Feb. 2005
SERVICE MANUAL CONTENTS
NOTICE
This form lists the contents of the complete Service Manual for this product. The items listed with form numbers are available and included in the manual.
If form numbers listed with mark(*) are, they are not available for the initial release of the manual. When items are updated, or supplements added, they will be announced in preview and should be ordered as they become available.
TITLE
FORM NUMBER
Service Manual Contents SB4183E00
Safety SB2003E00
Torque Specifications SB2004E00
DIRVE & CONTROL SYSTEM
MicroController Control Systems SB4177E00
POWER TRAIN
Power Train SB4185E00
VEHICLE SYSTEMS
Vehicle Systems SB4186E00
Vehicle Systems D & A SB4187E00
Hydraulic System Schematic SB4182E00
Electric Systems Schematic SB4181E00
Mast Systems SB2143E03
OPERATION & MAINTENANCE
Operation & Maintenance Manual SB2339E01
SB4183E00
Feb. 2005
SERVICE MANUAL CONTENTS
NOTICE
This form lists the contents of the complete Service Manual for this product. The items listed with form numbers are available and included in the manual.
If form numbers listed with mark(*) are, they are not available for the initial release of the manual. When items are updated, or supplements added, they will be announced in preview and should be ordered as they become available.
TITLE
FORM NUMBER
Service Manual Contents SB4183E00
Safety SB2003E00
Torque Specifications SB2004E00
DIRVE & CONTROL SYSTEM
MicroController Control Systems SB4177E00
POWER TRAIN
Power Train SB4185E00
VEHICLE SYSTEMS
Vehicle Systems SB4186E00
Vehicle Systems D & A SB4187E00
Hydraulic System Schematic SB4182E00
Electric Systems Schematic SB4181E00
Mast Systems SB2143E03
OPERATION & MAINTENANCE
Operation & Maintenance Manual SB2339E01
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Specifications
Systems Operation
Testing & Adjusting
MicroController Control Systems
B15T-5, B18T-5, B20T-5 (AC 36V/48V)
B16X-5, B18X-5, B20X-5 (AC 48V)
for Electric Lift Trucks
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING” as shown below.
The meaning of this safety alert symbol is as follows:
Attention ! Become Alert ! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication. DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current information available.
Index
Specifications
Assembly Layout of Controller (4 Wheel)...9
Assembly Layout of Motors...9
Component Measurements...5
Control Panel Layout...10
Controller AS Specification...6
Drive Motor Specification ...7
Fuses ...9
Instrument Panel Layout ...8
Pump Motor Specification ...7
Systems Operation
General Information ...13Advantage of AC motor...13
Basic ITC ...16
Comparison between AC and DC motor...13
ITC system characteristics...16
Main ITC(Intelligent Torque Control) features ...15
Glossary ... 11
Installation and Wiring...17
Accessory Circuits ...26
General ...17
Hydraulic Pump Motor Circuit ...25
K1 connector: list of all terminals ...19
System Circuit...23
Thermal protection circuit...26
Testing and Adjusting
Preparation Tests and Check ...27Programmable Parameters ...30
Adjustable Parameters Description...30
E-S-H Energetic Modes Parameters...37
Some Functions Management ...38
B.D.I. Measure Management ...38
Buzzer Management...38
Pump Motor Modes...38
Static Return to Off...38
Diagnostic and Troubleshooting
Alarm List ...39Electrical System Adjustment...95
General Description ...39
Instrument Panel
Accessing Stored Error Codes ...109Default Setting...106
Diagnostic Mode...107
Display Keys Utilization ...102
Instrument Panel ...99
LED Indicators...101
Lift truck operation mode...100
List of diagnostic...108
Parameter Calibration ...103
Sensor Initial Setting ...106
Eye Software Interface
Features ...114General Information...112
Installation ...113
Main Menu...115
Calibration ...124
Configuration Menu (Setup) ...119
Data Logging...144
Flash ...146
Not Actual Software / Eeprom Crc Fault...118
Password Insertion...116
Submenus ...118
Test...120
Troubleshooting of Eye Program
Flash Programmation ...147 Generality ...147 Other Problems ...147 Serial Communication ...147 Software Installation ...147Appendix
Appendix A : 48[V] Parameter List...148Appendix B : 36[V] Parameter List ...151
Appendix C : Error Code List...154
Appendix D : Contraction for dot matrix display...160
1. Alarm Code ...160
2. Calibration Code ...161
Specifications
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Component Measurements
SPECIFICATIONS
Multimeter Setting (+) Test Lead (-) Test Lead Results
Resistance +BATT Each U,V,W Over 1.4 Mohms
Resistance -BATT Each U,V,W Over 1.4 Mohms
Resistance U Termina V Terminal Below 0.5 ohms
Resistance U Termina W Terminal Below 0.5 ohms
Controller AS Specification
BATTERY VOLTAGE 24-60 V
MAXIMUM IMPULSIVE DRIVE INVERTER CURRENT 325 A
MAXIMUM IMPULSIVE PUMP INVERTER CURRENT 400 A
SWITCHING FREQUENCY 3-6-9 KHz
EFFICIENCY 95 %
PROTECTION LEVEL IP51
MECHANICAL SIZE 580x248x187
WEIGHT 24 Kg
VIBRATION 5g 10-500Hz in X,Y,Z axis
TEMPERATURE RANGE - 30 °C ¸ + 40 °C
MAXIMUM MODULE TEMPERATURE 100°C
CONTROLLER Complies with EN 1175-1 EN 12895-1
MAIN CONTACTOR 250A
MAIN FUSE 700A
KEY FUSE 10A
Drive Motor Specification
POWER 5 KW VOLTAGE 32 V CURRENT 157 A RATED SPEED 1500 RPM MAXIMUM SPEED 4500 RPM FREQUENCY 75 Hz Cos ÄłG 0,72 SERVICE S2 60' INSULATION CLASS F PROTECTION DEGREE IP 10 BEARINGS 6206 2RS WEIGHT 38.5 KgPump Motor Specification
POWER 12 KW VOLTAGE 30.5 V CURRENT 335 A RATED SPEED 2200 RPM MAXIMUM SPEED 4500 RPM FREQUENCY 73 Hz Cos ÄłG 0.84G SERVICE S3 15% INSULATION CLASS F PROTECTION DEGREE IP 20 BEARINGS 6206 2RS WEIGHT 43.5 Kg
Instrument Panel Layout
TYPE A
Fuses
Line ... 700A Key ... 10A Horn ... 10A DC / DC Converter... 10A Light ... 10A Option light ... 10AAssembly Layout of Controller
(4 Wheel)
Control Panel Layout
NOTE: Apply a small amount of D557047 Thermal Joint Compound on control panel plate and mating surface
prior to assembly. Communication cable’s assembly with power units and logic control unit uses the micro screw driver(2.5*100mm)
Communication cable's assembly with Power Unit and Logic Control Unit uses Micro Screw Driver (1) Logic Control Unit. Use a socket wrench(7mm) to hold bolts
(2) Left Drive Motor Power Unit. Use a hex bit socket(5mm) wrench(100mm) or L-wrench to hold bolts (3) Pump Motor Power Unit
(4) Right Drive Motor Power Unit
(5) FUSE. Use a socket wrench(13mm) and a wrench(13mm) to hold bolts (6) Line Contactor
Systems Operation
Glossary
NAME DESCRIPTION
Accelerator A device that converts mechanical movement into a analog voltage pattern to the logics for variable drive motor speed.
Ampere (or Amp) The unit of measurement of current flow. The amount of current that one volt can push through a resistance of one ohm.
Analog to Digital Converter
A device that converts an analog voltage into a pattern of digital HIGH and LOW voltage signals.
Battery Two or more cells connected together for a supply of electric current.
BDI Battery Discharge Indicator - An electrically controlled display showing the operator the state of batter y charge.
Bus Bar A heavy electrical conductor to which other smaller wires are connected. Capacitor Device used to store electrical energy for short periods of time.
Circuit A way for current to go from the positive (+) side of an electrical power source to the negative (-) side of an electrical power source. This can be through wires and electrical components.
Coil A component made from many circles or turns of wire used to concentrate a
magnetic field.
Connector Part of a wire assembly or harness that connects with another wire assembly or harness. Used for ease of assembly and disassembly.
Contactor Assembly An electrical component consisting of an electromagnetic coil and a set of heavy contact tips. Control current passes through the coil, building a magnetic field which closes or opens the contact tips.
Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly. Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened or closed. Current The movement or flow of electricity through a conductor. A circuit must be complete
for current to flow.
Current Limit The maximum allowable armature current of a stalled drive motor during pulsing. Digital Signal A signal in which the elements may be either of two distinct values.
For example high voltage, low voltage.
Diode A semiconductor device that allows current to flow in one direction, from the anode to the cathode.
Display An electrical device that converts voltage inputs to a visual output. Electrical Assist Braking
(EAB)
Electrically trying to rotate the drive motor opposite to the direction of truck movement.
Fuse A component in an electrical circuit that will open the circuit if too much current goes through it.
Harness An assembly made of two or more wires that are held together. Heat Sink A mounting frame used for semiconductor cooling.
NAME DESCRIPTION
Microprocessor A small computer chip preprogrammed to control the various electrical functions on a lift truck.
Normal Condition Words used with a switch or relay. Their normal condition is their condition when they are not controlled by the application of force, temperature, pressure, or electricity. MOSFET A semiconductor component used in electric lift trucks as an electronic switch. A
MOSFET most often has three terminals, a GATE(G), a DRAIN(D), a SOURCE(S). A MOSFET is a voltage-controlled device and required only a small input current. The switching speed is very high.
Ohm The unit of measurement of resistance. The amount of resistance that will let one volt push only one ampere of current through it.
ON-Time The amount of time current flows through a transistor. Open Circuit Wiring or components of a circuit that have no continuity.
Overload The presence of voltage or current which is greater than an electrical circuit or component is designed to handle.
Plugging A portion of electrical braking where the generated current is directed back through the armature.
Relay An electrical component consisting of an electromagnetic coil and a set of small contact tips. Control current passes through the coil, building a magnetic field which closes or opens the contact tips. When the contact tips are closed, low current can flow in a separate isolated circuit.
Resistor A component made of a material that has a specific resistance to the flow of current.
Rotor Part that rotate of motor
Schematic A line drawing of an electrical or electronic assembly which uses symbols to show individual components. It shows how the components, wires and connectors function electrically.
Short Circuit An electrical connection between two or more components that is not desired. Socket The female contact of a connector that slips over a male contact (pin) of another
connector.
Solid State Reference to semiconductor components or circuits that use semiconductor components that have no moving parts, such as diodes and transistors.
Stator Fixed part in driving state of motor
Switch A component used to control an electric circuit. It can close or open a circuit. Systems The electrical components, circuits, and connections that deliver power to perform
specific tasks.
Terminal An electrical connection point on an electrical component. Thermal Sensor A sensor that activates at a set temperature.
Volt The unit of measurement of electromotive force. One volt is the force needed to make one ampere of current flow through one ohm of resistance in a circuit.
Watt The unit of measurement of power. The amount of power used when one volt pushes
one ampere of current through a resistance of one ohm. The result of amperes (current) multiplied by volts (voltage) is watts (power).
General Information
Advantage of AC motor
AC induction motors are the most diffused for power conversion in industrial application. In the battery-fed lift-truck applications DC motors are more used, because they are easy to control in torque with a simple chopper drive with a current limitation. To reach the traction requirements the AC control has to be very advanced and the motor parameters have to be known by the control algorithms. The reason of their recent diffusion are related to the technological development and to deeper studies about this matter.
The advantages of using AC motors instead of DC motors are many:
1. More robust and easy to build
2. Less complex and more reliable
3. Practically maintenance free (no continuous brush maintenance)
4. Higher speed
5. More performance at high speed especially in regeneration
6. Absence of contactors for speed inversion
7. Continuous torque control during inversion (no delay with zero torque)
8. Safer because AC motor is not supplied and it doesn’t work in case of short circuit
See following tables and relative explanation for a comparison between AC and DC motor systems.
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Comparison between AC and DC
motor
Motor Characteristics
AC Motor systems DC Motor system
1 Little components More complex 2 Decreasing price Increasing price
3 More reliable Less reliable
4 Practically maintenance free
Continuous
maintenance to brushes
5 High speed Low speed
6 High torque performance at high speed Low torque performance at high speed 7 High braking performance at high speed Poor braking performance at high speed
8 Safer Less safe
Controller Characteristics
AC Motor systems DC Motor system
9 Complex controller Simple controller 10 No auxiliary contactor Presence of auxiliary
contactors 11 4 quadrants
continuous transition
Torque discontinuity and delay
12 Precise and smooth
AC and DC Motors Difference Explanation
DC motor is made with a rotor with power windings and a stator with excitation windings and brushes. The AC motor is composed by a rotor and a stator with windings.
Because of great diffusion of AC motors and the automatic industrial production process, their prices continue to decrease.
Because of DC motor more complexity, brush presence and poor environmental protection, the life of DC motor is greatly reduced, compared with AC motor.
The maintenance of DC motor must be continuous because of consumption of brushes.
The most critical component for AC motor are the bearings. AC motor reaches higher speed because of DC sparkling limitation of brushes.
AC motor has higher torque at high speed because of DC sparkling limitation of brushes. AC motor has much more regenerative braking torque at high speed because of DC sparkling limitation of brushes. AC motor is safer than DC because if a short circuit happens in armature, DC motor accelerates. The AC motor needs an AC voltage to accelerate. The AC controller is much more complex of a DC one. The reason why is the AC control algorithms requires the use of a very powerful microprocessor which performs a fast real time control.
In most of DC controllers are present auxiliary breakers which operate every drive inversion, introducing delays and compromising the controller life.
Most of DC controller systems has zero torque delays during inversion causing a poor driving performance. In AC the transition between forward and reverse and acceleration and braking is continuous giving an optimum performance even at very low speed and in sharp ramp.
Because of 4 quadrants continuous transition and the presence of a sophisticated controller the regulation of AC system is superior in precision, stability, smoothness and safety to DC one.
Main ITC(Intelligent Torque Control)
features
Most important features of Intelligent Torque Control system developed by DHIM the following:
1. Control unit: One panel assembly containing three power inverters for drive and pump and a control board; main board, wired directly to the power modules, could manage up to 4 inverters. The presence of 2 DSP (Digital Signal
Processors), working in mutual redundant control, guarantees powerful software performance: in case of such a system, managing both drive and pump motors, high dynamic performance in vectorial torque control can be obtained (see Appendix A for technical data)
2. Two asynchronous three-phase drive motors equipped with magnetic sensors(64 impulses/ rotation) (see Appendix A for technical data)
3. An asynchronous three-phase pump motor for lifting equipped with magnetic sensor (64 impulses/ rotation) (see Appendix A for technical data)
4. Compact Display
Software control algorithm is customised in order to best fit lift truck characteristics; you can set the value of a wide range of parameters, in order to optimise system performance and to adjust the settings of main functions in compliance with user’s needs.
User can interact with control board making use of a software application (named EYE) developed by DHIM, or with COMPACT display. In both cases, it’s possible to obtain an exhaustive “on line” diagnostic for all lift truck functional parameters and also to adjust them.
You can upgrade control board internal software connecting a PC via serial port (or via USB 1.x or higher, inserting the appropriate serial port-USB adapter); in fact, working with RS232
communication standard, EYE application permit to load and upgrade panel software in any working conditions, if only control board is correctly fed on .
Basic ITC
Following basic hardware and software functions characterize DHIM Company system: 1. Protection against reverse battery polarity
2. Anti-roll-back, with adjustable ramp stop time
3. Anti-roll-down
4. Regenerative braking
5. Electrically assisted braking
6. Management of static return to off function (SRO)
7. Drive speed compensation (load/unload)
8. Drive speed acceleration/deceleration
9. Drive speed reduction
10. Redundant control of acceleration pedal
(applying a control switch or a double potentiometer)
11. Continuous lift speed control
12. Pump speed compensation (load/unload) 13. Lift speed acceleration/deceleration
14. Continuous control of main contactor applied to
DC power line
15. Seat switch open check with delay time 16. Battery discharged indicator with adjustable
reset value
17. Overtemperature protection for inverters and
motors
18. Low and high battery voltage limit 19. Drive/pump speed feedback 20. Zero speed drive in ramp 21. Standby for supply
22. Diagnostics and stored error code 23. Power line fault detection (fuse/contactor) 24. Continuous temperature measuring (Controller,
drive/pump motor)
ITC system characteristics
You can obtain high performance for the lift truck with DHIM system, thanks to following specific features:
1. DSPs(Digital Signal Processor) high
performance control with custom software: this is resident in the internal FLASH memory, and allows to control 3 independent AC motors.
2. One serial asynchronous RS232 interface for PC communication in order to obtain:
a. Software update
b. Diagnosis of truck functionalities c. Parameters modification, in order to
custommize the system
3. One accelerator (0 - 5 V) and all on/off emergency micro-switches interface.
4. One encoder (0 - 5 V) interface for traction and pump motors.
5. Motor torque control by speed and current loop.
6. Controlled acceleration and deceleration ramps of drive and pump motors in order to avoid uncontrolled jolts of the load due to oversights of the operator.
7. Automatic truck speed limitation depending on steering angle.
8. Ramp stop of the lift truck.
9. Automatic energy recovery at each truck braking.
10. LIN (Local Interconnect Network) display
interface.
11. Automatic truck speed limitation, depending on
the height of the load lifted(option).
12. Automatic truck maximum speed limitation, in
function of:
13. Weight present on the forks(option) a. Fork height
b. Battery voltage level c. Any thermal alarm
d. Full protection of drives against overcurrent
of the motors, overheating of the power transistors and both maximum and minimum battery voltage.
14. Low maintenance costs by using A.C induction
motors
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Installation and Wiring
General
1. A metallic container encloses control board (Fig. 1). ( Refer to APPENDIX A for technical data and other details about control board)
2. There are three power modules (see fig 2 for single module) assembled to main board as shown in Fig. 3 and Fig. 4. ( Refer to APPENDIX A for technical data and other details about power inverters)
3. A 68 ways AMP connector (named K1), permits to interface control board to lift truck
electrical/electronic sub-devices. See Fig. 4 for a view of K1- 68 ways connector. ( Refer to APPENDIX B for technical data and other details about K1 connector and to APPENDIX D for a generic interconnection schemata)
4. Three 26 ways connectors (named C1 C2 C4) permit to wire and control 3 power inverters. No details are given about the pin-out of these connectors t, because they are not user accessible for maintenance or diagnostic operations. Power modules shall be connected also to battery supply (wire named +B and -B) and to corresponding motor phases.
Working on electrical systems is potentially dangerous; you should protect yourself against :
Uncontrolled operation: some conditions could cause the motor to run out of control:
disconnect the motor or jack up the vehicle and get the drive wheels off the ground before attempting any work on motor control circuitry. High current arcs: batteries can supply very high power, and arcs can occur if they are short circuited. Always open the battery circuit ground before working on motor control circuit. Wear safety glasses and use properly insulated tools to prevent shorts.
Lead acid batteries: charging or discharging generates hydrogen gas, which can build up and go around the batteries. Follow the battery
Fig. 1: Logic control board
Fig. 2: Single power module
Fig. 3: Power modules assembly with main contactor and fuses
K1 connector: list of all terminals
Pin
number Use Name Function
K1 – 1 IN -Battery Negative supply voltage of control board
K1 – 2 OUT + 24 V supply
K1 – 3
IN A
Lift pressure (optional) Proportional voltage signal (0-5V); you can connect a pressure linear sensor, made by SME cod B00ID160 working correctly in 0¸250 bar pressure range
K1 – 4 IN
D
start switch for accelerator pedal
START signal
N.O. with internal pull-up and Vmax(in)=24V
K1 – 5 IN
A
accelerator pedal 2° potentiometer
Proportional voltage signal (0-5V) or (0-12V) managed as accelerator pedal input
K1 – 6 IN
D
park brake switch Park brake signal
N.C., with internal pull-up and Vmax(in)=24V
K1 – 7 IN
D
seat switch Seat switch signal
N.O., with internal pull-up and Vmax(in)=24V
K1 – 8 IN
D
reverse drive direction switch reverse drive direction di selezione signal N.O., with internal pull-up and Vmax(in)=24V
K1 – 9 IN
D
forward drive direction switch forward drive direction signal
N.O., with internal pull-up and Vmax(in)=24V
K1 – 10 IN
A
accelerator pedal 1° potentiometer
Proportional voltage signal (0-5V) or (0-12V) managed as accelerator pedal input
K1 – 11 OUT + 12 V supply +12V supply voltage (self-protected electronic
component) with: Idc (nominal) =500mA; Imax = 1Adc
K1 – 12 IN/OUT
D
LIN data line (Display I/0)
Data line of LIN interface for COMPACT display
K1 – 13 IN
A/D
not used - Digital input, for an optional encoder, Vmax(in) =5V
- Analogue input (0-12V)
K1 – 14 OUT + 5 V encoder supply +5V supply voltage (self-protected electronic component)
with: Idc (nominal) =500mA; Imax = 1Adc
K1 – 15
OUT GND Negative supply voltage for data type signals, with self
protection against noises coming from DC power line; Imax=500mA
K1 – 16 IN
D
PHASE B of left drive motor encoder
PHASE B signal of the sensor bearing mounted into the left drive motor; internal pull-up; Vin:(0 – 5V)
K1 – 17 IN
D
PHASE A of left drive motor encoder
PHASE A signal of the sensor bearing mounted into the left drive motor; internal pull-up; Vin:(0 – 5V)
K1 – 18 OUT + coil main breaker Positive command of contactor coil; Inom=1A; Imax = 5A
K1 –19 OUT - coil main breaker Main breaker coil reference signal; Inom=1A; Imax = 5A
Pin
number Use Name Function
K1 – 21
OUT D
not used Self-protected open collector power output, you can
apply it to an ON/OFF or proportional electrovalve coil; Vmax =Vali; Inom=2A; Imax=6A
K1 – 22 IN + battery Control board supply voltage; V = Vsupply
K1 – 23 IN + battery key input Supply voltage of key and coils ; Vkey=Vsupply
K1 – 24 IN
A/D
not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;
- Analogue input (0-12V)
K1 – 25 IN
D
not used Digital input , N.O., internal pull-up, Vmax(in)=24V
K1 – 26 IN
A
not used Analogue input (0-12V)
K1 – 27 IN
A
not used Analogue input (0-5V)
K1 – 28 IN
D
PHASE B of pump motor encoder
PHASE B signal of the sensor bearing mounted into the pump motor; internal pull-up; Vin:(0 – 5V)
K1 – 29 IN
D
PHASE A of pump motor encoder
PHASE A signal of the sensor bearing mounted into the pump motor; internal pull-up; Vin:(0 – 5V)
K1 – 30 IN
D
Not used;
PHASE A of an optional encoder
Digital input for an optional encoder, motor; internal pullup; Vmax(in)=5V;
K1 – 31
IN/OUT A/D
Not used;
PHASE B of an optional encoder
- Digital input for an optional encoder, Vmax(in)=5V; - Open Collector power output, to command an ON/OFF electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 32 IN
D
Asynchronous RS232 serial RX input
RX input for asynchronous RS232 serial communication standard
K1 – 33 IN
D
PHASE A of left drive motor encoder
TX output for asynchronous RS232 serial communication standard
K1 – 34
OUT + coil main breaker H line input for CAN (Controller Area Network )
component; presence of internal termination resistance
K1 – 35 OUT - coil main breaker L line input for CAN component; presence of internal
termination resistance
K1 – 36 OUT
A
not used PHASE B signal of the sensor bearing mounted into
the right drive motor; internal pull-up; Vin:(0 – 5V)
K1 – 37 OUT
D
not used PHASE A signal of the sensor bearing mounted into
the right drive motor; internal pull-up; Vin:(0 – 5V)
K1 – 38 IN AUX 2 Digital input to activate pump motor auxiliary function
AUX2; N.O., internal pull-up, Vmax(in)=24V IN FANS Command (optional) Open Collector power output, to command fans (or
Pin
number Use Name Function
K1 – 41 IN
D
not used Open Collector power output, to command an ON/OFF
electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 42 IN
A
not used Open Collector power output, to command an ON/OFF
electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 43 IN
A
not used Open Collector power output, to command an ON/OFF
electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 44 IN
D
not used Open Collector power output, to command an ON/OFF
electrovalve coil; Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 45 IN
D
not used PWM supply voltage for electrovalve coils (or similar
devices)
K1 – 46 IN
D
lift high switch(optional) Voltage signal of lift critical high switch, N.O., internal pull-up, Vmax(in)=24V
K1 – 47 IN
A/D
Not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;
- Analogue input (0-12V)
K1 – 48 IN
D
Pedal brake switch Activation signal for park brake, N.O., internal pull-up, Vmax(in)=24V
K1 – 49 IN
A/D
Not used - Digital input , N.O., internal pull-up, Vmax(in)=24V;
- Analogue input (0-12V)
K1 – 50 IN
A
lift lever potentiometer voltage Proportional voltage signal (0-12V), input of lift lever potentiometer
K1 – 51 IN
A
Not used Proportional voltage signal (0-12V)
K1 – 52 IN
A
Not used Proportional voltage signal (0-12V)
K1 – 53 OUT
D
buzzer command Open Collector power output, to command buzzer
activation; Vmax =24V; Inom=30mA; Imax=100mA.
K1 – 54 IN
D
tilt switch Request of tilting, N.O., internal pull-up, Vmax(in)=24V
K1 – 55 IN D Not used; PHASE B of an optional encoder
- Digital input - PHASE B signal for an optional encoder; internal pullup; Vin:(0 – 5V)
K1 – 56
IN D
digital input for 3 / 4 wheels choice;
PHASE A of an optional encoder
- Digital input to select a lift truck with 3 wheels (Closed ) or 4 wheels (Open);
- PHASE A signal for an optional encoder; internal pull up; Vin:(0 – 5V)
K1 – 57 IN
D
AUX1 Digital input to activate pump motor auxiliary function
AUX1; N.O., internal pull-up, Vmax(in)=24V
K1 - 58 IN
A/D
right drive motor thermal sensor/ switch
Analogue input (or digital as optional) used for right drive motor thermal sensor (0-5V); internal pull-up;
Pin
number Use Name Function
K1 - 61 IN
A/D
Not in use - Digital input , N.O., internal pull-up, Vmax(in)=5V; - Analogue input (0-5V)
K1 – 62 IN
A
steering angle sensor voltage Proportional voltage signal (0-12V) or (0-5V), used as input to steering sensor circuit
K1 – 63 OUT
D
Not used;
Electrovalve (or alike) command
Open Collector power output, to command an ON/OFF electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 64
OUT D
Not used;
Electrovalve (or alike) command
Open Collector power output, to command an ON/OFF electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 65 OUT
D
Not used;
Electrovalve (or alike)
Open Collector power output, to command an ON/OFF electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 66 OUT
D
Not used;
Electrovalve (or alike)
Open Collector power output, to command an ON/OFF electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 67 OUT
A
Not used Power output, to command a proportional electrovalve coil;
Vmax =Vsupply; Inom=2A; Imax=6A
K1 – 68 OUT
D
Not used;
Electrovalve (or alike)
Open Collector power output, to command an ON/OFF electrovalve coil;Vmax =Vsupply; Inom=2A; Imax=6A
NOTES:
D : digital signal, with boolean values (ON/OFF) A : analogue signal, assuming values in
[Vground -Vmax] range
A/D : signal that could be both analogue and digital NO : normally open
NC : normally close IN : signal used as input OUT : signal used as output
NOTICE
Remember the controller contains ESD(Electro Static dischange) sensitive components. Use appropriate precautions in connecting, disconnecting and handling it.
System Circuit
Power Circuit
If divide greatly composition of electric controller system of this vehicles, is consisted of 1 Logic control board, Power Unit (Left Drive, Right Drive, Pump) 3, Line Contactor 1.
Actuation Circuit
This circuit supplies power to the Logic Control Board and the Instrument Panel(Display). It must be activated before power steering, hydraulics or drive will operate.
When the battery is connected and the key switch is closed, current flows from battery positive through the key fuse, key switch, wire #23 to the logic control board (logic) contactor K1-23.
The logic connection to battery negative is at K1-1.
When the seat switch is closed, current will flow from the logic K1-7 through the seat switch to controller negative. The logics then activates the line contactor by allowing current to flow from K1-18 through the line contactor coil (+) and K1-19 the line contactor coil (-).
With the line contactor tips closed the logics continues its checks for any “Run Time” faults. If no faults are detected the display will indicate the
1
Hydraulic Pump Motor Circuit
Only one hydraulic pump motor is used for all power steering, lift, tilt and auxiliary hydraulic functions. To activate the pump circuit, the seat switch, key switch and line contactor must be closed first as explained in the topic, Actuation Circuit.
Power Steering Circuit
The power steering speed of this vehicles operate by speed (default 500 rpm) that specify in pump motor calibration.
Lift Control Circuit
Location Components (1) Valve control card.
This control panel accept a linear speed lift signals and tilt/aux lever signals. The lift control system is controlled by valve control card (1) mounted at the top of the control valve.
The drive control card uses a hall-effect transducer (Lift Sensor) and magnet to sense lift lever
movement. The closer the magnet is to the transducer the greater the hydraulic pump motor speed.
Location Components (2) Lift Sensor. (3) Magnet.
When the operator pulls the lift lever, magnet (3) moves closer to the lift sensor (2). The sensor detects the increasing magnetic field and sends an increasing voltage to the valve control card. The input to the logics at K1-50. The logics uses these changing voltages to determine what speed to operate the pump motor. The logics then controls the pump power unit.
Thermal protection circuit
Control Panel
If the Power Unit’s MOSFETs overheat, a thermal senders mounted in the MOSFET heatsink will give a voltage signal to logic. If the temperature is over than preset value(100°C), the Instrument Panel will display a “Run Time” diagnostic symbol and E1, E2, E3. The logics will decrease the speed of the drive motors and the pump motor. The amount of current allowed to flow through the MOSFETs is decreased to permit them to cool. When the heatsink cools off the truck will return to normal operation. But due to the reduced speed, acceleration performance will be decreased. Each error code is stored in memory.
Drive Motor
If the drive motor overheats a thermal sensor mounted in the stator coil of drive motor will warn at a predetermined temperature (155°C). If reach in overheating temperature, the Instrument Panel will display a “Run Time” diagnostic symbol and E4, E5. To decrease the amount of current allowed to flow through the drive motor, the logics will reduce the speed. When the drive motor cools off, the truck will return to normal operation. Drive system
acceleration performance and top travel speed is affected by an overheated drive motor. “MOTOR TEMPERATURE” will be stored for Drive Motor overheating in memory.
Hydraulic Pump Motor
If the drive motor overheats a thermal sensor mounted in the stator coil of drive motor will warn at a predetermined temperature (155°C). If reach in overheating temperature, the Instrument Panel will display a “Run Time” diagnostic symbol and E6. To decrease the amount of current allowed to flow through the pump motor, the logics will reduce the speed. When the pump motor cools off, the truck will return to normal operation. “MOTOR
TEMPERATURE” will be stored for Pump Motor overheating in memory.
Accessory Circuits
Horn Circuit
The horn will operate when the battery is connected and the horn button is pushed. Current ows from ÍŤ battery positive through horn fuse, horn switch and horn, back to battery negative.
DC-DC Converter Circuit
The 12 volt output of the converter is protected against short circuits and overloading by an internal 15 amp current limit circuit. A fuse on the converter protects it from reverse connection of the battery voltage.
Notice: Do not connect the 12 volt negative output
of the DC-DC converter to battery negative. Damage to system components could occur.
The DC-DC converter changes the lift truck battery voltage to 12 volts. This 12 volts is used to power accessories such as floodlights, brakes/side lights and backup alarms.
Testing and Adjusting
Preparation Tests and Check
Battery Tests
A weak battery can cause or contribute to problems in the Logic Control Board and power circuits. Verify the battery is good before investigating other possibilities.
1. Verify proper polarity at the battery connector and the control panel. Positive cable should be at the line fuse and negative at the negative on control panel.
2. If the lift truck is operational, perform a battery load test.
3. If the truck is not operational and the battery is suspected, perform a cell voltage or specific gravity test.
Battery Load Test
1. Turn the range switch on the multimeter to read battery voltage.
2. Connect the battery.
Battery Voltage Test. (1) Positive cable connection. (2) Negative cable connection.
3. Connect the multimeter leads between positive (+) cable connection (1), and negative (-) cable connection (2).
4. In a safe area, operate the hydraulic system,
Cell Voltage Test
With the truck powered up and the pump(Idle) motor running, measure the voltage at each cell. Normal voltage should be between 1.95V and 2.12V per cell. If the voltage on each cell is below 1.95V the battery must be charged or repaired before continuing to troubleshoot.
NOTE: The indication between cells should not
differ more than 0.05 volts. If it does, the battery must have an equalizing charge or be repaired.
Hydrometer Test
Test each cell of the battery with a hydrometer. If the specific gravity indication is below 1.140, the battery must be charged. The battery is fully charged if the indication is 1.265 to 1.285.
NOTE: The indication between cells should not
differ more than .020. If it does, the battery needs an equalizing charge or needs to be repaired.
1
Battery Maintenance
NOTE: It is important that all batteries be charged
and maintained according to the battery manufacturers instructions.
The care and maintenance of batteries is most important to maximize battery life and efficient truck operation. Periodic inspection and service will increase the life of batteries. Special attention should be given to the rules that follow:
1. Keep batteries clean at all times. Cleaning will prevent corrosion, current leakage and shorts to chassis. Tighten all vent plugs, wash the battery with water and a brush, then dry with an air hose. It may be necessary to use a baking soda solution if water alone will not clean the top of the battery.
2. Add enough water to cover the plates before charging. This will ensure the proper chemical reaction over the entire plate surface. After charging is complete, add water until it is about 12.7 mm (.50 in) above the plates. Use distilled water or water that has tested free from minerals.
3. Charge the battery correctly. A battery should be discharged to 80% of its capacity then fully recharged. It should cool four to eight hours to allow the voltage to stabilize before being put back in use. The battery should have an equalizing charge (an extra three or four hour charge at a low finish rate) once a month to make sure all cells are in a fully charged condition. Properly charged batteries should be identified to prevent low batteries from being installed in trucks.
4. Operation with a low battery must be prevented. Low battery operation may damage the battery and will cause higher than normal current in the electrical system. High current draw due to a low battery will damage contactor tips and shorten motor brush life.
5. The battery's maximum temperature is critical. The electrolyte temperature should never exceed 43°C (110ȋF) either while operating or charging. Overcharging a battery will cause
6. Keep accurate battery records. Regular battery readings should be taken with a battery tester or voltmeter and a written record kept. Specific gravity and voltage of each cell should be checked and recorded at least once each month. This inspection should be made after an
equalizing charge. Readings should never be taken directly after water has been added. Records of all battery maintenance should be made and filed so it will be known which batteries are being abused or wearing out. Repairs should be made immediately otherwise the battery may become damaged. Batteries stored in a discharged condition may be difficult to recharge due to sulfate formation.
Visual Checks
1. Verify all components and wires are in their proper place. Check fuses, components, contactor tips, wires and connections. Verify that they are not burned, broken or loose.
2. Verify there is no mechanical binding or interference in the contactor.
3. Visually check the parking brake switch, the hydraulic switches and accelerator linkage for adjustment or interference problems.
Resistance to Chassis Checks
Resistance between any point in the truck wiring and the chassis should be a minimum of 10,000 ohms or more.
Many malfunctions are caused by shorts to chassis. Usually, two shorts must exist before a malfunction will occur. But, since batteries can have chassis leakage, only one short to chassis in the truck wiring can cause problems. To prevent problems because of shorts, do the following:
1. Disconnect the battery and discharge the Power Uint.
2. Randomly measure any component connection or wiring connection in respect to the lift truck chassis for a minimum resistance of 10,000 ohms. Any test point with low resistance must have the short to chassis removed.
3. Always keep batteries clean to minimize current leakage to the chassis.
4. Routinely clean the brush dust from the motors.
5. Be sure that all attachments, such as horns and lights are designed for no chassis connection (a two wire system).
Programmable Parameters
Adjustable Parameters Description
The possibility of interfacing by PC with the system allows to have an exhaustive real time analysis of the system working and of the condition of its components; moreover, you can choose among a wide range of parameters in order to reach the optimum operating of the system in compliance with your needs.
Adjustable parameters are listed below, divided by functional groups, both for a 36 V and a 48 V system. We briefly explain what’s the meaning of each programmable parameter, and which is the effect of its changes in lift truck performance.
<48V SYSTEM>
Drive Motor
Parameter
No Parameter Parameter Description Unit
Mini mum Def ault Maxi mum Varia tion 5 Deceleration steering ramp 1
as high it is as quickly the truck decreases its speed if the truck driver is turning the wheel quickly
rpm/s 10 800 5000 10
6 Deceleration steering ramp 2
as high it is as quickly the truck decreases its speed in relation to the drive speed of truck. This parameter increases the
deceleration ramp while the driver is steering at high speed.
rpm/s 1 6 1000 1
26 Stop on slop timer
Without stepping on pedal brake, time that is
doing stop in slope s 1 5 10 1 41 Drive maximum
current
Drive motors maximum current (expressed
in per cent of high energetic mode value) % 20 100 100 1 42 Forward
maximum speed
Maximum forward lift truck speed with no speed limitation
(no alarms present and turtle not active)
rpm 1,000 4,500 4,500 50 43 Reverse
maximum speed
Maximum reverse lift truck speed with no speed limitation
(no alarms present and turtle not active)
rpm 1,000 4,500 4,500 50 44 Drive limitation
maximum speed
Maximum lift truck speed with speed
limitation (turtle active) rpm 500 2,000 2,500 50 46
Critical height drive maximum speed (optional)
Maximum lift truck speed when forks high
is more than critical one rpm 400 2,000 4,500 50 47 Steer limitation
maximum speed
Maximum speed reference in the angle in
which the internal wheel is mechanically still. rpm 400 1,500 4,500 50 48
Drive acceleration ramp
Lift truck acceleration with accelerator pedal
pressed rpm/s 400 1,150 2,000 10 49 Drive inversion
ramp Lift truck deceleration in inversion rpm/s 400 1,200 2,000 10 50 Drive release
ramp
Lift truck deceleration with accelerator pedal
released rpm/s 400 900 2,000 10 51 Pedal brake ramp Lift truck deceleration with pedal brake
pressed rpm/s 400 1,000 2,000 10 52 Creep speed
If the truck speed is greater then this threshold, the speed reference becomes a parabolic function of the accelerator potentiometer voltage.
rpm 100 300 2,000 1 53 Diameter of drive
tyres Drive tyre's diameter mm 300 451 600 59 Partial release
ramp
Parameter that softens the drive inversion ramp if the traction motors are working with low rpm
rpm/s 10 50 500 10 93 Power mode
(E-S-H, limitations) Power mode setting up state digit
Accelerator signal 1 = E mode, 2 = S mode, 3 = H mode 94 Slow speed
If parameter is set to1, speed limitation is active; otherwise lift truck speed is managed as usual.
digit Disable = 0, Enable = 1 95 British unit
If parameter is set to 1, values are expressed in British unit, otherwise in international ones.
