PBV20N2 Service Manual PDF
PBV20N2 Service Manual PDF
PBV20N2 Service Manual PDF
PBV20N2
615023
English 2013
PBV20N2 Service Manual
Only adequately trained service persons are allowed to carry out service operations. 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 service organisation or your
truck dealer for qualified, authorized and efficient maintenance service.
Mitsubishi Forklift Trucks® is a registered trademark of Mitsubishi Heavy Industries®, Inc. All brand or product
names are or may be trademarks of, and are used to identify products and services of, their respective
owners.
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Contents
Contents ............................................................................................................................. 3
1 Foreword .................................................................................................................. 8
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PBV20N2 Service Manual
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PBV20N2 Service Manual
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PBV20N2 Service Manual
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PBV20N2 Service Manual
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1 Foreword
The long productive life of your lift truck depends on regular and proper servicing,
consistent with the instructions provided in this service manual.
Before starting to test, repair or rebuild a lift truck, read the respective sections of this
manual carefully and familiarize yourself with all of the components.
The descriptions, illustrations and specifications contained in this manual are for lift
trucks with serial numbers in effect at the time of printing.
The manufacturer reserves the right to change specifications or designs without notice
and without incurring obligations. For your convenience, the instructions are grouped by
systems as an easy reference.
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The following table explains the safety-related signs used in this document.
NOTE: Notes are used to indicate important information and useful tips.
Hazard symbols
These symbols indicates a hazardous situation or action. Symbols are used to warn of
situations, which may cause environmental damage and personal injury.
Hazard symbols
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These symbols are used in warnings and notifications to indicate an action that should
not be taken. The prohibited action symbols are presented below.
These symbols are used in warnings and notifications to indicate an action that must be
taken. The mandatory action symbols are presented below.
Read the
Wear eye
manual or
protection
instructions
General
symbol for
Doctor symbol
mandatory
action
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SYMBOL OR DESCRIPTION
ABBREVIATION
OP Option
2.3 Units
Weight 1 kg - 2.205 lb
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3 Safety instructions
WARNING
The proper and safe lubrication and maintenance of these lift trucks as recommended
by the manufacturer is outlined in this document. Read this manual before performing
any lubrication or maintenance on these trucks. Improper performance of lubrication or
maintenance procedures is dangerous and can result in injury or death.
Do not make any alterations or repairs that can weaken the truck’s structure or
endanger safety.
Do not operate the truck unless you have read and understood the instructions in the
operator manual. Improper truck operation is dangerous and can result in injury or
death.
Knowledge of the system and/or its components is important before the removal or
disassembly of any components.
The following sections list some basic precautions that should always be observed.
• Keep the service area clean. Oil, grease, and water make the floor slippery.
• If possible, make all repairs with the truck parked on a level, hard surface.
• Before starting to work on the truck, hang a "Do not Operate" sign in the operator
compartment.
• The truck must always be supported on jacks, if working underneath it.
• Do not work on any truck that is supported only by lift jacks or a hoist. Always use
blocks or jack stands to support the truck before performing any disassembly.
• Lower the forks or other implements to the ground before performing any work on
the truck. If this cannot be done, make sure the forks or other implements are
blocked correctly to prevent them from falling unexpectedly.
• Use steps and grab handles (if applicable) when mounting or dismounting a truck.
Clean any mud or debris from steps, walkways or work platforms before use.
Always face the truck when using steps, ladders and walkways. When it is not
possible to use the designed access system, use ladders, scaffolds, or work
platforms to perform safe repair operations.
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• To avoid back injury, use a hoist when lifting components weighing 23 kg (51 lb) or
more. Make sure all chains, hooks, slings, etc., are in good condition and of the
correct capacity. Make sure all hooks are positioned correctly. Lifting eyes are not
to be side-loaded during a lifting operation.
• Make sure all protective devices including guards and shields are properly installed
and functioning correctly before starting a repair. If a guard or shield must be
removed to perform the repair work, use extra caution.
• Always support the mast and carriage to keep the carriage or attachments raised
when performing maintenance or repair work that requires the mast to be in the
raised position.
• Remove all rings, watches and other pieces of metal jewellery before you start
working on the truck. If a metal object gets into contact with an electrically
conductive part, it may cause a short circuit or a serious burn.
• Always wear protective glasses and protective shoes when working around trucks.
In particular, wear protective glasses when using a hammer or sledge on any part of
the truck or its attachments. Use welder’s gloves, hood/goggles, apron and other
protective clothing appropriate to the welding job being performed. Do not wear
loose fitting or torn clothing.
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d. affixes a permanent and readily visible label to the truck stating the manner in
which the truck has been modified or altered, together with the date of the
modification or alteration and the name and address of the organization that
accomplished those tasks.
• Switch off the truck's power before opening the cover of the motor compartment or
the electrical system.
• Relieve all pressure in the air, oil or water systems before disconnecting or
removing any lines, fittings or related items. Release the residual pressure when
removing a pressurized device.
• With sit-on trucks, dismount the seat for the duration of the service work.
• Before operating, lubricating or repairing the product, read all warning plates and
decals on the truck.
• Do not use your hands to check for oil leaks.
• To avoid burns, pay attention to the hot sections and hot fluids in lines, tubes and
compartments, even when the truck is idle or off.
• Only use clean oil in the hydraulic system.
• Repairs requiring welding should be performed only with the appropriate reference
information and by personnel adequately trained and knowledgeable in welding
procedures. Determine the type of metal and select the correct welding procedure
and electrodes, rods or wire to provide a weld metal strength equivalent at least to
that of the parent metal.
• When welding, always disconnect the battery and electronic devices. Remove all
paint from a 10 cm radius from the welding point to avoid creating toxic gases
during welding.
• Use proper lifting procedures when removing any components.
• Be careful when removing cover plates. Gradually remove the last two bolts or nuts
located at opposite ends of the cover or device. Before removing the last two bolts
or nuts completely, pry the cover loose to relieve any springs or other pressures.
• Be careful when removing filler caps, breathers and plugs on the truck. Wrap a cloth
around the cap or plug to prevent being sprayed or splashed by liquids under
pressure. Be aware that the danger of being sprayed or splashed is always greater
immediately after stopping the truck, as the fluids are very hot.
• Use only well-maintained tools. Also make sure that you use the tools in a proper
way.
• Reinstall all fasteners with the same part number. If a replacement is needed, do
not use a fastener of lesser quality.
• Do not damage wiring during the removal process. Do not reuse any damaged
wiring. When reinstalling, make sure the wiring does not come into contact with any
sharp corners or hot parts. Place all wiring away from the oil pipe.
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• Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause
fires. Do not bend or strike any high pressure lines or install ones that have been
bent or damaged. Inspect all lines, tubes and hoses carefully. Pin hole (very small)
leaks can result in a high velocity oil stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal injury, so use cardboard or
paper to locate pin hole leaks.
• Tighten connections to the correct torque. Make sure that all heat shields, clamps
and guards are installed correctly to avoid excessive heat, vibration or rubbing
against other parts during operation. Protective shields against oil sprays onto hot
exhaust components in the event of a line, tube or seal failure must be installed
correctly.
• Do not operate the truck, if any rotating part is damaged or comes into contact with
any other part during operation. Every high speed rotating component that has been
damaged or altered should be checked for balance before reusing.
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4 General information
This service manual covers the service instructions of the following truck model:
NOTE: Throughout chapters 4 to 14, this manual provides service instructions for the
basic truck model. All material related to optional features is available in Chapter 15.
NOTE: Check that all the plates and stickers on the truck are legible and securely
attached!
Figure 1 below shows the truck’s plates and stickers and their locations. For more
details on the truck’s plates and stickers, see the APPENDIX A.
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• Manufacturer
• Truck type
• Serial number
• Battery minimum weight
• Battery terminal voltage
• Truck’s nominal lifting capacity
• Year of manufacture
• CE mark
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Safety button (belly button) The safety button prevents you from getting
squeezed between the truck and an obstacle.
When the safety button is pushed, the truck
reverses its travelling direction. When the button is
released, the truck stops.
Push buttons for lifting and lowering Push the Up button to lift the forks. Push the Down
button to lower the forks.
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Accelerator Use the accelerator with your right or left hand. The
more you turn the accelerator, the higher the speed.
The accelerator returns automatically to the central
position, when it is released. Brake smoothly by
turning the accelerator to the opposite direction.
Brake release / low speed button The button has two functions:
• Brake release
When the tiller arm is in the up position, hold the
button down to release the parking brake and
turn the accelerator to drive the truck in the slow
speed mode. Release the button to apply the
parking brake.
• Low speed mode
When the tiller arm is in the driving position,
activate the low speed mode by pressing the
button once. The Lo SPd symbol is shown in the
multi-function display. Deactivate the low speed
mode by pressing the button again.
Lever for lifting and lowering Pull the lever up to lift the forks. Push the lever
(optional) down to lower the forks.
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Press the emergency stop button to disconnect the truck's power supply. Release the
button by turning it clockwise.
• In case of a short circuit or some other electrical malfunction (for example, if the
pump motor does not stop running).
• In case of an accident.
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The key switch switches the truck's electrical system on and off.
When the key switch is in the off position, the truck’s electrical system is turned off. Note
however that power may be still connected to certain electronic devices.
When the key switch is turned once to the right, the truck’s electrical system is turned
on and the economy mode (lower energy consumption and deceleration, maximum
speed limited to 6 km/h) is activated. The ECO symbol is shown in the multi-function
display.
When the key switch is turned once more to the right, the standard mode (normal
energy consumption and deceleration, maximum speed 9 km/h) is activated.
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A pallet truck equipped with a foldable operator’s platform can be driven either walking
behind the truck (the pedestrian mode) or standing on the platform (the riding mode).
To drive the truck in the pedestrian mode, lift the operator’s platform up by lifting it
slightly and allowing the gas spring to lift it up completely and then fold the side guards
in.
To drive the truck in the direction of the forks, walk behind the truck and keep both
hands on the tiller arm. To drive in the opposite direction, walk beside the truck and
keep one hand on the tiller arm.
NOTE: The maximum driving speed in pedestrian mode has been limited to 6 km/h.
If you only lift the operator’s platform up but leave the side guards unfolded, the truck
will not move. For more detailed information about the functionalities of the side
guards and operator’s platform, see the section 8.5.1.
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To drive the truck in the riding mode, lower the operator’s platform to the horizontal
position and unfold the side guards. The side guards keep the operator within the
outlines of the truck and prevent the operator from losing balance.
To drive the truck in the riding mode, step on the platform and keep both hands on the
tiller arm. When you step off the platform, it stays in the horizontal position
automatically.
It is also possible to drive the truck on the platform without unfolding the side guards.
In this case, the maximum driving speed has been limited to 6 km/h.
There is also an optional 12 km/h speed mode available, where the top speed is
adjusted according to the load.
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To go forward, drive the truck in the direction of the forks. To go backward, drive the
truck in the opposite direction.
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Type 3-phase AC
Voltage 16 V
The correct tightening torque for the traction motor power terminals is 6 Nm.
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4.3.7 Sensors
The sensor consists of an induction loop. Electric current generates a magnetic field
that collapses, thus generating a current that falls asymptotically toward zero from its
initial level, when the electricity input ceases. The inductance of the loop changes
according to the material inside it and, since metals are much more effective inductors
than other materials, the presence of metal increases the current flowing through the
loop. This change can be detected by sensing circuitry, which can signal to some other
device whenever metal is detected.
• Tiller sensor
• Four side guard sensors, two on each side guard
• Operator’s platform sensors, two on the right-hand side
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The purpose of the suspension systems is to ensure the truck’s driving capabilities
regardless of the truck’s loading situation. The drive unit and castor wheel suspension
systems work together and they are tuned according to the truck’s load weight. The
platform suspension is designed to reduce the vibration and shock impact to the truck
driver.
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5 Mechanical maintenance
CAUTION
Lift or jack up the truck and support it with safety blocks or rigid stands.
Apply wheel chocks to the load wheels to prevent the truck from moving.
Figure 17 below indicates the correct jack points for lifting the truck up for maintenance.
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Figure 18 below indicates the correct hoist points for hoisting the truck up for
maintenance. Make sure that the capacity of the lifting device is sufficient.
5.2 Transportation
When transporting the truck, it is important that you secure it safely to prevent it from
moving. For transport, fold in the side guards and lift the operator’s platform up. Also
support the traction wheel with blocks.
CAUTION
Do not tie the truck from the tiller arm or it may break.
Figure 19 below shows an example on how to secure the truck safely for transportation.
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When ordering spare parts, always contact your maintenance centre. Only use original
spare parts. To ensure that you receive the correct parts, include the following
information in your order:
• Truck type
• Serial number of the truck
• Order number of the part
• Name of the part
• Number of parts ordered
CAUTION
Before opening the truck’s covers, turn the key switch to the OFF position and
disconnect the battery plug/connector.
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NOTE: You must remove the control panel before you can open the truck’s top cover.
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NOTE: When closing the battery cover, make sure that the locking button returns all
the way to the locking position.
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Remove the battery cover’s rubber absorbers by simply screwing them out.
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4. Release the side guard’s gas spring. For instructions, see steps 1-3 in the section
5.5.1 ) below.
5. Remove the side guard.
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5. Install the new gas spring. Make sure that the location of the wiring is the same
as it was with the old spring.
6. Fasten the front screw on the triangular mounting plate.
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Before you can remove the operator’s platform, remove the two rubber absorbers at the
base of the operator’s platform:
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CAUTION
After removing the rubber absorbers, beware of sharp edges when removing the
operator’s platform.
When installing the rubber absorbers, remember to use locking glue (for example,
Loctite 243).
After the rubber absorbers have been removed, you can remove the operator’s
platform:
CAUTION
NOTE: When installing the operator’s platform, place a support, such as a block or
similar, between the operator’s platform and the mounting bracket to prevent the
operator’s platform from lifting too much. See Figure 29 below.
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The gas spring of the operator’s platform can be replaced either with the platform in
place or with the platform removed completely from the truck frame. Instructions for
replacing the operator’s platform gas spring are provided below, but the same
instructions can be applied also while working with the platform removed.
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7. Carefully lift the operator’s platform, making sure that the new spring does not fall
out.
8. Tighten the gas spring locking spring and install the ball joint if it was removed
earlier.
9. Lower the operator’s platform.
10. Attach the rubber mat to the operator’s platform.
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1. Remove the operator’s platform from the truck frame. For instructions, see the
section 5.6.
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There is no need to change the transmission gear lubricant during the truck's lifetime.
CAUTION
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There is no need to change the bogie bearing lubricant during the truck's lifetime.
• The bearing rotates easily when the traction wheel is raised up.
• The drive unit’s mounting bolts are tightened properly.
CAUTION
Before installing the traction wheel, make sure that the wheel shaft, the face of the rim
mounting, the wheel nuts and wheel bolts are clean, free from grease and undamaged.
NOTE: To access the traction wheel, lift the truck up (see the correct lifting points in
the section 5.1 of this manual) and turn the transmission gear so that there is enough
space for you to access and remove the wheel.
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• When the traction wheel’s diameter reaches 220 mm, adjust the castor wheels as
instructed in section 5.12.2.
• When the traction wheel’s diameter reaches 214 mm, replace the traction wheel
and adjust the castor wheels as instructed in section 5.12.2.
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If the wheel shaft bolts of the traction wheel are defective, you need to replace them.
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NOTE: To access the load wheels, lift up the forks and the truck so that the load
wheels are off the floor (see the correct lifting points in the section 5.1 of this manual)
and turn the load wheel so that you can access the bolt holding the wheel in place.
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The lift cylinder handles the lifting of the fork carriage, while the push rod mechanism
assists in raising the fork tips. For stable lifting, it is important that there is not too much
play in the linkage mechanism. Below you can find the instructions regarding the
disassembly of the linkage mechanism. Assemble the linkage mechanism by repeating
the steps in reversed order.
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NOTE: To access the castor wheels, lift the truck up (see the correct lifting points in
the section 5.1 of this manual).
The castor wheels need to be adjusted according to the wear of the traction wheel:
• In a new truck, the castor wheels are in location 1 shown in Figure 39.
• When the traction wheel’s diameter reaches 220 mm, move the castor wheels to
location 2.
• When the traction wheel’s diameter reaches 214 mm, replace the traction wheel
and move the castor wheels back to location 1.
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1. Location 1 2. Location 2
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The castor wheel suspension mechanism makes the truck more stable. Check the
condition of the suspension rubbers at every maintenance. Also the wear of the castor
wheels and the traction wheel have a considerable effect on the truck’s driving
capability.
NOTE: To access the castor wheel suspension mechanism, lift the truck up (see the
correct lifting points in the section 5.1 of this manual).
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WARNING
When you lift the truck up, make sure that you support it properly to prevent it from
falling.
NOTE: If the truck is equipped with the electrical steering option, you need to
disassemble the electrical steering motor unit first before you can perform the steps
provided below. For more information about the disassembly of the electrical steering
motor unit, see section 15.11.5.
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1. Remove the covers. For more detailed information, see section 5.4.
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During the installation of the tiller arm, tighten the bolts of the tiller arm fastener first by
hand to make sure they fit the threads correctly. After that, cross-tighten the bolts with a
power tool, making sure that the fastener is aligned correctly.
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1. Remove the tiller head. For instructions, see the section 8.1.1.
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6 Electrical operation
This chapter describes the electrical operating principles of the power pallet truck. The
standard model and its electrical schematic diagram are used as an example.
CAUTION
Always use the correct schematic diagram for the specific model you are servicing. The
latest schematic diagrams are available from the manufacturer’s Web site.
CAUTION
The figures provided in this section are provided as examples only. Therefore the
information in the actual schematic diagram of the truck model you are servicing may
differ from the figures.
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Note the numbers above the wiring reference J14. These numbers (8/16) direct you to
the page and zone where the wire is connected.
This procedure is used to follow the circuits throughout the schematic diagram. If the
numbers are given without the slash (/), the connection is on the same page of the
schematics.
Table 2 below explains the different identifiers used in the schematic diagram. # stands
for a number.
IDENTIFIER DESCRIPTION
S# Switches and other state changing devices (for example, most sensors).
#F# Fuse
J# Reference.
All references marked with an even ”J” (e.g. J2) are positive (+). All
references marked with an odd “J” (e.g. J3) are negative (-).
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IDENTIFIER DESCRIPTION
M# Motor
V# Diode
Once again, note the numbers below the wiring reference J14. These numbers (1/13)
direct you back to the page (and zone) shown in Figure 44.
Figure 46. Page numbers (4/9), circuit diagram number (3-7109) and revision letter (H)
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Page numbers, the circuit diagram number and the revision letter can be found in the
bottom right corner of the page.
On the bottom left side of the circuit diagram, you can see the modification history of the
page.
This truck product family uses wet lead-acid batteries, which consist of 12 cells and
supply a nominal voltage of 24 volts. The batteries have the maximum capacity of
500 Ah, depending on the truck model. The batteries reside in a separate compartment
and are connected to the system via the X1 battery connector. In the electrical
schematic diagram, the battery is presented as G1 in zone 11 on page 1.
If the emergency stop button (S9) is in its normal closed position, B+ continues to flow
to the key switch (S1). B+ also flows to the main power contactor coil (K1). The operator
can shut down the system power at any time by pressing the emergency stop button.
When the button is pressed, the connection opens and removes B+ from the main
contactor coil (K1).
The main key switch S1 controls the electrical power supply to the entire system with
the help of the main contactor K1. The coil controlling the K1 contacts is presented in
zone 17 on page 1.
The key switch is activated by turning it to the ON position. When the key switch S1
closes, B+ flows to the coil of the main contactor K1, the negative is connected to the
battery via the controller pin 6 of the connector XA1B and the contactor K1 closes the
contacts. Positive electrical power is supplied to the system through the main fuse 5F1.
The fuse 5F1 is rated at 300 A. In the electrical schematic diagram, the location of the
main fuses is illustrated in zone 27 on page 1. After the main fuse 5F1, the +B supply is
fed to the contacts of the pump motor M2. The pump motor negative is controlled by the
pump controller. In the schematic diagram, the M2 contacts are presented in zone 21 on
page 1.
The traction motor is controlled by the traction controller. In the schematic diagram, the
M1 contacts are presented in zone 23 on page 1. The main voltage is supplied to the
terminal BF on the traction controller.
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6.5 Traction
The movement of the truck is controlled by the traction controller. Before the truck can
be driven, the battery must be connected, the main key switch must be closed and the
system must have passed the self-test procedure.
When the truck is powered on and in the standby mode, it can be driven by turning the
accelerator at the end of the tiller arm forward or backward. In the electrical schematic
diagram, the accelerator is presented in zones 12 to 15 on page 3 of the electrical
schematic diagram. The accelerator unit receives its positive 24 volt electrical supply
from the pin 2 of the connector XA1C. The negative connection is supplied directly from
- B. When the accelerator is turned forward or backward, it indicates the direction to the
traction controller via the pins 4 and 8 of the connector XA1B. It also provides a varying
voltage to the pin 4 of the connector XA1C. The voltage varies between 0, 3 and 4.7
volts, depending on the position of the accelerator control. The voltage increases as the
accelerator is moved to either extreme.
In the induction motor (= asynchronous motor), the stator is powered with alternating
current and designed to create a rotating magnetic field, which rotates in time with the
AC oscillations. In the induction motor, the rotor rotates at a slower speed than the
stator field and therefore the magnetic field through the rotor is changing (rotating). The
rotor has windings in the form of closed wire loops. The rotating magnetic flux induces
currents in the rotor windings as in a transformer. These currents in turn create
magnetic fields in the rotor that interact with the stator field. Due to Lenz's law, the
direction of the created magnetic field is such as to oppose the change in current
through the windings. The cause of induced current in the rotor is the rotating stator
magnetic field, so to oppose it, this rotor starts to rotate in the direction of the rotating
stator magnetic field to make the relative speed between the rotor and the rotating
stator magnetic field zero.
For these currents to be induced, the speed of the physical rotor must be lower than
that of the stator's rotating magnetic field or the magnetic field would not be moving
relative to the rotor conductors and no currents would be induced. As the speed of the
rotor drops below synchronous speed, the rotation rate of the magnetic field in the rotor
increases, inducing more current in the windings and creating more torque. The ratio
between the rotation rate of the magnetic field as seen by the rotor (slip speed) and the
rotation rate of the stator's rotating field is called "slip". Under load, the speed drops and
the slip increases enough to create sufficient torque to turn the load. For this reason,
induction motors are sometimes referred to as asynchronous motors. An induction
motor can be used as an induction generator, or it can be unrolled to form the linear
induction motor, which can directly generate linear motion.
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7 Battery maintenance
WARNING
Always keep the truck’s battery clean and dry to prevent tracking currents. Cleaning of
the battery must be done in accordance with the manufacturer’s instructions.
Any liquid in the battery tray must be extracted and disposed of in the prescribed
manner. After cleaning, repair all damages to the tray’s insulation to prevent tray
corrosion and to ensure that the insulation value complies with the standard
EN 50272-3.
If the battery is taken out of service for a longer period, make sure that the battery is
fully charged and store it in a dry, frost-free room. The storage time should be taken into
account when considering the lifetime of the battery.
In case of any malfunctions on the battery or in the charger, contact the battery
manufacturer without delay.
When using motive batteries and chargers, always make sure you follow the current
standards, laws, rules and regulations in force in the country of use
For batteries according to the ATEX directive 94/9 EC, the instructions for maintaining
the appropriate protection class during operation must be complied with (see the
relevant certificate).
Batteries that are not marked with this sign are not returned for the recycling process
and must be disposed of as hazardous waste.
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Pay attention to the battery’s operating instructions and fix them close to the battery.
Work on batteries should be carried out by skilled personnel only!
No smoking!
Do not expose batteries to naked flames, glowing embers or sparks, as it may cause the
battery to explode.
Acid splashes in the eyes or on the skin must be washed immediately with water.
In case of an accident, consult a doctor immediately!
Clothing contaminated by acid should be washed with water.
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For batteries with electrolyte circulation, check the electrolyte level towards the end of
the charging and, if necessary, top it up to the specified level with purified water
according to the manufacturer’s instructions. The electrolyte level must not fall below
the anti-surge baffle, the top of the separator or the electrolyte minimum level mark.
For batteries with filling level sensors, check the illuminated display daily. If the display
is green, the level is OK. If the display shows a blinking red colour, the filling level is too
low.
Check the electrolyte level visually by opening the standard vent plug or by the position
of the float indicator of the water refilling plug and top it up with demineralised water at
the end of the charge.
After recharging, check the battery visually for any signs of dirt or mechanical damages
to the battery’s components. Pay special attention to the battery charging plugs and
cables. In special cases when charging with an IU characteristic curve, also an
equalizing charge must be carried out.
At the end of the charge, switch the charger on and measure and record the voltages of
all cells or bloc batteries.
After the charging has been completed, measure and record the electrolyte density,
electrolyte temperature and the filling level (when filling level sensors are used) of all
cells. If there are any significant changes compared to earlier measurements or
differences between the cells or bloc batteries, charge the battery fully and allow it to
rest for the minimum of two hours. If the problem persists, contact the battery
manufacturer.
• Total voltage
• Voltage per cell
• If the voltage readings are irregular, also check the S.G. of each cell
In accordance with the standard EN 1175-1, the insulation resistance of the truck and
the battery must be checked by an electrical specialist at least once per year. The tests
on the battery’s insulation resistance must be conducted in accordance with the
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standard EN 1987 part 1. The insulation resistance of the battery must not fall below the
value of 50 Ω per Volt of nominal voltage, in compliance with the standard EN 50272-3.
For batteries up to 20 V nominal voltage, the minimum value is 1000 Ω.
For batteries fitted with an electrolyte circulation system, check the filter of the air pump
and clean or replace it, if needed. The filter may need to be replaced earlier than
expected if there are no leaks in the air pipes but for some reason the defect signal of
the air mixing system on the charger or on the battery (on the DC air pump or remote
signal) is illuminated.
During annual maintenance, also check the correct operation of the air pump.
CAUTION
Make sure that the charger is the appropriate model (correct battery type and voltage)
and that the battery has sufficient ventilation.
4. Open the battery cover. For instructions, see the section 5.4.4.
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After recharging
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Measure the specific gravity 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. The
gravity is:
CAUTION
When replacing the battery, use one with similar dimensions and weight to maintain the
stability and the braking properties of the truck. The battery’s minimum weight is
indicated on the identification plate of the truck.
When reinstalling batteries, use the appropriate tools for moving, connecting and
fastening the battery securely. Do not keep tools or other metal implements on top of
uncovered batteries.
Make sure that the capacity of the used lifting device is sufficient. When using a lifting
device 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.
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1. Open the battery cover. For instructions, see the section 5.4.4.
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CAUTION
Before opening the tiller head, turn the key switch to the OFF position and disconnect
the battery plug/connector. Record the places of the harness connections before
disassembly.
When disconnecting the connector, hold the connector housing and plug and then
unlock the connector. Holding the case may cause damage to the inside card, while
holding the cable may cause wire breakage.
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CAUTION
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NOTE: Before you can remove the accelerator knobs, you have to remove the rubber
tiller arm handles to make room.
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Keep the accelerator connector because the new accelerator is delivered without a
connector.
1. Remove the tiller head. For instructions, see section 8.1.1 above.
2. Remove the safety button. For instructions, see section 8.1.3 above.
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1. Connect the accelerator wires to the accelerator connector. The pin locations
from 1 to 3 are marked on the connector with lines and help you in determining
the rest of the pin locations. Details of the accelerator wires and their pin
locations are available in Figure 54 and Table 3 below.
2. Install the accelerator.
3. Install the mounting bracket and tighten the screws.
4. Fit the accelerator connector to the mounting bracket.
5. Install the microswitch bracket.
6. Install the safety button. For instructions, see the section 8.1.3 above, just
perform the steps in reversed order.
7. Assemble the tiller arm. For instructions, see the section 5.15 above, just perform
the steps in reverse order.
8. Calibrate the accelerator. For instructions, see the section 9.1.
2 - -
7 White/Brown Sensor 0 V
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WARNING
Never drive the truck without the electrical panel cover in place.
CAUTION
Before inspecting and replacing fuses, turn the key switch to the OFF position and
disconnect the battery plug/connector.
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The COMBIACX inverter has been developed to perform all the electric functions that
are usually present in walkie and rider pallet trucks, stackers and low level order
pickers.
CAUTION
Before any inspection or repair work, turn the key switch to the OFF position,
disconnect the battery plug/connector, discharge all inverters and record the places of
the harness connections before disassembly.
When disconnecting the connector, hold the connector housing and plug and unlock the
connector. Holding the case may cause damage to the inside card, while holding the
cable may cause wire breakage.
If the high-power cable terminals of the battery-operated vehicle are not tightened
properly, the increased contact resistance causes excessive heat generation, and can
even cause a fire. To prevent accidents and equipment problems, check the tightening
torque of the high-power cable terminals regularly. Do not pull the cables to check
connections or during adjustment. If the cable terminal sections are moved, re-tighten
the connections.
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Contact 0.2 – 0.8 mm2 for CNA, CNB, CNC and CND connectors, Spare part:
RL450666
CONNECTION DESCRIPTION
A4 DI5 (XA1 A/4) Input of the switch DI5. The input is activated when
(platform up S10) it is connected to +Batt. The default function is the
controller HORN input. When the switch is closed,
the horn output is activated.
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CONNECTION DESCRIPTION
A5 DI7 (XA1 A/5) Input of the switch DI7. The input is activated when
(lift cutoff option S7) it is connected to +Batt. The default function is the
controller LIFT enable input.
A6 DI9 (XA1 A/6) Input of the switch DI9. The input is activated when
(side guard out S13 & S17) the external switch is opened. The default function is
the controller PUMP CUTBACK input. When the
switch is opened, the pump speed is reduced.
A7 DI11 (XA1 A/7) Input of the switch DI11. The input is activated when
(brake release S3) the external switch is opened to ground. The default
function is the controller CUTBACK1 input. When
the switch is opened, the truck speed is reduced. In
the sense coil version, this input is connected to the
AC motor sense coil.
A10 GND (XA1 A/10) This is the ground of the logic board.
(brake release/lift cutoff option)
A11 DI6 (XA1 A/11) Input of the switch DI6. The input is activated when
(lower switch S5) it is connected to +Batt. The default function is the
controller LOWER enable input.
A12 DI8 (XA1 A/12) Input of the switch DI8. The input is activated when
(economy mode S1) it is connected to +Batt. The default function is the
controller 1ST input: the pump motor turns at the
defined speed.
A13 DI10 (XA1 A/13) Input of the switch DI10. The input is activated when
(driver present / platform down S11) it is connected to +Batt. The default function is the
controller 2ND input: the pump motor turns at the
defined speed.
A14 DI12 (XA1 A/14) Input of the switch DI12. The input is activated when
(battery lock sensor option S14) the external switch is opened to ground. The default
function is the controller CUTBACK1 input. When
the switch is opened, the truck speed is reduced. In
the sense coil version, this input is connected to the
AC motor sense coil.
CONNECTION DESCRIPTION
B1 PEB (XA1 B/1) This pin outputs the positive supply (equal to +Batt)
(magnetic brake Y31) of the electro-mechanical brake coil. Depending on
the hardware configuration, this pin can be
controlled by the microcontroller or tied to the B2
input or to the C6 input. See the connection drawing
for more details.
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CONNECTION DESCRIPTION
B2 PEV (XA2 B/2) Connect the positive supply of all the solenoid
(positive supply of all solenoid valves (EV1, EV2, EV3, LOWER EVP, HORN OUT)
valves) to this pin. Take the positive supply immediately
after the main contactor.
B3 NEVP (XA1 B/3) Output of the solenoid valve driver (driving to –Batt).
(solenoid valve negative Y1) A built-in freewheeling diode to B2.
B4 DI3 (XA1 B/4) Input of the switch DI3. The input is activated when
(backward B1) it is connected to +Batt. The default function is the
controller BACKWARD request input. When this
input is closed, the truck moves in the forward
direction.
B6 NLC (XA1 B/6) Main contactor coil driver output; PWM controlled; 3
(K1) A maximum continuous current (driving to –Batt). A
built-in freewheeling diode.
B8 DI4 (XA1 B/8) Input of the switch DI4. The input is activated when
(forward B1) it is connected to +Batt. The default function is the
controller FORWARD request input. When this input
is closed, the truck moves in the backward direction.
CONNECTION DESCRIPTION
C2 DI1 (XA1 C/2) Input of the switch DI1. The input is activated when
(Safety button S2) it is connected to +Batt. The default function is the
controller BELLY input. When the switch is closed,
the quick inversion function is activated.
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CONNECTION DESCRIPTION
C6 DI0 (XA1 C/6) Input of the switch DI0. The input is activated when
(tiller switch S12) it is connected to +Batt. With the logic hardware
properly configured, it can be used to supply the EB
and MC positive voltage. The default function is the
controller TILLER input.
C7 DI2 (XA1 C/7) Input of the switch DI7. The input is activated when
(side guard in S15 and S16) it is connected to +Batt. The default function is the
controller H&S (Hard & Soft) request input. When
this input is closed, the truck performances are
modified.
C10 CANL (XA1 C/10) Low level CAN bus voltage I/O.
(CAB bus green)
CONNECTION DESCRIPTION
D6 NTHERM (XA1 D/6) Negative (GND) for the motor thermal sensor.
(temperature sensor R31)
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CONNECTION DESCRIPTION
The correct tightening torque for the COMBIACX Power terminal bolts is
7 Nm (±1.4 Nm).
Switching output NO
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8.2.5 Fuses
NOTE: If the truck is equipped with the electrical steering option, the fuse locations
are described in section 15.11.3.2.
Table 4. Fuses
4F1 10 A Optional
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The controller fan is located behind the electric panel. To clean or replace the fan, you
have to move the electric panel out of the way:
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CAUTION
Before opening the motor compartment covers, turn the key switch to the OFF position
and disconnect the battery plug/connector.
Before any inspection or repair work, discharge the inverters. Record the places of
cables and harness connections before disassembly.
Use the correct power cables and terminate marked cable ends to the correct terminals
marked on the motor. Cables terminated at the wrong terminals may cause the motor to
rotate in the opposite direction when activated.
If the high-power cable terminals of the battery-operated vehicle are not tightened
properly, the increased contact resistance causes excessive heat generation, and may
even cause a fire. To prevent accidents and equipment problems, check the tightening
torque of the high-power cable terminals regularly. Do not pull the cables when
checking connections or during adjustment. If the cable terminal sections are moved, re-
tighten the connections.
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NOTE: If the truck has the electric steering option in use, see section 15.11.5 for
instructions.
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6. Lift the truck up and support it properly to prevent it from falling. See the correct
lifting points in the section 5.1 of this manual.
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The centring and locating face for connecting the electric motor must be perfectly clean
and undamaged. Using a dial indicator or similar tool, check the face run-out of the
motor’s connecting face to the motor shaft. The run-out must not exceed 0.04 mm.
Figure 61. Checking the face run-out of the motor’s connecting face
Excessive face run-out can have a negative effect on the noise behaviour and the load-
carrying capacity of the helical gear stage or cause unnecessary wear.
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CAUTION
If the motor is connected incorrectly to the transmission, the tooth flanks at the drive
pinion and the helical gear can be damaged, causing louder noise later on.
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After replacing the motor or controller, teach the motor resistance with the TruckTool
wizard or using the following button combination:
1. During key-on, move the tiller arm to the driving position and press the brake
release / low speed and safety buttons for 15 seconds.
2. After the contactor opens and recloses, restart the truck
The temperature sensor is located inside the motor and cannot be changed.
The condition of the temperature sensor can be verified with a multimeter. Measure the
ohms between the traction motor connector pins XM1/1 and XM1/2. The value should
be ~580 Ω.
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Vs 5 - 24Vdc
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Applying a direct voltage to the exciter winding in the magnet body generates a
magnetic force acting on the armature disk, which is then pulled via the air gap against
the pressure of the spring to the magnet body. The decelerating rotor is released and
the brake torque is neutralized.
1. Remove the drive unit. For more detailed instructions, see section 8.3.1.
2. Disassemble the drive unit. For more detailed instructions, see section 8.3.2.
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Use a multimeter to measure the brake coil resistance. The coil resistance has to be
measured between the brake wires. The value should be ~21 Ω.
The pump motor is an integral part of the hydraulic aggregate. For instructions, see
section 10.4.
The pump motor is maintenance free. Do not attempt to repair the pump motor.
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Solenoid valve is an electrically controlled hydraulic valve that has two main parts: a
solenoid (coil) and a valve. The solenoid converts electrical energy into mechanical
energy which, in turn, opens or closes the valve mechanically. This basic ON/OFF
function is used to control the oil flow to the cylinders.
Type Solenoid
The basic solenoid test is to measure the ohms between the solenoid terminals XY1/A1
and XY1/A2. The value should be ~27 Ω.
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8.5 Sensors
NOTE: If the truck is equipped with the electrical steering option, information about
the feedback sensor is available in section 15.11 and its subsections.
Size Flat, 15 mm x 32 mm x 8 mm
Vs 12 - 24 Vdc
Sensing range 2 - 4 mm
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Table 5 below presents a more detailed view of the functionality of the different sensors.
TILLER, OPERATOR’S
SENSOR
PLATFORM AND SIDE TRUCK FUNCTIONALITY
FUNCTIONALITY
GUARD POSITIONS
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TILLER, OPERATOR’S
SENSOR
PLATFORM AND SIDE TRUCK FUNCTIONALITY
FUNCTIONALITY
GUARD POSITIONS
1. Connect the supply voltage between the brown (+) and blue (-) wires.
2. Measure the supply voltage between the wires.
The value should be +24 Vdc.
3. Measure between the blue (-) and black (output) wires on the voltage area.
When a supply is connected and there are no metallic objects within the sensing
range, the value is approximately 0 V.
When a metallic object is moved within the sensing range, the value is the same as
the supply voltage, i.e. +24 Vdc.
If the values do not match the above, replace the sensor.
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Switching output 1 x NC
Measure at the ohms area that the contacts inside the emergency stop button are not
stuck together.
When the emergency stop button is released (the contacts are closed together), the
ohms value is ~0 Ω.
When the emergency stop button is pressed down, the ohms value is ~∞Ω.
If the contacts are stuck together or broken, replace the emergency stop button.
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Switching output 3 x NO
Measure at the ohms area that the contacts inside the key switch are not stuck together.
When the key switch is in the 0 position, the ohms value is ~0 Ω between the pins 6-1
and 4-5.
When the key switch is turned clockwise once, the ohms value is ~0 Ω between the pins
6-1, 4-5, 6-4, 6-3, 1-4 and 1-3.
When the key switch is turned clockwise for the second time, the ohms value is ~0 Ω
between the pins 6-1, 4-5, 6-5, 6-2, 1-5 and 1-2.
If the contacts are stuck together or broken, replace the key switch.
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Switching output 1 x NC + 1 x NO
When the micro switch is in the neutral position, the ohms value is ~∞ Ω.
If the contacts are stuck together or broken, replace the micro switch.
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8.7 Horn
Vs 24 Vdc
If the horn does not work properly, disconnect it and then measure with a multimeter
that the horn is not broken. Set the multimeter to the ohms range, and connect it
between the H1/ A1 and H1/A2 terminals. The value should be ~4 Ω.
Normally the horn creates voltage peaks that may cause problems to other electrical
devices. To prevent these voltage peaks, a diode (V8 in the circuit diagram) is installed
parallel to the horn terminals.
The basic diode test is very simple to perform; only two multimeter tests are needed to
ensure that the diode works correctly:
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If the results do not match the expected values, there is something wrong with the diode
connection:
• If the results are opposites of the expected values, the diode has been assembled
with incorrect polarity.
• If the ohms values are ~0 Ω in both directions, the diode is shorted and needs to be
replaced.
• If the ohms values are ~∞ Ω in both directions, the diode is broken and needs to be
replaced.
There are a few issues that need to be checked with the wire harnesses:
• To prevent disconnection of the switches, the protective spiral shield of the motor
cables must not touch the key switch or the emergency stop button.
• To prevent connector and pin damages, wires and cables must not be installed too
tightly.
• To prevent possible insulation damages, wires and cables must not lie on sharp
edges.
• To prevent wire or cable insulation damages, wires and cables must not be installed
so that a moving element could cause any damage.
The traction motor cables and wires are placed inside the protective spiral, see Figure
72. The wire harness should travel between the U- and V-cables. The correct order of
the cables is important to prevent twisting of the cables.
Figure 72. Traction motor cables and wires inside the protective spiral
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At the traction motor end, the cable and wiring lengths must be correct to prevent
insulation damage, see Figure 73. If you have to disassemble the factory-installed cable
set, remember to reassemble the cables and wires with the correct lengths, in the
correct order and making sure they are not twisted.
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The basis for calibrations is that all of the parameters are correctly set according to the
truck parameter list and settings. Before you start adjusting the calibration parameters,
make sure that the rest of the parameters are in order.
If the accelerator or the Zapi COMBIACX Power controller is changed, the accelerator
must be calibrated. Also if the truck does not drive smoothly, it is recommended that you
always first perform this calibration.
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7. In TruckTool, check that the displayed values are acceptable and click "Stop".
If the process fails, update the firmware on the controller and try again.
1. During key-on, lower the forks and turn the accelerator forward at the same time
and hold the buttons down for 15 seconds.
The truck enters the accelerator teach-in mode.
2. Release all the buttons.
3. Teach the accelerator by turning it first fully forward, then fully backward.
4. Release the accelerator.
5. Press the safety button to save the settings.
6. Restart the truck.
The insulation resistance of the truck and the traction battery is checked separately. The
test voltage is greater than the nominal voltage but no more than 100 V or three times
the nominal voltage:
Up to 24 V 50 V
Over 36 V 100 V
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Connect the test probe to the frame of the truck (for example, to a non-painted bolt or
bracket) and the other test probe to another bolt or bracket. The tester should show a
zero value.
The test is performed with the battery disconnected from the truck. All the electrical
components must be in place.
1. Release the emergency stop and turn the key switch to the ON position.
2. Connect the test probe to the frame of the truck (for example, to a non-painted bolt
or bracket) and the other test probe to the plus terminal of the battery connector.
3. Read the resistance value.
4. Measure and read the minus terminal of the battery connector in the same way.
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The insulation resistance between the live parts of all the electric components and the
frame of the industrial truck with the exception of the battery is at least 1000 Ω
multiplied by the nominal voltage of the truck system.
24 V 24,000 Ω
36 V 36,000 Ω
48 V 48,000 Ω
80 V 80,000 Ω
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The insulation resistance of the disconnected, filled and charged traction battery
mounted on the truck is at least 50 Ω multiplied by the nominal voltage of the truck
system between the live parts and the frame of the truck. If the battery is fitted into more
than one containers, this test is carried out with the electrically-connected sections
(including metal battery containers).
24 V 1,200 Ω
36 V 1,800 Ω
48 V 2,400 Ω
80 V 4,000 Ω
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10 Hydraulic operation
CAUTION
Make sure that you have the appropriate version of the hydraulic schematics for the
truck model under maintenance. Contact your supplier or technical support for
information on obtaining up to date documentation for your truck model.
The hydraulic schematic diagram shown in Figure 79 illustrates the operation of the
hydraulic system.
Figure 79. Hydraulic system overview (1.6 t / 1.8 t model and 2.0 t model)
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Lifting:
Lowering
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NOTE: Different truck models can have different hydraulic system configurations.
SYMBOL DESCRIPTION
Lifting cylinder
No-return valve
300 μ sieve
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SYMBOL DESCRIPTION
Solenoid valve
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CAUTION
Fill the hydraulic oil tank up to ¾ of the full volume. The filling hole for hydraulic oil is
shown in Figure 82 below.
During maintenance, clean the hydraulic oil suction filter in the oil tank.
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The hydraulic aggregate consists of the electric pump motor, the hydraulic gear pump
unit, the oil tank, the suction filter, the pressure relief valve, the solenoid valve, hydraulic
hoses and connections for various hydraulic equipment.
WARNING
Prepare a drip pan to catch any remaining oil in the pipes and hoses before
disconnecting each pipe. Take appropriate actions to prevent dust and dirt from
entering in the opening of the pipe and valve connections.
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To adjust the pressure relief valve or to clean the hydraulic oil suction filter, you must
disassemble the oil tank.
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CAUTION
Attach caps to the cylinder connectors to protect the threads of the connectors and to
prevent oil from flowing out of the cylinder when it is removed.
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NOTE: Support the fork sledge to its uppermost position before cylinder removal.
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11 TruckTool Diagnostics
TruckTool can be used to receive, display and modify settings, update (flash) controller
firmware, reset settings to hardware defaults, review and clear alarms, perform
calibrations, execute a quick truck setup and monitor digital and analogue inputs and
outputs.
The TruckTool program’s usage instructions are available in the application itself.
Additional training is required to use the program.
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12 Parameter descriptions
CAUTION
Always use the correct parameter list for the specific model you are servicing. The latest
parameter lists are available from the manufacturer’s Web site.
NOTE: If the truck is equipped with the electrical steering option, the parameter
descriptions of the steering controller are available in section 15.11.9.
PARAMETER DESCRIPTION
Acceleration ramp end smoothening This parameter controls the smoothness when the
STOP SMOOTH direction change ramp is stopped.
Value range:
• 3 Hz: Minimum
• 20 Hz: Maximum
Brake release cutback speed This parameter controls the speed reduction when
H&S CUTBACK the brake release is activated.
Value range:
• 10%: Enabled
• 100%: Disabled
Braking ramp end smoothening This parameter controls the smoothness when the
STOP BRK SMOOTH braking ramp is stopped.
Value range:
• 3 Hz: Minimum
• 20 Hz: Maximum
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PARAMETER DESCRIPTION
ECO: Deceleration ramp This parameter controls the deceleration rate when
DECEL. BRAKING E the speed is reduced but not stopped while moving
in the economy drive mode.
Value range:
• 0.1: Fastest
• 10: Slowest
ECO: Inversion braking ramp This parameter controls the deceleration rate when
INVERS. BRAK. E the direction switch is reversed while moving in the
economy drive mode.
Value range:
• 0.1: Fastest
• 10: Slowest
ECO: Maximum speed forward This parameter controls the maximum speed
MAX SPEED FORW E forward in the economy drive mode.
Value range:
• 10%: Slowest
• 100%: Fastest
NOTE: For safety reasons, do not exceed the
parameter table value!
ECO: Maximum speed reverse This parameter controls the maximum speed
MAX SPEED BACK E backward in the economy drive mode.
Value range:
• 10%: Slowest
• 100%: Fastest
NOTE: For safety reasons, do not exceed the
parameter table value!
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PARAMETER DESCRIPTION
ECO: Release braking ramp This parameter controls the deceleration rate when
RELEASE BRAK. E the accelerator is released in the economy drive
mode.
Value range:
• 0.1: Fastest
• 10: Slowest
ECO: Speed limit braking ramp This parameter controls the deceleration rate when
SPEED LIM BRK. E speed reduction is activated in the economy drive
mode.
Value range:
• 0.1: Fastest
• 10: Slowest
ECO: Steering cutback braking ramp This parameter controls the deceleration rate when
STEER BRAKING E electrical steering cutback is activated in the
economy drive mode.
Value range:
• 0.1: Fastest
• 10: Slowest
Inversion braking ramp This parameter controls the deceleration rate when
INVERS. BRAKING the direction switch is reversed while moving in the
standard drive mode.
Value range:
• 0.1: Fastest
• 10: Slowest
Max speed FWD PIN 3 Maximum speed forward with PIN code 3.
MAX SP. FW PIN3
Max speed FWD PIN1 Maximum speed forward with PIN code 1.
MAX SP. FW PIN1
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PARAMETER DESCRIPTION
Max speed FWD PIN2 Maximum speed forward with PIN code 2.
MAX SP. FW PIN2
Max speed REV PIN 1 Maximum speed backwards with PIN code 1.
MAX SP. BK PIN1
Max speed REV PIN 2 Maximum speed backwards with PIN code 2.
MAX SP. BK PIN2
Max speed REV PIN 3 Maximum speed backwards with PIN code 3.
MAX SP. BK PIN3
Maximum load speed cutback This parameter controls the maximum speed
MAX SPEED LOAD forward with maximum load in percentage of
absolute maximum driving speed.
Value range:
• 10%: Slowest
• 100%: Fastest
NOTE: For safety reasons, do not exceed the
parameter table value!
Maximum load weight This parameter controls the maximum load of the
MAX LOAD WEIGHT truck.
NOTE: This parameter is used only if the truck is
equipped with the pressure sensor option!
Proportional valve closing ramp This parameter controls the proportional valve
EVP CLOSE DELAY closing delay ramp.
Value range:
• 0.1: Fastest
• 12.75: Slowest
Proportional valve opening ramp This parameter controls the proportional valve open
EVP OPEN DELAY delay ramp.
Value range:
• 0.1: Fastest
• 12.75: Slowest
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PARAMETER DESCRIPTION
Pump acceleration ramp This parameter controls the acceleration ramp for
PU. ACCELER. DEL the pump motor.
Value range:
• 0.1: Fastest
• 25.5: Slowest
Pump deceleration ramp This parameter controls the deceleration ramp for
PU. DECELER. DEL the pump motor.
Value range:
• 0.1: Fastest
• 25.5: Slowest
Pump max speed This parameter controls the maximum lift speed.
SPEED LIMIT Value range:
• 10%: Slowest
• 100%: Fastest
Release braking ramp This parameter controls the deceleration rate when
RELEASE BRAKING the accelerator is released in the standard drive
mode.
Value range:
• 0.1: Fastest
• 10: Slowest
Speed limit braking ramp This parameter controls the deceleration rate when
SPEED LIM BRK. speed reduction is activated in the standard drive
mode.
Value range:
• 0.1: Fastest
• 10: Slowest
Steering cutback braking ramp This parameter controls the deceleration rate when
STEER BRAKING electrical steering cutback is activated in the
standard drive mode.
Value range:
• 0.1: Fastest
• 10: Slowest
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PARAMETER DESCRIPTION
Turtle cutback speed reduction This parameter controls the speed reduction when
TURTLE CUTBACK the low speed mode is activated.
Value range:
• 10%: Enabled
• 100%: Disabled
Walkie mode cutback This parameter controls the maximum speed in the
WALKING CUTBACK pedestrian mode.
Value range:
• 10%: Slowest
• 100%: Fastest
PARAMETER DESCRIPTION
Adjust battery voltage Because the traction motor controller monitors the
ADJUST BATTERY battery discharge level, this parameter must be set
to match the actual battery voltage. The difference
between the ADJUST BATTERY VALUE parameter
value and the voltmeter reading should be ±0.2 V.
Connect the voltmeter between –Batt and key input
K1/1. Use a high-quality voltmeter to check the
battery voltage and set this parameter as close to
the meter reading as possible. This measurement
can be carried out at any time (i.e. regardless
whether the battery is full or empty).
This parameter should be set after the controller has
been changed or if there are problems with battery
charge level monitoring.
Battery maximum value adjust This parameter controls the maximum level for
BAT MAX ADJ. charged battery.
Value range:
• Level = 0: Minimum
• Level = 9: Maximum
Battery minimum value adjust This parameter controls the minimum level for
BAT. MIN ADJ. discharged battery.
Value range:
• Level = 0: Minimum
• Level = 9: Maximum
BDI startup correction value At startup, the BDI is calculated with this voltage
BDI ADJ STARTUP adjust parameter.
Value range:
• Level = 0: Minimum
• Level = 9: Maximum
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PARAMETER DESCRIPTION
Electrobrake retain voltage This parameter controls the brake coil voltage one
EB VOLTAGE RED. second after the activation of the brake voltage. The
parameter should be set between 60% and 80%.
Value range:
• 0%: Minimum
• 100%: Maximum
Fan start temperature This parameter controls the temperature limit for
FAN TEMPERATURE fans. If any of the measured temperatures exceeds
this value, the fans are started.
Main contactor retain voltage This parameter controls the main contactor coil
MC VOLTAGE RED. voltage one second after the activation of the main
contactor voltage.
Value range:
• 0%: Minimum
• 100%: Maximum
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PARAMETER DESCRIPTION
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PARAMETER DESCRIPTION
Option: Pin code timeout PIN code lock timeout. The truck is automatically
PIN CODE TIMEOUT locked after the time set in this parameter (given in
minutes).
PARAMETER DESCRIPTION
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13 Alarm codes
This chapter explains the meaning of the various alarms that the different controllers
may produce. Refer to the chapter 11 for information on the TruckTool diagnostics
application.
NOTE: If the truck is equipped with the electrical steering option, the alarm codes of
the steering controller are available in section 15.11.10.
NOTE: Before you start to troubleshoot the truck, make sure that all the power
supplies, fuses and connections are in order. Low voltage in the traction controller
can cause different sorts of alarms.
The fault diagnostic system of the traction controller is divided into two main groups:
• Alarms
These are faults, which open the power bridge and, when possible, also the main
contactor is opened and the magnetic brake activated. Failures in the motor, the
controller or the safety functions cause alarms.
• Warning
These are faults, which do not stop the truck or stop the truck by using regeneration
braking. The controller is working well, but it has detected some conditions that
reduce the performance or stop the truck without opening the power devices.
Incorrect operation sequences or conditions requiring performance reductions (for
example, high temperatures) cause warnings.
The text “Stored” means that the alarm or warning is stored in the traction controller
logbook.
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This is a safety-related self diagnosis test within the logic between the master (drive) and slave
(pump) microcontrollers. The alarm indicates that the master and slave watchdog message is
missing or late.
This alarm can be caused by a CAN bus malfunction, which blinds the master-slave
communication. Check all the CAN bus cables and measure the bus resistance between CAN
high and low. The bus resistance value should be 60 Ω. Measure also the CAN cables’
resistance between the truck chassis and the 0 cables. There should not be any significant
connection and the resistance value should be over 1 MΩ.
If CAN bus is OK, the problem is in the controller and it must be replaced.
This warning is caused by a hardware or software defect of the non-volatile embedded memory
supporting the controller parameters. This alarm does not prevent truck operation, but the truck
will work with the default values.
In case of this warning, perform a CLEAR EEPROM operation. Switch the key off and on to
check the result. If the alarm occurs permanently, replace the COMBIACX controller. If the
alarm disappears, the previously stored parameter values will have been replaced by the
default values.
This alarm is caused by a hardware problem in the logic card circuit for high current (overload)
protection.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
This alarm is caused by a fault in the logic board managing the phase’s voltage feedback.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
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This alarm is displayed when the controller detects an overvoltage or undervoltage condition.
The overvoltage threshold is 35 V and the undervoltage threshold is 9.5 V in the 24V controller.
If the alarm is displayed at startup or in the standby mode, it is due to an undervoltage. In such
a case, check the following:
• The key input signal voltage drops below the undervoltage threshold due external loads,
such as DC/DC converters starting up or relays or contactors energizing or de-energizing.
• If no voltage transient is detected on the supply line and the alarm is displayed every time
the key is switched ON, the problem is in the COMBIACX controller.
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This test is carried out when the pump motor is turning. The alarm indicates that the pump
motor output is higher than expected.
In such a case, check the following:
• Motor connections
• If the motor windings or cables have leakages towards the truck frame
If no problems are found on the motor, the problem is in the COMBIAX controller.
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Cause 1:
Before switching the main contactor on, the software checks the power bridge. It turns the low
side and high side power mosfets on one by one and expects the phase voltage to decrease
down to –Batt. If the phase voltage does not decrease, this alarm occurs.
In such a case (the main contactor does not close at all), check the following:
• Motor internal connections (ohmic continuity)
• Motor power connections
• Motor leakage to the truck frame
If the motor connections are OK, the problem is in the COMBIACX controller.
Cause 2:
This alarm may also occur when the startup diagnosis has been completed and the main
contactor is closed. In this case, the phase voltage is expected to be lower than 50% of the
battery voltage. If it is higher than this value, this alarm occurs.
In such a case (the main contactor closes and then opens again), check the following:
• Motor connections
• Whether the motor’s phase windings or cables have leakages towards the truck frame
• That the main contactor closes properly, with a good contact
If no faults are found, the problem is in the COMBIACX controller.
Before driving the main contactor coil, the controller checks that the contactor is not stuck
(closed). The controller drives the mosfets for some milliseconds, trying to discharge the
capacitor bank. If the contactor is stuck, this alarm occurs.
In such a case, check the main contactor tips. If needed, replace the main contactor.
This alarm occurs if the main contactor has been driven by the controller, but the contactor
does not close.
In such a case, check that the wires to the main contactor coil are not interrupted or
disconnected.
The alarm can also be caused by a fault in the main contactor itself. If needed, replace the
contactor.
This test is carried out when the pump motor is running, and it verifies that the current feedback
sensor is not constantly stuck to 0.
If this warning is displayed, check that the motor connection has continuity. If the motor
connection is opened, the current cannot flow, so the test fails and the warning is displayed.
If the motor circuit is OK, the problem can be in the current sensor. In this case, replace the
COMBIACX controller.
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This alarm is displayed if the current transducer or the current feedback circuit is damaged in
the controller.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
When the main contactor is open, the rail capacitors are charged from the key line through a
charging resistor. If the voltage on the rail capacitors is low and does not increase, this alarm is
displayed.
In such a case, there are four possibilities:
• Another device connected in parallel with the rail capacitors has failed.
• Something is draining the current between the main contactor and the controller when the
main contactor is open.
• There is a problem in the charging section (for example, a bad contact in the key line).
• A power failure or a logic failure occurred in the controller. In this case, replace the
COMBIACX controller.
This alarm indicates that the controller temperature is over 85°C. The maximum current is
reduced proportionally to the temperature increase. The controller stops when 105°C is
reached.
If this alarm occurs when the controller is cold, there are three possibilities:
• There is a fault in the thermal sensor wiring.
• There is a failure in the thermal sensor.
• There is a failure in the logic.
In all of the above cases, replace the COMBIACX controller.
This alarm occurs when the analogue temperature sensor has exceeded the threshold 150°C.
In such a case, check the following:
• The thermal sensor inside the motor and the outside wiring. The resistance of the sensor
(type KTY83) is 960 Ω at 20°C.
• If the warning occurs when the motor is cold and the thermal sensor is OK, the problem is
in the COMBIACX controller.
• If the motor is overheating, check that air ventilates freely in the motor compartment.
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This warning occurs when the battery charge is calculated as being less or equal to 10% of a
full charge and the BATTERY CHECK parameter is set to a value other than 0 (located in the
SET OPTION menu).
In such a case, charge the battery. If it does not help, measure the battery voltage with a
voltmeter and compare it with the value of the BATTERY VOLTAGE parameter. If they are
different, adjust the value of the ADJUST BATTERY parameter.
When adjusting the battery voltage, voltage should be measured from the key line, after the
reverse polarity protection diode. A good measuring point is, for example, the emergency stop
button terminal. If the battery voltage is measured anywhere else, it will cause invalid operation
of the battery discharge indicator.
This alarm occurs if the driver of the main contactor coil is shorted or the coil is disconnected.
In such a case, check the following:
• If there is a short circuit between the connector XA1 C pin 6 and –Batt.
• Condition of the wiring of the main contactor related harness.
If there is no short circuit and the wiring is OK, the driver circuit in the COMBIACX controller is
damaged.
This alarm indicates that the main contactor driver is not able to drive the load. The device itself
or its driving circuit is damaged.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
This alarm occurs when the accelerator output voltage differs more than 1 V from the acquired
minimum during PROGRAM VACC.
In such a case, check the functionality of the accelerator. Perform the accelerator calibration
wizard function.
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This warning occurs when both travel demands are active at the same time.
Use a tester to check for possible reasons for this warning. If both directions are active at the
same time, check the accelerator and its wiring.
If no direction signals are active at the same time outside the controller, the problem is in the
COMBIACX controller.
This alarm occurs if the frequency supplied to the motor is higher than 40 Hz and the feedback
signal from the encoder has a jump higher than 40 Hz within 20-40 milliseconds. This condition
is related to a malfunction of the encoder. In such a case, check the encoder’s mechanical
functioning and its wirings connections. Also check the encoder’s mechanical installation; if the
encoder slips inside the housing, it causes this alarm.
Also electromagnetic noise on the encoder can cause this alarm. In such a case, replace the
encoder. If the alarm persists after replacing the encoder, the problem is in the COMBIACX
controller.
The software checks for the connection of the two supply ends of the accelerator’s
potentiometer. The test consists of reading the voltage drop on a sense diode connected
between NPOT and GND. If the accelerator gets disconnected on PPOT or NPOT, no current
flows in this sense diode and the voltage on the NPOT connection drops down.
This alarm occurs if the NPOT voltage is less than 0.3 V and also when the NPOT voltage is
higher than 2 V (to detect also the condition of a broken sense diode).
In such a case, check the voltage on the NPOT and the accelerator connections.
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If the truck is not equipped with side stabilizers, check that the parameter INITIAL LIFT is not
set to 2.
If the truck is equipped with side stabilizers:
• Check the wiring of the height sensor.
• Disconnect the height sensor and test the redundant switches. If the states are not equal,
test if the switch works by moving a magnet in front of it.
• Check that the magnet counterpart (attached to the lifting carriage) is intact.
• Check the wiring of the encoder card (extra I/O).
If the problem persists, replace the height sensor.
This is only a notification. To limit further heat generation, the parameter cutback starts when
the motor temperature reaches 120˚C. The truck can be used normally.
This is only a notification. To limit further heat generation, the parameter cutback starts when
the controller temperature reaches 75˚C. The truck can be used normally.
This warning indicates a pressure sensor problem. Either the pressure sensor’s voltage is not
within the calibrated value range or it exceeds the calibrated values too much.
One possible cause for this alarm is too steep braking ramp (parameter). Try to lower the
braking ramps from the parameters. Also braking at a slope when the truck is loaded can
cause this error.
This alarm indicates that there is some problem in the steering and the steering has frozen.
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This is a general warning indicating only that the truck is waiting for an operator.
This alarm occurs if the motor resistance is different than the value of the parameter MOTOR
RESIST.
In such a case, teach the new motor resistance value by setting the parameter MOTOR
RESIST to 0 and saving the value while holding the tiller arm in the drive position. Restart the
truck after the main contactor is opened. The new settings are active after the restart.
This warning occurs if the controller did not acquire the motor resistance value correctly.
In most cases, this alarm signals that the controller cannot inject current in the motor coils for
some reason. Check the motor connections. Also make sure that the main contactor is closed.
This alarm indicates damage to the controller’s hardware which provides feedback for the
sensorless motor control.
If the problem occurs permanently, replace the controller.
This warning is displayed when the PIN code teaching procedure is active. It disappears when
the teaching is finished.
This warning should occur only if the truck is equipped with a PIN code lock.
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This warning indicates that the controller is waiting for a valid PIN code. If it occurs in a truck
that does not use PIN code lock, check that the PIN CODE LOCK parameter is set to ABSENT.
This warning should occur only if the truck is equipped with a PIN code lock.
This alarm indicates that the controller entered the throttle lever teaching mode. It disappears
as soon as the teaching of the throttle lever is finished.
This warning is displayed when the lifting cut off timer has expired (the default value is seven
seconds).
In case of this warning, release the lift button. If the lift buttons are released and the warning
persists: check the following:
• The lift inputs are correct in the tester menu.
• Operation of the tiller and the lift buttons is correct.
• There are no short circuits in the lift button wirings.
Cause 1: At startup
The software checks the voltage on the –P terminal and expects it to remain at a steady value.
This alarm occurs if the value does not remain steady.
Cause 2: During operation
If this alarm is displayed during operation, it indicates that the voltage on the –P terminal is too
low when the main contactor is closed.
The software waits for 30 seconds before displaying this alarm, because there are situations
where the pump motor can rotate while the –P output is not activated (pump deceleration).
During this time, it shows the WAIT MOT P STILL warning.
In case of this alarm, check the following:
• Pump motor internal connections
• Pump motor power cable connections
• Pump motor leakage to the truck frame
If the pump motor connections are OK, the problem is in the COMBIACX controller.
See the description of the alarm 203 PUMP VMN NOT OK.
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Before switching the main contactor on, the software checks the power bridge voltage without
driving it. The software expects the voltage to be at a steady state value. If the voltage is too
high, this alarm occurs.
In such a case, check the following:
• Motor internal connections
• Motor power cable connections
• Motor leakage to the truck frame
If the motor connections are OK, the problem is in the COMBIACX controller.
Before switching the LC on, the software checks the power bridge voltage without driving it.
The software expects the voltage to be at a steady state value. If the voltage is too low, this
alarm occurs.
In such a case, check the following:
• Motor internal connections (ohm continuity)
• Motor power cable connections
• Motor leakage to the truck frame
If the motor connections are OK, the problem is in the COMBIACX controller.
This alarm is caused by a hardware or software defect in the non-volatile embedded memory
supporting the controller parameters. This alarm does not prevent the truck from operating, but
the truck will work with the default values.
In the case of this alarm, perform the CLEAR EEPROM operation. Switch the key off and on to
check the result. If the alarm persists, replace the COMBIACX controller. If the alarm
disappears, the previously stored parameter values will have been replaced by the default
parameter values.
This alarm is caused by a hardware or software defect in the volatile embedded memory.
The controller could be damaged and it should be replaced.
This alarm indicates that the traction rotor is stuck or the encoder signal is not correctly
received by the controller.
In the case of this alarm, check if the sign of FREQUENCY and ENCODER on the tester menu
are the same. Also check that it is not zero during a traction request.
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If this alarm occurs, the POSITIVE EB parameter is probably not set correctly. Set the
parameter to LEVEL=0.
This alarm is displayed if the microcontroller detects a mismatch between the valve set-point
and the voltage measured on the solenoid valve output. This can be caused by the following:
• The solenoid valve coil circuit is shorted.
• The COMBIACX solenoid valve driver is shorted.
If there is low impedance between the negative of the solenoid valve coil and –Batt, the driver
circuit is damaged and the COMBIACX controller must be replaced.
This alarm indicates that the pump motor’s current feedback sensor has detected current
flowing in the circuit while the pump motor is not running.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
This warning indicates a motor thermal sensor knockout, meaning that the motor thermal
sensor has either short or open circuited.
In such a case, check that the connector contacts and the cables are in order. Measure the
resistance of the thermal sensor (960 Ω at 20°C).
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This alarm indicates that the voltage on the positive line of the EV outputs (B2) is too high or
too low.
In such a case, check if the voltage dropped down because of a faulty load connected to B2. If
not, replace the COMBIACX controller.
This is a startup diagnostic for the key line. This alarm occurs if the key line (XA1 C/1) voltage
drops below the threshold level of 9.5 V.
In such a case, check if the key input signal voltage drops below the undervoltage threshold
due to external loads, such as DC/DC converters starting up or relays or contactors energizing
or de-energizing.
If no voltage transient is detected on the supply line and the alarm occurs every time the key is
switched ON, the problem is in the COMBIACX controller.
This alarm indicates that the built-in smart driver is open and not able to provide the magnetic
brake positive.
In such a case, check the harness to see if the smart driver output XA1 B/1 is shorted to –Batt.
If the output stays at a low level even when disconnecting the wire from the connector pin, the
problem is in the COMBIACX controller.
This alarm occurs when there is a short circuit in the main contactor or magnetic brake coil.
The typical root cause for this alarm is a problem in the harness or in the coil. Check the
connections and wiring between the controller and coils.
If there are no external failures or problems, the problem is in the controller and it needs to be
replaced.
This warning indicates that the controller has received a message from the CAN bus that
another controller or device in the network has experienced a failure. As a consequence, the
traction controller itself cannot operate, but has to wait for the other controller or device to
recover from the failure.
In case of this warning, check the additional CAN bus devices for faults.
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This warning occurs when the tiller is released after a fixed time in the standby mode with the
main contactor open (30 seconds).
After the next travel request, the warning disappears.
This alarm is displayed when the output of the built-in smart driver, which supplies the positive
to the electromechanical brake coil, is high when the tiller and the brake release switch are
open.
In such a case, check the wiring to see that there is no extra positive supply connected to the
electromechanical brake at the connector XA1 B/1 when the tiller and the brake release switch
are open.
If the output stays at a low value even when disconnecting the wire from the connector pin, the
problem is in the COMBIACX controller.
This is a safety related, self-diagnosis test within the logic. The watchdog circuit is composed of
two monostable multivibrators, so there is a double-check of the software execution.
This alarm can be caused by a hardware failure in one or both of the multivibrators or it can be
due to a software execution problem. In both cases, the problem is in the COMBIACX
controller, which must be replaced.
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This alarm is displayed if the hydraulic valve coil load is too high for the controller valve driver
circuit.
In such a case, check the following:
• Hydraulic valve coil condition
• Wiring
If the device or its driving circuit is damaged, replace the controller.
Before switching the main contactor on, the software checks the power bridge. It turns the low
and high side power mosfets on one by one and expects the phase voltage to decrease down
to –Batt. If the phase voltage does not decrease, this alarm occurs.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
This alarm is displayed if the solenoid valve EVXX (XX = 01, 02 or 03) driver is shorted.
Check if there is a short or low impedance between the negative of one of the coils and –Batt.
If not, the driver circuit is damaged and the controller must be replaced.
This warning is displayed if one of the solenoid valve’s EV (XY1 or XY2) coils is shorted.
Check if there is a short or low impedance between the negative of the EV coil and +Batt. If
not, the controller is damaged and must be replaced.
This alarm indicates that the maximum current gain parameters are at their default values,
meaning that the maximum current procedure has not been carried out.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
This alarm occurs when the conversion of the analogue inputs provides frozen values.
If the alarm occurs permanently, replace the COMBIACX controller.
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This alarm indicates that there is a mismatch between the brake release input and the tiller
switch input. If both inputs are connected at the same time, TILLER ERROR is displayed.
If this alarm occurs, release the brake release button and the tiller arm to the up position.
This alarm indicates that the software is not compatible with the controller.
In case of this alarm, flash new software to the controller. If the alarm occurs permanently
replace the COMBIACX controller.
This alarm is displayed if the solenoid valve driver is damaged or the solenoid valve coil
impedance is too low.
In such a case, check the following:
• Solenoid valve coil impedance
• Wiring
If the solenoid valve driver circuit is damaged, replace the controller.
This alarm occurs when lifting and lowering demands are active at the same time.
Use a tester to check the possible reasons for this alarm. If both demands are active at the
same time, check the switches and wiring.
If no lifting and lowering signals are active at the same time outside the controller, the problem
is in the COMBIACX controller.
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This alarm indicates that the lift lever voltage is out of range.
In such a case, check the following:
• Teach the lift lever values again.
• Check that the connectors and cables are in order.
• Replace the lift lever and teach the new values.
This alarm occurs when the lift lever output voltage differs from the values acquired at
calibration.
In such a case, check the functionality of the lift lever. Perform the lift lever calibration wizard
function.
This alarm indicates that the driver of the electromagnetic brake coil is not able to drive the
load.
The driver inside the COMBIACX controller is damaged, so the controller has to be replaced.
This alarm is displayed where there is no CAN message from the Curtis display.
This alarm can be caused by a CAN bus malfunction, which blinds the traction-display
communication. If not, it is an internal problem in the COMBIACX controller or in the Curtis
display.
This warning indicates that the output of the controller thermal sensor is out of range.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
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At startup, the controller checks the battery voltage and verifies that it is within a certain
window around the nominal value. If this is not the case, this alarm is displayed.
In such a case, do the following:
• Check that the controller’s SET BATTERY parameter value matches the battery nominal
voltage.
• Check from the tester menu that the BATTERY VOLTAGE parameter shows the same
value as the battery voltage measured with a voltmeter. If it does not match, perform the
ADJUST BATTERY function.
• Replace the battery.
When adjusting the battery voltage, voltage should be measured from the key line, after the
reverse polarity protection diode. A good measuring point is, for example, the emergency stop
button terminal. If the battery voltage is measured anywhere else, it will cause invalid operation
of the battery discharge indicator.
The outputs of the amplifiers (used to measure the traction motor voltage) are checked to be
within a certain range. This alarm occurs when the voltage signals exceed 3 V or fall below 2 V
at the startup.
This fault is not related to external components, so when it appears, replace the COMBIACX
controller.
This alarm indicates that there is an error in the chosen slip profile parameters.
Check the value of those parameters in the HARDWARE SETTING menu.
This alarm indicates that the driver of the magnetic brake is shorted.
Check if there is a shortcut between XA1 A/4 and –Batt. Otherwise, the driver in the
COMBIACX controller is damaged and the controller has to be replaced.
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14 Service data
Traction wheel 80 Nm
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MONTHLY 1,200 h OR
600 h OR
BEFORE (OWNER) EVERY
ONCE A
DAILY USE SECOND
YEAR
(USER) YEAR
(SERVICE)
(SERVICE)
Drive unit
Steering bearing C C
Hydraulics
Leakage checking C C C
Oil level C C C
Linkage
Bearings C C
Linkage C C
Wheels
Traction wheel C C C C
Load wheels C C C C
Battery
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MONTHLY 1,200 h OR
600 h OR
BEFORE (OWNER) EVERY
ONCE A
DAILY USE SECOND
YEAR
(USER) YEAR
(SERVICE)
(SERVICE)
Charger C C
Electrics
Sensors C C
Horn C C C C
Brake functions C C C C
General
Cleaning C C C C
Gas springs C C C C
Type plate C C C C
Covers C C C C
Safety functions C C C C
• Brake
• Safety button
• Battery lock
• Warning decals
• EMS - Emergency switch
• Key switch
Options
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MONTHLY 1,200 h OR
600 h OR
BEFORE (OWNER) EVERY
ONCE A
DAILY USE SECOND
YEAR
(USER) YEAR
(SERVICE)
(SERVICE)
DC converter C C
Internal charger C C
Load backrest C C C C
Working lights C C C C
Accessory bracket C C C C
14.4 Lubrication
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Crimp tool for traction / pump controller signal line connectors RL362138
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15 Options
This chapter provides information about the optional features available for the truck.
Most of the options, with the exception of quick battery replacement, lever for lifting and
lowering and electrical steering, can be installed to the truck after purchase.
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The pallet entry / exit rollers make it possible to handle the truck’s load pallets sideways.
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The load support protects the truck operator from unexpected load movements.
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With the accessory rack, the truck can be equipped with accessories that make the
operator’s work easier. The following accessory-specific racks can be installed to the
accessory rack:
• List bracket
With the list bracket, all work papers can be carried conveniently on the truck. The
list bracket is equipped with a holder, which keeps the papers in place.
• Computer rack
With the computer rack, the truck can be equipped with a computer. The computer
rack is suited for computers with a maximum width of 345 mm.
• Bottle rack
The bottle rack provides a holder for drink bottles and cups.
• Pen rack
The pen rack holds the truck operator’s pens and small tools in place even during
driving.
• Working lights
Working lights enhance the truck operation in dim lighting conditions.
NOTE: Since both the list bracket and the computer rack are installed in the middle of
the accessory rack, only one of these options can be installed at the same time.
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CAUTION
Always use the correct schematic diagram for the specific model you are servicing. The
latest schematic diagrams are available from the manufacturer’s Web site.
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4. Connect the wires to the working light according to the truck model specific
schematic diagram.
5. Tie the working light wires to the accessory rack and draw them via the hoist
point hole into the battery compartment. See Figure 91 below.
6. Draw the working light wires following the battery cables through the holes in the
battery compartment into the tractor compartment. See Figure 91 below.
7. Connect the working light wires according to the truck model specific schematic
diagram.
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NOTE: The lever for lifting and lowering option is installed to the truck during
manufacturing, so this option needs to be selected prior to purchasing the truck.
The levers for lifting and lowering allow easier operation with gloves on. The levers
function in parallel to the lifting and lowering buttons.
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Figure 93. Removing the controller for lifting and lowering overview
1. Screw 3. Connector
2. Controller for lifting and lowering 4. Controller levers
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1. Connect the lever wires to the connector. The pin locations from 1 to 3 are
marked on the connector with lines and help you in determining the rest of the pin
locations. Details of the controller wires and their pin locations are available in
Figure 94 and Table 11 below.
2. Install the controller and tighten the screws.
3. Connect the controller connector.
4. Install the levers.
5. Tighten the screws at the end of the levers.
6. Calibrate the controller. For instructions, see section 9.1.
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4 - -
5 - -
If the controller for lifting and lowering or the Zapi COMBIACX Power controller is
changed, the controller for lifting and lowering must be calibrated. Also if the truck does
not drive smoothly, it is recommended that you always first perform this calibration.
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7. In TruckTool, check that the displayed values are acceptable and click "Stop".
If the process fails, update the firmware on the controller and try again.
1. During key-on, lower the forks and turn the accelerator forward at the same time
and hold the buttons down for 15 seconds.
The truck enters the accelerator teach-in mode.
2. Release all the buttons.
3. Teach the controller for lifting and lowering by moving the lever for lifting and
lowering to one end position, then to the other end position.
4. Release the lever for lifting and lowering.
5. Press the safety button to save the settings.
6. Restart the truck.
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The voltage converter (12 V, 12.5 A) allows multiple peripherals, such as a PC, a
barcode scanner or a label printer, to be connected to the truck's electrical system.
CAUTION
Always use the correct schematic diagram for the specific model you are servicing. The
latest schematic diagrams are available from the manufacturer’s Web site.
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The pressure sensor is used for monitoring the hydraulic pressure of the hydraulic
system. With this sensor, the traction controller can adjust the driving speed according
to the lifted load. The pressure sensor has an output signal of 1–6 Vdc in the range of 0-
250 bar oil pressure.
Vs 9 - 30 Vdc
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CAUTION
Always use the correct schematic diagram for the specific model you are servicing. The
latest schematic diagrams are available from the manufacturer’s Web site.
4. Connect the pressure sensor wires according to the truck model specific
schematic diagram.
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1. Lower the load handling fork to its lowest position to minimize the hydraulic
system’s oil pressure.
2. Measure the output signal voltage level with a multimeter between the signal output
terminal (XB42/2) and the minus terminal (XB42/3).
The nominal output signal level is ~1 Vdc when the hydraulic pressure is 0 bar.
The output signal level rises relatively to the hydraulic oil pressure and with the
maximum load (2000 kg) the value is close to 4 Vdc.
3. If the pressure sensor values do not match the above, replace the sensor.
The battery lock sensor prevents the operation of the truck, if the battery is not properly
locked in place.
Size Rectangular, 10 mm x 16 mm x 28 mm
Vs 10 - 30 Vdc
Sensing range 3 - 6 mm
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CAUTION
Always use the correct schematic diagram for the specific model you are servicing. The
latest schematic diagrams are available from the manufacturer’s Web site.
3. Draw the battery lock sensor wires following the battery cables through the holes
in the battery compartment into the tractor compartment. See Figure 99 below.
4. Connect the battery lock sensor wires according to the truck model specific
schematic diagram.
5. With TruckTool, set the parameter A14 function to OPTION #1.
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1. Connect the supply voltage between the brown (+) and blue (-) wires.
2. Measure the supply voltage between the wires.
The value should be +24Vdc.
3. Measure between the blue (-) and black (output) wires on the voltage area.
When a supply is connected and there are no metallic objects within the sensing
range, the value is approximately 0V.
When a metallic object is moved within the sensing range, the value is the same as
the supply voltage, i.e. +24Vdc.
4. If the values do not match the above, replace the sensor.
NOTE: Make sure that you set the mechanical voltage selector to the correct battery
voltage (24 V)! Also note the polarity of the battery cables.
NOTE: Make sure that you set the mechanical voltage selector to the correct battery
voltage (24 V)! Also note the polarity of the battery cables.
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Instructions for removing the recharging plug are provided below. Install the recharging
plug by repeating the steps in reversed order.
2. Remove the electric panel. For instructions, see the steps 1-3 in the section 8.2.6.
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NOTE: The quick battery replacement option is installed to the truck during
manufacturing, so this option needs to be selected prior to purchasing the truck.
The quick battery replacement device enables changing the battery without the use of a
lifting device.
1. Open the battery cover. For instructions, see the section 5.4.4.
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Figure 101. Rubber absorbers with the quick battery replacement option
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NOTE: The electrical steering option is installed to the truck during manufacturing, so
this option needs to be selected prior to purchasing the truck.
Electrically powered steering helps the driver to steer the vehicle by augmenting the
steering effort of the steering wheel. The electric motor adds controlled energy to the
steering mechanism, so the driver needs only a modest effort to turn the truck. Power
steering helps considerably when the vehicle is stopped or moving slowly.
The power steering system has no direct mechanical connection to the steering. The
electric motor provides assistance force, which is controlled by the electric steering
controller.
When the tiller is turned to the right or left, the tiller sensor informs the steering
controller that the tiller is turned. The controller starts to turn the steering mechanism
with the steering motor. There are two feedbacks devices; the sensor bearing in the
steering motor and the outer feedback sensor, which provides feedback information to
the controller. With this information, the controller knows the actual position of the
turned wheel and can handle the steering movements carefully.
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Figure 102. Motor and electrical system with electrical steering overview
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The EPS AC0 inverter has been developed to perform steering functions that are
usually present in walkie and rider pallet trucks, stackers and low-level order pickers.
CAUTION
Before any inspection or repair work, turn the key switch to the OFF position,
disconnect the battery plug/connector, discharge all inverters and record the places of
the harness connections before disassembly.
When disconnecting the connector, hold the connector housing and plug and unlock the
connector. Holding the case may cause damage to the inside card, while holding the
cable may cause wire breakage.
If the high-power cable terminals of the battery-operated vehicle are not tightened
properly, the increased contact resistance causes excessive heat generation, and can
even cause a fire. To prevent accidents and equipment problems, check the tightening
torque of the high-power cable terminals regularly. Do not pull the cables to check
connections or during adjustment. If the cable terminal sections are moved, re-tighten
the connections.
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Contact 0.2 – 0.8 mm2 for CNA, CNB, CNC and CND connectors, spare part:
RL450666
CONNECTION DESCRIPTION
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CONNECTION DESCRIPTION
CONNECTION DESCRIPTION
CONNECTION DESCRIPTION
The correct tightening torque for the Zapi EPS AC0 terminal bolts is 2.5 – 3 Nm.
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The feedback sensor is used for monitoring the steering wheel position. With this
sensor, the steering controller can adjust the steering angle of the truck. The feedback
angle sensor has an output signal from 0.5–4.5 Vdc.
Vs +5 Vdc
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1. Connect the supply voltage +5 Vdc between the supply (XP2/1) and negative
(XP2/3) wires.
2. Measure the supply voltage between the wires.
The value should be +5 Vdc.
3. Measure between the negative (XP2/3) and output (XP2/2) wires on the voltage
area.
When a supply is connected and the sensor axis is rotated, the value varies
between 0.5 - 4.5 Vdc. When the value is increasing toward 4.5 Vdc, and the sensor
axis is rotating more, the value returns to 0.5 Vdc. Also, when rotating to the other
direction, the value decreases.
4. If the values do not match the above, replace the sensor.
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13. Remove the drive unit. For instructions, see section 8.3.1.
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During maintenance, check the condition of the motor belt and tighten it, if needed.
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If any of the electric steering components are changed, the electrically powered steering
must be adjusted.
The tiller and feedback sensors have two output signals that are crossed together.
Because the output signals are not fully rotating, the sensor axis has to be set to the
correct position (center) when installed to the truck.
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1. Connect the supply voltage +5 Vdc between the + terminal (XP1/1) and the
- terminal (XP1/3).
2. With a multimeter, measure the voltage area between the minus terminal (XP1/3)
and output 1 (XP1/2) or output 2 (XP1/4).
3. Turn the sensor axis so that the multimeter shows ~2.5 Vdc.
Now the sensor is centered and can be installed to the truck system.
4. It is very important to assemble the sensor axis in the correct position. When the
tiller sensor or the feedback sensor is at the center position, make sure that also the
tiller and the steering mechanism are in the center position.
5. To minimize the mechanical strain of the sensor axis, make sure that the sensor is
assembled on its bracket as centered as possible.
NOTE: Make sure that all the steering controller parameters are set according to the
latest parameter list.
1. Connect the Zapi hand console to the steering controller and switch the truck on.
2. Go to the SET OPTIONS menu and set FEED BACK DEVICE = OPTION1 and
LIMIT DEVICE = OFF.
3. Press OUT and ENTER.
4. Restart the truck.
5. Make sure that the tiller and the steering mechanism turn to the same direction.
6. Turn the tiller straight forward.
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7. With the Zapi hand console, go to the ADJUSTMENTS menu and to the ZERO SP
POT parameter. Then press OUT and ENTER.
The value should be ~2.5 Vdc.
8. Turn the tiller slowly to the left until the steering mechanism almost reaches its
mechanical limit. Stop approximately 5 mm before the limit.
9. With the Zapi hand console, go to the ADJUSTMENTS menu and to the SET MAX
FB POT parameter. Then press OUT and ENTER.
The value should be ~3.5 Vdc.
10. Turn the tiller slowly to the right until the steering mechanism almost reaches its
mechanical limit. Stop approximately 5 mm before the limit.
11. With the Zapi hand console, go to the ADJUSTMENTS menu and to the SET MIN
FB POT parameter. Then press OUT and ENTER.
The value should be ~0.7 Vdc.
12. Go to the SET OPTIONS menu and set FEED BACK DEVICE = OPTION2 and
LIMIT DEVICE = ON.
13. Press OUT and ENTER.
14. Restart the truck.
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1. With the Zapi hand console, go to the SET OPTIONS menu and set TILLER DEAD
ZONE = ON.
2. Restart the truck.
When the truck is restarted, there is a 20 degree dead zone in the middle of the
steering area. Inside this dead zone, turning the tiller does not turn the steering
mechanism.
Be careful while calibrating the straight forward position.
3. Go to the ADJUSTMENTS menu and find the SET STEER 0-POS parameter. By
increasing this value, the steering mechanism turns to the left and by decreasing
this value, the steering mechanism turns to the right.
4. Drive carefully and adjust the tiller and the steering mechanism as straight as
possible. Then drive forward and backward to see how straight the truck is
travelling. If needed, adjust the SET STEER 0-POS. parameter to adjust the straight
forward driving.
5. Press OUT and ENTER to save the settings.
6. After the calibration, restart the truck.
7. After the restart, the TILLER DEAD ZONE parameter has turned to the OFF state
and the dead zone is no longer present. When the tiller is in the straight forward
position, make sure that the truck really travels straight forward. If not, repeat the
calibration steps and restart the truck again.
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Make sure that the electrically powered steering runs as it should and no errors are
present. ALARM STEER HAZARD is not a relevant error. It is present when the steering
mechanism is turned to the left or right end limit.
1. Go to ALARMS.
2. Press ENTER and OUT, and then press ENTER twice.
3. Exit the menu.
4. Restart the truck.
PARAMETER DESCRIPTION
Max steering angle limit coarse This parameter defines the steering angle limitation.
1ST ANGLE COARSE It sets the tiller angle on which the maximum
steered wheel angle is achieved.
Max steering angle limit fine This parameter defines the fine adjustment for "Max
1ST ANGLE FINE steering angle limit coarse".
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PARAMETER DESCRIPTION
Min steering angle limit coarse This parameter defines the steering angle limitation.
2ND ANGLE COARSE It sets the tiller angle on which the minimum steered
wheel angle is achieved.
Min steering angle limit fine This parameter defines the fine adjustment for "Min
2ND ANGLE FINE steering angle limit coarse".
Steering angle cutback This parameter defines the steering angle reduction
AUX FUNCTION 3 in respect to the truck speed. The controller limits
the maximum steering angle depending on the
truck’s travel speed. It is strongly recommended that
you do not touch this setting.
Value range:
• 0: Maximum steered angle at full speed is 73%
• 9: Maximum steered angle at full speed is 10%
Steering angle cutback start speed This parameter defines the steering angle reduction
AUX FUNCTION 2 ramp starting speed. It is strongly recommended
that you do not touch this setting.
Value range:
• 0: Maximum angle starts to reduce when the
truck speed is 1% of the maximum speed
• 9: Maximum angle starts to reduce when the
truck speed is 100% of the maximum speed (=
no angle reduction)
Straight ahead steering numbness This parameter reduces the steering sensitivity
NUMBNESS close to the straight-ahead direction.
Value range:
• 0: No reduction
• 9: Maximum reduction
PARAMETER DESCRIPTION
Limit steering angle This parameter limits the maximum steering angle.
LIMIT DEVICE The maximum angles are set by the parameters
"Minimum wheel angle" (SET MIN FB POT) and
"Maximum wheel angle" (SET MAX FB POT).
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PARAMETER DESCRIPTION
Steering feedback type This parameter defines the steering feedback type.
FEEDBACK DEVICE Value range:
• 1: Feedback potentiometer only. This setting
must be temporary only, and is meant for the
setup of the EPS. Set this parameter to 2 after
the setup is done.
• 2: Feedback potentiometer and encoder.
PARAMETER DESCRIPTION
NOTE: Before you start to troubleshoot the truck, make sure that all the power
supplies, fuses and connections are in order. Low voltage in the controller can cause
different sorts of alarms.
The fault diagnostic system of the steering controller is divided into two main groups:
• Alarms
These are faults, which open the power bridge and, when possible, also the main
contactor is opened and the magnetic brake activated. Failures in the motor, the
controller or the safety functions cause alarms.
• Warning
These are faults, which do not stop the truck or stop the truck by using regeneration
braking. The controller is working well, but it has detected some conditions that
reduce the performance or stop the truck without opening the power devices.
Incorrect operation sequences or conditions requiring performance reductions (for
example, high temperatures) cause warnings.
The text “Stored” means that the alarm or warning is stored in the steering controller
logbook.
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0 No alarms
NONE
1 No errors (Warning)
CHOPPER RUNNING
2 No Communication (Warning)
NO COMMUNICATION
This warning is caused by a hardware or software defect of the non-volatile embedded memory
supporting the controller parameters. This warning does not prevent the truck from operating,
but the truck will function with default values.
In the case of this warning, try to execute a CLEAR EEPROM operation. Switch the truck’s
power off and on and check the result.
If the alarm occurs permanently, replace the COMBIACX controller. If the alarm disappears,
the previously stored parameter values will have been replaced by the default values.
This alarm occurs in the rest state if the output of the voltage amplifier Wv-Vv has a drift larger
than ±0,25 V. In such a case, replace the steering controller.
This alarm is caused by a hardware problem in the logic card circuit for high current protection.
This fault is not related to external components, so when it appears, replace the steering
controller.
This alarm is caused by a fault in the logic board, which manages the phase’s voltage
feedback.
This fault is not related to external components, so when it appears, replace the steering
controller.
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This alarm is displayed when the controller detects an overvoltage or undervoltage condition.
The overvoltage threshold is 45 V and the undervoltage threshold is 9 V in the 24 V controller.
If the fault is displayed at startup or in the standby mode, it is due to an undervoltage condition.
In such a case, the check following:
• The key input signal voltage drops below the undervoltage threshold due external loads,
such as DC/DC converters starting up or relays or contactors energizing or de-energizing.
• If no voltage transient is detected on the supply line and the alarm is displayed every time
the key is switched ON, the problem is in the steering controller.
If the alarm is displayed during motor steering, it is due to an undervoltage or an overvoltage
condition.
If the alarm happens during traction acceleration or driving hydraulic functions, it is due to an
undervoltage condition. In such a case, check the battery charge level and the power cable
connections.
This alarm occurs in the initial rest state after startup if the outputs of the motor voltage
amplifiers are not in the window from 2.2 V to 2.8 V. In such a case, replace the controller.
This alarm occurs only when the parameter CAN BUS is set to PRESENT. In such a case, the
steering controller must receive event messages from the traction controller. See the traction
controller alarms in chapter 12 for the reason for keeping the main contactor open.
This alarm occurs if the controller base plate temperature exceeds 75°C. Improve the cooling
of the controller; otherwise it is necessary to replace the steering controller.
This alarm occurs when the analogue temperature sensor has exceeded the threshold of
150°C.
In such a case, check the thermal sensor inside the motor and the wiring outside. The
resistance of the sensor is 580 Ω at 20°C.
If the warning is present when the motor is cold and the thermal sensor is OK, improve the
cooling of the motor. If that does not help, the problem is in the COMBIACX controller.
This alarm indicates that the output current amplifier has been over the maximum current level
(not adjustable) for too long. If this alarm occurs permanently, replace the steering controller.
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This alarm occurs when the current in phase voltage of the motor is zero and the motor is
commanded for turning.
In such a case, check the following:
• The condition of the main fuse 3F1
• There is positive supply to the controller
• Continuity of the phase cable from the controller to the motor
If the above points are OK, replace the steering controller.
This alarm occurs when the current in phase U of the motor is zero and the motor is
commanded for turning.
In such a case, check the following:
• Condition of the main fuse 3F1
• There is positive supply to the controller
• Continuity of the phase cable from the controller to the motor
If the above points are OK, replace the steering controller.
This alarm occurs when the current in phase W of the motor is zero and the motor is
commanded for turning.
In such a case, check the following:
• Condition of the main fuse 3F1
• There is positive supply to the controller
• Continuity of the phase cable from the controller to the motor
If the above points are OK, replace the steering controller.
This alarm occurs in this application with the toggle switches applied (straight and 90° position
switches) when FREQUENCY and ENC SPEED have opposite polarity. In such a case, swap
the encoder channels.
This is just a warning indicating that the steering controller is limiting the angle in steering
direction. No speed reduction occurs on traction.
This alarm occurs when the encoder counting of the main microprocessor does not match the
encoder counting. In such a case, replace the steering controller.
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This alarm occurs if one of the internal analogue signals is incorrect. In such a case, replace
the steering controller.
This alarm occurs if the frequency and the amplitude of the voltages from the stepper motor
lines are mismatched in between the D and Q lines of the stepper motor. In such a case,
replace the steering controller.
This alarm occurs if the current in the steering motor stays close to the maximum current for
longer than one second. In such a case, look if there is a mechanical problem locking the
steering motor.
This alarm occurs if the feedback sensor or potentiometer does not change the value (or
changes the value to the opposite direction) even if it is commanded to change.
In such a case, check the following:
• The feedback sensor is not mechanically loosened.
• The connectors and cables of the feedback sensor are in order.
• The motor phases are OK and the cables are installed in the correct places.
This alarm occurs if the feedback sensor or potentiometer voltage changes more than 0.3 V in
16 milliseconds. This alarm is used to catch potentiometer discontinuities. In the case of this
alarm, replace the feedback sensor.
This warning occurs when the parameters compensate for the gain if the current amplifiers
have the default values (the maximum current was not regulated). In such a case, replace the
steering controller.
This alarm occurs when the inside checking cycle does not update the information and the
controller cuts of the steering and traction. In such a case, replace the steering controller.
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This alarm occurs when there is a problem in the internal communication. In such a case,
replace the steering controller.
This is a warning shown while the steering controller receives information from the COMBIACX
controller. The safety relays remain open when this warning is shown and the steering is not
activated.
This is a real alarm, which cuts off the traction function. It occurs at the initial alignment if the
straight ahead condition is not met within six seconds. Throughout this time, the steering is not
activated, the safety relays are open and the traction is stopped.
239 EPS waiting for system start. (Warning) Not shown in the display
WAITIN FOR TRAC
At startup, the steering controller needs information from the traction controller to close the
internal safety contacts and to switch to the operational mode. Until this information is received,
this warning occurs. The steering is not activated and the safety relays remain open while this
warning is present.
This alarm occurs in the application when ENCODER CONTROL is set to ON and the real
frequency does not match the commanded frequency. This condition is often due either to a
mismatching between the encoder resolution used in the SW and the real encoder resolution,
or to a wrong connection between the two encoder channels. In the later case, switch between
the two encoder channels.
This warning indicates that the parameters to compensate values for current gain are no longer
in memory. In such a case, replace the steering controller.
This warning indicates that the acquisition of the current gains is in progress. The warning
disappears when the acquisition is finished.
This alarm occurs if the microprocessor detects a mismatch between the commanded and
active steering directions. In such a case, replace the steering controller.
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This warning occurs if the steering controller does not receive a message from the traction
controller within one second. In such a case, check the CAN bus wiring from the COMBIACX
controller to the steering controller.
This alarm occurs if the command HALL sensor (or potentiometer) signal voltage is out of
range (from 0.8 Vdc to 4.2 Vdc). In such a case, check that the connectors and cables are in
order and measure that the command sensor signal voltage is within tolerance.
This alarm occurs if the feedback HALL sensor (or potentiometer) signal voltage is out of range
(from 0.3 Vdc to 4.7 Vdc). In such a case, check that the connectors and cables are in order
and measure that the feedback sensor signal voltage is within tolerance.
This alarm occurs when the internal microprocessor information does not match. In such a
case, replace the steering controller.
This alarm occurs when the microprocessor detects that the internal safety contact is open
when it is expected to be closed. In such a case, replace the steering controller.
This alarm occurs when the microprocessor detects that the second internal safety contact is
open when it is expected to be closed. In such a case, replace the steering controller.
This alarm occurs when the microprocessor detects that the internal safety contact is closed
when it is expected to be open. In such a case, replace the steering controller.
This alarm occurs when the microprocessor detects that the second internal safety contact is
closed when it is expected to be open. In such a case, replace the steering controller.
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16 Technical specification
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1 IDENTIFICATION
1.8 Load wheel shaft to fork face (forks lowered) x [mm] 960
2 WEIGHTS
2.2 Shaft loadings (with nominal load and battery [kg] 950 / 1,710
weight), drive / load side
2.3 Shaft loadings (without load / with battery), drive [kg] 535 / 125
/ load side
3.6 Track width (centre of tyres), drive side b10 [mm] 480
3.7 Track width (centre of tyres), load side b11 [mm] 375
4 DIMENSIONS
4.9 Height of the tiller arm in travel position (min. / h14 [mm] 1,180 / 1,350
max.)
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4.19 Overall length (battery sideload +72 mm for l1 [mm] 1,852 / 2,346
250 Ah and 375 Ah)
4.20 Length to face of forks (battery sideload +72 mm l2 [mm] 702 / 1,195
for 250 Ah and 375 Ah)
4.22 Fork dimensions (thickness / width / length) s/e/l [mm] 55 / 165 / 1,150
4.33 Working aisle width Ast, pallet 1,000x1,200, load Ast [mm] 1,920 / 2,400
crosswise
4.34 Working aisle width Ast, pallet 800x1,200, load Ast [mm] 2,120 / 2,600
lengthwise
5 PERFORMANCE
5.1 Travel speed, laden / unladen / (unladen opt.) [km/h] 9.0 / 9.0 / (12)
6 MOTORS
8 MISCELLANEOUS
8.4 8) Level of noise at the driver’s ear level according [dB (A)] 66
to EN 12 053:2001 and EN ISO 4871 in work
LpA
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17 Index
Battery cover D
Opening the battery cover ................... 38 Drive unit suspension
Removing the battery cover lock ......... 40 Disassembly of the drive unit
Removing the battery cover’s rubber suspension .......................................... 64
absorbers ............................................ 41
Driving direction ...................................... 25
Battery cover lock
Driving position ....................................... 23
See ..................................... Battery cover
Battery lock sensor
E
Battery lock sensor functionality
Electric panel
check ................................................. 200
Installation of the battery lock Accessing the controller fan .............. 104
sensor ............................................... 199 Contactors and relays ....................... 101
Fuses................................................. 103
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Lubrication
Q
Hydraulic oil....................................... 178
Transmission oil ................................ 178 Quick battery replacement
Quick battery replacement ................ 203
M
Removing the rubber absorbers with
Maintenance check list.......................... 176 quick battery replacement ................. 204
Motor compartment
R
Assembly of the splined shaft-hub
Recharging plug
connection ......................................... 110
Coil resistance measurement ............ 115 Replacing the recharging plug........... 201
Disassembly of the drive unit ............ 108
Installation of the traction motor ........ 109 S
Magnetic brake.................................. 114 Safety button
Removing the drive unit .................... 107
See ........................................... Tiller arm
Replacing the HALL sensor .............. 113
Temperature sensor check ............... 111 Safety instructions
Personal safety.................................... 13
O Service area safety.............................. 12
Operating devices ................................... 17 Work safety ......................................... 13
Sensors
Operator’s platform
Tiller, side guard and operator’s
Removing the operator’s platform ....... 44 platform sensors ................................ 117
Removing the operator’s platform
Side guards
slide bearing ........................................ 50
Replacing the operator’s platform Removing the side guards................... 41
gas spring............................................ 48 Replacing the side guard’s gas
spring................................................... 42
P Solenoid valve
Pallet entry / exit rollers See ...................................... Pump motor
Disassembly of the pallet entry / exit Special tools .......................................... 178
rollers ................................................ 181
Steering controller
Pen rack
See ..............................Electrical steering
See .................................. Accessory rack
Stickers ................................................. 238
Pressure sensor
Installation of the pressure sensor .... 197 T
Pressure sensor functionality check .. 198
Technical specification .......................... 230
Pump motor
Temperature sensor
Solenoid valve ................................... 116
See ........................... Motor compartment
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APPENDIX A: Stickers
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Copyright © 2013 Rocla Oy. All rights reserved. Unauthorized copying and lending are prohibited.
MCFA
2121 W. Sam Houston Pkwy. N.
Houston, TX 77043-2305
USA
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Hefbrugweg 77
1332 AM Almere
The Netherlands
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