Caterpillar NR16 Lift Truck Operation & Maintenance Manual - PDF DOWNLOAD

EN

Operation & Maintenance Manual NR14 NR16 NR16C NR20 NR20H NR25H

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

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REACH TRUCK Type:

__________________________________

Manufacturing year and number: _____________________

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

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

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Table of contents FOREWORD ............................................................................................................................................ 3 1. INSTRUCTIONS ON OPERATING THE TRUCK ............................................................................ 3 2. OCCUPATIONAL SAFETY .................................................................................................................. 5 3. LOAD HANDLING .............................................................................................................................. 6 4. DRIVING .............................................................................................................................................. 7 5. PARKING ............................................................................................................................................. 7 6. OTHER WORKING INSTRUCTIONS............................................................................................... 8 7. RECHARGING AND REPLACING THE BATTERY ........................................................................ 8 8. HAZARDOUS WASTE AND DISPOSAL .......................................................................................... 10 9. ORDERING SPARE PARTS .............................................................................................................. 10 10. USE OF THE TRUCK ...................................................................................................................... 11 11. THE OPERATOR’S NORMAL DRIVING POSITION .................................................................. 11 12. NOISE ............................................................................................................................................... 11 13. CONTROLS AND THEIR DISPLAYS ............................................................................................ 12 14. ADJUSTING THE DRIVING POSITION ....................................................................................... 16 15. OPERATION .................................................................................................................................... 17 16. “FLY BY WIRE” ELECTRONIC STEERING ................................................................................ 17 17. HANDLING THE LOAD ................................................................................................................. 19 18. EMERGENCY PROCEDURE ......................................................................................................... 19 19. INSPECTIONS, MAINTENANCE AND REPAIR ......................................................................... 20 20. ADDITIONAL INSTRUCTIONS FOR THE COLD STORAGE TRUCKS .................................. 23 21. TROUBLESHOOTING .................................................................................................................... 24

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Otherwise normal daily maintenance and inspection are sufficient.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The truck must always be driven with its forks lowered.

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

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

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

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

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

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

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

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

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

Sudden starts and stops should be avoided.

Steering and braking movements should be made smoothly.

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

Take great care when driving on a slanted surface.

Do not drive over any loose objects on the floor.

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

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

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

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

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

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

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

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

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

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

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

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

When using an elevator, it must be ensured that the combined weight of the truck, the load and the operator does not exceed the maximum load capacity of the elevator. The truck should always be driven with the load in front to elevators, as well as any other narrow premises. ! Do not let any other people be in an elevator when driving the truck in or out. ! The parking brake of the truck must be on before the elevator starts.

WORKING ON RAMPS The operator must get permission from the site supervision to drive on a slope or ramp. When the truck is loaded, travel with the load uphill. Without a load, you can also travel with the forks downhill. ! Do not turn the steering wheel abruptly on a ramp. The truck might overturn.

WORKING ON LOADING BRIDGES Before starting with loading or unloading, always check the bearing capacity and the fastening of the bridge. If the truck is to be driven into another vehicle, it must be ensured that the vehicle cannot move during the work. Do not drive to the edges of a loading bridge, because there is always the risk of overturning.

7. RECHARGING AND REPLACING THE BATTERY Only appointed and trained personnel may replace and recharge batteries. Individuals maintaining batteries must have sufficient protective clothing. ! Do not handle naked flame in the vicinity of batteries because of a risk of explosion. ! Do not smoke when working with batteries. ! Do not leave tools or other metal implements on top of the battery. Sparking or a short circuit may cause the battery to explode.

-9! When the batteries are recharged, the cell plugs must be screwed tight to prevent battery fluid splashing. ! Battery fluid is a corrosive acid solution, so caution should be exercised to avoid it getting on the skin or in the eyes. Battery fluid develops an explosive gas at the end phase of recharging. Therefore, make sure that the battery has sufficient ventilation. ! A low battery charge status may damage the battery during long-time use.

RECHARGING THE BATTERY ! Make sure that the charger is the appropriate model for recharging the battery. ! Park the truck in a specially reserved recharging place. ! Make sure that the battery has sufficient ventilation.

Connecting the battery to a charger: 1.

2.

3.

4.

Switch off the truck current Make sure that the charger has been switched off.

Disconnect the battery connector and connect it to the charger.

Connect the current to the charger.

After charging, when beginning the work: 1. Switch off the charger.

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

3. Check the battery according to the manufacturer’s and maintenance instructions.

Measuring the Cell Density of the Battery Measure the acid density of the battery fluid according to the manufacturer’s instructions. The acid density of a fully charged battery is 1.28 to 1.30 at + 30 °C. 1.24 1.20 1.16 1.15

3/4 charged 1/2 charged 1/4 charged Empty. The battery must be charged immediately.

REPLACING THE BATTERY The battery must be replaced according to the manufacturer’s instructions. When reinstalling batteries, use the appropriate tools for moving, connecting and fastening the battery solidly. Tools and other metal implements must not be kept on top of uncovered batteries.

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

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

- 10 ACQUIRING A NEW BATTERY When acquiring a battery for the truck, pay attention to the standard prEN 1175-1, section “Traction batteries”, which lays down the requirements on the protective cover of the battery case, ventilation and interior surface treatment, and section “Minimum markings”, which lays down the requirements on the truck battery plate.

The battery plate should give at least the following information: • manufacturer • type • serial number • rated voltage • capacity (Ah/5h) • service weight

8. HAZARDOUS WASTE AND DISPOSAL Hydraulic and gear oils as well as batteries are hazardous waste, which must be disposed of accordingly.

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

9. ORDERING SPARE PARTS When ordering spare parts, always turn to your dealer or maintenance centre. Use only original spare parts.

To make sure you receive the correct parts, include the following information in the order: • TYPE OF TRUCK • SERIAL NUMBER OF TRUCK • ORDER NUMBER OF PART • NAME OF PART • NUMBER OF PARTS ORDERED Of the above information, items 3 and 4 are listed on the spare part pages of the manual supplied with the truck, and items 1 and 2 on the front page of the manual or on the identification plate of the truck.

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10. USE OF THE TRUCK This product is designed for handling pallets and other similar picking units in pallet transfer and stacking tasks.

The truck is intended to be used on dry indoor premises, on even and straight floors. A standard truck can work continuously at a working temperature from + 25 to +5 ° C, with occasional variation from + 45 to 0 °C. If your working environment has a different temperature range, contact Rocla, because cold and freezer premises require a specially constructed machine. A special frost machine can be used down to - 35 °C. The truck meets all the relevant requirements of the EU directive on machine safety, indicated by a CE label.

FORBIDDEN USES OF THE TRUCK Never use the truck: • to transport and lift people • on premises with fire risk • on premises with explosion risk • on premises with insufficient floor bearing capacity • if damaged • as a mounting surface • to tow another truck • under the influence of intoxicating substances.

11. THE OPERATOR’S NORMAL DRIVING POSITION The driver’s normal position while driving is sitting with the left hand on the steering wheel and the right on the valve levers. The left foot should always be on the chosen drive direction switch or on the brake pedal.

NOTE !

When driving, no part of the body must be outside the operator’s cab.

12. NOISE The maximum noise level the driver may be subjected to is 70 dB (A). This noise level can be reached when raising classified load.

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13. CONTROLS AND THEIR DISPLAYS TRUCK PLATES (1) Identification plate The identification plate gives the following information: • manufacturer • truck type • serial number • unloaded mass of the truck in working order without a battery and removable attachments • permitted maximum and minimum battery weight • terminal voltage • rated load capacity • CE- label Capacity plate On the high-lifting trucks, there is a capacity plate that tells the maximum lifting capacity with maximum lifting height and the lifting height with a nominal lifting ability. Only one lifting ability is announced, when needed, between these two heights. In addition, the plate tells the center of gravity distances with these lifting abilities.

WARNING !

Recognize and know in every situation the load’s weight and center of gravity. the truck is a safety hazard and thus forbidden.

Overloading

The capacity plate for accessories If the truck uses detachable accessories, the corresponding plates are fastened to the truck and the lifting capacity changes are mentioned on the capacity plate where the type of accessory is marked.

- 13 Speed Control and Direction Switches (2), (4), (5) Press the speed control pedal (2) gently with your right foot. The lower you press the pedal, the greater the speed. The pedal returns to the upper position when released.

In a truck equipped with a hand reverser, select the desired direction of travel by using the hand lever (5). When driving, press the safety press key (4) with your left foot and adjust the speed with the speed control pedal.

• Use the speed control gently !

• The security switch connected to the manual direction change is a safety measure that insures that the driver is completely in the truck.

Option: Foot reverser As an option, the truck can be equipped with a foot reverser.

Press the reverser of the desired direction of travel with your left foot.

The truck cannot be driven if the reverser is not pressed.

BRAKES Operating and parking brake (3), (6) The left pedal is the brake pedal (3). The deceleration force is adjusted by the movement of the pedal.

The operating and parking brake affect the drive wheel. When the truck is equipped with load wheel brakes (TES, TEH), they can be operated only with pedals.

The operating brake is a magnetic brake that is always switched on (6) when the driver leaves the truck. The magnetic brake is also switched on with the operating brake pedal if pressed hard enough (“panic braking”).

Recharging (regenerating) braking The truck is equipped with a recharging motor brake system. This enables conserving the energy generated by braking, which otherwise would be wasted. This increases the life expectancy of the battery and spares the driving motor.

Motor braking recharges the battery and decelerates the truck in the following cases: 1. When the brake pedal is pressed 2. When the direction is reversed 3. When the truck rolls freely • Practice using the brake both with and without a load before starting work.

• The parking brake is always used when the truck is not in use.

- 14 Charging Plug (7) The charging plug of the truck is equipped with a handle and it is detachable.

On using the charging plug for recharging the battery, see the section “Recharging the Battery”.

Opening of the panel:

NOTE !

When welding with electrical welding equipment, the battery must be disconnected.

CONTROL PANEL

Key switch (8) The key switch connects the electrical devices of the truck to the battery circuit.

0 = Power off (power remains on for certain electronic devices) 1 = Power on Valve Levers (9) A reach truck usually has four levers. From left to right: 1. Lifting and lowering the forks 2. Pushing the mast forward and backward 3. Tilting the mast 4. Side-shifting the carriage If the truck is equipped with a fork adjustment device, there is a rockingswitch instead of a covering plate.

• Familiarize yourself with the operation of the levers Steering wheel (10) The steering wheel turns the drive unit by ±100° or without limits. For the adjustment of the steering wheel, see “Adjusting the position of the boomerang.”

• See Section “Fly by Wire ”Electronic Steering for more details.

The emergency stop button(11) Press this button to disconnect the truck current circuit from the battery. Use this button: • in case of a short circuit or other electrical malfunction, for example, if the pump motor is on continuously • in case of an accident.

The switch is released by rotating the button clockwise.

Horn Signal Button (12)

- 15 Display (1) Power-on LED • The green LED is lit when the power is on.

(2) Problem monitoring of the speed control • The red LED flashes if the speed control has a fault. The truck cannot be driven before the fault has been corrected.

• When the LED flashes, switch off the power with the ignition key, wait for about 5 seconds, then switch on the power again (do not touch any drive or load management controls). The controller gives also a fault message if the start order is wrong. Correct order: push first the safety controller or direction switch down and then the speed control pedal. The fault is fixed by taking the feet of the pedals, waiting ca. 2 s and trying to start again in the right order.

If the fault is not removed, contact your maintenance centre.

(3) Problem monitoring of the pump control • The red LED flashes when the pump speed control has a fault. The truck cannot be driven before the fault has been corrected. When the LED flashes, switch off the power from the ignition key, wait for about 5 seconds, then switch on the power again (do not touch any drive or load management controls).

If the fault is not removed, contact your maintenance centre.

(4) Travel direction arrows • The blue LED arrow indicates the direction of travel.

(5) Liquid crystal display • In connection with the powering-on, the LCD displays the operating hours of the truck for about 5 seconds, after which the LCD shows the charge status of the battery.

• The hour meter calculates the active working time of the truck. It is always on when the electronic devices are operating. If the charge status of the battery is too low, the charge indicator / hour meter combination stops lifting.

(6) Seat heating (optional) • As an option, the truck can be equipped with seat heating, in which case the green LED is lit when seat heating is on.

(7) Problem monitoring of control electronics • A red LED warns you about a steering disturbance. When the indicator is lit, immediately stop the truck using the foot brake ! See Section “Fly by Wire” Electronic Steering for more details.

(8) Monitoring of carbon brushes (optional) • A red LED is lit when the carbon brushes of the driving motor or the pump motor have worn too short.

The carbon brushes of the motor in question must then be replaced immediately.

- 16 (9) Magnetic brake (parking brake) LED • A red LED is lit when the magnetic brake is switched on.

(10) Thermal monitoring (optional) • As an option, the truck can be equipped with thermal monitoring of drive and pump speed controls. In this case the red LED indicates that the control has overheated. If this happens, drive the truck slowly to to a place where it is not in anybody’s way and does not pose a danger to anybody. Let the truck cool down. The reason for overheating must be found out, before the truck is driven again.

14. ADJUSTING THE DRIVING POSITION SEAT The springs of the seat are adjusted according to the driver’s weight. Then the tilt of the backrest and the distance from the seat to the pedals are adjusted.

A = Seat spring tension adjustment B = Seat tilt C = Seat distance adjustment

CONTROL PANEL The turning angle of the control panel can be adjusted by rotating the screw behind the panel.

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15. OPERATION Before start, make sure that the daily maintenance has been carried out. See ”The Operator’s Daily Routines before Work”.

Turn on the truck and grab the knob of the steering wheel with your left hand. Release the parking brake by pushing the brake lever forward.

Hold on to the knob of the steering wheel with your left hand and use the valve levers with your right. The left foot must always be on either the driving direction switch or the stopping button (manual direction change). Press the speed control panel with the right foot.

The reach truck is always driven with the mast tilted backwards and pulled in, and the fork and the load low. The pushing and pulling movement of the mast is only used in stacking and unstacking.

• Practice steering and controlling the truck • Make the truck’s control movements calmly • Anticipate the braking situations in plenty of time and brake softly • Drive slowly in intersections and while turning • Practice using an unfamiliar truck in a safe area • Warning ! With sudden movements of the speed control or brake pedal, you may lose control of the truck or load.

16. “FLY BY WIRE” ELECTRONIC STEERING The truck is equipped with a new and completely electronic steering system. The steering wheel movement in electronic steering is transmitted without a mechanical connection to the motor that controls the drive wheels.

The system consists of three main components, a tachometer located in the steering wheel, a control unit located in the motor compartment, and a servo motor, which is also in the motor compartment. The control unit processes the signal coming from the tachometer and controls the servo motor to turn the drive wheel in the desired direction. In addition, the control unit constantly monitors how the system is functioning and its status. The control unit reacts immediately whenever something goes wrong.

The drive wheel turns ± 360° or ± 100°.

SAFETY When the power is turned on by the main switch and the ignition key, the system performs a diagnostic test which lasts no more than 0.3 seconds. After the test is done, the truck is fully operational and ready to use.

When the power is turned on, the system constantly performs a diagnostic check by sending a check signal throughout the system. This signal can be heard as the tapping noise emitting from the truck. In case something goes wrong, the control unit will react immediately to the situation by turning on the STEERING STOP indicator and applying the magnetic brake.

The truck immediately stops when a problem appears.

Wait for at least 2 seconds before you turn the power on again after it has switched off.

- 18 OPERATION Completely acquaint yourself with the truck and please note that when the turning wheel reaches the turning limit (± 100°), the steering wheel may continue turning as it has no mechanical stops to prevent it from doing so.

The “STEERING STOP” indicator The STEERING STOP light is lit when there is a fault in the control system or if the power is switched off and on too quickly (<2 seconds). The truck cannot be driven if the light is on.

NOTE ! Do not turn the steering wheel unnecessarly, when the truck is not moving!

MAINTENANCE The system has been designed to be as maintenance free as possible. The user only has a few simple maintenance tasks to take care of.

Quarterly maintenance check (300 hrs.)

• Fastening of the steering control unit terminals NOTE: • DO NOT under any circumstances adjust the control unit as it has been pre-set at the factory.

• DO NOT subject the control unit to running water.

An authorized serviceman can, when needed, tune the steering, e.g. the number of rotations for the steering wheel.

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17. HANDLING THE LOAD Familiarize yourself with the load handling instructions that are in the general instructions !

Set the load so that its weight is distributed as evenly as possible on both of the lift forks. You can see the truck’s maximum capacity on the type plate and you may not exceed that capacity.

WARNING: DO NOT TRANSPORT BADLY PILED OR BOUND LOADS. DO NOT EXCEED THE TRUCK CAPACITY. STACKING AND UNSTACKING While stacking and unstacking with the reach truck, you must follow the following guidelines.

Stacking: 1. Drive calmly perpendicular to the front of the stack of shelf with the load low and the mast tilted backwards.

2. Straighten the mast into an upright position.

3. Lift the load so high that it clearly is higher than the stacking or shelf level.

4. Push the mast forward until the forks and the load are above the shelf level.

5. Lower the fork so they are no longer touching the pallet but at the same time not touching the shelf level. Make sure that the load is stable.

6. Pull in the mast and carefully drive backwards. Tilt the mast backwards and lower the forks to the driving position.

Unstacking: 1. Drive calmly perpendicular to front of the stack of shelf with the forks low and the mast tilted backwards.

2. Straighten the mast into an upright position.

3. Raise the forks to the height of the desired pallet and approach the pallet by driving carefully. Make sure that the forks can freely go underneath the pallet the whole time.

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

5. Lift up the forks so that the pallet is no longer on the stacking level. Make sure that the load is stable.

6. Pull in the mast and carefully drive backwards. Lower the load to the lower position and tilt the mast backwards.

Note !

• Always compare the load weight to the lifting height and capacity that are on the truck's type plate.

• Always observe the space above the load.

• While the load is up, the steering and braking movements have to be done carefully and softly.

• A broken pallet or an unstable load may not be lifted nor left on a stack or shelf.

18. EMERGENCY PROCEDURE If the truck overturns, keep hold of the steering wheel and warn others. If the truck behaves strangely, brake and power off the truck. The truck must not be returned to operation until it has been repaired by an individual authorised by the site supervision.

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19. INSPECTIONS, MAINTENANCE AND REPAIR SAFETY INSTRUCTIONS IN MAINTENANCE WORK • Only individuals trained for maintaining and repairing this type of trucks may repair and maintain the truck.

• The maintenance site should be kept clean: oil, grease and water make the floor slippery.

• When working with the truck’s electrical system, there is a risk of a short circuit and skin burn if a metal object touches live connectors. No watches, rings or other metal jewellery should therefore be worn.

• Power off the truck before opening the cover of the drive unit or the electrical system.

• Remove hydraulic pressure before opening the system.

• Do not use your hand when checking possible oil leaks.

• Note that hydraulic system oil or motor surfaces may be hot.

• Use only clean oil for filling the hydraulic system.

• Disconnect the battery when welding. To prevent formation of toxic gases during welding, remove paint up to 10 cm from the work object.

• Support the truck with jacks when working underneath the truck.

DRIVER’S DAILY ROUTINES BEFORE OPERATION • As an operator, you are responsible for the daily checking and maintenance of the truck.

• Carry out the daily maintenance according to the list below before the start of a working day or shift, before the truck is used.

• Neglecting the daily maintenance may decrease the safety and reliability of the truck.

• Notify the site supervision immediately if you notic any error or deficiency during the check.

• Check the truck externally to see that no oil leaks can be observed.

• Check all wheels for damage or outer wear.

• Check the battery fluid in each battery cell. Top up with battery water if needed. The fluid surface should be about 15 mm above the plates.

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

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

• Check the operation of the speed control by driving slowly forward and backward. Also check the operation of the other electrical functions.

• Make sure that the stopping pedal returns to the upper position and that the parking brake functions properly.

• Test the sound signal.

• Make sure that the fastenings of the lifting chain have not loosened.

• Make sure that the steering is working

- 21 DRIVER’S WEEKLY MAINTENANCE PROGRAMME • Check and clean the fastenings of the battery cables.

• Make sure that the air holes of the battery cell plugs are not plugged up.

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

• Check the length of the lifting chains. When the mast is upright and the top of the mast bars is on the same level, all the chains should be somewhat loose. Adjust, when needed, the adjust screws at the end of the chains.

• Thinly oil the mast’s, push sled’s and lifting sled’s grooves.

• Check the amount of hydraulic oil in the oil container when the forks are down. If necessary, add oil.

See the separate oil recommendation (Section 17.4) for more details.

• Check that the driving wheel’s fastening bolts are tight. The tightening moment is 190 Nm. • Make sure that screws, nuts and pipe connectors are tight.

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

• Clean the truck if necessary.

NB: DO NOT LET WATER IN THE ELECTRICAL DEVICES, especially if the power is on !

THE TRUCK’S LUBRICATING POINTS SHOULD BE LUBRICATED ABOUT ONCE A MONTH. pivoting bearing grease nipples (2 nipples)

Reach carriage grease nipples (4 nipples)

OIL RECOMMENDATIONS Hydraulic oil: ISO VG 32 In freezer warehouses: ISO VG 15 Gearbox oil: SAE 80W/90, API: GL-4 • Fill to the volume of 4.5 l Lubricating grease: NLGI No. 2. containing molybdenumdisulfide.

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

- 22 QUARTERLY MAINTENANCE INSPECTION (300H) The most convenient arrangement is to make a maintenance agreement on inspection and scheduled maintenance with your service centre. Only competent maintenance guarantees a fault-free operation of your truck.

Following the maintenance programme is easier when you enter the maintenance dates in the maintenance record.

In addition to the weekly programme, the Rocla service engineer checks and adjusts, if necessary, the following: • operation of the hydraulic valve • the action of the speed control • the contactors, microswitches and solenoids • the condition of the cables • the amount of brake fluid (TES, TEH) • If necessary add SAE J 1703 F brake fluid into the tank.

• the brake pipes and tubes • Press the brake pedal strongly and check that there aren’t any fluid leaks.

• the cylinders’ fastenings and the adjustments’ locking • the condition of the forks and the connection of the mast to the body • thinly oiling the lift chain with oil • horizontal and vertical play of the reach carriage • If necessary, you can reduce play by loosening up the tension screws and turning the adjustment screw. collectors, carbon brushes and guides of the driving, steering and pump motors • strain percentage of the lifting chains SEMIANNUAL SCHEDULED MAINTENANCE (600 H) In addition to the quartely and weekly procedures, the service engineer will • check the collectors, carbon brushes and wiring of the driving and pump motors and clean the coal dust off the motors.

• change the hydraulic oil once a year (1200 h) • change the gearbox oil once a year (1200 h) • replace the oil filter • check the operation of the hydraulics and the pressure-limiting valves • check the fastening of the gearbox • check the wear on the driving wheel • The wheels are exchanged at last when there is 10 mm of surfacing left on the wheel • check, clean and oil the lifting chains • oil the motors’ bearings once a year (1200 hrs.)

• check the lifting chains’ wheels • check how the battery locking mechanism works • check the driver’s cover

- 23 LOCATION OF THE FUSES: 1. Main fuse of the driving and pump motor 2. Steering motor fuse 3. Main fuse

WARNING: DO NOT MAKE ANY CHANGES OR REPAIRS IN THE TRUCK THAT MAY WEAKEN ITS CONSTRUCTION OR ENDANGER SAFETY.

20. ADDITIONAL INSTRUCTIONS FOR THE COLD STORAGE TRUCKS You can use trucks with a cold storage specification for working in temperatures above -35°C. You can also use them when working in humid or difficult environments, but not in environments that are too warm, due to limited cooling capacity.

The classification of these machines is Class 3. This classification replaces the old classes (Class 1, Class 2, Class 3).

Whenever the truck is used or left idle for short periods of time (e.g. during a lunch break) in temperatures below 0°C, the heating must be left on. If the truck is left unused for a longer time, it should be kept in a warm area.

Grease the truck lubricating points once a month. The lubricating points include the following: • Swivel bearing grease nipples, 2 pcs • Grease nipples of speed adjustment and brake pedals, 2 pcs • Grease nipples of reach carriage, 4 pcs • Grease nipples of mast tilting bearing, 2 pcs • Sprocket wheel grease nipples, 4 pcs • Grease nipples of leaders, 12 pcs • Lubricate the gear wheel of the swivel ring and steering motor • Lubricate the lifting chains • Lubricate the mast leader surfaces • Lubricate the leader surfaces of the lift carriage • Lubricate the leader surfaces of the reach carriage Perform the following maintenance operations every six months or when the red indicator pin of the moisture trap has risen: • Change the hydraulic oil • Replace the oil filter • Replace the oil tank moisture trap

- 24 -

21. TROUBLESHOOTING SYMPTOM:

FAULT:

PROCEDURE:

Truck does not move

• the battery connector is loose • the battery is empty • the emergency stop button is activated • the key switch is faulty • the microswitch for the safety pedal is broken • the drive motor fuse has blown

• plug in the battery connector • recharge the battery • release the emergency stop button

• the main power fuse has blown • the drive motor carbon brushes are worn out • the speed control is faulty The lift pump doesn’t run

• replace the key switch • replace the microswitch • check the connections and cables and replace the fuse • check the connections and cables and replace the fuse • replace the carbon brushes • contact your truck dealer

• Pump fuse has blown • Control current fuse has blown • Pump motor carbon brushes are worn out • Drive switch is broken

• Replace the fuse • Replace the fuse and check cables • Replace the carbon brushes

lifting functions improperly

• Overload • Battery is empty • Not enough oil in tank • Oil leak • Pump is faulty • Dirt in valve

• Decrease the load • Recharge the battery • Add oil • Check joints and seals • Replace the pump • Clean the valve, replace if necessary

Battery does not charge

• Charger is connected incorrectly • Charge fuse has blown or mains voltage is missing • the battery cells’ water level or specific gravity is low

• Check the connection • Replace the fuse

• The control motor fuse has blown • The control power fuse has blown • A short voltage break (<2 sec.). It could be caused by switching the power on too soon.

• faulty steering controller (indicators are not lit)

• Change the fuse • Change the fuse • Switch the power off and wait more than 2 seconds. Turn the power on.

• The steering motor carbon brushes are worn out • The steering hits an obstacle when strongly turning to extreme position

• Replace the carbon brushes

The steering isn’t working properly

The steering works poorly

• Replace the switch

• check the cells current and specific gravity. Add water and / or acid when necessary. See Section “Recharging the battery”

• Contact your truck dealer

• the end line switches are faulty or misadjusted. Replace and adjust

Index Pag. 1

4

5

6

General characteristics ................................................................................ 3 1.1 Technical specifications .......................................................................... 3 1.2 General scheme ..................................................................................... 3 1.3 Performance features ............................................................................ 4 1.4 Driving devices ....................................................................................... 5 1.5 The concept of compensation ................................................................ 6 1.6 Protection features ................................................................................. 6 1.7 General notes and warnings . .......................................................... 7 1.8 Main contactor and safety switch . ................................................... 8 1.9 Susceptibility and electromagnetic emission . ................................... 8 2 Installation ............................................................................................ 9 2.1 Positioning and thermal dispersion ......................................................... 9 2.2 Connection cables .................................................................................. 9 2.3 Contactors .............................................................................................. 9 2.4 Fuses ..................................................................................................... 9 2.5 Suppression ......................................................................................... 10 2.6 C1 controller mechanical drawing ........................................................ 11 3 C1 Combi connectors ........................................................................ 12 3.1 Connectors disposition ......................................................................... 12 3.2 C1 Combi power connectors description .............................................. 14 Programming and setting using the console ........................................... 15 4.1 Setting by console ................................................................................ 15 4.2 Ppogrammable console ........................................................................ 15 4.3 Map of the console function ................................................................. 16 4.4 Options: description and programming instructions ............................. 17 4.5 Adjustment: description and programming instructions........................ 20 4.6 Parameters: description and programming instructions ....................... 23 4.7 Tester: functions descriptions .............................................................. 27 4.8 Save parameters: description .............................................................. 30 4.9 Restore parameters: description .......................................................... 31 4.10 Alarms: menu description ..................................................................... 32 4.11 Program VACC: description ................................................................. 33 4.12 Instructions for making adjustments .................................................... 33 Diagnosis ..................................................................................................... 36 5.1 Traction led diagnosis........................................................................... 36 5.2 Deconding console displayed traction alarms ...................................... 37 5.3 Diagnosis pump control ........................................................................ 45 5.4 Decoding console displayed alarms ..................................................... 45 Wiring diagram ............................................................................................ 47 6.1 Diagram legend .................................................................................... 47 6.2 Decoding colours symbol ..................................................................... 47

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1 GENERAL CHARACTERISTIC 1.1 TECHNICAL SPECIFICATIONS Version Version 24 V 36V & 48V Traction maximum current (3’) ....................................... 400A ........................ 350A Traction booster current (3”) .......................................... 460A ........................ 400A Traction current 1 hour ................................................... 150A ........................ 120A Pump maximum current (3’) ........................................... 350A ........................ 350A Pump current 1 hour ...................................................... 150A ........................ 120A Traction motor maximum power..................................... 3 kW ................... 4 kW, 5kW Pump motor maximum power ........................................ 3 kW ................... 4 kW, 5kW Voltage drop (IM = 120A) ............................................. 280 mV .................... 400 mV Type of motors requested .................................... traction: DC series wound 4 terminals ............................................... pump: DC series wound Power switching device ................................................................ MOSFET Control unit ................................................................... 8 bit 12 MHz Microprocessor Maximum operating ambient temperature .................................... + 40 °C Minimum operating ambient temperature ......................................- 25 °C Relative Humidity ....................................................................... 20 % ÷ 95 % IP protection degree ........................................................................ IP 54 AC insulation ................................................................................ 550 VAC Weight (controller only) .................................................................. 4,9 kg 1.2 GENERAL SCHEME

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1.3 PERFORMANCE FEATURE – Two controllers included in a single unit, one for the traction motor with energy recovery and one for the pump motor.

– Optimum sensitivity to low speeds.

– High motor and battery efficiency due to high frequency commutation.

– Internal arc suppression of contactor coils.

– ARC less operation of contactors.

– Driving of a main contactor.

– Diagnosis with indication of the fault type via 2 LEDS. – Configuration by console.

– Modification of the parameters by console.

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

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

– Tester by console for real time checking of the main parameters such as inputs, motor voltage, battery, etc..

– Programming of the traction and pump potentiometer stroke.

– Regenerative braking both in inversion and at release.

– Traction and pump speed reductions with compensation for the dropping voltage.

– Conforms to 86/663 rules referring to the point 9.7.3.5.5 and 9.7.3.1.7.

– Conforms to DRAFT PREN 1175 rules referring to the point 5.9.3,5.9.4,5.9.5,5.13,5.14,5.15.

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1.4 DRIVING DEVICES 1.4.1 Microswitches Microswitches send a voltage signal when the request for start-up or the desired function is made. Microswitches for forward, reverse are sized for carrying the current of one contactor (3A).

1.4.2 Pedal and lifting potentiometer If the 3 - wire configuration is implemented; the CPOT (G2) useful input signal goes from 0V to 10V, while at the input CPOTS (L2) the signal goes from 0V to 5V. The resistive value of the potentiometer must be between 500W and 10 kW . Lower values overload the power supply.

Relationship between the voltage signal at the pin G2 and the motor voltage.

The procedure for automatic potentiometer signal acquisition is carried out from the console. This makes it possible to adjust the minimum and maximum useful signal of the pedal stroke and of the lifting potentiometer.

The procedure is described at the paragraphs 4.11.

The acquisition procedure is invalidated by the controller if the difference between the minimum and the maximum value is less than 1 V.

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1.5 THE CONCEPT OF COMPENSATION Compensation means that the voltage on the pump motor does not depend only on the position of the potentiometer or the fixed value but also on the current drawn by the controlled pump motor. Through the parameter "COMPENSATION" it is possible to choose how much this effect influences the lifting speed, that means how much the current absorbed can affect the voltage on the pump motor. In this way the rotational speed of the pump become almost constant, even though the load on the forks changes, allowing a good control of the speed independently of the load.

1.6 PROTECTION FEATURES - Battery Inversions: Respect the connections indicated in the diagrams in order to avoid damage to the power unit. Protection against battery polarity inversion can be achieved by an external main contactor. In lifting versions, it can be connected a main contactor controlled by the logic against battery polarity inversion. The logic is internally protected.

- Connections errors: All the inputs are protected against connections errors.

Contactors do not accept loads greater than 3A and are protected against overloads and short circuits.

- Thermal Protection: If the temperature exceeds 80° C the maximum current is reduced in proportion to the thermal increase. The temperature may never exceed 85° C. - Low Battery charge: When the battery charge is too low all functions except steering are cut off.

This feature may be excluded by the Console.

- External Agents: The controller is protected against dust and splashes (IP 54) It is completely enclosed.

- Protections against accidental start-up: A precise sequence of operations is necessary for starting the machine.

If these operations are not carried out correctly the machine will not start.

The request for running must be activated after the key and seat microswitches.

The pump will not start if there is a speed request present when they key is closed.

The steering is always activated.

- Protection against uncontrolled movements: The contactors do not close if: - the power unit potentiometer has failed; - the accelerator does not go below the minimum value stored increased by 2 Volt; - the logic is not perfectly operational; - one running microswitch is closed.

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1.7 GENERAL NOTES AND WARNINGS - Never combine SCR low frequency choppers with C1 modules. The filter capacitors contained in the C1 module alter SCR chopper operation, subjecting it to excessive workloads.

If it is required to use two or more control units (e.g. lift + traction), they must all be of the high frequency ZAPIMOS family.

- Do not connect the chopper to a battery with a different nominal voltage than that indicated on the chopper identification plate. A higher battery voltage can cause MOS failure. A lower battery voltage prevents the module from operating.

- During battery recharge, the C1 module must be completely disconnected from the battery. In addition to altering the charge read by the battery charger, the module can be damaged by the higher voltage generated by the charger, and by the ripple current generated in the capacitors if the battery charger operates at low frequency.

- The C1 module must only be supplied with a traction battery. Do not use outputs of converters or power supplys. For special applications, please consult the nearest ZAPI service centre.

- Start the machine the first time with the wheels raised, to ensure that connection errors do not create safety risks.

- With the key off, the filter capacitors inside the module may remain charged for several minutes.

For safe operation, we recommend that after the battery has been disconnected, short circuit the power positive and negative on the chopper for a few seconds with a resistance of between 10W and 100W , min 2W. - Susceptibility and the Electromagnetic emission are considerably influenced by the installation. Take particular care with the length, of the electrical connections and of the braided wires.

ZAPI declines any responsibility for incorrect operation that can be attributed to the above mentioned circumstances, above all if the manufacturer of the machine doesn't carry out the tests required by the regulations in force (conducted emissions, irradiated emissions, IEC 801 - 2 (ESD), IEC 801 - 3 (irradiated susceptibility), IEC 801 - 4 (burst), IEC 801 - 5 (surge), IEC - 6 (conducted immunity)).

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1.8 MAIN CONTACTOR AND SAFETY SWITCH WARNINGS FOR THE CONNECTION - Emergency disconnection my be achieved using one at the following: - With mechanical Safety Switch (Power):

- With switch and general contactor:

- One of these circuits is necessary to prevent controller failure when the connection to the battery is opened during the phase of regenerative braking. The controller falls out automatically from braking if the battery voltage is exceed by 30% of the battery nominal voltage.

1.9 SUSCEPTIBILITY AND ELECTROMAGNETIC EMISSION Susceptibility and electromagnetic emission are considerably influenced by the installation. Take care with the length and the path of the electrical connections and to the braided wires.

Zapi declines any responsibilities for badrunning caused by the circumstances above mentioned, above all if the manufacturer of the machine doesn’t carry out the tests required by the regulations in force (EN50081-2).

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2 INSTALLATION 2.1 POSITIONING AND THERMAL DISSIPATION 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 allow a good heat dissipation.

Despite the protection provided against external agents, the continuous presence of corrosive substances may cause the connector contacts to oxidise, thus jeopardising good operation.

Keep this in mind when choosing the installation position on the vehicle.

Use the special holes on the base-plate for fixing the chopper.

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

Fit 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, if the latter is not controlled by the chopper itself.

2.2 CONNECTION CABLES For the auxiliary circuits, use cables of 0,5 mm2.

For power connections to the motor and to the battery use cables of 35mm 2 - 50mm2.

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

2.3 CONTACTORS Choose the type of contactors with respect to the maximum operating current of the motor and the specific chopper configuration.

- The current drawn by the coil must not be greater than 3A. - The coil suppressors are inside the chopper. Do not use contactors with arc suppressors.

- For contactors with magnetic suppressors, ensure that the polarity indicated on the cap is respected.

- Protect the contacts against dust, dirt and, external agents which may jeopardise performance and good operation.

2.4 FUSES - Use a 10A fuse for auxiliary circuit protection.

- Use a 500A fuse for power unit protection.

The value shown is the maximum allowable. For special applications or requirements this value can be reduced.

For safety reasons, we recommend that protected fuses are used in order to prevent the spread of fused particles in the event of blowout.

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2.5 SUPPRESSION - Solenoid valves, contactors not controlled by chopper, horn and, any other kind of inductive loads shall have suppression devices connected in parallel.

Provided the arc suppresser consists of a diode, this is required to carry the same current as the coil.

- Examples: a) for pump contactor or relay.

R resistor value shall be about the same of coil resistance value; power level is to be computed as follows: V2 PW = 10R EXAMPLE: Calculate the correct value for an arc-suppresser of a contactor that has an 18W coil resistance, 24 V .

R Ω = 18Ω 24 2 576 = = 3.2W 10 ⋅18 10 ⋅ 18 therefore you will use a 18W /3W resistor.

PW =

b) Motor-horn: Combine a 10µF/100V capacitor in parallel to motor-horn contacts.

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2.6 C1 CONTROLLER MECHANICAL DRAWING

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3 C1 COMBI CONNECTORS 3.1 CONNECTORS DISPOSITION

pin A1 A2

function -LED +LED

B1 B2 B3 B4 B5 B6 B7 B8

PCLRXD NCLRXD PCLTXD NCLTXD GND +12 F.SELECT UP/DOWN

description Alarm LED negative: to be connected to the cathode Alarm LED positive: to be connected to the anode Output current 12mA, for standard type LED Serial reception positive Serial reception negative Serial transmission positive / pump alarm LED (anode) Serial transmission negative / pump alarm LED (cathode) Console supply negative Console supply positive Channel for mini - console Channel for mini - console

E1 E2 E3 E4 E5 E6 E7 E8 E9

+CH IN PT NTINDT NTIDR NTG NTI NTA PTFR NTFR

Input key that has to be connected to the feed return key.

Positive direction coil contactors.

Negative for weakening traction contactor Negative for hydrodrive contactor Negative for main contactor or state Negative for reverse contactor Negative for forward contactor Positive for braking contactor Negative for braking contactor

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F1 F2

MSED Seat microswitch input, active when high 4TH/RV1*/SLOW Carries out the same function of the input L9, it is connected with L9.

G1 G2

NPOTT CPOTT

G3 G4 G5

PPOTT ----CMM

G6 G7 G8

MF MI MA

Negative potentiometer is Battery negative Central potentiometer, it must be connected with the wiper of the accelerator potentiometer for the regulation of the traction motor speed.The useful signal goes form 0 Volt (minimum speed) to 10 Volt (maximum speed).

Positive potentiometer of the accelerator is 13V output.

Not used Common running microswitches, is a voltage output with battery potential (max 3A) Brake microswitch input is high level active (+VB) Reverse running microswitch input is high level active (+VB) Forward running microswitch input is high level active (+VB)

H1 H2 H3

----St. REC. PT AUX

Not used Output regenerative state for battery level indicator Positive for auxiliary load (max. 2A)

L1 L2 L3 L4 L5 L6 L7 L8 L9

NPOTS CPOTS -BATT PPOTS ABP 1ST 2ND 3RD/RV2*/HYD 4TH/RV1*/SLOW

Negative for lifting potentiometer Input for lifting potentiometer (range 0 ÷ 5V) Negative for common speed request micro Positive for lifting potentiometer (8,2V) Input for potentiometer enable request 1st pump speed 2nd pump speed 3rd pump speed / cutback speed n°2 / hydrodrive request 4th pump speed / cutback speed n° 1 associated to the braking in curve / pump speed reduction.

* = Connect these inputs to the normally closed contacts when they are used as (CUT BACK SPEED).

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3.2 C1 COMBI POWER CONNECTORS DESCRIPTION

+SH T - SH T +SH P - SH P

Input for traction motor current sensor Output for traction motor current sensor Input for pump motor current sensor Output for pump motor current sensor

VMN P +B -B VMN T

Power drive of pump motor Positive of the battery Negative of the battery Power drive of the traction motor

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4 PROGRAMMING AND SETTINGS USING A CONSOLE 4.1 SETTING BY CONSOLE Adjustments of the parameters and the configurations are to be carried out by the programmable Console. The Console is connected to the relative connector B. The connection is to be carried out with the key sw. open or the battery disconnected.

Pay attention to the connector polarity of the console when it is connected to the controller.

4.2 PROGRAMMABLE CONSOLE

The Console to be connected to the controller C1 is to be equipped with the EPROM CONSOLE starting from “release 2.00”.

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4.3 MAP OF THE CONSOLE FUNCTIONS

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4.4 OPTIONS: DESCRIPTIONS AND PROGRAMMING INSTRUCTIONS Configuration of the options (menu SET OPTIONS) allow selection of the operating mode of some inputs and outputs and the operating management as follows: BATTERY CHECK:

ANTIROLLBACK:

RELEASE BRAKING:

HOUR COUNTER:

ON=

The logic reading battery voltage and state of change is enabled.

When the charge is less than 10%, the traction maximum current is halved, the pump functions are disabled except the power steering.

OFF=

Management of the discharged battery alarm is disabled.

ON=

Antirollback management enabled.

OFF=

Antirollback management disabled.

ON=

Braking upon release of the running pedal (RELEASE BRAKING) is enabled.

OFF=

At the release of the running pedal the truck continues without release braking.

KEYON=

The hourmeter is always operational when the logic unit is supplied.

RUNNING= The hourmeter is activated only under the following conditions: traction running, braking, pump, power steering.

MAIN CONTACTOR:

CUTBACK INPUT #1:

PRESENT= The output E5 (NTG) is ready for the control of the main contactor. It needs to connect a resistance for the capacitors charge, see the following wiring diagrams.

NONE=

The output E5 (NTG) is disabled.

ON=

The input L9 is programmed as cutback speed request (RV1) of the traction adjustable with the parameter CUTBACK SPEED 1 (the cutback speed is activated when the microswitch is open).

OFF=

The input L9 is programmed as cutback speed request of the pump (4TH) adjustable with the parameter 4TH SPEED. The cutback speed is accepted when the microswitch is closed to battery negative.

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SLOW LIFT INPUT:

ON=

The input L9 is programmed as cutback speed of the pump set by the potentiometer, the speed is reduced to the value programmable with the parameter SLOW LIFT SPEED.

OFF=

The input L9 is accepted for working in the way defined by the option CUTBACK INPUT #1.

CUTBACK INPUT #2: ON=

HYDRO INPUT:

PUMP MODE:

OFF=

The input L8 is programmed as cutback speed request of the pump (3TH) adjustable with the parameter 3RD SPEED. The cutback speed is accepted when the microswitch is closed to battery negative.

ON=

The input L8 is programmed as power steering request from an external drive, the power steering function is activated only by this input when the microswitch is closed battery negative .

OFF=

The input L8 can work in the way defined by option CUTBACK INPUT #2.

STAND PUMP= Programme this way if there is a single motor for lifting and power steering.

PUMP+HYD=

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The input L8 is programmed as cutback speed request (RV2) of the traction adjustable with the parameter CUTBACK SPEED 2 (the cutback speed is activated when the microswitch is open).

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Programme this way when the power steering is activated by a third motor, so the power steering function works only on the output E4 (NTIDR) for activating a contactor.

Programming "options", using the console: 1) Opening Display 2) Press ROLL UP + SET UP to simultaneously enter the menu SET. 3) Headline of the menu SEL MODEL. 4) Press ROLL UP to select the menu SET OPTIONS.

5) Headline of the menu SEL OPTIONS. 6) Press ENTER to entering in the menu.

7) The first item of the menu appears.

8) Press ROLL UP or ROLL DOWN to scroll the different items.

9) A new item appears.

10) Press SET UP or SET DOWN to modify the configuration.

11) The new configuration appears.

12) Press OUT to come out of the menu.

13) Confirmation of the modification request appears.

14) Press ENTER to confirm the modifications or press OUT to cancel.

15) Headline of the menu SEL OPTIONS appears.

16) Press OUT to return back to the opening display.

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4.5 ADJUSTMENT: DESCRIPTION AND PROGRAMMING INSTRUCTIONS 4.5.1 Lifting potentiometer acquisition This function allows to carry out the acquisition of the minimum and maximum values of the lifting potentiometer output.

ADJUSTMENT operations with the console: 1) Opening display.

2) Press ROLL UP + SETUP to enter the menu CONFIG. 3) Headline of the menu SET MODEL (function not available) appears.

4) Press ROLL UP to select the menu ADJUSTMENT. 5) Headline of the menu ADJUSTMENT appears.

6) Press ENTER to enter in the menu.

7) The first item of the menu set LIFT MIN appears.

8) Press ENTER to enable the acquisition.

9) Push the lifting lever up to the closure of the microswitch (minimum voltage value).

10) While the lever is in this position press OUT. 11) Request for the confirmation appears.

12) Press ENTER to confirm the acquisition or OUT to cancel it.

13) Headline of the menu adjustments appears.

14) Press ROLL UP to select the next menu.

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15) SET LIFT MAX appears.

16) Press ENTER to enable the acquisition.

17) Push the lifting lever up to the end of its stroke (maximum voltage value).

18) While the lever is at the end-of-stroke, press OUT. 19) Request for the confirmation appears.

20) Press ENTER to confirm the acquisition or OUT to cancel it.

21) Headline of the menu.

22) Press OUT to return to the main menu.

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4.5.2 Set battery voltage This function allows fine settings of the internal measurement of the battery voltage if it is too high the voltage dropout to the key is disabled. This setting operation requires the same measurement values, read in the console to be the same as measured on the battery.

ADJUSTMENT operations with the console: 1) Opening display.

2) Press ROLL UP + SETUP to enter the menu CONFIG. 3) Headline of the menu SEL MODEL (function not available) appears.

4) Press ROLL UP to select the menu ADJUSTMENT. 5) Headline of the menu ADJUSTMENT appears.

6) Press ENTER to enter in the menu.

7) The first item of the menu (only ADJUSTMENT BATTERY is available) appears.

8) The button SETUP increases the value shown on the display, the button SET DOWN decreases it.

Set to the same value as measured on the battery with a multimeter.

9) Press OUT to come out from the menu.

10) Confirmation of the request for modifications appears.

11) Press ENTER to confirm the modifications or OUT to cancel them.

12) Headline of the menu ADJUSTMENTS appears.

13) Press OUT to return to the opening display.

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4.6 PARAMETERS: DESCRIPTION OF THE PROGRAMMING INSTRUCTIONS The Controllers adjustment parameter levels are carried out in the menu PARAMETERS CHANGE. For each parameter 10 adjustment levels are available (9 for the pump speeds).

The traction parameters are indicated with the symbol T. The pump parameters have the symbol P. 1)

ACCELER DELAY (t) = acceleration time, that is the minimum time during which the motor voltage comes from 0V to the maximum value.

9)

CUTBACK SP.1 (t) = speed reduction RV1 associated to the input L9 and F2. The accelerator is reduced and put on scale. The parameter can be activated if the option CUTBACK INPUT #1 is programmed ON.

3)

CUTBACK SP.2 (t) = speed reduction RV2 associated to the input L8. The parameter can be activated if the option CUTBACK INPUT #2 is programmed ON.

4)

BRAKE CUTBACK (t) = speed reduction level applied when the braking pedal is pressed and accelerator is not released.

5)

TRACTION IMAX (t) = defines the maximum current of the traction controller both during running and braking.

All the adjustments of current are defined in percentage of this value. The adjustment range is from 50% (level 0) to 100% (level 9).

6)

INVERSION BRAKING (t) = braking base current at running inversion.

Added to a value in response to the accelerator, plus a fixed increment each second.

7)

RELEASE BRAKING (t) = braking current at pedal or running release.

8)

PEDAL BRAKING (t) = braking current at running release with braking pedal pressed (pin G6 activated).

9)

HYDRO TIME (p) = delay time for the power steering drop out.

10) WEAK DROPOUT (t) = current threshold for the opening of the weakening contactor.

11) CREEP SPEED (t) = this defines the minimum voltage applied to the motor with the running request on. This allows a more prompt response when starting.

12) PLUG CURRENT (t) = braking current when the controller is braking in plugging mode (only for emergency brakings, when the regenerative braking does not trigger off).

13) BRAKING MODUL (t) = defines the entity of the accelerator for increasing of braking current during inversion.

Pressed completely, during inversion, the braking becomes as stronger when the accelerator is as the higher the value of the parameter.

14) COMPENSATION (t) = speed compensation (motor voltage) in association to the current when speed reductions are activated. It is activated only with the pedal pressed more than 80%.

15) PU. ACCELER DELAY (P) = pump motor acceleration time.

16) PU. DECELER DELAY (p) = deceleration time, for cancelling the voltage on the motor at release.

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17) PUMP IMAX (p) = defines the maximum current of the pump controller. All the adjustment of the pump are defined in percentage of this value. The adjustment range is from 50% (level 0) to 100% (level 9).

18) SLOW LIFT SPEED (p) = pump speed reduction set by the potentiometer, the speed is put on scale for the programmed coefficient. The function is activated only when the option SLOW LIFT OPTION is selected ON. 19) HYD SPEED COARSE (p) = coarse power steering speed (from 0% to 100% Vbatt on the motor). The parameter is activated if the option PUMP MODE is programmed STANDARD PUMP. 20) HYD SPEED FINE (p) = fine power steering speed (it is added a value from 0% to 10% Vbatt to the coarse speed). The parameter is activated if the option PUMP MODE is programmed STANDARD PUMP. 21) HYDRO COMPENS (p) = compensation for power steering. The parameter is activated if the option PUMP MODE is programmed STANDARD PUMP. 22) 4TH SPEED COARSE (p) = n° 4 pump speed coarse regulation. The parameter is activated if the option CUTBACK INPUT #1 is programmed OFF. 23) 4TH SPEED FINE (p) = n° 4 pump speed fine regulation. The parameter is activated if the option CUTBACK INPUT #1 is programmed OFF. 24) 4TH SPEED COMP. (p) = n° 4 pump speed compensation. The parameter is activated if the option CUTBACK INPUT #1 is programmed OFF. 25) 3RD SPEED COARSE (p) = n° 3 pump speed coarse regulation. The parameter is activated if the option CUTBACK INPUT #2 is programmed OFF. 26) 3RD SPEED FINE (p) = n° 3 pump speed fine regulation. The parameter is activated if the option CUTBACK INPUT #2 is programmed OFF. 27) 3RD SPEED COMP. (p) = n° 3 pump speed compensation. The parameter is activated if the option CUTBACK INPUT #2 is programmed OFF. 28) 2ND SPEED COARSE (p) = n° 2 pump speed coarse regulation.

29) 2ND SPEED FINE (p) = n° 2 pump speed fine regulation.

30) 2ND SPEED COMP. (p) = n° 2 pump speed compensation.

31) 1ST SPEED COARSE (p) = n° 1 pump speed coarse regulation.

32) 1ST SPEED FINE (p) = n° 1 pump speed fine regulation.

33) 1ST SPEED COMP. (p) = n° 1 pump speed compensation.

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4.6.1 C1 Adjustment chart

PARAMETERS

PROGRAMMED LEVEL UNIT

0

1

2

3

4

5

6

7

8

9

sec.

0.9

0.9

1

1.1

1.3

1.5

1.7

1.9

2.1

2.3

CUTBACK SPEED 1 E 2

%

20

28

36

45

53

62

69

78

86

100

BRAKE CUTBACK

%

20

28

36

45

53

62

67

78

86

100

TRACTION IMAX (24V)

Amp.

200

222

244

266

288

310

332

354

376

400

TRACTION IMAX (36 / 48V)

Amp.

175

194

213

233

252

271

290

310

329

350

INVERS. BRAKING

%IMax.

15

18

22

25

28

32

35

38

42

45

RELEASE BRAKING

%IMax.

15

19

23

27

31

36

38

42

46

50

PEDAL BRAKING

%IMax.

15

19

23

27

31

36

38

42

46

50

sec.

0

0.5

2

4

7

9

12

14

17

20

WEAK DROPOUT

%IMax.

10

20

30

40

50

60

70

80

90

100

CREEP SPEED

%VBatt

0

1.9

3.9

5.9

7.8

9.8

12

14

16

18

PLUG CURRENT

%IMax.

10

20

30

40

50

60

70

80

90

100

BRAKING MODUL

%IMax.

0

3

5

8

11

14

17

20

22

25

COMPENSATION

K (I)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

PU ACCELER DEL

sec.

0.15 0.24 0.39 0.50 0.63 0.74 0.86 0.97

1.1

1.2

PU. DECELER DEL

sec.

0.06 0.13 0.19 0.25

0.31 0.38 0.44 0.50 0.56 0.62

PUMP IMAX

Amp.

175

194

213

233

252

271

290

310

329

350

%

2

4

8

10

15

20

25

30

40

50

HYDRO 1/2/3/4 SPEED COARSE

%Vbatt

0

11

22

33

44

55

66

77

88

100

HYDRO 1/2/3/4 SPEED FINE

%VBatt

0

1.2

2.4

3.6

4.8

6

7.3

8.5

9.7

10.9

K (I)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

ACCELER. DELAY

HYDRO TIME

SLOW LIFT SPEED

HYDRO 1/2/3/4 SPEED COMP.

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How make the programming operations with the console: 1) Opening display.

2) Press ENTER to enter the main menu .

3) The headline of the first item, PARAMETER CHANGE appears.

4) Press ENTER to enter to the function PARAMETERS. 5) The first parameter of the list appears.

6) Scroll the list of the parameters with the buttons ROLL UP and ROLL DOWN. 7) The item of the parameters appear.

8) Change the programmed level with the buttons SET UP and SET DOWN. 9) The new value adjusted appears.

10) Press OUT when programming is finished.

11) The confirmation request appears.

12) Press ENTER to confirm the modifications or OUT to cancel.

13) The headline of the item PARAMETER CHANGE appears.

14) Press ROLL UP or ROLL DOWN for scrolling the other items, or press OUT for coming back to the opening display.

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4.7 TESTER: FUNCTIONS DESCRIPTION Some of the most important input/output signals can be measured in real time using the tester function of the console. Here are the hems and their meanings: TRACTION VMN:

Is the value of the voltage measured between B-'ve and the terminal VMNT; 3 voltage ranges are available: 0% = from 0% to 22% of the battery voltage; 50% = from 22% to 70% of the battery voltage; 100% = from 70% to 100% of the battery voltage.

PUMP VMN:

Is the value of the voltage measured between B-'ve and the terminal VMNP; 3 voltage ranges are available: 0% = from 0% to 22% of the battery voltage; 50% = from 22% to 70% of the battery voltage; 100% = from 70% to 100% of the battery voltage.

TR V. MOTOR PU:

Is the voltage applied to the motors measured between the terminals -SHT and VMNT for the traction and between the terminals -SHP and VMNP for the pump. The value TR is the traction motor voltage; the value PU is the pump motor voltage. All the values are in Volts.

TR I. MOTOR PU:

Is the current drawn by the motors measured between the terminals -SHT and VMNT for the traction and between the terminals -SHP and VMNP for the pump. The value TR is the traction motor current and the value PU is the pump motor current. All the values are in Amps.

BATTERY VOLTAGE:

Is the battery voltage on the input CH pin E1. Capacity = 60V; resolution = 0,3V; accuracy = ± 1,5%.

TEMPERATURE:

Is the temperature of the aluminium baseplate close to the MOSFET devices. Range = -27°C ÷ 100°C; resolution = 1°C; accuracy = ± 1°C.

ACCELERATOR:

Is the voltage of the traction accelerator signal on the input CPOT pin G2, range 0V ÷ 10V, resolution 0,04V, accuracy = ± 1%. The voltage value is on the left side of the display whilst on the right there is the percentage value of the signal relative to the function PROGRAM VACC.

LIFTING CONTROL:

Is the voltage of the pump accelerator signal on the input CPOTS pin L2.The voltage value is on the left side of the display whilst on the right there is the percentage value of the signal relative to the function PROGRAM VACC. Range 0V ÷ 5V, resolution 0,02V, accuracy = ± 1%.

FORWARD SWITCH:

Is the state of the forward running digital input, MA pin G8.ON ), input active, voltage on the connector. / +VB = ( ), input in stand-by, connector OFF / GND = ( free.

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BACKWARD SWITCH: Is the state of the reverse running digital input, MI pin G7. ON ), input active, voltage on the connector. / +VB = ( OFF / GND = ( ), input in stand-by, connector free.

CUT BACK SWITCH 1: Is the state of the cutback speed 1 digital input (RV1 pin L9).

The tester of the function is activated when the option CUTBACK INPUT #1 is programmed ON. ), input in stand-by, connector to OFF / GND = ( battery negative.

ON / +12 = ( ), input active, connector free.

CUT BACK SWITCH 2: Is the state of the cutback speed 2 digital input (RV2 pin L8).

The tester of the function is activated when the option CUTBACK INPUT #2 is programmed ON. OFF / GND = ( ), input in stand-by, connector to battery negative.

ON / +12 = ( ), input active, connector free.

BRAKE SWITCH:

Is the state of the braking pedal digital input, FR pin G6. ), input active, voltage on the conON / +VB = ( nector. OFF / GND = ( ), input in stand-by, connector free.

SEAT SWITCH:

Is the state of the digital input from the seat microswitch, MSED pin F1. ON / +VB = ( ), input active, voltage on the connector.

OFF / GND = ( ), input in stand-by, connector free.

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How to enter the TESTER function of the console: 1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select TESTER. 5) The selected item (TESTER) appears.

6) Press ENTER to enter the function TESTER. 7) The first signal tested appears.

8) Scroll the signals tested with the buttons ROLL UP and ROLL DOWN. 9) The following signal appears.

10) Press OUT to return to the item list.

11) The selected item appears.

12) Press ROLL UP and ROLL DOWN for scrolling the remaining items, or press OUT to return to the opening display.

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4.8 SAVE PARAMETERS: DESCRIPTION The function SAVE PARAM. allows loading on the console memory parameter values and the controller configuration data. It is possible to load max 64 configurations.

The data stored on the console memory can be loaded again on another controller by means of the function RESTORE (par. 4.9).

Data loaded with the function SAVE is: - all the parameters values (PARAMETERS CHANGE); - the settings of the options (SET. OPTION); - the setting of the battery (ADJUST BATTERY).

How to enter the SAVE function by the console: 1) Opening Display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select SAVE PARAM. 5) The selected item (SAVE PARAM.) appears.

6) Press ENTER to enter the SAVE function.

7) In the first line the model code selected, appears in the second line it appears FREE if the memory box is free or the name of the model if it is busy.

8) Select the model code with the buttons ROLL UP and ROLL DOWN. 9) The new model code selected and its condition (FREE/BUSY) appears.

10) Press ENTER to confirm the reading operation.

11) On the second line the items of the parameters stored scroll.

12) At the end of the operation it returns to the main menu SAVE PARAM.

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4.9 RESTORE PARAMETERS: DESCRIPTION The function RESTORE PARAM allows transfer of data stored in the console memory to the controller in the same way of the model loaded with the function SAVE PARAM. Data loaded in the controller by means of the function RESTORE PARAM. is: - all the parameters values (PARAMETERS CHANGE); - the settings of the option (SET. OPTION); - the setting of the battery (ADJUST BATTERY).

ATTENTION:

the function RESTORE overwrites all the data of the controller.

After this operation, old configuration data is cancelled.

How to enter in the RESTORE function by the console: 1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select RESTORE PARAM. 5) The selected item (RESTORE PARAM.) appears.

6) Press ENTER to enter the function RESTORE PARAM. 7) In the first line the model code selected appears and in the second line the type of controller stored in the memory appears.

8) Select the model code with the buttons ROLL UP and ROLL DOWN. 9) The model code selected and the type of controller stored appears.

10) Press ENTER to confirm the loading operation.

11) The confirmation request for the operation appears (ENTER = YES, OUT = NO).

12) Press ENTER to confirm the loading operation (OUT for cancelling).

13) The list of the parameter items during the loading phase appears.

14) At the end of the operation it returns to the main menu RESTORE PARAM.

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4.10 ALARMS: MENU DESCRIPTION The controllers stores the last five alarms, recording the following information: alarm code; how many times this is occurred; the temperature and the hourmeter value in the occurrence of the alarm. In the menu ALARMS of the console, it is possible to enter in this data memory.

This function allows a deeper diagnosis, knowing the sequence of the alarms occurred.

How to enter the menu ALARMS. 1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select ALARMS. 5) The selected item (ALARMS) appears.

6) Press ENTER to enter the function ALARMS. 7) The first alarm occurred with the number of times, hourmeter and temperature, appears.

8) The button ROLL UP scrolls the previous alarms, the button ROLL DOWN returns to the more recent.

9) If there were no other alarms, ALARM NULL appears.

10) Press OUT to leave the menu ALARMS. 11) The confirmation request for cancelling all the alarms stored, appears.

12) Press ENTER to confirm the operation (OUT for returning to the main menu).

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4.11 PROGRAM VACC: DESCRIPTION This function allows storing of the minimum and maximum values for the accelerator signal in each running direction. This is necessary to compensate for the asymmetry in the mechanical operation of the potentiometer.

This operation is made using the pedal. After entering the menu PROGRAM VACC, the following the operations are described below.

How to enter in the menu PROGRAM VACC and carry out the operations: 1) Opening display.

2) Press ENTER to enter in the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN. Select PROGRAM VACC. 5) The selected item (PROGRAM VACC) appears.

6) Press ENTER to enter the function PROGRAM VACC. 7) The maximum current values matched to the forward and backward running appears.

8) Press ENTER. 9) The controller is now ready to record the minimum and the maximum value of the potentiometer signal.

10) Press the pedal. Move slowly at the start and complete the stroke.

N.B. : select the direction before pressing the pedal.

11) The new maximum and minimum values for each running direction appears.

The arrow indicates the direction selected.

12) Press OUT. 13) The confirmation request for storing new values appears.

14) Press ENTER to confirm or OUT to cancel.

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4.12 INSTRUCTIONS FOR MAKING ADJUSTMENTS With the machine switched off, connect the programming console and then switch on. If no errors are found, the display shows the manufacturer's name, program release, configuration, and hourmeter value.

4.12.1 Traction adjustment sequence 1) Select the desired options.

2) Select and set battery voltage.

3) Check the operation of all the wired inputs, including the potentiometer, by means of the tester functions on the console.

4) Carry out accelerator signal acquisition on the “PROGRAM VACC” menu.

5) Set the maximum current by selecting the level corresponding to the desired value shown on the table of modifications (point 5.1.4 and 5.2.4).

6) Set acceleration by moving the machine forward and backward.

7) Set the CREEP speed starting from level 0. With the machine stopped, press the pedal lightly in order to close the direction microswitch, leaving the potentiometer at the minimum value, and then raise the level of the CREEP until the machine begins to move.

8) To set the speed reductions, activate the desired reduction request microswitch, take the compensation level to 0, set the speed (CUTBACK SP.l, etc.) with machine in standby on a flat surface and the accelerator pedal pressed all the way down.

Then, apply a load on the machine or put it on a slope. In these conditions set the compensation level until you reach the desired speed.

9) RELEASE BRAKING is set by running the machine and then completely releasing the accelerator pedal without pressing other pedals.

10) For INVERSION BRAKING, first set the MODUL BRAKING level at 0, run the machine and invert the direction with the pedal pressed down, then regulate the braking level.

11) MODUL BRAKING with accelerator. A parameter that increases the inversion braking according to the level of the accelerator signal; set this by inverting the direction with the pedal pressed all the way down.

12) Release braking with brake pressed (PEDAL BRAKING). Set by pressing the brake pedal lightly during release.

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4.12.2 Pump adjustment sequence 1) Select and set battery voltage.

2) Check the operation of all the wired inputs, including the potentiometer, by means of the tester functions on the console.

3) Carry out accelerator signal acquisition on the “PROGRAM VACC” menu.

4) Set the maximum current by selecting the level corresponding to the desired value.

5) Set the speed of the respective functions with the machine in standby, and the level of compensation set at “0”. Apply a load and set the compensation until it reaches the desired speed.

The adjustment of speed and compensation are interdependent. Therefore further adjustments must be made before reaching the optimum condition.

6) Set the hydrodrive speed in the same way as the others. The only difference being that the speed is set with the steering in standby, while the compensation is set with the steering is under load.

7) Set acceleration, deceleration, and creep as necessary.

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5 DIAGNOSIS 5.1 TRACTION LED DIAGNOSIS Description of the alarms signalled by the diagnostic LED. The alarm code is shown in parentheses. A detailed description is given in the section “DECODING THE ALARMS DISPLAYED ON CONSOLE” on point 5.5.

1 FLASH = Logic Anomaly (EEPROM KO, WATCH DOG).

2 FLASHES

=

Running request on startup or error in handle/speeds sequence (INCORRECT START).

3 FLASHES

=

Error on VMNT test (NO FULL CONDUCTION, VMN LOW, CAPACITOR CHARGE).

4 FLASHES

=

Accelerator high in standby - this error inhibits operation (VACC NOT OK).

5 FLASHES

=

Error in reading current - this error inhibits operation (I HIGH AT STAND, I=0 EVER).

6 FLASHES

=

Malfunction of the contactor driver circuit (DRIVER SHORTED, COIL SHORTED).

7 FLASHES

=

Excessive temperature, greater than 80°C (TH. PROTECTION).

8 FLASHES

=

Contactors do not open or VMN high in standby (BRAKE CONT. OPEN, DIR CONT. OPEN, VMN HIGH).

9 FLASHES

=

Contactor failure (BRAKE CON CLOSED, DIR CONT CLOSED).

CONTINUOUS FLASHING (32 FLASHES) =

Low battery charge, battery with <10% of residual charge (BATTERY).

LED REMAINS ON = Double running request (FORW BACK).

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5.2 DECODING CONSOLE DISPLAYED TRACTION ALARMS 1)

BRAKE CON CLOSED Test carried out in the transition to running state or when starting the regenerative braking. When a direction contactor closes, if the VMNT is > 2/3 VBATT, an alarm is issued. Possible causes are: a) The normally open contact of the braking contactor has failed or welded. Free the contact and clean it: if it is damaged replace the contactor. b) The braking contactor remains closed to much, due to a detect in the logic board or because the NTFR wire is in shorted to b-'ve.

To understand if the defect is produced by one of these causes, select a direction, press the pedal without giving the seat or tiller request, if the operation of the braking contactor occours at the same time as the pedal (or selector) command verify what follows: disconnect the wire from the NTFR connector and repeat the test above. If the contactor remains disactivated replace the logic, otherwise if the contactor moves check that there is not a short circuit with some metallic part.

2) DIR. CONT. OPEN Test carried out at running request: direction contactor closure is verified by checking that the VMN signal is consistent. a) To find the causes follow the diagnosis procedure below: CONDITION UNDER WHICH FAULT IS DETECTED

TEST

ONLY AT FORWARD RUNNING REQUEST

YOU SEE FORWARD CONTACTOR (TA) CLOSING FOR 0.3sec. THEN OPENING?

ONLY AT BACKWARD RUNNING REQUEST

AT BOTH RUNNING REQUEST

YOU SEE BACKWARD CONTACTOR (TI) CLOSING FOR 0.3sec. THEN OPENING?

YOU SEE FORWARD OR BACKWARD CONTACTOR (TA OR TI) CLOSING FOR 0.3sec.

THEN OPENING

TEST

RESULT

FAULT DESCRIPTION AT POINT:

YES

→

→

A1

YES

B1

NO

WHEN REQUESTING FORWARD RUNNING YOU FIND ANY VOLTAGE AT COIL CONTACTS FOR 0.3 sec.?

NO

C1

→

A2

YES

B2

NO

C2

→

A3

YES

B3

NO

C3

RESULT

YES

→

NO

WHEN REQUESTING BACKWARD RUNNING YOU FIND ANY VOLTAGE AT COIL CONTACTS FOR 0.3sec.?

YES

→

NO

WHEN REQUESTING FORWARD RUNNING YOU FIND ANY VOLTAGE AT TA COIL'S CONTACTS (OR AT BACKWARD CONTACTOR COIL'S CONTACTS (BTI)) FOR 0.3sec.?

A1) There is not a good contact either on TA (=forward contactor) NA (normally open) or on TI (=backward contactor) NC (normally closed), due to dust, dirt or any particles which prevent a valid contact.

Clean contacts by means of compressed air; if necessary remove dirt applying a soft abrasive movement.

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It may be necessary to change both contactors.

A2) There is not a good contact either on TI NA or on TA NC, due to dust, dirt or any particles.

Clean contacts by means of compressed air; if necessary remove dirt applying a soft abrasive movement.

It may be necessary to change both contactors.

A3) The most likely reason is that the normally closed contact of the braking contactor doesn’t make good contact Battery Negative. This dust, may be due to dirt or because the contact doesn’t close completely due to an internal mechanical defect.

It may be necessary to replace the contactor.

Due to 1 of following causes: a) Open circuit brushes (fig.1). b) Burning of brush cables (fig.2). c) B-'ve missing on regen contactor (fig. 3) d) Open circuit motor or cables.

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B1) Forward contactor (TA) supplied with correct voltage but it does not close.

Possible causes: 1) Contactor coil is open circuit, verify its resistance using an ohmmeter.

2) Mechanical restriction.

3) Incorrect coil voltage.

B2) Reverse contactor (TI) is supplied with a correct voltage but it does not close; everything relative to point B1 for TA is valid here.

B3) Reverse and forward contactors are supplied with correct voltage but do not close; see point B1.

C1) Supply is not present on TA. Check cables and connections from TA coil to connectors E2 (PT) and E7 (NTA).

C2) Supply is not present on TI. Check cables and connections from TI coil to connectors E2 (PT) and E6 (NTI).

C3) Supply is not present on TA and TI. Check cables and connections from the coils to connectors E2 (PT), E6 (NTA) and E7 (NTI).

- For points C1, C2, C3 replacement controller of the may be necessary.

3)

BRAKE CONT. OPEN. (regenerative only) Test carried out during the passage to running state. After closure of the running contact, the braking contactor closes, verifying that the VMNT goes from < 1/3 to > 2/3. Not, an alarm is shown.

To find the cause follow the diagnosis procedure below:

TEST

RESULT

2° TEST

RESULT

3° TEST

YES

→

→

→

FAULT RESULT DESCRIPTION AT POINT A4 → A5 YES

AT RUNNING REQUEST THE TFR CLOSES FOR 0.3sec?

NO

WHEN THERE'S THE RUNNING REQUEST, IS THERE A VOLTAGE AT PIN BTFR FOR A TIME OF 0.3sec?

YES

CHECK WITH AN OHMMETER OF THE TFR COIL IS INTERRUPTED

B4 B5

NO B6

NO

→

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→

C4

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A4) There is not good contact on the NA of TFR. Clean the contact, if it is damaged too much, replace the contactor.

A5) Positive is missing on the braking contactor.

B4) Replace the contactor coil or the complete contactor.

B5) Contactor mechanically locked, Rectify or replace.

B6) Contactor has incorrect coil fitted. Fit correct coil.

C4) Supply does not appear at the contactor coil. Check the cables and the connections from the coil to the connector E8 (PTFR) and E9 (NTFR). If there are no errors in the cables, there may be failures in the electronic board. In this case it is necessary to replace the logic.

4) DIR. CON. CLOSED The running contactor remains closed (locked).

Test carried out during the passage to standby or braking. Check that the running contactor opens by comparing the consistent status of the VMNT potential. Possible causes: a) Running contactor locked or slow to open; b) Logic failure.

5) VMN LOW. The test is carried out at standby and in running up to 80% of PWM. If the VMNT voltage is lower than 1/3 of the battery voltage, an alarm is shown.

To find the causes follow the diagnosis procedure following:

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CONDITIONS UNDER WHICH FAULTS IS DETECTED

1° TEST

AT THE KEY ON

DISCONNECT THE MOTOR CABLE CONNECTED TO THE BATTERY AND THEN VERIFY IF THE ALARM STILL PRESENT

RUNNING WITH CONTACTORS ON RUNNING POSITIONS

→

AS SOON AS THE ACCELERATOR IS IT PRESENT THE PEDAL IS BYPASS OR THE COMPLETLY WEAKENING RELEASED FOR CONTACTOR? DOING A RELEASE BRAKING

FAULT RESULT DESCRIPTION POINT:

RESULT

2° TEST

RESULT

3° TEST

YES

→

→

→

→

C5 B7

YES

NO

THE LOCKED CONTACTOR COIL IS SUPPLIED?

YES

A RUNNING CONTACTOR IS LOCKED IN WORKING POSITION

NO

B8 D1 D2 D3

NO

→

→

→

→

→

C5

YES

→

→

→

→

E1

NO

→

→

→

→

C5

B7) If the running contactor remains locked, verify: 1) if the wire going from NTA to NTI is sometimes shorted to a metallic part connected to the battery negative; 2) disconnecting the contactor wire always excited from board connector if the contactor is no longer excited, replace the logic board.

B8) A direction contactor is locked in the working position, unlock the contact. It may be necessary to replace the contactor.

D1) Incorrect connection of the motor cables. The stator and the armature are crossed.

D2)

There is a current leakage in the motor between the stator winding and the armature. Otherwise there are some electric parts of the windings that make contact inside the motor.

D3)

Check that there are no metallic parts inside the contactor board that cause a short toward negative in the points connected to -SHT and +SHT.

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C5)

The most likely reason is that the failure is inside the controller. Replace it.

E1)

If there is a bypass contactor check that it is not locked or it is too slow in opening. To verifying this possibility, disconnect the bypass and check if the failure disappears: if this happens, replace the logic.

ATTENTION: the contactors connected to the controller must not have arc suppressers fitted on the contactor coils. These are internally connected to the controller. Any external suppression will modify the contactor opening times.

6) VMN HIGH. Test carried out in standby. If the VMN voltage is greater than 2/3 VBATT, an alarm is shown. Possible causes: a) Short circuit between +BATT and VMN. Check if there are any metallic parts causing short circuit in the contactor board. b) The traction motor cable could have been crossed with a pump motor cable. c) Logic failure, probably the braking diode has failed. Replace the power block.

7) NO FULL COND. The test is carried out in full conduction. If, in this condition, the VMN is found to be greater than 1/3 VBATT, the diagnostic circuit is faulty, causing a safety risk, thus machine operation is inhibited. If the defect persists, replace the logic.

8) HIGH TEMPERATURE An indication that the controller temperature has exceeded 80° C. The maximum current is gradually reduced, reaching 0 at a temperature of 85° C. a) If the alarms occurs while cold, the most probably reason is the failure of the thermal circuit on the power, or on the logic board, replace as appropriate or replace the complete controller. b) If the alarm occurs after short time after the machine has been working, it is probably due to inadequate heat sink. Check the retaining fixing nuts and the correct installation.

9) BATTERY The battery charge is low.

The alarm is signalled only if the “battery check” option has been selected from the console (default). When this alarm occurs, the maximum current is reduced to 50%.

10) INCORRECT START An incorrect starting sequence.

The machine only starts if the following sequence is made: key-handle (or seat) running. Possible causes: a) Direction microswitch or handle microswitch failure. b) Error in sequence made by the operator, pedal pressed at the key on. c) Incorrect wiring. If there are no defects externally, it may be necessary to replace the logic.

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11) FORW - BACK The test is carried out continuously. An alarm is signalled when two requests for running are made simultaneously. Possible causes: a) Defective wiring. b) Running microswitch closed or failed. c) Incorrect manoeuvre. d) If there are no external defects, replace the logic.

12) VACC NOT OK The test is made in standby.

The alarm indicates that the accelerator voltage is greater than 1V with respect to the minimum value stored. Possible causes: a) A potentiometer wire is open circuit. b) The potentiometer is not correctly calibrated. c) The potentiometer is defective (interrupted).

13) STBY I HIGH Test carried out in standby. Checks that the current is zero.

If this is not verified, an alarm is signalled. This alarm inhibits machine operation.

Possible causes: a) Current sensor failure or logic failure.

First replace the logic. If the defect persists, replace the power unit.

14) I=0 EVER Test carried out in running.

Checks that the current during running is greater than a minimum value. If not, an alarm is signalled and the machine is shut down. Possible causes: a) The current sensor is faulty. Replace the power unit. b) Incorrect connection of the motor cables to the power bars -SHT and +SHT. 15) 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.

16) WATCH - DOG The test is made in both running and standby.

It is a self-diagnosis test within the logic. If an alarm should occur, replace the logic.

17) COIL SHORTED An overload or a short circuit toward +BATT on the contactor negative driver outputs. Possible causes: a) The contactor coils are short circuit or draw more than 6 A continuous. b) Short circuit with +BATT of the wiring that comes from the contactor connector.

The alarm indicates an overload, not the breakdown of a chopper component. Once the external cause is removed, the chopper can be restarted.

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18) DRIVER SHORTED The test is carried out in standby, and checks that the voltage of the drivers that control the contactors is consistent with the preset value.

Possible causes: a) Logic failure. b) Driver breakdown caused by overvoltage in the contactor negative wiring.

Replace the logic after having removed the cause.

19) CAPACITOR CHARGE Test is carried out at the key on when the option MAIN CONTACTOR has been selected at the PRESENT mode. It verifies that the VMNT rises to a value > 1/3 Vbatt in less 1 sec.; if the VMNT overcomes 1 sec, there is a fault that stops the capacitors charging. An alarm appears and the main contactor does not close.

Possible causes: a) Power circuit failure. b) A short circuit or leakage between the motor and battery negative.

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5.3 DIAGNOSIS PUMP CONTROL Description of the alarms signalled by the diagnostic LED. The alarm code is shown in parentheses. A detailed description is given in the section “DECODING THE ALARMS DISPLAYED ON CONSOLE”.

1 FLASH = Logic Anomaly (EEPROM KO, WATCH DOG).

2 FLASHES = Running request at the startup (INCORRECT START).

3 FLASHES = Error on VMN test (PU NO FULL CONDUCTION, PUMP VMN LOW, CAPACITOR CHARGE).

4 FLASHES = Lift potentiometer not calibrated.

5 FLASHES = Error in reading current - this error inhibits operation (PUMP STBY I HIGH, PUMP I=0 EVER).

6 FLASHES = Malfunction of the contactor driver circuit (DRIVER SHORTED, COIL SHORTED).

7 FLASHES = Excessive temperature, greater than 80°C (HIGH TEMPERATURE).

CONTINUOUS FLASHING (32 FLASHES) = Low battery charge, battery with < 10% of residual charge (BATTERY).

5.4 DECODING CONSOLE DISPLAYED ALARMS 1)

PUMP VMN LOW. The test is carried out in standby. If the VMNP voltage is lower than 1/3 of the battery voltage, an alarm is signalled. Possible causes: a) Check the motor wiring. b) Chopper failure. Replace.

2)

PU NO FULL COND. The test is carried out in full conduction.

If, in this condition, the VMNP is found to be greater than 1/3 VBATT, the diagnostic circuit is faulty, causing a safety risk, and thus machine operation is inhibited. If the defect persists, replace the logic.

3)

INCORRECT START. A running request is present at the key start-up.

Possible causes: a) Operator error; b) Request microswitch closed. The presence a power steering only request at the key on does not cause an alarm.

4)

PUMP STBY I HIGH Test carried out in standby, checks that the current is zero.

If this is not verified, an alarm is signalled. This alarm shuts down the machine.

Possible causes: a) Current sensor failure and logic failure.

First replace the logic. If the defect persists, replace the power unit.

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5) PUMP I=0 EVER Test carried out in running.

Checks that the current during running is greater than a minimum value. If not, an alarm is signalled and the machine is shut down. Possible causes: a) The current sensor is faulty. Replace the power unit.

6) EEPROM KO See the description indicated at the par. 5.2, alarm n° 15 7) WATCH-DOG See the description indicated at the par. 5.2, alarm n° 16 8) HIGH TEMPERATURE See the description indicated at the par. 5.2, alarm n° 8 9) CAPACITOR CHARGE See the description indicated at the par. 5.2, alarm n° 19 10) COIL SHORTED See the description indicated at the par. 5.2, alarm n° 17 11) DRIVER SHORTED See the description indicated at the par. 5.2, alarm n° 18 12) BATTERY See the description indicated at the par. 5.2, alarm n° 9

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6 WIRING DIAGRAM 6.1 DIAGRAM LEGEND AP AUX AV BTA BTFR BTG BTI BTIDR BTIND CH EV IN MA MCL MD MF MI MS MSED MT MUM NT POT RV TA TFR TG TI TIDR TIND

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

Micro potentiometer Auxiliaries (load) Forward Forward direction contactor coil Braking contactor coil Main contactor coil Reverse direction contactor coil Hydrodrive contactor coil Weakening contactor coil Key Solenoid valve Reverse Forward running microswitch Horn microswitch Descent microswitch Mechanical brake pedal microswitch Reverse running microswitch Lifting microswitch Seat microswitch Tiller microswitch Dead man microswitch Negative of the contactor Potentiometer Speed reduction Forward direction contactor Braking contactor Main contactor Reverse direction contactor Hydrodrive contactor Weakening contactor 6.2 DECODING COLOURS SYMBOL

Colour coding of wires: A B BB C G GG

ORANGE WHITE BLUE CYAN YELLOW GREY

M N R RR V VV

BROWN BLACK PINK RED GREEN PURPLE

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Page 48

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ZAPIMOS

C1 COMBI

OPERA TING HANDBOOK AND ATING FUNCTIONAL DESCRIPTION

MOTOR CONTROLLER FOR ELECTRONIC POWER STEERING

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

TABLE OF CONTENTS Content 1.

page

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

2.

Specifications

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

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

3.

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

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

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

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

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

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

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

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

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

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

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

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

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

1

2. SPECIFICATIONS 2.1

GENERAL Models

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

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

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

Part no

Motor type

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

FBW 4820 (48V battery voltage)

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

54Q020PB

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

54Q020NB / 54Q020RB / 54Q020QB

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

PM DC -motors

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

min. 0,5mH

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

4Q

Modulation

PWM (Puls Width Modulation)

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

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

2.2

FBW 2440 (24V battery voltage)

16kHz

BATTERY VOLTAGE Nominal

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

24VDC

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

48VDC

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

16-30VDC

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

33-58VDC

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

12VDC (Start level > 20V)

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

24VDC (Start level > 40V)

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

36VDC

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

72VDC

Tolerances: Continuous

Intermittent <50ms

<100µs

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

2

2.3

CURRENT CAPACITY Peak

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

40A

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

20A

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

25A

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

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

15A

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

2.4

At +55oC environmental temperature

50-100% of peak current.

Adjustable in 4 steps with dipswitches

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

2.5

Progressive characteristic input, meaning increased sensitivity when faster rotation.

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

2.6

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

+24VDC via 50 Ohm PTC

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

24VDC

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

48VDC

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

3

2.7

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

2.8

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

The same input as internal supply

Logic 1/logic 0

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

Logic 0: no limiting Logic 1: limiting

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

Logic 0: no limiting Logic 1: limiting

SAFETY RELAY OUTPUT Safety relay

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

24VDC (closed): ok

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

48VDC (closed): ok

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

2.9

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

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

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

Adjustable in 4 levels with dipswitches

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

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

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

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

4

Tachometer circuit

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

Disconnections and short circuits are detected.

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

Motor output voltage above commanded values detected.

Motor circuit

Disconnections and short circuit are detected.

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

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

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

Linear reduction of current limit starting at 75oC .

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

At every start-up: checking that contactor is open

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

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

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

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

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

2.11 INDICATIONS LED-indications

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

Outputs indications

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

5

2.12 OPERATION ENVIRONMENT Temperature: Operation Storage

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

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

Humidity

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

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

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

Contact cooling to metal plate or frame

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

500VAC according to prEN 1175-1

2.14 EMC Immunity:

According to prEN50081-2

Emmission:

According to prEN50082-2

6

Common

Error signal 2

Error signal 1

Direction blocking

-

+

Potentiometer

Tachometer

-12V

Tachometer 0V

+12V

Start/Stopp Safety relay

9

12

3

5

11

10

6

7

13 4

8

1

+ +

-

Monitor puls

IR-sensitivity

R

C

Blocking and sensitivity Speed regulator

Sensors monitor

Current limit

DC

+

-

Current monitor

Voltage monitor

PWM

Voltage monitor

Logic circuits monitor

R

C

Current regulator

DC

Temperatur sensor

Bat.-

M2

M1

Bat. +

2.15 BLOCK DIAGRAM

7

2.16 MECHANICAL DIMENSIONS

64

152 139 125

145

210

6.5

10

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

8

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

Safety brake

Truck computer

Limit switches

Steering wheel tachometer

0 1

Key switch

Control fuse

9

12

10

3

5

11

6

4

13

8

1

Error indication no 2, low

Error indication no 2, high

Controller

LED

LED

Battery-

Motor-

Current limit adjust.

Motor+

LED

Error indication no 1, low

Tachometer input scaling

Battery +

IxR-comp. adjust.

LED

Error indication no 1,high

- Direction limiting

+ Direction limiting

Tachometer

0V Tachometer

+24V

Safety circuit relay

Start/Stop Internal supply

-

M2

M1

+

Steer motor

Supply contactor

Power fuse

B-

B+

3.INSTALLATION INSTRUCTIONS

3.1 CONNECTION

9

3.2

COMPONENTS REQUIRED

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

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

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

50A

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

25A

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

30A slow

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

15A slow

3.2.2 POWER FUSE Current

3.2.3 CONTROL FUSE Current

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

6-10A slow

3.2.4 BATTERY AND MOTOR CABLES Dimension

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

min. 4mm2

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

min. 2,5mm2

3.2.5 CONTROL WIRING Dimension

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

min. 1mm2

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

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

10

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

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

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

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

11

3.3

CONNECTORS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

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

Function

1 2 3

Input:

4 5 6 7 8 9 10 11 12

Input: Input: Input:

13

Output:

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

Input: Output:

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

Output:

Supply for limit switches

Output: Output:

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

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

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

Function Input: Input: Output: Output

Battery voltage+ Battery voltageMotor connection + Motor connection -

24,48 V 0V

12

3.4

ADJUSTMENTS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

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

4820

2440

10A 14A 17A 20A

20A 28A 34A 40A

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

No compensation 1/3 2/3 Max compensation

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

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

5+6+7+8 open:

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

13

3.5 INDICATIONS

RE1 1

ON

2

LIM-

1 2 3

3

LIM+

4 5 6

4

ERROR

5

ERROR

RELAY SW1 1

K2

2

3

4

5

6

7

OFF

M1

7 8

K1 M2

8

9

10

11

12

13

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

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

supply contactor closed or voltage on emergency brake coil *

Outputs:

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

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

supply contactor closed or voltage on emergency brake coil *

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

14

CAT

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

1/1

PARAMETERS

Rev. Date

Zapi C1 Combi 48V 350A+350A C1S RO1.13 9190 1067

1 7.12.2001

NR14 NO BRAKE

NT12

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

8 0 0 0 9 4 4 4 0 5 0 5 4 5 3 3 9 9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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

8 0 0 0 9 6 6 9 0 5 1 5 4 5 3 3 9 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

RUN ON ON ON PRE OFF ON OFF OFF STA

RUN ON ON ON PRE OFF ON OFF OFF STA

RUN ON ON ON PRE OFF ON OFF OFF STA

RUN ON ON ON PRE ON OFF OFF OFF STA

0/5V 0/5V 0/5V Ubat Ubat Ubat

0/5V Ubat

SLOW SPEED

NR14 HYDR.BRAKE

MAIN MENU/ PARAMETER CHANGE: ACCELERATION CUTBACK SPEED 1 CUTBACK SPEED 2 BRAKE CUTBACK TRACTION IMAX INVERS. BRAKING RELEASE BRAKING PEDAL BRAKING HYDRO TIME WEAK DROPOUT CREEP SPEED PLUG CURRENT BRAKING MODUL COMPENSATION PUMP ACCELER. DELAY PUMP DECELER. DELAY PUMP IMAX SLOW LIFT SPEED HYD. SPEED COARSE HYD. SPEED FINE HYDRO COMPENS. 4TH SPEED COARSE 4TH SPEED FINE 4TH SPEED COMP. 3RD SPEED COARSE 3RD SPEED FINE 3RD SPEED COMP. 2ND SPEED COARSE 2ND SPEED FINE 2ND SPEED COMP. 1ST SPEED COARSE 1ST SPEED FINE 1ST SPEED COMP. CONFIG MENU/ SET OPTIONS: HOUR COUNTER BATTERY CHECK RELEASE BRAKING ANTI ROLLBACK MAIN CONTACTOR CUTBACK INPUT #1 SLOW LIFT INPUT CUTBACK INPUT #2 HYDRO INPUT PUMP MODE ADJUSTMENTS: SET LIFT MIN./ MAX. BATTERY VOLTAGE

NR16C/NR16/NR20H/ NR20/NR25/NR25H

TRUCK TYPES:

NOTE

1 do not change

not used

do not change

ON

do not change do not change do not change do not change do not change do not change do not change do not change do not change do not change volts do not change

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

B+48V 2.5 mm2

X1: B+

X3: 15

A: B+ 35 mm2

1

2

2

F0 500A

K0 2/27

SW200 1

F00 10A

2.5 mm2

1

2

F9 25A

3/26

X80: 14

3

6

X80: 15

2

A

X3: 1

F1 10A

C

F3 10A

1

E

F5 10A

3

G

F7 10A

5

L00

L5

L0

L1

L2

L31

L42

3/13

8/12

2/13

3/15

10/12

4/24

9/16

L11

L21

L22

L3

6/20

8/20

12/17

13/12

+

G1

5

K20

X4: 1

1

4

L32

7

L41 12/25

48V -

M1

M12

M2

M3

M41

3/16

4/27

10/12

13/12

12/26

M00

M5

M0

M11

6/20

8/12

2/13

3/17

M21 M14

M32

8/20

M31

15/27

X3: 14

X1: B35 mm2

B

10A

6

8

F8

F6 D

10A

F

10A

H

X4: 2

A1: -BATT DISCHARGE/ HOUR METER

4

F4

10A

9/16

12/20

2

F2

M42

2.5 mm2

ELECTR. STEERING

MAIN CONTACTOR

TRACTION MOTOR/ PUMP MOTOR

CIRCUIT DIAGRAM

TRACTION CIRCUIT

TS601299

PUMP CIRCUIT

AUX.DEVICES 1 WORKING LIGHTS

AUX.DEVICES 2

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

POWER SUPPLIES

1/17

REV

3-6726

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

B+48V L0

J68

J32

J69

1/21

6/23

3/14

6/24

X3: 3

X3: 2

X4: 11

2

1,0 mm2

100R 50 W

1,0 mm2

4

1,0 mm2

1,0 mm2

K3 24

+BATT

SW181

+SH P

REGEN. CONT. K2 3

3

M1

DC182 2

K1 26

A2

A1

B+48V E1

25

SUPPLY FOR COILS E2

48V

2 SUPPLY

K2

48V 1

-SH P

M2

DC182

A2

E2

1

E8 (H3)

25

D1

TRACTION MOTOR

PUMP MOTOR

E1

VMN P

+SH T

A1

C1 COMBI TRACTION /PUMP

E

48V CO

K3 A2

A1

A1 48V

K2

48V

A2

HOUR METER

26

ST REC

1,0 mm2

K1

A1

H2

4

4

PT AUX H3

1,0 mm2

1

3

1,0 mm2

11

K1

48V CO A2

A1

K0 A2

REGEN. E9 -SH T D2

1N4005

REVERSE E6

1N4005

FORWARD E7

1N4005 LINE

E5

J480

D1 VMN T

AUX

5/26

E3

-BATT

M0 1/21

CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

TRANS.CONTROLLER

2/17

REV

3-6726

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

B+48V L12

S4 MAGN.BRAKE SWITCH S3 HAND OPERATED DIRECTION SWITCH

S2 HORN SWITCH

15

X80: 4

OPTIONAL SEAT SWITCH

M13 16/15

1) S9

1

S2

13

S3

S1

6

14

22

S0 EMERG. STOP

J8503

J8502

16/14

16/13

21

2

S4

1) K47

5

30

4

FORWARD

KEY SWITCH

13

S4

5

1

K46

J52

L12

8/19

28

2

2

K45

K46

10

10

4

H8 K43

J515

L00

J32

L1

M1

M11

J906

J904

J615

J511

12/20

1/16

2/27

1/23

1/23

1/23

15/20

15/24

6/27

8/29

SUPPLY

HORN

11

S

1)

2

K47 10

10/27

8/24

E1

28

11

M25

A1 A2

B+48VDC

9

X5: 11

X5: 9

X5: 6

X5: 8

X5: 7

X7:12

X7:11

X5: 5

X5: 4

17/30

X5: 3

M55

17/29

X5: 2

X5: 1

- 1

X5: 15

4

K46

27

AUX. FANS

27

4

K45

K20

2

K45

28

+ 8

X12: 1

1

9

L55

COM

3

6

3

BACKWARD

14

NO

B-

2

5

7

K43 3

8/24

6

M27 X80: 5

X80: 3

X80: 2

4/23

1) IN USE ONLY WITH SEAT SWITCH CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

DRIVE CONTROL 1

3 /17

REV

3-6726

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

B+48V MAGNETIC BRAKE FOOT PEDAL ACCELERATOR

L31

J445

1/27

8/29

B1 C2: 47uF/100V -

3

+

2

1

X9: 5

0.4uF +

14

S7

X8: 2

K45

SAFETY SWITCH

X9: 1 13V

X8: 1

+ 8

6 48V

3/27

3

S10

- 1

5 7

23

K46 3/28

1ohm

6

7

X80: 7

X8: 5

COM

4

WITHOUT HYDRALIC BRAKE: MICRO SWITCH

K65

6

X8: 7

WITH HYDRAULIC BRAKE: P PRESSURE SWITCH

NC

K65 5

X8: 6 X8: 3

X80: 12

X80: 6

13

0.1-13V

X80: 13

X80: 8

X11: 1

NO

S6

A1 COM

DRIVE SWITCH

U

Y11

X8: 4

A2

MAGN. BRAKE

X11: 2 X8: 9 COM

S8 NO

X8: 10

FORWARD

BRAKE PEDAL SWITCH

BACKWARD

12

0V (B-) POT LOW

11

M28 17/17

J35

J36

J37

J38

J39

J310

J311

M27

J813

M12

5/14

5/15

5/16

5/17

5/18

5/19

5/20

3/30

13/28

1/23

SUPPLY

CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

DRIVE CONTROL 2

4/17

REV

3-6726

12

13

14

15

16

17

18

ACCELERATOR

J36

J37

4/14

4/15

4/16

15/13

15/14

15/15

19

20

DIRECTION CONTROL

J802 J801

J803

X3: 7

8/30

J35

X3: 6

J34

J38

J39

4/19

4/20

J804

J310 J311 4/21

4/22

21

22

23

24

25

26

27

28

29

30

PUMP SPEED CONTROL

J45

J46

J47

J48

J480

J49

J410

17/26

10/16

7/21

7/21

2/29

17/26

7/18

J810 J903 J902

15/18

15/19

15/21

15/23

V34

1

2

1

2

F

3

4

5

6

7

8

1

2

G

A1

3

6

7

3RD/RV2/HYDRO

8

X4:10 4TH/RV1/SLOW

X4: 9

5

2ND PUMP SWITCH

1ST PUMP SWITCH

X4: 8

4

LIFT INPUT

POT SUPPLY 8,2V

X4: 7 B-

X4: 6 CONTROL 0-5V

X4: 5 POT LOW (B-)

X3:11 FORWARD

X3:10 BACKWARD

X3: 9 FOOTBRAKE SWITCH

X3: 8 COMMON (+)

POT SUPPLY 13V

CONTROL 1-13V (0-10V)

POT LOW (B-)

4TH/RV1/SLOW

X3: 5

X3: 4

1N4007

SEAT SWITCH

11

9

L

C1 COMBI TRACTION/PUMP CONTROL INPUTS

CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

DRIVE CONTROL 3

5/17

REV

3-6726

STEERING STOP (OPTIONAL)

X61: 2 X61: 3 X61: 4 X61: 5 X61: 6 X61: 7

X62: 1 X62: 2 X62: 3 X62: 4 X62: 5 X62: 6 X62: 7 X62: 8

X6: 2 X6: 3 X6: 4 X6: 5 X6: 6 X6: 7

X6: 8 X6: 9 X6: 10 X6: 11 X6: 12 X6: 13 X6: 14

J512 J513

8/26 8/27

J61 J62 L11 M00 J66 J67 J68 J69 J610 J611 J612 J613 J614

9/13 10/18 1/23 12/17 12/13 2/25

1/16

CIRCUIT DIAGRAM

BLU ORA

TS601299

-IN

BRN GRY

2/29

Y/W

7/25

WHT

7/26

LTB

7/27

BLU

7/28

CONTROL CIRCUITS 1

8/28

B-

GRN

TEMP

X62:10

+IN

BRUSH

26

HAND BRAKE

+IN

STOP

25

X62: 9

BLK +IN

SEAT

DIAG. LED (-) P.

RED (OPT)

24

DIAG. LED (+) P.

ON

23

DIAG. LED (-) T.

BLK

22

DIAG. LED (+) T.

VIO

21

HOUR METER

PIN

20

BATT. DISABLE

19

MOTOR BRUSH IND

18

TEMPERATURE

G1

17

SEAT HEATER

RED

16

B-

15

B+

X45: 2 BLK (-)

+

14

X6: 15

LIFT RELAY IN

X61: 1

X6: 1

X45: 1

RED (+)

13

LIFT RELAY OUT

STEERING PULSE

X5: 13

STEERING PULSE

12

X5: 12

11 27 28

-IN -IN -IN

GRY WHT YEL

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

29

6/17

30

G1 STEERING TACHO A5 D-CHECK INFORMATION BOARD

T

P

BRAKE

BLK

J615 3/23

REV

3-6726

15

16

17

18

19

20

21

22

23

21

13

22

14

28

J612

J613

5/24

6/24

6/25

6/25

6/26

REACH LIMIT SW.

X4: 13

X4: 14

29

30

X4: 15

X44: 12

4

3

K12

2

2

10/27

3

1

REACH RELAY

X44: 13

J410

J48

5/28

5/25

SPEED CONTROL

3

4

4

A X44: 11

27

J611

X13: 3

X44: 10

26

J610

X4: 12

S11

10/26

25

J47

X13: 1

K11

24

DIAGNOSE LED (-) PUMP

14

DIAGNOSE LED (+) PUMP

13

DIAGNOSE LED (-) TRACTION

12

DIAGNOSE LED (+) TRACTION

11

PUMP RELAY

B

A1 C1 COMBI TRACTION/PUMP ALARM OUTPUTS

PUMP CONTROL

CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

CONTROL CIRCUITS 2

7/17

REV

3-6726

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1) IN USE ONLY WITH LIMITED STEERING 2) IN USE ONLY WITH FREE STEERING

B+48V L5

J52

L21

1/18

3/14

1/25

B41,B42,B81 STEERING LIMIT SWITCHES

L23

J512

J513

J614

J511

16/18

6/14

6/16

6/26

3/24

X44: 3

X44: 4

2

K41 1

X47: 1

X46: 1

X4: 3

BRN 2,5 mm2

X43: 1

X41: B+

48 V BLK

X46: 2

GRN 2,5 mm2

X43: 11 RED

X41: M1

BRN

B41 1) BLU

X81: 1 B42 1)

BLK

X47: 2

3

BLU

3

BRN

B81 2)

BLK

X81: 2

BLU

LIMIT SWITCH (R)

X81: 1

X42: 1

6

A1

M3 STEERING MOTOR -

7

3/30

A2

X42: 2 2,5 mm2

2,5 mm2

A40 ACC

X43: 5 RED

X81: 2 STEERING PULSE

X41: B-

INTERLOCK RELAYS

RED

RED

C3 7

X43: 6 STEERING (*4) CONTROLLER (*INVERTED (4820) STEERING) X43: 4 12345678 X41: (*6) OPEN M2 CLOSED X43: 8

1)

LIMIT SWITCH (L)

4

21

+ -

K42

R 6

3

STEERING PULSE

X44: 5

ERROR

X3: 12

X4: 4

STEERING STOP

+

4) K47

3

X80: 1

X44: 1

+ A1

+ 8

K41

K42

A2

-

X3: 13

3)

+ 8

K43

MAGN.BRAKE

20

- 1

- 1

X44: 2 J4405 15/27

M5

M21

J8001

M23

M24

J445

J34

1/18

1/25

16/16

16/22

10/26

4/27

5/12

3) K43 removed if footdirection switch

4) IN USE ONLY WITH SEAT SWITCH CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

CONTROL CIRCUIT 3

8/17

REV

3-6726

17

LIFT/LOWER

18

REACH

19

20

P1

4

1

2

3

25

26

BACK/FORE

27

28

29

SIDE SHIFT RIGHT/LEFT

P2

P3

P4

5kOhm

5kOhm

5kOhm

4

1

2

3

30

4

1

2

3

4

6V

e

*USED ONLY WITH HEIGHT INDICATOR AND TOPLIMIT

X7:7

5 X72:5

X7:3

4 X72:4

X72: 1

3 X72:3

X72:2

1

X72: 3

*V331

X7:6

d

c

OPTION

12V

0V

X72:1

X7:2

24

HEIGHT SELECT +48V

f

1,5-6-10,5V

0V

A322

V321

X7:1

23

0,5 mm2

3

0,5 mm2

2

0,5 mm2

1

22

TILT

IN/OUT

5kOhm

21

0,5 mm2

16

0,5 mm2

15

0,5 mm2

14

X7:5

13

0,5 mm2

12

X7:4

11

J722 17

J74

J75

J76

J77

10/22

10/20

10/25

10/26

26

J722

1/29

M42

1/29

L42

17/24

10/24

J723

J73

6/19 17/23

J61

10/16

J721

J71

CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

LIFT CIRCUIT 1

9/17

REV

3-6726

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

B+48V LIFT/LOWER

SIDE SHIFT

TILT

REACH

CENTER POINT

PRESS.SWITCH

L2

L201

J71

J62

J75

J74

J73

J76

J77

L204

1/25

11/12

9/12

6/19

9/25

9/23

9/19

9/26

9/29

14

+24V

L202 17/19

L203 14/13

L204

A1 Vi+

Gi-

A20 DC/DC 48/24V

Vo+

A3

A4

A5

A6

A7

B9

B3

0,5 mm2

0,5 mm2

0,5 mm2

0,5 mm2

1

0,5 mm2

F11 5A

0,5 mm2

2

0,5 mm2

1,0 mm2

29

A8

B1

A30 VALVE CONTROLLER Go-

B12 B10

B11

B2

B4

B5

B6

B7

B8

0,5 mm2

0,5 mm2

0,5 mm2

0,5 mm2

0,5 mm2

0,5 mm2

X44: 6

S12

P 2

X44: 9

1N4005

+ 8

24V

24V

24V

24V

24V

24V

24V

X44: 7

0-10V

0-5V

X44: 8

K11

A1

+ 8 24V

- 1

K12

Y5

24V

1N4005

2

0,5 mm2

F12 5A

0,5 mm2

1

0,5 mm2

0,5 mm2

1,0 mm2

3

+ 24V

A2

- 1

M201 14/25

M202 17/21

M2

M204

J46

J703

J704

J709

J7010

J708

J707

J705

J706

M24

M25

M204

1/25

29

5/23

11/13

11/15

11/18

11/19

11/21

11/22

11/25

11/26

8/28

3/26

14

B-

LIFT

LOWER

LIFT

SIDE SHIFT

TILT

REACH

REACH RELAY

PUMP RELAY CONTROL VALVE FOR 2ND PUMP

CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

LIFT CIRCUIT 2

10/17

REV

3-6726

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

B+24V LOWER: 0-10V

SIDE SHIFT

LIFT

TILT

REACH

L201

J703

J704

J709

J7010

J708

J707

J705

J706

10/14

10/17

10/18

10/19

10/20

10/21

10/22

10/23

10/24

X70: 1

X70: 3

X70: 4

X70: 9

X70: 8

X70: 7

X70: 5

X70: 6

X70: 10

Y6 +24V

C+

1

3

Y1

Y4 A1 Y1 A2

2 OV

X70: 2

Y3 A1 Y4.1 A2

A1 Y4.2 A2

Y2 A1 Y3.1 A2

A1 Y3.2 A2

A1 Y2.1 A2

A1 Y2.2 A2

4 C-

X70: 12

X70: 13

X70: 14

X70: 15

VALVE BLOCK

ADJUSTMENT POTS OF LOWER VALVE (Y6):

M203 14/26

B-

1 2 3 4

R3 DEAD BAND ADJUSTMENT (TURN CCW TO INCREASE COMP)

1 2 3 4

R4 DITHER ADJUSTMENT 0-10V 0V 24V

R2 OUTPUT ADJUSTMENT (TURN CCW TO INCREASE OUTPUT) R1 RAMP ADJUSTMENT (TURN CW TO INCREASE RAMP)

CIRCUIT DIAGRAM

2

1

1

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

LIFT CIRCUIT 3

2

Y6 Y1 Y4 Y3 Y2 1

TS601299

2

1

11/17

REV

3-6726

11

12

13

14

15

16

17

18

19

20

MOTOR TEMPERATURE CONTROL

MOTOR BRUSH DETECTION

J66

J515

6/22

6/21

3/11

X15: 1

24

25

26

27

A1

A1

A1

M2 A2

M1 T-A2

28

29

30

OPTION: FORK CAMERA SYSTEM

A312

X17: 1

X15: 2

NO

A2

23

X14: 2

X14: 1

M1

22

AUXILIARY FANS

J67

A1

21

X19: 1

RED

X20: 1

+48V

X316: 1

2

3

4

X315: 1

2

3

4

X314: 1

2

3

4

0V

L41

M41

1/29

1/29

RED

RED

NO

M2 T--

S21

COM 118°C

A2

S22

COM 118°C

M4 BLK

M5 BKL

M6 BKL

Vi+

Gi-

G311

48V 24V / 5A

X20: 2 1

F311 5A

F312 5A

X313: 1

L22

M31

1/25

1/27

TRACTION MOTOR M1 TEMPERATURE

4

X312: +24V

PUMP MOTOR M2 BRUSHES

3

2

X311:

TRACTION MOTOR M1 BRUSHES

2

1

PU

X14: 3

2

MU 0V

X19: 2

PU +12V

X17: 2

VA

X15: 2

Go-

S

Vo+

POWER

PUMP MOTOR M2 TEMPERATURE

CIRCUIT DIAGRAM

0V CAMERA

A311

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

AUX. DEVICES 1

12/17

REV

3-6726

11

12

13

14

15

16

17

18

19

20

21

22

B+48V

23

B+48V

24

25

26

27

28

29

30

B+24V

L3

L33

L33

L221

J813

J305

1/27

22

13

17/20

4/24

15/22

RIGHT X332: 10

X332: 12

H50 +

ANTENNA

X30: 1 X50: 1 1,0 mm2

S31

X30: 5

X30: 3 1

S65 S61

RED

BLK

LIGHT SW.

X60: 1

Vo+

1 2

LIGHT SW. X1

E30

A50 DC/DC 48/12V

A51 RADIO RECEIVER B-

BLK

GoRED

Gi-

2

X2

X60: 2

H65

H61 24V

RED X1

X1

X60: 3

X2

M7

CURTIS 48V

X2 BKL

BLK

X1 1,0 mm2

X75: 1

X65: 1

24V

RED

Vi+

1

S71

2

2

B+

1

E31

X65: 2

X2 24V

X75: 2

X60: 4

X50: 2

X30: 4

X30: 2

X30: 6

+ H51 -

X332: 11 M3

M33

M33

M34

M221

M34

1/27

22

13

27

17/22

23

B-

LEFT RADIO RECEIVER

WORKING LIGHTS

CIRCUIT DIAGRAM

TS601299

CABIN LIGHT

FLASHING LIGHT

DRIVER FAN

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

AUX. DEVICES 2

13/17

REV

3-6726

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

OPTIONAL HYDRAULICS SPREAD/NARROWING

J79

S5 MODE SWITCH

S5

16

2 3

VD51S00C-0000

X71: 1

Y9 A1 Y9

A2

X7: 8

X71: 2

X7: 9

L203

J79

M201

M203

10/14

25

10/14

11/12

B-

CIRCUIT DIAGRAM

TS601299

B-

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

LIFT CIRCUIT 4

14/17

REV

3-6726

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

OPTION: FOOT DIRECTION SWITCH MAGNETIC BRAKE FOOT PEDAL ACCELERATOR

J4405 8/29

X26: 1

B1 C2

47uF/100V -

12

X9: 1

+

X27: 1 12

S26

S27

11

3

2

0.4uF

11

1 X26: 2

X8: 3

X8: 2

X27: 2

X27: 4 13V

0.1-13V

0V (B-) POT LOW

11

X8: 1

X26: 4

14

X8: 7

S27

X8: 6

X27: 3

NC

S10

FOOT PEDAL SWITCH

P

COM 1ohm

14

S26

13

13

X26: 3 X11: 1

X8: 5

V30

V31 A1

NO

X9: 6

S6 COM

X8: 4

PRESSURE SWITCH

DRIVE SWITCH

X9: 3

XX:

X9: 2

X9: 4

Y11 U

MAGN. BRAKE

A2

X11: 2 X8: 9 COM

S8

PEDAL BRAKE

NO

X8: 10

J803

J802

J801

J804

J810

J906

J903

J305

J902

J904

M14

5/14

5/15

5/16

5/17

5/18

3/18

5/19

13/27

5/20

3/19

1/23

SUPPLY (+)

BACKWARD

CIRCUIT DIAGRAM

FORWARD

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

DRIVE CONTROL 4

15/17

REV

3-6726

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1) IN USE ONLY WITH FREE STEERING

J8502

J8503

M13

J8001

L23

M23

3/19

3/18

3/18

8/23

8/24

8/25

X82: 1

X83: 1

BRN

B82 1)

BRN

BLK

BLU

BLK

X82: 2

X85: 2 E(+)

X85: 3 T(+)

X85: 10 -

3

X84: 2

X84: 3

X85: 4

X85: 5

X85: 6 B

B83 1) BLU

X83: 2

X84: 1

A

2) IN USE ONLY WITH LIMITED STEERING

3

C B81 B82

2)

T

E

B83

A80

DIRECTION INDICATOR BOARD

CIRCUIT DIAGRAM

TS601299

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

CONTROL CIRCUITS 4

16/17

REV

3-6726

12

13

14

15

G331 PULSE ENCODER

16

17

18

19

20

B

BLU-

A

BLK LOAD

-

BRN+

+

21

22

23

24

25

26

27

S331 LIMIT SWITCH +24V

+24V

0V

2

3

X335: 1

4

2

L202

L221

M202

M221

J721

J723

J45

10/14

13/25

10/14

13/25

9/15

9/15

5/22

2

3

4

14

42

13

41

48V

X1 X2

3

X80: 10 X333: 1

30

OPTIONAL: S55:SPEED SWITCH

0V

YEL

GRN

WHT

X334: 1

29

28

S55 BRN

X55: 1

X55: 2

5 4

K30 16

X332: 1

2

3

4

5

X332: 6

X332: 7

X332: 8

X332: 9

X331: 6

X331: 7

X331: 8

X331: 9

3

X80: 11

X80: 9

K30 25

M28

X331: 1

2

3

4

4/23

5

+ 8 24V - 1

L55

M55

3/15

3/17

10

1

2

3

A331: PULSE COUNTER 4342

J49 5/27

LIFT LIMIT

CIRCUIT DIAGRAM

TS601299

0V

4

0V

9

+24V

8

RST

11

IN2

12

IN1

7

OUT-

+48V OUT+

11

IF SPEED REDUCTION IS USED, SET THE FOLLOWING PARAMETERS: CUTBACK SPEED2 1 CUTBACK INPUT#2 ON

NR14/NR16/NR16C/NR20/NR20H/NR25/NR25H

HEIGHT INDICATOR/SPEED SLOW

17/17

REV

3-6726

A