Caterpillar NSV16K Lift Trucks Operation & Maintenance Manual - PDF DOWNLOAD

EN

Operation & Maintenance Manual NSV12K NSV12KI NSV16K NSV16KI

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

1. Stacker ................................................................................... 4 2. Safety instructions ................................................................. 5 3. Operating environment .......................................................... 6 4. Operating devices .................................................................. 7 5. Driving instructions ................................................................ 9 6. Load handling ...................................................................... 11 7. Batteries ............................................................................... 12 8. Maintenance ........................................................................ 14 9. Transportation and storage .................................................. 17 10. Troubleshooting .................................................................. 18

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Emergency procedures If the truck or a load falls over or down on a ramp, release your grip from the tiller and warn people near you. If the truck malfunctions, release the tiller arm to the up position or push it down completely. For instructions on switching off the main power, see Chapter 4. Operating devices.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

WARNING! Do not overload the truck.

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

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

0 = Power off (the power is still connected to certain electronic devices) 1 = Power on Recharging plug and main switch (2) The recharging plug works as the main switch and also as an emergency stop switch. See Section "Recharging the battery" in Chapter 7 for instructions on using the plug to recharge the battery.

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

NOTE: In the event of emergency, disconnect the truck from the power source by disconnecting the recharging plug.

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 battery discharge indicator shows the level of the battery charge and stops the lift if the battery charge is too low. However, you should recharge the battery before the charge drops too much.

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Controls Safety button (1) The safety button prevents you from getting squeezed between the truck and an obstacle. When you push the safety button, the truck reverses the travelling direction and stops when the button is released, if the speed control is released at the same time.

NOTE: Never use the safety button for normal driving. Check the operation of the safety button daily before you start working with the forklift truck.

Push buttons for lifting and lowering (2) The truck has push buttons for lifting and lowering.

Horn (3)

Accelerator (4) The accelerator is used for controlling the driving speed and for braking. Handle the accelerator gently.

Push button for the initial lift, optional (5) The truck has push buttons for lifting and lowering the initial lift.

Push button for stepless lifting and lowering (1600 kg capacity truck) (6) NOTE: Familiarise yourself with the operation of push buttons Steering (7) The tiller arm turns ±100 degrees..

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

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

• Check all wheels for damage or wear.

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

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

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

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

• Also check the operation of the other electrical functions.

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

• Check the operation of the horn.

• Check that the safety button works and that the parking brake functions properly.

• Check that the emergency stop operates properly.

• Check that the tiller arm returns to the up position.

Before you start: • Make sure that the daily maintenance has been carried out.

• Switch on the power and tilt the tiller arm to the driving position.

Driving • Turn the accelerator lightly in the driving direction.

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

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

• The tiller arm turns ±90°. The movement limiter allows 5° dampened increase in the total movement.

Adjusting the straddle forks (optional) • Lift the truck off the ground.

• Open the straddle fork locking screw.

• Adjust the straddle forks. Their maximum distance is 1300 mm. Both forks must be equidistant from the machine’s centreline.

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

• Drive slowly at intersections and when turning.

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

• Avoid sudden starts and stops.

• Steer and brake smoothly.

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

• Take great care when driving on a slanted surface.

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

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

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

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

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

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

To drive the machine from the riding position, fold down the platform (1) and lift up the safety bars (3). The safety bars keep you within the outlines of the machine and prevent you from losing your balance.

NOTE: Always lift up the safety bars when operating the machine standing on the platform.

When the platform and safety bars are in the riding position, the machine moves faster. When you step off the platform, driving is prevented.

To return the safety bars back to the pedestrian operating position, lift them from the hinging point and pull the lock lever (2). The safety bars will fold down. Then lift the platform and gas springs will fold it up.

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

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

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

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

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

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

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

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

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

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

• Always drive the truck with its forks lowered.

• When the load is raised, steer and brake carefully.

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

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

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

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

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

• Only handle undamaged loads.

• Place the load correctly.

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

• Do not overload.

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

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

Stacking and unloading To stack: • Drive towards the shelf or stacking level with the load and initial lift lowered.

• Make sure that the support forks go all the way underneath the lowest pallet.

• If the truck has side stabilisers, lower them.

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

• Drive forward towards the stack.

• When the load is in the correct position, lower it to the stacking level.

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

To unload: • • • • • •

Drive towards the shelf or stacking level with the forks so low that they can go under the lowest pallet.

Reverse far enough until the forks can be raised.

If the truck has side stabilisers, lower them.

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

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

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

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

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

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

• Do not smoke when working with batteries.

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

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

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

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

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

1. Park the truck in a reserved recharging place.

2. Switch off the power from the key switch.

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

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

5. Switch on the charger.

After recharging 1. Switch off the charger.

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

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

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

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

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

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

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

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

Battery charging with an inbuilt charger You can access the plug (1) for the power supply of the integrated charger from the outside of the truck. To activate the charger, extract the plug for the power supply from the safety socket on the machine and insert it into the correct outlet (230 V ±10% / 50 Hz).

After activating the charger, charging starts automatically.

The charging phase is indicated with two indicator lights: • Flashing green and yellow (the power is connected to the charger) • Yellow (charging begins) • Flashing yellow (charging in progress) • Green (fully charged) • Flashing green indicates a fault in the system and charging is stopped automatically.

NOTE: If the charger is not unplugged after the charging is complete, the charger will stop automatically.

WARNING! No inflammable materials are allowed within 2 meters of the truck under charge or the charger.

When the charging is finished, you can unplug the charger plug and connect it to the safety socket of the truck. If the plug is not connected to the safety socket, all electrical functions will remain switched off and the truck cannot be used.

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

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

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

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

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

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

• Release the hydraulic pressure before opening the system.

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

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

• Only use clean oil in the hydraulic system.

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

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

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

Weekly maintenance • Check and clean the battery cable fastenings.

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

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

• Check that the hydraulic system has no leaks.

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

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

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

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

• Clean the truck if necessary.

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

• Lubricate lightly the grooves of the mast, reach carriage, and the lift carriage.

• With straddle models, check the locking bar of the straddle forks.

NOTE: Do not let water onto the electrical devices.

Quarterly maintenance (300 hours) • • • • • • • • •

Contactors, microswitches, and solenoids and their cables Brake air gap: correct dimension 0.3–0.8 mm Accelerator operation Speed limiter operation Play of the forks and their slope and condition Tiller arm gas spring Lifting cylinder operation Lifting hydraulics operation Collectors, carbon brushes, and electric cables of the drive and pump motors

Semi-annual maintenance (600 hours) Check and adjust or repair, if necessary: • Operation of the hydraulics and pressure limit valves • Drive wheel for wear • Oil filter 14

• Fastening of the gearbox and the amount of transmission oil • Condition of the side castor wheels and load wheels • Fastening of the tiller arm

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

• Change the transmission oil once a year.

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

Turning bearings of the load wheels Bearings of the side castor wheels Suspension rail of the drive unit Turning bearings of the drive unit

Lubricant recommendation Filling hole for hydraulic oil (1) Hydraulic oil: ISO VG 15 In freezer warehouses: ISO VG 32 Fill the tank to ¾ volume Transmission oil: SAE 80W/OP, API: GL–4 Fill to the volume of 0.6 l.

Lubricating grease: NLGI No. 2, containing molybdenumdisulfide In freezer warehouses: NLGI No. 1 or No. 0 Filling hole for transmission oil (1) Opening to check the oil level (2) Oil outlet (3)

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Location of fuses in the speed control unit 1200 kg capacity stackers: Control circuit fuse (1) Lift motor fuse (2) Drive motor fuse (3)

1600 kg capacity stackers: Main fuse for drive and pump motor (1) Control circuit fuses (2)

Ordering spare parts When ordering spare parts, always contact your dealer or the maintenance centre. Only use original spare parts. To ensure that you receive the correct parts, include the following information in the order: 1. Truck type 2. Serial number of the truck 3. Order number of the part 4. Name of the part 5. Amount of parts ordered Items 1 and 2 are listed on the front page of the manual or on the identification plate of the truck. Items 3 and 4 are listed on the spare part pages of the manual supplied with the truck.

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

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

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

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

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

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

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

Otherwise normal daily maintenance and inspection are sufficient.

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10. Troubleshooting

Symptom

Fault

Action

Truck does not move

Battery connector is loose

Plug in the battery connector.

Battery is empty

Recharge the battery.

Charger plug is not in safety socket

Plug in the charger plug.

Key switch is faulty

Replace the switch.

Drive motor fuse has blown

Check the connections and cables and replace the fuse.

Microswitch for tiller arm is broken

Replace the microswitch.

Control circuit fuse has blown

Check the connections and cables and replace the fuse.

Drive motor carbon brushes are worn out

Replace the carbon brushes.

Speed controller is faulty

Contact maintenance personnel.

Lift pump does not run

Pump fuse has blown

Check the connections and cables and replace the fuse.

Lifting functions improperly

Overload

Decrease the load.

Battery is empty

Recharge the battery.

Not enough oil in tank

Add oil.

Oil leak

Check the joints and seals.

Pump is faulty

Replace the pump.

Dirt or wear in valves

Clean the valves, replace if necessary.

Charger is incorrectly connected

Check the connection.

Charger fuse has blown or main voltage is missing

Check the connections and cables and replace the fuse.

Battery cell’s water level or specific gravity is low

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

Battery does not charge

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

ADJUSTMENT INSTRUCTIONS ZAPI COMBISEM

1/3

NSP16K/KI, NSV16K/KI

Rev. Date

Zapi CombiSEM 24V 300A+300A COMBI RO 1.23-1.25

20 22.11.2007

option

Default values

NSP16KI NSV16KI

NSP16K NSV16K sidestab.

NSV16KI

cold store

NSV16K

cold store

NSP16KI

cold store

NSP16K

cold store

NSV16K/KI

NSP16K/KI

TRUCK TYPES:

RO-A RO-A RO-A RO-A RO-A RO-A RO-A RO-A RO-A RO-A RO-A MAIN MENU/ PARAMETER CHANGE: ACCELERATION DELAY 5 5 5 5 5 FLD ACCELERATION 5 5 5 5 5 DECELERATION DELAY 5 5 5 5 5 RELEASE BRAKING 3 3 3 3 3 INVERSE BRAKING 7 7 7 7 7 CURVE BRAKING (RO-D) 5 5 5 5 5 CUTBACK SPEED 1 (LOW) 2 2 1 2 2 2 CUTBACK SPEED 2 (MIDDLE) 8 8 6 8 8 8 MAX. SPEED FORWARD 6 9 6 9 6 MAX. SPEED BACKWARD 6 9 6 9 6 TRACTION IMAX 0 9 0 9 0 ARMA. NOM. CURRENT 3 0 3 0 3 WEAK DROPOUT 1 0 1 0 1 FIELD CURRENT MAX. 5 5 2 5 5 5 FIELD NOM. CURRENT 3 3 1 3 3 3 CREEP SPEED 0 0 0 0 0 BACKING TIME 0 0 0 0 0 BACKING SPEED 0 0 0 0 0 AUXILIARY TIME 0 0 0 0 0 PUMP ACCELER.DELAY 0 0 0 0 0 PUMP DECELER.DELAY 0 0 0 0 0 PUMP CREEP 1 1 1 1 1 1ST SPEED COARSE 9 9 9 9 9 SLOW LIFT SPEED 0 0 0 0 0 FORK LIFT SPEED 9 9 9 9 9 2ND SPEED COARSE 0 0 0 0 4 0 3RD SPEED COARSE 0 0 0 0 4 0 MIN. VALVE VOLT 4 4 4 4 4 MAX. VALVE VOLT 5 5 5 5 5 SLOW LOW SPEED 0 0 0 0 0 FORK DOWN SPEED 7 7 7 7 7 EV.ACCELER.DELAY 7 7 7 7 7 EV.DECELER.DELAY 0 0 0 0 0 2ND EV.DECELER.DELAY 0 0 0 0 0 BRAKE DELAY 2 2 2 2 2 CONFIG MENU/ SET OPTIONS: HOUR COUNTER RUN RUN RUN RUN RUN BATTERY CHECK ON ON ON ON ON AUX FUNCTION #2 PRE PRE PRE PRE PRE LIFTING POT PRE PRE PRE PRE PRE QUICK INVERSION BEL BEL BEL BEL BEL I-LIFT FUNCTION ON ON OFF ON OFF ON ON ON ON AUX INPUT #1 1 1 1 1 3 1 1 GATE MODE OFF ON OFF ON OFF INVERSION MODE OFF ON OFF ON OFF AUX CURRENT #1 ON OFF ON OFF ON SAFETY SWITCH OFF OFF OFF OFF OFF BRAKING MODULATION OFF OFF OFF OFF OFF AUX FUNCTION #3 OFF OFF OFF OFF OFF AUX OUTPUT #1 0 9 0 9 0 ADJUSTMENTS: ADJUST BATTERY Ubat Ubat Ubat Ubat Ubat ADJUSTMENT #01 4 4 4 4 4 ADJUSTMENT #02 4 4 4 4 4 THROTTLE 0 ZONE 1 1 1 1 1 THROTTLE X POINT 3 3 3 3 3 THROTTLE Y POINT 1 1 1 1 1 MAIN MENU/ ALARMS/ SPECIAL MENU: HARDWARE SETTINGS: SET CURRENT 300A 300A 300A 300A 300A SET FIELD CURRENT 20A 20A 20A 20A 20A FIELD CURRENT MIN. 4 0 4 0 4 AUX FUNCTION #1 OFF OFF OFF OFF OFF CHECK UP DONE OFF OFF OFF OFF OFF CHECK UP TYPE NON NON NON NON NON

NOTE

not used mast 1800mm (NSV16K) platform or sideguards (NSV16K)

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

lift speed adjustment on/off-lift speed adjustment sidestabilizers down sidestabilizers up propor.lower speed adjustment on/off-lower speed adjustment lower acceleration ramp lower deceleration ramp init.lift lower deceleration ramp magn.brake apply delay

do not change do not change do not change do not change initial lift option additional initial lift buttons side guard option belly switch option 800W motor setting (NSP16K) hydr.functions after tiller sw. motor braking at slow speeds parallel functions blocked programmable output do not change discharge ind. 100%-level discharge ind. 10%-level accelerator neutral zone length accelerator input curve x-point accelerator input curve y-point

do not change do not change do not change Load HM from MDI not used not used

CAT RD Technical Specifications

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

ADJUSTMENT INSTRUCTIONS ZAPI COMBISEM

NSP16K/KI, NSV16K/KI Zapi CombiSEM 24V 300A+300A COMBI RO 1.23-1.25 0

Calibration instructions for accelerator and lift/lower potentiometer: 1. Program all the parameters and options of CombiSEM controller.

2. Check that SLOW LIFT is not activated (Zapi Console/Main Menu/Tester/).

3. Check that SLOW LOW is not activated (Zapi Console/Main Menu/Tester/).

4. Turn key switch off.

5. Locate connector J1 in Zapi Serial Tiller Card and close it with jumper.

6. Turn key switch on.

7. Rotate accelerator slowly fully forward.

8. Wait 2 seconds.

9. Release accelerator slowly to the neutral position.

10. Wait 2 seconds.

11. Rotate accelerator slowly fully backward.

12. Wait 2 seconds.

13. Release accelerator slowly to the neutral position.

14. Wait 2 seconds.

15. Push lift lever slowly fully forward.

16. Wait 2 seconds.

17. Release lever slowly to the neutral position.

18. Wait 2 seconds.

19. Pull lift lever slowly fully backward.

20. Wait 2 seconds.

21. Release lever slowly to the neutral position.

22. Wait 2 seconds.

23. Open J1.

24. Wait 5...10 seconds.

25. Turn key switch off.

26. Turn key switch on.

27. Check acceleration forward and backward.

28. Check lifting and lowering.

INSTRUCTIONS

2/3

Rev. Date

20 22.11.2007

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

NSP16K/KI, NSV16K/KI Zapi CombiSEM 24V 300A+300A COMBI RO 1.23-1.25 0

Rev. 20 Date 22.11.2007

AUX INPUT #1 programming CombiSEM1 RO 1.05 AUX INPUT #1 can be programmed in 4 different ways: > OPTION #1: no sidestabilizers, reset lift limit by closing E3-E13 (CombiSEM) > OPTION #2: no sidestabilizers, reset lift limit by closing E3-E13 (CombiSEM) or A5-B6 (SERTIL) > OPTION #3: sidestabilizers, reset lift limit by closing E3-E13 (CombiSEM) > OPTION #4: sidestabilizers, reset lift limit by closing E3-E13 (CombiSEM) or A5-B6 (SERTIL) NOTE: After changing AUX INPUT #1 parameter press OUT and save changes.

Turn power off and on again in order to activate the selected option.

1.) Closing E3-E13 is handled though pressure switch.

2.) Closing A5-B6 is handled though joystickin reset button or separate reset button in control panel.

3.) If lift limit acts as a top lift limit, E3-E13 (CombiSEM) and A5-B6 (SERTIL) shall be left unconnected.

AUX OUTPUT #1 programming CombiSEM1 RO 1.08 AUX OUTPUT #1 can be programmed in 10 different ways: > LEVEL 0: output disabled > LEVEL 1: output active, when forward direction selected > LEVEL 2: output active, when backward direction selected > LEVEL 3: output active, when forward or backward direction selected > LEVEL 4: output active, when lift selected > LEVEL 5: output active, when lower selected > LEVEL 6: output active, when lift or lower selected > LEVEL 7: output active, when forward direction, backward direction, lift or lower selected > LEVEL 8: output active, when horn selected > LEVEL 9: output active, when line contactor active (->drive motor fan)

Index 1

Page General characteristics ................................................................................. 3 1.1 Technical specifications ........................................................................ 3 1.2 General description ............................................................................... 3 1.3 Main features ........................................................................................ 3 1.4 Safety & protection features .................................................................. 4 1.5 Thermal considerations ......................................................................... 4 1.6 Combi Sem-1 chopper diagnosis .......................................................... 5 1.7

2

3

4

5

Main Contactor and safety button

.................................................. 5

1.8 General instructions and precautions ............................................ 6 Installation ..................................................................................................... 7 2.1 Connection cables ................................................................................. 7 2.2 Contactors ............................................................................................. 7 2.3 Fuses .................................................................................................... 7 2.4 Combi Sem-1 controller mechanical drawing ........................................ 8 2.5 Serial tiller mechanical drawing ............................................................. 9 Connection .................................................................................................. 10 3.1 Combi Sem-1 connection drawing ...................................................... 10 3.2 Serial tiller connection drawing............................................................ 11 3.3 Description of combi sem-1 connectors .............................................. 12 3.3.1 Connector "A" description .......................................................... 12 3.3.2 Connector "B" description .......................................................... 12 3.3.3 Connector "C" description .......................................................... 13 3.3.4 Connector "D" description .......................................................... 14 3.3.5 Connector "E" description .......................................................... 14 3.3.6 Connector "F" description .......................................................... 16 3.4 Combi Sem-1 power connection ......................................................... 16 Regulation .................................................................................................... 17 4.1 Zapi Programming handly console ...................................................... 17 4.2 Description of standard console menu ................................................ 18 4.3 "Parameter Change" menu ................................................................. 19 4.4 "Tester" menu ..................................................................................... 21 4.5 "Adjustment" menu .............................................................................. 21 4.6 "Set Option" menu ............................................................................... 21 Alarms .......................................................................................................... 23

Page 1

1 GENERAL CHARACTERISTICS 1.1 TECHNICAL SPECIFICATIONS

Motor Types (Traction): .............................................................................. DC SEM Motor Types (Pump): ............................................................................ DC SERIES Power ratings (Traction): ........................................................................... 1 to 2 kW Supply Voltage: ......................................................................................... 24V / 48V Armature Switching frequency: ..................................................................... 16 kHz Field Switching frequency: ............................................................................ 800 Hz Temperature range: ....................................................................... -30 °C to +40 °C Maximum controller temperature: ................................................................... 75 °C Version

Maximum Traction current

Maximum Pump current

200+250

200 A

250 A

300+300

300 A

300 A

400+250

400 A

250 A

1.2 GENERAL DESCRIPTION ZAPI COMBI SEM-1 controller performs all the electric functions that are usually presents in transpallet, stacker, low order picker etc.

The controller can perform the following functions: - Traction controller for SEM motor; full-bridge on the field, half-bridge on the armature.

-

Lifting controller for series excited motors.

-

Drivers for ON/OFF electrovalves and for one proportional valve (electrodistributor)

-

Interface for serial tiller head

-

MDI interface (Multifunction Digital Instrument) battery discharge indicator, hourmeter, alarms, programmed maintenance.

1.3 MAIN FEATURES

-

High frequency MOSFET controller (high efficency, silent, etc.).

-

Speed control with regenerative braking (controls the truck also on the slope)

-

Idraulic functions control with different programmable speeds and ramps, It is possible to use proportional functions.

-

Lowering speed control through proportional valve.

-

All the parameters are programmable by means of the ZAPI console.

-

Complete diagnosis through console or MDI.

-

High temperature protection with current reduction.

-

Drivers real time diagnosis (electro-brake, general contactor and proportional valve.

-

Electrobrake and general contactor are controlled with a PWM.

-

Drivers protected against short-circuits.

Page 3

1.4 SAFETY & PROTECTION FEATURES - Reverse Battery Polarity.

Electrical Circuit diagrams must be followed in order to avoid damage to the power unit. A Main contactor, controlled by the logic unit, is necessary to protect the system against reverse battery polarity.

- Connection errors All inputs are protected against connections errors. Contactor drivers are suitable for loads up to 2 Amps, and are protected against overload.

- Thermal protection If the controller temperature exceeds 77°C, the maximum current will be reduced proportionaly to the thermal increase. The temperature can never exceed 90°C. - Low Battery charge When the battery charge is low, the maximum current is reduced.

- External Agents The chopper is protected against dust and spray of liquid to a degree of protection meeting IP64.

- Protection against accidental Start Up A precise sequence of operations is necessary before the machine starts. If these operations are not carried out correctly the machine stops. Driving requests must be made after closing the Key Switch.

- Protection against uncontrolled movements.

The Main Contactor will not close if: - The Power Unit is not operating correctly - The Logic Unit is not operating correctly - The Serial Tiller is not operating correctly 1.5 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 4

1.6 COMBI SEM-1 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: watch-dog, Current Sensors, VMN point, contactor drivers, presence of a start requirement, and connection with the Serial Tiller ok.

2) Standby Diagnosis that checks: watch-dog, VMN Point, Contactor Drivers, Current Sensors.

3) Driving diagnosis that checks: Watchdog, VMN Point, Current, Contactor(s).

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

1.7 MAIN CONTACTOR AND SAFETY BUTTON - Battery disconnection should be made according to the Diagram below.

- In order to avoid damage to the controller during the regenerative phase, the supply to the Key Switch must be cut off at the same time.

Wiring with cut off in series to positive supply.

- An internal protection is activated when the voltage on B12 connector is greater than 30% of battery voltage, or when the key switch is opened before the battery is opened.

Page 5

1.8 GENERAL INSTRUCTIONS AND PRECAUTIONS - Never combine SCR low frequency choppers with COMBI SEM-1 modules. The filter capacitors contained in the COMBI SEM-1 module would change the SCR chopper operation and subject it to excessive workload. If it is necessary to use two or more control units, the choppers should both 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. A lower voltage may prevent the logic operating.

- During battery recharge, the COMBI SEM-1 must be completely disconnected from the battery. Beside changing the charging current seen by the battery charger, the module can be damaged by higher than normal voltages supplied via the charger.

- The COMBI SEM-1 module should only be connected to a traction battery. Do not use converters outputs or power supplies. For special applications please contact the nearest Zapi Service Centre.

- In the first instance, start the machine with the drive wheels raised from the floor to ensure that any installation error 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 6

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

Apply a very 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 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 (maximum screwing torque: 3 Nm for M5 and 4Nm for M8 screws).

Verify that the wiring of the cable terminals and connectors has been carried out correctly.

2.1 CONNECTION CABLES For the auxiliary circuits use cables bigger or equal to 0.5mm2 section.

For power connections to the motor (pump and traction rotor) and to the battery use cables of 16÷25 mm2 section. The cables from chopper to battery should be run side by side and be as short as possible.

2.2 CONTACTORS A Main 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 2A. Suppression for this contactor coil is inside the chopper logic. Do not use any additional external suppression.

2.3 FUSES - Use a 10A fuse for protection of the auxiliary circuits.

- The power fuse is alrady installed on the chopper by Zapi. For special applications or requirements this value can be reduced.

Page 7

2.4 COMBI SEM-1 CONTROLLER MECHANICAL DRAWING

Page 8

2.5 SERIAL TILLER MECHANICAL DRAWING

Page 9

3 CONNECTION

3.1 COMBI SEM-1 CONNECTION DRAWING

Page 10

3.2 SERIAL TILLER CONNECTION DRAWING The folllowing drawing is an example of typical tiller head functions.

Page 11

3.3 DESCRIPTION OF COMBI SEM-1 CONNECTORS

3.3.1 Connector "A" description The "A" connector is connected by Zapi.

A1

KEY OUT

This pin is connected to the pin1 of the F connector; is a key signal.

A2

BACKING

This pin is connected to the pin2 of the F connector; is a backing signal.

3.3.2 Connector "B" description The "B" connector managed the main contactor, the brake and the electrovalves coils.

B1

+ BATT

Positive after the main contactor; is the electrovalves positive.

B2

NMC

Negative of the main contactor

B3

-BATT

Negative free for the customer.

B4

-BATT

Negative free for the customer.

B5

NEB

Negative of the electromechanical brake.

B6

NEVP

Negative of the proportional electrovalve.

B7

NEV2-NHO Negative of the electrovalve 2; (option: negative of the horn).

B8

NEV1

Negative of the electrovalve 1.

B9

NEV4

Negative of the electrovalve 4.

B10 NEV3

Negative of the electrovalve 3.

B11 NEV5

Negative of the electrovalve 5.

B12 KEY IN

Input of the Key switch signal.

Page 12

B13 PMC

Positive of the main contactor.

B14 KEY OUT

Output of the Key switch signal.

B15 NOT USED Free.

B16 PEB

Positive of the electromechanical brake.

B17 PEVP

Positive of the proportional electrovalve.

B18 PEV2

Positive of the electrovalve 2.

B19 PEV1

Positive of the electrovalve 1.

B20 PEV4

Positive of the electrovalve 4.

B21 PEV3

Positive of the electrovalve 3.

B22 PEV5

Positive of the electrovalve 5.

Note: Proportional valve can be programmed by console as proportional or ON/OFF: if proportional the valve has an acceleration and deceleration ramp and its current is controlled by the lifting potentiometer.

If ON/OFF the valve is completely opened/closed without ramps.

The positive supply to the main contactor is provided from the key (pin 12) trough a diode against polarity inversion. The positive supply for the electrobrake is available in the pin 16 only if the tiller switch is closed.

The positive for the brake and all the other ON/OFF valves comes from the main contactor, so these loads do not affect the key input but only the auxiliary fuse.

3.3.3 Connector "C" description The "C" connector manages the serial link of the tiller card.

C1

-BATT

Negative free for the customer.

C2

BELLY

Quick inversion microswitch input. This signal is directly connected with the Combi for safety reason.

C3

SNAIL + T

Snail microswitch input. It is necessary that the tiller microswitch is cabled in the serial tiller card; in this case it is possible to run the truck also with the handle released at a slow speed.

C4

TILLER

Tiller microswitch input. In this case the tiller is directly connected with the Combi.

C5

DRFT

Data from the serial tiller

C6

-BATT

Negative for the serial tiller card.

C7

KEY OUT

Positive for the serial tiller card (is a key switch signal).

C8

KEY OUT

Positive for the tiller microswitch (is a key switch signal).

Note: The tiller microswitch can be cabled in the serial tiller (see serial tiller drawing) or directly in the controller (PIN 4 and 8 for the key in the serial tiller).

Page 13

3.3.4 Connector "D" description The "D" connector manages the MDI instrument or a Zapi console.

D1

NOT USED Free.

D2

PCLRXD

Positive of the reception from the console or the MDI instrument.

D3

-BATT

Negative of the console or the MDI instrument.

D4

+12

Positive of the console or the MDI instrument.

D5

NOT USED Free.

D6

NOT USED Free.

D7

NCLTXD

Negative of the transmission to the console or the MDI instrument.

D8

PCLTXD

Positive of the transmission to the console or the MDI instrument.

D9

NCLRXD

Negative of the reception from the console or the MDI instrument.

D10 NOT USED Free.

Note: The console must be connected to "D" at the place of MDI by means of an adaptor (follow the table for the right connections).

3.3.5 Connector "E" description The "E" connector manages the inputs from the chassis of the truck.

E1

INPUT 1

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E2

-BATT

Negative free for the customer.

E3

CM

Positive for the "Input 2"; is a key switch signal interrupted by a diode for safety reason.

Page 14

E4

INPUT 3

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E5

-BATT

Negative free for the customer.

E6

INPUT 4

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E7

CM

Positive for the "Input 5"; is a key switch signal interrupted by a diode for safety reason.

E8

CM

Positive for the "Input 6"; is a key switch signal interrupted by a diode for safety reason.

E9

SELECT 1

This is a digital input for model configuration.

E10 SELECT 2

This is a digital input for model configuration.

E11 CM

Positive for the "Input 1"; is a key switch signal interrupted by a diode for safety reason.

E12 -BATT

Negative free for the customer.

E13 INPUT 2

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E14 CM

Positive for the "Input 3"; is a key switch signal interrupted by a diode for safety reason.

E15 -BATT

Negative free for the customer.

E16 CM

Positive for the "Input 4"; is a key switch signal interrupted by a diode for safety reason.

E17 INPUT 5

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E18 INPUT 6

This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

E19 -BATT

Negative of the "Select 1" input.

E20 -BATT

Negative of the "Select 2" input.

Note: For the inputs is acceptable a PNP sensor with a 24V output. The maximum load for single inputs is less than 5mA.

Page 15

3.3.6 Connector "F" description The "F" connector is connected by Zapi.

F1

KEY OUT

This pin is connected to the pin1 of the A connector; is a key signal.

F2

BACKING

This pin is connected to the pin2 of the A connector; is a backing signal.

3.4 COMBI SEM-1 POWER CONNECTION

+BATT before FUSE +BATT after FUSE -BATT F1, F2 VMNT VMNP

Page 16

Positive of the battery after the main contactor Positive of the battery after the main cont. and after the fuse.

Negative of the battery.

Field connections for traction motor.

Traction motor current sensor input.

Pump motor input (without the current sensor).

4 REGULATION

4.1 ZAPI PROGRAMMING HANDLY CONSOLE In Combi Sem-1 controller is possible to program several functions through the console.

In this way is possible to modify the performances of the truck following the customer needings.

The console can remain connected to the controller while running and the parameters can be changed in real time. In this case it is important to go in stand by condition before switch off the controller in order to give the possibility to store the new values in the Eeprom.

This section describes the ZAPI console functions.

Six buttons provide the capability of changing or reading the parameter of the Combi: 1

Roll-Up

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

2

Roll-Down

push to scroll down the submenu and to select a parameter;

3

Enter

push to have access to the selected submenu or to confirm a changement;

4

Out

push to exit the selected menu or to refuse a changement;

5

Set-Up

push to increase a parameter;

6

Set-Down

push to decrease a parameter;

Note: After a modify, memoriz the new value pushing the "4" (Out) button and the "3" (Enter) button. Double pushing of the "4" (Out) button doesn't save the value.

Numbers inside the triangles in the following map correspond to the same number on the console keyboard buttons shown in the figure below. The orientation of the triangle indicates the way to the next function.

Important CONNECT AND DISCONNECT THE CONSOLE ONLY WITH THE CONTROLLER SWITCHED OFF.

Page 17

4.2 DESCRIPTION OF STANDARD CONSOLE MENU

Page 18

4.3 "PARAMETER CHANGE" MENU The following parameters are an example of a typical Parameter Change menu; some of this parameters could be changed from customer requests.

The parameters with (p) symbol are related to the pump, those with (t) are related to the traction motor.

1) ACCELERATION DELAY (t) = Sets the acceleration ramp.

2) FLD ACCELERATION (t) = Field acceleration ramp: is the time needed to lower the field till to the weakened value, is a function of "Acceler. delay".

3) DECELERATION DELAY (t) = Sets the deceleration ramp according to the accelerator potentiometer position.

4) RELEASE BRAKING (t) = Sets the deceleration ramp when the driving request is released.

5) INVERS BRAKING (t) = Sets the deceleration ramp when is inverted the driving direction.

6) CUTBACK SPEED 1 (t) = Speed reduction 1.

7) CUTBACK SPEED 2 (t) = Speed reduction 2.

8) MAX. SPEED FORW. (t) = Maximum Forward speed, obtained by weakening the field current after reaching 100% conduction on the armature. With the parameter set at level 0, the armature is in full conduction but the field current does not decrease below the nominal value (low speed).

9) MAX SPEED BACK (t) = Maximum Reverse speed, obtained by weakening the field current after reaching 100% conduction on the armature. With the parameter set at level 0, the armature is in full conduction but the field current does not decrease below the nominal value (low speed).

10) TRACTION I MAX (t) = Sets the maximum current of the Chopper (Armature).

11) ARMA NOM. CURR (t) = 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.

12) WEAK DROPOUT (t)= This parameter fixes a limit on the armature current above which the field current is increased linearly up to the nominal field current (proportionally to the armature current).

13) FIELD CURR. MAX. (t) = Maximum field current. This parameter fixes the maximum field current when the armature reaches the maximum value.

14) FIELD NOM. CURR. (t)= Nominal field current. This parameter fixes the minimum field current when the accelerator is between 0% and 60% without full conduction on the armature. Adjustment should be made with reference to the data on the motor label. (The indication of Nominal Field Current).

15) CREEP SPEED (t)= Minimum speed. This parameter sets the minimum start voltage applied to the motor.

16) SOFT WORKING (t) = Sets the entity of the acceleration and deceleration curves with the Snail (H&S) function selected.

Page 19

17) PUMP ACC DELAY (p) = Pump motor acceleration time:during this time the voltage on the pump motor goes to the desired value.

18) PUMP DEC DELAY (p) = Pump motor deceleration time:during this time the voltage on the pump motor decreases to the desired value..

19) PUMP CREEP (p) = This parameter sets the minimum voltage applied to the pump motor.

20) 1ST SPEED COARSE (p) = Main lift maximum speed.

21) FORK LIFT SPEED (p) = Forks lift maximum speed.

22) FORK DOWN SPEED (p) = Forks down maximum speed.

23) R - SHIFT SPEED (p) = Right shift maximum speed.

24) L - SHIFT SPEED (p) = Left shift maximum speed.

25) MIN EVP COARSE (p) = Sets the minimum voltage applied to the EVP. This is a big regulation.

26) MAX EVP COARSE (p) = Sets the maximum voltage applied to the EVP. This is a big regulation.

27) MIN EVP FINE (p) = Sets the minimum voltage applied to the EVP. This is a fine regulation.

28) MAX EVP FINE (p) = Sets the maximum voltage applied to the EVP. This is a fine regulation.

29) EVP ACC. DELAY (p) = Sets the acceleration time of the EVP. 30) EVP DEC. DELAY (p) = Sets the deceleration time of the EVP. 31) BACKING SPEED (t) = Sets the maximum backing (inching) speed.

32) BACKING TIME (t) = Sets the duration of the backing function.

Page 20

4.4 "TESTER" MENU 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.

4.5 "ADJUSTMENT" MENU 1) ADJUST BATTERY = Battery voltage reading adjustment according with the real battery voltage.

2) ADJUSTEMENT #01 = Sets the maximum value of the battery discarge curve.

3) ADJUSTEMENT #02 = Sets the minimum value of the battery discarge curve.

4.6 "SET OPTION" MENU 1)

2)

3)

4)

5)

HOUR COUNTER Keyon

hourmeter always updated.

Running

hourmeter updated only if traction, lifting or hydraulics functions are activated.

BATTERY CHECK On

the battery discarge level check is carried on; when the battery level reaches 10%, an alarm is signaled and the maximum current is reduced to the half of the programmed value.

Off

the battery discarge level check is carried on but no alarm is signaled.

AUX FUNCTION 2 Present

Proportional electrovalve present.

Absent

Proportional electrovalve not present. Will be driven like an On/Off electrovalve.

QUICK INVERSION Belly

the truck goes backward direction (at 50% of maximum speed) till the belly button is pressed.

Timed

the truck goes backward direction (at 50% of maximum speed) only for some seconds.

SHIFT FUNCTION Present

The Shift function is enabled.

Absent

The Shift function is not used. In this case the output for the shift left valve can be used to drive an external horn. The Combi buzzer will be driven in parallel with the horn.

Page 21

6)

7)

8)

AUX FUNCTION #1 On

the Combi hour-meter is immediately over-written by that of MDI instrument.

Off

In this configuration the alarm "AL98" will be displayed on the MDI for 1 minute. If during this minute the user doesn't set ON the "Aux function #1", the MDI hour-meter will be over-written by that of the controller.

CHECK UP ENABLE On

This function sets an alarm (AL99, Check Up Needed) after 300 hours which informs the operator that it is necessary to make assistance service on the machine.

Off

This function is disabled.

CHECK UP DONE On

This option enables to reset the check-up hour-meter and the alarm "Check Up Needed".

Off

This function is disabled.

Page 22

5 ALARMS "ZAPI CONSOLE" 1) POWER FAILURE #1

"MDI" 73

Short-circuit on the ON/OFF valves, or in the main contactor coil, or in the electrobrake coil.

2) EEPROM KO

13

Fault in the area of memory where the parameters are stored. This alarm inhibits machine operation. If the fault continues when the Key switch is turned off and on again, replace the logic. If the fault disappears, the previously stored parameters will be replaced by the default parameters.

3) INCORRECT START

79 (Traction), 95 (Pump)

Alarm generated by an incorrect starting sequence. Possible reasons: a) The Enable microswitch has welded or failed. b) Error in the starting sequence from the operator. c) Error in the wiring. d) Lifting operation awaiting when the key is turned on.

4) CAPACITOR CHARGE

60

This check is made during the initial diagnosis. This Alarm is generated if the capacitors are not charged within 500 mSec after the Key switch on. Probable cause is a failure within the power block.

5) VMN NOT OK

32

This test is performed at rest, with the Main Contactor closed, and also during operation. This Alarm is generated if the VMN is lower than battery voltage in standby. This alarm is generated if VMN does not follow the duty-cycle of the chopper while driving. Possible causes: a) Incorrect motor connection. b) Frame fault of motor to chassis. c) Defect in the power unit.

6) VACC NOT OK

78

This Alarm is generated if the accelerator output voltage from the serial tiller is higher than 1V. Possible causes to be checked on the serial tiller: 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 during the acquisition procedure are wrong.

Page 23

7) VFIELD NOT OK

3

This test is made in standby with the Main Contactor open. In this condition the voltage on both the connections of field must be around ½ VBatt. This alarm is generated if the field voltage is different from this value. Possible causes: a) Frame fault on the motor to chassis. b) Incorrect connection of the field winding to the chopper. c) Failure of the chopper in the section relative to the field.

8) PUMP VACC NOT OK

4

This alarm is generated if the lifting potentiometer output voltage from the serial tiller is higher than 1V. Possible causes to be checked on the serial tiller: 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 during the acquisition procedure are wrong.

9) I = 0 EVER

49

This check is made while driving. 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" alarm.

10) HIGH FIELD CURRENT

57

Problem detected with the field current sensor. Possible causes: a) Failure of the field current sensor. b) Failure of the field power unit.

11) NO FIELD CURRENT

58

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.

12) DRIVER SHORTED

74

The test is carried out with Main Contactor open. The logic unit verifies that the coil of the Main Contactor is not shorted. Possible causes: a) Driver shorted. b) Problems in the feed back circuit of the Main Contactor coil. c) Wiring error. d) Fault in the protection circuit.

Page 24

13) COIL SHORTED

76

When the key is turned on, the microprocessor tests the overloads protection circuit of the contactor driver. If a problem is detected, this alarm is generated. Possible causes: a) Failure within the contactor coil. b) Incorrect wiring. c) Failure of the protection circuit.

14) CONTACTOR DRIVER

75

This alarm is generated if there is a problem with the Main Contactor. Possible causes: a) The Main Contactor coil driver is open-circuit. c) Defect in the Main Contactor coil voltage feed back circuit.

15) CONTACTOR CLOSED

37

This check is made before closing Main Contactor. It checks that the driver is not open. Possible causes: a) the contactor s power poles are not welded. b) This alarm could be generated if the line contactor is opened, but there is a problem within the field circuit.

16) FORW + BACK

80

This check is made continuosly. The Alarm is generated when forward and reverse directions are requested simultaneously. Possible causes: a) Incorrect Wiring. b) Welding or failure of a direction switch. c) Incorrect operation from the operator.

17) BATTERY LOW

66

This Alarm is generated when the battery becomes 90% discharged from the nominal value. If there is the alarm and the battery is not discharged, check the battery value in the Tester menu of the console; if it is incorrect, re-adjust via the Adjustment menu.

18) STBY I HIGH

53

This test is made during the initial diagnosis and in standby. The test verifies that the currents are zero. This alarm disables the machine. Possible causes: a) Defective current sensor. b) Feed back circuit failure or logic failure or power unit failure.

19) BRAKE DRIVER KO

2

The alarm is present when there is a problem on the electrobrake driver. Possible causes: a) driver in short-circuit b) driver broken, cannot drive the brake; c) current feedback circuit for the brake coil faulted Page 25

20) EVP NOT OK

1

At stand: proportional valve opened. Running: the proportional valve doesn t follow the applied PWM. 21) SERIAL ERROR #1

6

Wrong message or no message from serial tiller 22) INPUT ERROR #1

99

No belly switch on the tiller card 23) INPUT ERROR #2

98

Clearing hour meter.

24) THERMAL PROTECTION

67

This alarm is generated if the chopper temperature rises above 77°C, . If this alarm is displayed when the chopper s temperature is the same as ambient: a) check the connection of the temperature sensor. b) the temperature sensor may be defective. c) the logic may be defective.

25) WATCHDOG

8

The test is executed at key on, in stand-by and on running. Possible causes: a) Watch-dog hardware circuit not OK; b) Software not OK. 26) CHARGING BATTERY Battery charger connected

Page 26

68

COMBI SEM-1 OPERATING AND USER MANUAL

HYDRAULIC DIAGRAM NSP16K, NSV16K TH58 0800

HYDRAULIC DIAGRAM NSP16KI, NSV16KI

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

TS910801

NSV16K/NSV16Ki POWER SUPPLIES 24V

1/6

REV

3-6775

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: 1,5kW-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

TS910801

NSV16K/NSV16Ki POWER CIRCUITS

2/6

REV

3-6775

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

3

5

3

1

4

C

SERIAL TILLER INTERFACE

1

A

2

2

F

2

12

LOWER

+24VDC +BATT

LIFT 9

LOWER

LIFT

0-5VDC 7

B

13 14

1

1

1

OPTION: BRAKE RELEASE KEY (+BATT)

BELLY SWITCH

S17 COM

2

3

4

-BATT

PLATFORM SWITCH NC DRFT

-BATT

KEY OUT

BACK

BACK

KEY OUT

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

A

5

RXD

A5

0-5VDC

+5VDC

B

+5VDC

6

I.LOWER

11

I.LIFT

+BATT

2

BELLY SWITCH

7

FW

3

8

BW

+BATT

A

6

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

POT LOW

0-5 V

-BATT

+24VDC

+24VDC

-BATT

C

5

6

NC

NO

S2

TILLER SWITCH

COM

7

S11

COM

8 KEY OUT

SPEED CONTROLLER CombiSEM-1

A1 CIRCUIT DIAGRAM

TS910801

NSV16K/NSV16Ki CONTROL DEVICES 1

3/6

REV

3-6775

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

SIGNAL HORN

COM

X11: 1

X10: 1

X10: 3

M1

RED A1

H1

V5

+ 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

**) APPLIED ONLY TO COLD STORE TRUCKS

M3

*) APPLIED ONLY TO TRUCKS WITH INITIAL LIFT

2/18

CIRCUIT DIAGRAM

TS910801

NSV16K/NSV16Ki 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)

MOLEX MiniFit 6-pin

1

2

3

GRY +12VDC

BRN

6

-BATT

NCLTXD

BLK PCLTXD

NCLRXD

PCLRXD

+12VDC

6

5

4

5

6

2

9

8

-BATT

+12VDC

MOLEX 5195 8-pin

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

NSV16K/NSV16Ki DISPLAY DEVICES 1

5/6

REV

3-6775

12

13

14

LIFT TOP LIMIT

15

16

17

SIDE GUARDS

18

19

PLATFORM

20

SPEED LIMIT (1800 mm)

21

22

23

24

25

ILIFT TOP LIMIT OPTION.LIMIT

26

27

28

29

30

TRUCK MODE SELECT

X8: 1

COM

COM

6 TOP LIMIT

1

11 CUTBACK SPEED 2

13

3 CUTBACK SPEED 2

4

E

X20: P

X20: S/P

14

CUTBACK SPEED 1

COM

TOP MAST 2

COM

SR

COM

FLOOR

COM

COM

16

GATES

X20: S

17

7

18

I.LIFT LIMIT

8 HEIGHT LIMIT

9

19 SELECT MODE 2

-BATT

X8: 2

S2

A

-BATT

COM

S12

S1

COM

S15

COM

S16

(462560)

S14

NC

NC

HEIGHT LIMIT

NC

NC

TOP MAST

11

10

20 SELECT MODE 1

A1 SPEED CONTROLLER CombiSEM-1

A1

CIRCUIT DIAGRAM

TS910801

NSV16K/NSV16Ki DISPLAY DEVICES 2

6/6

REV

3-6775

A

11

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

2

A1: F

8

A1: C

22

A1: B

2

A1: A

S1:3

12

S2:COM

S2:NC

9

L100

L100

4F1

L200

L150

A1:B-

1K1:2

1K1:1 0F1

L850

L550

L150

L100

L250

L100

L450

L900

L700

L200

L700

S4:COM

L700

L200

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

CIRCUIT DIAGRAM

TS910201

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

NSV16K/NSV16Ki WIRE HARNESS W5: RL450789

8/6

REV

3-6775

F

18

19

20

21

22

23

24

25

26

27

28

29

30

X8 RL211074

2

A1: E 20 L600

X20:S/P

CIRCUIT DIAGRAM

S16:COM

17

L900

16

S16:NC

15

S15:NC

14

L400

13

L2000

12

S15:COM

11

TS910201

NSV16K/NSV16Ki WIRE HARNESS W5.2: RL461357

9/6

REV

3-6775

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