Caterpillar NSP12K Lift Trucks Operation & Maintenance Manual – PDF DOWNLOAD

EN

Operation & Maintenance Manual NSP10K NSP12K NSP12KI NSP16K NSP16KI

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

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PALLET TRUCK / STACKER Type:

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

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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.

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

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

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

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

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

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

Otherwise normal daily maintenance and inspection are sufficient.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The truck must always be driven with its forks lowered.

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

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

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

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

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

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

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

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

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

Sudden starts and stops should be avoided.

Steering and braking movements should be made smoothly.

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

Take great care when driving on a slanted surface.

Do not drive over any loose objects on the floor.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Connecting the battery to a charger: 1.

2.

3.

4.

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

Disconnect the battery connector and connect it to the charger.

Connect the current to the charger.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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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 in dry indoor spaces, on even and level floors. The temperature range, in which the truck can operate continuously is +25 - +5°C, and for short periods +45 - +25°C. If the operating conditions differ from those temperatures, contact your truck dealer, because in cold and freezing temperatures a separate machine intended for such conditions is needed. A special machine for freezing conditions can be used in temperatures down to -35°C. This truck conforms to all the relevant requirements of the EU machine safety directive and thus has a CE marking.

NEVER USE THE TRUCK: • to transport and lift people • on premises with fire risk • on premises with explosion risk • on premises with insufficient floor load capacity • if damaged • as a mounting surface • to tow another truck • under the influence of intoxicating substances.

THE OPERATOR’S NORMAL DRIVING POSITION The normal drive position of the driver when driving in the direction of the forks is behind the truck, with both hands on the tiller arm. When driving in the opposite direction, the driver walks beside the truck with one hand on the tiller arm.

NOISE The maximum noise level the driver may be subjected to is 76 dB (A). This noise level can be reached when raising classified load.

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CONTROLS AND THEIR DISPLAYS KEY SWITCH (1) The key switch connects the truck’s electrical equipment to the battery circuit.

• 0 = Power off (power is still connected to certain electronic devices) • 1 = Power on BATTERY CONNECTOR / MAIN CURRENT SWITCH (2) The battery connector is the main current switch of the forklift truck, and it also serves the purpose of emergency switch. For further information on charging the battery via the battery connector, please see section on charging the battery.

NOTE !

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

• In case of an emergency the forklifttruck can be disconnected from the power source by unplugging the battery connector HOUR METER AND BATTERY DISCHARGE INDICATOR (3) The hour meter counts the time that the truck has been in active operation. It is always on, when the electrical devices are operating. The discharge indicator shows the level of the battery charge and stops the lift function, if the battery charge is too low. However, the battery should be recharged, before the charge level drops too much.

STEERING (4) HORN BUTTON (5) SPEED CONTROL (6) The speed control is used for controlling driving speed and for braking the truck.

• Handle the speed control gently !

VALVE PUSH-BUTTONS (7) (8) The truck has push-buttons for raising and lowering.

Stacking (7) and Initial lift (8) • Familiarize yourself with the operation of the pushbuttons.

IDENTIFICATION PLATE (9) 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

- 13 Capacity plate: High-lift trucks have a capacity plate, which states the maximum lifting capacity at the maximum lifting height, and the lifting height with the nominal lifting capacity. If necessary, a lifting capacity between the heights referred to above is stated. In addition, the plate states the centre of gravity distances for the relevant lifting capacities.

Warning!

Check and know the load and centre of gravity distance in every situation. it is dangerous and therefore forbidden to overload the truck.

SAFETY REVERSER (10) The safety reverser prevents the driver from getting squeezed between the truck and an obstacle. By pushing it the truck reverses the direction of travel (direction of the forks), and stops when the button is released, if the speed control is released.

• Never use the safety reverser for normal driving.

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

CHARGE OF BATTERY WITH THE INTEGRATED CHARGER DEVICE The plug (11) for the power supply of the integrated charger is accessible from the outside of the truck. Two LED’s (Yellow - Green) on the cover of the truck indicate the operating status of the charger: • The green LED indicates the presence of main power; • The yellow LED indicates the status of the charge cycle.

To activate the charger extract plug for the power supply from the safety socket on the machine and insert it into the correct outlet (230V ± 10% - 50 Hz). After connecting the power to the charger, the two LED’s will start blinking for some seconds simultaneously. Next the yellow LED will show the status of the charge cycle: • LED is On during phase 1; • LED is flashing quickly during phase 2 • LED is flashing slowly during phase 3 • LED is flashing irregularly during phase 4 • LED is Off when the charge cycle is completed or when the charger no longer powered As long as the charger is connected to the main power, the green LED will be on.

In case of a problem on charge duration, the green LED will start to flash. This may happen if a battery element failed (short-circuit) or when the ambient temperature is too high.

NOTE: • Do not disconnect the battery connector during the charge cycle!

• If the charger remains connected to the power after completing the charge cycle, the charger will automatically restart the charge cycle 48 hours after the end of the last charge to compensate the autodischarge of the battery.

• The power to the charger can be disconnected before the charge cycle has been completed since the charger will memorise its last charge. Repetitive short charge sessions may reduce the lifetime of the battery.

•After charging the battery the main power plug has to be inserted into the safety socket, otherwise all the electric functions of the truck are disconnected.

• DANGER! No inflammable materials are allowed within 2 meters either from the truck under charge or from the charger.

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

Switch on the power of the truck and tilt the tiller arm to the driving position. Turn the speed control gently to in the desired direction of travel. To brake or stop the truck, turn the speed control against the truck’s direction of travel so that the motor does the braking.

The tiller arm turns ± 90 degrees. The movement limiter allows for an approximately 5 degree dampened increase in the total movement.

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

• Practice steering and controlling the truck.

• Drive slowly at intersections and when turning.

• Always drive with the load lowered when not in a collection aisle.

STOPPING As a rule you should brake the truck smoothly by turning the speed control against the truck’s direction of travel (tiller arm in position 1).

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

HANDLING A LOAD Lift and lower a load with the push-buttons on the tiller arm.

Place the load so that its weight is distributed evenly on the lifting forks. The maximum lifting capacity of the truck is given on the identification plate. Do not overload.

• Handle only undamaged loads.

• Place the load correctly.

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

WARNING: Do not transport badly piled or bound loads.

Do not exceed the truck capacity.

- 15 STACKING: 1. Drive calmly perpendicular to front of the stack of shelf with the load and ground allowance down.

2. Ensure that the support forks go all the way underneath the pallet. This is best done by aligning the transported pallet’s sides with the lowest pallet’s sides. When you use the ground-level pallet for aligning, the stacking and unstacking becomes easier.

3. If there are side supports, lower them down.

4. Lift the load so high that it is clearly higher than the stacking level.

5. Drive the pallet carefully to the stacking level. When the load is correct spot above the level, lower it carefully so that the forks detach from the pallet.

6. Back up perpendicularly so far that the forks can be lowered unhindered.

7. Lower the forks.

8. Lift up side supports, if fitted UNSTACKING 1. Drive calmly perpendicular to the front of the stack of shelf with the forks low enough to go under the lowest pallet. Then backup perpendicularly to the corridor so far that the forks can be lifted up unhindered.

Lower the side supports if fitted.

2. 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 and that the load is stable on top of the forks.

3. Lift up the forks so that the pallet is no longer on the stacking level.

4. Back up calmly perpendicular to the corridor so that the load can be lowered to the floor unhindered.

5. Lower the load down.

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.

• Always approach the stacking shelves perpendicularly with the forks low.

• 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.

EMERGENCY PROCEDURES If the truck or a load falls over or down in a ramp, release your grip from the tiller and warn everybody near you. If the truck behaves unexpectedly, release the tiller arm to the up position, or push it down completely.

INSPECTIONS, SERVICE, AND REPAIRS SAFETY INSTRUCTIONS FOR SERVICE • Only persons trained in the service and repair of this type of truck may carry out service and repairs.

• The service area should be kept clean: oil, grease, and water will make the floor slippery.

• Short circuits and burns are possible when working with the truck’s electrical system, if a metal object touches a charged electrical connection. Therefore, rings, watches, and other metal jewellery must be removed.

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

• Release the hydraulic pressure, before opening the system, by lowering down the forks.

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

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

• The hydraulic system may only be filled with clean oil.

• Always disconnect the battery when welding. Paint should be removed from an area 10 cm around a point being welded, to avoid toxic gases being formed during welding.

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

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

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

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

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

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

• Check all wheels for damage or outer wear.

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

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

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

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

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

• Test the horn signal.

• Check the operation of the safety reverser DRIVER’S WEEKLY MAINTENANCE PROGRAM • Check and clean the fastenings of the battery cables.

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

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

• Check the amount of hydraulic oil in the oil tank, when the forks are in lowered position. Add if necessary.

• Make sure that screws, nuts and pipe connectors are tight.

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

• Clean the truck if necessary.

• Apply a thin layer of oil on the grooves of the mast, reach carriage and lift carriage • 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 NOTE:

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

The truck’s lubricating points should be lubricated about once a month: • the turning bearings of the load wheels • the bearings of the side castor wheels • the suspension rail of the drive unit • the turning bearings of the drive unit

- 17 OIL RECOMMENDATIONS Hydraulic oil (11): ISO VG 32 In freezer warehouses: ISO VG 15 Fill 3/4 of the tank’s volume.

• Gearbox oil (12): SAE 80W/OP,API:GL-4 • Fill to the volume of 0.6 l • Checking the oil level (13) • Lubricating grease (3): NLGI No. 2. containing molybdenum disulphide • In freezer warehouses: NLGI No. 1 or No. 0.

QUARTERLY INSPECTION SERVICE (300 H) It is most economical to make an inspection and regular interval service agreement with your truck dealer. Only professional service will ensure trouble-free truck operation. Service programme monitoring is facilitated by entering the service dates in a service logbook.

Besides the weekly programme, also the following points need to be inspected and, if necessary adjusted or repaired: • the collectors, carbon brushes and connections of the drive motor and of the pump motor. Clean the carbon dust from the motors • the operation of the speed control • the operation of the speed limiter • the operation of the lifting hydraulics • the microswitches • the contactors and solenoids • the cables • the air gap in the brake • the tiller arm gas spring • the function of the lift cylinder • the play of the fork carriage, and the slope of the forks and their condition

- 18 SEMIANNUAL SCHEDULED MAINTENANCE (600 H) In addition to the quarterly and weekly procedures, the following points need to be carried out: • change the hydraulic oil once a year (1200 h) • change the gearbox oil once a year (1200 h) • clean the oil filter • check the operation of the hydraulics and the pressure-limiting valves • check the fastening of the gearbox and the amount of gearbox oil (see 17.4) • check the fastening of the tiller arm • check the condition of the side castor wheels and load wheels • check the wear of the drive wheel LOCATION OF THE FUSES IN THE SPEED CONTROL UNIT

Drive current fuse Lift motor fuses

WARNING! NO ALTERATIONS OR REPAIRS MAY BE MADE TO THE DEVICE THAT MAY WEAKEN ITS STRUCTURE OR ENDANGER SAFETY.

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TROUBLESHOOTING

SYMPTOM:

FAULT:

PROCEDURE:

Truck does not move

• The battery connector is loose • The battery is empty • The charger plug not in the safety socket • The emergency stop button is activated • The key switch is faulty • The microswitch for the tiller arm is broken • The drive motor fuse has blown

• Plug in the battery connector • Recharge the battery • Plug in the charger plug

• Pump fuse has blown • Control current fuse has blown • Drive switch is broken

• Replace the fuse • Replace the fuse and check cables • Replace the switch

• Release the emergency stop button • Replace key switch • Replace the microswitch

• Check the connections and cables and replace the fuse • Check the connections and cables • The main power fuse has blown and replace the fuse • The drive motor carbon brushes are • Replace the carbon brushes worn out • Contact your truck dealer • The speed control is faulty

The lift pump doesn't run

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

• 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

• Check the connection • Replace the fuse

• Charger is connected incorrectly • Charge fuse has blown or mains voltage is missing • The battery cell's water level or specific gravity is low

• Check the cells current and specific gravity. Add water and / or acid when necessary. See Section "Recharging the battery"

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

Page 1

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

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

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

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

A

- Orange

M

-

Brown

B

- White

N

-

Black

BB - Blue

R

-

Pink

C

RR -

Red

G - Yellow

V

-

Green

GG - Grey

VV

-

Purple

- Sky Blue

Page 3

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

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

- Economical costs.

- Maximum safety.

- Maximum flexibility.

- Open to future technical innovations.

- Optimum level of protection.

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

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

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

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

- Future technological updates are made easy for the user.

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

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

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

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

Page 4

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

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

VERSIONS

MAXIMUM CURRENT

BOOSTER CURRENT

VOLTAGE DROP IN FULL CONDUCTION

24 / 36V

150A (3')

180A (10'')

0.23V at 50A, 25°C

24 / 36V

200A (2')

230A (10")

0.23V at 50A, 25°C

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

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

Page 5

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

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

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

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

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

Page 6

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

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

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

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

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

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

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

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

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

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

Page 7

2.5 OPERATIONAL FEATURES - Speed Control .

- Optimum sensitivity at low speeds.

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

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

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

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

This provides optimum performance on a gradient.

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

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

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

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

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

- Internal Hour Meter that is displayed on the Console.

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

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

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

Page 8

2.6 SEM-ZERO CHOPPER DIAGNOSIS The microprocessor continually monitors the chopper and carries out diagnostic procedures on the main functions.

The diagnosis is made in 4 points: 1) Diagnosis on key Switch closing that checks: the Watch Dog Circuits, the current sensor, VMN point, Contactor Drivers, the switch sequence for operation is correct, and the output of the accelerator or tiller is correct.

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

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

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

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

2.7 THERMAL CONSIDERATIONS - The heat generated by the power block must be dissipated. For this to be possible, the compartment must be ventilated and the heat sink materials ample.

- The heat sink material and system should be sized on the performance requirement of the machine. Abnormal ambient air temperatures should be considered. In situations where either ventilation is poor, or heat exchange is difficult, forced air ventilation should be used.

- The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle.

Page 9

2.8 GENERAL INSTRUCTIONS AND PRECAUTIONS - Never combine SCR low frequency choppers with SEM-Zero modules. The filter capacitors contained in the SEM-Zero module will change the SCR chopper operation and subject it to excessive workload. If it is necessary to use two or more control units (eg. Lift + traction), the choppers must be of the High Frequency Zapi family.

- Do not connect the chopper to a battery with a different nominal voltage to the value indicated on the chopper. A higher battery voltage may cause MOS failure, and a lower voltage may prevent the logic operating.

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

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

- Start the machine the first time with the drive wheel(s) raised from the floor to ensure that any installation errors do not compromise safety.

- After operation, even with the Key Switch open, the internal capacitors may remain charged for some time. For safe operation, we recommend that the battery is disconnected, and a short circuit is made between Battery Positive and Battery negative power terminals of the chopper using a Resistor between 10W and 100W .

Minimum 5 W. - The susceptibility and electromagnetic emmission levels are seriously influenced by installation conditions. Take particular care with the length of cables and wires, types of electrical connections, and braided/screened wires.

Zapi declines any responsibility for incorrect or bad operation that can be attributed to the above circumstances. Above all, the manufacturer of the machine must ensure that the requirements of EN 50081-2 are met.

Page 10

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

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

Despite the protection provided against external agents, the continuous attack of corrosive elements and substances may cause oxidization of connector contacts, resulting in bad operation. Remember this point when deciding the installation position on the vehicle.

Fix the chopper using the special holes located on the baseplate.

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

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

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

For the Field connections use cable of 4mm² section.

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

3.2 CONTACTORS A Line Contactor, designed for Continuous Operation should be installed. This contactor should be fitted with a coil corresponding to the battery voltage. The current absorbed by the coil must not be greater than 3A. Suppression for this contactor coil is within the chopper. Do not use external suppression. For any Contactor using external suppression, ensure that connections are made respecting correct polarity.

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

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

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

Page 11

3.4 DESCRIPTION OF SEM-ZERO CONNECTORS.

PIN REFERENCE DESCRIPTION A1

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

A2

KEY

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

A3

NMC

Negative main contactor coil.

A4

NEMB

Negative electro-brake.

A5

TILLER

Tiller micro-switch.

A6

-BATT

-BATT.

A7

PMC

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

A8

H&S

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

B1

CPOT

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

B2

NPOT

Provides a negative supply to accelerator's potentiometer.

B3

PPOT

Provides a positive supply to accelerator's potentiometer.

B4

REV

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

B5

B SW

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

Active HIGH (+VB).

B6

FORW

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

Page 12

PIN REFERENCE DESCRIPTION C1

CM

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

C2

SR1

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

C3

SR2

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

D1

REG SIGNAL Regenerative braking status.

Normally high, low while regenerating.

D2

PHORN

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

D3

NHORN

Negative horn, it is -BATT.

D4

PPC

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

D5

NPC-NEV

Negative supply for pump contactor.

D6

PEV

Positive electro-valve for lowering.

E1

PCLRXD

Positive serial reception.

E2

NCLRXD

Negative serial reception.

E3

PCLTXD

Positive serial transmission.

E4

NCLTXD

Negative serial transmission.

E5

GND

Negative console power supply.

E6

+VL

Positive console power supply.

E7

---

Free.

E8

---

Free.

3.5 DESCRIPTION OF POWER CONNECTIONS +BATT

=

Positive Supply from Battery.

-BATT

=

Negative Supply from Battery.

VMN

=

Negative Supply (via chopper) to Motor.

F1, F2

=

Connections to Drive Motor Field Winding.

Page 13

3.6 MECHANICAL DRAWING & DIMENSIONS

Page 14

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

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

4.2 DESCRIPTION OF CONSOLE & CONNECTION

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

Page 15

4.3 DESCRIPTION OF STANDARD CONSOLE MENU

Page 16

5 SEM-ZERO: CABLING AND CONFIGURATION 5.1 POWER DIAGRAM

Page 17

5.2 CONNECTIONS

Page 18

5.3 DESCRIPTION OF PROGRAMMABLE FUNCTIONS (OPTIONS).

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

HOUR COUNTER: - RUNNING:

The counter registers travel time only.

- KEY ON:

The counter registers when the key switch is Closed.

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

2

3

QUICK INVERSION - BELLY:

Quick inversion is activated while the Belly Button is pressed.

- TIMED:

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

AUX OUTPUT #1: -FREE:

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

-BRAKE:

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

Page 19

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

1) Opening Zapi Menu.

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

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

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

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

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

9) A new Option appears on the Display.

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

12) Press OUT to exit the Menu.

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

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

Page 20

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

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

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

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

ACC. DELAY = Determines the acceleration ramp.

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

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

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

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

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

7 CUTBACK SPEED 1 = First speed reduction.

8 CUTBACK SPEED 2 = Second speed reduction.

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

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

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

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

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

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

15 MAXIMUM CURRENT = Maximum controller current.

16 ARMA NOM.CURR. = Nominal Armature Current. This parameter fixes a limit for the armature current above which the Field Current is at least the Nominal Value (FIELD NOM.CURR.), regardless of accelerator position.

Page 21

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

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

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

Page 22

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

PROGRAMMED LEVEL PARAMETERS UNIT

0

1

2

3

4

5

6

7

8

9

ACC. DELAY

sec.

0.30 0.50 0.70 0.90 1.10 1.25 1.40 1.55 1.75 2.00

DEC. DELAY

*

9

8

7

6

5

4

3

2

1

0

RELEASE BRAKING

*

0

1

2

3

4

5

6

7

8

9

INVERS BRAKING

*

0

1

2

3

4

5

6

7

8

9

SOFT BRAKING

** %

50

40

33

28

25

22

20

18

16

15

SOFT ACCELERATION

*** %

50

40

33

28

25

22

20

18

16

15

CUTBACK SPEED 1

%ACC

30

38

45

51

57

64

72

80

90

100

CUTBACK SPEED 2

%ACC

30

38

45

51

57

64

72

80

90

100

H&S CUTBACK

%ACC

30

38

45

51

57

64

72

80

90

100

MAX SPEED FORW.

%FCN

100

90

80

71

62

53

45

40

36

33

MAX SP FORW. FINE

**** %FCN

0

1

2

3

4

5

6

7

8

9

MAX. SPEED BACK.

%FCN

100

90

80

71

62

53

45

40

36

33

MAX SP BACK. FINE

**** %FCN

0

1

2

3

4

5

6

7

8

9

COMPENSATION

***** %IA

0

5

10

16

22

27

33

38

44

78

MAXIMUM CURRENT

%IMax

82

84

86

88

90

92

94

96

98

100

ARMA CUR. NOM. (ACN)

%IMax

45

47

50

52

54

56

58

61

63

65

WEAK DROP OUT

%ACN

40

44

48

52

57

62

66

70

75

80

FIELD CURR. NOM. (FCN)

A

7.5

8.1

8.7

9.3

10

CREEP SPEED

%VBatt

4

5

6

7

8

10.6 11.2 11.8 12.5 9

10

11

12

13.1 13

*=

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

**=

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

***=

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

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

Page 23

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

2) Press ENTER to go into the General Menu.

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

5) The Display will show the first Parameter.

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

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

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

9) The Display will show the New Level.

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

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

13) The Display will show :

Page 24

5.4 SEM-ZERO TRACTION STANDARD WIRING DIAGRAMS

Page 25

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

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

2) Select and set the Battery Voltage.

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

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

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

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

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

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

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

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

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

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

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

Page 26

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

NOTES Problem with Logic or Line Contactor.

1

Watch-dog:

Logic board and/or software failure.

1

EEPROM KO:

Problem with EEPROM or Logic.

2

INCORRECT STARTS:

Starting sequence for travel not correct.

2

FORW + BACK:

Double running requests.

3

CAPACITOR CHARGE

Problem in Power Block.

3

VMN NOT OK

Problem with Chopper.

3

VFIELD NOT OK

Problem with Field Voltage

4

VACC NOT OK

Potentiometer Wiper.

4

PEDAL WIRE KO

Pedal wire not OK.

5

NO FIELD CUR.

Field wiring not OK or field current sensor not OK.

5

HIGH FIELD CUR.

Field wiring not OK or field current sensor not OK.

5

STBY I HIGH

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

5

I= 0 EVER

No current: sensor of armature current not OK.

6

CONTACTOR DRIVER

Contactor Driver not OK.

6

COIL SHORTED

Coil contactor shorted.

6

CONTACTOR CLOSED

Line Contactor contact not OK.

7

TH. PROTECTION

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

32

BATTERY LOW

Battery too low.

Page 27

6.1 ANALYSIS OF ALARMS DISPLAYED ON THE CONSOLE 1

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

Possible cause: failure of the logic board

2

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

3

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

4

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

5

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

6

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

7

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

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

Page 28

8

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

9

VACC NOT OK This Alarm is generated if the accelerator output voltage differs more than 2V from the acquired minimum during the PROGRAM VACC. Possible causes: a) the track of the potentiometer has become open. b) the potentiometer is not wired correctly. c) the potentiometer itself is defective. d) the values set in PROGRAM VACC routine have not remained or made correctly.

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

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

12 I = 0 EVER This check is made during travel. If the current is not higher than a preset minimum value, this Alarm is generated and the machine disabled. Possible causes: see STBY I HIGH. Check the motor armature (brush connections).

13 HIGH FIELD CUR, NO FILD CUR Problem detected with the field winding current. Possible causes: a) Failure of the field current sensor. b) Field cables not connected or incorrectly connected. c) Failure of the Field Power Unit.

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

Page 29

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

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

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

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

Page 30

6.2 TESTER DESCRIPTION OF THE FUNCTIONS The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage, current and temperature. The following definition listing shows the relative measurements : 1) BATTERY VOLTAGE: level of battery voltage measured at the input to the key switch.

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

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

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

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

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

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

ON /+ VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

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

ON /+ VB = active entry of closed switch.

OFF / GND = non active entry of open switch.

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

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

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

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

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

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

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

ON / GND = active entry of speed reduction microswitch.

OFF / + VB = non active entry of microswitch.

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

ON / GND= active entry of speed reduction microswitch.

OFF / +VB = non active entry of microswitch.

Page 31

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

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

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

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

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

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

9) Next variable is shown.

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

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

Page 32

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

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

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

- Options (SET. OPTIONS).

- The Level of the Battery (ADJUST BATTERY).

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

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

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

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

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

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

9) Press ENTER to commence SAVE routine.

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

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

Page 33

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

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

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

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

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

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

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

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

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

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

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

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

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

Page 34

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

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

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

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

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

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

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

7) The Display will show the most recent Alarm.

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

Pressing ROLL DOWN returns to the most recent.

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

11) The Display will ask CLEAR LOGBOOK ?

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

Page 35

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

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

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

1) Opening Zapi Display.

2) Press ENTER to go into the General Menu.

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

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

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

8) Press ENTER to clear these values.

9) Display will show 0.0.

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

11) Select the Reverse Direction and repeat Item 10.

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

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

Page 36

INSTALLATION AND USER MANUAL CHOPPER SEM-ZERO-ONE

ADJUSTMENT INSTRUCTIONS ZAPI SEM

CAT

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

NPP / NSP / NSV Zapi SEM-0 RO 1.76

1/1

Rev. Date

NPV / NSD Zapi SEM-1 RO 1.78

16 27.10.2004

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

NSD16K

NSV12K (C)

NSV12K/12Ki

NSP12K/12Ki

NO20T NO25T

NPV30K

NPV25K

NPV22K

NPV20K

NPP25K

NPP16K/20K

TRUCK TYPES:

NOTE

SEM1 SEM1 SEM1 SEM1 SEM1 SEM0 SEM0 SEM1 SEM1

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

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

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

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

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

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

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

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

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

RUN BEL BRA ON HAN OFF OP2

RUN BEL BRA ON HAN OFF NOR

RUN BEL BRA ON HAN OFF OP2

RUN BEL BRA ON HAN OFF OP2

RUN BEL BRA ON HAN OFF OP1

RUN BEL BRA ON HAN OFF NOR

RUN BEL BRA ON HAN OFF NOR

RUN BEL BRA ON HAN OFF OP2

RUN BEL BRA ON HAN OFF OP1

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

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 150A 14A

OFF OFF 0 4 4 150A 14A

OFF OFF 0 4 4 300A 22A

OFF OFF 0 4 4 300A 22A

optional optional NPV20K pedestrian mode NPV20K without side guards optional

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

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

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

HYDRAULIC DIAGRAM NSP12KI, NSV12KI

HYDRAULIC DIAGRAM NSP16KI, NSV16KI

NSP 10K,12K,12KI,12KS: COLD STORE

NSP 10K,12K,12KI,12KS: COLD STORE

NSP 10K,12K,12KI,12KS: COLD STORE

NSP 10K,12K,12KI,12KS: COLD STORE

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

TILLER HEAD

26

27

4

S1

COM

+

0-5V

M2

M2.1

2/18

3/18

B-

X5:6

X5:8

WHT/ BLK BRN GRY

X5:7

ORA

X5:5

COM

X5:4

S13:

C5

1F1 160A

POT LOW

R5

2 KEY

2

WHT/ BLK WHT

COM

1

1

2F1 160A

10A

BW

NO

X5:3

A:B+

2

J1.2

B+

X5:2

1

3/14

NO

S2

X5:1

3F1

L2.1

2/14

S13:

NC RED/ GRN

L2

2/27

-

X1: B+

S3

J1.1

B1 ACCELERATOR

GRN

FW

X4: 1

30

3/27

S2 TILLER SWITCH

X4: 2

29

BELLY SWITCH

KEY SWITCH 3

28

2K1

1 A2

1

1K1 2

20

2

A7

PMC A1

1K1

+

A2

G2 -

D1

10mm2

A3

NMC

A8

H&S

SOFT

A5

PEMB

BRAKE

B4

FORW SW

B6

REV SW

B2

NPOT

POT.LOW

B1

CPOT

0-5V INPUT

B5

B SW

A6

-BATT

A1

A4

NEMB

SEM-0 150A

D3

NHORN HORN LOW

+BATT

24V 4,0mm2 E1

A2

M2 A2

F1

M1 A1

E2 4,0mm2

F2

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

10mm2

X1 BATTERY CONNECTOR, EMERGENCY ISOLATION

A1

F10

1Y1 A2

VMN

16mm2

X1: B-

X10: 1

X10: 2

-BATT BRAKE LOW

CIRCUIT DIAGRAM

TS850999

NSP10K/NSP12K/NSP12KI STANDARD EQUIPMENTS

1/8

REV

3-6728

A

12

13

14

15

16

17

TILLER HEAD

18

19

20

21

SIGNAL HORN

S4

22

COM

S6 COM

S5

24

25

LOWER

LIFT

COM NO

23

26

27

28

29

30

BRAKE RELEASE

FAST SPEED

NO

S11 OPTION

NO DOWN SLOW FAST

NO

S8

A

COM

COM

S6 ON ON

S8 ON

NO

X12: 1

X12: 2 LOWER

LIFT

KEY

L2 1/29

A2

11

C1 C2 C3

SUPPLY SLOW2 SLOW1

D4

PPC

+BATT

F1

PUMP

F2 +

A1

+ VMN

H1

-

V6

A2

+

A1

A1

A1

2K1

2Y1

2Y2

A2

A2

A2

-

1/13

-

C6 -BATT

M2

A1 SEM-0 150A

1/29

D5

NPC

LIFT LOWER

COILS LOW

CIRCUIT DIAGRAM

TS850999

2K1 ON

2Y1

HYDRAULIC BLOCK DEFINITIONS:

2Y2

SLOW FAST

J1.1 1/28

NSP10K/NSP12K/NSP12KI HYDRAULIC EQUIPMENTS

2K1 LIFT CONTACTOR 2Y1 LOWER VALVE (SLOW) 2Y2 LOWER VALVE (FAST)

2/8

REV

3-6728

A

11

12

13

14

15

16

17

TILLER HEAD

18

19

SIGNAL HORN

S4

COM

20

21

I.LOWER I.LIFT

COM

S10

NO

COM

S9

NO

22 LIFT

COM

S5

23

25

LOWER

COM

S6

NO

NO

24

26

27

28

29

30

BRAKE RELEASE

FAST SPEED

NO

S11 OPTION

S8

COM NO DOWN SLOW FAST

COM

S6 ON ON

S8 ON

NO

S12

X18: 1 C1 C2 C3

V11

SUPPLY SLOW2 SLOW1

EA PPC

LOWER

2

4

5

7

8

V12

V13

V14

V15

V16

X18: 3

D4

COM

X18: 13 14

10 11 V17

V18

V19

V20

Diodi 6A4

+BATT

F1

I.LIFT

1/29

A2

KEY

L2.1

S12 MAX.INITIAL LIFT LIMIT

NC

LIFT

X12: 2 I.LOWER

X12: 1

X18: 6

X18: 9

X18: 12

X18: 15

PUMP

F2 + A1

+ VMN

H1

-

V6

A2 -

+

+

+

A1

A1

A1

A1

A1

1Y1

2K1

1Y2

2Y1

2Y2

A2

A2 1/13

A2 -

A2

A2

-

-

C6 -BATT

M2.1

A1 SEM-0 150A

1/29

D5

NPC

I.LIFT I.LOWER LIFT LOWER

COILS LOW

CIRCUIT DIAGRAM

1Y1 ON ON

1Y2

ON ON

TS850999

2K1 ON

2Y1

2Y2

ON

ON

HYDRAULIC BLOCK DEFINITIONS:

J1.2

ON SLOW FAST

1/28

1Y1 1Y2 2K1 2Y1 2Y2

INITIAL LIFT/LOWER VALVE LIFT/LOWER VALVE LIFT CONTACTOR LOWER VALVE (SLOW) LOWER VALVE (FAST)

NSP10K/NSP12K/NSP12KI HYDRAULIC EQUIPMENTS/INIT.LIFT

3/8

REV

3-6728

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

KEY SWITCH 3

SAFETY SOCKET LED DISPLAY

X1: B+

1

GRN

A2 DISPLAY MDI

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

S0 X4: 1

3F1

A:B+

4

S1

X4: 2

MAINS SOCKET

2

10A

YEL 1

WHT BLU RED

1F1 160A

2 KEY

A3:1 2 3 1

1K1 1/20

A2

11

2

~230VAC RED

+ G2

BLK

-

16 mm2

+BATT

E1

PCLRXD

WHT

E2

NCLRXD

PUR

E3

PCLTXD

GRN

E4

NCLTXD

YEL

E5

GND

BLK

E6

+12V

RED

24V

+24VDC F1

A3 CHARGER 24V30A

F2

VMN 16 mm2

E7 E8

-BATT

X1: B-

A1 SEM-0 150A

X1 BATTERY CONNECTOR, EMERGENCY ISOLATION

CIRCUIT DIAGRAM

TS850999

NSP10K/NSP12K/NSP12KI ACCESSORIES

4/8

REV

3-6728

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

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

B-

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

A1:-BATT

R-2 0.75mm2 (1300mm)

1

R-2 0.75mm2 ( 300mm)

2

R-2 0.75mm2 (1300mm)

3 +

R-2 0.75mm2 (1300mm)

4

R-2 0.75mm2 (1300mm)

6

R-2 0.75mm2 (1300mm)

SA4

h

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

-

8 7 6 5 4 3 2 1

5

N M L K

O P R S T U

DISCHARGE

B+ 24 V

A1: B+

R-2 0.75mm2 (1300mm)

7 CONNECTIONS & ADJUSTMENT

ADAPTOR HARNESS RL462855

CIRCUIT DIAGRAM

RL197674

TS850999

NSP10K/NSP12K/NSP12KI ACCESSORIES 2

5/8

REV

3-6728

11

12

13

14

15

16

17

18

19

20

21

22

23

24

X4:1

26

29

28

30

L150

S1:3

3F1:2

2K1:A2

S1:4

2K1:A1

1K1:A2

1K1:A1

S2:NC

27

X4:2 L50

S2:COM

L1150

L750

25

L75

L75

S4:NO

S4:COM

9

L100 2

X12 RL211074

L300

L150

6

A1: B

L150

6

A1: D

L150

8

A1: A

L150

X 5 RL108288

L250

L1150

L250

L300

L120

S6:COM

L250

S8:NO

L850

S8:COM

L700

L120

L300

L900

S6:NO

L300

L250

L120

S11:COM

S5:NO

2Y2

2Y1

CIRCUIT DIAGRAM

H1:A2

L250

H1:A1

S5:COM

S13:NO

L250

S13:COM

S11:NO

L250

TS850999

X10 RL211074

2

NSP10K/NSP12K WIRE SET W5:RL450578

6/8

REV

3-6728

E

11

12

13

14

15

16

17

18

19

20

21

22

23

24

X4:1

9

L250 L120

L1150

S1:3

2K1:A2

3F1:2

2K1:A1

1K1:A2

S13:NO

30

S1:4

L75

L75

2

X12 RL211074

L300

L250

S4:NO

L1150

L300

X18 X18 RL210026 RL210028 15 15

L120

S8:NO

29

L150

6

A1: B

L150

6

A1: D

L150

8

A1: A

L250

S6:COM S8:COM

28

L150

S6:NO

27

L150

L150

L100

L900

S13:COM

X 5 RL108288

1K1:A1

S2:NC

26

X4:2 L50

S2:COM

L750

25

L1100

L500

L500

L250

L500

L250

S5:NO

L500

L250

S5:COM

L850

L800

S4:COM

L250

S10:NO

S10:COM

2

L150

S11:COM

H1:A2

H1:A1

2Y2

S9:NO

2Y1

L250

1Y2

L250

1Y1

S9:COM

S12:COM

X10

S12:NC

RL211074

L250

S11:NO REV

CIRCUIT DIAGRAM

TS850999

NSP12KI/NSV12KI WIRE SET W5: RL450741

7/8

3-6728

B

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

A1: C 3

A1:C1 <---75 ----> A1:C2 A1:C1 <---75 ----> A1:C3 R-2 / 0,50mm2

X12

No: RL350777-1 No: RL926894-1

2 X12:1P <---75 ----> X12:2P R-2 / 0,75mm2

CIRCUIT DIAGRAM

TS850999

NSP10K/NSP12K/NSP10KI/NSP12KI WIRE SET W5.1:RL461342

8/8

REV

3-6728

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1K1 4/18

2

1,0 mm2

1

1.0 mm2

25 mm2

1

1

4F1 10A

2

2

25,0 mm2

0F1 10A

X1: B+

DRIVE CIRCUITS

-

4/13

PUMP MOTOR

24V

4L1

2/17

DRIVE MOTOR

G1

1L1

4/12

BATT.DISCARGE IND.

+

0L1

MAIN CONTACTORS

1M1 2/17

X1: B-

25,0 mm2

12

25 mm2

11

CIRCUIT DIAGRAM

TS901000

NSP16K POWER SUPPLIES

1/6

REV

3-6757

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1L1 1/23

+B:1 1 2

1F1 325A 16.0 mm2

16.0 mm2 +B:2

A2

E1

A1 SPEED CONTROLLER

13

25,0 mm2

12

4,0 mm2 F1

M1 A1

E2 4,0 mm2 F2 TRACTION MOTOR: 0,8kW-24VDC (SEM-MOTOR)

D1

M2 D2 16.0 mm2

16.0 mm2

-T

SH

SH

-P

-B

25,0 mm2

11

CombiSEM-1

A1

1M1

1M2

1/23

4/12

DRIVE MOTOR

PUMP MOTOR

CIRCUIT DIAGRAM

TS901000

NSP16K POWER CIRCUITS

2/6

REV

3-6757

17

18

19

20

21

22

23

24

(INIT.) LIFT LOWER COM

ACCELERATOR NM3V

X5: 6

X5: 1

X5: 5

X5: 3

X5: 4

28

29

30

(STACKING MODELS) 5kOhm

S8

X5: 8

R1

COM NO

YEL/RED

X5: 7

WHT

LIFT/LOWER

27

COM

BELLY

B-

0-5 V

POT LOW

B1

GRN

26

NO

S6

COM

NC GRY

WHT/ BLK

FW

ORA

BW

BLK

B+

WHT/ BRN

NO

S5

S3

25

JS8

X6: 1

2

3

BLK

16

BLU/ORA

15

GRN

14

WHT/RED

13

PINK

12

PIN/GRY

11

X6: 4

5

6

4/15

SERIAL TILLER INTERFACE

4

C

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

1

A

2

2

F

1

1

2

3

12

LOWER

+24VDC

LOWER

+BATT

LIFT 9

B

13 14

1

RXD

2

7

LIFT

+5VDC

A

5

OPTION:

DRFT

TILLER SWITCH

TILLER SWITCH

BELLY SWITCH

-BATT

KEY OUT

BACK

BACK

KEY OUT

A5

0-5VDC

+5VDC 3

1

-BATT

5

B

4

C

KEY (+BATT)

6

I.LIFT

11

I.LOWER

+24VDC 3

+BATT

2

BELLY SWITCH

7

FW

3

8

BW

+BATT

+24VDC POT LOW

0-5 V

-BATT

A

6

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

0-5VDC

-BATT

5

6

BRAKE RELEASE NC

NO

S2 COM

7

TILLER SWITCH

S11

COM

8 KEY OUT

SPEED CONTROLLER CombiSEM-1

A1 CIRCUIT DIAGRAM

TS901000

NSP16K CONTROL DEVICES

3/6

REV

3-6757

11

12

13

0L1

4L1

1/17

1/26

14

15

A1

16

START-UP

17

18

MAIN CONTACTOR

19

20

21

22

PROPOVALVE

MAGN.BRAKE

23

24

25

26

INIT.LIFT/LOWER LIFT/LOWER

27

28

29

30

MOTOR FAN

CombiSEM-1

X4: 1

A1 SPEED CONTROLLER 22

20

PMF

9

NMF

11

PMV

21

NMV

10

PMV

17

NMV

B

PEV

6

NEV

16

PEB

5

NEB

13

PMC

2

NMC

+BATT

3

12

KEY IN

1

X4: 2

S1 4 KEY SWITCH

S4

JS8

NO

X9: 1

3/24

COM

X11: 1

SIGNAL HORN

X10: 1

X10: 3

M1

RED A1

V5

H1

+ C5 **) -

A2

A1

A1

2Y2 A2

1/17

F10

1N4005 100uF 63V

A1

1K1 A2

Y1 F10

A2

A1

A1

2Y1

*)

A2

2Y2 A2

A1 *)

2Y3 A2

BLK

X10: 4

X10: 2

X11: 2

X9: 2

1M2 2/18

**)

M3

*) APPLIED ONLY TO COLD STORE TRUCKS

APPLIED ONLY TO TRUCKS WITH INITIAL LIFT

CIRCUIT DIAGRAM

TS910801

NSP16K CONTROL DEVICES 2

4/6

REV

3-6775

15

16

17

18

19

20

A20

21

22

23

24

25

26

27

28

29

30

A2 MDI

CONSOLE

A2 DISPLAY A20 PROGRAMMER (OPTIONAL)

2

9

8

GRY +12VDC

BRN

4

5

6

+12VDC

3

-BATT

NCLTXD

BLK

2

6

-BATT

1

PCLTXD

NCLRXD

PCLRXD

+12VDC

6

5

NCLTXD

5

4

PCLTXD

4

NCLRXD

3

-BATT

BLU

2

PCLRXD

1

3

WHT

2

YEL/GRN

XA2: 1

NCLTXD

14

PCLTXD

13

NCLRXD

12

PCLRXD

11

7

3

4

D MOLEX MiniFit 10-pin A1 SPEED CONTROLLER CombiSEM-1

A1

CIRCUIT DIAGRAM

TS910801

NSP16K DISPLAY DEVICES 1

5/6

REV

3-6775

12

13

14

15

16

17

18

19

LIFT TOP LIMIT

20

SPEED LIMIT

21

22

23

24

25

ILIFT TOP LIMIT 1800mm LIMIT

26

27

28

29

30

TRUCK MODE SELECT

6 TOP LIMIT

1

11 CUTBACK SPEED 2

13

3 CUTBACK SPEED 2

(RL462560)

S12

X20: S

X20: P

4

E

14

CUTBACK SPEED 1

17

7

18

I.LIFT LIMIT

8 HEIGHT LIMIT

9

19 SELECT MODE 2

-BATT

S2

-BATT

S1

COM

COM

X20: S/P

HEIGHT LIMIT

COM

TOP MAST 2

COM

SR

COM

FLOOR

COM

COM

16

GATES

NC

TOP MAST

11

10

20 SELECT MODE 1

A1 SPEED CONTROLLER CombiSEM-1

A1

CIRCUIT DIAGRAM

TS901000

NSP16K DISPLAY DEVICES 2

6/6

REV

3-6757

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

S1:3

11

S2:COM

S2:NC

9

L150

L100

L250

L450

L900

L700

L200

L700

L700

L200

S4:COM

A1: F

8

A1: C

22

A1: B

2

A1: A

L100

L100 L550

2

4F1

L200

L150

A1:B-

1K1:2

1K1:1 0F1

L850

L100 L100

X 5 RL108288

1K1:A2

A5:C 6

1K1:A1

A5:B

L150

L150

6

L1000

X 6

L250

S11:NO

L250

X4:1

L200

14

L50

S11:COM

A5:A

S1:4

X4:2

L150

10

L750

S4:NO 2

S5:COM

2

H1:A2

H1:A1

2Y3:A2

2Y3:A1

S6:COM

2Y2:A2

L200

2Y2:A1

S6:NO

2Y1:A2

L120

2Y1:A1

X11 X 9 RL211074 RL210020

S17:NC

S5:NO

S17:COM

L200

REV

CIRCUIT DIAGRAM

TS901000

NSP16K WIRE HARNESS W5:RL450789

8/6

3-6757

F

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

WIRE: R-2 / 0,75mm2

A1: E 20

L:mm A1:E1 <---75 ----> A1:E11 A1:E3 <---75 ----> A1:E13 A1:E4 <---75 ----> A1:E14 A1:E6 <---75 ----> A1:E16 A1:E8 <---75 ----> A1:E18 A1:E7 <----75 ----> X20:S A1:E17 <---75 ----> X20:P

NOTE:CONNECT, X20:S AND X20:P !

X20:S= A1504HO X20:P= A1504HA

CIRCUIT DIAGRAM

TS901000

NSP16K WIRE HARNESS W5.1: RL461337

9/6

REV

3-6757

12

13

14

SAFETY SWITCH (BELLY)

15

16

19

BW

POT LOW

FW

20

21

22

23

TILLER SWITCH

B2

0-5V B-

B+

com

COLD STORAGE

25

26

27

28

29

30

HORN

BRAKE RELEASE

LIFT / INITIAL LIFT

LOWER / INITIAL LOWER

R2

-

no

COM

S6

R1 WH/

NC

24

R1 + R2 for stacker trucks R1 for pallet trucks.

ACCELERATOR

NO

S3

COM

S4

NO COM

S5

NO COM

COM NO

COM S2.2

XB1/8

3

WH 4

OR 5

BK 6

BN 7

RED/ GRN 1

BN 2

XB2/1

BK 2

X20

BU 3

XT3/

2

1

XT5/

3

4

2

12

11

10

DATE: 2008-09-29

XB4.1/ 2

4

X21 6

5

1

XB4.1/ 1

WH/ BK

XB4.1/ 5

NC GRY

NAME: IR

CHANGE: TILLER SWITCH CONNECTIONS

18

RD B1

S2.1

17

XB4.1/ 3

c ROCLA OYJ 2006

11

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

REV E

X22

XT1/7

6

5

4

3

2

1

9

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

8

15

NAME: JL

14

13

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1150908

XT2/2

NEW TILLER LAVANSIIRTÄJÄT JA PINOAJAT PALLET AND STACKER TRUCKS

3

1

1/2

REV

3-6969

E

c ROCLA OYJ 2006

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

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

B3 1 SPEED LIFT, 2 SPEED LOWER

2 SPEED LOWER

1 SPEED LOWER

LIFT

B-

LIFT/LOWER

B+

0-2.5-5V B-

B+

BK OR WH/ BK

WH

WH/ BR

GR

XB4/ 5

4

3

2

1

XT4/5

4

3

2

1

GR

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

REV

DATE: 2006-09-14

NAME:

CHANGE:

GRY

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

NAME: JL

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1150908

NEW TILLER PINOAJAT STACKER TRUCKS

2/2

REV

3-6969

E