA1F: 8

-

U

XA4B: 6

A1 48V A2

XA4C: 15

K12

XA4C: 5

A1 48V A2

Y31

X13:6

K11

F103

XA4B: 19

+

X13:7

+

1 48V 2

XA4B: 7

F102

XA1F: 9

F101

M1

X13:8

X34: 1

XA4B: 8

X12: 2

MAX BRAKING

X21: 12

START BRAKING

S22

21

X23: 2

X21: 11

KEYSWITCH

MAIN CONT. CONTROL TRACTION MOTOR CONTROLLER

BRAKE CONTROL

A1

1M1

(I7) (I6) SICOS/DISPLAY-UNIT

A4

1/13

MAINCONTACTORS

MAGN.BRAKE

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN DRIVE CIRCUIT 1

4 / 23

REV

3-6777

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

"DEAD MANS SW."

TROTTLE PEDAL SENSOR

TROTTLE PEDAL SWITCH

FOOT SWITCH

HAND DIRECTION SWITCH

3

0V

S21

X22:1

2

0,2...7,5V

7,5V

1

X21:4

B21

S25

COM

S13

13

NO

2

3

14

5 1

6

BW

J1

X13:13

X13:14

X22:5

X21:5

X21:3

X21:2

FW X21:1

4

J1

X13:9 XA4B: 17

XA4C: 19

XA4C: 10

XA4C: 20

48V

(I5)

48V

48V

(I1)

(I2)

CREEPER 48V (I16)

SPEED REDUCTION 48V (I8)

XA1F: 4

XA4C:17

XA4C: 7

XA4C: 16

XA4C: 6

X22:2

X13:10 XA4B: 5

(I3)

X22:3

X13:4 XA4B: 16

X13:3 XA4B: 9

X13:5

X13:2 XA4B: 11

SENSOR TROTTLE SENSOR SUPPLY SIGNAL GND SICOS/DISPLAY-UNIT

18

XA4B: 4

X13:1 XA4B: 10

27

TRACTION MOTOR CONTROLLER

A1

A4

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN DRIVE CIRCUIT 2

5 / 23

REV

3-6777

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

STEERING FEEDBACK SENSORS

S31

STEERING WHEEL SENSOR

SENSOR C

XA4B: 1

(I18)

BLU

X33:3

BLK

X33:2

BRN

X33:1

X32:3

BLU

X12:6

1/24

BLK

XA4B: 13

10M3

1/24

X12:4

10L5

BRN

X32:2

BLU

X12:5

X31: 1

ORA

X14:6 X11:6 0 - 10VAC

XA3B: 3

WHT

X14:5 X11:5 0V

XA3A: 7

BLU

X14:4 X11:4 0 - 10VAC

XA3A: 20

YEL

X14:3 X11:3 0 - 10VAC

XA3A: 10

BLK

X14:2 X11:2 0V

XA3B: 4

RED

BLK

(I17)

A3

S33

BBRN

STEER MOTOR CONTROLLER

SENSOR B

XA4B: 2

B+

S32

X32:1

A-

X31: 3

A+

SENSOR A

X31: 2

B11

X14:1

14

X11:1

13

0 - 10VAC

12

XA3B: 9

11

(I19)

SICOS/DISPLAY-UNIT

A4

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN STEERING CIRCUIT

6 / 23

REV

3-6777

2,5V

0V (I10) 5V SICOS/DISPLAY-UNIT (I11) (I12)

CIRCUIT DIAGRAM (I13)

A4

TS841200 (I14)

S41

1

(I15) 48V

NR14-25K,KC,KE,KH,KN HYDRAULIC CONTROL CIRCUIT 1

XS42:2

28

REACH SPEED LIMIT SWITCH

22

29

S42 P

21

(DI1) 48V (DI2) MHYRIO/VALVECONTROLLER

7 / 23

XA5A: 25

3

2

XS42:3

AUX DEVICE

27

XA5A: 11

S16

26

XA5A: 38

R14

X45:1

R13

X45:3

R12

25

XA5A: 10

R11

24

XA4C: 18

SIDESHIFT

23

XA4C: 9

22

XA4C: 8

TILT

XR14:4

REACH

XR14:3

LIFT/LOWER

XA4D: 10

SHIFT LEFT 0,5V - 2,5V - 4,5V SHIFT RIGHT

XR14:2

21

XA4D: 11

XA4D: 12

20

XR14:1

XR13:4

XR13:3

19

XA4D: 16

XA4D: 7

TILT DOWN 0,5V - 2,5V - 4,5V TILT UP

XR13:2

18

XA4D: 8

XA4D: 9

17

XR13:1

XR12:4

XR12:3

16

XA4D: 15

XA4D: 4

REACH OUT 0,5V - 2,5V - 4,5V REACH IN

XR12:2

15

XA4D: 5

XA4D: 6

14

XR12:1

XR11:4

XR11:3

13

XA4D: 14

XA4D: 1

LOWER 0,5V - 2,5V - 4,5V LIFT

XR11:2

XR11:1

12

XA4D: 2

XA4D: 3

XA4D: 13

11 30

LIFT PRESSURE SWITCH

2

3

48V

A5

REV

3-6777

13

14

15

16

17

XA5A:34

12

XA5A:16

11

18

19

20

21

22

23

24

25

26

27

28

29

30

A5

XA5B:15

XA5B:16

XA5B:14

XA5B:4

XA5B:7

XA5B:8

XA5A:29

XA5A:20

XA5A:15

XA5A:33

XA5A:1

XA5A:4

XA5A:30

XA5A:27

XA5A:2

XA5A:22

XA5A:3

XA5A:17

XA5A:31

XA5A:19

MHYRIO/VALVECONTROLLER 48V OUT

LIFT

LOWER

TILT

ROCLA OYJ CIRCUIT DIAGRAM

Y32

X41:8

XY32: 1

X44:4

X44:3 XY46.2:1

X44:2 XY46.1:2

Y46

Y46.2

XY46.2:2

XY32:2

(m10)

XY46.1:1

(m9)

XY45.2:2 RIGHT B3

SIDESHIFT

TS841200

X44:1

X43:4

X43:3

Y46.1

(m8)

A3 LEFT

20-24V

Y45.2

(m7)

XY45.1:1

XY44.2:2 BW B2

Y45

20-24V

XY45.2:1

X43:2 XY45.1:2 Y45.1

(m6)

XY44.1:1

20-24V

Y44.2

(m5)

A2 FW

X43:1

X42:12

X42:11 Y44

20-24V

XY44.2:1

X42:10 XY44.1:2

XY43.2:2 BW B1 REACH

X42:9

X42: 8

Y44.1

(m4)

A1 FW

20-24V

Y43.2

(m3)

XY43.1:1

(m1)

X42:7

XY43.1:2 Y43.1

Y43

20-24V

XY43.2:1

XY41:1 Y41.1

(m2)

X42:6

X42:4

Y41

Y41.2

X42:5

X42:3

20-24V

X42:2

20-24V

XY41:3

0-24V

XY41:2

X42:1

20-24V

X41:7

20-24V

A4

B4 AUX DEVICE

NR14-25K,KC,KE,KH,KN HYDRAULIC CONTROL CIRCUIT 2

PUMPCONTROL

8 / 23

REV

3-6777

14

15

16

17

18

19

20

21

OPTION

28

29

30

BLK

BLU

X49:3

BRN

M

XA5B: 6

BLK

L+

X49:2

BLU

M

XA5B: 12

COM

(I20)

48V

X46:6

X46:7

XA5A: 6

XA5A: 23

0 / 14V

XA5A: 13

X46:5

X46:2 0 / 14V

XA5A: 12

14V SENSOR SUPPLY

XA5A: 39

X46:1 XA5A: 32

NO

XA4C: 14

0 / 5V

XA4A: 4

S10

XA4C: 4

0 / 5V

NO

XA4A: 3

NO

0 / 5V

NO

XA4A: 2

NO

0 / 5V

COM

XA4A: 1

COM

WHT

OUT B

X49:1

OUT A

S43

XA5B: 1

PULSE ENCODER

X48:3

B41

X47:1

S20

COM

XA4A: 5

S19

COM

0V

A4

27

LIFTING HEIGHT REFERENCE SENSOR

X48:2

ESC

X48:1

TOP LIMIT OVER-RIDE

RED

SICOS/DISPLAYUNIT

26

OPTION

X47:4

KEYBOARD ENT

S18

25

OPTION, FOR FUTURE USE

L+

S17

24

X46:4

-

23

OPTION

X47:2

+

22

XA5A: 42

13

X47:3

12

X46:3

11

0V

48V

0V

14V

0V

MHYRIO/VALVECONTROLLER

A5

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN HYDRAULIC CONTROL CIRCUIT 3

9 / 23

REV

3-6777

12

13

14

15

19

20

21

22

23

24

25

26

27

28

29

30

TEMP SENSOR TRACTION MOTOR CONTROLLER 0V

12v SENSOR SUPPLY

BLU

BLK

X36:6

X36:3

X36:2

X36:1

XA2D: 2

XA2F: 6

XA2F: 12

R32

0 / 10V

XA2D: 5

WHT

X35:1 XA1F: 12

X36:5

X35:2 XA1F: 6

0 / 10V

BLK

X35:3 XA1D: 2

XA2D: 3

BLU

X35:6

R31

TEMP. SENSOR

PULSE ENCODER

0 / 10V

XA1D: 5

WHT

X35:5 XA1D: 3

0 / 10V

RED

X35:4

B32

RED

TEMP. SENSOR

PULSE ENCODER

12V SENSOR SUPPLY

A1

18

M2

XA1D: 1

B31

17

X36:4

M1

16

XA2D: 1

11

TEMP SENSOR PUMP MOTOR CONTROLLER 0V

A2

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN CONTROL CIRCUIT 1

10 / 23

REV

3-6777

18

SUPPLY SICOS/DISPLAY-UNIT

48VIN CANL CANH CANL CANH TRACTION MOTOR CONTROLLER

20

21

22

23

24

25

SUPPLY CANL CANH CANL CANH

XA2B: 2

XA2B: 1

MOD5

XA2F: 11

A2

A3

MOD6

X41:4

X41:5

X41:6

XA5C: 3

XA5C: 5

X41:2 XA5C: 1

+KEY PAUX SUPPLY

29

XA5C: 6

X41:1 XA5C: 4

XA3A: 4

XA2C: 4

48VIN CANL CANH CANL CANH PUMP MOTOR CONTROLLER

XA3A: 14

1/25

XA3A: 3

11M1

1/25

XA3A: 13

11L3

1/25

XA3B: 11

11L2

1/24

XA2C: 2

10L6

XA2F: 5

XA1F: 11

MOD2

XA1F: 5

XAF:1 XAF:2 XAF:3 XAF:4 XAF:5 XAF:6 PCLRXD NCLRXD PCLTXD NCLTXD GND +12V

A1

28

30

-BATT

120R CANL CANH MHYRIO/VALVECONTROLLER

A5

MOD9

X15:2 X15:9 X15:8 X15:7 X15:3 X15:4

MOD1

27

1/25

STEER MOTOR CONTROLLER

A4

26

11L1

XA1C: 4

XA1C: 2

XA1C: 3

XA1C: 1

XA1F: 1

X12:10

120R CANL CANH

19

XA2C: 3

17

XA2C: 1

16

13/12

XA4E: 3

13/12

15

10L3

XA4B: 3

10M2

13/12

XA4B: 14

10L2

X12:8

1/24

XA4E: 4

1/24

X12:7

10M1

XA4E: 1

10L1

14

XA2F:1

13

X12:9

12

XA4E: 2

11

PROGRAMMING CONNECTOR

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN CONTROL CIRCUIT 2

11 / 23

REV

3-6777

12

13

14

SIGNAL HORN +48V

15

16

WARNING LIGHTS

1L2 PCM/DISPLAY-UNIT

XA4C:1

XA4C:12

4/13

17

18

19

20

21

22

WORKING LIGHTS +48V

CABINLIGHTS +48V

A4

23

24

25

26

27

28

29

30

WARNING LIGHTS +48V

12L5

12L6

12L7

12L4

23

18

20

2/20

12L6

12L7

12L8

12L5

20

22

13/15

18

X51:3 S51

1

S52

S53

1

1

13

S15

4

K31 2

2

2

15

3

14

X12:11

X12:12

R51

X12:3

11

1 68R/50W 2

X51:4

X55: 1

X53:1 1

1 24V/10W

E51 2

E52

1 24V

H51 FLASHLIGHT

2

48V 2

LEFT

X53: 2

X55: 2

X54:1 1

E53

24V 2

A1

K

V1 A

RIGHT

H1

X54: 2

48V A2 8

K31 1

12M5

12M6

12M7

20

22

13/15

1M2

12M4

12M5

12M6

4/12

2/20

18

20

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN SIGNAL/LIGHT CIRCUIT

12 / 23

REV

3-6777

11

12

13

14

15

CONTROLLER FAN

DRIVER FAN

+48V

48V

16

17

18

19

20

21

22

23

24

25

26

+24 V

0 V

10L3

12L8

21L1

41L1

41M1

11/16

12/22

2/15

2/28

2/28

27

28

29

30

A312 CAMERA

10L2 11/12

W51

B51

+ ANTENNA 1

S54

2 1

2

3

4

X314:

1

2

3

4

X56: 1

X10: 1

+12V

48V BLK

M51

48V

+

SPEAKER

RED

RED

M10

X315:

RADIO RECEIVER

BLK

GND

1

F312 3A

RED

2

S

1 X313:

1

2

3

4

2

BLK

F311 3A

BLK

X56: 2

WHT

X10: 2

RED

A51

X311:

X312:

+24V

0V

VIDEO

POWER

+12V CAMERA

0V

MONITOR

10M2

12M7

21M1

11/12

12/22

2/15

CIRCUIT DIAGRAM

A311

TS841200

NR14-25K,KC,KE,KH,KN FANS, AUX. DEVICES

13 / 23

REV

3-6777

L220

X10 RL211074 2 L100

CIRCUIT DIAGRAM

L50

6 L100

TS841200

L350

L900

2 X34 RL211074

L50

L350

L70

X23 RL211074

L50

NR14-25K,KC,KE,KH,KN WIRE HARNESS W6: RL450681 15 / 23

29 G2:Go-

G2:Vo+

G2:Gi-

28

L350

L350

27

G2:Vi+

H1:A2

H1:A1

12F

11F

10F

5F

26

L250

8

7

G H

6

5

E F

4

3

C D

2

B

25

L200

L200

L200

L200

1F

24

6 X36 RL210352

X22 RL210353

23

L350

1

K11:2

L250

A

K11:1

L250

22

L350

L620 L350

A51:GND

K12:A2

K12:A1

K11:A1

K11:A2

XA3B RL450662

21

L350

A51:+12V

L350

12

20

L250

L250

L250

L170

L170

XA3A RL450664

A3:B+

L600

20

A3:B-

L400

19

6 X35 RL210352

3

4

X33 RL210022

XA1C RL450660

X32 RL210022

L220

3

6

3

XA1F 12 L220 RL450662 15 L110 X13 RL210028

L220

L100

L220

L120

X31 RL210022

XA1D RL450661 L250

18

12

L350

17

X41 RL210366

A2:BL220

12 L110 X12 RL210366

L120

XA2F 12 L220 RL450662

16

L400

2

15

12 X21 RL210366

XA2B

4

14

6 X11 RL210353 6 x RL210030

XA2C RL450660 6

L120

XA2D RL450661

13

L100

12

L120

11 30

L120

X51 6 L100 RL210353 2 L800

L1500

L450

L380

L250

REV

3-6777

XA4C 20 RL450664 L100

XA4E RL450661 6

L100

XA4D RL450663 16

L330

XA4A RL450661 5 x RL450666 6

L200

XA4F RL450671 8 L200

10

CIRCUIT DIAGRAM

TS841200

L100

S16:3

26 27

NR14-25K,KC,KE,KH,KN WIRE HARNESS W7: RL450682

300mm

RL197678

S12:22

25

L100

L100

S16:2

L250

24

15

L100

S16:1

L100

RL197678

S12:21

23

X13 RL210026

L100

S13:6

L100

RL197678

S14:3

22

L300

L100

S13:4

L100

RL197678

S14:2

21

L100

L100

S13:5

L100

RL197678

S15:14

RL197678

S15:13

RL197237

S10

20

12 X12 RL210025

L100

S13:3

L100

L100

L300

RL197237

S10

19

L100

L100

S13:2

L65 L100

L150

S13:1

7

L300

RL197678

S11:14

18

6

XR14 RL199215

L25

L100

RL197678

17

RL197237

L50

7

L25 L40

S20

RL197237

L50

XR13 RL199215

7

16

S19

RL197237

L50

XR12 RL199215

L40

S18

RL197237

L50

L50

L50

15

S17

RL197237

S20

RL197237

S19

14

RL197237

L50

X11 RL210352

L100

S11:13

24

L100

XA4B RL450665

L25

L250

S18

13

RL197237

12

7 XR11 RL199215

6

L50

X14 RL210353 6 x RL210030

S17

11 28 29

16 / 23

30

L400

X15

REV

3-6777

L250

L300

L300

XA5B 16 RL450460

XA5C 6 RL450673

3 X45 RL210022

L400

9

X46 RL108288

19

XS42

X49 RL210022

3

18

L400

X44 RL211075

4

17

L400

L250

X43 RL211075

4

16

L200

L1550

15

XA5A 42 RL450459

X41 12 RL210025

14

X42 RL210366

13

12

12

L250

L250

11 20 21

CIRCUIT DIAGRAM

22 23

TS841200

24 25 26 27

NR14-25K,KC,KE,KH,KN WIRE HARNESS W8: RL450683

28 29

17 / 23

30

L350

REV

3-6777

11

12

13

14

15

X46 RL210044

16

9

17

18

19

20

21

22

23

24

25

26

L250

4

X47 RL211075

L100

3

X48 RL210022

27

28

29

30

L4800

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN WIRE HARNESS W9: RL450684

18 / 23

REV

3-6777

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

L75

L95

K12:2

X1 RL108461

2

L800

K11:1

L80

3F1:1 3F1:2

A2:B+

L180

A1:B+

L180

A1:B-

A2:B+

L650

A2:B-

L950

A2:B-

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN WIRE HARNESS W2 RL450734

19 / 23

REV

3-6777

11

12

13

14

15

16

A3:U

L100

A3:V

L100

A3:W

L100

17

18

19

20

21

22

23

L1500

CIRCUIT DIAGRAM

TS841200

24

25

26

L100

M3:U

L100

M3:V

L100

M3:W

27

NR14-25K,KC,KE,KH,KN WIRE HARNESS W5 RL450735

28

29

20 / 23

30

REV

3-6777

G3:Go-

G3:Vo+ L100

CIRCUIT DIAGRAM

TS841200

L100

2

X54 RL211074

26

L600

27

NR14-25K,KC,KE,KH,KN WIRE HARNESS W10: RL450804

28

L150

25

2 X55 RL211074

L150 L250

RL197678

S54:2

24

S51:1

R51

RL197678

S54:1

RL197678

S53:2

23

L300

L300

RL197678

S53:1

RL197678

22

S51:2

L100

S52:2

21 RL197678

S52:1

20

E51:1

L4200 G4:Gi-

G4:Vi+

X53 RL211074

19

L300

L250

2

18

E51:2

G3:Gi-

17

L200

L150

16

31M1:GND

G3:Vi+

15

L150

6 14

31L1:24V

L100

13

L100

X51 RL210352

2

12

X56 RL211074

L150

11 29

21 / 23

30

L250

L100

REV

3-6777

11

12

13

14

15

X41:7 RL210030

L50

X41:8 RL210030

L50

16

17

18

19

20

21

22

23

L1950

CIRCUIT DIAGRAM

TS841200

24

25

3

XY32 RL509985

26

27

NR14-25K,KC,KE,KH,KN WIRE HARNESS W11: RL450860

28

29

22 / 23

30

REV

3-6777

11

12

13

14

15

XY46.2 RL461312 2 x RL450461

2

XY46.1 RL461312 2 x RL450461

2

XY45.2 RL461312 2 x RL450461

2

XY45.1 RL461312 2 x RL450461

2

XY44.1 RL461312 2 x RL450461

2

XY43.2 RL461312 2 x RL450461

2

XY44.2 RL461312 2 x RL450461

2

XY43.1 RL461312 2 x RL450461

2

XY41 RL461313 3 x RL450461

3

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

L230 L310 4

X44 RL210045 4 x RL210029

4

X43 RL210045 4 x RL210029

L120 L200 L280 L360 L170 L250

L100 L290 L310

L150

12

L100

X42 RL210025 11 x RL210029

L180

L150

L200

L250

CIRCUIT DIAGRAM

TS841200

NR14-25K,KC,KE,KH,KN WIRE HARNESS W16: RL461314

23 / 23

REV

3-6777

11

12 +48V K11:1

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1

F341 2

2

X1

H341 X2

1

X342: 4

X342: 5

R341 68R

MINILEVERS

HEATING ON

X361: 1 S356

1

t

2

1

R342 2

100R

1

R344 2

1

100R

X341: 4

X341: 5

X353: 1 R346.1

X354: 1

X355: 1

HYDR. VALVE

ACCEL.SENSOR

BRAKE PEDAL

X355: 3

X355: 2

X362: 1

1

25W

2 2 1

X353: 2

1

2

X353: 3 R346.2

1

R347

R348

100R

220R

2

2

S352

t

R345 2 50W,2m 2

X361: 2

S353

t

1

1

1

2

2

2

R349 2 220R

R350 220R

R351 220R

1

1

1

25W

2

X353: 4 X351: 2

X343: 13

X356: 1

R343 220R

X343: 9

ACCELERATOR PEDAL

X352: 1

3

SWITCHES

S341

DEAD MAN´S PEDAL

X351: 1

SEAT HEATER

X342: 1

X343: 8

X343: 7

MOTOR CONTROLLER

X343: 3

STEERING WHEEL

X341: 1

DISPLAY

8A

X354: 2

X355: 4

X352: 2

X355: 5

X355: 6

X362: 2 X356: 2

341M1 2/13

X343: 6

X343: 10

X343: 11

X343: 12

X343: 14

2

F342 8A

1

R341,R342,R343,R344: NOT USED IN CABIN VERSION

A1: B-

CIRCUIT DIAGRAM

TS920101

NR14-25K,KC,KE,KH,KN COLD STORE MODIFICATION

HEATING

1/6

REV

3-6778

12

13 +48V K11: 1

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10.0mm2

1

1

K341

F343

13

2

8A

2

10.0mm2

1

X341: 2

50A

1

F345

F344 2

50A

2

2x4.0mm2

X342: 2 A

5

C

F351 6

S341

12A

E

F353 1

12A

F357

F355 3

12A

G

5

12A

7

X343: 1

R353 290W

R354 2

290W

1

R355 2

140W

1

R356 2

340W

1

R357 2

575W

B+

R361 ROOF

1

X371: B+ FRONT WINDOW

1

LEFT DOOR WINDOW

X341: 3

RIGHT DOOR WINDOW

X342: 3

RIGTH WINDOW

HEATING ON

LEFT WINDOW

11

HEATER 48V 1

R358 2

449W

2

S342 DOOR SWITCH

X343: 2 X343: 4 S343

X371: BCABIN THERMOSWITCH

t

2

X343: 5

K341

B-

A1 48V A2

341M1

F354

F352 12A

6

4

B

12A

F358

F356 D

12A

8

F

12A

H

2x4.0mm2

A1: B-

1/11

CIRCUIT DIAGRAM

TS920101

NR14-25K,KC,KE,KH,KN COLD STORE MODIFICATION

CABIN HEATING

2/6

REV

3-6778

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

X356

X41a 1 2 3 4 5 6 7 8 9 10 11 12

1 2

No:RL450170

L 1300mm

Cable S200 12x1.0

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

X41b

1 2

X362

CIRCUIT DIAGRAM

TS920101

NR14-25K,KC,KE,KH,KN COLD STORE MODIFICATION

REACH CARRIAGE CABLE

3/6

REV

3-6778

12

13

14

15

16

17

18

19

20

21

22

THE SIDESHIFT VALVE (X43) MUST BE CONNECTED TO X44 SUPPLY CONNECTOR

23

24

25

26

27

28

29

30

AUX DEVICE

VALVECONTROLLER

XA5B:14

XA5B:4

XA5B:7

XA5B:8

XA5A:29

XA5A:20

XA5A:15

XR14:1

XR14:2

XR14:3

XR14:4

XA4D: 16

XA4D: 12

XA4D: 11

XA4D: 10

3

S16 2 1

X44:4

X44:3

20-24V

X44:2

20-24V

X44:1

X43:4

X43:3

X43:2

20-24V

R11 R12 R13

S16

20-24V

THE SIDESHIFTLEVER (R14) IS REPLACED

BY THE SWITCH (S16)

SIDESHIFT

(R14)

Y45.2

A3 LEFT

XY45.2:2

(m8)

XY45.1:1

(m7)

XA4C:18

Y45.1

XA4C: 8

Y45

XY45.2:1

XY45.1:2

X43

XA4C: 9

XA5A:33

A CONNECTION BETWEEN PINS 1 AND 3 MUST BE MADE IN CONNECTOR XR14

X43:1

11

RIGHT B3

A4

B4

AUX DEVICE SIDESHIFT

CIRCUIT DIAGRAM

TS920101

NR14-25K,KC,KE,KH,KN COLD STORE MODIFICATION

HYDRAULIC LEVERS

4/6

REV

3-6778

11

12

13

14

X343:

15

l=400

16

17

19

20

21

22

23

24

25

26

27

28

29

30

X351: 1 2

3 6

18

BOOMERANG X352:

l=800

1 2 l=1000

X353: 1 2 3 4 5

7 10

SEAT HEATER

X354:

l=2500 8 11

1 2

DEAD MAN’S PEDAL

1 2

HYDR.VALVE

X355:

l=2000

1 2 3 4 5 6

9 12

BRAKE PEDAL ACCELERATOR PEDAL ACCELERATOR SENSOR

X356:

l=2000 13 14

X362: 1 2

ALL CABLES 2x0.75

CIRCUIT DIAGRAM

REACH CARRIAGE CABLE

TS920101

NR14-25K,KC,KE,KH,KN COLD STORE MODIFICATION

HEATING SUPPLY WIRING

5/6

REV

3-6778

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

CONTROLLER FAN +48V

10L3 11/16

10L2 11/12

X10a: 1

S354

1

t

S355

1

t

2

2

X10b: 1

RED

M10

48V BLK

X10b: 2

X10a: 2

10M2 11/12

CIRCUIT DIAGRAM

TS920101

NR14-25K,KC,KE,KH,KN COLD STORE MODIFICATION

AUXILIARY FAN

6/6

REV

3-6778

INDEX 1 2

Introduction ....................................................................................................

Specification ..................................................................................................

2.1 Technical specifications .........................................................................

2.2 Control unit .............................................................................................

2.2.a Microswitches ...............................................................................

2.2.b Accelerator unit .............................................................................

2.2.c Other analog control unit ................................................................

2.2.d Speed feedback ............................................................................

3 3 3 4 4 4 5 5

2.3

Protection features

.......................................................................... 6

2.4 2.5 2.6

Operational features ............................................................................... 7 Diagnosis .............................................................................................. 8 Thermal consideration ............................................................................ 8

2.7

General instructions and precautions

2.8

Susceptibility and electromagnetic emission

2.9

Main contactor and emergency switch .................................................... 9

. .............................................. 8 .................................. 9

.......................................................................... 10

3

Safety and protection

4

Installation .................................................................................................... 11 4.1 Connection cables ............................................................................... 11 4.2 Contactors ........................................................................................... 11 4.3 Fuses ................................................................................................... 11 4.4 Description of connectors - Traction configuration ............................... 12 4.5 Description of connectors - Pump configuration .................................... 15 4.6 Encoder installation .............................................................................. 18 4.7 Description of power connections......................................................... 19 4.8 Mechanical drawing ............................................................................. 20 4.9 Connection drawing - Traction configuration ......................................... 21 4.10 Connection drawing - Pump configuration ............................................ 22 4.11 Connection drawing - Combi configuration ........................................... 23 Programming & Adjustments using Digital Console ................................ 24 5.1 Adjustments via Console ...................................................................... 24 5.2 Description of Console & Connection ................................................... 24 5.3 Description of Standard Console Menu ................................................ 25 5.3.a Traction configuration .................................................................. 25 5.3.b Pump configuration ...................................................................... 26 5.4 Function configuration .......................................................................... 27 5.4.a Traction ....................................................................................... 27 5.4.b Pump .......................................................................................... 31 5.5 Parameter regulation: Traction configuration ........................................ 37 5.6 Parameter regulation: Pump configuration ............................................ 39 5.7 Programming console functions ........................................................... 41 5.8 Sequence for Ac Inverter Traction setting .............................................. 42 5.9 Tester: description of the function; Traction configuration ...................... 43

5

Page 1

5.10 Tester: description of the function; Pump configuration ......................... 45 6 Other functions ............................................................................................ 47 6.1 Description of the Console Save function ............................................. 47 6.2 Description of Console Restore function. .............................................. 48 6.3 Description of Alarms menu ................................................................. 49 6.4 Description of Console Program Vacc function .................................... 50 7 AC2 Inverter diagnostic - Traction configuration ...................................... 51 7.1 Analysis of alarms displayed on console .............................................. 51 8 AC2 Inverter diagnostic - Pump configuration .......................................... 55 8.1 Analysis of alarms displayed on console .............................................. 55 9 Recommended Spare parts for inverter .................................................... 59 10 Periodic Maintenance to be repeated at times indicated .......................... 60

=

The informations included into the marked paragraphs by this symbol are essential for the safety.

SIGNATURES TABLE COMPANY DEPT. SERVICES ENGINEERING SECTION EXECUTIVE EXPORT MANAGER

Publications N°: ADEZP0AD Edition: January 2003 Page 2

MANAGEMENT EXECUTIVE

1 INTRODUCTION Within the ZAPIMOS family, the AC2 inverter is the model suitable for control of 3.0kW to 8.0kW motors. It has been expressly designed for battery electric traction.

It is fit for electric truck, golf cars, utility cars.

2 SPECIFICATION 2.1 TECHNICAL SPECIFICATIONS Inverter for AC asyncronous 3-phase motors Regenerative braking functions Can-bus interface Digital control based upon a microcontroller Voltage: .................................................................................. 24 - 36 - 48 - 72 - 80V Maximum current (24V,36V): ......................................................... 450A (RMS) for 3' Maximum current (48V): ................................................................ 350A (RMS) for 3' Maximum current (72V,80V): ......................................................... 250A (RMS) for 2' Booster (all version) .............................. 10% of maximum current for some seconds; Operating frequency: ..........................................................................................8kHz External temperature range: ................................................................. -30°C ÷ 40°C Maximum inverter temperature (at full power): .................................................... 75°C BLOCK DIAGRAM

Page 3

2.2 CONTROL UNIT 2.2.a Microswitches - The microswitches must have a contact resistance lower than 0.1W and a leakage current lower than 100µA. - When full load connected, the voltage between the key switch contacts must be lower than 0.1V. - The microswitches send a voltage signal to the microprocessor when a function request (for ex.: running request) is made.

2.2.b Accelerator unit The accelerator unit can consist of a potentiometer or an Hall effect device.

It should be in a 3-wire configuration.

CPOT (E1) signal ranges from 0 to 10V. Potentiometer value should be in the 0.5 - 10 Kohm range; generally, the load should be in the 1.5mA to 30 mA range. Faults can occur if it is outside 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 mechanical elements associated with the potentiometer, especially relating to the minimum level.

The sequence of procedure is described in the programming console manual.

Page 4

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.

2.2.c Other analog control unit 1) Input E8 is an analog input, whose typical application is for proportional braking. It should be in a 3 wire configuration. Potentiometer value should be in the 0.5-10KW range. Generally, the load should be in the 1.5mA to 30 mA range.

The CPOTB (E8) signal range is from 0 to 10V. 2) Connections F6 (PTHERM) and F12 (NTHERM) are used for a motor thermal sensor. It can be digital (on/off sensor, normally closed) or analog. See also chapter 4.4 for more explanation.

2.2.d Speed feedback The motor control is based upon the motor speed feedback. The speed trasducer is an incremental encoder, with two phases shifted at 90°. The encoder can be of different types : - power supply: +5V or +12V -

electric output:

open collector ( NPN or PNP), push-pull, line driver

-

standard (A and B) or differential (A, A, B, B) output

For more details about encoder installation see also chapter 3.6.

Page 5

2.3 PROTECTION FEATURES - Battery polarity inversion: It is necessary to fit a MAIN CONTACTOR to protect the inverter against reverse battery polarity and for safety reasons.

- Connection Errors: All inputs are protected against connection errors.

- Thermal protection If the chopper temperature exceeds 75°C, the maximum current is reduced in proportion to the thermal increase. The temperature can never exceeds 100°C. - External agents: The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP54.

- Protection against uncontrolled movements: The main contactor will not close if: - The Power unit is not functioning.

- The Logic is not functioning perfectly.

- the output voltage of the accelerator does not fall below the minimum voltage value stored, with 1V added.

- Running microswitch in closed position.

- Low battery charge: when the battery charge is low, the maximum current is reduced to the half of the maximum current programmed.

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

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

Requests for drive, must be made after closing the key switch

Page 6

2.4 OPERATIONAL FEATURES - Speed control.

- Optimum behaviour an a slope due to the speed feedback: - the motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set-point.

- the system can perform an electrical stop on a ramp (the machine is electrically hold on a slope) for a programmable time (see also chapter 4.4) - Stable speed in every position of the accelerator.

- Regenerative release braking based upon deceleration ramps.

- Regenerative braking when the accelerator pedal is partially released (deceleration).

- Direction inversion with regenerative braking based upon deceleration ramp.

- Regenerative braking and direction inversion without contactors: only the main contactor is present.

- The release braking ramp can be modulated by an analog input, so that a proportional brake feature is obtained.

- Optimum sensitivity at low speeds.

- Voltage boost at the start and with overload to obtain more torque (with current control).

- The inverter can drive an electromechanical brake - Hidraulic steering function: 1) traction inverter - the traction inverter sends a "hydraulic steering function" request to the pump inverter on the can-bus line (see also OPTION chapter 4.4) - moreover , if the pump inverter is not present (for ex: tractor application), the traction inverter can manage an "hydraulic steering function" by driving a hydro contactor which drive a hydraulic steering motor (output F9), see also OPTION chapter.

2) pump inverter - the pump inverter manage an "hydraulic steering function". That is, it drives the pump motor at the programmed speed for the programmed time.

- High efficiency of motor and battery due to high frequency commutations.

- Self diagnosis with indication of the fault shown by a flashing led.

- Modification of parameters through the programming console.

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

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

- Test function within console for checking main parameters.

Page 7

2.5 DIAGNOSIS The microprocessor continually monitors the inverter and carries out a diagnostic procedure on the main functions. The diagnosis is made in 4 points 1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging, phase's voltages, contactor drives, can-bus interface, if the switch sequence for operation is correct and if the output of accelerator unit is correct.

2) Standby diagnosis at rest that checks: watchdog circuit, phase's voltages, contactor driver, current sensor, can-bus interface.

3) Diagnosis during operation that checks: watchdog circuits, contactor driver, current sensors, can-bus interface.

4) Continuos diagnosis that check: temperature of the inverter, motor temperature.

Diagnosis is provided in two ways. The digital console can be used, which gives a detailed information about the failure; the failure code is also sent on the Can-Bus. 2.6 THERMAL CONSIDERATION - 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.

2.7 GENERAL INSTRUCTIONS AND PRECAUTIONS

.

- Never connect SCR low frequency chopper with ASYNCHRONOUS INVERTER because the ASYNCHRONOUS filter capacitors alter the SCR choppers' work. If it is necessary to use two or more control units (traction + lift. for ex.), they must belong to the ZAPIMOS family.

- Do not connect the inverter to a battery with a nominal value different from the value indicated on the chopper plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit does not "power up".

- During battery charge, disconnect ASYNCHRONOUS from the battery.

- Supply the ASYNCHRONOUS only with battery for traction; do not use a power supply.

- When the chopper is installed, make tests with the wheels raised from the ground, in order to avoid dangerous situations due to connection errors.

- After the chopper is switched off (key off), the filter capacitor remains charged for some minutes; if you need to work on the inverter, discharge them using a 10W ÷ 100W resistance connected from the +Batt to the -Batt.

Page 8

2.8 SUSCEPTIBILITY AND ELECTROMAGNETIC EMISSION Electromagnetic susceptibility and emission are strongly influenced by the installation.

Special attention must be given to the lengths and the paths of the electric connections and the shields.

This situation is beyond ZAPI's control. Therefore ZAPI declines any responsibility for noncompliance if correct testing is not made (the irradiated emission directive is EN50081-2).

2.9 MAIN CONTACTOR AND EMERGENCY SWITCH - The connection of the battery line switches must be carried out following ZAPI instructions.

- If a mechanical battery line switch is installed, it is necessary that the key supply to the inverter is open together with power battery line; if not, the inverter may be damaged if the switch is opened during a regenerative braking.

- An intrinsic protection is present inside the logic when the voltage on the battery power connection overtakes 40% more than the battery nominal voltage or if the key is switched off before the battery power line is disconnected.

Page 9

3 SAFETY AND PROTECTION ZAPI controllers are designed according to the prEN954-1 specifications for safety related parts of control system and to UNI EN1175-1 norm.

The safety of the machine is strongly related to installation; length, layout and screening of electrical connections have to be carefully designed.

AC2 inverter electronic implements an hardware safety circuit, which is able to open the Line Contactor (LC) and the Electric Brake (EB) - and therefore to cut the power line stopping the machine via HARDWARE, that is bypassing the software control of the LC and EB. This safety circuit is driven by "SAFETY" input (see next chapter). If safety input is connected to -BATT, the "SAFETY" circuit is inactive; if the input is open, the "SAFETY" circuit becomes active and, within a timeout, it is able to open the drivers of LC coil and EB coil. The safety circuit is also periodically checked by the AC2 microcontroller; if the microcontroller detects a failure in the "SAFETY" circuit, the microcontroller itself will bring the machine in a safe status.

Suggested connection of "SAFETY" circuit: - STANDALONE CONFIGURATION: it is suggested to connect safety input to the "SEAT" microswitch or to the "DEADMAN" microswitch (it depends on the application); in this way the machine will be brought to a safe status as soon as the operator leaves the machine.

- COMBI CONFIGURATION: in this case the pump controller acts as supervisor, checking the traction controller functionality by the CANBUS. So it is suggested to connect the "SAFETY" input of traction controller to a dedicated output of pump controller, so that the pump controller can drive the traction safety input and open the power line in case of malfunctioning of traction controller.

ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions. Furthermore, ZAPI is available to develop new SW or HW solutions to improve the safety of the machine, according to customer requirements.

Machine manufacturer holds the responsibility for the truck safety features and related approval.

Page 10

4 INSTALLATION Install the chopper with the base-plate on a flat metallic surface that is clean and unpainted.

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

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

Fit transient suppression devices to the horn, solenoid valves, and contactors not connected to the chopper such as those for activating the pump motor or steering motor.

4.1 CONNECTION CABLES For the auxiliary circuits, use cables of 0.5mm² section.

For power connections to the motor and to the battery, use cables having section of 35 mm² (as a minimum).

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

4.2 CONTACTORS The main contactor must be installed. Depending on the position of a jumper installed in the logic board: - the output which drives the main contactor coil is on/off (the coil is driven with the full battery voltage).

-

the output which drives the main contactor coil is switched at high frequency (1 KHz) with a duty cicle of 70%; this feature is useful to decrease the power dissipation of the contactor coil.

4.3 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

4.4 DESCRIPTION OF CONNECTORS - TRACTION CONFIGURATION

A1

PCLRXD

Positive serial reception.

A2

NCLRXD

Negative serial reception.

A3

PCLTXD

Positive serial transmission.

A4

NCLTXD

Negative serial transmission.

A5

GND

Negative console power supply.

A6

+12

Positive console power supply.

A7

FLASH

Must be connected to A8 for the Flash memory programming (if used).

A8

FLASH

Must be connected to A7 for the Flash memory programming (if used).

Page 12

B1

-BATT

-Batt.

B2

MODE

This input allows the customer to select the software for traction or lifting application.

Configuration: MODE: Open (not connected) Traction inverter MODE: Close (connected with A5) Pump inverter

C1

CAN-L

Low level CAN-BUS voltage I/O.

C2

CAN-L-OUT

Low level CAN-BUS voltage I/O.

C3

CAN-H

High level CAN-BUS voltage I/O.

C4

CAN-H-OUT

High level CAN-BUS voltage I/O.

D1÷D6

Incremental ENCODER connector (see chapter 3.6).

E1

CPOT

Accelerator potentiometer wiper.

E2

PPOT

Potentiometer positive: 10V output; keep load > 1KW.

E3

NPOT

Negative of accelerator unit, tested for wire disconnection diagnosis.

E4

CM

Common of FW / BW / SR / PB / SEAT / BACK. FW / BACK. BW / EXCLUSIVE HYDRO microswitches.

E5

FORW

Forward direction request input. Must be connected to the forward direction microswitch, active high.

E6

REV

Backward direction request input. Must be connected to the backward direction microswitch, active high.

E7

PB

Brake request input. Must be connected to the brake pedal switch, active high.

E8

CPOTB

Brake potentiometer wiper.

E9

PPOTB

Brake potentiometer positive. 10V output; keep load >1KW.

E10 NPOTB

-Batt.

E11 -BATT

-Batt.

E12 BACK. FORW Inching function, forward direction input. Must be connected to the inching forward switch. Active high.

E13 BACK. BACK Inching function, reverse direction input. Must be connected to the inching reverse switch. Active high.

E14 EX. HYDRO

Exclusive hydro function input. Must be connected to the exclusive hydro microswitch. Active high (see also OPTION chapter)

Page 13

F1

KEY

Connected to the power supply through a microswitch (CH) with a 10A fuse in series.

F2

PLC

Positive of main contactor coil.

F3

PBRAKE

Positive of the electromechanical brake coil.

F4

SEAT

SEAT input; must be connected to the SEAT microswitch; it is active high.

F5

SAFETY

If not connected to -Batt the MC coil power output will be disabled.

Can also be used as a general purpose input.

F6

PTHERM

Input for motor temperature sensor.

F7

CM

Common of FW / BW / SR / PB / SEAT / INCHING FW / INCHING BW / EXCLUSIVE HYDRO microswitches.

F8

NLC

Negative of main contactor coil.

F9

NBRAKE

Output for driving a brake or an hydraulic steering contactor coil; drives the load to -Batt maximum current : 3A.

F10 SR/HB

Speed reduction (handbrake) input. Active low (switch opened). See also OPTION chapter.

F11 GND

-Batt.

F12 NTHERM

-Batt.

Page 14

4.5 DESCRIPTION OF CONNECTORS - PUMP CONFIGURATION

A1

PCLRXD

Positive serial reception.

A2

NCLRXD

Negative serial reception.

A3

PCLTXD

Positive serial transmission.

A4

NCLTXD

Negative serial transmission.

A5

GND

Negative console power supply.

A6

+12

Positive console power supply.

A7

FLASH

Must be connected to A8 for the Flash memory programming (if used).

A8

FLASH

Must be connected to A7 for the Flash memory programming (if used).

Page 15

B1

-BATT

-Batt.

B2

MODE

This input allows the customer to select the software for traction or lifting application.

Configuration: MODE: Open (not connected) Traction inverter MODE: Close (connected with B1) Pump inverter

C1

CAN-L

Low level CAN-BUS voltage I/O.

C2

CAN-L-OUT

Low level CAN-BUS voltage I/O.

C3

CAN-H

High level CAN-BUS voltage I/O.

C4

CAN-H-OUT

High level CAN-BUS voltage I/O.

D1÷D6

Incremental ENCODER connector (see chapter 3.6).

E1

CPOT

Accelerator potentiometer wiper.

E2

PPOT

Potentiometer positive: 10V output; keep load > 1KW.

E3

NPOT

Negative of accelerator unit, tested for wire disconnection diagnosis.

E4

CM

Common of LIFT ENABLE / 1st SPEED / 2nd SPEED / 3rd SPEED / 4th SPEED / HYDRO / SR microswitches.

E5

LIFT ENABLE Input for potentiometer lifting enable input; it is active HIGH.

E6

1st SPEED

Input for first speed request; it is active HIGH.

E7

3rd SPEED

Input for third speed request; it is active HIGH.

E8

AN. IN.

Free analog input.

E9

PPOT

Potentiometer positive: 10V output; keep load > 1KW.

E10 -BATT

-Batt.

E11 -BATT

-Batt.

E12 HYDRO REQ.

Input for hydraulic steering request. Active high.

E13 SR

Speed reduction input. Active low (switch opened).

E14 DIG. IN.

This is a digital input, free for customer request.

Page 16

F1

KEY

Connected to the power supply through a microswitch (CH) with a 10A fuse in series.

F2

PAUX

Positive of the auxiliary output.

F3

PHYDRO

Positive for the hydraulic steering contactor.

F4

4th SPEED

Input for fourth speed request; it is active HIGH.

F5

SAFETY

If not connected to -Batt the MC coil power output will be disabled.

Can also be used as a general purpose input.

F6

PTHERM

Input for motor temperature sensor.

F7

CM

Common of LIFT ENABLE / 1st SPEED / 2nd SPEED / 3rd SPEED / 4th SPEED / HYDRO / SR microswitches.

F8

NAUX

This output can be used for drive the main contactor coil (single pump configuration) or to drive an auxiliary load (combi configuration)

F9

NHYDRO

Output for driving an hydraulic steering contactor; drives the load to Batt. Maximum current: 3A.

F10 2nd SPEED

Input for second speed request; it is active HIGH.

F11 GND

-Batt.

F12 NTHERM

-Batt.

Page 17

4.6 ENCODER INSTALLATION 1) AC2 card is fit for different types of encoder. To control AC motor with Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90°. The encoder power supply can be +5 or +12V. It can have different electronic output.

D1

+5V/+12V

positive of encoder power supply.

D2

GND

negative of encoder power supply.

D3

A

phase A of encoder.

D4

A

phase A inverted (encoder with differential output).

D5

B

phase B of encoder.

D6

B

phase B inverted (encoder with differential output).

2) Connection of encoder with differential outputs; +5V power supply.

3) Connection of encoder with open collector output; +5V power supply.

4) Connection of encoder with open collector output: +12V power supply.

VERY IMPORTANT It is necessary to specify in the order the type of encoder used, in terms of power supply, electronic output and n° of pulses for revolution, because the logic unit must be set in the correct way by Zapi.

Page 18

4.7 DESCRIPTION OF POWER CONNECTIONS View of the power bars:

-BATT +BATT U; V; W

Negative of the battery.

Positive of the battery.

Connection bars of the three motor phases; follow this sequence and the indication on the motor.

Page 19

4.8 MECHANICAL DRAWING

Page 20

4.9 CONNECTION DRAWING - TRACTION CONFIGURATION

Page 21

4.10 CONNECTION DRAWING - PUMP CONFIGURATION

Page 22

4.11 CONNECTION DRAWING - COMBI CONFIGURATION

Page 23

5 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 5.1 ADJUSTMENTS VIA CONSOLE Adjustment of Parameters and changes to the inverter’s configuration are made using the Digital Console. The Console is connected to the “A” connector of the inverter.

5.2 DESCRIPTION OF CONSOLE & CONNECTION

Digital consoles used to comunicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02".

Page 24

5.3 DESCRIPTION OF STANDARD CONSOLE MENU 5.3.a Traction configuration

Page 25

5.3.b Pump configuration

Page 26

5.4 FUNCTION CONFIGURATION 5.4.a Traction Using the CONFIG MENU of the programming console, the user can configure the following functions (see "OPERATIONAL FEATURE" chapter for an explanation of "hydraulic steering function") : SUBMENU "SET OPTIONS" 1 HOUR COUNTER - RUNNING: - KEY ON:

the counter registers travel time only. the counter registers when the "key" switch is closed.

2 BATTERY CHECK - ON:

the battery discharge level check is carried out; when the battery level reaches 10%, an allarm is signalled and the maximum current is reduced to the half of the programmed value.

- OFF:

the battery discharge level check is carried out but no allarm is signalled.

3 CUTBACK MODE - PRESENT:

input F10 is managed as a cutback speed input.

- ABSENT:

input F10 is managed as an handbrake input.

4 HYDRO KEY ON - ON / OFF:

if this option is programmed ON the traction inverter manages an hydraulic steering function when the "key" is switched ON (only if the "aux output #1" option is programmed as "hydro contactor" or as "exclusive hydro").

5 STOP ON RAMP - ON:

the stop on ramp feature (truck electrically hold on a ramp) is managed for a time established by "auxiliary time" parameter.

After this time, the behaviour depends on the "aux output #1" option programmation (see also the following table).

- OFF:

the stop on ramp feature is not performed.

6 AUX OUTPUT #1 - BRAKE:

output F9 drives an electromagnetic brake coil (see also the table below).

- HYDRO CONT.: the inverter manages an hydraulic steering function when the direction input or brake pedal input are active or a movement of the truck is detected.

- EX. HYDRO:

the inverter manages an hydraulic steering function when the exclusive hydro input is active.

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7 PEDAL BRAKING - ANALOG:

the mechanical brake pedal has a switch and a potentiometer installed. When the accelerator is released and the pedal brake is pushed the inverter performs an electrical braking whose intensity is proportional to the brake pedal potentiometer. The minimum intensity is estabilished by the "Release braking" parameter, when the brake pedal is slightly pressed (brake switch close but brake potentiometer at the minimum). The maximum intensity is established by the "Pedal braking" parameter when the brake pedal is fully pressed (brake potentiometer at the maximum). In the middle positions, the electrical braking intensity is a linear function between minimum and maximum intensity.

- DIGITAL:

The truck does not have a potentiometer installed on the mechanical brake pedal, but only a microswitch; when the accelerator pedal is released and the brake pedal is pushed (brake switch closed), the inverter performs an electrical braking following "Pedal braking" parameter.

8 SET TEMPERATURE - DIGITAL:

a digital (ON/OFF) motor thermal sensor is connected to F6 input.

- ANALOG:

an analog motor thermal sensor is connected to F6 (the curve can be customized on a customer request).

- NONE:

no motor thermal sensor switch is connected.

SUBMENU "ADJUSTEMENT" 1 SET POT BRK MIN:

records the minimum value of braking pedal potentiometer when the braking pedal switch is closed; the procedure is similar to the "Program Vacc" function (see chapter 5.4). This procedure must be carried out only if the "Pedal braking" option is programmed as "Analog".

2 SET POT BRK MAX:

records the maximum value of braking pedal potentiometer when the braking pedal is fully pressed; the procedure is similar to the "Program Vacc" function (see chapter 5.4). This procedure must be carried out only if the "Pedal braking" option is programmed as "Analog".

3 SET BATTERY TYPE:

selects the nominal battery voltage;

4 ADJUST BATTERY:

fine adjustement of the battery voltage measured by the controller.

5 ADJUSTMENT #04:

this parameter determines the motor temperature level at which the “Motor temperature” alarm is signalled. The range is from 70°C to 160°C with 10°C steps. This parameter must be adjusted only if the “Set temperature” (menu “Set option”) parameter is programmed “Analog”.

Page 28

6 THROTTLE 0 ZONE:

establishes a deadband in the accelerator input curve (see also curve below).

7 THROTTLE X POINT:

These parameter change the characteristic of the accelerator input curve.

8 THROTTLE Y POINT:

These parameter change the characteristic of the accelerator input curve.

VACC MIN and VACC MAX are values programmable by the "Program Vacc" function.

9 ADJUSTMENT #01: 10

adjust the upper level of the battery discharge table.

ADJUSTMENT #02: adjust the lower level of the battery discharge table.

Page 29

11 LOAD HM FROM MDI: for an explanation of this point see the MDI instrument handbook 12 CHECK UP DONE:

for an explanation of this point see the MDI instrument handbook

13 CHECK UP TYPE:

for an explanation of this point see the MDI instrument handbook

AUX OUTPUT

BRAKE

BRAKE

HYDRO CONT.

HYDRO CONT.

EXCL. HYDRO

EXCL. HYDRO

Page 30

STOP ON RAMP

F9 OUTPUT

BEHAVIOUR ON A SLOPE

ON

The truck is electrically hold on a -Drives the coil of a electromagnetic slope; when the time set by brake. "auxiliary time" parameter is elapsed -The hydraulic steering function the brake is applied and the 3request is sent to the pump inverter phase bridge is released. Do not use this combination if the by the can-bus link negative brake is not instolled.

OFF

The truck is not electrically hold on a slope, but comes down very -Drives the coil of a electromagnetic slowly; when the time set by brake. "auxiliary time" parameter is -The hydraulic steering function elapsed, the brake is applied and request is sent to the pump inverter the 3-phase bridge is opened. Do by the can-bus link not use this combination if the negative brake is not instolled.

ON

-Drives the coil of a hydraulic steering contactor.

-The hydraulic steering function request is also sent to the pump inverter by the can-bus link

The truck is electrically hold on a slope; when the time set by "auxiliary time" parameter is elapsed, the truck comes down very slowly, till the flat is reached.

OFF

-Drives the coil of a hydraulic steering contactor.

-The hydraulic steering function request is also sent to the pump inverter by the can-bus link

The truck is not electrically hold on a slope, but comes down very slowly till the flat is reached.

ON

-Drives the coil of a hydraulic steering contactor.

-The hydraulic steering function request is also sent to the pump inverter by the can-bus link

The truck is electrically hold on a slope; when the time set by "auxiliary time" parameter is elapsed, the truck comes down very slowly, till the flat is reached.

OFF

-Drives the coil of a hydraulic steering contactor.

-The hydraulic steering function request is also sent to the pump inverter by the can-bus link

The truck is not electrically hold on a slope, but comes down very slowly till the flat is reached.

5.4.b Pump Using the config menu of the programming console, the user can configure the following functions.

SUBMENU "SET OPTIONS" 1 HOUR COUNTER - RUNNING:

the counter registers travel time only.

- KEY ON:

the counter registers when the "key" switch is closed.

2 BATTERY CHECK - ON:

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

- OFF:

the battery discarge level check is carried out but no allarm is signalled.

Very important: In the combi system (pump + traction), the battery discharge calculation for the complete system is carried out by the traction inverter; the information about the pump inverter consumption is sent on the can-bus line from the pump inverter to the traction inverter. So the correct programmation for the "Battery check" option is : traction inverter: ON pump inverter: OFF 3 SET TEMPERATURE - DIGITAL:

a digital (ON/OFF) motor thermal sensor is connected to F6 input.

- ANALOG:

an analog motor thermal sensor is connected to F6 (the curve can be customized on a customer request).

- NONE:

no motor thermal sensor switch is connected.

SUBMENU "ADJUSTEMENT" 1 SET BATTERY TYPE:

selects the nominal battery voltage;

2 ADJUST BATTERY:

fine adjustement of the battery voltage measured by the controller.

3 ADJUSTMENT #04:

this parameter determines the motor temperature level at which the “Motor temperature” alarm is signalled. The range is from 70°C to 160°C with 10°C steps. This parameter must be adjusted only if the “Set temperature” (menu “Set option”) parameter is programmed “Analog”.

Page 31

4 THROTTLE 0 ZONE:

establishes a deadband in the accelerator input curve (see also curve below).

5 THROTTLE X POINT:

These parameter change the characteristic of the accelerator input curve.

6 THROTTLE Y POINT:

These parameter change the characteristic of the accelerator input curve.

VACC MIN and VACC MAX are values programmable by the "Program Vacc" function.

7 ADJUSTMENT #01:

adjust the upper level of the battery discharge table.

8 ADJUSTMENT #02:

adjust the lower level of the battery discharge table.

Page 32

Flow chart showing how to make changes to OPTION Menu.

1) Opening Zapi Menu 2) Press Top Left & Right Buttons to enter SET Menu.

3) The Display will show: SET MODEL 4) Press ROLL UP or ROLL DOWN button until SET MODEL Menu appears.

5) SET OPTIONS appears on the display.

6) Press ENTER to go into the SET MODEL Menu.

7) The display will shows the first OPTION. 8) Press ROLL UP or ROLL DOWN button until desired OPTION appears 9) Desired OPTION appears.

10) Press SET UP or SET DOWN button in order to modify the changes.

11) New OPTION appears.

12) Press OUT to exit the Menu.

13) Confirmation request appears.

14) Press ENTER to accept the changes, or press OUT if you do not accept the changes.

15) SET OPTIONS Menu appears.

16) Press OUT again. Display now show the Opening Zapi Menu.

Page 33

Flow chart showing how to make changes to ADJUSTMENT Menu 1) Opening Zapi Menu 2) Press Top Left & Right Buttons to enter CONFIG Menu.

3) The display will show: SET MODEL 4) Press ROLL UP or ROLL DOWN button until ADJUSTMENTS Menu appears.

5) ADJUSTMENTS appears on the display.

6) Press ENTER to go into the ADJUSTMENTS Menu.

7) The display will shows SET BATTERY TYPE. 8) Press ROLL UP or ROLL DOWN button until the desired parameter is reached.

9) The desired parameter is appears.

10) Press SET UP or SET DOWN button to modify the adjustment.

11) Press OUT. 12) Press ENTER to confirm.

13) Repeat the same from 5 to 12 points for the other adjustment.

Page 34

Flow chart showing how to use the SET BATTERY TYPE adjustment 1) Opening Zapi Menu 2) Press Top Left & Right Buttons to enter CONFIG Menu.

3) The Display will show: SET MODEL 4) Press ROLL UP button until ADJUSTMENTS. menu appears.

5) ADJUSTMENTS appears on the display.

6) Press ENTER to go into the ADJUSTMENTS Menu.

7) The display will show: SET BATTERY TYPE. 8) Press SET UP to choose nominal value of the battery.

9) New battery value appears.

10) Press OUT. 11) Confirmation request appears.

12) Press ENTER to accept the changes, or press OUT if you do not accept the changes.

13) Press OUT. Display now shows the Opening Zapi Menu.

Page 35

Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console.

1) Opening Zapi Menu 2) Press Top Left & Right Buttons to enter CONFIG Menu.

3) The Display will show: SET MODEL 4) Press ROLL UP button until ADJUSTMENT Menu appears.

5) ADJUSTMENTS appears on the display.

6) Press ENTER to go into the ADJUSTMENTS Menu.

7) The display will show the first OPTION. 8) Press ROLL UP or ROLL DOWN button until desired OPTION appears 9) ADJUST BATTERY appears.

10) Press SET UP or SET DOWN button in order to increase or decrease respectively. Set the value read by an external meter.

11) Battery value appears on the display.

12) Press OUT to exit the Menu.

13) Confirmation request appears.

14) Press ENTER to accept the changes, or press OUT if you do not accept the changes.

15) ADJUSTMENTS Menu appears.

16) Press OUT. Display now show the Opening Zapi Menu.

Page 36

5.5 PARAMETER REGULATION: TRACTION CONFIGURATION In addition to the input configuration, parameter modification is made directly by ZAPI on customer specifications, or by the customer, making the adjustments using the programming console. The following parameters can be modified: 1 2

ACC DELAY: RELEASE BRAKING:

determines the acceleration ramp. controls the deceleration ramp when the travel request is released.

3 INVERSION BRAKING: controls the deceleration ramp when the direction switch is inverted during travel.

4 PEDAL BRAKING: determines the deceleration ramp when the travel request is released and the brake pedal switch is closed.

5 SPEED LIMIT BRAKING: deceleration ramp when the pedal position is changed but not completely released.

6 BRAKE CUTBACK: determines the deceleration ramp when the speed reduction input becomes active and the motor slow down.

7 MAX SPEED FORWARD: determines the maximum speed in forward direction.

8 MAX SPEED BACKWARD: determines the maximum speed in backward direction.

9 CUTBACK SPEED: speed reduction when the cutback switch is active.

10 FREQUENCY CREEP: minimum speed when the forward or reverse switch is closed, but the accelerator is on a minimum position.

11 MAXIMUM CURRENT: this changes the maximum current of the inverter.

12 BACKING SPEED: determines the speed in inching function.

13 BACKING TIME: determines the time of the inching function.

14 AUXILIARY TIME: determines the time that the truck is hold on the ramp if the "stop on ramp" option is ON. The following table shows the different values at which the parameters can be set.

Page 37

PROGRAMMED LEVEL UNIT

0

1

2

3

4

5

6

7

8

9

ACCELERATION DELAY (*)

Sec.

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

RELEASE BRAKING (**)

Sec.

5.5

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

INVERS BRAKING (**)

Sec.

5.5

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

PEDAL BRAKING (**)

Sec.

5.5

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

SPEED LIMIT BRAKING (**)

Sec.

8.9

8.3

7.7

7.1

6.6

6.0

5.5

4.9

4.4

3.8

BRAKE CUTBACK (**)

Sec.

5.5

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

MAX SPEED FW

Hz

65

80

95

110

125

140

155

170

185

200

MAX SPEED BW

Hz

65

80

95

110

125

140

155

170

185

200

CUTBACK SPEED

%Max Sp

10

20

30

40

50

60

70

80

90

100

Hz

0.3

0.6

0.9

1.2

1.5

1.8

2.1

2.4

2.7

3.0

% IMAX

47

53

58

64

70

76

82

88

94

100

BACKING SPEED

Hz

0

2

4

6

8

10

12

14

16

18

BACKING TIME

Sec.

0.2

0.5

1.0

1.4

1.8

2.3

2.7

3.1

3.6

4.0

AUXILIARY TIME

Sec.

0

1

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5

PARAMETER

FREQUENCY CREEP MAXIMUM CURRENT

After changing a parameter, press ENTER to confirm data when requested by the message on the console. Parameters modified and optimized on one unit can be stored by the console (SAVE) and then released (RESTORE) on another chopper, thus allowing fast and standardized settings (see console manual for details). (*) The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load. (**) The braking feature is based upon deceleration ramps. The value shown in the table is the time to decrease the speed from 100 Hz to 0 Hz. This is the ideal ramps calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load.

Page 38

5.6 PARAMETER REGULATION: PUMP CONFIGURATION The following parameters can be modified: 1 PU. ACCELER DEL: acceleration ramp.

2 PU. DECELERATION DEL: deceleration ramp.

3 MAX SPEED UP determines the maximum lifting speed with a potentiometer control.

4 MIN SPEED UP determines the minimum lifting speed with a potentiometer control when the lifting enable switch is closed.

5 1ST SPEED FINE: first speed, fine regulation.

6 2ND SPEED FINE: second speed, fine regulation.

7 3RD SPEED FINE: third speed, fine regulation.

8 4TH SPEED FINE: fourth speed, fine regulation.

9 HYD SPEED FINE: hydro speed, fine regulation.

10 MAXIMUM CURRENT: the maximum current of the inverter.

11 AUXILIARY TIME: time delay when an hydraulic steering function request is switched off.

The following table shows the different values at which the parameters can be set.

PARAMETER

PROGRAMMED LEVEL UNIT

0

1

2

3

4

5

6

7

8

9

ACCEL. DELAY (*)

Sec.

0.5

0.7

1.0

1.4

1.9

2.5

3.2

4.0

4.8

5.5

DECEL. DELAY (**)

Sec.

0.5

0.7

1.0

1.4

1.9

2.5

3.2

4.0

4.8

5.5

MAX SPEED UP

Hz

65

80

95

110

125

140

155

170

185

200

MIN SPEED UP

Hz

0

SPEED FINE (ALL) (***)

Hz

-

-

-

-

-

-

-

-

-

-

% IMAX

47

53

58

64

70

76

82

88

94

100

Sec

0

0.2

0.4

0.8

1.0

1.5

2.0

3.0

4.0

5.0

MAX CURRENT AUXILIARY TIME

13.5 15.0 16.5 18.0 19.5 21.0 22.5 24.0 25.5

(*)

The acceleration time shown is the time from 0 Hz to 100 Hz (maximum selectable speed). This is the ideal ramp calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load.

(**)

The deceleration time shown in the table is the time from 100 Hz to 0 Hz. This is the ideal ramp calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load.

(***) Adjustable with a 1Hz resolution in the 0 to 200 Hz range.

Page 39

After changing a parameter, press ENTER to confirm data when requested by the message on the console. Parameters modified and optimized on one unit can be stored by the console (SAVE) and then released (RESTORE) on another chopper, thus allowing fast and standardized settings (see console manual for details).

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 and 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 40

5.7 PROGRAMMING CONSOLE FUNCTIONS - Functional configuration (see 4.1 , 4.2 , 4.3 , 4.4) - Parameter programming (see 4.5 , 4.6) - Tester: the user can verify the state of the following parameters: TRACTION motor voltage (%) frequency (Hz) encoder (Hz) slip value (Hz) current rms (A) temperature (°C) motor temperature (°C) accelerator (V) forw. switch (ON/OFF) back. switch (ON/OFF) inching forw. (ON/OFF) inching back. (ON/OFF) cutback switch (ON/OFF) brake switch (ON/OFF) seat switch (ON/OFF) exclusive hydro (ON/OFF) hand brake (ON/OFF) voltage booster (%) battery voltage (V) cos fi battery current (A) battery charge (%)

PUMP motor voltage (%) frequency (Hz) encoder (Hz) slip value (Hz) current rms (A) temperature (°C) motor temperature (°C) accelerator (V) lifting switch (ON/OFF) 1st speed switch (ON/OFF) 2nd speed switch (ON/OFF) 3rd speed switch (ON/OFF) 4th speed switch (ON/OFF) hydro speed req. (ON/OFF) voltage booster (V) battery voltage (V) cos fi battery current (A) battery charge (%)

- Save function (for storing data) - Restore function (for loading parameters on another chopper) - Display of the last 5 alarms including hour-meter value and temperature at the moment of the alarm.

- Accelerator range programming: records the minimum and maximum useful accelerator stroke values for both direction of running.

- See the console manual for a detailed description of function and parameters.

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5.8 SEQUENCE FOR AC INVERTER TRACTION SETTING 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 Chapter 5.2 . 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. See Chapter 4.1 ÷ 4.4.

2) Select and set the Battery Voltage. See Chapter 4.4.

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”. Procedure is detailed on Chapter 5.4.

5) Set the "MAXIMUM CURRENT” Current, using the table on Chapter 4.5 , 4.6.

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

7) Set the FREQUENCY CREEP level starting from level 0.6 Hz. 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 SPEED” 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) PEDAL BRAKING (If used). Operate the machine at full Speed. Release the accelerator pedal and press the Pedal Brake. Set braking level to your requirements.

12) Set “MAX SPEED FORW”.

13) Set “MAX SPEED BACK” (Reverse).

14) Make the choice for the truck behaviour on a slope (see chapter 4.4). If the "Stop on ramp" option is ON, set the desired value of "auxiliary time" parameter.

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5.9 TESTER: DESCRIPTION OF THE FUNCTION; TRACTION CONFIGURATION 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) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage).

2) FREQUENCY: this is the frequency of the voltage and current supplied to the motor.

3) ENCODER: this is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.

4) SLIP VALUE: this is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.

5) CURRENT RMS: Root Mean Square value of the motor current.

6) TEMPERATURE: the temperature measured on the aluminum heat sink holding the MOSFET devices.

7) MOTOR TEMPERATURE: this is the temperature of the motor; if the option is programmed "None" (see chapter 4.4.a) it shows 0°.

8) ACCELERATOR: the voltage of the accelerator potentiometer's 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.

9) FORWARD SWITCH: the level of the Forward direction digital entry FW. ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

10) BACKWARD SWITCH: the level of the Reverse direction digital entry BW. ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

11) BACKING FORW: status of the inching function (forward direction) input.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

12) BACKING BACK: status of the inching function (backward direction) input.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

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

ON / GND = active entry of speed reduction microswitch.

OFF / +VB = non active entry of microswitch.

14) BRAKE SWITCH: the level of the Pedal Brake Microswitch.

ON / +VB = active entry of Brake pedal Microswitch.

OFF / GND = non active entry of microswitch.

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15) SEAT SWITCH: the level of the Seat Microswitch digital entry.

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

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

16) EXCLUSIVE HYDRO: status of the exclusive hydro switch.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

17) HAND BRAKE: the level of the Handbrake Microswitch.

ON / GND = active entry of Handbrake Switch (open switch).

OFF/ +VB = non active entry of microswitch (closed switch).

18) VOLTAGE BOOSTER: this is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.

19) BATTERY VOLTAGE: level of battery voltage measured at the input to the key switch.

20) COS FI: this is the cos j (real time calculated) of the motor.

21) BATTERY CURRENT: this is the battery current (not measured but calculated).

22) BATTERY CHARGE: the percentage Charge level of the battery.

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5.10 TESTER: DESCRIPTION OF THE FUNCTION; PUMP CONFIGURATION 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) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage).

2) FREQUENCY: this is the frequency of the voltage and current supplied to the motor.

3) ENCODER: this is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.

4) SLIP VALUE: this is the difference of speed between the rotating field and the shaft of the motor, expressed inthe same unit of the frequency.

5) CURRENT RMS: Root Mean Square value of the motor current.

6) TEMPERATURE: the temperature measured on the aluminum heat sink holding the MOSFET devices.

7) MOTOR TEMPERATURE: this is the temperature of the motor; if the option is programmed "None" (see chapter 4.4.b) it shows 0°.

8) ACCELERATOR: the voltage of the accelerator potentiometer's 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.

9) LIFTING SWITCH: status of the lifting switch.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

10) 1 ST SPEED SWITCH: status of the first speed switch of the pump.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

11) 2 ND SPEED SWITCH: status of the second speed switch of the pump.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

12) 3 RD SPEED SWITCH: status of the third speed switch of the pump.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

13) 4 TH SPEED SWITCH: status of the fourth speed switch of the pump.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

14) HYDRO SPEED REQ.: status of the hydro speed request of the pump.

ON / +VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

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15) VOLTAGE BOOSTER: this is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.

16) BATTERY VOLTAGE: level of battery voltage measured at the input to the key switch.

17) COS FI: this is the cos j (real time calculated) of the motor.

18) BATTERY CURRENT: this is the battery current (not measured but calculated).

19) BATTERY CHARGE: the percentage Charge level of the battery.

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 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) When you have finished, Press OUT. 10) The Display shows : 11) Press OUT again and return to Opening Zapi Display.

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.

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6 OTHER FUNCTIONS 6.1 DESCRIPTION OF THE CONSOLE SAVE FUNCTION The SAVE 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 ROLL UP or ROLL DOWN button until SAVE PARAM. appears on the display 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 Main with a 2 digit reference.

8) Keep pressing either ROLL UP or ROLL DOWN keys until the second Main 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 : 13) Press OUT to return to the Opening Zapi Display.

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6.2 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 is available via the RESTORE PARAM. function is 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 tto 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 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) Press ENTER to commence the Restore operation.

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

Press ENTER for YES, or OUT for No.

11) You can see the items that are being stored in the chopper memory whilst the RESTORE routine is happening.

12) When finished the Console displays : 13) Press OUT to return to the Opening Zapi Display .

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6.3 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.

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6.4 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.

Display will show 0.0.

9) Select Forward Direction, close any interlock switches that may be in the system.

10) 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.

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7 AC2 INVERTER DIAGNOSTIC - TRACTION CONFIGURATION The alarms are signalled by a diagnostic LED. 1 blink:

logic failure ("WATCHDOG", "EEPROM KO", "LOGIC FAILURE #1", "LOGIC FAILURE #2", "LOGIC FAILURE #3", "CHECK UP NEEDED").

2 blinks:

running request on start-up or error in seat sequence or double direction request ("INCORRECT START", "HANDBRAKE", "FORW + BACK").

3 blinks:

phase voltage or capacitor charge failure ("CAPACITOR CHARGE", "VMN LOW", "VMN HIGH").

4 blinks:

failure in accelerator ("VACC NOT OK", "PEDAL WIRE KO").

5 blinks:

failure of current sensor ("STBY I HIGH").

6 blinks:

failure of contactor driver ("COIL SHORTED", "DRIVER SHORTED", "CONTACTOR DRIVER", "AUX OUTPUT KO", "CONTACTOR OPEN").

7 blinks:

excessive temperature ("HIGH TEMPERATURE", "MOTOR TEMPERATURE", "THERMIC SENSOR KO").

8 blinks:

failure detection from can-bus ("WAITING PUMP", "CAN-BUS KO").

long blink:

discharge battery ("LOW BATTERY") 7.1 ANALYSIS OF ALARMS DISPLAYED ON CONSOLE

1. WATCH DOG The test is made in both running and standby. It is a self-diagnosing test within the logic. If an alarm should occur, replace the logic.

2. EEPROM KO Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits machine operation. If the defect persists when the key is switched OFF and ON again, replace the logic. If the alarm disappears, remember that the parameters stored previously have been cancelled and replaced by the default values.

3. LOGIC FAILURE #1 This alarm signals that an undervoltage / overvoltage protection operation has occured.

Two possible reasons: a. A real undervoltage / overvoltage situation happened. b. Fault in the hardware section of the logic board which manages the overvoltage protection. Replace the logic card.

4. LOGIC FAILURE #2 Fault in the hardware section of the logic board which manages the phase' s voltage feedback. Replace the logic board.

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5. LOGIC FAILURE #3 Fault in the hardware section of the logic board which manages the hardware current protection. Replace the logic board.

6. CHECK UP NEEDED This is a warning. It is an information for the user that the programmed time for maintenance is elapsed.

7. INCORRECT START This alarm signals an incorrect starting sequence. Possible causes: a. running microswitch failure; b. error in sequence made by the operator; c. incorrect wiring; d. if the default persists, replace the logic.

8. FORW + BACK The test is carried out continuously. An alarm is signalled when a double running request is made simultaneously. Possible causes: a. defective wiring; b. running microswitch failure; c. incorrect operation; d. if the defect persists, replace the logic.

9. HANDBRAKE The truck does not start because the handbrake switch is opened. Possible causes: a. defective wiring; b. failure of the microswitch; c. incorrect operation of the operator; If the defect persist , replace the logic.

10. CAPACITOR CHARGE Follows the charging capacitor system:

When the key is switched ON, the inverter tries to charge the capacitor through a power resistance, and check if the capacitor are charged within a timeout. If this is not true: an alarm is signalled; the main contactor is not closed.

Possible reasons: a) the charging resistance is opened; if it is opened. b) The charging circuit has a failure. c) There is a problem on the power modules.

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11. VMN LOW, VMN HIGH The test is carried out during initial diagnosis and in standby.

Possible causes: a. problem with the motor connections or the motor power circuit; check if the 3 phases are correctly connected; check if there's a dispersion of the motor towards ground; b. inverter failure, replace it.

12. VACC NOT OK The test is made in standby. This alarm indicates that the accelerator voltage is 1V greater than the minimum value programmed by the PROGRAM VACC function.

Possible causes: a. the potentiometer is not correctly calibrated; b. the potentiometer is defective.

13. PEDAL WIRE KO This alarm is signalled if a fault is detected in the accelerator unit wiring (NPOT or PPOT cable is interrupted).

14. STBY I HIGH Test carried out in standby. Check if the current is 0. If not verified, an alarm is signalled which inhibits machine operations. Possible causes: a. current sensor failure; b. logic failure: first replace the logic; if the defect persists, replace the power unit.

15. MAIN CONTACTOR ALARMS COIL SHORTED: When the key is switched ON the µP checks the MC driver FF SR. If it does not react in a correct way to the µP stimulus, the alarm is signalled. Replace the logic board. The FF SR makes an hardware control of the current in the MC coil. If this is too high, it opens the MC and the alarm is signalled.

Check if there are external shortcircuit and if the ohmic value of the MC is correct; otherwise replace the logic.

DRIVER SHORTED: When the key is switched ON, the µP checks that the MC coil driver is not shorted; if it is, this allarm is signalled; replace the logic board.

CONTACTOR DRIVER: When the initial diagnosis is finished, the traction logic closes the MC and checks the voltage on the Drain of the driver. If this is not low , an alarm is signalled.

Replace the logic.

CONTACTOR OPEN: The main contactor coil has been driven by the logic board, but the contactor does not close. Two possible reasons: a) the wires to the coil are interrupted or not well connected. b) the contact of the contactor is not properly working.

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16. AUX OUTPUT KO The µP checks the driver of the electromechanical brake. If the status of the driver output does not correspond to the signal coming from the µP, the allarm is signalled.

Replace the logic.

17. HIGH TEMPERATURE Chopper temperature is greater than 75°C. The maximum current is reduced proportionally to the temperature increase. The chopper stops at 100°C. If the alarm is signalled when the chopper is cold: a) check the wiring of the thermal sensor; b) thermal sensor failure; c) logic failure.

18. MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens (digital sensor) or if the analog signal overtakes the cut off level. If it happens when the motor is cold, check the wiring. If all is ok, replace the logic board.

19. THERMIC SENSOR KO The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range.

When this alarm is signalled, check the connection of the sensors.

20. WAITING PUMP This allarm is present in combi sistems (traction+pump). The pump has detected a failure, the traction cannot close the main contactor because of the allarm status of the pump (which the traction knows by the CAN-BUS line). The failure must be looked for in the pump inverter.

21. CAN BUS KO The diagnosis of the CAN-BUS line is present only if the inverter uses this link (depends on the software version). It is signalled if the inverter does not receive any message from the CAN-BUS line. First of all, check the wiring. If it is ok, the problem is on the logic board, which must be replaced.

22. BATTERY LOW If the "battery check" option is ON, a battery discarge algorithm is carried out. When the charge level is 10% , this allarm is signalled and the current is reduced to the half of the programmed level.

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8 AC2 INVERTER DIAGNOSTIC - PUMP CONFIGURATION The alarms are signalled by a diagnostic LED. 1 blink:

logic failure ("WATCHDOG", "EEPROM KO", "LOGIC FAILURE #1", "LOGIC FAILURE #2", "LOGIC FAILURE #3").

2 blinks:

running request on start-up or error in seat sequence ("INCORRECT START").

3 blinks:

phase voltage or capacitor charge failure ("CAPACITOR CHARGE", "VMN LOW", "VMN HIGH").

4 blinks:

failure in accelerator ("VACC NOT OK", "PEDAL WIRE KO").

5 blinks:

failure of current sensor ("STBY I HIGH").

6 blinks:

failure of contactor driver ("COIL SHORTED", "DRIVER SHORTED", "CONTACTOR DRIVER", "CONTACTOR OPEN").

7 blinks:

excessive temperature ("HIGH TEMPERATURE", "MOTOR TEMPERATURE", "THERMIC SENSOR KO").

8 blinks:

failure detection from can-bus ("WAITING TRACTION", "CANBUS KO").

long blink:

discharge battery ("LOW BATTERY") 8.1 ANALYSIS OF ALARMS DISPLAYED ON CONSOLE

1. WATCH DOG The test is made in both running and standby. It is a self-diagnosing test within the logic. If an alarm should occur, replace the logic.

2. EEPROM KO Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits machine operation. If the defect persists when the key is switched OFF and ON again, replace the logic. If the alarm disappears, remember that the parameters stored previously have been cancelled and replaced by the default values.

3. LOGIC FAILURE #1 This alarm signals that an undervoltage / overvoltage protection operation has occured.

Two possible reasons: a. A real undervoltage / overvoltage situation happened. b. Fault in the hardware section of the logic board which manages the overvoltage protection. Replace the logic card.

4. LOGIC FAILURE #2 Fault in the hardware section of the logic board which manages the phase' s voltage feedback. Replace the logic board.

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5. LOGIC FAILURE #3 Fault in the hardware section of the logic board which manages the hardware current protection. Replace the logic board.

6. INCORRECT START This alarm signals an incorrect starting sequence. Possible causes: a. running microswitch failure; b. error in sequence made by the operator; c. incorrect wiring; d. if the default persists, replace the logic.

7. CAPACITOR CHARGE Follows the charging capacitor system:

When the key is switched ON, the inverter tries to charge the capacitors through a power resistance and check if the capacitors are charged within a timeout. If this is not true: an alarm is signalled; the main contactor is not closed.

Possible reasons: a) check if the charging resistance is opened. b) The charging circuit has a failure. c) There is a problem on the power modules.

8. VMN LOW, VMN HIGH The test is carried out during initial diagnosis and in standby.

Possible causes: a. problem with the motor connections or the motor power circuit; check if the 3 phases are correctly connected; check if there's a dispersion of the motor towards ground; b. chopper failure, replace it.

9. PEDAL WIRE KO This alarm is signalled if a fault is detected in the accelerator wiring (NPOT or PPOT cable is interrupted).

10. VACC NOT OK The test is made in standby. This alarm indicates that the accelerator voltage is 1V greater than the minimum value programmed by the PROGRAM VACC function.

Possible causes: a. the potentiometer is not correctly calibrated; b. the potentiometer is defective.

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11. STBY I HIGH Test carried out in standby. Check if the current is 0. If not verified, an alarm is signalled which inhibits machine operations. Possible causes: a. current sensor failure; b. logic failure: first replace the logic; if the defect persists, replace the power unit.

12. MAIN CONTACTOR ALARMS In the combi system (pump + traction) the main contactor is driven by the traction inverter. So the following description concerns the pump inverter used independently from the traction inverter. In this configuration the pump inverter manages its own main contactor.

COIL SHORTED: When the key is switched ON the µP checks the MC driver FF SR. If it does not react in a correct way to the µP stimulus, the alarm is signalled. Replace the logic board. The FF SR makes an hardware control of the current in the MC coil. If this is too high, it opens the MC and the alarm is signalled.

Check if there are external shortcircuit and if the ohmic value of the MC is correct; otherwise replace the logic.

DRIVER SHORTED: When the key is switched ON, the µP checks that the MC coil driver is not shorted; if it is, this allarm is signalled; replace the logic board.

CONTACTOR DRIVER: When the initial diagnosis is finished, the traction logic closes the MC and checks the voltage on the Drain of the driver. If this is not low , an alarm is signalled.

Replace the logic.

CONTACTOR OPEN: The main contactor coil has been driven by the logic board, but the contactor does not close. Two possible reasons: a) the wires to the coil are interrupted or not well connected. b) the contact of the contactor is not properly working.

13. HIGH TEMPERATURE Chopper temperature is greater than 75°C. The maximum current is reduced proportionally to the temperature increase. The chopper stops at 100°C. If the alarm is signalled when the chopper is cold: a. check the wiring of the thermal sensor; b. thermal sensor failure; c. logic failure.

14. MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digital sensor or if the analog signal overtakes the cut-off level. If it happens when the motor is cold, check the wiring. If all is OK, replace the logic board.

15. THERMIC SENSOR KO The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range.

When this alarm is signalled, check the connection of the sensors.

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16. WAITING TRACTION This allarm is present in combi sistems (traction+pump). The traction has detected a failure has informed the pump inverter through the can-bus line. The pump is waiting for the traction ok. The failure must be looked for in the traction inverter.

17. CAN BUS KO The diagnosis of the CAN-BUS line is present only if the inverter uses this link (depends on the software version). It is signalled if the inverter does not receive any message from the CAN-BUS line. First of all, check the wiring. If it is ok, the problem is on the logic board, which must be replaced.

18. BATTERY LOW If the "battery check" option is ON, a battery discarge algorithm is carried out. When the charge level is 10% , this allarm is signalled and the current is reduced to the half of the programmed level.

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9 RECOMMENDED SPARE PARTS FOR INVERTER

Part Number

Description

C16507

Protected 500A strip Fuse.

C16505

Protected 355A strip Fuse.

C16520

6.3A 20mm Control Circuit Fuse

C29523

SW 180 80V Single Pole Contactor

C29522

SW 180 48V Single Pole Contactor

C29508

SW 180 24V Single Pole Contactor

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10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors’ moving and fixed contacts.

Electrical Contacts should be checked every 3 months.

Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals. Switches should operate with a firm click sound.

Microswitches should be checked every 3 months.

Check the Battery cables, cables to the chopper, and cables to the motor. Ensure the insulation is sound and the connections are tight.

Cables should be checked every 3 months.

Check the mechanical operation of the pedal or tiller . Are the return springs ok. Do the potentiometers wind up to their full or programmed level.

Check every 3 months.

Check the mechanical operation of the Contactor(s). Moving contacts should be free to move without restriction.

Check every 3 months.

Checks should be carried out by qualified personnel and any replacement parts used should be original. Beware of NON ORIGINAL PARTS. The installation of this electronic controller should be made according to the diagrams included in this Manual. Any variations or special requirements should be made after consulting a Zapi Agent. The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual.

During periodic checks, if a technician finds any situation that could cause damage or compromise safety, the matter should be bought to the attention of a Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine.

Remember that Battery Powered Machines feel no pain.

NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.

ELECTRONIC INDUSTRIAL DEVICES 42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - e-mail: zapi@zapispa.it

AC2 INVERTER OPERATING HANDBOOK AND FUNCTION DESCRIPTION

Index 1 2

3

Introduction to Zapi can system ..................................................................

General characteristic ...................................................................................

2.1 Functional characteristics ..........................................................................

2.2 Input ..........................................................................................................

Operational features ......................................................................................

3.1 Mechanical drawing ...................................................................................

2 3 3 3 4 5

4

Safety and protection

5

Connectors description ................................................................................ 7 5.1 Connector CNA: AMP SAAB 42 poles ...................................................... 7 5.2 Connector CNB: AMP SAAB 16 poles ...................................................... 8 5.3 Connector CNC: AMP SAAB 6 poles ........................................................ 9 Programming and adjustments using digital console ............................. 10 6.1 Adjustments via console .......................................................................... 10 6.2 Description of console and connection .................................................... 10 6.3 Description of standard console menu .................................................... 11 6.4 Mhyrio functional ..................................................................................... 12 6.5 Description of programmable functions (options) .................................... 13 6.6 Description of parameters that may be programmed (parameter change)15 6.7 Adjustments table .................................................................................... 16 6.8 Alarms associated with the flashing red led ........................................... 18 6.9 Analysis of alarms displayed on the console ........................................... 18 6.10 Description of the tester function .......................................................... 19 6.11 Description of the console save function ............................................... 22 6.12 Description of the console restore function ........................................... 22 6.13 Description of the set model Function ................................................... 23 6.14 Description of alarms menu ................................................................... 25 Periodic maintenance to be repeated at times indicated ......................... 26

6

7

............................................................................ 6

SIGNED IN APPROVAL

COMPANY DEPT. SERVICES

MANAGEMENT EXECUTIVE

ENGINEERING SECTION EXECUTIVE EXPORT MANAGER Publication n°: ADPZP0BA Edition: January 2002 Page 1

1 INTRODUCTION TO ZAPI CAN SYSTEM Distributed intelligent systems are not new in Zapi: the first one has gone in production in the '95 with a serial communication link (RS232).

Today we use a more sophisticated and safe communication protocol: CAN BUS. In this way it is possible to reduce the harness allocating the modules exactly near the sensor or the actuators and connecting the modules with only 4 wires (CAN and supply).

Mhyrio is one of this modules born to drive the hydraulic electrovalves and connect some inputs which normally are in the actuators proximity but with a complete independent functions.

Page 2

2 GENERAL CHARACTERISTIC 2.1 FUNCTIONAL CHARACTERISTICS Voltage [V] ................................................................................................... 24/36/48/80V Output for ON-OFF valves [n°] ........................................................................................ 3 Output for proportional valves [n°] ................................................................................... 8 Incremental Encoder (phase A and B) [n°] ...................................................................... 1 Digital inputs [n°] ............................................................................................................. 8 Analog inputs [n°] ............................................................................................................ 2 RS-232 [n°] ...................................................................................................................... 1 CAN [n°] .......................................................................................................................... 1 Protection .................................................................................................................. IP64 Mhyrio is produced to work with one defined battery voltage (the required voltage has to be specified in the order).

2.2 INPUT Digital inputs: accepts PNP type sensor or switches connected to the positive.

The voltage can be battery voltage or 24V if the valves are supplied at 24V (specify in the order).

Analog inputs: Mhyrio accepts two analog inputs. The range have to be specified in the order (0-20mA, 0-5V, 0-10V, 0-VBatt).

13V, 200mA output is provided to supply potentiometer or similar device.

Encoder: encoder electronic output can be PNP, NPN or PUSH PULL type. Encoder supply is 13V. Maximum frequency 500Hz. ON-OFF valves drivers are set via hardware to work in full conduction, 66%, 50% or 30% depending of the valves supply voltage and the nominal valves coil voltage (ex.: if the valves are fed at 48V and they are 24V, the PWM has to be set at 50%).

The valves supply voltage can be different from the battery voltage (input C1).

Proportional valves are driven in current mode with fixed frequency. The voltage is the same used for ON-OFF valves and the current range have to be defined. Via handset it is adjustable in a big range, but the shunts can be adapted to every types of valves (minimum current 200mA, maximum current up to 2A).

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3 OPERATIONAL FEATURES Mhyrio has been designed to work on a CANBUS system. So, it follows the commands received by CAN communication and broadcast the input status and the encoder counting on the CAN. The 8 proportional valves are separated in 4 groups used for 4 different functions. Only one valve of the group can be active.

It is possible to activate more function at the same time. These can be: - function 1-2-3 - function 1-2-4 3 and 4 cannot be activate at the same time.

FUNCTION1 is related to EVP1 and 2 (outputs A3, A31); typically this function is lifting-lowering.

FUNCTION2 is related to EVP3 and 4 (outputs A16, A2); typically this function is reach in/out.

FUNCTION3 is related to EVP5 and 6 (outputs A1, A30); typically this function is tilting fw/rev.

FUNCTION4 is related to EVP7 and 8 (outputs A29, A15); typically this function is shifting right/left.

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3.1 MECHANICAL DRAWING

Page 5

4 SAFETY AND PROTECTION Connectors are sealed: AMP type ................................................................................................... 16 poles AMP type ..................................................................................................... 6 poles AMP type ................................................................................................... 42 poles On the connection pins A17-B10-C2 is output a positive coming from the valves positive voltage but controlled with an electronic high-side switch. This positive can be used to feed one or more valves involved in safety problems. In this way MHYRIO opens not only the negative side of the valve coil, but also the positive one.

The positive switch is tested by the microprocessor at every key switching on, by feedbacking this output voltage to the µC A/D converter.

Furthermore, it is possible to input a positive for valves, independent by the Mhyrio supply, to input C1. It is strongly suggested that this positive is cut by a device controller by another intelligent module, which is thus able to open the valves positive in case of Mhyrio failures or misfunctioning.

Thus the more safe solution is: - PEV supplied to C1, controlled by another intelligent module.

- Positive to group 1 valves (lifting-lowering), taken by outputs A17-B10-C2.

ZAPI controller are designed according to the prEN954-1 specifications for safetyrelated parts of control system and to UNI EN1175-1 norm.

The safety of the machine is strongly related to harness solutions, so the truck manufacturer holds the responsibility for the truck safety features and related approvals.

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5 CONNECTORS DESCRIPTION 5.1 CONNECTOR CNA: AMP SAAB 42 POLES

PIN

FUNCTION

DESCRIPTION

A1

NEVP5

Negative of the proportional electrovalve N° 5

A2

NEVP4

Negative of the proportional electrovalve N° 4

A3

NEVP1

Negative of the proportional electrovalve N° 1

A4

PEVP

Positive of the proportional electrovalve N° 5

A5

I5

Digital Input N° 5

A6

I3

Digital Input N° 3

A7

I4

Digital Input N° 4

A8

I7

Digital Input N° 7

A9

I6

Digital Input N° 6

A10

I1

Digital Input N° 1

A11

I2

Digital Input N° 2

A12

A

Encoder input phase A

A13

B

Encoder input phase B

A14

PEVP

Positive of the digital signal N° 5 (PEV)

A15

NEVP8

Negative of the proportional electrovalve N° 8

A16

NEVP3

Negative of the proportional electrovalve N° 3

A17

PEVS

Positive electrovalve (Safety)

A18

-BATT

Negative digital input N° 6 (GND)

A19

PEV

Positive of the proportional electrovalve N° 2

A20

PEV

Positive of the proportional electrovalve N° 7

A21

-BATT

Negative of the digital input N° 1 (GND)

A22

PEV

Positive of the proportional electrovalve N° 3

A23

-BATT

Negative of the digital input N° 3 (GND)

A24

-BATT

Negative of the digital input N° 2 (GND)

A25

PEV

Positive of the digital input N° 2 (PEV) Page 7

A26 -BATT

Negative of the digital input N° 4 (GND)

A27 PEV

Positive of the proportional electrovalve N° 6

A28 PEV

Positive of the digital input N° 4 (PEV)

A29 NEVP7

Negative of the proportional electrovalve N° 7

A30 NEVP6

Negative of the proportional electrovalve N° 6

A31 NEVP2

Negative of the proportional electrovalve N° 2

A32 +12

Positive supply for Encoder (+12V)

A33 PEV

Positive of the proportional electrovalve N° 8

A34 PEV

Positive of the proportional electrovalve N°4

A35 PEV

Positive of the digital input N° 7 (PEV)

A36 PEV

Positive of the digital input N° 6 (PEV)

A37 -BATT

Negative of the digital input N° 5 (GND)

A38 PEV

Positive of the digital input N° 1 (PEV)

A39 PEV

Positive of the digital input N° 3 (PEV)

A40 PEV

Unused positive (PEV)

A41 -BATT

Unused negative (GND)

A42 -BATT

Negative supply for Encoder (GND) 5.2 CONNECTOR CNB: AMP SAAB 16 POLES

PIN

FUNCTION

DESCRIPTION

B1

+12

Positive of the analog input N° 1

B2

PEV

Positive of the digital input N° 8

B3

I8

Digital input N° 8

B4

PEV

Positive of the ON-OFF electrovalve N°1

B5

-BATT

Negative of the digital input N°8 (GND)

B6

-BATT

Negative of the analog input N°1 (GND)

B7

NEV2

Negative of the ON-OFF electrovalve N° 2

B8

PEV

Positive of the ON-OFF electrovalve N° 2

Page 8

B9

+12

Positive of the analog input N° 2 (+12V)

B10

PEVS

Positive of the electrovalve (safety)

B11

AN2

Analog input N° 2

B12

AN1

Analog input N° 1

B13

-BATT

Negative of the analog input N° 2

B14

NEV1

Negative of the ON-OFF electrovalve N° 1

B15

NEV3

Negative of the ON-OFF electrovalve N° 3

B16

PEV

Positive of the ON-OFF electrovalve N° 3 5.3 CONNECTOR CNC: AMP SAAB 6 POLES

C1

PAUX

Positive supply for electrovalves

C2

PEVS

Positive supply for safety electrovalves

C3

CANL

CAN low signal

C4

KEY

Positive

C5

CANH

CAN high signal

C6

-BATT

Negative

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6 PROGRAMMING AND ADJUSTMENTS USING DIGITAL CONSOLE 6.1 ADJUSTMENTS VIA CONSOLE Adjustment of Parameters and changes to the chopper’s configuration are made using the Digital Console. Mhyrio has not an external connector for console connection. The Console must be connected to the console connector of another ZAPI product that communicate with MHYRIO via CAN-BUS line.

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

6.2 DESCRIPTION OF CONSOLE AND CONNECTION

Digital consoles used to communicate with MHYRIO controllers must be fitted with EPROM CK ULTRA, minimum “Release Number 3.06”.

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6.3 DESCRIPTION OF STANDARD CONSOLE MENU

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6.4 MHYRIO FUNCTIONAL

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6.5 DESCRIPTION OF PROGRAMMABLE FUNCTIONS (OPTIONS) The options can be set on the “SET OPTIONS” Menu.

1) 1) 1) 1) 1) 1) 1) 1) 1)

Function

Option

Meaning

EV2 TYPE

OPTION1

Set EV2 to ON-OFF valve type.

OPTION2

Set EV2 to PROPORTIONAL valve type.

OPTION1

Set EV1 to ON-OFF valve type.

OPTION2

Set EV1 to PROPORTIONAL valve type.

OPTION1

Set EV3 to ON-OFF valve type.

OPTION2

Set EV3 to PROPORTIONAL valve type.

OPTION1

Set EV4 to ON-OFF valve type.

OPTION2

Set EV4 to PROPORTIONAL valve type.

OPTION1

Set EV5 to ON-OFF valve type.

OPTION2

Set EV5 to PROPORTIONAL valve type.

OPTION1

Set EV6 to ON-OFF valve type.

OPTION2

Set EV6 to PROPORTIONAL valve type.

OPTION1

Set EV7 to ON-OFF valve type.

OPTION2

Set EV7 to PROPORTIONAL valve type.

OPTION1

Set EV8 to ON-OFF valve type.

OPTION2

Set EV8 to PROPORTIONAL valve type.

OPTION1

Set pin A8 as ZERO ENCODER.

OPTION2

Set pin A11 as ZERO ENCODER.

EV1 TYPE EV3 TYPE EV4 TYPE EV5 TYPE EV6 TYPE EV7 TYPE EV8 TYPE SET INPUT #1

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Flow chart showing how to make changes to Option Menu.

1) Opening Zapi Menu 2) Press TOP LEFT & RIGHT buttons together to enter the SET MENU. 3) The Display will show: SET MODEL 4) Press ROLL UP or ROLL DOWN buttons until SET OPTIONS Menu appears.

5) SET OPTIONS appears on the display.

6) Press ENTER to go into the SET OPTIONS Menu.

7) The display will shows the first option.

8) Press ROLL UP or ROLL DOWN buttons until desired option appears 9) Desired option appears.

10) Press SET UP or SET DOWN buttons in order to modify the value for selected option.

11) New value for selected option appears.

12) Press OUT to exit the Menu.

13) Confirmation request appears.

14) Press ENTER to accept the changes, or press OUT if you do not accept the changes.

15) SET OPTIONS Menu appears.

16) Press OUT again. Display now shows the Opening Zapi Menu.

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6.6 DESCRIPTION OF PARAMETERS THAT MAY BE PROGRAMMED (PARAMETER CHANGE) In addition to the Configuration, Parameter settings may be made by Zapi using standard default settings, settings to Customer Specifications, or the customer can 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 20 of this Manual for connection details.

CONNECTION OF THE CONSOLE TO THE CONTROLLER MUST BE MADE WITH THE KEY SWITCH TURNED OFF. The following Parameters can be modified : 1) MIN LIFT = This parameter set the minimum current of valve 2, if set as proportional 2) MIN LOWER = This parameter set the minimum current of valve 1, if set as proportional 3) MIN REACH FWD = This parameter set the minimum current of valve 3, if set as proportional 4) MIN REACH BWD = This parameter set the minimum current of valve 4, if set as proportional 5) MIN TILT UP = This parameter set the minimum current of valve 5, if set as proportional 6) MIN TILT DOWN = This parameter set the minimum current of valve 6, if set as proportional 7) MIN SHIFT RGT = This parameter set the minimum current of valve 7, if set as proportional 8) MIN SHIFT LFT = This parameter set the minimum current of valve 8, if set as proportional 9) MAX LIFT = This parameter set the maximum current of valve 2, if set as proportional 10) MAX LOWER = This parameter set the maximum current of valve 1, if set as proportional 11) MAX REACH FWD = This parameter set the maximum current of valve 3, if set as proportional 12) MAX REACH BWD = This parameter set the maximum current of valve 4, if set as proportional 13) MAX TILT UP = This parameter set the maximum current of valve 5, if set as proportional 14) MAX TILT DOWN = This parameter set the maximum current of valve 6, if set as proportional 15) MAX SHIFT RGT = This parameter set the maximum current of valve 7, if set as proportional

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16) MAX SHIFT LFT = This parameter set the maximum current of valve 8, if set as proportional 17) LIFT/LOW ACC DELAY = Lift/lowering acceleration delay: this parameter sets the valve 1 and 2 current ramp, to change from 0A to operating current.

18) REACH ACC DELAY = Group 2 acceleration delay: this parameter sets the valve 3 and 4 (group 2) current ramp, to change from 0A to operating current.

19) TI/SH ACC DELAY = Group 3 and 4 acceleration delay: this parameter sets the valve 5 and 6 (group 3), 7 and 8 (group 4) current ramp, to change from 0A to operating current.

20) LIFT/LOW DEC DELAY = Lift deceleration delay: this parameter sets the valve 1 and 2 closing ramp, to change the coil current from operating current to 0A. 21) REACH DEC DELAY = Group 2 deceleration delay: this parameter sets the valve 3 and 4 (group 2) closing ramp, to change the coil current from operating current to 0A. 22) TI/SH DEC DELAY = Group 3 and 4 deceleration delay: this parameter sets the valve 5 and 6 (group 3), 7 and 8 (group 4) closing ramp, to change the coil current from operating current to 0A. 6.7 ADJUSTMENTS TABLE PARAMETERS

PROGRAMMED LEVEL UNIT

0

1

2

3

4

5

6

7

8

9

LIFT/LOW ACC DELAY

sec.

0.5

0.7

0.9

1.1

1.4

1.6

1.8

2.0

2.3

2.5

REACH ACC DELAY

sec.

0.25 0.35 0.45 0.55 0.70 0.80 0.90 1.00 1.15 1.25

TI/SH ACC DELAY

sec.

0.25 0.35 0.45 0.55 0.70 0.80 0.90 1.00 1.15 1.25

LIFT/LOW DEC DELAY

sec.

0.5 0.72 0.9

REACH DEC DELAY

sec.

0.25 0.35 0.45 0.55 0.70 0.80 0.90 1.00 1.15 1.25

TI/SH DEC DELAY

sec.

0.25 0.35 0.45 0.55 0.70 0.80 0.90 1.00 1.15 1.25

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1.1

1.4

1.6

1.8

2.0

2.3

2.5

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

2) Press ENTER to go into the GENERAL MENU. 3) The Display will show : PARAMETER CHANGE. 4) Press ENTER to go into the PARAMETER CHANGE menu.

5) The Display will show the first parameter.

6) Press ROLL UP and ROLL DOWN buttons until desired parameter appears.

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 : PARAMETER CHANGE 14) Press either ROLL UP and ROLL DOWN to display other parameters or press OUT to return into the Opening Zapi Menu.

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6.8 ALARMS ASSOCIATED WITH THE FLASHING RED LED The type /code of Alarm is shown in parenthesis. A more detailed description is given in chapter 6.9.

1 flash =

Eeprom corrupted (EEPROM KO).

6 flashes =

Problem with valves driver (FF VALVES, DRIVER OPEN, DRIVER EPV GR1, DRIVER EPV GR2, DRIVER EPV GR3, DRIVER SHORTED).

8 flashes =

Problem with CAN BUS connection (CAN BUS KO).

6.9 ANALYSIS OF ALARMS DISPLAYED ON THE CONSOLE 1) EEPROM KO 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.

2) CAN BUS KO There is a problem related to the CAN-BUS line. The error is signalled if the MHYRIO controller does not receive any message from the SICOS CAN-BUS line.

First of all, check the wiring. If it is ok, the problem is on the logic board, which must be replaced.

3) FF VALVES Flip-flop circuit, that manages valve drivers short-circuit protection, has been set.

The cause can be an external short across the valve coil; it can be set also by a disturb coming into Mhyrio logic.

4) DRIVER OPEN The high side switch that drives positive to valves (used for safety related valves) is opened when it should be closed.

5) DRIVER EPV GR1 One of the MOS (or more than one) that drives the valves 1, 2 is shorted.

6) DRIVER EPV GR2 One of the MOS (or more than one) that drives the valves 3, 4 is shorted.

7) DRIVER EPV GR3 One of the MOS (or more than one) that drives the valves 5, 6, 7, 8 is shorted.

8) DRIVER SHORTED The high side switch that drive positive to valves (used for safety related valves) is closed when it should be opened.

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6.10 DESCRIPTION OF THE TESTER FUNCTION 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 listing shows the measurements that may be made : 1) DIGITAL INPUT 1: indicate the state of the digital input 1 (CNA10). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 2) DIGITAL INPUT 2: indicate the state of the digital input 2 (CNA11). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 3) DIGITAL INPUT 3: indicate the state of the digital input 3 (CNA6). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 4) DIGITAL INPUT 4: indicate the state of the digital input 4 (CNA7). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 5) DIGITAL INPUT 5: indicate the state of the digital input 5 (CNA5). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 6) DIGITAL INPUT 6: indicate the state of the digital input 6 (CNA9). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 7) DIGITAL INPUT 7: indicate the state of the digital input 7 (CNA8). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 8) DIGITAL INPUT 8: indicate the state of the digital input 8 (CNB3). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 9) EV 1: indicate the state of the electrovalve 1 (CNA3). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 10) EV 2: indicate the state of the electrovalve 2 (CNA31). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 11) EV 3: indicate the state of the electrovalve 3 (CNA16). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 12) EV 4: indicate the state of the electrovalve 4 (CNA2). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential)

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13) EV 5: indicate the state of the electrovalve 5 (CNA1). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 14) EV 6: indicate the state of the electrovalve 6 (CNA30). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 15) EV 7: indicate the state of the electrovalve 7 (CNA29). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 16) EV 8: indicate the state of the electrovalve 8 (CNB3). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 17) STATUS 1: indicate the state of the electrovalve STATUS1 (CNB14). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 18) STATUS 2: indicate the state of the electrovalve STATU2 (CNB7). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 19) STATUS 3: indicate the state of the electrovalve STATUS31 (CNB15). Options: ON = active entry of closed switch (equal to battery positive potential) OFF = inactive entry of open switch (equal to GND potential) 20) ENCODER: indicate the digital count of encoder. This value will be acquired by SICOS. In this menu, it's present only for functionality check of encoder.

21) ANALOG INPUT 1: indicate the voltage relative to analog input. The value is between 0 and 255. Every step correspond to 1/256 of maximum voltage.

22) ANALOG INPUT 2: indicate the voltage relative to analog input. The value is between 0 and 255. Every step correspond to 1/256 of maximum voltage.

Page 20

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

1) Opening Zapi Menu.

2) Press ENTER to go into the GENERAL MENU. 3) The Display will show : PARAMETER CHANGE 4) Press ROLL UP or ROLL DOWN button until TESTER menu appear on the display.

5) The Display shows: TESTER. 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.

9) Next variable for measurement appears.

10) When you have finished, Press OUT. 11) The Display shows: TESTER 12) Press OUT again and return to Opening Zapi Menu.

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.

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6.11 DESCRIPTION OF THE CONSOLE SAVE FUNCTION The SAVE PARAM. function is allowed in the MHYRIO controller, but it's useless because console cannot save all parameters correctly.

Use of this function don't create problems to the console functionality and to the others ZAPI device functionality.

6.12 DESCRIPTION OF THE CONSOLE RESTORE FUNCTION The RESTORE PARAM function is allowed in MHYRIO controller, but ZAPI recommend don't use this because should make several problems to the controller.

As a result of using this function, all parameters will be overwritten with incorrectly values and MHYRIO controller will not work correctly.

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6.13 DESCRIPTION OF THE SET MODEL FUNCTION The only parameter present in SET MODEL function is CONNECTED TO. By setting this parameter, operator can connect ZAPI Console to every ZAPI product connected to CAN-BUS line. This functionality allow completely control of every ZAPI product without changing the position of the Console connector.

This is the only way to connect ZAPI Console to Mhyrio controller because the Console connector is not present in Mhyrio controller.

1) Opening Zapi Menu.

2) Press TOP LEFT & RIGHT buttons together to enter SET MENU. 3) The Display will show: SET MODEL. If another menu is displayed, press ROLL UP or ROLL DOWN until SET MODEL appears.

4) Press ENTER to go into the SET MODEL Menu.

5) The display will shows the first option, only CONNECTED TO option is present in this menu.

6) Press SET UP or SET DOWN buttons in order to select the desired value for selected option.

7) New desired value appears.

8) Press OUT to exit the Menu.

9) Confirmation request appears.

10) Press ENTER to accept the changes, or press OUT if you do not accept the changes.

11) SET MODEL Menu appears.

12) Press OUT again. Console now disconnect and reconnect.

13) Display now shows the Opening Zapi Menu of the ZAPI product corresponding to option selected at point 7.

Page 23

The table below indicate which parameter can be set to connect ZAPI product to Console.

PARAMETER

CONNECTED PRODUCT

1

SICOS

2

TRACTION CONTROLLER

5

PUMP CONTROLLER

6

EPS

9

MHYRIO

The range for this parameter is 0~32, but only above number are enabled. If operator select a not specified value, ZAPI Console reconnect the product physically connected to Console. To have a confirmation of the product connected, see the Opening ZAPI Menu.

Page 24

6.14 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 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.

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7 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors’ moving and fixed contacts. Electrical Contacts should be checked every; _______________________________ 3 MONTHS Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals. Switches should operate with a firm click sound. Microswitches should be checked every; _______________________________________ 3 MONTHS Check the Battery cables, cables to the chopper, and cables to the motor. Ensure the insulation is sound and the connections are tight. Cables should be checked every; ___________________________________________________________ 3 MONTHS Check the mechanical operation of the pedal or tiller . Are the return springs ok. Do the potentiometers wind up to their full or programmed level. Check every; ___ 3 MONTHS Check the mechanical operation of the Contactor(s). Moving contacts should be free to move without restriction. Check every; _____________________________ 3 MONTHS

Checks should be carried out by qualified personnel only and any replacement parts used should be original. Beware of NON ORIGINAL PARTS. The installation of this electronic controller should be made according to the diagrams included in this Manual.

Any variations or special requirements should be made after consulting a Zapi Agent.

The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual. During periodic checks, if a technician finds any situation that could cause damage or compromise safety, the matter should be bought to the attention of a Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine. Remember that Battery Powered Machines feel no pain.

NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER

Page 26

COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI

42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - e-mail: zapi@zapispa.it

INSTALLATION AND USER MANUAL FOR MHYRIO CONTROLLER (MULTIFUNCTIONAL HYDRAULIC REMOTE I/O)