Baumann Side Loader Service and Repair Manual

B a tte ry
S e r v ic e a n d R e p a ir M a n u a l Is s u e 0 8 /9 7
E le c t r ic S id e lo a d e r P a g e 1
H o w D o e s T h e L e a d S to ra g e B a tte ry W o rk ?
S t o r a g e b a t t e r y o p e r a t io n c o n s is t s o f t w o o p p o s it e
V o lt m e t e r p r o c e s s e s , t e r m e d c h a r g e a n d d is c h a r g e . B o t h
p r o c e s s e s a r e e le c t r o - c h e m ic a l a n d a r e b a s e d
3 4
2 5 o n c h e m ic a l c h a n g e s in t h e a c t iv e m a s s e s , t h e
1 6 + e le c t r o d e s , t h r o u g h r e a c t io n w it h t h e e le c t r o ly t e s .
W h e n t h e b a t t e r y is c h a r g e d , e le c t r ic a l e n e r g y is
s u p p lie d , c o n v e r t e d t o c h e m ic a l e n e r g y a n d
t r a n s m it t e d . T h e s u b s t a n c e s c o n v e r t e d in t h is
p r o c e s s , t h e a c t iv e m a s s e s , a r e m a d e u p in t h e
P b P b O c h a r g e d le a d c e ll o f le a d d io x id e P b 0 2 in t h e
2
p o s it iv e e le c t r o d e s , f in e ly d is t r ib u t e d le a d ( s p o n g e
lo a d ) P b in t h e n e g a t iv e e le c t r o d e s a n d d ilu t e d
s u lp h u r ic a c id ( H 2 S 0 4 ) a s t h e e le c t r o ly t e . T h e
p r o c e s s e s t h a t t a k e p la c e d u r in g c h a r g e a n d
d is c h a r g e a r e s h o w n in t h e f o llo w in g c h e m ic a l
f o r m u la :
H 2S O 4
d is c h a r g e
P b O 2 + P b + 2 H 2 S O 4 P b S O 4 + P b S O 4 + 2 H 2 O
c h a rg e
D u r in g t h e d is c h a r g e p r o c e s s , b o t h t h e le a d d io x id e in t h e p o s it iv e e le c t r o d e s a n d t h e f in a ly
d is t r ib u t e d le a d ( s p o n g le a d ) in t h e n e g a t iv e e le c t r o d e s a r e c o n v e r t e d t o le a d s u lp h a t e b y
c o m b in in g c h e m ic a lly w it h t h e s u lp h u r ic a c id s e r v in g a s t h e e le c t r o ly t e . A t t h e s a m e t im e ,
w a t e r is f o r m e d a n d t h e a c id c o n c e n t r a t io n o f t h e e le c t r o ly t e d e c r e a s e s a c c o r d in g ly a s t h e
d is c h a r g e p r o c e s s c o n t in u e s . T h e s e p r o c e s s e s b r in g a b o u t a d e c r e a s e in t e r m in a l v o lt a g e
in t h e c e ll, s lo w ly in it ia lly t h e n in c r e a s in g ly f a s t e r . D is c h a r g e m u s t b e c o m p le t e d a t a c e r t a in
lim it , d e p e n d e n t o n d is c h a r g e c u r r e n t in t e n s it y , b e c a u s e t e r m in a l v o lt a g e in t h e c e ll t h e n
d r o p s v e r y s h a r p ly ( f in a l d is c h a r g e v o lt a g e ) . T h e a m o u n t o f c u r r e n t w h ic h t h e b a t t e r y c a n
g iv e o f f b e f o r e r e a c h in g it s f in a l d is c h a r g e v o lt a g e is t e r m e d c a p a c it y . It is t h e p r o d u c t o f
c u r r e n t in t e n s it y in a m p e r e s X t im e in h o u r s a n d is e x p r e s s e d in a m p e r e h o u r s A h .
C a p a c it y is d e p e n d e n t o n d is c h a r g e c u r r e n t in t e n s it y a n d f o llo w s t h e f o llo w in g r u le :
T h e h ig h e r t h e d is c h a r g e c u r r e n t in t e n s it y ,
t h e lo w e r t h e a v a ila b le c a p a c it y .
B a t t e r y c a p a c it y is a ls o e f f e c t e d b y t e m p e r a t u r e . It d e c r e a s e s a s t h e t e m p e r a t u r e
f a lls .
In o r d e r t o c a t e g o r is e d if f e r e n t m o d e ls , t h e t e r m r a t e d c a p a c it y w a s in t r o d u c e d ( D IN 4 0 7 2 9 ).
B a tte ry
T h e r a t e d c a p a c it y is d e f in e d a s th e c a p a c it y t h a t m u s t b e a c h ie v e d b e f o r e f in a l d is c h a r g e
v o lt a g e is r e a c h e d a t a g iv e n d is c h a r g e c u r r e n t in t e n s it y , d is c h a r g e p e r io d a n d t e m p e r a t u r e .
In v e h ic le d r iv e b a t t e r ie s t h e g e n e r a l r a t e d c a p a c it y is 5 h o r s ( K 5 ) a t a n o m in a l e le c t r o ly t e
t e m p e r a t u r e o f 3 0 ° C . D u r in g t h e c h a r g e p r o c e s s , e le c t r ic a l e n e r g y is s u p p lie d t o c o n v e r t
t h e le a d s u lp h a t e f o r m e d in t h e p o s it iv e a n d n e g a t iv e e le c t r o d e s d u r in g d is c h a r g e b a c k
in t o t h e a c t iv e s u b s t a n c e s le a d d io x ie d e a n d f in e ly d is t r u b t e d le a d ( s p o n g e le a d ) w h o s e
e n e r g y c o n t e n t is h ig h e r .
In t h e p r o c e s s t h e w a t e r f o r m e d d u r in g d is c h a r g e is u s e d u p a n d t h e b o n d e d s u lp h u r ic
a c id is r e le a s e d w it h t h e r e s u lt t h a t t h e a c id c o n c e n t r a t io n o f t h e e le c t r o ly t e r e t u r n s t o
it s o r ig in a l v a lu e . C h a r g e v o lt a g e in c r e a s e s s lo w ly in it ia lly , f a s t e r la t e r . W a t e r d e c o m p o s it io n
b e g in s a t a t e r m in a l v o lt a g e o f 2 . 4 V w h e r e b y p a r t o f t h e e le c t r ic c u r r e n t r e d u c e s t o h y d r o g e n
g a s a n d o x y g e n g a s a n d t h e b a t t e r y b e g in s t o g a s . T h e v o lt a g e r n a g e o f 2 . 4 V is t h e r e f o r e
t e r m e d h e a v y g a s s in g r a n g e ( g a s s in g v o lt a g e ) . A s e x c e s s iv e g a s g e n e r a t io n s h o r t e n s
e le c t r o d e lif e , t h e c h a r g e c u r r e n t in t e n s it y m u s t b e r e d u c e d t o s e t le v e ls d e r iv e d f r o m
e x p e r ie n c e w h e n t h is t e r m in a l v o lt a g e le v e l is r e a c h e d . T h e s e le v e ls a r e lis t e d in D IN
5 7 5 1 0 ( V D E 0 5 1 0 ) . B e c a u s e o f t h e g a s in g t h a t o c c u r s d u r in g t h e c h a r g e p r o c e s s , w h ic h
a m o n g s t o t h e r t h in g s s e r v e s t o m ix t h e a c id a n d is t h e r e f o r e d e s ir a b le t o a c e r t a in d e g r e e ,
a n d d u e t o s e c o n d a r y r e a c t io n s , a g r e a t e r a m o u n t o f c u r r e n t is r e q u ir e d f o r f u ll c h a r g e t h a n
c a n b e r e t r ie v e d d u r in g d is c h a r g e . T h e r a t io o f c h a r g e c u r r e n t t o d is c h a r g e c u r r e n t is t t e r m e d
t h e c h a r g e f a c t t o r . T h is r a n g e s f r o m 1 . 0 5 t o 1 . 2 0 d e p e n d in g o n e le c t r o d e t y p e a n d b a t t e r y
m o d e l, ie 1 0 5 t o 1 2 0 % o f t h e c u r r e n t r e t r ie v e d d u r in g d is c h a r g e is r e q u ir e d f o r t h e c h a r g e
p ro c e s s .
T h e r e c ip r o c a l v a lu e o f th e c h a rg e fa c to r is t h e b a tte ry 's a m p e re e f f ic ie n c y le v e l w h ic h ra n g e s
fro m 0 .8 3 to 0 .9 5 . V e r y lit t le s e lf - d is c h a rg e ta k e s p la c e in le a d b a t t e r ie s , d u e t o in t e r n a l
p r o c e s s e s . T h e c h a r g e lo s s h e r e is a p p ro x . 0 .5 to 1 .0 % /d a y a t 3 0 °C . R e g u la r r e c h a r g in g is
n e c e s s a ry to m a k e u p fo r th e s e lo s s e s o r e ls e a c o n t in u o u s lo w -c u rre n t c o m p e n s a t in g c h a rg e .
B a tte ry
E le c t r ic S id e lo a d e r
P a g e 3
D is c h a r g e P r o c e s s
D IN 5 7 5 1 0 (V D E 0 5 1 0 ) s e t s t h e r a t e d v o lt a g e o f a
V o lt m e t e r le a d s t o r a g e b a t t e r y a t 2 . 0 V t e r m in a l v o lt a g e . A
3 4 b a tte ry 's ra te d o r a g g re g a te v o lt a g e is d e t e r m in e d
2 5 b y t h e n u m b e r o f c e lls a r r a n g e d in s e r ie s . T h e
1 6 + r e s t v o lt a g e U 0 o f a c h a r g e d c e ll is b e t w e e n 2 .0 4
a n d 2 . 1 4 V , d e p e n d in g o n e le c t r o ly t e d e n s it y , b a s e d
o n t h e f o llo w in g f o r m u la :
P b S O 4 P b S O 4 U 0 = e le c t r o ly t e d e n s it y + 0 , 8 4
T h is m e a n s th a t re s t v o lt a g e is c a lc u la te d a s a
f u n c t io n o f e le c t r o ly t e d e n s it y . T h e re s t v o lt a g e
b e c o m e s e ffe c t iv e o n c e th e c h a rg e c u rre n t h a s
b e e n s w it c h e d o ff a n d a f t e r a g iv e n s e t t lin g p h a s e .
H 2O
W h e n d is c h a r g e c u r r e n t is s w it c h e d o n , t h e t e r m in a l v o lt a g e o f a c e ll d r o p s v e r y r a p id ly
t o t h e in it ia l v o lt a g e le v e l U a . T h is v o lt a g e is a n a p p r o x im a t e f u n c t io n o f t h e d is c h a r g e
c u r r e n t le v e l a s a r e s u lt o f in t e r n a l r e s is t a n c e s , in lin e w it h t h e f o llo w in g e q u a t io n :
U a = U 0 - I x R i
A s d is c h a r g e p r o c e e d s t h e t e r m in a l v o lt a g e d e c r e a s e s c o n s t a n t ly a s a r e s u lt o f t h e
in c r e a s e in e le c t r ic a l r e s is t a n c e a n d t h e f a ll in e le c t r o ly t e d e n s it y . D is c h a r g e is c o m p le t e d
w h e n t h e f in a l d is c h a r g e v o lt a g e is r e a c h e d . T h is r e p r e s e n t s a p o in t b e y o n d w h ic h
t e r m in a l v o lt a g e e n t e r s r a p id d e c lin e . T h e f in a l d is c h a r g e v o lt a g e is d e t e r m in e d f o r n o r m a l
d is c h a r g e c u r r e n t in t e n s it ie s a n d v a lu e s b e lo w t h is a r e in a d m is s ib le . T h e m e a n d is c h a r g e
v o lt a g e is c a lc u la t e d f r o m t h e t im e a v e r a g e o f t h e d is c h a r g e c u r v e . T h is c o r r e s p o n d s t o a
c e ll t e r m in a l v o lt a g e r e a c h e d b y d is c h a r g e t o a p p r o x . 1 / 3 c a p a c it y . T h e p r o d u c t o f m e a n
d is c h a r g e v o lt a g e in v o lt s a n d c a p a c it y in a m p e r e h o u r s g iv e s u s a b a t t e r y ' s w a t t h o u r , o r
w o r k , c a p a c it y . A t lo w m a s s e s t h e b a t t e r y ' s c a p a c it y is d e p e n d e n t o n t e m p e r a t u r e . A
t e m p e r a t u r e in c r e a s e o r d e c r e a s e o f 1 % in c r e a s e s o r d e c r e a s e s c a p a c it y b y a b o u t 1 % .
T h e r e f e r e n c e t e m p e r a t u r e f o r v e h ic le - b a s e d le a d b a t t e r ie s is 3 0 ° C . F o r e x t e n d e d b a t t e r y
lif e a n d g iv e a h ig h b a t t e r y c y c le , o n ly a r o u n d 8 0 % o f r a t e d c a p a c it y s h o u ld b e u s e d f o r
w o r k o p e r a t io n s . T h is h e lp s r e d u c e t h e h e a v y m e c h a n ic a l s t r e s s e s a c t in g o n t h e e le c t r o d e s
a s a r e s u lt o f t h e in c r e a s e in t h e v o lu m e o f a c t iv e s u b s t a n c e s d u r in g f u ll d is c h a r g e . T h e
d is c h a r g e le v e l o f t h e b a t t e r y c a n b e f o u n d b y m e a s u r in g in a m p e r e h o u r s t h e a m o u n t o f
c u r r e n t r e t r ie v e d .
B a tte ry
P a g e 4
T h e m o s t c o m m o n ly u s e d m e th o d - m e a s u r in g e le c t r o ly t e d e n s it y - r e lie s o n th e fa c t th a t
e le c t r o ly t e d e n s it y d e c r e a s e s in p ro p o r t io n to th e a m o u n t o f c u rre n t r e t r ie v e d . W h e n
m e a s u r in g e le c t r o ly t e d e n s it y it s h o u ld b e re m e m b e re d th a t it is d e p e n d e n t o n te m p e ra tu re ,
in c r e a s in g a s t h e t e m p e ra tu re d ro p s a n d d e c r e a s in g a s t e m p e ra tu r e r is e s . A 1 0 ° C c h a n g e
in t e m p e r a t u r e p r o d u c e s a f a ll o r r is e in e le c t r o ly t e d e n s it y o f a ro u n d 0 .0 0 0 7 k g / l.
M e a n d is c h a r g e v o lta g e
B a tte ry
P a g e 5
C h a rg e P ro c e s s
T h e c h a r g e p r o c e s s c o m p r is e s t w o s t a g e s . T h e
f ir s t s t a g e is lim it e d a t t h e u p p e r le v e l b y t h e
t e r m in a l v o lt a g e o f 2 . 4 V c o v e r in g t h e r a n g e o f
C h a rg e r h e a v y g a s s in g . T h e s e c o n d s t a g e e n d s w h e r e
+ t h e f in a l c h a r g e v o lt a g e r e a c h e s s t e a d y - s t a t e
c o n d it io n . W h e r e a s in t h e f ir s t s t a g e t h e c h a r g e
c u r r e n t is u s e d a lm o s t e x c lu s iv e ly t o c o n v e r t t h e
a c t iv e m a t e r ia l, a f t e r t h e g a s s in g r a n g e a r o u n d
P b 2 . 4 V / c e ll t h e c u r r e n t s u p p lie d d e c o m p o s e s w a t e r
P b O 2
o n ly . In t h e f ir s t s t a g e , t h e in c r e a s e in e le c t r o ly t e
d e n s it y t h a t o c c u r s d u r in g c h a r g e - a p r o c e s s
w h ic h in it ia lly o n ly t a k e s p la c e in t h e p o r e s o f
t h e a c t iv e m a s s - p r o d u c e s a c o n s t a n t r is e in
v o lt a g e . T e r m in v o lt a g e in t h e c e ll is d e r iv e d
f r o m t h e f o llo w in g e q u a t io n :
H 2 S O 4
U k l = U 0 + I x R i (b is 2 , 4 V )
A lt h o u g h in t e r n a l e le c t r ic a l r e s is t a n c e f a lls c o n s t a n t ly d u r in g t h e c h a r g e p ro c e s s ,
t e r m in a l v o lt a g e in c r e a s e s b e c a u s e r e s t v o lt a g e U 0 r is e s s t e a d ily . W h e n th e h e a v y
g a s s in g r a n g e o f 2 . 4 V / c e ll is r e a c h e d , a n a d d it io n a l v o lt a g e is t r a n s p o s e d w h ic h is
a t t r ib u t a b le t o w a t e r d e c o m p o s it io n a n d g a s f o r m a t io n . T h e in c r e a s e e n d s o n c e
e le c t r o ly t e d e n s it y s t a b ilis e s a f t e r f u ll c h a r g e is r e a c h e d . T h e t e r m in a l v o lt a g e n o w
r e a c h e d is t e r m e d t h e f in a l c h a r g e v o lt a g e . G a s d a m a g e t h e p la t e s , c u r r e n t in t e n s it y
m u s t b e r e d u c e d t o s a f e le v e ls . D IN 5 7 5 1 0 lis t s t h e f o llo w in g g u id e v a lu e s a s a d m is s ib le
c h a r g e c u r r e n t s in v e h ic le - b a s e d le a d b a t t e r ie s :
C h a r g e w it h c o n s t a n t c u r r e n t
a n d c u t- o ff a fte r c h a rg e - 5 A / 1 0 0 A h 5
C h a r g e w it h f a llin g c u r r e n t - f r o m 2 , 4 V / c e ll u p f r o m 8 A / 1 0 0 A h 5
a n d c u t- o ff a fte r c h a rg e to 4 0 0 A / 1 0 0 A h 5
A d m is s ib le c h a r g e c u r r e n t - 2 A / 1 0 0 A h 5
f o r p e r io d s u p t o 3 d a y s
B a tte ry
P a g e 6
In t h e f ir s t s t a g e o f t h e c h a r g e p r o c e s s u p t h e h e a v y g a s s in g r a n g e , a n y c u r r e n t in t e n s it y
m a y b e u s e d . C u r r e n t in t e s it y is r e s t r ic t e d o n ly b y t h e d e s ig n o f t h e c e lls a n d t h e c r o s s -
s e c t io n o f t h e c u r r e n t - c o n v e y in g e q u ip m e n t . H o w e v e r , t h e c u r r e n t le v e l c h a r g e d u p t o
2 . 4 V / c e ll is d e p e n d e n t o n c u r r e n t in t e n s it y . T h e g r e a t e r t h e c u r r e n t in t e n s it y , t h e lo w e r
le v e l o f c u r r e n t c h a r g e d ( lo w c h a r g e e f f ic ie n c y ) . C h a r g in g is c o n t in u e d w it h a c o r r e s p o n d in g ly
r e d u c e d c u r r e n t in t e n s it y . It is a ls o p o s s ib le , h o w e v e r , t o c h a r g e f r o m t h e o u t s e t u s in g a
r e a c h e d o r e x c e e d e d o n ly s lig h t ly . T h is r e q u ir e s a c o r r e s p o n d in g ly lo n g e r c h a r g e p e r io d .
T h is m e t h o d is u s e d , f o r e x a m p le , in d e s u lp h a t is in g c h a r g e p ro c e s s e s .
N o t e s O n M a in t e n a n c e
T h e v e h ic le ' s t r a c t io n b a tte r y is it s e n e r g y s o u r c e a n d t h e r e f o r e it s m o s t im p o rta n t p a rt.

S p e c ia l c a r e o f t h e b a tte ry is b o t h b e n e f ic ia l t o m a n y o t h e r o f t h e lo a d e r 's c o m p o n e n ts
a n d h e lp s t h e v e h ic le a c h ie v e m a n y y e a r s t r o b le - f r e e s e r v ic e . If w e r e m e m b e r th a t th e
s p e e d o f t h e e le c t r ic m o to r s (p u m p d r iv e s a n d d r iv e m o t o r s ) is p r o p o r t io n a l to v o lt a g e ,
w e c a n s e e t h e in f lu e n c e th e b a t t e r y h a s o n d r iv e s p e e d h y d r a u lic s .
Ir r e s p e c t iv e o f t h e a b o v e , lo n g b a t t e r y lif e r e q u ir e s c a r e f u l m a in t e n a n c e . S o p le a s e
o b s e r v e t h e f o llo w in g p o in t s :
1 . K e e p a m a in t e n a n c e lo g a n d c h e c k it r e g u la r ly ( c h e c k a c id s t r e n g t h b e f o r e a n d
a f t e r c h a r g in g e a c h c e ll) .
2 . O n ly f ill w it h d is t ille d w a t e r a f t e r t h e c h a r g e p r o c e s s h a s b e e n c o m p le t e d .
3 . R e c o rd th e c h a rg e c u rre n t.
4 . K e e p p o le s c le a n , r e p la c e d a m a g e d c a b le s a n d c o n n e c t o r s , m a k e s u r e c o n n e c t o r s
a r e f ir m ly s e a t e d .
5 . If a b a t t e r y " b o ils o v e r " , c le a n t h e b a t t e r y s u m p ( w a s h s e v e r a l t im e s a n d r e m o v e

e x c e s s w a te r ).
6 . A lw a y s w e a r g o g g le s a n d p r o t e c t iv e c lo t h in g w h e n w o r k in g o n b a t t e r ie s . D o n o t
s m o k e , n o n a k e d f la m e s . R e m o v e a n y t r a c e s o f a c id w it h s o a p s u d s .
7 . T h e b a t t e r y a ls o h e lp s s t a b ilis e t h e v e h ic le . T a k e c a r e w h e n e v e r t h e b a t t e r y
is r e m o v e d .
8 . D o n o t f it a b a t t e r y lig h t e r t h a n t h a t s p e c if ie d o n t h e id e n t if ic a t io n p la t e .
Service and Repair Manual Issue 02/2006
Electric Sideloader
Overview History
Speed Controller and Pump Controller
Speed Controller MC400G, P/N: 46369 no longer available

Speed Controller MC610G, P/N: 44272 no longer available
Speed Controller Pulsar 1000R, P/N: 209000 no longer available
Speed Controller MCM400M, P/N: 241838 only as replacement part available

Speed Controller MC610R, P/N: 244218 only as replacement part available
Pumpe Controller P500, P/N: 46195 only as replacement part available
Pump Controller P1000, P/N: 46196 only as replacement part available
Speed- and Pump Controller SC2000, P/N: 245727 actual standard

Speed Controller SC2000, P/N: 31698 actual standard
Speed Controller SC2000, P/N: 248369 actual standard
Speed Controller PowerPAK SEM, P/N: 251398 actual standard
Pump (Controller Serie, P/N: 251399 actual standard
C o n tro l S y s te m s
R e p a ir a n d S e r v ic e M a n u a l Is s u e 0 3 /2 0 0 6
P u ls e C o n t r o l S y s t e m M O S F E T S C 2 0 0 0
1 . In t r o d u c t io n
T h e n e w M O S F E T S C 2 0 0 0 r a n g e o f c o n t r o lle r s u s e a p o w e r f u l m ic r o p r o c e s s o r t o c o n t r o l
t w o p o w e r f r a m e s w it h r e g e n a n d p lu g g in g f o r t r a c t io n a n d a p u m p c o n t r o lle r .
T h e t w o p o w e r f r a m e s w it h in t h e u n it a r e c o n f ig u r e d a s a t r a c t io n D u a l- M o t o r p lu s p u m p
c o n t r o lle r .
S e t t in g s a n d a d ju s t m e n t s a s w e ll a s c h e c k s a n d t e s t s c a n b e c a r r ie d o u t w it h t h e C A N -
C o n t r o lle r .
T h e C A N - C o n t r o lle r is a n e a s y t o u s e t o o l a n d m u s t b e c a r r ie d b y s e r v ic e p e r s o n a l.
S e r v ic e a n d R e p a ir M a n u a l
Is s u e 0 3 /2 0 0 6
P a g e 2
2 . C o n t r o lle r F e a t u r e s
T h e S C 2 0 0 0 r a n g e o f c o n t r o lle r s o f f e r t h e f o llo w in g f e a t u r e s :
* E n c lo s e d u n it t o IP 3 4 w it h F e ld - r e p la c e a b le lo g ic .
* T r a c t io n a n d p u m p m o t o r c o n t r o lle r s in o n e e n c lo s u r e .
* M ic r o p r o c e s s o r c o n t r o l.
* H ig h f r e q u e n c y ( 1 5 , 7 k H z ), s ile n t o p e r a t io n .
* In t e r n a l " W a t c h d o g " , m o n it o r in g in t e r n a l m ic r o p r o c e s s o r o p e r a t io n .
* A r c le s s c o n t a c t o r s w it c h in g a n d b u ilt - in c o n t a c t o r c o il s u p p r e s s io n .
* T h e r m a lly c o m p e n s a t e d c u r r e n t lim it .
* A d ju s t a b le c r e e p s p e e d .
* S e a t s w it c h t im e r .
* B r a k in g in n e u t r a l.
* U n d e r v o lt a g e p r o t e c t io n
* A c c e le r a t o r w ir e - o f f d e t e c t .
* H a r d w a r e a n d S o f t w a r e f a il- s a f e p r o t e c t io n a n d a u t o f a ils a f e c h e c k e v e r y p o w e r u p .
* F a u lt d e t e c t io n w it h L E D d is p la y .
* A d ju s t m e n t s m a d e u s in g p lu g - in c a lib r a t o r .
* D ia g n o s t ic s , S e r v ic e in f o r m a t io n w it h c a lib r a to r.
3 . G e n e ra l / S a fe ty
3 .1 E le c t r ic v e h ic le s c a n b e d a n g e r o u s . A ll t e s t in g , f a u lt - f in d in g a n d a d ju s t m e n t s h o u ld
b e c a r r ie d o u t b y c o m p e t e n t p e r s o n n e l. A lw a y s , t h e d r iv e w h e e ls s h o u ld b e o f f t h e
f lo o r a n d f r e e t o r o t a t e d u r in g t h e f o llo w in g p r o c e d u r e s .
3 .2 T h e S C 2 0 0 0 c o n t r o lle r c o n t a in s a t r ip le f a il- s a f e s y s t e m t o g iv e t h e h ig h e s t le v e l o f
s a f e t y . If t h e d ia g n o s t ic L E D is n o t illu m in a t e d o r f la s h e s t h e s a f e t y c ir c u it m a y h a v e
t r ip p e d a n d t h e t r u c k m a y n o t d r iv e .
3 .3 T o e n s u r e c o n t in u e d s a f e t y o f t h e S C 2 0 0 0 s y s t e m t h e f a il- s a f e c ir c u it s h o u ld b e
c h e c k e d w h e n e v e r t h e t r u c k is s e r v ic e d ( s e e 3 . 7 ). T h e m a x im u m p e r io d b e t w e e n
c h e c k s s h o u ld n o t e x c e e d 3 m o n t h s .
3 .4 T h e b a t t e r y m u s t b e d is c o n n e c t e d b e f o r e r e p la c in g o r a t t e m p t in g a n y r e p a ir s o f t h e
c o n t r o ls .
3 .5 F a il- S a f e C h e c k
3 .5 .1 E n s u r e t h e d r iv e w h e e ls a r e c le a r o f t h e f lo o r a n d f r e e t o r o t a t e .
3 .5 .2 S w it c h o n k e y s w it c h , p r e s s s e a t s w it c h , r e le a s e b r a k e , s e le c t d ir e c t io n a l a n d
F S 1 . T h e w h e e ls s h o u ld r o t a t e a n d t h e d ia g n o s t ic L E D s h o u ld g iv e a s t e a d y
illu m in a t io n .
S e r v ic e a n d R e p a ir M a n u a l Is s u e 0 3 /2 0 0 6
P a g e 3
3 .5 .3 S w it c h o f f , d is c o n n e c t b a t t e r y a n d c o n n e c t F 1 a n d B - t e r m in a ls t o g e t h e r w it h ,
a t le a s t , 1 0 m m ² c a b le .
3 .5 .4 R e c o n n e c t b a t t e r y , s w it c h o n w it h d ir e c t io n in n e u t r a l. T h e d ia g n o s t ic L E D
s h o u ld e x t in g u is h . S e le c t a d ir e c t io n . C o n t a c t s o f r e la y s s h o u ld n o t c lo s e ,
n o d r iv e is e x p e c t e d .
If t h e t r u c k d r iv e s , t h e c o n t r o lle r is d e f e c t iv e a n d n e e d s t o b e r e p la c e d .
D o n o t f o r g e t t o r e m o v e t h e lin k b e t w e e n a n d B - t e r m in a l.
3 .6 N o te
3 .6 .1 A s b lo w - o u t m a g n e t s a r e f it t e d t o c o n t a c t o r s , e n s u r e t h a t n o m a g n e t ic
p a r t ic le s c a n a c c u m u la t e in t h e c o n t a c t g a p s a n d c a u s e m a lf u n c t io n .
E n s u r e t h a t c o n t a c t o r s a r e w ir e d w it h t h e c o r r e c t p o la r it y t o t h e ir p o w e r
t e r m in a ls a s in d ic a t e d b y t h e + s ig n t o t h e t o p m o u ld in g .
3 .6 .2 T h e S C 2 0 0 0 c o n t r o lle r m u s t n o t b e u s d w it h p e r m a n e n t ly c o n n e c t e d c h a r g e r s
o r d a m a g e to th e s y s te m .
4 . T e c h n ic a l S p e c if ic a t io n s
4 .1 E n v ir o n m e n t a l
4 .1 .1 P r o t e c t io n : IP 3 4
4 .1 .2 O p e r a t in g T e m p e r a t u r e : - 3 0 ° C t o + 4 0 ° C a m b ie n t a r o u n d c o n t r o lle r
4 .1 .3 H u m id it y : 9 5 % m a x im u m , n o n c o n d e n s in g
4 .1 .4 H u m id it y R e s is t a n c e : N o f u n c t io n a l d e f e c t s a f t e r c o n t r o lle r is le f t a t
6 0 ° C a n d 1 0 0 % h u m id it y f o r o n e h o u r a f t e r
f r e e z e r u s e (- 3 0 ° C m in im u m ).
P a g e 4
5 . C o n t r o l C o n n e c t io n s
T h e f o llo w in g c o n n e c t io n s a r e p r o v e d e d f o r in f o u r c u s t o m e r c o n n e c t o r s . C o n n e c t o r 1
is f o r t r u c k s w it c h a n d a c c e le r a t o r c o n n e c t io n s , c o n n e c t o r 2 is f o r t h e c o n t a c t o r
c o n n e c t io n s a n d t h e k e y s w it c h in p u t . C o n n e c t o r s 3 a n d 4 a r e f o r t h e C A N c o m m u n a t io n
in t e rfa c e .
5 .1 C o n n e c to r A - 2 4 w a y
P IN F u n c t io n S e c o n d a r y F u n c t io n P in T y p e
1 . F o r w a r d s w it c h d ig it a l in p u t
2 . r e v e r s e s w it c h d ig it a l in p u t
3 . F S 1 s w it c h d ig it a l in p u t
4 . S e a t s w it c h d ig it a l in p u t
5 . H a n d b r a k e s w it c h d ig it a l in p u t
6 . S p e e d c u tb a c k 1 d ig it a l in p u t
7 . S p e e d c u tb a c k 2 (d u a l m o to r o u te r s w ) d ig it a l in p u t
8 . P u m p in h ib it in p u t d ig it a l in p u t
9 . S t e e r p o t e n t io m e t e r in p u t a n a lo g u e in p u t
1 0 . T r a c t io n a c c e le r a t o r a n a lo g u e in p u t
1 1 . S t e e r p o t s u p p ly o u tp u t
1 2 . T r a c t io n a c c e le r a t o r s u p p ly o u tp u t
1 3 . R e s e rv e d s p e e d e n c o d e r 1 d ig it a l in p u t
1 4 . P o w e r s t e e r t r ig g e r in p u t d ig it a l in p u t
1 5 . P u m p s w it c h 2 d ig it a l in p u t
1 9 . P u m p s w it c h 6 (In c h fo r w a r d / D M in n e r le f t s w ) d ig it a l in p u t
2 0 . P u m p s w it c h 7 (In c h r e v e r s e / D M in n e r r ig h t s w ) d ig it a l in p u t
2 1 . * P u m p a c c e le r a t o r / p u m p s w it c h 1 a n a lo g u e in p u t
2 2 . * F o o t b r a k e p o t / f o o t b r a k e s w it c h
(e c o n o m y p o t.) a n a lo g u e in p u t
2 3 . P u m p a c c e le r a t o r s u p p ly o u tp u t
2 4 . + 1 2 V S u p p ly o u tp u t
* N o te : T h e fo o t b r a k e s w it c h ( if r e q u ir e d ) s h o u ld b e c o n n e c t e d in s e r ie s
w it h t h e f o o t b r a k e p o t e n t io m e t e r ( if f it t e d ) , a n d p u m p s w it c h 1
(if re q u ir e d ) s h o u ld b e c o n n e c t e d in s e r ie s w it h p u m p a c c e le r a t o r
(if f it t e d ).
Is s u e 0 3 /2 0 0 6
P a g e 5
5 .2 C o n n e c to r B - 1 2 w a y
P in F u n c t io n ( S e c o n d a r y F u n c t io n ) P in T y p e
1 . L in e c o n t a c t o r d ig it a l o u tp u t
2 . F o rw a rd c o n ta c to r (D M r ig h t m o t o r f w d ) d ig it a l o u tp u t
3 . R e v e rs e c o n ta c to r (D M r ig h t m o t o r r e v ) d ig it a l o u tp u t
4 . R e g e n c o n ta c to r d ig it a l o u tp u t
5 . B y p a s s c o n ta c to r (D M le f t m o t o r f w d ) d ig it a l o u tp u t
6 . F ie ld W e a k e n in g c o n t a c t o r (D M le f t m o t o r r e v ) d ig it a l o u tp u t
7 . P o w e r s te e r c o n ta c to r d ig it a l o u tp u t
8 . P u m p b y p a s s /f. w e a k c o n ta c to r
( D M b a la n c e c o n t . ) d ig it a l o u t p u t
9 . R e g e n c o n t a c t o r d e t e c t in p u t d ig it a l o u t p u t
1 0 . R e s e r v e d (c le a n B D I ( i/ p ) a n a lo g u e in p u t
1 1 . C o n t a c t o r p o s it iv e s u p p ly o u tp u t
1 2 . B + v e k e y s w it c h in p u t in p u t
5 .3 C o n n e c to rs C a n d D - 6 w a y
T h e s e tw o c o n n e c to rs a re c o n n e c te d in p a r a lle l a n d p r o v id e in p u t / o u t p u t
c a p a b ilit y f o r t h e C a lib ra t o r , d is p la y s a n d o t h e r e q u ip m e n t n e e d in g t o
c o m m u n ic a t e w it h th e c o n t r o lle r . T h e y a re p a rt o f a s e r ia l C A N ( c o n t r o lle r
a re a n e tw o rk ) b u s s y s te m a n d p ro to c o l. T h e C a lib r a t o r c a n b e c o n n e c te d
t o e it h e r o f th e s e c o n n e c to rs .
A ll t h e p in s a r e p r o t e c t e d a g a in s t m is c o n n e c t io n t o e a c h o t h e r a n d B - v e . T h e
s o c k e t p r o v id e p h y s ic a l p r o t e c t io n a g a in s t s h o r t c ir c iu t s t o B + v e . .
P in F u n c t io n S e c o n d a r y F u n c t io n P IN T y p e
1 . 1 0 ,5 V (S C 2 0 0 0 s e le c t ) d ig it a l in p u t
2 . B - (- v e s u p p ly ) o u tp u t
3 . 1 0 ,5 V (S C 2 0 0 0 s e le c t ) d ig it a l in p u t
4 . 1 0 ,5 V (+ v e s u p p ly ) o u tp u t
5 . C A N + (D a ta ) d ig it a l in p u t/o u tp u t
6 . C A N - (D a ta ) d ig it a l in p u t/o u t
Is s u e 0 3 /2 0 0 6
P a g e 6
6 . C A N C o n t r o lle r
A s o p h is t ic a t e d , y e t e a s y to u s e h a n d h e ld a d ju s t m e n t u n it , c a lle d th e C A N C o n t r o lle r is u s e d
to m a k e a d ju s t m e n ts to th e c o n t r o lle r a n d s e le c t c o n f ig u r a t io n s . T h e C A N C o n t r o lle r is a ls o
u s e d a s a d ia g n o s t ic t o o l d is p la y in g th e s ta tu s o f a ll v o lt a g e s , c u rre n ts a n d te m p e r a t u r e s w it h in
th e c o n t r o lle r t o g e th e r w it h t h e c o n d it io n o f a ll t h e c o n t r o lle r s s w it c h a n d a n a lo g u e in p u t s .
T h e d ia g r a m b e lo w d e s c r ib e s h o w t h e C A N C o n t r o lle r is u s e d . T h e le f t a n d r ig h t a r r o w s m o v e
b e tw e e n s c r e e n s o n t h e s a m e le v e l. T h e u p a n d d o w n a r r o w s m o v e b e t w e e n le v e ls a n d t h e
+ a n d - b u t o n s in c r e m e n t o r d e c r e m e n t t h e p a r a m e t e r s b y t h e a m o u n t in d ic a t e d in t h e S T E P
c o lu m n .
T r a c tio n B D I P U M P
1 .1 1 .2 1 .3 S e tu p C u to u t 2 .1 2 .2 2 .3
b is b is
1 .3 .2 0 2 .3 .1 2 .3 .1 1
1 .3 .1
b is
b is 2 .2 .1 2 .2 .8
1 .2 .1 1 .2 .8
b is
b is 2 .1 .1 2 .1 .2 5
1 .1 .1 1 .1 .3 4
T h e m a n u f a c t u r e r o f t h e t r u c k d o e s n o t t a k e a n y r e s p o n s ib ilit y if s e t t in g s
a r e c h a n g e d w it h o u t p r io r w r it t e n p e r m is s io n .
7 . P a ra m e te r
7 . 1 T r a c t io n P e r s o n a lit ie s ( C o n t r o lle r A d ju s t m e n t s )
C a l. M a x . M a x .
M in . S e t t in g S e t t in g S e t t in g S t e p s iz e
R e f. P a r a m e t e r A d ju s t e d
( A ll U n it s ) 5 0 0 A 6 5 0 A (A ll u n it s )
N o .
1 .1 .1 C u r r e n t lim it 5 0 A 5 0 0 A 6 5 0 A 1 0 A m p s
1 .1 .2 A c c e le r a t io n d e la y 0 ,1 s 5 ,0 s 5 ,0 s 0 ,1 S e c .
1 .1 .3 D e c e le r a t io n d e la y 0 ,1 s 0 ,5 s 0 ,5 s 0 ,1 S e c .
1 .1 .4 C re e p s p e e d 0 % 2 5 % 2 5 % 1 ,0 %
M a x im u m s p e e d 0 % 1 0 0 % 1 0 0 % 1 ,0 %
1 .1 .5
C u tb a c k s p e e d 1 0 % 1 0 0 % 1 0 0 % 1 ,0 %
1 .1 .6
1 .1 .7 A c c e le r a t io n d e la y 0 ,1 s 5 ,0 s 5 ,0 s 0 ,1 S e c .
1 .1 .8 C u tb a c k s p e d 2 0 % 1 0 0 % 1 0 0 % 1 ,0 %
1 .1 .9 A c c e le r a t io n d e la y 2 0 ,1 s 5 ,0 s 5 ,0 s 0 ,1 S e c .
1 .1 .1 0 D ir e c t io n b r a k e c u r r e n t 5 0 A 5 0 0 A 6 5 0 A 1 0 A m p s
1 .1 .1 1 F o o tb ra k e c u rre n t 1 0 A (0 = d is a b le s ) 5 0 0 A 6 5 0 A 1 0 A m p s
1 .1 .1 2 N e u tra l b ra k e c u rre n t 1 0 A (0 = d is a b le s ) 5 0 0 A 6 5 0 A 1 0 A m p s
1 .1 .1 3 B y p a s s o v e r c u rre n t 1 0 A (0 = d is a b le s ) 7 5 0 A 9 7 0 A 1 0 A m p s
1 .1 .1 4 F ie ld w e a k p u ll in 5 0 A 5 0 0 A 6 5 0 A 1 0 A m p s
1 .1 .1 5 F ie ld w e a k d r o p o u t 5 0 A 5 0 0 A 6 5 0 A 1 0 A m p s
1 .1 .1 6 P o w e r s t e e r d e la y 0 s 5 0 s 5 0 1 ,0 S e c .
1 .1 .1 7 S e a t s w it c h d e la y 0 s 5 ,0 s 0 ,5 s 0 ,1 S e c .
1 .1 .1 8 R e g e n s p e e d fa c to r 0 % 2 5 5 % 2 5 5 % 1 ,0 %
1 .1 .1 9 B ra k e c o n s ta n t fa c to r 0 % 2 5 5 % 2 5 5 % 1 ,0 %
1 .1 .2 0 A c c e le r a t o r z e r o le v e l 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
1 .1 .2 1 A c c e le r a t o r f u ll le v e l 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
1 .1 .2 2 F o o t b r a k e p o t z e r o le v e l 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
1 .1 .2 3 F o o t b r a k e p o t f u ll le v e l 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
1 .1 .2 4 E c o n o m y p o t z e r o le v e l 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
1 .1 .2 5 E c o n o m y p o t f u ll le v e l 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
1 .1 .2 6 S t e e r p o t le f t le v e l 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
1 .1 .2 7 S t e e r p o t r ig h t le v e l 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
M in s e t t in g S e t t in g S t e p S iz e
R e f. P a r a m e t e r A d ju s t e d S e t t in g
( A ll U n it s ) 5 0 0 A ( A ll U n it s )
N o . 6 5 0 A
1 .1 .2 8 D u a l m o to r s te e r fa c to r 0 ,1 5 ,0 5 ,0 -----
1 .1 .2 9 D u a l m o t o r in n e r a n g le 5 8 5 8 5 1 ,0 °
1 .1 .3 0 D u a l m o t o r in n e r r a m p 0 ,1 s 5 ,0 s 5 ,0 s 0 ,1 S e c .
1 .1 .3 1 D u a l m o t o r o u t e r a n g le 5 8 5 8 5 1 ,0 °
1 .1 .3 2 D u a l m o to r o u te r ra m p 0 ,1 s 5 ,0 s 5 ,0 s 0 ,1 S e c .
In c h s p e e d 0 % 2 5 % 2 5 1 ,0 %
1 .1 .3 3
1 .1 .3 4 B u r s t in c h d e la y 0 ,1 s 5 ,0 s 5 ,0 s 0 ,1 S e c .
1 .1 .3 5 C o n t a c t o r c h o p p in g s e le c t o ff (n o c h o p ) o n o n -----
N o te :
D e p e n d in g o n c o n t r o lle r t y p e a n d c o n f ig u r a t io n s o m e o f t h e a b o v e a d ju s t m e n t s w ill
n o d is p la y e d if t h e y a r e n o t r e le v a n t .
7 . 2 T r a c t io n S t a t u s In f o r m a t io n
C a l.
R e f. M in . D is p la y M a x . D is p la y S t e p S iz e
P a r a m e t e r D is p la y e d
N o . ( A ll U n it s ) ( A ll U n it s ) ( A ll U n it s )
1 .2 .1 B a t t e r y v o lt a g e 0 V 1 2 7 V 0 , 5 V o lt s
1 .2 .2 T r a c t io n m o t o r v o lt a g e 0 V 1 2 7 V 0 , 5 V o lt s
1 .2 .3 (L / R )* T r a c t io n m o t o r c u r r e n t 0 A 1 2 0 0 A 6 A m p s
1 .2 .4 (L / R )* T r a c t io c o n t r o lle r t e m p . -3 0 ° C + 2 2 5 ° C 1 °C
1 .2 .5 T r a c t io n M O S F E T v o lt a g e 0 V 1 2 7 V 0 , 5 V o lt s
C a p a c it o r v o lt a g e 0 V 1 2 7 V 0 , 5 V o lt s
1 .2 .6
1 .2 .7 K e y s w it c h h o u r s c o u n t 0 H rs 6 5 2 7 9 ,9 H rs 6 M in .
1 .2 .8 T r a c t io n p u ls in g h o u r s c o u n t 0 H rs 6 5 2 7 9 ,9 H rs 6 M in .
N o t e : O n t r a c t io n d u a l m o t o r p r o p o r t io n a l c o n t r o lle r s , t h e r e w ill b e 2 d is p la y s e . g . 1 . 2 . 2 L a n d
1 . 2 . 2 R t o in d e p e n d e n t ly s h o w b o t h t h e le f t a n d r ig h t m o t o r s t a t u s in f o r m a t io n .
Is s u e 0 3 /2 0 0 6
P a g e 9
7 . 3 T r a c t io n T e s t In f o r m a t io n
C a l.
In p u t D is p la y e d
N o . ( a ll U n it s ) ( A ll U n it s ) ( A ll U n it s )
1 .3 .1 A c c e le r a t o r % ra n g e 0 % 1 0 0 % 1 ,0 %
1 .3 .2 A c c e le r a t o r v o lt a g e r a n g e 0 ,0 V 5 ,5 V 0 ,1 V
1 .3 .3 F o o tb ra k e p o t % ra n g e 0 % 1 0 0 % 1 ,0 %
1 .3 .4 F o o t b r a k e p o t v o lt a g e r a n g e 0 ,0 V 5 ,5 V 0 ,1 V
1 .3 .5 E c o n o m y p o t % ra n g e 0 % 1 0 0 % 1 ,0 %
1 .3 .6 E c o n o m y p o t v o lt a g e r a n g e 0 ,0 V 5 ,5 V 0 ,1 V
1 .3 .7 D u a l m o to r s te e r p o t % ra n g e 0 % 1 0 0 % 1 ,0 %
1 .3 .8 D u a l m o t o r s t e e r p o t v o lt a g e r a n g e 0 ,0 V 5 ,5 V 0 ,1 V
1 .3 .9 F o r w a r d s w it c h o p e n c lo s e d ------
1 .3 .1 0 R e v e r s e s w it c h o p e n c lo s e d ------
1 .3 .1 1 F S - 1 s w it c h o p e n c lo s e d ------
1 .3 .1 2 S e a t s w it c h o p e n c lo s e d ------
1 .3 .1 3 H a n d b r a k e s w it c h o p e n c lo s e d ------
1 .3 .1 4 S p e e d c u t b a c k 1 s w it c h o p e n c lo s e d ------
1 .3 .1 5 S p e e d c u t b a c k 2 s w it c h o p e n c lo s e d ------
1 .3 .1 6 P o w e r s t e e r t r ig g e r in p u t o p e n c lo s e d ------
1 .3 .1 7 In c h f o r w a r d s w it c h o p e n c lo s e d ------
1 .3 .1 8 In c h r e v e r s e s w it c h o p e n c lo s e d ------
1 .3 .1 9 D u a l m o t o r in n e r le f t s w it c h o p e n c lo s e d ------
1 .3 .2 0 D u a l m o t o r in n e r r ig h t s w it c h o p e n c lo s e d ------
1 .3 .2 1 D u a l m o t o r o u t e r s w it c h o p e n c lo s e d ------
1 .3 .2 2 S o f t w a r e v e r s io n / r e v is io n 0 0 0 .0 0 9 9 9 .9 9 ------
A t t e n t io n :
A s w it h t h e p e r s o n a lit ie s , o n ly r e le v a n t s w it c h t e s t s w ill b e s h o w n .
Is s u e 0 3 /2 0 0 6
P a g e 1 0
7 . 4 P u m p P e r s o n a lit ie s (C o n t r o lle r P a r a m e t e r s )
M in . S e t t in g S e t t in g S e t t in g S t e p S iz e
R e f. P u m p P a r a m e t e r A d ju s t e d
( A ll U n it s ) 5 0 0 A 6 5 0 A ( A ll U n it s )
N o .
2 .1 .1 C u r r e n t lim it 5 0 A 5 0 0 A 6 5 0 A 1 0 A m p s
2 .1 .2 R a m p u p d e la y 0 ,1 s 5 ,0 s 5 ,0 s 0 ,1 s e c .
2 .1 .3 R a m d o w n d e la y 0 ,1 s 0 ,5 s 0 ,5 s 0 ,1 s e c .
2 .1 .4 C re e p s p e e d 0 % 2 5 % 2 5 % 1 ,0 %
P u m p s p e e d 1 0 % 1 0 0 % 1 0 0 % 1 ,0 %
2 .1 .5
P u m p c o m p e n s a t io n 1 1 % (0 = o ff) 2 5 5 % 2 5 5 % 1 ,0 %
2 .1 .6
2 .1 .7 P u m p s p e e d 2 0 % 1 0 0 % 1 0 0 % 1 ,0 %
2 .1 .8 P u m p c o m p e n s a t io n 2 1 % (0 = o ff) 2 5 5 % 2 5 5 % 1 ,0 %
2 .1 .9 P u m p s p e e d 3 0 % 1 0 0 % 1 0 0 % 1 ,0 %
2 .1 .1 0 P u m p c o m p e n s a t io n 3 1 % (0 = o ff) 2 5 5 % 2 5 5 % 1 ,0 %
2 .1 .1 1 P u m p s p e e d 4 0 % 1 0 0 % 1 0 0 % 1 ,0 %
2 .1 .1 2 P u m p c o m p e n s a t io n 4 1 % (0 = o ff) 2 5 5 % 2 5 5 % 1 ,0 %
2 .1 .1 3 P u m p s p e e d 5 0 % 1 0 0 % 1 0 0 % 1 ,0 %
2 .1 .1 4 P u m p c o m p e n s a t io n 5 p r io r it y a d d it iv e a d d it iv e ------
2 .1 .1 5 P u m p s p e e d 6 0 % 1 0 0 % 1 0 0 % 1 ,0 %
2 .1 .1 7 P u m p s p e e d 7 0 % 1 0 0 % 1 0 0 % 1 ,0 %
2 .1 .1 9 P o w e r s te e r s p e e d 0 % 1 0 0 % 1 0 0 % 1 ,0 %
2 .1 .2 0 P o w e r s t e e r c o m p e n s a t io n 1 % (0 = o ff) 2 5 5 % 2 5 5 % 1 ,0 %
2 .1 .2 1 P o w e r s t e e r r a m p u p d e la y 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
2 .1 .2 2 P o w e r s t e e r r a m p d o w n d e la y 0 V 5 ,5 V 5 ,5 V 0 , 1 V o lt s
2 .1 .2 3 C o n t a c t o r c h o p p in g s e le c t o ff (n o c h o p ) o n o n ------
E le c t r ic S id e lo a d e r P a g e 1 1
7 .5 P u m p S t a t u s In f o r m a t io n - P a r a m e t e r s D is p la y e d a s f o llo w s :
C a l.
M in . D is p la y M a x . D is p la y ' S t e p S iz e
R e f. P u m p P a r a m e t e r D is p a y e d ( A ll U n it s ) ( A ll U n it s ) ( A ll U n it s )
N o .
2 .2 .1 B a t t e r y v o lt a g e 0 V 1 2 7 V 0 , 5 V o lt s
2 .2 .2 P u m p m o t o r v o lt a g e 0 V 1 2 7 V 0 , 5 V o lt s
2 .2 .3 P u m p m o to r c u rre n t 0 A 1 2 0 0 A 6 A m p s
2 .2 .4 P u m p c o n t r o lle r t e m p . -3 0 ° C + 2 2 5 ° C 1 °C
2 .2 .5 P u m p M O S F E T v o lt a g e 0 V 1 2 7 V 0 , 5 V o lt s
2 .2 .6 C a p a c it o r v o lt a g e 0 V 1 2 7 V 0 , 5 V o lt s
2 .2 .7 K e y s w it c h h o u r s c o u n t 0 H rs 6 5 2 7 9 ,9 H rs 6 M in .
2 .2 .8 P u m p p u ls in g h o u r s c o u n t 0 H rs 6 5 2 7 9 ,9 H rs 6 M in .
7 . 6 P u m p T e s t In f o r m a t io n ( C o n d it io n O f T h e F o llo w in g U n it s )
C a l.
P u m p In p u t D is p la y e d
N o . ( A ll U n it s ) ( A ll U n it s ) ( A ll U n it s )
2 .3 .1 A c c e le r a t o r % ra n g e 0 % 1 0 0 % 1 ,0 %
2 .3 .2 A c c e le r a t o r v o lt a g e r a n g e 0 ,0 V 5 ,5 V 0 ,1 V
2 .3 .3 P u m p s w it c h 1 o p e n c lo s e d ------
2 .3 .1 0 P u m p in h ib it s w it c h o p e n c lo s e d ------
2 .3 .1 1 S o f t w a r e v e r s io n / r e v is io n 0 0 0 .0 0 9 9 9 .9 9 ------
N o te : W h e n s e t t in g u p t h e a n a lo g u e in p u t s o n e it h e r t h e t r a c t io n o r th e p u m p a
"s h o r t c u t " e x is t s t o s w a p o v e r fro m th e s ta tu s a c c e le r a t o r v o lt a g e a n d %
in r a n g e d is p la y s , t o t h e p e r s o n a lit y z e r o a n d f u ll a d ju s t m e n t s . P re s s in g
d o w n a rro w b u tto n o n c e o n t h e c a lib r a t o r w ill s w a p b e tw e e n th e s e 2
c a lib r a t o r s e c t io n s , t o a id r a p id s e t - u p .
Is s u e 0 3 /2 0 0 6
P a g e 1 2
7 . 7 T r a c t io n A n d P u m p P e r s o n a lit ie s D e s c r ip t io n
T r a c t io n
P a ra m e te r O r D e s c r ip t io n
P u m p
C u r r e n t lim it T + P M a x im u m a llo w a b le m o t o r c u r r e n t .
A c c e le r a t io n d e la y T + P T im e t a k e n t o r a m p u p f r o m 0 to 1 0 0 % o n .
D e c e le r a t io n d e la y T + P T im e t a k e n t o r a m p d o w n f r o m 1 0 0 to 0 % o n .
M in im u m a p p lie d % o n w h e n d r iv e f ir s t s e le c t e d .
C re e p s p e e d T + P
O n ly P S 1 o n p u m p
M a x im u m s p e e d T M a x im u m a llo w a b le % o n .
C u tb a c k s p e e d s 1 & 2 T M a x im u m a llo w a b le % o n w h e n c u t b a c k s w it c h e s a c t iv e .
In d e p e n d e n t ly a d ju s t a b le a c c e le r a t io n d u r in g s p e e d
A c c e le r a t o r d e la y 1 & 2 T c u tb a c k s .
D ir e c t io n b r a k e c u r r e n t T M a x im u m b r a k in g c u r r e n t d u r in g d ir e c t io n s w it c h
c h a n g e .
F o o tb ra k e c u rre n t T M a x . b r a k in g c u r r e n t in n e u t r a l w h e n f o o t b r a e s w it c h a c t iv e .
N e u tra l b ra k e c u rre n t T M a x im u m b r a k in g c u r r e n t in n e u t r a l.
B y p a s s o v e r c u rre n t T M a x . a llo w a b le c u r r e n t in b y p a s s b e f o r e c o n t a c t o r o p e n s .
F .W . F . w e a k c o n t a c t o r a llo w e d t o p u ll in a t c u r r e n t s < p u ll
T
p u ll in c u r r e n t in le v e l.
F .W . F . w e a k c o n t a c t o r w ill d r o p o u t a t c u r r e n t s > d r o p o u t
d ro p o u t c u rre n t T le v e l.
P o w e r s t e e r d e la y T D e la y a f t e r p o w e r s t e e r t r ig g e r r e m o v e d u n t il c o n t a c t o r
o p e n s .
S e a t s w it c h d e la y T D e la y a fte r s e a t s w it c h o p e n s u n t il p u ls in g is in h ib it e d .
U s e d to p re v e n t d e la y s f o r u n s u c c e s s f u l r e g e n a t t e m p t s
R e g e n s p e e d
T a t lo w s p e e d s . R e g e n a t t e m p t e d a t lo w s p e e d (lo w n o s . )
o r h ig h e r s p e e d s (h ig h / n o s . )
M u lt ip lic a t io n f a c t o r u s e d t o s c a le r e g e n c u r r e n t s in t o
B ra k e fa c to r T e n d p lu g c u r r e n t s t o im p r o v e r e g e n t o p lu g t r a n s is t io n .
U s e d t o s e le c t m in im u m v o lt a g e in p u t le v e l f o r f u c n t io n .
Z e r o le v e ls T + P E .g . a n a c c e le r a t o r z e r o le v e l= 0 . 5 V m e a n s t r a c t io n
p u ls in g b e g in s a t 0 . 5 V I/ P .
U s e d t o s e le c t m a x im u m v o lt a g e in p u t le v e l f o r f u n c t io n ,
F u ll le v e ls T + P e .g . a n a c c e le r a t o r f u ll le v e l o f 4 . 0 V m e a n s 1 0 0 %
p u ls in g is r e a c h e d a t 4 V I/ P .
F a c to r u s e d t o o p t im is e p e r f o r m a n c e d e p e n d in g o n w h e e l
D u a l m o to r s te e r fa c to r T b a s e g e o m e t r y f o r d u a l m o t o r p r o p o r t io n a l c o n t r o lle r s
o n ly . ( L e n g t h f r o m d r iv e t o s t e e r w h e e l/ w id t h b e t w e e n
d r iv e w h e e ls .
Is s u e 0 3 /2 0 0 6
P a g e 1 3
S e t s a n g le a t w h ic h in n e r m o t o r f r e e w h e e ls , o n d u a l
D u a l M o t o r in n e r a n g le T m o t o r n o n p r o p o r t io n a l s y s t e m s w it h a s t e e r in g
p o t e n t io m e t e r f it t e d .
D u a l m o t o r o u t e r a n g le A s a b o v e , e x c e p t s e t s a n g le a t w h ic h in n e r w h e e l
T
re v e rs e s .
D u a l m o t o r in n e r r a m p T T im e t a k e n t o r a m p u p p u ls in g a f t e r in n e r m o t o r d r o p
o u t o n a n y d u a l m o t o r n o n p r o p o r t io n a l s y s t e m .
D u a l m o to r o u te r ra m p T A s a b o v e , e x c e p t r a m p u p t im e a f t e r in n e r m o t o r
r e v e s a l.
In c h s p e e d T M a x im u m a llo w a b le % o n d u r in g in c h in g o p e r a t io n .
B u r s t in c h d e la y T T im e r t o a llo w in c h in g f o r a s e t p e r io d o n ly .
C o n t a c t o r c h o p s e le c t T + P S e le c t s c h o p p in g f o r 2 4 V c o n t a c t o r s .
M a x im u m a llo w a b le % o n ' s w h e n r e s p e c t iv e s w it c h
P u m p s p e e d s 1 -7 P
a c t iv e .
P o w e r s te e r s p e e d P A s a b o v e , b u t fo r p o w e r s te e r s p e e d .
S e tu p c o m p e n s a t io n b y a d ju s t in g t h e r e le v a n t p u m p t o
P u m p c o m p e n s a t io n g iv e th e re q u ir e d m in im u m n o lo a d s p e e d , t h e n s e t t h e
1 -4 P a s s o c ia te d c o m p e n s a t io n a d ju s t m e n t t o g iv e t h e s a m e
s p e e d u n d e r f u ll lo a d c o n d it io n s .
L o w e r n u m b e r s s p e e d d e m a n d h a s p r io r it y o v e r h ig h e r
P u m p c o m p e n s a t io n n u m b e r s if m o r e t h a n 1 s w it c h is c lo s e d , o r a d d it iv e
5 -7 P
w h e r e t h e s p e e d s 5 - 7 a r e a d d e d t o lo w e r n u m b e r e d
s w it c h .
P o w e r s te e r c o m p . P A s a b o v e b u t f o r p o w e r s t e e r s p e e d c o m p e n s a t io n .
P o w e r s te e r In d e p e n d e n t a c c e le r a t io n d e la y f o r p o w e r s t e e r
ra m p u p P f u n c t io n .
P o w e r s te e r ra m p P A s a b o v e b u t d e c e le r a t io n d e la y .
d o w n
8 . C o n t r o lle r O p e r a t io n a n d F e a t u r e D e s c r ip t io n
8 .1 T r a c t io n O p e r a t io n
8 .1 .1 P o w e r S te e r
A c o n ta c to r d r iv e is a v a ila b le t o c o n t r o l a s e p a ra te p o w e r s te e r m o to r . A n a d ju s t a b le
d e la y is a v a ila b le t h a t a llo w s th e m o to r to o p e r a t e f o r a s e t t im e , a fte r th e p o w e r s te e r
t r ig g e r o r p o w e r s te e r d e m a n d h a s b e e n r e m o v e d . T y p ic a lly s t a n d a rd t r ig g e r , i. e w h e n
th e c o n ta c to r is c lo s e d , is w h e n e it h e r F S 1 o r f o o t b r a k e s w it c h is c lo s e d , o r t h e t r a c t io n
u n it is p u ls in g . It is a n e it h e r - o r s it u a t io n , s o a n y o n e o f th e s e 3 in p u t s is s u f f ic ie n t t o
t r ig g e r t h e p o w e r s te e r.
T h is s t a n d a r d t r ig g e r is d e s ig n e d t o g iv e p o w e r s te e r w h e n e v e r th e tr u c k is m o v in g , b u t
n o t to h a v e a s it u a t io n w h e re th e p w e r s t e e r c o u ld b e o n c o n t in u o u s ly , i. e o n a d ir e c t io n
s w it c h w h e re th e tru c k c o u ld b e le f t w ir h a d ir e c t io n s e le c t e d a n d t h e k e y s w it c h le f t o n . If
F S 1 o r th e f o o t s w it c h is c lo s e d th e n th e v e h ic le is e it h e r a b o u t t o m o v e o r is m o v in g , a n d
t h e t r a c t io n p u ls in g is u s e d if t h e t r u c k w a s n e u t r a l b r a k in g ( p u ls in g ) d o w n a lo n g ra m p ,
w h e n it is c o n c e iv a b le t h a t n e it h e r o f t h e 2 s w it c h e s w o u ld b e c lo s e d .
A n in d e p e n d e n t in p u t p in (c o n n e c to r 1 , p in 1 4 ) a ls o e x is t s t o t r ig g e r p o w e r s t e e r o p e r a t io n .
T h is is n o r m a lly u s e d in c o n ju c t io n w it h a s t e e r o n d e m a n d s y s te m w h e re a n o u t p u t is
g e n e ra te d w h e n th e s te e r in g w h e e l is t u r n e d . T h is g iv e s p o w e r s te e r o n d e m a n d a n d is
m o r e e f f ic ie n t s in c e t y p ic a lly n o s t e e r in g d e la y , o r o n ly a s h o u rt d e la y is n e e d e d .
T h e in d e p e n d e n t t r ig g e r o n ly , o r o t h e r t r ig g e r c o m b in a t io n s c a n b e c o n f ig u re d if n e c e s s a r y .
S o m e v e h ic le s d e r iv e t h e p o w e r s t e e r in g a s s is t a n c e f r o m t h e m a in p u m p h y d r a u lic m o t o r
in s t e a d o f h a v in g a s e p a r a t e s t e e r m o t o r . In t h is s it u a t io n t h e t r ig g e r is f e d t o t h e p u m p
c o n t r o lle r a n d r u n s t h e p u m p a t t h e s p e e d s e t b y t h e P . S . s p e e d p e r s o n a lit y .
In d e p e n d e n t r a m p u p a n d r a m p d o w n d e la y s a r e p r o v id e d w h e n p o w e r s t e e r a s s is t a n c e
is d r iv e d f r o m t h e m a in p u m p c o n t r o lle r , t o h e lp t u n e s t e e r in g r e s p o n s iv e n e s s w it h o u t
a f f e c t in g t h e m a in p u m p o p e r a t io n .
8 .1 .2 R e g e n B r a k in g
R e g e n p ro v id e s v e h ic le b r a k in g b y c o n t r o llin g t h e m o t o r a s a g e n e r a t o r a n d r e t u r n in g t h e
g e n e ra te d e n e rg y b a c k t o t h e b a t t e r y , w h ic h in t u r n r e d u c e s h e a t d is s ip a t io n in t h e m o t o r .
R e g e n e r a t iv e b ra k in g c a n b e in it ia t e d in n 3 w a y s , e a c h w it h a n in d e p e n d e n t ly s e t a b le
b r a k in g le v e l, a s fo llo w s :
1 . A d ir e c t io n s w it c h c h a n g e w ill in it ia t e r e g e n b r a k in g a t a le v e l s e t b y th e d ir e c t io n b r a k e
c u r r e n t le v e l. B r a k in g e f f o r t is p r o p o r t io n a l to th e a c c e le r a t o r p o s it io n , w it h a m in im u m
a c c e le r a t o r p e d a l p o s it io n g iv in g 5 0 % o f th e s e t b r a k e le v e l in c r e a s in g to 1 0 0 % fo r a
f u lly d e p r e s s e d p e d a l. T h e p r o p o r t io n a lit y fe a t u r e is o p t io n a l a n d c a n b e c o n f ig u r e d t o
g iv e f ix e d b r a k in g a t t h e s e t p e r s o n a lit y le v e l.
2 . C lo s u r e o f th e fo o tb ra k e s w it c h in n e u t r a l, w ill in it ia t e r e g e n b r a k in g a t t h e f o o t b r a k e
p e rs o n a lit y le v e l. A n in p u t is p r o v id e d t o a llo w b r a k in g e f f o r t t o b e p r o p o r t io n a l t o t h e
fo o tb ra k e p o s it io n if a p o t e n t io m e t e r is f it t e d . S e t t in g a 0 in o t t h e p e r s o n a lit y d is a b le s
b r a k in g o n th e fo o tb ra k e s w it c h .
3 . W h e n n e u tr a l is s e le c te d , re g e n is in it ia te d a t th e n e u tra l b ra k e c u rre n t le v e l. S e t t in g
a 0 in t o t h e p e rs o n a lit y d is a b le s n e u t r a l b r a k in g a n d a llo w s fre e w h e e lin g . N e u tra l
b r a k in g w ill o n ly b e a tte m p te d if t h e % o n in t h e p re v io u s d ir e c t io n e x c e e d e d 2 0 %
a b o v e th e s e t c re e p le v e l. T h is h e lp s m in im is e u n n e c e s s a r y d e la y s a n d c o n ta c to r
o p e r a t io n s .
R e g e n b r a k in g is s o m e t im e s n o t p o s s ib le a t lo w s p e e d s d e p e n d in g o n t h e m o to r
c h a r a c t e r is t ic . T o h e lp p r e v e n t u n n e c e s s a r y d e la y s a t t e m p t in g t o r e g e n , a re g e n s p e e d
a d ju s t m e n t is o f f e r e d w h ic h c a n b e s e t s o t h a t r e g e n is o n ly a t t e m p t e d a b o v e c e r t a in
s p e e d s , k n o w n to in it ia t e r e g e n . L o w e r n u m b e r s s e t a llo w t h e c o n t r o lle r t o a tte m p t re g e n
a t lo w s p e e d s w h ils t p r o g r e s s iv e ly h ig h e r n u m b e r s o n ly a llo w r e g e n t o b e a tte m p te d a t
h ig h e r s p e e d s w h e n r e g e n is m o re lik e ly t o b e s u c c e s s f u lly in it ia t e d . W h e n th e s p e e d
is le s s t h a n t h e s e t re g e n s p e e d a d ju s t m e n t e it h e r p lu g b r a k in g o r f r e e w h e e lin g w ill
b e in it ia t e d in s t e a d .
T o w a rd s th e e n d o f t h e r e g e n b r a k in g c y c le , p lu g b r a k in g is in it ia t e d t o b r in g t h e m o to r
to a c o m p le t e s t o p . T h is h a p p e n s o n a d ir e c t io n c h a n g e re g e n c y c le , b u t is o p t io n a l
fo r th e fo o t b ra k e a n d n e u t r a l b r a k in g c y c le s , in w h ic h c a s e th e tru c k m a y fre e w h e e l
s lig h t ly a t th e e n d . T h e s w it c h in g f r e q u e n c y in r e g e n is v a r ia b le d u e t o t h e c u rre n t
b e in g c o n t r o lle d b y p e a k a n d t r o u g h le v e ls i. e . t h e M O S F E T S a re tu rn e d o ff w h e n th e
c u rre n t h a s f a lle n b e lo w t h is le v e l.
8 .1 .3 P lu g B r a k in g
P lu g b r a k in g is a c h ie v e d b y c o n t r o llin g t h e r o t a t in g m o t o r a r m a t u r e a s a g e n e r a t o r
a n d d is s ip a t in g m o s t o f t h e e n e r g y in t o t h e m o t o r a n d t h e p lu g d io d e .
P lu g b r a k in g is in it ia t e d in p lu g g in g o n ly c o n t r o lle r s e x a c t ly a s th e re g e n m o d e s o f
o p e r a t io n d e s c r ib e d p r e v io u s ly , o n a d ir e c t io n c h a n g e , fo o tb ra k e s w it c h a n d in n e u t r a l.
P lu g g in g a ls o o p e r a te s o n re g e n c o n tro lle r s if t h e t r u c k h a s b e e n tra v e llin g to o s lo w ly
t o in it ia t e re g e n -b ra k in g , d e t e r m in e d b y th e re g e n s p e e d s e t t in g , o r a t th e e n d o f a
re g e n b ra k in g c y c le .
T h e s w it c h in g f r e q u e n c y is a ls o v a r ia b le in t h e p lu g b r a k in g m o d e , s im ila r t o t h e r e g e n
d e s c r ip t io n a b o v e .
8 .1 .4 B ra k e C o n s ta n t F a c to r
T h is a d ju s t m e n t h a s b e e n a d d e d t o m a t c h b r a k in g le v e ls a n d im p r o v e t h e t r a n s it io n
b e t w e e n r e g e n a n d p lu g b r a k in g . It a ls o s a v e s h a v in g 3 a d d it io n a l p lu g b r a k e
p e r s o n a lit ie s f o r d ir e c t io n c h a n g e , f o o t b r a k e a n d n e u t r a l s e t t in g s o n r e g e n c o n t r o lle r s .
In r e g e n c o n t r o lle r s it w o rk s b y m u lt ip ly in g th e 3 a d ju s t a b le re g e n c u rre n ts , d ir e c t io n
c h a n g e , fo o tb ra k e a n d n e u tra l, b y th e b ra k e c o n s ta n t fa c to r to o b t a in t h e p lu g b r a k in g
le v e l. E . g . if r e g e n in n e u t r a l is o p e r a t in g a t 1 0 0 A , a fa c to r o f 0 .8 w o u ld g iv e 8 0 A o f
p lu g b r a k in g a t t h e e n d o f th e c y c le , w h ils t a fa c to r o f 1 .7 w o u ld g iv e 1 7 0 A o f p lu g
b r a k in g .
In p lu g o n ly c o n t r o lle r s t h is a d ju s t m e n t is n o t n e c e s s a r y a s t h e 3 b r a k in g a d ju s t m e n t s
a r e n o w d e d ic a t e d t o p lu g b r a k in g le v e ls o n ly .
8 .1 .5 A n t i- R o llb a c k
T h is is a s t a n d a r d f e a t u r e a n d is u s e d t o h e lp p r e v e n t r o ll b a c k c o n d it io n s o n r a m p s .
It w o r k s o n t h e b a s is t h a t if t h e s a m e d ir e c t io n is r e s e le c t e d a f t e r a n e u t r a l c o n d it io n ,
t h e n b r a k in g is n o t c h e c k f o r a n d f u ll d r iv e p o w e r is a v a ila b le t o r e s t a r t o n a h ill.
8 .1 .6 A n a lo g u e In p u t s
T h e t r a c t io n a c c e le r a t o r in p u t, a s w e ll a s th e o th e r 3 a n a lo g u e in p u t s a r e v e r y f le x ib le
in t h e ra n g e o f in p u t s t h e y c a n a c c o m m o d a te a n d c a n b e a d ju s t e d t o m in im is e
d e a d b a n d s a n d m e c h a n ic a l t o le ra n c e s . E a c h o f th e 4 a n a lo g u e in p u ts h a v e 2
a d ju s tm e n t s a s s o c ia t e d w it h t h e m , th a t e f f e c t iv e ly a llo w s th e in p u t v o lt a g e r a n g e
to b e d e te r m in e d .
O n t h e t r a c t io n a c c e le r a t o r in p u t f o r e x a m p le , t h e in p u t v o lt a g e w h ic h d e f in e s t h e
m in im u m p u ls in g le v e l a n d t h e v o lt a g e w h ic h d e f in e s t h e m a x im u m p u ls in g c a n b e
a d ju s t e d , d e p e n d in g o n t h e t y p e o f a c c e le r a t o r u n it a n d t h e w a y it is c o n n e c t e d .
F o r th e tra c t io n a c c e le r a t o r t h e 2 a d ju s t m e n t s a re c a lle d th e a c c e le r a to r z e ro le v e l
a n d th e a c c e le r a t o r f u ll le v e l. If t h e s e a r e s e t t o 0 .2 V a n d 4 .8 V fo r e x a m p le t h e n 0 %
p u ls in g w ill s t a r t a t 0 . 2 V a t t h e in p u t , in c r e a s in g to 4 .8 V fo r 1 0 0 % o n . F o r a c c e le r a t o r s
w it h d e c re a s in g v o lt a g e o u t p u t s , t h e z e r o a d ju s tm e n t m ig h t b e s e t to 3 .5 V a n d t h e f u ll
a d ju s t m e n t t o 0 . 0 V f o r e x a m p le .
U s in g t h e C A N c o n tr o lle r t e s t in f o r m a t io n , s e t - u p o f t h e a n a lo g u e in p u t s is s t r a ig h t
fo rw a rd a s it d is p la y s th e a c tu a l v o lt a g e r a n g e o f t h e in p u t p in , a s w e ll a s t h e e q u iv a le n t
% in r a n g e w h ic h t h e v o lt a g e w ill b e in t e r p r e t e d a s . T h e r e is a s h o r t - c u t f a c ilit y o n t h e
c a lib r a t o r w h ic h a llo w s e a s y s w a p p in g b e t w e e n t h e in p u t v o lt a g e a n d % r a n g e d is p la y s
a n d th e z e ro a n d f u ll a d ju s t m e n t p e rs o n a lit y s e t t in g s , b y s im p le p r e s s in g t h e d o w n
b u tto n o n c e , t o a id s e t-u p .
F o r f u r t h e r f le x ib ilit y 3 o f t h e 4 a n a lo g u e in p u t s h a v e f e e d s u p p ly o u t p u t s a s s o c ia te d
w it h t h e m t h a t a llo w c o n n e c t io n o f 3 w ir e p o t e n t io m e t e rs o r a c c e le r a t o r u n it s . F o r
p o t e n t io m e t e r s w ir e d a s 2 w ir e s y s t e m s , le a v e t h e o u t p ut p in u n c o n n e c t e d . F o r
v o lt a g e s o u r c in g a c c e le r a t o r u n it s t h a t d e r iv e t h e ir o w n p
o w e r s u p p lie s , c o n n e c t th e
a s s o c ia t e d s u p p ly p in t o 0 V . T h is d is a b le s a n in t e r n a l p u ll u p r e s is t o r a n d p r e s e n ts
t h e p in a s a h ig h im p e d a n c e in p u t . T h e F ig . 1 w ir in g d ia g r a m s h o w s a n e x a m p le
o f e a c h w a y o f c o n n e c t in g t h e a n a lo g u e in p u t s .
8 .1 .7 T r a c t io n A c c e le r a t o r
W h e n d r iv e is s e le c t e d a n d t h e a c c e le r a t o r is f ir s t p r e s s e d , p u ls in g w ill c o m m e n c e
a t t h e c r e e p s p e e d s e t t in g in c r e a s in g t o w a r d s t h e m a x im u m % o n .
If t h e a c c e le r a t o r is d e p r e s s e d a t p o w e r u p , p u ls in g w ill b e in h ib it e d a n d a 6 f la s h f a u lt
w ill b e in d ic a t e d , u n t il t h e p e d a l is r e le a s e d . In c a s e o f a w ir e o f f t y p e f a u lt , p u ls in g w ill
b e lim it e d t o t h e c r e e p s e t t in g a n d a 6 f la s h f a u lt w ill a ls o b e g iv e n .
Is s u e 0 3 /2 0 0 6
P a g e 1 7
8 .1 .8 D ig it a l S w it c h In p u t s
T h e d ig it a l s w it c h in p u ts o n th e c o n t r o lle r c a n b e c o n f ig u re d a s a c t iv e lo w in p u ts , w h e re
t h e s w it c h e s a r e w ir e d to B -v e , o r a s a c t iv e h ig h in p u ts w h e re th e s w it c h e s a re c o n n e c te d
to B + v e . T h e s ta n d a rd is a c t iv e lo w , a n d is re c o m m e n d e d fo r it ' s lo w im p e d a n c e in p u t
s t a g e a n d im m u n it y t o m o is t u r e r e la t e d p r o b le m s . A c t iv e h ig h in p u t s a re a h a rd w a r e
o p t io n .
a d d it io n a f u r t h e r c o n
In f ig u r a t io n a llo w s e a c h in p u t t o b e s p e c if ie d a s n o r m a lly o p e n
o r n o r m a lly c lo s e d . M o s t s w it c h e s a re n o rm a lly o p e n , w it h t h e e x c e p t io n o f th e 2 s p e e d
c u t b a c k s w it c h in p u t s w ih ic h a r e n o rm a lly c lo s e d , s o th a t a w ir e o f f t y p e f a u lt , o r b a d
c o n n e c t io n in it ia t e s t h e c u tb a c k s p e e d , ra th e r t h a n a h ig h e r s p e e d . O n c o m p e n s a te d
p u m p s y s te m s th e p o w e r s te e r in p u t c a n b e c o n v e n ie n t ly c o n f ig u r e d a s n o r m a lly c lo s e d .
8 .1 .9 C o n ta c to rs
T h e r e a r e u p t o 8 o u t p u t s f o r d r iv in g c o n t a c t o r s a s d e s c r ib e d in p r e v io u s s e c t io n s . It is
a ls o p o s s ib le t o r e c o n f ig u r e o n e o f t h e o u t p u t s , n o r m a lly c o n t a c t o r d r iv e 8 , a s a n
e x te r n a l L E D o r la m p d r iv e r t o a llo w d a s h b o a r d in d ic a t io n o f t h e c o n t r o lle r s in t e g r a l
L E D .
T h e c o n tro lle r c a n d ia g o n s e n o n c lo s u r e , o p e n c ir c u it (o / c ) a n d s h o r t c ir c u it (s /c )
p r o b le m s w it h c e r t a in c o n ta c to rs , a s d e s c r ib e d in t h e d ia g n o s t ic s e c t io n . G e n e r a lly ,
f o llo w in g r e q u e s t to c lo s e o r o p e n a c o n ta c to r, th e c o n t r o lle r w ill re p o rt a 4 f la s h f a u lt ,
a n d a c a lib ra to r m e s s a g e a fte r a p p r o x im a t e ly 5 0 0 m s e c o n d s if a s u c c e s s fu l o p e r a t io n
w a s n o t d e te c te d .
A n o p t io n a l lin e c o n ta c to r c a n b e c o n n e c te d b e tw e e n th e B + te rm in a l o f t h e c o n t r o lle r
a n d b a tte ry p o s it iv e t o h e lp p r e v e n t la r g e c u r r e n t s f lo w in g th ro u g h th e b a tte ry c o n n e c to rs
a n d in t o t h e in t e rn a l c a p a c it o r s w h e n t h e c o n t r o lle r is t f ir s t c o n n e c te d to th e b a tte ry .
O n c e th e c a p a c it o r s h a v e c h a r g e d u p (v ia in t e r n a l r e s is t a n c e ) a n d a f t e r t h e k e y s w it c h
h a s b e e n s w it c h e d o n , t h e lin e c o n t a c t o r w ill b e e n e r g is e d . A n in t e r n a l d io d e f it t e d in t h e
k e y s w it c h lin e w ill p r e v e n t a n y c o n t a c t o r e n e r g is in g if t h e p o la r it y o f t h e b a t t e r y v o lt a g e is
re v e rs e d . O n p u m p c o n t r o lle r s t h e lin e c o n t a c t o r a ls o g iv e s a m e c h a n ic a l b r e a k .
U n d e r n o r m a l o p e r a t in g c o n d it io n s w ill o p e r a t e w it h o u t a r c in g . H o w e v e r , u n d e r c e r t a in
f a u lt c o n d it io n s , c o n t a c t o r s m a y a r c w h e n o p e n in g . T h e b y p a s s c o n t a c t o r m a y a ls o a r c
d u r in g b y p a s s o v e r - c u r r e n t d r o p o u t c o n d it io n s .
8 . 1 . 1 0 C o n t a c t o r C h o p p in g
T h is f e a t u r e a llo w s 2 4 v o lt c o n t a c t o r s t o b e u s e d a t a ll b a t e r y v o lt a g e s 2 4 V - 9 6 V , b y
c o n t in u o u s ly m o n it o r in g t h e b a t t e r y v o lt a g e a n d c h o p p in g t h e c o n t a c t o r o u t p u t p in s
a c c o r d in g ly , t o p r e s e n t a n a v e r a g e v o lt a g e s u it a b le f o r 2 4 V c o ils . C h o p p in g is s e le c t a b le
b y t h e c a lib r a t o r . A ll t h e c o n t a c t o r d r iv e s w ill b e e it h e r c h o p p e d o r n o t c h o p p e d . It is n o t
p o s s ib le t o s e le c t in d iv id u a l d r iv e s t o c h o p . C a r e m u s t b e t a k e n t o e n s u r e t h a t c h o p p in g
is a lw a y s > 2 4 v o lt s c o n t a c t o r s m u s t b e f it t e d w it h b lo w o u t m a g n e t s .
Is s u e 0 3 /2 0 0 6
P a g e 1 8
T h is f e a t u r e c a n r e d u c e t h e o v e r a ll d is s ip a t io n in t h e c o ils a n d a llo w s o n ly o n e s e t o f
c o n t a c t o r s t o b e s t o c k e d f o r a ll b a t t e r y v o lt a g e s .
C h o p p in g f r e q u e n c y a p p r o x . : 6 5 0 H z ( s lig h t ly a u d ib le a t h ig h e r b a t t e r y v o lt a g e s )
T y p ic a l c o n t a c t o r c o il v o lt a g e d u r in g c h o p p in g : 1 6 v o lt s
T y p ic a l c o n t a c t o r c o il v o lt a g e d u r in g e n e r g is a t io n : 2 4 v o lt s ( 1 s e c o n d )
8 . 1 . 1 1 F a il- S a f e
T h e c o n tro lle r s s a fe ty s y s te m h a s b o th h a rd w a re w a tc h d o g a n d s o f t w a r e f a il- s a f e s y s t e m s

to p re v e n t d a n g e ro u s ru n a w a y c o n d it io n s . In a d d it io n , e v e r y t im e t h e c o n t r o lle r is p o w e r e d
u p a n a u to f a ils a fe c h e c k is c a r r ie d o u t , w h ic h c h e c k s a n d g u a ra n te e s th a t th e h a rd w a re
w a tc h d o g c ir c u it is a b le t o s w it c h o f f a ll t h e M O S F E T S a n d o p e n a ll c o n t a c t o r s , if
re q u e s te d b y th m ic r o p r o c e s s o r o r if t h e m ic r o p ro c e s s o r s y s te m it s e lf h a s f a ile d .
T h e m ic r o p r o c e s s o r a ls o h a s a n in t e r n a l w a t c h d o g t im e r , w h ic h w ill r e s e t t h e s y s t e m ,
d is a b lin g a ll M O S F E T a n d c o n t a c t o r d r iv e s , o n t h e e v e n t o f a s o f t w a r e c r a s h o r f a ilu r e .
8 . 1 . 1 2 D u a l M o t o r T r a c t io n N o n P r o p o r t io n a l O p e r a t io n
D u a l m o to r n o n p r o p o r t io n a l t r a c t io n s y s t e m s a re c a t e r e d f o r b y r e a s s ig n in g 2 c o n t a c t o r
d r iv e s fo r th e a d d it io n a l s e t o f d ir e c t io n c o n t a c to rs r e q u ir e d f o r t h e s e c o n d t r a c t io n m o t o r .
A ll t h e a d d it io n a l c ir c u it r y r e q u ir e d is in t e g r a l t o th e c o n t r o lle r f o r e it h e r s t a n d a lo n e d u a l
m o to r t r a c t io n c o n t r o lle r s o r d u a l m o to r c o n tro lle r s p u m p .
8 . 1 . 1 3 D u a l M o t o r T r a c t io n P r o p o r t io n a l O p e r a t io n
D u a l m o t o r p r o p o r t io n a l s y s t e m s r e q u ir e 2 in d e p e n d e n t c h o p p e rs to c o n tro l e a c h
m o t o r in d e p e n d e n t ly t o p r o v id e s t e e r in g . T h e f e a t u r e s a v a ila b le a r e s im ila r t o th e
n o n p r o p o r t io n a l s y s t e m , a lt h o u g h s p e c if y in g a p u m p c h o p p e r n o w r e q u ir e s a n
a d d it io n a l c o n t r o lle r . A fa c to r (d u a l m o to r s te e r f a c t o r ) is u s e d t o o p t im is e t u r n in g
p e rfo rm a n c e d e p e n d in g o n w h e e l b a s e g e o m e tr y . (L e n g th fr o m d r iv e t o s t e e r w h e e l/
w id t h b e t w e e n d r iv e w h e e ls ).
Is s u e 0 3 /2 0 0 6
P a g e 1 9
8 .2 P u m p O p e r a t io n
8 .2 .1 P u m p O p e r a t io n
T h e r e is n o s t a r t - u p s e q u e n c e s o p u ls in g w ill b e in it ia t e d a f t e r a s m a ll d e la y a t p o w e r-u p
if o n e o r m o r e o f t h e p u m p s w it c h e s is s e le c te d . T h e r e a r e a d ju s ta b le ra m p u p a n d ra m p
d o w n d e la y s . A p u m p c o n ta c to r c a n b e s p e c if ie d a s a n o p t io n . T h e re a re fa c ilit ie s fo r
p r io r it is in g p u m p s p e e d s , f o r h a v in g d if f e r e n t p u m p s p e e d s a d d e d to g e th e r a n d fo r
h a v in g s p e e d c o m p e n s a t io n f o r d if f e r e n t lo a d c o n d it io n s .
8 .2 .2 P u m p S p e e d s A n d P r io r it ie s
T h e p u m p s p e e d s a r e p r io r it is e d in n u m e r ic a l o r d e r s o t h a t s p e e d 1 h a s p r io r it y o v e r
a ll o t h e r s p e e d s a n d s p e e d 2 h a s p r io r it y o v e r s p e e d s 3 t o 7 , e t c .
T h e r e a r e 7 in d e p e n d e n t ly a d ju s t a b le s p e e d s f o r e a c h o f t h e 7 p u m p s w it c h in p u t s .
A s s o o n a s p u m p s w it c h 1 is c lo s e d t h e % o n w ill r a p id ly r a m p u p t o t h e a d ju s t a b le
p u m p c r e e p s e t t in g .
8 .2 .3 A d d it iv e S p e e d s
T h e r e is a ls o a n a d d it iv e f e a t u r e a v a ila b le o n p u m p s w it c h e s 5 , 6 a n d 7 w h ic h is
s e le c t e d w h e n t h e p e r s o n a lit y a f t e r t h e re s p e c t iv e p u m p s p e e d a d ju s t m e n t is s e t t o
" a d d it iv e " . W h e n t h is a d ju s t m e n t is s e t to p r io r it y th e p u m p s p e e d s b e h a v e a s
d e s c r ib e d in 8 . 2 . 2 . T h e a d d it iv e f e a t u r e w o rk s b y a d d in g a s p e e d s e le c t e d b y e it h e r
p u m p s w it c h 5 , 6 o r 7 t o a n o t h e r s e le c te d s p e e d t o g iv e in c re a s e d p o w e r t o h a n d le t h e
s im u lt a n e o u s p u m p o p e r a t io n s .
8 .2 .4 P u m p A c c e le r a t o r In p u t
T h e p u m p a c c e le r a t o r d e m a n d is a s s o c ia t e d w it h s p e e d 1 . T h e p u m p w ill o p e ra te a t
th e c re e p s p e e d s e t t in g w h e n t h e a c c e le r a t o r is a t m in im u m d e m a n d a n d c h a n g e
lin e a r ly t o s p e e d 1 a s th e a c c e le r a t o r is in c r e a s e d to th e m a x im u m d e m a n d . T h e
p u m p p o t a c c e le r a t o r in p u t c a n b e c o n n e c te d a n d a jd u s te d a s p e r th e p re v io u s ly
d e s c r ib e d t r a c t io n a c c e le r a t o r in p u t .
8 .2 .5 P u m p In h ib it In p u t
T h is in p u t c a n b e u s e d in c o n ju n c t io n w it h e x t e r n a l e q u ip m e n t s u c h a s a s e p a r a t e
B D I u n it f o r e x a m p le , t o d is a b le p u m p o p e r a t io n w h e n t h e b a t t e r y is lo w . A ll p u m p
s p e e d s a r e in h ib it e d e x c e p t t h e p o w e r s t e e r s p e e d .
Is s u e 0 3 /2 0 0 6
P a g e 2 0
8 .3 G e n e r a l O p e r a t io n
8 .3 .1 O p e r a t in g F r e q u e n c y
T h e d r iv e f r e q u e n c y o f b o th th e tra c t io n a n d p u m p p o w e r fra m e s is 1 5 . 6 7 K h z , fo r
s ile n t o p e r a t io n . F o r t r a c t io n p lu g a n d re g e n - b r a k in g th e fre q u e n c y w ill v a r y s in c e
t h e c o n t r o lle r s a lg o r it h m w o rk s o n p e a k a n d tro u g h ty p e c o n t r o l, a n d w ill d e p e n d
o n t h e s e t b r a k in g c u rre n ts , m o to r c h a ra c t e r is t ic s a n d th e s p e e d o f th e tru c k . In
s o m e a p p lic a t io n s p u ls in g m a y b e s lig h t ly a u d ib le d u r in g b ra k in g .
8 .3 .2 T e m p e r a t u r e M o n it o r in g
If t h e t e m p e r a t u r e o f e it h e r p o w e r fra m e e x c e e d s 7 5 ° C it s m a x im u m a v a ila b le
c u r r e n t w ill b e r e d u c e d . T h is is to e n s u re th a t th e m a x im u m h e a t s in k t e m p e ra tu re
is lim it e d t o 9 5 ° C . W h e n t h e te m p e ra tu re o f e it h e r p o w e r fra m e e x c e e d s 7 5 ° C th e
d ia g n o s t ic L E D w ill f la s h 8 t im e s . In s p e c t io n o f th e c a lib r a to r fa u lt m e s s a g e s w ill
in d ic a t e w h ic h u n it is in t h e rm a l c u tb a c k .
8 .3 .3 S a f e O p e r a t in g A r e a (S O A )
T h e m a x im u m c u r r e n t o f e a c h c o n t r o lle r w ill b e lim it e d a t h ig h a n d lo w d u t y c y c le s

( p e r c e n t a g e o n s ) d e p e n d in g o n t h e p a r t ic u la r u n it s p o w e r . T h is r e d u c e s t h e t h e r m a l
s t r e s s o n t h e p o w e r c o m p o n e n t s a n d h a s b e e n im p le m e n t e d t o in c r e a s e lo n g t e r m
r e lia b ilit y .
8 .3 .4 U n d e r v o lt a g e
If t h e a v e r g e b a tte ry v o lt a g e f a lls b e lo w a p r e - s e t v o lt a g e , t h e c o n t r o lle r w ill s t o p

p u ls in g a n d t h e d ia g n o s t ic L E D w ill f la s h 7 t im e s , u n t il t h e v o lt a g e r is e s a b o v e th e
t h r e s h o ld le v e l, a n d n e u t r a l is s e le c t e d o n t r a c t io n a n d p u m p . T h e lo w b a t t e r y v o lt a g e
t h r e s h o ld c a n b e a d ju s t e d b u t is n o t a g e n e r a lly a v a ila b le c a lib r a t o r f e a t u r e . F o r
4 8 V c o n t r o lle r s th e th r e s h o ld is t y p ic a lly s e t t o 1 4 . 4 V w h ils t f o r 8 0 V u n it s t h e le v e l
is 4 3 . 0 V . T h e s e le v e ls r e p r e s e n t 6 0 % o f t h e lo w e s t n o m in a l b a t t e r y v o lt a g e .
Is s u e 0 3 /2 0 0 6
P a g e 2 1
8 .3 .5 D ia g n o s t ic L E D
T h is is m o u n t e d b e t w e e n t h e c o n n e c t o r s o n t h e f r o n t o f t h e c o n t r o lle r . It s e r v e s a s
a s im p le d ia g n o s t ic t o o l a s e x p la in e d b e lo w :
C o n s t a n t illu m in a t io n : N o f a u lt , n o r m a l c o n d it io n
L E D e x t in g u is h e d : In t e r n a l c o n t r o lle r f a u lt
2 f la s h e s : Ille g a l s t a r t c o n d it io n (t r a c t io n )
3 f la s h e s : B y p a s s c o n ta c to r w e ld e d
4 f la s h e s : C o n t a c t o r f a u lt o r m o t o r o p e n - c ir c u it
5 f la s h e s : C a p a c it o r f a u lt
6 f la s h e s : A c c e le r a t o r f a u lt
7 f la s h e s : L o w b a t t e r y v o lt a g e
8 f la s h e s : O v e r te m p e ra tu re
9 f la s h e s : C o n t a c t o r c o il s / c
F u r t h e r e x p la n a t io n o f t h e L E D f la s h e s a r e d is p la y e d o n t h e c a lib r a t o r f a u lt m e s s a g e
s e c t io n .
8 .3 .6 F a u lt C le a r a n c e
A n y f a u lt in d ic a t io n w ill b e c le a r e d b y r e - in it ia t in g t h e s t a r t s e q u e n c e a f t e r t h e c a u s e
o f t h e f a u lt h a s b e e n r e m o v e d .
Is s u e 0 3 /2 0 0 6
P a g e 2 2
Is s u e 0 3 /2 0 0 6
P a g e 2 3
S C 2 5 x x
D im e n s io n s
4 8 V 4 2 4 m m (" X " = 2 1 2 m m )
8 0 V 5 2 2 m m (" X " = 2 6 1 m m )
P a g e 2 4
P lu g A 1 - 2 4
P lu g C a n d D 1 -6
Is s u e 0 3 /2 0 0 6
P lu g B 1 - 1 2
S E V C O N P O W E R P A K
T h is u s e r m a n u a l d e t a ils t h e f e a t u r e s o f t h e f o llo w in g P o w e r p a K S e r ie s c o n t r o lle r s a n d v a r ia n t s .
1 . T r a c t io n S e r ie s 2 4 -4 8 V 3 0 0 A M e d . I/ O L o g ic
5 . P u m p S e r ie s 2 4 -4 8 V 3 0 0 A P u m p I/ O L o g ic
9 . T r a c t io n S e r ie s 2 4 -4 8 V 3 0 0 A H ig h I/ O L o g ic
1 0 . T r a c t io n S e r ie s 2 4 -4 8 V 4 5 0 A H ig h I/ O L o g ic
1 1 . T r a c t io n S e r ie s 2 4 -4 8 V 6 5 0 A H ig h I/ O L o g ic
Is s u e 0 3 /2 0 0 6
P a g e 2 6
1 .1 T h e P o w e rp a K ra n g e o f c o n tro lle r s u s e s a n e w c o n c e p t in p o w e r s w it c h in g t e c h n o lo g y
to p ro v id e a f u ll r a n g e o f p o w e r fra m e s 2 4 V -8 0 V , 3 0 0 -6 5 0 A in o n e s m a ll, h ig h ly e f f ic ie n t
p a c k a g e . T h is is a c h ie v e d u s in g a n e w p o w e r s w it c h in g s c h e m e a n d r a d ic a l n e w
c o n s tru c t io n t e c h n iq u e s , b o th th e s u b je c t o f p a t e n t a p p lic a t io n s , w h ic h e n a b le la r g e
p o w e rs to b e in c o r p o r a t e d in t o v e ry s m a ll p a c k a g e s .
T h e P o w e rp a K ra n g e o f c o n t r o lle r s a r e a v a ila b le in s ta n d a lo n e t r a c t io n a n d p u m p
fo rm a ts , w it h t h e tra c t io n o f f e r in g e it h e r r e g e n a n d p lu g b ra k in g o r p lu g b r a k in g o n ly . T o
im p ro v e f le x ib ilit y a n d s e r v ic e a b ilit y t h e lo g ic is p lu g g e d in t o th e p o w e r fra m e a n d c a n b e
re m o v e d e a s ily w it h o u t d is t u r b in g t h e p o w e r c o n n e c t io n s o r h a v in g t o re m o v e th e p o w e r
fra m e c o v e r.
T o f u r t h e r in c r e a s e f le x ib ilit y a n d t r a ilo r t h e c o n t r o lle r t o s p e c if ic a p p lic a t io n s , t h e r e a r e 3

c o r e v e r s io n s o f lo g ic w h ic h v a r y in c o m p le x it y a n d t h e a m o u n t o f I/ O , in p u t a n d o u t p u t
f u n c t io n s , t o h e lp e n s u r e t h e m o s t c o s t e f f e c t iv e c o n t r o lle r p a c k a g e is o f f e r e d f o r a
p a r t ic u la r a p p lic a t io n . T h e lo w I/ O lo g ic is a m in im u m f e a t u r e lo g ic a im e d a t w a lk ie s a n d
b a s ic f o r k lif t t r u c k a p p lic a t io n s . T h e m e d iu m lo g ic is m o r e s u it a b le f o r m o r e s o p h is t ic a t e d
v e h ic le s in c lu d in g f o r k lif t a n d r e a c h t r u c k t y p e s , w h ils t t h e h ig h I/ O lo g ic is t a r g e t e d a t
t h e a e r ia l lif t m a r k e t w h e r e in c r e a s e d I/ O is r e q u ir e d . A ll lo g ic s h a v e C A N
c o m m u n ic a t io n s .
A ll P o w e r p a K c o n t r o lle r s a r e m ic r o p r o c e s s o r b a s e d w it h f le x ib le s o f t w a r e a n d s e t u p
o p t io n s , a n d u s e h ig h f r e q u e n c y M O S F E T p o w e r s w it c h in g t e c h n o lo g y . C o n t r o lle r s h a v e
b e e n d e s ig n e d t o s a t is f y t h e r e q u ir e m e n t s o f t h e r e le v a n t U L a n d E C s t a n d a r d s .
P o w e r p a K c o n t r o lle r s h a v e b e e n o p t im is e d f o r u s e w it h C . S . s e r ie s w o u n d m o t o r s . T h e r e
is a s e p a r a t e r a n g e o f P o w e r p a K S E M c o n t r o lle r s .
P a g e 2 7
2 . P o w e r p a K C o n t r o lle r V a r ia n t s
3 . C o n t r o lle r F e a t u r e s W it h T h e D if f e r e n t L o g ic V a r ia n t s
P a g e 2 9
4 . S a fe ty
4 .1 E le c t r ic v e h ic le s c a n b e d a n g e ro u s . A ll t e s t in g , f a u lt - f in d in g a n d a d ju s t m e n t s h o u ld b e
c a r r ie d o u t b y c o m p e te n t p e rs o n n e l. T h e d r iv e w h e e ls s h o u ld b e o f f t h e f lo o r a n d f r e e t o
ro ta te d u r in g th e fo llo w in g p r o c e d u re s . T h e v e h ic le m a n u f a c t u r e r ' s m a n u a l s o u ld b e
c o n s u lt e d b e fo re a n y o p e r a t io n is a tte m p t.
4 .2 T h e P o w e r p a K c o n t r o lle r c o n t a in s a t r ip le f a il- s a f e s y s t e m t o g iv e a h ig h le v e l o f s a f e t y . If
t h e d ia g n o s t ic L E D is n o t illu m in a t e d o r f la s h e s , t h e s a f e t y c ir c u it m a y h a v e t r ip p e d a n d
t h e t r u c k m a y n o t d r iv e .
4 .3 T o e n s u r e c o n t in u e d s a f e t y P o w e r p a K s y s t e m , t h e f a il- s a f e c ir c u it s h o u ld b e c h e c k e d
w h e n e v e r t h e t r u c k is s e r v ic e d . T h e p e r io d b e t w e e n c h e c k s s h o u ld n o t e x c e e d 3 m o n t h s .
4 .4 T h e b a t t e r y m u s t b e d is c o n n e c t e d b e f o r e r e p la c in g o r a t t e m p t in g a n y r e p a ir s o f t h e
c o n t r o ls .
4 .5 B e f o r e w o r k in g o n t h e c o n t r o ls d is c o n n e c t t h e b a t t e r y a n d c o n n e c t B + a n d B - c o n t r o lle r
t e r m in a ls v ia a 1 0 o h m 2 5 w a t t r e s is t o r t o d is c h a r g e t h e in t e r n a l c a p a c it o r s .
4 .6 N e v e r c o n t a c t t h e c o n t r o lle r t o a b a t t e r y w it h it s v e n t c a p s r e m o v e d a s a n a r c m a y o c c u r
d u e t o t h e c o n t r o lle r s in t e r n a l c a p a c it a n c e w h e n it is f ir s t c o n n e c t e d .
4 .7 F a il- S a f e C h e c k :
4 .7 .1 E n s u r e t h e d r iv e w h e e ls a r e c le a r o f t h e f lo o r a n d f r e e t o r o t a t e .
4 .7 .2 S w it c h o n , s e le c t s e a t s w it c h , r e le a s e b r a k e , s e le c t d ir e c t io n a n d F S 1 , t h e w h e e ls s h o u ld
r o t a t e a n d t h e d ia g n o s t ic L E D s h o u ld g iv e a s t e a d y illu m in a t io n .
4 .7 .3 S w it c h o f f , d is c o n n e c t b a t t e r y a n d c o n n e c t t h e A a n d B - t e r m in a ls t o g e t h e r w it h , a t le a s t ,
1 0 m m ² c a b le . E n x u r e t h a t n o t o t h e r f a u lt t h a t w o u ld a llo w d r iv e is p r e s e n t .
4 .7 .4 R e c o n n e c t b a t t e r y , s w it c h o n k e y w it h d ir e c t io n in n e u t r a l. T h e L E D s h o u ld s t a y o f f . S e le c t
a d ir e c t io n a n d c h e c k t h a t t h e d ir e c t io n c o n t a c t o r s d o n o t c lo s e a n d t h e w h e e ls d o n o t
ro ta te .
4 .7 .5 S w it c h o f f a t k e y a n d r e m o v e t h e A / B - c o n n e c t io n . S w it c h o n a t k e y , r e s e le c t t h e p o w e r -
u p s e q u e n c e a n d c h e c k t h a t t h e L E D illu m in a t e s a n d t h e t r u c k w h e e ls r o t a t e . If t h e t r u c k
d r iv e s in 4 . 7 . 4 t h e c o n t r o lle r is f a u lt y a n d m u s t b e r e p la c e d .
4 .8 . A s b lo w - o u t m a g n e ts a re f it t e d t o c o n t a c t o r s (e x c e p t 2 4 V ) e n s u r e t h a t n o m a g n e t ic
p a r t ic le s c a n a c c u m u la t e in t h e c o n t a c t g a p s a n d c a u s e m a lf u n c t io n . E n s u r e t h a t
c o n ta c to rs a re w ir e d w it h t h e c o r r e c t p o la r it y t o t h e ir p o w e r t e r m in a ls a s in d ic a t e d b y t h e +
s ig n o n th e to p m o u ld in g .
4 .9 T h e P o w e r p a K c o n t r o lle r m u s t n o t b e u s e d w it h p e r m a n e n t ly - c o n n e c t e d o n - b o a r d
c h a r g e r s o r d a m a g e t o t h e s y s t e m m a y r e s u lt .
Is s u e 0 3 /2 0 0 6
P a g e 3 0
5 . T e c h n ic a l S p e c if ic a t io n s
5 .1 E le c t r ic a l
5 .1 .1 V o lt a g e s p e c if ic a t io n s
5 .1 .2 C u r r e n t s p e c if ic a t io n s :
5 .1 .3 S w it c h in g F r e q u e n c y : 1 6 K H Z t r a c t io n / r e g e n / p u m p d r iv e a n d 6 K H Z
p lu g b r a k in g .
5 .1 .4 E le c t r ic a l Is o la t io n : E n c lo s u r e t o a n y liv e p a r t = 1 K V . C o n t r o lle r
in t e r n a l in s u la t io n s p e c if ie d a t > 1 0 0 M O h m @ 5 0 0 V D C .
D ie le c t r ic s t r e n g t h 1 0 0 0 V @ 5 0 H z f o r 1 m in u t e .
5 .1 .5 B a t t e r y P la r it y : A lin e c o n t a c t o r f r o m t h e k e y s w it c h , w it h a 2 A d io d e in
s e r ie s w it h t h e c o il, w ill p r e v e n t lin e c o n t a c t o r c lo s u r e
if t h e b a t t e r y p o s it iv e a n d n e g a t iv e c o n n e c t io n s a r e
re v e rs e d .
5 .2 E n v ir o n m e n t a l
5 . 2 . 1 . 1 P r o t e c t io n - L o g ic T h e e n c lo s u r e is p ro te c te d to IP 6 6 .
1 s t d ig it (6 ) = P r o t e c t io n a g a in s t d u s t in g r e s s
2 n d d ig it ( 6 ) = P r o t e c t io n a g a in s t h ig h p r e s s u r e je t s o f
w a t e r in a n y d ir e c t io n .
5 . 2 . 1 . 2 P r o t e c t io n - P o w e r F r a m e : T h e e n c lo s u r e is p r o t e c te d to IP 5 5 .
1 s t d ig it ( 5 ) = L im it e d d u s t in g re s s p e r m it t e d
2 n d d ig it ( 5 ) = P r o t e c t io n a g a in s t lo w p r e s s u r e je t s o f
w a t e r in a n y d ir e c t io n . L im it e d in g r e s s
p e r m it t e d .
5 .2 .2 V ib r a t io n : 6 G , 4 0 - 2 0 0 H z f o r 1 h o u r , in x , y a n d z p la n e s .
5 .2 .3 O p e r a t in g T e m p e r a t u r e : - 3 0 ° C t o + 4 0 ° C a m b ie n t a r o u n d c o n t r o lle r .
Is s u e 0 3 /2 0 0 6
P a g e 3 1
5 .2 .4 S to ra g e T e m p e ra tu re : -4 0 ° C to + 7 0 ° C .
5 .2 .5 H u m id it y : 9 5 % m a x im u m , n o n - c o n d e n s in g .
5 .2 .6 H u m id it y R e s is t a n c e : N o f u n c t io n a l d e f e c t s a f t e r c o n t r o lle r is le f t a t 6 0 ° C
1 0 0 % h u m id it y f o r o n e h o u r a f t e r f r e e z e r u s e (- 3 0 ° C
m in im u m ).
5 .2 .7 H a lt : P o w e r p a K h a s b e e n h ig h ly a c c e le r a t e d lif e t e s t e d .
5 .3 M e c h a n ic a l
5 .3 .1 U n it s iz e ( a ll u n it s ): L e n g t h 1 4 2 m m , W id t h 1 4 2 m m , H e ig h t 1 4 0 m m w it h
lo g ic f it t e d . ( H ig h t is 8 6 m m w it h lo g ic u n p lu g g e d ).
5 .3 .2 E n c lo s u r e : A lu m in iu m d ie c a s t b a s e - p la t e w it h A B S p la s t ic
in je c t io n m o u ld e d p o w e r f r a m e a n d lo g ic c o v e r s .
5 .3 .3 P o w e r C o n n e c t io n s : A lu m in iu m v e r t ic a l p o w e r b u s h e s f o r M 8 c o n n e c t io n .
5 .3 .4 F ix in g s : 4 x M 6 c le a r a n c e h o le s .
5 .3 .5 W e ig h t : 1 .8 k g
5 .4 L o g ic I/ O S p e c if ic a t io n s
5 .4 .1 S w it c h / D ig it a l In p u t s :
O p e r a t io n : A c t iv e - lo w ( t h e in p u t b e c o m e s a c t iv e w h e n c o n n e c t e d
t o b a t t e r y n e g a t iv e , o t h e r w is e in a c t iv e ) .
V o lt a g e R a n g e : L o w ( C lo s e d ) - 1 . 0 t o + 1 . 8 V
H ig h (O p e n ) + 4 . 5 t o 1 5 0 V ( o r o p e n - c ir c iu t )
In p u t Im p e d a n c e : M a x . r e s is t a n c e t o g r o u n d f o r a ' lo w ' = 5 0 0 O h m .
M in . r e s is t a n c e t o g r o u n d f o r a ' h ig h ' = 2 . 7 k O h m
N o t e : N e g a t iv e s w it c h r e t u r n s m u s t b e c o n n e c t e d t o
c o n t r o lle r B - t e r m in a l a n d n o t a t b a t t e r y n e g a t iv e .
5 .4 .2 A n a lo g u e In p u t s : 0 - 5 V in p u t s a v a ila b le a n d 5 K p o t e n t io m e t e r / 3 V 5 - 0 V
in p u t s a v a ila b le . F u lly p r o t e c t e d i/ p s a n d t h r e s h o ld
s e t t a b le .
5 .4 .3 S u p p ly o u t p u t : A n u n r e g u la t d + 1 2 V . 5 m A p o w e r s u p p ly is a v a ila b le
f o r s u p p ly in g a c c e le r a t o r s , s p e e d s e n s o r s , e t c .
5 .4 .4 C o n t a c t o r D r iv e s : M a x im u m C u r r e n t: 2 A
P r o t e c t io n : D r iv e s a r e p r o t e c t e d a g a in s t d ir e c t c o n n e c t io n t o
B + a n d B -.
S u p p r e s s io n : C o il s u p p r e s s io n b u ilt - in .
+ v e c o il s u p p ly L o g ic v a r ia n t d e p e n d a n t , s e e w ir in g d ia g r a m s f ig s . 1 - 3 .
6 . C o n t r o lle r W ir in g A n d C o n n e c t io n s
6 .1 .1 P o w e r C o n n e c t io n s
S e e p o w e r w ir in g d ia g r a m s f o r s p e c if ic c o n n e c t io n s .
6 .1 .2 P o w e r w ir in g
M in im u m c a b le s iz e s : C u r r e n t lim it s u p t o 5 0 0 A 3 5 m m ²
6 5 0 A 5 0 m m ²
6 .1 .3 F u s e r a t in g s
M a x im u m f u s e r a t in g s : C u r r e n t lim it s u p t o 3 0 0 A 3 2 5 A (a ir b r e a k )
4 5 0 A 5 0 0 A ( a ir b r e a k )
6 5 0 A 7 0 0 A ( a ir b r e a k )
6 .1 .4 C o n ta c to r T y p e s
T h e r e c o m m e n d e d c o n t a c t o r s f o r c o n t r o lle r s w it h c u r r e n t lim it s u p t o 3 0 0 A a r e :
L in e ( O p tio n ) A lb r ig h t S W 8 0 C o n tin u o u s R a tin g

D ir e c t io n
A lb r ig h t D C 8 8 In te rm itte n t R a tin g
R e g e n
(O p tio n ) A lb r ig h t D C 8 4 C o n tin u o u s R a tin g
T ra c t io n B y p a s s
(O p tio n ) A lb r ig h t S W 8 0 In te rm itte n t R a tin g
F ie ld W e a k e n in g
(O p tio n ) A lb r ig h t S W 8 0 In te rm itte n t R a tin g
P o w e r S te e r
(O p tio n ) A lb r ig h t S W 8 0 C o n tin u o u s R a tin g
T h e r e c o m m e n d e d c o n t a c t o r s f o r c o n t r o lle r s w it h c u r r e n t lim it s u p t o 4 5 0 A a r e :
L in e
D ir e c t io n
R e g e n ( O p tio n a l) A lb r ig h t S W 1 8 0 C o n tin u o u s R a tin g
T ra c t io n B y p a s s A lb r ig h t D C 1 8 2 In te rm itte n t R a tin g
F ie (O
ld W e a k e n in g p tio n a l) A lb r ig h t S W 1 8 1 C o n tin u o u s R a tin g
P o w e r S te e r (O p tio n a l) A lb r ig h t S W 1 8 0 In te rm itte n t R a tin g
(O p tio n a l) A lb r ig h t S W 8 0 In te rm itte n t R a tin g
T h e r e c o m m e n d e d c o n( O t a p c t t i oo rn s a f l o) r c o n t r o l l A e r l bs r wi g i ht h t Sc u W r r 8 e 0n t l i m i t s u p o nt o t i n 6
C u5 o0 uA s a R r ea :t in g
L in e
D ir e c t io n
R e g e n
T ra c t io n B y p a s s ( O p tio n a l) A lb r ig h t S W 2 0 0 C o n tin u o u s R a tin g
F ie ld W e a k in g A lb r ig h t S W 2 0 2 In te rm itte n t R a tin g
P o w e r S te e r (O p tio n a l) A lb r ig h t S W 2 0 1 C o n tin u o u s R a tin g
(O p tio n a l) A lb r ig h t S W 2 0 0 In te rm itte n t R a tin g
(O p tio n a l) A lb r ig h t S W 8 0 In te rm itte n t R a tin g
I t i s r e c o m m e n d e d t h a (t O 2 p4 t iVo nc ao l n) t a c t o r s a A r e l b u r si g e hd t tS o Wg e 8 t h0 e r w i t h tC h o e n c t ih n o i up op u i n s g R f ea a t i tn u g r e .
6 .1 .5 R e g e n D io d e - a v a ila b le a n d c o n n e c t e d a s f o llo w s :
C a th o d e L e a d c o n n e c t e d t o r e g e n c o n t a c t o r c o m m o n t e r m in a l.
A n o d e S t u d s c r e w e d in t o r e g e n c o n t a c t o r B - .
6 .2 L ig h t W ir in g C o n n e c t io n s (F ig . 1 )
T h e f o llo w in g s e c t io n d e t a ils th e c o n n e c to rs o n t h e m in im u m , m e d iu m a n d h ig h lo g ic s .
T h e m in im u m lo g ic h a s 2 c o n n e c to rs , 1 fo r th e v e h ic le / c o n t a c t o r c o n n e c t io n s a n d 1 fo r
s e r ia l c o m m u n ic a t io n s . T h e m e d iu m I/ O lo g ic h a s 3 c o n n e c to rs , 1 fo r t h e v e h ic le I/ O
c o n n e c t io n s , 1 fo r th e c o n ta c to r c o n n e c t io n s a n d 1 f o r s e r ia l c o m m u n ic a t io n s . T h e h ig h
lo g ic h a s 3 c o n n e c t o r s in t o t a l, 1 f o r t h e v e h ic le c o n n e c t io n s , 1 fo r th e c o n ta c to r
c o n n e c t io n s , a n d 1 f o r s e r ia l c o m m u n ic a t io n s .
C u s t o m e r C o n n e c t o r & C o n t r o lle r In t e r c o n n e c t P in O u t s
N o te 1
T h e u s e r c a n c o n f ig u r e t h e s e in p u t s t o b e a n y o f t h e f o llo w in g : N o n e , S p e e d 1 , S p e e d 2 , S p e e d 3 ,
In c h F w d , In c h R e v , P u m p , P o w e r S t e e r T r ig g e r , H a n d b r a k e , F o o t b r a k e .
N o te 2
T h e u s e r c a n c o n f ig u r e t h is in p u t t o b e a n y o f t h e f o llo w in g : N o n e , S p e e d 1 , S p e e d 2 , S p e e d 3 ,
In c h F w d , In c h R e v , P u m p , P o w e r S t e e r T r ig g e r , H a n d b r a k e , F o o t b r a k e , S p e e d E n c o d e r .
Is s u e 0 3 /2 0 0 6
P a g e 3 4
6 .2 .3 S e r ia l C o m m u n ic a t io n s O v e r v ie w
T h e P o w e rp a K h a s a s ta n d a r d s e r ia l c o m m u n ic a t io n s in t e r f a c e f o r c o n n e c t io n t o a
S E V C O N C a lib r a t o r a n d o t h e r f u t u r e S E V C O N p r o d u c t s . A s e p e r a t e T T L t o R S 2 3 2 le v e l
c o n v e rte r m o d u le is a v a ila b le f r o m S E V C O N t o a llo w c o n n e c t io n t o a P C .
6 .2 .4 C A N (C o n t r o lle r A r e a N e tw o rk ) O v e rv ie w
C A N is a n a c ro n y m fo r C o n tro lle r A r e a N e t w o r k . It is a b u s s y s t e m , m e a n in g t h a t it is a
c o lle c t io n o f in t e llig e n t "n o d e s " w h ic h a r e c o n n e c t e d t o t h e s a m e p h y s ic a l p ie c e o f w ir e . If
o n e n o d e t r a n s m it t s s o m e t h in g o n th e w ir e , a ll n o d e s w ill r e c e iv e it ( in c lu d in g t h e o n e d o in g
th e tra n s m it t in g ) .
C A N b u s w a s d e v e lo p e d ( in 1 9 8 4 ) b y B o s c h , th e G e rm a n e le c tro n ic s m a n u fa c tu re r, fo r u s e
in r o a d v e h ic le s . T h e a im o f C A N b u s is t o r e d u c e v e h ic le w ir in g , a s a ll e le c t r ic a l f u n c t io n s
(s u c h a s lig h t s , e le c t r ic w in d o w s , ig n it io n ) s h a re th e s a m e p h y s ic a l w ir e . It s e m p h a s is o n
r e lia b le d a ta tra n s m is s io n h a s m a d e it p o p u la r w it h m a n u fa c tu re r s o f in d u s t r ia l e q u ip m e n t
a n d m a t e r ia ls h a n d lin g v e h ic le s .
T h e m a in a p p lic a t io n s f o r C A N c o m m u n ic a t io n s a r e a u t o m o t iv e a n d in d u s t r ia l e le c t r o n ic s
w h e r e h ig h s p e e d , n o is e im m u n e s e r ia l c o m m u n ic a t io n s a r e r e q u ir e d t o w o r k r e lia b ly in
h ig h v ib r a t io n a n d h ig h t e m p e r a t u r e e n v ir o n m e n t s .
T h e m a in a p p lic a t io n s f o r C A N c o m m u n ic a t io n s a r e a u t o m o t iv e a n d in d u s t r ia l e le c t r o n ic s
w h e r e h ig h s p e e d , n o is e im m u n e s e r ia l c o m m u n ic a t io n s a r e r e q u ir e d t o w o r k r e lia b ly in
h ig h v ib r a t io n a n d h ig h t e m p e r a t u r e e n v ir o n m e n t s .
S E V C O N ' s C A N s y s t e m is d e f in e d a s C A N 2 . 0 A (B a s ic C A N , e r r o r a c t iv e ) a n d is
im p le m e n t e d u s in g a P h ilip s S e m ic o n d u c t o r c h ip - s e t w it h a n 8 0 C 2 5 0 t r a n s c e iv e r c h ip .
T h e P o w e r p a K C A N p r o t o c o l s e t s t h e b a u d r a t e t o b e 1 0 0 K b it s p e r s e c o n d .
Is s u e 0 3 /2 0 0 6
P a g e 3 5
C a n is e x tre m e ly f le x ib le a n d v e r s a t ile , a llo w in g m u lt i- m a s te r o p e r a t io n in a s e r ia l

c o m m u n ic a t io n n e tw o rk w it h a n a lm o s t u n lim it e d n u m b e r o f n o d e s . D a ta ra te s o f u p to 1
M b it / s a re p o s s ib le t r a n s m it t in g o v e r d is t a n c e s o f u p to 4 0 m e te r s , w it h a v e r y lo w
p ro b a b ilit y o f u n d e te c te d e rro rs . C A N is b a s ic a lly a 2 -w ir e t w is t e d - p a ir d if f e r e n t ia l s y s te m
w it h 1 0 V 5 a n d 0 v s u p p ly r a ils . C o n n e c t io n s a r e m a d e v ia a 6 -w a y M o le x c o n n e c to r.
P r e s e n t ly t h e C A N b u s is u s e d t o c o m m u n ic a t e w it h t h e c a lib r a t o r . It c a n b e u s e d t o
c o m m u n ic a t e w it h a d a s h b o a r d d is p la y a n d f o r r e m o t e c o n t r o l f r o m a h o s t P C . L o n g t e r m ,
c o m m u n ic a t io n s w it h a u x ilia r y c o n t r o lle r s a n d e q u ip m e n t w ill b e p o s s ib le .
E . g . b a t t e r y c h a r g e r s , s t a n d a lo n e p o w e r s t e e r c o n t r o lle r s , c o n t r o lle r I/ O e x p a n d e r s
. . . e t c . A t p r e s e n t it is p o s s ib le t o c o n n e c t u p t o 8 p ie c e s o f e q u ip m e n t o n t o t h e C A N b u s .
7 . C a lib r a t o r A n d A d ju s t m e n t
A s o p h is t ic a t e d , y e t e a s y t o u s e h a n d h e ld a d ju s t m e n t u n it ,
c a lle d t h e C a lib r a t o r is u s e d t o m a k e a d ju s t m e n t s t o t h e
c o n t r o lle r a n d s e le c t c o n f ig u r a t io n s . T h e C a lib r a t o r is a ls o
u s e d a s a d ia g n o s t ic t o o l d is p la y in g t h e s t a t u s o f a ll v o lt a g e s ,
c u rre n ts a n d t e m p e r a t u r e s w it h in t h e c o n t r o lle r t o g e t h e r w it h
th e c o n d it io n o f a ll t h e c o n t r o lle r ' s s w it c h a n d a n a lo g u e in p u t s .
T h e d ia g r a m b e lo w d e s c r ib e s h o w th e C a lib r a t o r is u s e d . T h e
le ft a n d r ig h t a r r o w s m o v e b e tw e e n s c re e n s o n th e s a m e le v e l.
T h e u p a n d d o w n a rro w s m o v e b e tw e e n le v e ls a n d t h e + a n d -
b u tto n s in c r e m e n t o r d e c re m e n t th e p a ra m e te rs b y th e a m o u n t
in d ic a t e d in t h e S T E P c o lu m n o f th e fo llo w in g t a b le s .
T h e c a lib r a t o r C A N b e s p e c if ie d t o h a v e v a r io u s le v e ls o f
a c c e s s t o c e r t a in a d ju s t m e n t s .
Is s u e 0 3 /2 0 0 6
P a g e 3 7
7 . 1 . 1 T r a c t io n C o n t r o lle r P e r s o n a lit ie s ( C o n t r o lle r A d ju s t m e n t s )

Is s u e 0 3 /2 0 0 6
P a g e 3 8
7 . 1 . 2 T r a c t io n C o n t r o lle r S t a t u s In f o r m a t io n
7 . 1 . 3 T r a c t io n C o n t r o lle r T e s t In f o r m a t io n
7 . 1 . 4 B D I A d ju s t m e n t s ( if e n a b le d in s e t u p m e n u )
7 . 1 . 5 F a u lt L o g
C a n b e d is a b le d v ia s e t u p m e n u . S e e s e c t io n 9 f o r m o r e d e t a ils
7 . 1 . 6 T r a c t io n C o n t r o lle r S e t u p M e n u ( E n a b le s / D is a b le s f e a t u r e s )
7 . 2 . 1 P u m p C o n t r o lle r P e r s o n a lit ie s ( C o n t r o lle r A d ju s t m e n t s )

7 . 2 . 2 P u m p C o n t r o lle r S t a t u s In f o r m a t io n
7 . 2 . 3 P u m p C o n t r o lle r T e s t In f o r m a t io n
7 .2 .4 P u m p B D I (a s T r a c t io n 7 . 1 . 4 )
7 . 2 . 5 P u m p F a u lt L o g ( a s T r a c t io n 7 . 1 . 5 )
7 . 2 . 6 P u m p S e t u p M e n u E n a b le s / D is a b le s F e a t u r e s
7 . 3 . 1 T r a c t io n A n d P u m p A d ju s t m e n t D e s c r ip t io n
Is s u e 0 3 /2 0 0 6
P a g e 4 2
7 . 3 . 2 B D I A d ju s t m e n t D e s c r ip t io n
7 . 3 . 3 S e t u p M e n u D e s c r ip t io n
Is s u e 0 3 /2 0 0 6
P a g e 4
8 . D ia g n o s t ic s
T r a c t io n a n d P u m p F a u lt M e s s a g e s a n d L E D s t a t u s / n u m b e r o f f la s h e s
Is s u e 0 3 /2 0 0 6
P a g e 4 4
9 . S e r v ic e A n d F a u lt L o g s (A ll L o g ic s )
T h e s e r v ic e a n d f a u lt lo g s h a v e b e e n in c o r p o r a t e d t o a llo w e n d u s e r s a n d s e r v ic e
p e r s o n n e l t o in s p e c t a n d n o t e t h e c o n t r o lle r ' s p e r f o r m a n c e a n d f a u lt h is t o r y . U t ilis in g th e
c o n t r o lle r ' s e x is t in g s t a t u s m e a s u r e m e n t s a n d d ia g n o s t ic s c a p a b ilit ie s , in f o r m a t io n ( s u c h
a s t h e m a x im u m te m p e r a t u r e t h e c o n t r o lle r h a s o p e r a t e d a t o r t h e n u m b e r a n d t y p e o f
f a u lt s t h a t h a v e b e e n d e t e c t e d ) c a n b e s t o r e d in n o n - v o la t ile m e m o r y a n d p r e s e n t e d a t a
la t e r d a t e . B o t h th e s e r v ic e a n d f a u lt lo g s c a n b e s e le c t e d / d e s e le c t e d v ia t h e s e t u p m e n u
o n t h e c a lib r a t o r, a n d w h e n s e le c t e d c a n b e c le a r e d a t a n y t im e t o s t a r t r e c o r d in g n e w
d a ta .
9 .1 S e r v ic e L o g
S e r v ic e in f o r m a t io n is a v a ila b le in t h e t r a c t io n a n d p u m p s t a t u s m e n u s , w h e r e h o ld in g
d o w n th e ' + ' k e y s h o w s t h e m a x im u m v a lu e o f t h e c u r r e n t it e m , a n d h o ld in g d o w n t h e ' - '
k e y s h o w s t h e m in im u m v a lu e . T h e f o llo w in g it e m s a r e lo g g e d :
- M a x im u m b a t t e r y v o lt a g e
- M a x im u m m o to r c u rre n t
- M a x im u m c o n t r o lle r t e m p e r a t u r e a n d m in im u m c o n t r o lle r t e m p e r a t u r e .
T o c le a r t h e lo g , a c c e s s t h e " s e r v ic e lo g + t o r e s e t lo g " m e s s a g e a t t h e e n d o f t h e s t a t u s
m e n u , a n d f o llo w t h e p r o m p t s . T h e s e r v ic e lo g c a n b e e n a b le d a n d d is a b le d in t h e s e t u p
m e n u .
9 .2 F a u lt L o g
T h e f a u lt lo g is a v a ila b le a t lo c a t io n 1 .5 o n th e c a lib r a t o r . F a u lt s a r e g r o u p e d t o g e t h e r b y
" L E D f la s h fa u lt " ; th e ty p e s o f f la s h fa u lt a n d w h e th e r e a c h is lo g g e d is s h o w n b e lo w .
G e n e r a lly fa u lt s t h a t c a n o c c u r d u r in g n o rm a l o p e r a t io n e .g . a 2 f la s h d r iv e r p r o c e d u r e
e rro r o r a n 8 f la s h th e rm a l c u tb a c k in d ic a t io n , a r e n o t lo g g e d .
- L E D o ff fa u lt s L o g g e d ( In t e r n a l c o n t r o lle r p o w e r u p c h e c k f a u lt s )
- 1 f la s h fa u lt s L o g g e d ( P e r s o n a lit y / C R C f a u lt s )
- 2 f la s h fa u lt s N o t L o g g e d ( D r iv e r p r o c e d u r e / s e q u e n c e / w ir in g t y p e f a u lt s )
- 3 f la s h fa u lt s L o g g e d ( M O S F E T / b y p a s s w ir in g t y p e f a u lt s
- 4 f la s h fa u lt s L o g g e d ( C o n t a c t o r O / c o r s / c o r w ir in g t y p e f a u lt s )
- 5 f la s h fa u lt s N o t L o g g e d (N o t u s e d )
- 6 f la s h fa u lt s N o t L o g g e d ( P o t e n t io m e t e r w ir e o f f t y p e f a u lt s )
- 7 f la s h fa u lt s L o g g e d ( B a t t e r y lo w o r h ig h f a u lt s )
- 8 f la s h fa u lt s N o t L o g g e d ( T h e r m a l c u t b a c k f a u lt s )
- 9 f la s h fa u lt s L o g g e d (C o n t a c t o r c o il s / c t y p e f a u lt s )
E a c h o f t h e a b o v e lo g g e d c a t e g o r ie s c o n t a in s - T h e t o t a l n u m b e r o f f a u lt s o f t h is t y p e , t h e
k e y h o u r s c o u n t o f t h e m o s t r e c e n t f a u lt a n d a t e x t d e s c r ip t io n o f t h e f a u lt . A n e x a m p le o f
h o w t h e f a u lt lo g in f o r m a t io n is p r e s e n t e d is s h o w n b e lo w :
Is s u e 0 3 /2 0 0 6
P a g e 4 5
1 2 *0 4 F 1 2 3 4 5 .6 h r T h is d is p la y s h o w s t h a t 1 2 4 - f la s h f a u lt s h a v e o c c u r e d a n d b e e n
C o n ta c to r c /o lo g g e d , t h e m o s t r e c e n t a t 1 2 3 4 5 . 6 k e y h o u r s a n d it w a s a
c o n t a c t o r o / c f a u lt .
O n c e in t o t h e f a u lt lo g m e n u , t h e le f t a n d r ig h t a r r o w s a r e u s e d t o v ie w a n y f a u lt s s t o r e d a n d a t t h e
e n d o f t h e lis t a " f a u lt lo g + t o r e s e t lo g " m e s s a g e is s h o w n , w h e r e t h e f a u lt lo g c a n b e r e s e t in a
s im ila r w a y t o t h e s e r v ic e lo g . T h e f a u lt lo g c a n b e e n a b le d a n d d is a b le d in t h e s e t u p m e n u .
Is s u e 0 3 /2 0 0 6
P a g e 4 6
1 0 . C o n t r o lle r O p e r a t io n A n d F e a t u r e D e s c r ip t io n s
1 0 .1 T r a c t io n O p e r a t io n - A p p lic a b le t o a ll t r a c t io n lo g ic s u n le s s o t h e r w is e s p e c if ie d .
1 0 .1 .1 S ta rt U p S e q u e n c e
A t k e y s w it c h o n , t h e d ir e c t io n a n d F S 1 s w it c h e s m u s t b e in t h e n e u t r a l c o n d it io n
s im u lt a n e o u s ly a t le a s t o n c e b e f o r e d r iv e c a n b e s e le c t e d . T h is is a s a f e t y f e a t u r e t o h e lp
p re v e n t u n e x p e c t e d m o v e m e n t im m e d ia t e ly a f t e r p o w e r u p .
1 0 .1 .2 S R O ( S t a t ic re tu rn to o ff)
T h is fe a tu re is o p t io n a l in t h e s e t u p m e n u a n d w h e n s p e c if ie d , fo rc e s th e f o llo w in g
s e q u e n c e s o f s w it c h in p u t s t o b e f o llo w e d b e f o r e d r iv e is a llo w e d : K e y s w it c h - d ir e c t io n -
F S 1 o r k e y s w it c h - F S 1 - d ir e c t io n (w it h in 2 s e c o n d s o f F S 1 ) . A n y o th e r s e q u e n c e w ill n o t
a llo w d r iv e . D r iv e w ill b e in h ib it e d if F S 1 is a c t iv e f o r m o r e t h a n 2 s e c o n d s w it h n o
d ir e c t io n s e le c t e d . In t h is c a s e t h e F S 1 w ill n e e d t o b e r e c y c le d .
1 0 . 1 . 3 S e a t S w it c h
If t h e s e a t s w it c h is o p e n e d a n d t h e s e a t s w it c h t im e r h a s t im e d o u t d u r in g d r iv e t h e
c o n t r o lle r w ill s t o p p u ls in g a n d a s e a t f a u lt w ill b e in d ic a t e d . B e f o r e d r iv e c a n b e r e s t a r t e d
t h e s e a t s w it c h m u s t b e c lo s e d , a n d F S 1 a n d t h e d ir e c t io n s w it c h m u s t b e r e c y c le d
t h r o u g h n e u t r a l. N o t e t h e s t a r t s e q u e n c e f o r d r iv e r e q u ir e s t h a t t h e s e a t s w it c h is c lo s e d
a n d b o t h t h e d ir e c t io n a n d F S 1 s w it c h e s a r e in t h e n e u t r a l p o s it io n s im u lt a n e o u s ly b e f o r e
d r iv e c a n b e in it ia t e d . T h e t im e p e r io d is p r o g r a m m e d b y m e a n s o f t h e c a lib r a t o r ( s e a t
s w it c h d e la y ). A s a s e t u p m e n u o p t io n t h e s e a t s w it c h c a n a ls o in h ib it p u m p o p e r a t io n if
r e q u ir e d . T h e r e a r e a ls o a d d it io n a l s e a t s w it c h s t a r t u p s e q u e n c e s a v a ila b le a s o p t io n s ,
a lt h o u g h t h e a b o v e d e s c r ib e d S E V O N s t a n d a r d is r e c o m m e n d e d .
1 0 . 1 . 4 B e lly S w it c h (n o t a v a ila b le o h n h ig h I/ O lo g ic )
A b e lly s w it c h f u n c t io n is a v a ila b le w h e n th e c o n t r o lle r is u s e d o n a w a lk ie t y p e t r u c k . T h e
fe a tu re c a n b e e n a b le d in t h e s e t u p m e n u . S e e t h is s e c t io n a n d w ir in g d ia g r a m s f o r
a d d it io n a l in f o r m a t io n . B a s ic o p e r a t io n is a s f o llo w s :
T ru c k m o v in g in r e v e r s e a n d a c t iv a t in g t h e b e lly s w it c h , a c c e le r a t o r in r e v e r s e p o s it io n :
a ) T h e c o n t a c t o r s c h a n g e d ir e c t io n t o f o r w a r d d r iv e ( t h is in it ia t e s p lu g b r a k in g ) .
b ) 1 5 0 % m a x im u m p lu g g in g is a p p lie d f o r a m x im u m o f 1 . 5 s e c o n d s , w h e n it w ill t h e n
re v e rt t o m a x im u m p lu g g in g .
c ) T h e v e h ic le w ill a c c e le r a t e a t f u ll s p e e d a lo n g t h e a c c e le ra to r c u rv e .
d ) A ll d r iv e w ill c e a s e 1 . 5 s e c o n d s f r o m t h e s t a r t o f ( c ) a b o v e .
e ) T h e c o n t r o lle r w ill w a it f o r n e u t r a l t o b e s e le c t e d b e f o r e d r iv e w ill o p e r a t e . If t h e b e lly
s w it c h is p r e s s e d a g a in , h o w e v e r , a c t io n a s a t c ) a b o v e .
A c c e le ra to r in n e u t r a l: A s a b o v e .
A c c e le ra to r in fo rw a rd p o s it io n : S ta rt a t c ) a b o v e .
T ru c k m o v in g in f o r w a rd a n d a c t iv a t in g t h e b e lly s w it c h , a c c e le r a t o r in f o r w a r d p o s it io n :
A c c e le ra to r in fo rw a rd p o s it io n : N o e ffe c t.
A c c e le ra to r in re v e rs e p o s it io n : B e lly s w it c h c lo s e d , t r u c k d r iv e s a s p e r s t a r t o f c ) a b o v e .
1 0 .1 .4 H a n d b r a k e S w it c h (n o t a v a ila b le o n lo w I/ O lo g ic )
A n in p u t is p r o v id e d fo r th e c o n n e c t io n o f a h a n d b r a k e s w it c h , w h ic h if o p e r a t e d w ill
d is a b le t r a c t io n p u ls in g b u t le a v e t h e d r iv e r e la t e d c o n t a c t o r s in p o s it io n t o e f f e c t a
m in im u m r o ll b a c k h ill s ta rt w h e n d r iv e is s e le c t e d a n d t h e h a n d b r a k e is r e le a s e d .
Is s u e 0 3 /2 0 0 6
P a g e 4 7
1 0 .1 .6 D e c e le r a t io n D e la y
T h is is a n a d ju s t a b le d e la y t o r a m p d o w n t h e p u ls in g f r o m 1 0 0 % o n t o 0 % o n , a n d c a n b e
u s e d t o lim it t h e in h e r e n t t r u c k lu r c h w h e n a c c e le r a t io n is in t e r r u p t e d . W h e n n e u t r a l is
s e le c t e d , c o n t a c t o r s a r e o n ly o p e n e d w h e n t h e % o n h a s r a m p e d d o w n t o 0 .
1 0 .1 .7 C re e p
T h e c r e e p s p e e d is a d ju s t a b le a n d is u s e d t o s e le c t a m in im u m p u ls in g le v e l a s s o o n a s
d r iv e is r e q u e s t e d , t o m in im is e d e la y s a n d d e a d - b a n d s . T h e m o t o r v o lt a g e is r a p id ly
ra m p e d t o t h e c r e e p le v e l (e q u iv a le n t t o a 1 0 0 m S a c c e le r a t io n d e la y ).
1 0 .1 .8 C u tb a c k S p e e d s
T h e r e a r e 2 c u t b a c k s w it c h in p u t s a s s t a n d a r d . A n a d d it io n a l c u t b a c k 3 f u n c t io n c a n b e
c o n f ig u r e d in t h e s e t u p m e n u . E a c h o n e h a s a n a s s o c ia t e d p e r s o n a lit y t o a d ju s t t h e
m a x im u m % o n w h e n t h e s w it c h is a c t iv e . In a d d it io n e a c h c u t b a c k h a s a n in d e p e n d e n t ly
a d ju s t a b le a c c e le r a t io n d e la y a s s o c ia t e d w it h it t o f u r t h e r e n h a n c e lo w s p e e d
m a n o e u v r a b ilit y . W h e n b o t h s w it c h e s a r e a c t iv e t o g e t h e r , t h e lo w e r s p e e d is s e le c t e d
t o g e t h e r w it h t h e s lo w e s t a c c e le r a t io n d e la y . T h e c u t b a c k s p e e d in p u t s a r e u s u a lly
n o r m a lly c lo s e d s o t h a t a w ir e o f f t y p e f a u lt o r b a d c o n n e c t io n in it ia t e s a lo w e r s p e e d .
W h e n t h e B D I f e a t u r e is e n a b le d a n d t h e c u t - o u t le v e l is r e a c h e d t h e s p e e d 2 c u t b a c k is
a u t o m a t ic a lly in it ia t e d .
A m a x im u m s p e e d a d ju s t m e n t is a ls o a v a ila b le t o lim it t h e m a x im u m a p p lie d 0 % o n . (If

t h e s e t t in g is le s s t h a n 9 5 % t h e n b y p a s s a n d f ie ld w e a k in g a r e d is a b le d ) .
1 0 .1 .9 B y p a s s ( n o t a v a ila b le o n lo w I/ O lo g ic )
T h e b y p a s s c o n t a c t o r is u s e d t o s h o r t o u t t h e m a in M O S F E T s w it c h in g d e v ic e t o in c r e a s e
s p e e d a n d e f f ic ie n c y a t h ig h s p e e d s a n d t o a llo w h ig h e r m o t o r c u r r e n t s t h a n t h e c o n t r o lle r s
m a x im u m c u r r e n t lim it , t o c lim b r a m p s la d e n o r t o e s c a p e f r o m r u t s o r p o t h o le s .
B y p a s s c a n b e in it ia t e d in 2 w a y s :
C u r r e n t - lim it B y p a s s :
T h e a c c e le r a t o r is f u lly d e p re s s e d a n d th e c o n t r o lle r h a s b e e n in c u r r e n t lim it f o r lo n g e r
t h a n 2 s e c o n d s . In o r d e r to p re v e n t a s u d d e n lu r c h o f t h e t r u c k t h e c o n t a c t o r w ill n o t b e
e n e r g is e d if t h e m o t o r v o lt a g e d u r in g c u r r e n t lim it is le s s t h a n 2 0 % b a t t e r y v o lt a g e . T h is
m o d e o f o p e r a t io n c a n b e d is a b le d v ia t h e s e tu p m e n u .
H ig h -s p e e d B y p a s s :
If t h e a c c e le r a t o r is f u lly d e p r e s s e d a n d t h e c o n t r o lle r h a s b e e n p u ls in g a t m a x im u m % o n
fo r 1 .5 s e c o n d s a n d t h e b y p a s s d e la y p e r s o n a lit y h a s t im e d o u t . T h e b y p a s s d e la y t im e r is
a fe a tu re th a t c a n b e u s e d t o a llo w t h e t r u c k t o o b t a in f u ll s p e e d , b e f o r e c o n t a c t o r c lo s u r e .
T h e b y b a s s c o n t a c t o r w ill b e d e - e n e r g is e d if t h e a c c e le r a t o r d e m a n d is r e d u c e d b e lo w 8 6
% , o r if t h e m o to r c u rre n t e x c e e d s th e b y p a s s o v e r-c u rre n t d ro p o u t le v e l, a d ju s t a b le b y th e
c a lib r a t o r . T o a llo w f o r in it ia l o v e r s h o o t s t h e o v e r - c u r r e n t t e s t is d is a b le d f o r t h e f ir s t 2
s e c o n d s o f b y p a s s . A lt h o u g h t h e s o f t w a r e a t t e m p t s t o m in im is e a r c in g w h e n t h e c o n t a c to r
o p e n s , s o m e a r c h in g is in e v it a b le u n d e r c e r t a in lo a d c o n d it io n s . A fte r a n o v e r- c u rre n t d ro p
o u t, th e b y p a s s f u n c t io n w ill b e in h ib it e d u n t il n e u t r a l is r e c y c le d to p re v e n t re p e a te d
o p e n in g a n d c lo s in g o f t h e t ip s u n d e r h e a v y c u r r e n t c o n d it io n s .
Is s u e 0 3 /2 0 0 6
P a g e 4 8
B y p a s s c a n b e d is a b le d b y s e t t in g t h e o v e r-c u rr e n t d ro p o u t to 0 A . A ls o b y p a s s w ill b e
d is a b le d if e it h e r o f th e 2 s p e e d c u tb a c k s w it c h e s a re e n a b le d a n d t h e s e t t in g s a r e
a d ju s te d b e lo w 9 5 % o r th e m a x im u m s p e e d s e t t in g is le s s th a n 9 5 % . A p p ly in g t h e
fo o tb ra k e s w it c h o r e c o n o m y > 0 % w ill a ls o p r e v e n t b y p a s s e c lo s u re .
1 0 .1 .1 0 F ie ld W e a k e n in g ( n o t a v a ila b le o n lo w I/ O lo g ic )
T h is is c a r r ie d o u t b y c o n n e c t in g a lo w v a lu e / h ig h w a tta g e re s is t o r c o n n e c t e d in s e r ie s
w it h a c o n t a c t o r a c r o s s t h e t r a c t io n m o to r f ie ld t o w e a k e n th e f ie ld a n d h e n c e in c r e a s e
s p e e d w h ils t r e d u c in g t o r q u e . A s a g u id e lin e t h e v a lu e o f th e r e s is t o r s h o u ld b e t h e s a m e
a s th e m o t o r f ile d r e s is t a n c e a n d it s h o u ld b e ra te d to c a r r y f ie ld c u r r e n t.
A t f u ll a c c e le r a t o r d e p r e s s io n a n d m a x im u m %
o n , a n d a fte r b y p a s s c o n t a c t o r c lo s u r e (if
f it t e d ) t h e f ie ld w e a k e n in g c o n t a c t o r is e n e r g is e d p r o v id in g t h e c u r r e n t is b e lo w t h e p u llin
le v e l. If t h e m o t o r c u r r e n t in c r e a s e s a b o v e th e d ro p - o u t le v e l o r t h e a c c e le r a t o r d e m a n d is
le s s t h a n 8 6 % o r th e b y p a s s c o n ta c to r is d e -e n e rg is e d , t h e f ie ld w e a k e n in g c o n t a c t o r w ill
b e o p e n e d . B o t h t h e f ie ld w e a k e n in g d ro p -o u t a n d p u llin c u r r e n t le v e s a r e a d ju s t e d w it h
t h e c a lib r a t o r .
1 0 .1 .1 1 P o w e r S te e r, T ra c t io n C o n t r o lle r
A c o n t a c t o r d r iv e is a v a ila b le t o c o n tro l a s e p a ra te p o w e r s te e r m o to r. A n a d ju s t a b le d e la y
a llo w s t h e m o t o r to o p e ra te fo r a s e t t im e , a fte r t h e p o w e r s t e e r t r ig g e r o r p o w e r s te e r
d e m a n d h a s b e e n re m o v e d . S V C O N 's s ta n d a rd t r ig g e r , i. e . w h e n t h e c o n ta c t o r is c lo s e d ,
is w h e n e it h e r F S 1 o r th e fo o tb ra k e s w it c h is c lo s e d , o r t h e t r a c t io n u n it is p u ls in g . It is a n
e it h e r - o r s it u a t io n , s o a n y o n e o f t h e s e 3 in p u ts is s u f f ic ie n t t o t r ig g e r t h e p o w e r s te e r.
T h is s t a n d a r d t r ig g e r is d e s ig n e d t o g iv e p o w e r s t e e r w h e n e v e r t h e t r u c k is m o v in g , b u t
n o t to h a v e a s it u a t io n w h e r e t h e p o w e r s t e e r c o u ld b e o n c o n t in u o u s ly , i. e . o n a d ir e c t io n
s w it c h w h e r e t h e t r u c k c o u ld b e le f t w it h a d ir e c t io n s e le c t e d a n d t h e k e y s w it c h le f t o n . If
F S 1 o r th e f o o t b r a k e is a p p lie d t h e n t h e v e h ic le is e it h e r a b o u t t o m o v e o r is m o v in g , a n d
t h e t r a c t io n p u ls in g is u s e d if t h e t r u c k w a s n e u t r a l b r a k in g ( p u ls in g ) d o w n a lo n g r a m p ,
w h e n it is c o n c e iv a b le t h a t n e it h e r o f t h e 2 s w it c h e s w o u ld b e c lo s e d . O n a to w -tra c to r,
p o w e r s te e r is d is a b le d d u r in g in c h in g .
A n in d e p e n d e n t in p u t p in (s e e f ig u r e s 2 + 3 ) a ls o e x is t s t o t r ig g e r p o w e r s te e r o p e r a t io n .
T h is is n o r m a lly u s e d in c o n ju n c t io n w it h a s te e r o n d e m a n d s y s te m w h e re a n o u t p u t is
g e n e ra te d w h e n th e s te e r in g w h e e l is t u rn e d . T h is g iv e s p o w e r s te e r o n d e m a n d a n d is
m o r e e f f ic ie n t s in c e ty p ic a lly n o s te e r in g d e la y , o r o n ly a s h o r t d e la y is n e e d e d .
T h e in d e p e n d e n t t r ig g e r o n ly , o r o t h e r t r ig g e r c o m b in a t io n s c a n b e c o n f ig u r e d if
n e c e s s a r y in t h e s e t u p m e n u .
S o m e v e h ic le s d e r iv e t h e p o w e r s t e e r in g a s s is t a n c e f r o m t h e m a in p u m p h y d r a u lic m o t o r ,
in s t e a d o f h a v in g a s e p a r a t e s t e e r m o t o r . In t h is s it u a t io n t h e t r ig g e r is f e d t o t h e p u m p
c o n t r o lle r a n d r u n s t h e p u m p a t t h e s p e e d s e t b y t h e P . S . s p e e d p e r s o n a lit y .
In d e p e n d e n t r a m p u p a n d r a m p d o w n d e la y s a r e p r o v id e d w h e n p o w e r s t e e r a s s is t a n c e
is d e r iv e d f r o m t h e m a in p u m p c o n t r o lle r , t o h e lp t u n e s t e e r in g r e s p o n s iv e n e s s w it h o u t
a f f e c t in g t h e m a in p u m p o p e r a t io n .
Is s u e 0 3 /2 0 0 6
P a g e 4 9
1 0 .1 .1 2 R e g e n B r a k in g
R e g e n p r o v id e s v e h ic le b r a k in g b y c o n t r o llin g t h e m o t o r a s a g e n e r a t o r a n d r e t u r n in g
th e g e n e ra te d e n e rg y b a c k to th e b a tte ry . R e g e n b r a k in g r e d u c e s m o t o r h e a t d is s ip a t io n
c o m p a re d w it h p lu g b r a k in g . R e g e n e r a t iv e b r a k in g c a n b e in it ia t e d in 3 w a y s , e a c h w it h
a n in d e p e n d e n t ly a d ju s t a b le b r a k in g le v e l, a s f o llo w s :
i) A d ir e c t io n s w it c h c h a n g e w ill in it ia t e r e g e n b r a k in g a t a le v e l s e t b y t h e d ir e c t io n
b r a k e c u r r e n t le v e l. B r a k in g e f f o r t is p r o p o r t io n a l t o t h e a c c e le r a t o r p o s it io n , w it h a
m in im u m
a c c e le r a t o r p e d a l p o s it io n g iv in g 5 0 % o f th e s e t b ra k e le v e l in c r e a s in g t o 1 0 0 % fo r a
f u lly d e p r e s s e d p e d a l. T h e p ro p o r t io n a lit y r a n g e a llo w s th e d r iv e r t o m o d if y t h e b r a k in g
e f f o r t w it h o u t a llo w in g f r e e w h e e lin g . T h e p r o p o r t io n a lit y fe a tu r e is o p t io n a l a n d c a n b e
c o n f ig u r e d in t h e s e t u p m e n u to g iv e f ix e d b r a k in g a t t h e s e t p e rs o n a lit y le v e l.
ii) C lo s u r e o f th e fo o t-b ra k e s w it c h in n e u t r a l, w ill in it ia t e r e g e n b r a k in g a t t h e f o o t b r a k e

p e rs o n a lit y le v e l. A n in p u t is p r o v id e d t o a llo w b r a k in g e f f o r t t o b e p r o p o r t io n a l t o t h e
fo o tb ra k e p o s it io n if a p o te n t io m e t e r is f it t e d . S e t t in g a 0 in t o t h e p e r s o n a lit y d is a b le s
b r a k in g o n th e fo o tb ra k e s w it c h .
iii) W h e n n e u t r a l is s e le c te d , re g e n is in it ia te d a t th e n e u tra l b ra k e c u rr e n t le v e l. S e t t in g a
0 in t o th e p e r s o n a lit y d is a b le s n e u tra l b ra k in g a n d a llo w s fre e w h e e lin g . N e u tra l
b r a k in g w ill o n ly b e a tte m p te d if t h e % o n in t h e p r e v io u s d ir e c t io n e x c e e d e d 2 0 %
a b o v e th e s e t c re e p le v e l. T h is h e lp s m in im is e u n n e c e s s a ry d e la y s a n d c o n ta c to r
o p e ra t io n s .
R e g e n b r a k in g is n o t p o s s ib le a t lo w s p e e d s d e p e n d in g o n th e m o to r c h a r a c t e r is t ic s . T o
h e lp m in im is e d e la y s a t t e m p t in g t o re g e n , a r e g e n t im e a d ju s t m e n t is o f f e r e d w h ic h c a n
b e s e t s o t h a t r e g e n is o n ly a t t e m p te d f o r a s h o r t p e r io d o f t im e , w h ic h is s u f f ic ie n t to
in it ia t e r e g e n a t m e d iu m t o h ig h s p e e d s b u t n o t to c a u s e u n n e c e s s a r ily lo n g d e la y s a t
v e r y s lo w s p e e d s w h e r e r e g e n is n o t p o s s ib le . If t h e r e g e n t im e s e t t in g is in c r e a s e d th e n
r e g e n c a n b e in it ia t e d a t lo w e r s p e e d s . S e t t in g t h e r e g e n t im e t o 0 d is a b le s r e g e n a n d
f o r c e s p lu g b r a k in g o n ly .
If r e g e n is n o t p o s s ib le d u e t o lo w v e h ic le s p e e d , t h e f o llo w in g a c t io n w ill b e t a k e n :
1 ) F o r d ir e c t io n b r a k in g , p lu g g in g w ill b e u s e d t o s lo w , t h e n r e v e r s e t h e v e h ic le .
2 ) F o r n e u t r a l o r f o o t b r a k e b r a k in g , t h e v e h ic le w ill f r e e w h e e l.
T h e s w it c h in g f r e q u e n c y in r e g e n is h ig h f r e q u e n c y a n d s ile n t .
1 0 . 1 . 1 3 P lu g P a r k in g
P lu g p a r k in g is a c h ie v e d b y c o n t r o llin g t h e r o t a t in g m o t o r a r m a t u r e a s a g e n e r a t o r a n d
d is s ip a t in g m o s t o f t h e e n e r g y in t h e m o t o r a n d t h e p lu g d io d e .
F o r p lu g g in g - o n ly c o n t r o lle r s , t h e c o n d it io n s f o r in it ia t in g b r a k in g a r e id e n t ic a l t o t h o s e
fo r re g e n c o n t r o lle r s : o n a d ir e c t io n c h a n g e , f o o t b r a k e s w it c h a n d in n e u t r a l. P lu g g in g
a ls o o p e r a t e s o n re g e n c o n t r o lle r s if t h e t r u c k h a s b e e n t r a v e llin g t o s lo w ly t o in it ia t e
r e g e n d ir e c t io n b ra k in g .
T h e s w it c h in g f r e q u e n c y in t h e p lu g b r a k in g m o d e is 6 K H z .
1 0 .1 .1 4 In c h in g ( n o t a v a ila b le o n lo w I/ O lo g ic )
T h is f a c ilit y is n o r m a lly u s e d o n to w t r a c t o r s t o m a n o e u v r e t h e t r a c t o r t o w a r d s t h e lo a d
fro m th e re a r o f th e v e h ic le , u s in g 2 in c h in g b u t t o n s , o n e f o r f o r w a r d a n d o n e f o r r e v e r s e .
T h e in c h s p e e d is a d ju s t a b le v ia t h e c a lib r a t o r .
In c h in g w ill o n ly o p e r a t e if t h e m a in d ir e c t io n c o n t r o l a n d F S 1 s w it c h e s a r e in t h e n e u t r a l
p o s it io n a n d t h e s e a t s w it c h is o p e n , a n d h a n d b r a k e o f f . T h e s e s a f e t y in t e r lo c k s p r e v e n t
a n y o n e f r o m s it t in g in t h e d r iv e r s c a b w h ils t a n o p e r a t o r is u s in g t h e in c h in g s w it c h e s a t
th e re a r .
A b u r s t in c h in g f e a t u r e is a ls o a v a ila b le w h ic h u s e s in c h in g in c o n ju n c t io n w it h a n
a d ju s t a b le t im e r t o p r o v id e in c h in g f o r a lim it e d p e r io d . T h is is ty p ic a lly u s e d in
c o n ju n c t io n w it h a n e le c t r o m e c h a n ic a l b ra k e t o p r o v id e in c h in g o n g ra d ie n t s a n d t o h e lp
p r e v e n t a g a in s t u n lim it e d t r a v e l if a n in c h in g b u tto n b e c a m e ja m m e d in t h e c lo s e d
p o s it io n o r f a ile d s h o r t c ir c u it .
1 0 . 1 . 1 5 A n t i- R o llb a c k
T h is is a s t a n d a r d S E V C O N f e a t u r e a n d is u s e d t o h e lp p r e v e n t r o ll b a c k c o n d it io n s o n
r a m p s . If t h e d r iv e r r e s e le c t s t h e p r e v io u s d ir e c t io n a f t e r a n e u t r a l c o n d it io n , b r a k in g is
n o t a t t e m p t e d , a n d f u ll d r iv e p o w e r is a v a ila b le t o r e s t a r t o n a h ill.
1 0 . 1 . 1 6 A n a lo g u e In p u t s
T h e a c c e le r a t o r / a n a lo g u e in p u t s a r e f le x ib le in t h e r a n g e o f s ig n a l s o u r c e s t h e y c a n
a c c o m o d a te a n d c a n b e a d ju s t e d t o m in im is e d e a d - b a n d s a n d m e c h a n ic a l t o le r a n c e s .
E a c h a n a lo g u e in p u ts h a s 2 a d ju s t m e n t s a s s o c ia t e d w it h it , t h a t a llo w t h e in p u t v o lt a g e
ra n g e to b e d e te rm in e d .
F o r t h e t r a c t io n a c c e le r a t o r , f o r e x a m p le , t h e 2 a d ju s t m e n t s a r e c a lle d t h e " a c c e le r a t o r
z e r o le v e l" a n d t h e " a c c e le r a t o r f u ll le v e l" . If t h e s e w e r e s e t t o 0 . 2 0 V a n d 4 . 8 0 V t h e n
0 % p u ls in g w o u ld s t a r t a t 0 . 2 0 V a t t h e in p u t , in c r e a s in g t o 1 0 0 % p u s lin g a t 4 . 8 0 V . F o r
a c c e le r a t o r s w it h d e c r e a s in g v o lt a g e o u t p u t s , t h e z e r o a d ju s t m e n t m ig h t b e s e t t o 3 . 5 V
a n d t h e f u ll a d ju s t m e n t t o 0 . 0 V . T h e c a lib r a t o r t e s t m e n u s h o w s t h e in s t a n t a n e o u s
v o lt a g e r e a d in g , a n d t h e e q u iv a le n t % " p u s h " f o r e a c h in p u t , a n d t o a llo w e a s y s e t - u p ,
p r e s s in g t h e " d o w n " k e y o n t h e c a lib r a t o r f r o m e it h e r o f t h e s e t e s t d is p la y s , a llo w s a
d ir e c t ju m p t o t h e z e r o v o lt a g e a n d f u ll v o lt a g e p e r s o n la lit y s e t t in g s . N o t e t h a t a 6 f la s h
f a u lt w ill o c c u r if t h e f u ll a n d s e r o le v e ls a r e s e t w it h in 0 . 5 0 V o f e a c h o t h e r . F o r w ir in g
d e t a ils s e e f ig u r e s 1 t o 3 .
1 0 . 1 . 1 7 T r a c t io n A c c e le r a t o r
W h e n d r iv e is s e le c t e d a n d th e a c c e le r a t o r is f ir s t p re s s e d , p u ls in g w ill c o m m e n c e a t t h e
c r e e p s p e e d s e t t in g in c re a s in g to w a rd s th e m a x im u m % o n .
If t h e a c c e le r a t o r is d e p re s s e d a t p o w e r u p , p u ls in g w ill b e in h ib it e d a n d a 6 f la s h f a u lt
w ill b e in d ic a t e d , u n t il th e p e d a l is r e le a s e d . In c a s e o f a w ir e o f f t y p e f a u lt , p u ls in g w ill
b e lim it e d t o t h e c r e e p s e t t in g a n d a 6 f la s h f a u lt w ill a ls o b e g iv e n .
V a r io u s a c c e le r a t o r c h a r a c te r is t ic s i. e . r e la t io n s h ip b e t w e e n a c c e le r a t o r p u s h a n d t h e
a p p lie d m o t o r v o lt a g e , c a n b e s e le c t e d v ia t h e s e t u p m e n u . T h e r e a r e 4 o p t io n s : L in e a r,
c u rv e d , 2 * s lo p e a n d c r a w l. S e t t o lin e a r f o r a s t r a ig h t lin e a c c e le r a t o r c h a r a c t e r is t ic ,
c u rv e d fo r m o r e lo w s p e e d m a n o e u v r a b ilit y , 2 * s lo p e f o r a b a la n c e b e t w e e n lin e a r a n d
c u rv e d , a n d c ra w l fo r a v e ry s h a llo w lo w s p e e d m a n o e u v r a b ilit y c u r v e . S e e g r a p h 2 fo r
a c tu a l c h a r a c t e r is t ic s .
R e p a r a t u r - u n d W a r t u n g s a n le it u n g
A u s g a b e 0 2 /2 0 0 6
E le k t r o s t a p le r
O v e r v ie w B A U M A N N
E le c t r o n ic S t e e r in g G e n e r a t io n
E L A U 1 5 0 n o lo n g e r a v a ila b le
E V L 0 1 2 5 0 0 E T - N r.: 2 0 5 4 1 2 0 0 0 o n ly a s r e p la c e m e n t p a r t a v a ila b le
M o b il 0 1 9 2 6 1 E T - N r . : 2 5 0 3 5 1 0 0 0 o n ly a s r e p la c e m e n t p a r t a v a ila b le
M o b il 0 1 9 5 0 5 E T - N r.: 2 5 5 0 6 0 a c tu a l s ta n d a rd n e w a n d a s r e p la c e m e n t p a r t
P / N 2 5 5 0 6 0 0 0 0 a v a ila b le
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Steering Position Computer

Type: BAUMANN LPC 019 260
Steering Position Computer

Type: SLC 019 505
4-Axle Steering System with propotional working hydraulic

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1. General Information
The operation of the electronics is done by the diagnostic panel of the steering computer.
The LPC 019 260 features a LCD sized 2 lines by 16 characters for readout of
information and 4 keys for menu selection and data input.
Key functions:
Escape key
ESC - Exit the present menu without saving data
- Backspace when in data input mode.
Minus key:
- Go to previous menu.
Decrease input data by one.
Plus key:
- Go to next menu.
Increase input data by one.
Enter key:
- Select current menu.
Confirm or save input data.
Via this 4 keys together with the menu, an easy operation can be performed, also for
less trained service staff.
1234567890123456
1234567890123456
ESC
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2. Display of Software Version

The LPC indicates for 2,5 sec. the software version and date of this version every time
power is switched on.
LPC 019 261 'A'

18.12.2001
ESC
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3. Error and Status Display

When no key is pressed or all submenus are exited, the display indicates following status
information:
3.1 Display in Normal Operation (no error)
no error
>
ESC
A „>“-mark on the second line moving left to right signalisizes that the steering computer
is active and the software is in process.
3.2 Display of Present Error
error code
10-07-01
ESC
As soon as an error is detected, the display shows the current error code. Separated by a
hyphen the display shows the error location, the error type and the error priority. If more
than one error is detected at the same time, the display shows all messages alternating
with 2.5 seconds delay. If the all errors solved, the display changes back to normal
operation mode (see chapter 3.1). The error codes are shown on page 101.
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3.3 Display of Incorrect Parameters
parameter error
number: 126
ESC
For each parameter there is a lower and upper limit. If the value stored in the EEPROM
(non volatile memory) is outside the allowed value range, the index number of the
incorrect parameter is displayed. The error can only be corrected by setting the indicated
parameter to a correct value. In the parameter list of each truck the correct value for each
parameter is listed.
3.4 Process Data Display
Process data display is selected by pressing the ENTER key either in the „normal mode“
or in the „error display“. After pressing the ENTER key the display swaps from displaying
errors to the operational data. Pressing the ESCAPE key or not pressing any key for
more than 5 minutes it will automatically switch back to the status display.
no error PX: -13761.87

> PY: 1400.00

ESC ESC

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In the operational data mode, there are 13 menus for the steering system and 8 menus
for the working hydraulic. The menus to be displayed can be selected by pressing the
PLUS or the MINUS key.
PX: +INF
PY: 2000.00
ESC
Previous display Next display
3.4.1 Displaying the Steering Pole

Display of the X- and Y-coordinates from the steering poles in [mm]. The steering pole is
centre of the driving curve. One value of the steering pole goes infinte if the steering is
straight ahead. In this case the display shows “INF”.
PX: +INF
PY: 2000.00
ESC
3.4.2 Displaying the Steering Setpoint
Display of the current steering setpoint in degrees (with signed). The first line shows the
steering angle read in from the programmed steering setpoint generator. In cases of an
orbitrol steered axle the first line shows the actual value of the leading axle.
The second line shows the steering setpoint after low-pass filtering. This value is used to
calculate the set point for the axle(s).
setp: 43.71
Ramp: 32.08
ESC

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3.4.3 Setpoint and Actual Angle of Single Axle
The display shows the Setpoint and the actual angle from a steering axles 1 ...4 in four
separate displays.
The value is shown in degree (°). The following example shows values of axle 1:
setp 1: 12.00
act 1: 11.96
ESC
3.4.4 Control of Proportional Valves
The control of the proportional valves is devided in two displays (one display for axle 1/2
and one display for axle 3/4). The display shows the the actual setpoints of the power
outputs in the range between 0 % and 100%. 100% is equivalent to an output voltage of
+24V.
PWM1: 73% 0%
PWM2: 0% 22%
ESC
One of both values per line is 0 % because only one solenoid of the proportional valve
(per axle) is powered. If the left value is not 0, the axle has to turn left. If the right value is
not 0, the axle has to turn right.
The example shows: Axle 1 turning left

Axle 2 turning right

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Code for the steering programs Code for the release flags
01 Cross-rear axleLengthways-fix axle 4 axle 3 axle 2 axle 1

2 Lengthways-all wheel
3 Lengthways-diagonal 0 out out out out
4 Lengthways-front steering 1 out out out on
5 Lengthways-rear steering 2 out out on out
6 Sideways-fix 3 out out on on
7 Sideways-all wheel 4 out on out out
8 Sideways-diagonal 5 out on out on
9 Sideways-front steering 6 out on on out
11 Circular driving 7 out on on on
12 Parking program 8 on out out out
255 No program selected 9 on out out on
10 on out on out
11 on out on on
12 on on out out
13 on on out on
14 on on on out
15 on on on on
3.4.7 Hydraulic Accumulator Loading System (Option)
When working with a hydraulic accumulator pressure system the display shows the
actual pressure (first line) and the switch on value (lo) and the switch off value (hi) onto
the second line. All value shows in [mV].
pressure: 1300
lo:3000 hi:4000
ESC
3.4.8 ELS Setpoint Value (Option)
The display shows the actual control value (in % of +24 V) of the proportional pressure
relief valve (ELS). The maximum pressure is controlled if the display shows the value for
the nominal voltage of the proportional solenoid. For example the maximum value for a
10 V solenoid is 42% (of 24V).
ELS pressure out

23%
ESC

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3.4.9 Impulses of Steering Setpoint Generator

The internal counter values of the steering setpoint generator can be displayed. When
turning the stering wheel the counter value of the detected impulses is shown onto the
display. The max. counter range is from 32768 to +32767 pulses.
steering-wheel
counter: 236
ESC
3.4.10 Working Hydraulic Functions (Option)
Each working hydraulic function (max= five functions) is shown on a separate display. The
displayed values are internally standardized from 32768 to +32767. The first line shows
the actual value of the joystick and the second line shows the calculated value (after ramp
function and other limitations).
joyst.1: -32188
setp.1: -32065
ESC
3.4.11 Control of Proportional Valve for Lifting and Lowering (Option)
The display shows the setpoint for the proportional solenoid in %. At least one value is
always 0 % because only one solenoid of the valve can be operated at the same time.
lifting: 43%
lowering: 0%
ESC

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3.4.12 Proportional Valve for Mast-Reach (Option)
The display shows the setpoint for the proportional solenoid in %. At least one value is always 0 %
because only one solenoid of the valve can be operated at the same time.
mast out: 0%
mast in: 33%
ESC
3.4.13 Revolution Setpoint for Hydraulic Pump (Option)
The revolution of the hydraulic pump is controlled by a servo-amplifier. The setpoint for
the servo-amplifier is generated by the steering computer. The display shows the actual
analog value in V [range: 0 V to +10 V].
pump set point:

3.75V
ESC

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4. Menu for Service Functions

The service menu is activated by pressing the ENTER- and the ESCAPE key at the same time for
more than 3 sec. (the service menu is activated when the display shows “i(o data display”).
no error
>
ESC
Keep both buttons pressed for 3 seconds

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i/o data display
back to ESC ESC

execute
the display
error memory
back to ESC ESC execute

the display
parameter

the display
axle alignment

the display
access code

the display

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Key functions:
ESCAPE - back to status menu
MINUS - previous submenu
PLUS - next submenu
ENTER - enter submenu.
4.1. I/O-Data Menu
The I/O-data menu gives access to all the current I/O-states. This menu is useful by
doing start up and service of the machine. While active service functions (see chapter 4)
the I/O-Data submenu is executed by pressing the enter key (see picture below).
i/o data display
ESC
The following 19 submenus can be accessed using the PLUS or MINUS keys.
DI 1 ... 8:
00010100
ESC
Exit data display
Previous data display
Next data display

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4.1.1 Digital Inputs
The LPC 019 260 has got 24 digital inputs (DI). The logical state (on or off) is shown
separately for each input. A „1“ indicates an active digital input.
DI 1 ... 8:
00010100
ESC
Digital input 1 Digital input 8

Example: input 1=low, 2=low, 3=high, 4=high, 5=low, 6=high, 7=low, 8=low
DI 9 ... 16:
11000001
ESC
Example: input 9=high, 10=high, 11=low ......
DI 17 ... 24:
00000100
ESC

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4.1.2 Analog Inputs
The LPC 019 260 has got 8 analog inputs that can be used for the application. In addition
there are several more analog inputs whitch are used for internally controll functions
(temperature control, supply voltage control, ...).
AI1: 2798mV
AI2: 1211mV
ESC
The display shows the values of the analog input in millivolts (range: 0 mV ... 5000 mV).
4.1.3 Proportional Outputs
The LPC 019 260 has got 10 proportional outputs (PWM power outputs). Their voltage
output level is from 0..100% of VCC (+UB, typically +24VDC). When connecting a valve
solenoid the the PWM output, the output voltage is corrected to a nominal value of +24V.
This functionality prevents a change of the output voltage while power supply voltage
(+Ubat) changes.
The displayed value is in % of +Ubat (21 % means: 5,04V when supply voltage is +24V)
PWM1: 21%
PWM2: 0%
ESC

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4.1.4 Analog Outputs
The LPC 019 260 has one analog output which is potential separated. For this the output
must have its own (external) power supply. If theres no potential separation neccessary,
the power supply could be connected to the main power supply of the electronics.
The output range is 0V to +10V when the power supply is more than 12V. When the
power supply of the analog output is less than 12V, the display shows a maximum output
of +10V even if the output signal is reduced (caused by a reduced power supply)!
AA1: 5.28V
ESC
4.1.5 Digital Outputs
The LPC 019 260 has got 16 digital outputs:

Digital output 1...12 are high active: 1 means +Ubat,
0 means high impedance
Digital output 13...16 are low active: 1 means output switches to power ground (0V),
0 means high impedance.
DO 1 ... 8:
10000100
ESC
Digital output 1 Digitial output 8
DO 9 ... 16:
01110100
ESC

Digital output 9 Digital output 16
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4.1.6 Counter Inputs (Option)
The LPC 019 260 has got two counter inputs. The displayed values is the actual value
and changes in positive or negative (dependent on the detected impulses).
INC1:-32760
INC2: 0000 E49A
ESC
Cycle and timebase counter
Insides info:
Besides the second counter value, the right value onto the second line displays the cycle
counter (in the above example “E4”) and the timebase counter (in the above example
“9A”). Both the cycle counter and the timebase counter must change fast when the
system works correctly. If the timebase counter changes no more, the time base of the
electronics did not work. If the cycle counter changes no more, the programm did not
longer work.

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4.2 Error Memory
Up to 32 detected errors are stored permanently in the error memory on their first
occurrence. The error is stored in the form location/type/priority as three separate
numbers.
To read out or erase the error memory the menu item „error memory“ has to be selected.
error memory
ESC
By pressing the ENTER key, the first position of the error memory is displayed. The next
or previous positions can be accessed by pressing the PLUS- and MINUS keys. The
submenu can be left by pressing the ESCAPE key.
The code „255, 255, 255“ indicates that no more errors are located inside the memory. If
there is no error at all, all numbers are 255.
error number: 1
code:001 001 003
ESC
Previous error Next error
(See also page 100)

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4.2.1 Clear Error Memory
Clearing the error memory can be done at any displayed error number. It will always clear
all errors inside the memory. You cannot clear a single error.
error number: 1
code:001 001 003
ESC
Keep pressedfor 3 seconds
After the PLUS-key is pressed for 3 seconds the systems ask if the error memory should
be cleared.
error memory
Clear ?
ESC
Exit without clearing Clear
By pressing the ESCAPE-key the error memory is not cleared and the system changes
back to the error display. Pressing the ENTER-key starts the clearing procedure.
The clearing progress is displayed with a barograph in the second line.
clear memory
----------
ESC

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After clearing the memory all error codes are set to 255 (means no error). The display
automatically changes back to the first error number.
error number: 1
code:255 255 255
ESC
Exit the submenu 'error memory' by pressing the ESCAPE-key.
4.3. Programming of Parameters
The steering system and the working hydraulic functions of the LPC 019 260 are defined
by 256 parameters. The submenu 'parameter' is used to check or modify these
parameters. The submenu 'parameter' is activated as decribed in chapter 4 of this
manual.
parameter
ESC
The parameter submenu is started with the ENTER-key. The display changes to the
parameter number input. The input cursor is flashing right of the actual parameter
number.
Exit the parameter submenu by moving the input cursor with the ESCAPE-key left until
the most left digit of the parameter number is reached. Pressing the ESCAPE-key once
more the parameter submenu is exited.
parameter
number: 000
ESC

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4.3.1 Reading Parameters in Sequenz
By using the ENTER-key the parameter values can be read easily without changing the
values.
parameter
number: 000
ESC
On the display of the parameter number press the ENTER-key once to show the value of
the selected parameter.
parameter no:000
value: 0000
ESC
On the display of the parameter value press the ENTER-key once to move to the next
parameter number. The parameter number is automatically incremented by one.
parameter
number: 001
ESC
The next press of the ENTER-key changes to the value of the parameter again. Exit this
submenu as described in chapter 4.3.

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4.3.2 Direct Entering of Parameter Numbers
To read or to modify single parameters the parameter number can be entered directly.
parameter
number: 000
ESC
The ESCAPE-key shifts the cursor one digit to the left side. The actual cursor position is
flashing. If the ESCAPE-key is pressed with the cursor at the most left digit the parameter
submenu is exited.
parameter
ESC
The ENTER-key shifts the cursor one digit to the right side. If the ENTER-key is pressed at
a digit without numbers or at the most right digit the parameter number input is finished
and the display changes to parameter values. In this case it doesnt matter if the parameter
number is given as 1, 2 or 3 digits.
parameter
number: 00
ESC
The MINUS-key is used to reduce the value of the blinking digit by one. If the value is '0'
the MINUS-key changes it to '9'. If the MINUS-key is pressed at the beginning of the
parameter number input (cursor is right of the parameter number) the cursor jumps to the
most left digit without clearing the value.

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parameter
number:
ESC
The PLUS-key is used to increment the value of the blinking digit by one. If the value is '9'
the PLUS-key changes it to '0'. If the PLUS-key is pressed to the beginning of the
most left digit clearing the parameter number to '0'.
4.3.3 Parameter Value Input
After the parameter number input (see chapter 4.3.2) the display shows the actual
parameter value. The cursor is on the right side of the parameter value.
parameter no:007
value: 0001
ESC
The ESCAPE-key shifts the cursor one digit to the left side. The actual cursor position
digit is blinking. If the ESCAPE-key is pressed at the most left digit the display changes
back to the parameter number without saving the parameter value.
parameter no:007
Value: 00 1
ESC
The ENTER-key shifts the cursor one digit to the right side. If the ENTER-key is pressed
at a digit without value or at the most right digit of a 4-digit display the parameter value is
saved and the display changes to the next parameter number. It does not matter if the
parameter values are programmed with 1, 2, 3 or 4 digits.
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Before saving the first modified parameter value an access code has to be set (see
chapter 4.3.4). The value is only saved with correct access code
min: 0
max: 1
ESC
The parameter value is checked to be within the allowed parameter range prior to saving.
If the value is outside the allowed range the minimum and maximum value is shown on
the display. Press any key to switch back to the parameter value input again.
parameter no:007
value: 0091
ESC
The MINUS-key is used to decrement the blinking digit by one. If the value is '0' the
MINUS-key changes it to '9'. If the MINUS-key is pressed at the beginning of the input
sequence (cursor is located behind the parameter value), the cursor jumps to the first
input digit without clearing the parameter value.
parameter no:007
value:
ESC
The PLUS-key is used to increment the value of the blinking digit by one. If the value is '9'
the PLUS-key changes it to '0'. If the PLUS-key is pressed to the beginning of the
most left digit clearing the parameter number to '0'. This can be used mainly to set one
digit values.

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4.3.4 Access Code Input
Only authorised persons should be able to change the parameter and alignment values.
So an access code must be entered before parameters can be changed or an alignment
can be made.
During parameter programming the access code is requested at the first parameter value
change. Then other parameters can be changed without setting the access code again.
The axle alignment access code must be entered once at the beginning of the alignment
mode.
set access code

000
ESC
The access code input is made the same way as parameter value input (see 4.3.3). After
the correct access code is entered the display continues with the parameter programming
or alignment mode.
If the access code is incorrect an error message is displayed. This message can be
confirmed with any key. Then during parameter programming the parameter number is
displayed again and during alignment procedure the alignment mode is finished (the
display changes to 'i/o data display' in main menu).
access code
Incorrect !
ESC
CAUTION: The Master Code approves the changes for all functions. In addition the
master code allows to change the access code for parameter programming
and alignment mode ( see 4.5 to change the access codes).

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4.4 Alignment of the Axles
To align the axle the actual voltage feedback at 0° steering angle (longitudinal driving) and
at the 90° position (lateral driving) is saved into the EEPROM memory of the steering
computer. During normal steering the steering computer uses these values to keep best
tracking.
The menu 'axle alignment' is activated as described in chapter 4.
axle alignment
ESC
The ENTER-key starts the alignment menu. The display first changes to the access code
request (see 4.3.4).
With the correct access code the basic menu of the alignment mode is displayed. Pressing
the ESCAPE-key in this mode quits the alignment. mode and pressing the ENTER-key
select the alignment mode.
select axle for

alignment: 0
ESC
CAUTION:
During alignment mode the steered axle can be operated without consideration to
maximum steering angles or sensor errors and without error control. The error
monitoring is not active! So therefore in case of an error the axle can uncontrollably
strike out.
No persons are permitted to stay withing the working area of the axle. This mode
may be useful to turn an axle back to straight positions (in cases of an error).

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4.4.1 Select the Axle for the Alignment
To align the axle by the initial start-up, the alignment procedure is done step by step for
each axle separately. It is possible to align only only one axle separately too.
A alignment is not possible if „0“ or a wrong axle is selected.
select axle for

alignment: 0
ESC
Back to align mode
Axle -1
Axle +1
Start the alignement
4.4.2 Alignment of 0° and 90°
At first the selected axle has to be aligned to the 0° position (in the following example
axle 2 is selected). If just the 90° alignment should be done, the 0° alignment can be
skiped by pressing the ESC-key.
Turn the axle using the MINUS-key to the left and the PLUS-key to the right. If the key is
only pressed short time the steering angle is changed by 0.1°. To turn the axle 0.2° ...
0.3° the key has to be pressed several times.
If the key is held pressed for more than 0.5 s the steering starts to turn continuously. The
steering speed is increased in three steps up to approximately 10 °/s (depending on the
time the key is pressed).
NOTE: If the axle does not turn by pressing the MINUS- or the PLUS-key, the
following points have to be checked:
(1) Hydraulic supply pressure available?
(2) Axle mechanically blocked?
(3) Steering computer powere? and hydraulic valve as well as angle
wheel poti connected according to the wiring diagrams?

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CAUTION: If the axle turns against the end stop without pressing the MINUS- or
PLUS-key check the following definitions:
(1) Wheel poti voltage must increase if the steering is
steered to the right side (if not, swap the supply voltage of the wheel poti.
The voltage at straight position of the axle must be
approximately +2,50V.
(2) If the oilflow through the proportional valve is from P to A the steering
has to steer to the right side (if not, swap the two solenoid plugs of the
proportional valve).
(3) The wheel poti must be mechanically fixed to the axle.
There must be no angular play between wheel and wheel poti.
(4) Check for the valve not to be "sticking" open.
set axle to 0
actual: 2453mV
ESC
Skip 0° alignement
Steer left
Steer right
Save alignement value
The second line of the display shows the wheel poti feedback. So during alignment the
actual values can be checked easily. In addition to the MINUS- or the PLUS-keys the axle
could be steered by activating digital input 10 (turns axle right) and digital input 11 (turns
axle left).
If the axle is positioned to the precise straight position, save the wheel poti values by
pressing the ENTER-key. The actual value of the angle tansducer feedback voltages must
be in the range of 2400 mV ... 2600 mV. If the voltage is outside this range the values are
not saved and the following error message appears on the display:
out of tolerance
2400mV .. 2600mV
ESC
Confirm
Confirm the error message with the ENTER-key. Then the steering mode is active again
to correct the position or the mechanical installation of the wheel poti.
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NOTE: At straight position of the axle the feedback voltage of the wheel poti must be in
the range of 2400 mV ... 2600 mV.
If the wheel poti voltage is correct, it will be saved into an EEPROM memory. The saved value is
shown on the display.
saved value is:

2453mV
ESC
Confirm
After confirming with the ENTER-key the program changed to the 90°- alignment mode.
set axle 2 to 90
actual: 3819mV
ESC
Skip 90° alignment
, Steer left
Steer right
Save alignment values
Steer the axle using the MINUS-key and the PLUS-key to the 90° position (lateral
driving). It doesnt matter if the axle is turned to +90° or 90° position. The position mostly
depends onto the mechanically construction of the machine. The turning direction from
longitudinal to lateral driving is set via parameter for each axle separately.

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If the steering is positioned to the precise 90° position save the wheel poti values by
pressing the ENTER-key. Is the actual value smaller than 2400mV and higher as
2600 mV shows the display a error message.
out of tolerance
>2600mV <2400mV
ESC
Confirm
Confirm the error message with the ENTER-key. The display change back to the steering
mode. Then the steering mode is active again to correct the 90° position or the
mechanical installation of the wheel poti.
If the voltage is correct, the value is saved into an EEPROM memory. The saved value is
shown on the display.
saved value is:

3819mV
ESC
Confirm
After confirming with the ENTER-key the program called the next axle and started the
next alignment.

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4.5 Programming Access codes
The Master-code is neccessary to change the access codes for parameter programming
and alignmet procedure. This menu is only active after enter the master-codes (see
4.3.4). The codes for parameter programming and for axle alignments is not accepted
here.
set master code

000
ESC
4.5.1 Access Code for the Parameter Programming
After entering the correct master-code the display changes to enter the access code for
parameter programming.
parameter code
_234
ESC
Skip over the code input
Value -1
Value +1
Save the code input

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After saving the access code for parameter programming (or skip the menu) the display
shows the new code.
parameter code
is 1234
ESC
4.5.2 Access Code for the Alignment Procedure
After entering the access code for parameter programming the display changes to enter
the access code for the alignment procedure.
alignment code
_345
ESC
Skip over the code input
Value -1
Value +1
Save the code input
After saving the access code for alignment procedure (or skip the menu) the display
shows the new code.
alignment code
is 2345
ESC

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5. Error Format
All errors are saved and displayed with 3 error codes. These error codes allow a detailed
determination of the error and its consequences.
1. Code - error location a Which component has caused the error?

2. Code - error type a Which error is active?
3. Code - priority a How critical is the actual error?
0 = operating message
1 = warning / error of load handling
2 = enable driving is switched off, steering is still active
3 = steering of faulty axles is switched off, enable driving is off.
The errors of the steering computer LPC 019 260 can be seen at the following error table.
The rows of the table shows a list of possible error locations. The columns contains the
possible error types. Each cell of this table that has a priority number determines a possible
error. Cells without a number are not monitored.

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Error List Electronic Steering 019 261
error types
90°-alignment out of tolerance

0°-alignment out of tolerance
higher than maximum value
resistance out of tolerance

lower than minimum value
open loop / short circuit /

cable break, open loop
deviation warning
deviation error
short circuit
plausibility
overload
time-out
no error
-
error locations 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
no error 0
wheel poti axle 1 1 3 1 2 3 1 1
proportional valve axle 1 5 1 3
ELS pressure-relief valve 9 1
power supply voltage 10 1 1
+5V reference voltage 11 3
EEPROM memory 12 1
- 13
- 14
joystick track 1 15 1
joystick track 2 16 1
prop.valve lifting/lowering 17 1
prop valve mast outreach 18 1
mast limit switches 19 1
- 20

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6. Parameter List LPC 019 261
step value unit range description
0 0001 - 0000 – 0001 vehicle type

0000 = fully electronic steering with steering set point generator
(EMS)
0001 = orbitrol steered leading axle (EVS, EVU, DANCER
1 0003 Stück 0001 – 0004 number of steeres axles

Number of all axles that are steered by the steering computer
including the orbitrol steered leading axle.
2 0000 - 0000 – 0001 enable steering program longitudinal fixed

0000 = disabled
0001 = enabled
3 0001 - 0000 – 0001 enable steering program longitudinal normal

0000 = disabled
0001 = enabled
4 0000 - 0000 – 0001 enable steering program longitudinal diagonal

0000 = disabled
0001 = enabled
5 0000 - 0000 – 0001 enable steering program longitudinal front

0000 = disabled
0001 = enabled
6 0000 - 0000 – 0001 enable steering program longitudinal rear

0000 = disabled
0001 = enabled
7 0000 - 0000 – 0001 enable steering program lateral fixed

0000 = disabled
0001 = enabled
8 0000 - 0000 – 0001 enable steering program lateral normal

0000 = disabled
0001 = enabled
9 0000 - 0000 – 0001 enable steering program lateral diagonal

0000 = disabled
0001 = enabled
10 0001 - 0000 – 0001 enable steering program sideways front

0000 = disabled
0001 = enabled
11 0000 - 0000 – 0001 enable steering program sideways rear

0000 = disabled
0001 = enabled
12 0001 - 0000 – 0001 enable steering program circular mode

0000 = disabled
0001 = enabled
13 0001 - 0000 – 0001 enable steering program parking mode

0000 = disabled
0001 = enabled
14 mm 0000 – 9999 X co-ordinate axle1

15 mm 0000 – 9999 Y co-ordinate axle1
16 mm 0000 – 9999
X co-ordinate axle2
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22 mm 0000 – 9999 steering line of steering program longitudinal normal
Y co-ordinate of the steering line. With symmetrical vehicles the
steering line is positioned to half vehicle length. Thies causes the front
and rear angles to be the same with inverse sign.
23 0001 axle no. 0001 – 0004 right reference axle for longitudinal normal
The reference axle is the axle with the biggest steering angle at right
hand curves. For orbitrol steering the number of the orbitrol steered
axle has to be set here.
24 0180 ° 0000 – 0180 maximum right steering angle for longitudinal normal
Maximum steering angle of the reference axle specified in parameter
23. With orbitrol steering the maximum steering angle is limited by the
mechanics and not by software.
25 0001 axle no. 0001 – 0004 left reference axle for longitudinal normal
The reference axle is the axle with the biggest steering angle at left
hand curves. For orbitrol steering the number of the orbitrol steered
axle has to be set here.
26 0180 ° 0000 – 0180 maximum left steering angle for longitudinal normal
Maximum steering angle of the reference axle specified in parameter
25. With orbitrol steering the maximum steering angle is limited by the
mechanics and not by software.
27 0001 axle no. 0001 – 0004 reference axle for longitudinal diagonal
This axle has only to be specified with an orbitrol steering. With a fully
electronic steered system the diagonal steering program does not
need a reference axle for all steering angles are the same.
28 0000 ° 0000 – 0180 maximum right steering angle for longitudinal diagonal
See parameter 24.
29 0000 ° 0000 – 0180 maximum left steering angle for longitudinal diagonal
See parameter 26.
30 0000 mm 0000 – 9999 steering line of steering program longitudinal front

Y co-ordinate of the steering line. The steering line is often positioned
exactly into the rear axles, so they are fixed to straight.
31 0001 axle no. 0001 – 0004 right reference axle for longitudinal front
See parameter 23.
32 0000 ° 0000 – 0180 maximum right steering angle for longitudinal front
See parameter 24.
33 0001 axle no. 0001 – 0004 left reference axle for longitudinal front
See parameter 25.
34 0000 ° 0000 – 0180 maximum left steering angle for longitudinal front
See parameter 26.
35 0000 mm 0000 – 9999 steering line of steering program longitudinal rear

Y co-ordinate of the steering line. The steering line is often positioned
exactly into the front axles, so they are fixed to straight.
36 0001 axle no. 0001 – 0004 right reference axle for longitudinal rear
Created by eDocPrinter PDF Pro!! See parameter 23.
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37 0000 ° 0000 – 0180 maximum right steering angle for longitudinal rear
See parameter 24.
38 0001 axle no. 0001 – 0004 left reference axle for longitudinal rear
See parameter 25.
39 0000 ° 0000 – 0180 maximum left steering angle for longitudinal rear
See parameter 26.
40 0000 mm 0000 – 9999 steering line of steering program lateral normal

X co-ordinate of the steering line. With symmetrical vehicles the
steering line is positioned to half vehicle width. This causes the front
and rear angles to be the same with inverse sign.
41 0003 axle no. 0001 – 0004 right reference axle for lateral normal
The number of the axle with the biggest steering angle at right hand
curves has to be set. For orbitrol steered vehicles the number of the
orbitrol steered leading axle has to be set.
42 0000 ° 0000 – 0180 maximum right steering angle for lateral normal
Maximum steering angle of the reference axle (parameter 41). For
orbitrol steered vehicles the maximum steering angle is not taken from
this parameter, but is limited by the mechanics of the axle.
43 0003 axle no. 0001 – 0004 left reference axle for lateral normal
The number of the axle with the biggest steering angle at left hand
curves has to be set. For orbitrol steered vehicles the number of the
orbitrol steered leading axle has to be set.
44 0000 ° 0000 – 0180 maximum left steering angle for lateral normal
Maximum steering angle of the reference axle (parameter 43). For
orbitrol steered vehicles the maximum steering angle is not taken from
this parameter, but is limited by the mechanics of the axle.
45 0003 axle no. 0001 – 0004 reference axle for lateral diagonal
This axle has only to be specified with an orbitrol steering. With a fully
electronic steered system the diagonal steering program does not
need a reference axle for all steering angles are the same.
46 0000 ° 0000 – 0180 maximum right steering angle for lateral diagonal
See parameter 42.
47 0000 ° 0000 – 0180 maximum left steering angle for lateral diagonal
See parameter 44.
48 mm 0000 – 9999 steering line of steering program lateral front

X co-ordinate of the steering line. The steering line is often positioned
exactly into the rear axles, so they are fixed to straight.
49 0003 axle no. 0001 – 0004 right reference axle for lateral front
See parameter 41.
50 0045 ° 0000 – 0180 maximum right steering angle for lateral front
See parameter 42.
51 0003 axle no. 0001 – 0004 left reference axle for lateral front
See parameter 43.
52 0018 ° 0000 – 0180 maximum left steering angle for lateral front
See parameter 44.
53 0000 mm 0000 – 9999 steering line of steering program lateral rear

exactly into the front axles, so they are fixed to straight.
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54 0003 axle no. 0001 – 0004 right reference axle for lateral rear
See parameter 41.
55 0000 ° 0000 – 0180 maximum right steering angle for lateral rear
See parameter 42.
56 0003 axle no. 0001 – 0004 left reference axle for lateral rear
See parameter 43.
57 0000 ° 0000 – 0180 maximum left steering angle for lateral rear
See parameter 44.
58 0001 - 0000 – 0001 axle 1 turning direction to lateral

0000 = axle 1 turns right from longitudinal to lateral
0001 = axle 1 turns left from longitudinal to lateral



62 mm 0000 – 9999 X co-ordinate of the circular turning point

At circular steering program the vehicle turns around a fixed point
(e.g. the center of the vehicle). This point is defined with parameters
62 and 63.
63 mm 0000 – 9999 X co-ordinate of the circular turning point

See parameter 62.
64 0000 - 0000 – 0001 axle 1 turning direction to circular

0000 = axle 1 turns the short way to circular angle
0001 = axle 1 turns the long way to circular angle



68 0020 ° 0000 – 0180 parking angle axle1

With active parking program the steering angles are positioned to
fixed angles which are defined at parameters 68 to 71. The angles
should be selected in a way that avoids the vehicle moving even if the
parking brake is not applied.

See parameter 68.

See parameter 68.

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See parameter 68.
72 0001 - 0000 – 0001 sign of axle 1 parking angle

0000 = right
0001 = left

0000 = right
0001 = left

0000 = right
0001 = left

0000 = right
0001 = left
76 0350 ° 0000 – 0360 function angle of the wheel poti

The actual angles of the steered axles are measured with a
potentiometer. To calculate the steering angle out of the
potentiometer voltage the electrical function angle must be set. The
function angle is the angle range that equals a voltage rise from 0V to
+5V.
77 0050 % 0000 – 0100 Maximum output voltage for steering valves

The solenoids of the steering valves are driven by proportional power
outputs of the steering computer. The maximum output voltage is
+24V. The nominal voltage of the valve solenoids is often lower than
+24V even if the valve is declared as a 24V valve. So this parameter
can be used to adapt the output voltage to the valve.
Example: nominal solenoid voltage = 10V
 parameter value = 10/24 * 100% = 42%
78 0200 factor 0000 – 9999 control gain of control circuit axle 1

The actual control deviation is multiplied with the parameter value. The
proportional valve is fully opened if the result of the multiplication is
higher than 4095.
Example: A parameter value of 4095 causes the
proportional valve to be open at a control
deviation of 1°.
Example: To open the proportional valve completely at a
control deviation of 10° the parameter value has
to be programmed to 410.

See parameter 78.

See parameter 78.

See parameter 78.
82 0020 % 0000 – 0100 deadband compensation for proportional valve 1

This function is used to compensate for a center deadband of the
proportional valve. As soon as the control deviation is not zero the
power output is set to the programmed value. So the reaction time of
the valve is improved.

See parameter 82.

Electronic Steering
Issue 03/2006
Electric Sideloader
Page 100

See parameter 82.

See parameter 82.
86 0000 - 0000 – 0001 select steering program selector

0000 = steering program selection by DI1 ... DI4
0001 = steering program selection by terminal EEA 092 120
87 0000 - 0000 – 0003 installation direction of terminal EEA 092 120

0000 = facing positive Y co-ordinates (longitudinal forward)
0001 = facing negative Y co-ordinates (longitudinal reverse)
0002 = facing positive X co-ordinates (lateral forward)
0003 = facing negative X co-ordinates (lateral reverse)
88 0002 - 0000 – 0014 steering program selected by DI1

0000 = lateral rear
0001 = longitudinal fixed
0002 = longitudinal normal
0003 = longitudinal diagonal
0004 = longitudinal front
0005 = longitudinal rear
0006 = lateral fixed
0007 = lateral normal
0008 = lateral diagonal
0009 = lateral front
0010 = -
0011 = circular
0012 = parking program
0013 = -
0014 = -

See parameter 88.

See parameter 88.

See parameter 88.
92 0000 - 0000 – 0001 configuration of EEA 092 120 button A

0000 = pushbutton
0001 = on/off toggle switch
93 0000 - 0000 – 0001 configuration of EEA 092 120 button B

0000 = pushbutton
94 0000 - 0000 – 0001 configuration of EEA 092 120 button C

0000 = pushbutton
95 0000 - 0000 – 0001 configuration of EEA 092 120 button D

0000 = pushbutton
96 0001 - 0000 – 0001 select steering set point generator

0000 = analog steering set point generator at AI8
0001 = incremental steering set point generator MLS
97 0000 - 0000 – 0001 turning direction of the incremental steering-wheel

0000 = normal

0001 = inverse
Electronic Steering
Issue 03/2006
Electric Sideloader
Page 101

98 0192 Impulse 0001 – 9999 pulses per revolution of the incremental steering-wheel
Number of pulses generated by the incremental steering-wheel at
every steering-wheel turn.
99 0015 ° 0001 – 9999 steering set point change per steering-wheel revolution
Gearing from steering-wheel to steered axle. At each steering-wheel
turn the steering angle of the reference axle changes by the
parameter value.
100 0100 °/s 0001 – 9999 maximum steering speed

The steering angle change per second is limited to the programmed
value. This is important to limit the opening of the proportional valves
and keep good tracking of the steering.
This value has to be adapted to the real available steering speed of
the axles depending on hydraulic oil flow and pressure.
101 0000 0.1° 0000 – 9999 steering brake deadband

If a steering-force simulator is used to steer the vehicle the steering
brake is controlled proportionally to the actual steering deviation. The
steering-force simulator has its own internal steering brake control
circuit. To avoid disturbance of this circuit the steering computer
should not influence the steering brake at normal small deviations.
This deadband must be programmed higher than the normal
deviations during steering without errors.
102 0000 0.1° 0000 – 9999 steering brake rise

As soon as the steering deviation is higher than parameter 101
(deadband), the steering force is increased proportionally to the
steering deviation. The maximum steering force is reached at a
deviation of deadband + rise.
If a steering set point generator without steering brake is used this
parameter should be programmed to 0000.
103 0000 - 0000 – 0003 type of hydraulic supply

0000 = accumulator charge system with two pressure switches
0001 = accumulator charge system with analog pressure sensor
0002 = constant pump with electric load sensing (ELS)
0003 = completely separate hydraulic supply.
104 0000 mV or ° 0000 – 9999 pump switch on threshold at standstill

Accumulator charge system with analog sensor:
Pressure sensor voltage (mV), to activate the charging function and
the hydraulikc pump.
Constant pump with ELS:
Steering deviation (°) at which the hydraulic pump is switched on.
105 0000 mV or s 0000 – 9999 pump switch off threshold at standstill

Accumulator charge system with analog sensor:
Pressure sensor voltage (mV), to switch off the charging function as
well as the hydraulic pump.
Switch off delay time (s) of the steering pump after the steering
deviation has been equalised.
106 0000 mV or ° 0000 – 9999 pump switch on threshold during driving

See parameter 104.
107 0000 mV or s 0000 – 9999 pump switch off threshold during driving
See parameter 105.
108 0000 mV or ° 0000 – 9999 pump switch on threshold during driving with straight
steering
See parameter 104.

Electronic Steering
Issue 03/2006
Electric Sideloader
Page 102
109 0000 mV or s 0000 – 9999 Pump switch off threshold during driving with straight
steering
See parameter 105.
110 0000 % 0000 – 0100 Maximum output voltage for ELS pressure valve
The solenoid of the ELS pressure valve is driven by a proportional
power output of the steering computer. The maximum output voltage
is +24V. The nominal voltage of the valve solenoid is often lower than
+24V even if the valve is declared as a 24V valve. So this parameter
can be used to adapt the output voltage to the valve.
Example: nominal solenoid voltage = 10V
 parameter value = 10/24 * 100% = 42%
111 0020 % 0000 – 0100 ELS minimum pressure

The minum system pressure is set if the steering deviation is less than
the programmable deviation deadband (parameter 113).
This function can also be used to for beadband compensation of the
ELS-valve.
112 0100 % 0000 – 0100 ELS maximum pressure

The maximum system pressure is set set if the steering deviation is
bigger than the deviation deadband (parameter 113) + Slope of ELS
valve (parameter 114).
In case of steering program change from lengthways to sideways the
system pressure is always set to this maximum pressure.
113 0000 0.1° 0000 – 9999 Deadband for ELS pressure rise
If the steering deviation is less than this value, the system pressure is
set to the minimum ELS pressure of parameter 111.
114 0100 0.1° 0000 – 9999 Slope of ELS pressure rise

If the steering deviation is bigger than parameter 113 the
systempressure increases linear up to the maximum pressure (defined
in parameter 112). The slope defines how fast the system pressure
increases dependend on the steering deviation.
115 0050 0.01 s 0000 – 9999 ELS pressure rise ramp

This parameter defines the minimum time for a pressure rise from 0 to
maximum.
116 0200 0.01 s 0000 – 9999 ELS pressure drop ramp

This parameter defines the minimum time for a pressure drop from
maximum to 0.
117 0000 % 0000 – 0100 ELS constant pressure during axle alignment
During axle alignment mode a constant system pressure is made
available to guarantee a precise positioning of the axle.
118 0080 % 0000 – 0100 ELS constant pressure for charging the accumulator
During charging the accumulator a constant system pressure is set by
the ELS pressure relief valve.
119 0050 % 0000 – 0100 pump speed set point for charging the accumulator
During charging the accumulator or during a ‚pump on‘ request a
constant pump speed set point is given to the hydraulic pump
controller. A set point of +10V equals 100% pump speed.
120 0020 ° 0000 – 0360 deviation warning threshold

If the steering deviation is bigger than the programmed value a
warning is active. At the same time the steering speed is reduced to
25% of parameter 100 to allow the deviating axle to close up to the
others. Steering and driving stays active during the warning.
Electronic Steering
Repair Manual
Issue 03/2006
Electric Sideloader
Page 103
121 0030 ° 0000 – 0360 deviation error threshold

If the steering deviation is bigger than the programmed value a error is
active. The vehicle is stopped by switching off the ‚enable driving‘
output. The steering stays active to allow the faulty axle to close up to
its set point.
122 0001 - 0000 – 0001 Steering valve monitoring

0000 = no monitoring
0001 = the steering valves are monitored for open loop, short circuit
and overload.
123 0001 - 0000 – 0001 ELS pressure relief monitoring

0000 = no monitoring
0001 = the ELS pressure relief valve is monitored for open loop,
short circuit and overload.
124 0100 0.01 s 0000 – 9999 delay steering program change after driving
After the driving contact is switched off the steering program change
is delayed. This is important because the vehicle needs a time to
come to a real stop before the axles are allowed to turn to their new
positions.
125 0000 0.1° 0000 – 0050 Steering controller deadband at standstill

The digital steering controller is not activated during standstill of the
vehicle, as long as the steering deviation is less than the programmed
value. This function can be used to avoid oscillations of the
electrohydraulic axles in orbitrol steering mode.
126 0000 0.1° 0000 – 0050 Steering controller deadband during driving
See parameter 125.
127 0000 - 0000 – 4095 Steering deviation influence on the pump speed during
charging of the accumulator
The actual steering deviation is multiplied with the programmed factor
and is added to the constant pump speed of parameter 119. So the
accumulator can be charged even if the oil consumption of the
steering system is high.
If the parameter is programmed to 4095 the maximum pump speed is
reached at a steering deviation of 1°. With a value of 409 the
maximum pump speed is reached at a deviation of 10°.
128 0000 - 0000 – 9999 -

129 0000 - 0000 – 9999 -
130 0000 - 0000 – 9999 -
131 0000 - 0000 – 9999 -
132 0000 - 0000 – 9999 -
133 0000 - 0000 – 9999 -
134 0000 - 0000 – 9999 -
135 0000 - 0000 – 9999 -
136 0000 - 0000 – 0001 Working hydraulic functions
0000 = disabled
0001 = enabled

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137 0000 - 0000 – 0001 charge accumulator during working hydraulic functions
0000 = no
0001 = yes
138 0001 - 0000 – 0001 proportional valve monitoring for working hydraulic
0000 = not active
0001 = active
139 0100 % 0000 – 0200 calibration of working hydraulic joysticks

The set point voltage of the joysticks can be normalised by this
parameter. If the value is set higher than 100% the maximum speed
of the function is reached at lower movement of the joystick lever.
140 0000 - 0000 – 0001 joystick set point type

0000 = +5 V ... 0 V ... +5 V
0001 = 0 V ... +2.5 V ... +5 V
141 0100 mV 0000 – 1000 start set point of joysticks

The working hydraulic function gets active, if the joystick contact is
closed and the set point is higher than the programmed threshold.
The threshold is measured based on the actual center voltage (see
parameter 140).
142 0050 % 0000 – 0100 maximum output voltage to working hydraulic valves
The solenoids of the proportional valves for working hydraulic are
driven directly by power outputs of the steering computer. The
maximum output voltage is +24V. To drive solenoids with lower
nominal voltage the output voltage can be reduced by this parameter.
Example: nominal voltage = 12V
 parameter value = 12/24 * 100% = 50%
143 0001 - 0000 – 0002 select joystick track for lifting/lowering

0000 = no (function disabled)
0001 = track 1
0002 = track 2
144 0000 - 0000 – 0001 Inversion of lifting/lowering

0000 = no inversion
0001 = inversion active.
145 0000 % 0000 – 0100 valve deadband compensation for lifting

As soon as lifting is activated, the proportional valve is powered with
the programmed value to compensate for a valve deadband in center
position. So the proportional movement of the function starts at once.
146 0000 % 0000 – 0100 valve deadband compensation for lowering

As soon as lowering is activated, the proportional valve is powered
with the programmed value to compensate for a valve deadband in
center position. So the proportional movement of the function starts
at once.
147 0100 % 0000 – 0100 maximum valve opening for lifting

With maximum joystick set point, the programmed valve opening is
reached. So this parameter is used to set the maximum speed for
lifting.
148 0100 % 0000 – 0100 maximum valve opening for lowering

With maximum joystick set point, the programmed valve opening is
lowering.
149 0100 0.01 s 0000 – 1000 acceleration ramp for lifting

During lifting the acceleration is limited to the programmed value even
if the joystick lever is moved faster.

Electronic Steering
Repair Manual
Issue 03/2006
Electric Sideloader
Page 105
149 0100 0.01 s 0000 – 1000 acceleration ramp for lifting

150 0050 0.01 s 0000 – 1000 deceleration ramp for lifting

During lifting the deceleration is limited to the programmed value even
151 0100 0.01 s 0000 – 1000 acceleration ramp for lowering

152 0050 0.01 s 0000 – 1000 deceleration ramp for lowering

During lifting the deceleration is limited to the programmed value even
153 0000 - 0000 – 0001 hydraulic pump for lowering

0000 = off
0001 = on
154 0050 % 0000 – 0100 lifting speed reduction with low battery
If the battery is low (DI21 set to 0V) the lifting speed is reduced to the
programmed value. A value of ‚0100‘ does not reduce the speed at
all. A value of ‚0000‘ disables lifting at low battery.
155 0002 - 0000 – 0002 select joystick track for mast outreach
0001 = track 1
0002 = track 2
156 0000 - 0000 – 0001 Inversion of mast outreach

0000 = no inversion
157 0000 % 0000 – 0100 valve deadband compensation for mast reach out
As soon as mast reach out is activated, the proportional valve is
powered with the programmed value to compensate for a valve
deadband in center position. So the proportional movement of the
function starts at once.
158 0000 % 0000 – 0100 valve deadband compensation for mast reach in
As soon as mast reach in is activated, the proportional valve is
powered with the programmed value to compensate for a valve
deadband in center position. So the proportional movement of the
function starts at once.
159 0100 % 0000 – 0100 maximum valve opening for mast reach out
With maximum joystick set point the programmed valve opening is
mast reach out.
160 0100 % 0000 – 0100 maximum valve opening for mast reach in
With maximum joystick set point the programmed valve opening is
mast reach in.
161 0100 0.01 s 0000 – 1000 acceleration ramp for mast reach out
During mast reach out the acceleration is limited to the programmed
value even if the joystick lever is moved faster.

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163 0100 0.01 s 0000 – 1000 acceleration ramp for mast reach in
During mast reach in the acceleration is limited to the programmed
164 0050 0.01 s 0000 – 1000 Deceleration ramp for mast reach in
During mast reach in the deceleration is limited to the programmed
165 0050 % 0000 – 0100 Maximum valve opening at outer end

At the outer end position the maximum valve opeining is reduced to
the value of von Parameter 159. The proportional controll of the valve
opening is still active.
166 0050 % 0000 – 0100 Maximum valve opening at inner end

At the inner end position the maximum valve opening is ruduced to
the value of von Parameter 160. The proportional controll of the valve
opening is still active.
167 0100 0,01 s 0000 – 1000 deceleration ramp for outer end
When the outer end position is reached a separate deceleration is
limited (normal deceleration: see parameter 162).
168 0100 0,01 s 0000 – 1000 Deceleration ramp for inner end
When the inner end position is reached a separate deceleration is
limited (normal deceleration: see parameter 164).
169 0000 - 0000 – 9999 -

170 0001 - 0000 – 0002 select joystick track for platform tilt
0001 = track 1
0002 = track 2
171 0000 - 0000 – 0001 Inversion of platform tilt

0000 = no inversion
172 0100 0,01 s 0000 – 1000 acceleration ramp for platform tilt up
During platform tilt up the acceleration is limited to the programmed
173 0050 0,01 s 0000 – 1000 deceleration ramp for platform tilt up
During platform tilt up the deceleration is limited to the programmed
174 0100 0,01 s 0000 – 1000 acceleration ramp platform tilt down
During platform tilt down the acceleration is limited to the
programmed value even if the joystick lever is moved faster.
175 0050 0,01 s 0000 – 1000 Deceleration ramp for platform tilt down
During platform tilt down the deceleration is limited to the
programmed value even if the joystick lever is moved faster.
176 0000 - 0000 – 0001 Hydraulic pump for platform tilt down
0000 = off

0001 = on
Electronic Steering
Repair Manual
Issue 03/2006
Electric Sideloader
Page 107
178 0001 - 0000 – 0002 select joystick track for fork tilt
0001 = track 1
0002 = track 2
179 0000 - 0000 – 0001 Inversion of fork tilt

0000 = no inversion
180 0100 0,01 s 0000 – 1000 acceleration ramp for fork tilt up
During fork tilt up the acceleration is limited to the programmed value
even if the joystick lever is moved faster.
181 0050 0,01 s 0000 – 1000 deceleration ramp for fork tilt up
During fork tilt up the deceleration is limited to the programmed value
even if the joystick lever is moved faster.
182 0100 0,01 s 0000 – 1000 acceleration ramp fork tilt down
During fork tilt down the acceleration is limited to the programmed
183 0050 0,01 s 0000 – 1000 Deceleration ramp for fork tilt down
During fork tilt down the deceleration is limited to the programmed
184 0000 - 0000 – 9999 -
185 0001 - 0000 – 0002 select joystick track for fork shift
0001 = track 1
0002 = track 2
186 0000 - 0000 – 0001 Inversion of fork shift

0000 = no inversion
187 0100 0,01 s 0000 – 1000 acceleration ramp for fork shift right
During fork shift right the acceleration is limited to the programmed
188 0050 0,01 s 0000 – 1000 deceleration ramp for fork shift right
During fork shift right the deceleration is limited to the programmed
189 0100 0,01 s 0000 – 1000 acceleration ramp fork shift left
During fork shift left the acceleration is limited to the programmed
190 0050 0,01 s 0000 – 1000 Deceleration ramp for fork shift left
During fork shift left the deceleration is limited to the programmed
191 0000 - 0000 – 9999 -

192 0000 - 0000 – 9999 -
193 0000 - 0000 – 9999 -

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194 0050 % 0000 – 0100 Maxium Setpoint for Revolution of Hydraulic Pump
This value limited the maximum setpoint for the revolution of the
hydraulic pump. If this value is 100 % the steering computer
generates in analog output of +10V for the servo amplifier of the
hydraulic pump motor.
195 0050 0,01 s 0000 – 1000 Delay Hydraulic Functions after Pump On
If the joystick is moved first the hydraulic pump is switched on. After
the programmed delay the selected hydraulic function is started.
196 0100 0,01 s 0000 – 1000 Delay Pump Off after Stop Hydraulic Function
After stop the hydraulic function (move joystick back to the middle
position) the hydraulic pump is still on for the programmed time.
197 0000 % 0000 – 0100 Minimum Setpoint for Revolution of Hydraulic Pump
This value is defines the minimum revolution of the hydraulic pump.
The value is in % of the maximum setpoint (parameter 194). The
minimum setpoint (voltage for the servo amplifier) is to avoid too much
wear of the pump.
198 0000 % 0000 – 0100 Offset Pump Revolution when Lifting

If lifting is activated, the revolution setpoint for the hydraulic pump is
increased by this value referring to the maximum setpoint (parameter
194). actual setpoint = (min. setpoint (parameter 197) + offset „lifting“)
* max. setpoint (parameter 194).
199 0000 % 0000 – 0100 Offset Pump Revolution when Lowering

See parameter 198.
200 0000 % 0000 – 0100 Offset Pump Revolution when Mast reach out
See parameter 198.
201 0000 % 0000 – 0100 Offset Pump Revolution when Mast reach in
See parameter 198.
202 0000 % 0000 – 0100 Offset Pump Revolution when Platform tilt up
See parameter 198.
203 0000 % 0000 – 0100 Offset Pump Revolution when Platform tilt down
See parameter 198.
204 0000 % 0000 – 0100 Offset Pump Revolution when Fork tilt up
See parameter 198.
205 0000 % 0000 – 0100 Offset Pump Revolution when Fork tilt down
See parameter 198.
206 0000 % 0000 – 0100 Offset Pump Revolution when Fork shift right
See parameter 198.
207 0000 % 0000 – 0100 Offset Pump Revolution when Fork shift left
See parameter 198.
208 0100 % 0000 – 0100 Maximum Setpoint Pump Revolution when Lifting
Pump setpoint if joystick is maxiumum moved. The value is in % of
the maximum setpoint (parameter 194).
209 0100 % 0000 – 0100 Maximum Setpoint Pump Revolution when Lowering
See parameter 208.
210 0100 % 0000 – 0100 Max. Setpoint Pump Revolution when Mast reach out
See parameter 208.
211 0100 % 0000 – 0100 Max. Setpoint Pump Revolution when Mast reach in
See parameter 208.
Electronic Steering
Repair Manual
Issue 03/2006
Electric Sideloader
Page 109
212 0100 % 0000 – 0100 Max. Setpoint Pump Revolution when Platform tilt up
See parameter 208.
213 0100 % 0000 – 0100 Max. Setpoint Pump Revolution when Platform tilt
down. See parameter 208.
214 0100 % 0000 – 0100 Max. Setpoint Pump Revolution when Fork tilt up
See parameter 208.
215 0100 % 0000 – 0100 Max. Setpoint Pump Revolution when Fork tilt down
See parameter 208.
216 0100 % 0000 – 0100 Max. Setpoint Pump Revolution when Fork shift right
See parameter 208.
217 0100 % 0000 – 0100 Max. Setpoint Pump Revolution when Fork shift left
See parameter 208.
218 0000 % 0000 – 0100 Bending Point for Pump Setpoint Lifting
The analog setpoint for the pump revolution is calculated with curve
which have a bending point. This parameter defines at which setpoint
this bending point is located.
219 0000 % 0000 – 0100 Bending Point for Pump Setpoint Lowering
See parameter 218.
220 0000 % 0000 – 0100 Bending Point for Pump Setpoint Mast reach out
See parameter 218.
221 0000 % 0000 – 0100 Bending Point for Pump Setpoint Mast reach in
See parameter 218.
222 0000 % 0000 – 0100 Bending Point for Pump Setpoint Platform tilt up
See parameter 218.
223 0000 % 0000 – 0100 Bending Point for Pump Setpoint Platform tilt down
See parameter 218.
224 0000 % 0000 – 0100 Bending Point for Pump Setpoint Fork tilt up
See parameter 218.
225 0000 % 0000 – 0100 Bending Point for Pump Setpoint Fork tilt down
See parameter 218.
226 0000 % 0000 – 0100 Bending Point for Pump Setpoint Fork shift right
See parameter 218.
227 0000 % 0000 – 0100 Bending Point for Pump Setpoint Fork shift left
See parameter 218.
228 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Lifting
The setpoint for the electronics (generated by the joystick) is
calculated with curve which have a bending point. This parameter
defines at which joystick setpoint this bending point is located
229 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Lowering
See parameter 228.
230 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Mast reach out
See parameter 228.
231 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Mast reach in
See parameter 228.
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232 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Platform tilt up
See parameter 228.
233 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Platform tilt down
See parameter 228.
234 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Fork tilt up
See parameter 228.
235 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Fork tilt down
See parameter 228.
236 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Fork shift right
See parameter 228.
237 0000 % 0000 – 0100 Bending Point for Joystick Setpoint Fork shift left
See parameter 228.
238 0000 - 0000 – 9999 -

239 0000 - 0000 – 9999 -
240 0000 - 0000 – 3333 Inversion of Digital Inputs 1...8
xxx0 = Digital input 1 normal 2 normal
xxx1 = Digital input 1 invers 2 normal
xxx2 = Digital input 1 normal 2 invers
xxx3 = Digital input 1 invers 2 invers
xx0x = Digital input 3 normal 4 normal
xx1x = Digital input 3 invers 4 normal
xx2x = Digital input 3 normal 4 invers
xx3x = Digital input 3 invers 4 invers
x0xx = Digital input 5 normal 6 normal
x1xx = Digital input 5 invers 6 normal
x2xx = Digital input 5 normal 6 invers
x3xx = Digital input 5 invers 6 invers
0xxx = Digital input 7 normal 8 normal
1xxx = Digital input 7 invers 8 normal
2xxx = Digital input 7 normal 8 invers
3xxx = Digital input 7 invers 8 invers


Electronic Steering
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Electric Sideloader
Page 111

243 0000 - 0000 – 9999 -

244 0000 - 0000 – 9999 -
245 0000 - 0000 – 9999 -
246 0000 - 0000 – 9999 -
247 0000 - 0000 – 9999 -
248 0000 - 0000 – 9999 -
249 0000 - 0000 – 9999 -
250 0000 - 0000 – 3333 Configuration Digital-/Analog inputs (DI/AI)
xxx0 = Input 1: AI Input 2: AI
xxx1 = Input 1: DI Input 2: AI
xxx2 = Input 1: AI Input 2: DI
xxx3 = Input 1: DI Input 2: DI
xx0x = Input 3: AI Input 4: AI
xx1x = Input 3: DI Input 4: AI
xx2x = Input 3: AI Input 4: DI
xx3x = Input 3: DI Input 4: DI
x0xx = Input 5: AI Input 6: AI
x1xx = Input 5: DI Input 6: AI
x2xx = Input 5: AI Input 6: DI
x3xx = Input 5: DI Input 6: DI
0xxx = Input 7: AI Input 8: AI
1xxx = Input 7: DI Input 8: AI
2xxx = Input 7: AI Input 8: DI
3xxx = Input 7: DI Input 8: DI
251 0000 - 0000 – 3333 Configuration Digital Inputs (DI) 17...24

xxx0 = DI 17: high side DI 18: high side
xxx1 = DI 17: low side DI 18: high side
xxx2 = DI 17: high side DI 18: low side
xxx3 = DI 17: low side DI 18: low side
xx0x = DI 19: high side DI 20: high side
xx1x = DI 19: low side DI 20: high side
xx2x = DI 19: high side DI 20: low side
xx3x = DI 19: low side DI 20: low side
x0xx = DI 21: high side DI 22: high side
x1xx = DI 21: low side DI 22: high side
x2xx = DI 21: high side DI 22: low side
x3xx = DI 21: low side DI 22: low side
0xxx = DI 23: high side DI 24: high side
1xxx = DI 23: low side DI 24: high side
2xxx = DI 23: high side DI 24: low side
3xxx = DI 23: low side DI 24: low side

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252 0000 - 0000 – 9999 -

253 0000 - 0000 – 9999 -
254 0000 - 0000 – 9999 -
255 0000 - 0000 – 9999 -

Electronic Steering
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Error List 019 505

The occuring errors of the steering-computer SLC 019505 can be read out form the following error
tabel. In the first table column the possible locations of fault are listed, in the first table line the
possible types of errors. Every table cell with priority entry characterizes a possible error and its
priority. Cells without priority entry are not checked.
Type of error
circuit/overload
90° alignment out of tolerance
Higher than maximum value
Lower than minimum value
Cable break/short
Deviation warning
Module detection
Deviation error
Cable break
Short circuit
Terminated
Plausibility
Time out
No error
Failure location 0 1 2 3 4 5 6 7 8 9 10 11 12 13
No error 0
Angle transducer 3 0 2 3 1
1
axle1
2
axle 2
3
axle 3
4
axle 4
Prop. valve axle 1 5 0 3
ELS pressure valve 9 2
Shock sensor 10 2
Maintenance interval 11 1
- 12
- 13
- 14
Joystick lift/lowering 15 0
Joystick mast in/out 16 0
Joystick platform tilt 17 0
Joystick fork tilt 18 0
Prop. valve lowering 19 1 1
Prop. valve lifting 20 1 1
Prop. valve mast out 21 1 1
Prop. valve mast in 22 1 1
Electronic Steering
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Page 114
Type of error
circuit/overload
Higher than maximum value
Lower than minimum value
Cable break/short
Deviation warning
Module detection
Deviation error
Cable break
Short circuit
Terminated
Plausibility
Time out
No error
Failure location 0 1 2 3 4 5 6 7 8 9 10 11 12 13
Prop. valve platform 1 1

23
down
Prop. valve platform 1 1
24
up
Prop. valve forks 1 1
25
down
Prop. valve forks up 26 1 1
-- 27
-- 28
-- 29
Extension module 1 30 1 1
Extension module 2 31 1 1
-- 32
-- 33
EEA 092 131 34 1
- 35
- 36
- 37
Safety-steering- ½ 2
38
setpoint generator
-- …
EEPROM 99 1

Electronic Steering
Issue 03/2006
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Page 115
Electronic faults / U - error codes

Steering controller 019 505
Self test by switching on:
Error Error cause Description/Remedy

code
U..1 CPU-Self test Please return controller for repairing
U..2 RAM-Self test 0F600H-0FDFFH IRAM Please return controller for repairing
U..3 RAM-Self test 0E600H-0E7FFH SRAM Please return controller for repairing
U..4 RAM-Self test 80000H-0BFFFFH XRAM Please return controller for repairing
U..5 EEPROM-Self test parameter 0-511 Bad parameter will be advised or error in
EEPROM signature.
Reprogramming
U..6 Flash-ROM-Self test: signature analysis Reprogramming software by Flash-
download
U..7 Self test: 10ms-Interrupt Please return controller for repairing
U.10 Self test: 5V power supply (PIC)Pin9=1 Please return controller for repairing
U.11 Self test: Triggering of mono-stable trigger circuit Please return controller for repairing
not possible
U.12 Self test: t_mono-stable trigger circuit < min Please return controller for repairing
U.13 Self test: t_ mono-stable trigger circuit > max Please return controller for repairing
U.14 Self test: Triggering in time and to fast Please return controller for repairing
U.15 Self test: t_Watchdog < min Please return controller for repairing
U.16 Self test: t_Watchdog > max Please return controller for repairing
U.17 Self test: Undervoltage monitoring not possible Please return controller for repairing
U.18 Self test: Overvoltage monitoring not possible Please return controller for repairing
U.19 Self test Security – FET FET does connect not or not fast enough.
Check up DA1…8 for short circuit or
external voltage
U.20 Program flow monitoring Reprogramming software by Flash-
download. When without success
please return controller for repairing
U.21 Self test Digital output n°1 (DA) Digital output DA1 can’t be connected.
Short circuit to Ground or +Ub.
Short circuit to another digital output.
U.22 Self test Digital output n°2 (DA2) See above U.21

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code
U101 Cyclic CPU test Please return controller for repairing
U102 Cyclic test: RAM Reprogramming software by Flash-
U103 Cyclic test: EPROM-signature Reprogramming software by Flash-
U104 Signature fault RAM-image of parameter Signature of converted parameter at
RAM are incorrect
U105 Cyclic test: 5V power supply PIC Pin9 Please return controller for repairing
U106 Power supply U_bat > Max. (31V) Power supply battery to high
U107 Power supply U_bat < min. (14V) Power supply battery to low
U108 Ambient air temperature > Max. (85°C) Ambient air temperature to high
U109 Cyclic program flow monitoring Please return controller for repairing
U110 Programm flow monitoring Please return controller for repairing
Key – pivot
U111 Cyclic test: Watchdog time is up: Please return controller for repairing
PIC PIN13=1
U112 Cyclic test: Zen-MA-Interrupt Please return controller for repairing
U113 Program in infinite loop Please return controller for repairing
U114 Reference voltage external out of tolerance Check up reference voltage
(Vfrefex) (Power supply potentiometer)
U115 Power Supply of safety part out of tolerance Please return controller for repairing
U116 Cyclic test of safety part without success Please return controller for repairing
U121 Error by monitoring digital output n° 1 (DA1) Digital output DA1 can’t be
connected.
Short circuit to Ground or +Ub.
Short circuit to another digital output.
U122 Error by monitoring digital output n° 2 (DA2) See above U121

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Cyclic tests
code
U161 Error by monitoring digital input n° 1 (DE1) Comparing digital input + redundant
memorises value. Bit by bit comparison of
non-chattered datas.
Check up if incoming voltage is out of
tolerance 5V…9V
U162 Error by monitoring digital input n° 2 (DE2) See above U161
U201 Error by monitoring analog input n° 1 (AE1) Verifying with memorised value.
Tolerance +/- 3.0V. Check up input
on electrical oscillations
U202 Error by monitoring analog input n° 2 (AE2) See above U201
U-error codes could be shown in error memory as following:
239 – 201 -003
Indicates U-error-code Non information

U-error-code U 201

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Location of error 1: Steering control axle 1

Type of error Description
4 Steering deviation error
The steering deviation of the axle is higher than the limit programmed in parameter
parameter 121. The vehicle is stopped. The steering remains active.
Causes/trouble shooting:
- Hydraulics supply not sized sufficiently.
- Axle machanically blocked. Hydraulics pressure not suficing.
- Too high steering speed programmed in parameter 100.
- Too scmall error treshold programmed in parameter 121.
5 Error 0°-alignment
The alignment of the steering axle is not in the range 2,4 V ... 2,6 V or was not
carried out at all. The steering-axle is switched off, the vehicle is stopped.
Causes / trouble shooting:

- Angle transducer mechanically not adjusted in lengthways straight line correctly.
Steering axle to lengthways straight and turn angle transducer into the tolerance
zone in this position with inactive steering,. The repeat the 0°-alignment.
6 Error 90°-alignment
The 90°-alignment is in the rage of the 0°-alignment or was not carried out at all.
Steering and drive unit are active. The steering-computer uses parameters 76 to the
calculation of the steering-angles from the angle transducer.
Causs / trouble shooting:

- Carry out 90°-alignment

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Location of error 5: Proportional valve axle 1

9 Error of power driver.

The power driver of the PWM-output has a diagnostic function which is evaluated
by the steering-computer. The steering axle is switched off and the vehicle stopped.

- Cable break to the proportional valve. The cable break can be recognized only if
if the proportional valve is controlled. Test cable and solenoid of the proportional
valve. The error can become also active if proportional valves with very high-
impedance solenoid are used.
- Short circuit or overload of the power output. Test cabling and solenoid of the
proportional valve.
7 Continuous maximum output of the power driver.

The power driver for the proportional valve is at its maximum longer than 2 minutes.
The steering and the drive-unit remain active. The control of the proportional valve is
reduced to dead-band plus 10 % of the valve opening.

- The hydraulics pressure is too low in order to set the steering-axles onto the
desired nominal position.
- The hydraulic pump does not work.
Location of error 9: Proportional-pressure relief valve for ELS

by the steering-computer. The steering and the drive-unit remain active.

- Cable break to the ELS pressure relief valve. The cable break can be recognized
only if the ELS pressure relief valve is powered. Testing circuit and solenoid of the
ELS-pressure relief valves. The error can also become active if ELS-pressure relief
valves with very high-impedance solenoid are used.
- Short circuit or overload of the power output. Test cabling and solenoid of the ELS-
pressure relief valve

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Location of error 9: Proportional-pressure relief valve for ELS

by the steering-computer. The steering and the drive-unit remain active.

- Cable break to the ELS pressure relief valve. The cable break can be recognized
only if the ELS pressure relief valve is powered. Testing circuit and solenoid of the
ELS-pressure relief valves. The error can also become active if ELS-pressure relief
valves with very high-impedance solenoid are used.
- Short circuit or overload of the power output. Test cabling and solenoid of the ELS-
pressure relief valve
Location of error 10: Shock Sensor
7 Exceeding maximum value

The shock sensor has detected a crash and applied a voltage toA16 which is larger
as the threshold programmed in parameter 134.

- Inform the service. In order to erase the error, the login must be carried out at the
EEA 092 431 with the service code. If login is deactivated, the password must be
set at parameter programming, axle alignment, driver code programming, etc.
When EEA 092431 (-1) is not active, code input must be made at parameter
programming or axle alignment on the SLC 019 505 steering computer.
Location of error 11: Service internal
13 Interval terminated.
The service interval is terminated. The countdown and check of the service interval
is only possible with active EEA 092 431.

- Inform the service. In order to erase the error, the service intervalm ust be reset.

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Location of error 15: Joystick level 1 (lift / lowering)

Location of error 16: Joystick level 2 (mast shifting- in/out)
Location of error 17: Joystick level 3 (forks tilt)
Location of error 18: Joystick level 4 (fork adjustment)
11 Signals not plausible.

Every joystick of the load handling has an analog singal 0 ... +5V and a switching
contact. These signals are tested against each other. In the case of an error the
appropriate load handling function is blocked.

- Cable break to the joystick contact.
- Cable break to the potentiometer of the joystick.
- Erroneous programming of the joystick threshold (parameter 261). If the analog
joystick voltage exceeds the joystick threshold (2,5 V ± parameter 261), the
joystick contact must be closed.
Location of error 19: Proportional valve lowering

Location of error 20: Proportional valve lifting
Location of error 21: Proportional valve mast shifting in
Location of error 22: Proportional valve mast shifting out
Location of error 23: Proportional valve platform tilting down
Location of error 24: Proportional valve platform tilting up
Location of error 25: Proportional valve fork tilting down
Location of error 26: Proportional valve fork tilting up
1 Cable break
The proportional valve is powered by a current controlled PWM-output. The cable
break error becomes acting, if the current set point is higher than 600 mA and the
actual current is lower than 100 mA.

- Cable break of the circuit to the solenoid of the proportional valve.
- Defect of the solenoid.
- Defect of the extension module.

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Location of error 19: Proportional valve lowering

Location of error 20: Proportional valve lifting
Location of error 21: Proportional valve mast shifting in
Location of error 22: Proportional valve mast shifting out
Location of error 23: Proportional valve platform tilting down
Location of error 24: Proportional valve platform tilting up
Location of error 25: Proportional valve fork tilting down
Location of error 26: Proportional valve fork tilting up
2 Short circuit
The proportional valve is powered by a current controlled PWM-output. The short
circuit error becomes acting, if the current set point is lower than 2500 mA and the
actual current is higher than 2800 mA.

- Short circuit of the cable to the solenoid of the proportional valve.
- Short circuit inside the solenoid of solenoid cartridge too low-impedance.
- Defect of the extension module.
Location of error 30: Extension module right

Location of error 31: Extension module left
12 Module detection failed

During power up of the supply voltage the module detection of both extension
modules is activated. With unseccuessful module detection the load handling is not
available.

- Testing supply voltage of the extension modules.
Location of error 34: Operation terminal EEA 092 131
10 CAN Bus Timeout.

The operator terminal EEA 092 131 is connected by CAN bus with the steering-
computer. If no dates are received from the operation terminal for 100 ms, the
timeout error becomes active.

- Testing CAN bus cable between the steering-computer and the operation terminal.
A resistance measurement with a meter between CAN-H and CAN-L must approx.
show 60 ohm (power supply must be off).
- Testing voltage supply of the operator terminal.

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Location of error 38: Steering set point generator
1 Cable break
The CLOCK-signal of the steering controller is bridge connected to the analog input
AE7 (AE8 for channel 2) in order to read the signal levels. The sterring of the vehicle
remains active. The drive-unit is stopped.
At a 2-channel steering-setpoint-generator the erroneous is ignoed the steering is

kept active with the residual operative channel.

- The test cable of the CLOCK-signal or the connection to the analog output is
interrupted.
- Test the supply voltage of the steering setpoint generator.
11 Plausibility
At a 2-channel steering-setpoint generator the output signals at the steering-
computer are read via 2 separate incremental counters. The steering set points
generated from that are compared with each other and an error is caused if the two
steering set points deviate too very much.

- The cable of the UP/DOWN-signal of one channel of the steering set point
generator is unterrupted.
- Wiring error. Interchanging of the signals with use of an A/B trace steering setpoint
generator.
- Defect of the steering setpoint generator.

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E le c t r o n ic S t e e r in g
P a g e 6 1
S t e e r in g P o s it io n C o m p u t e r
T y p e : B A U M A N N L P C 0 1 9 2 6 0
S t e e r in g P o s it io n C o m p u t e r
T y p e : S L C 0 1 9 5 0 5
4 - A x le S t e e r in g S y s t e m w it h p r o p o t io n a l w o r k in g h y d r a u lic
P a g e 6 2
1 . G e n e r a l In f o r m a t io n
T h e o p e r a t io n o f t h e e le c t r o n ic s is d o n e b y t h e d ia g n o s t ic p a n e l o f t h e s t e e r in g c o m p u t e r .
T h e L P C 0 1 9 2 6 0 f e a t u r e s a L C D s iz e d 2 lin e s b y 1 6 c h a r a c t e r s f o r r e a d o u t o f
in f o r m a t io n a n d 4 k e y s f o r m e n u s e le c t io n a n d d a t a in p u t .
K e y f u n c t io n s :
E s c a p e k e y
- 5 + - E x it t h e p r e s e n t m e n u w it h o u t s a v in g d a t a
- B a c k s p a c e w h e n in d a t a in p u t m o d e .
M in u s k e y :
- G o t o p r e v io u s m e n u .
D e c r e a s e in p u t d a t a b y o n e .
P lu s k e y :
- G o to n e x t m e n u .
In c r e a s e in p u t d a t a b y o n e .
E n te r k e y :
- S e le c t c u r r e n t m e n u .
C o n f ir m o r s a v e in p u t d a t a .
V ia t h is 4 k e y s t o g e t h e r w it h t h e m e n u , a n e a s y o p e r a t io n c a n b e p e r f o r m e d , a ls o f o r
le s s t r a in e d s e r v ic e s t a f f .
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6
- 5 +
P a g e 6 3
2 . D is p la y o f S o f t w a r e V e r s io n
T h e L P C in d ic a t e s f o r 2 , 5 s e c . t h e s o f t w a r e v e r s io n a n d d a t e o f t h is v e r s io n e v e r y t im e
p o w e r is s w it c h e d o n .
L P C 0 1 9 2 6 1 'A '
1 8 .1 2 .2 0 0 1
- 5 +
P a g e 6 4
3 . E r r o r a n d S t a t u s D is p la y
W h e n n o k e y is p r e s s e d o r a ll s u b m e n u s a r e e x it e d , t h e d is p la y in d ic a t e s f o llo w in g s t a t u s
in f o r m a t io n :
3 .1 D is p la y in N o r m a l O p e r a t io n (n o e r r o r )
n o e rro r
>
- 5 +
A > - m a r k o n t h e s e c o n d lin e m o v in g le f t t o r ig h t s ig n a lis iz e s t h a t t h e s t e e r in g c o m p u t e r

is a c t iv e a n d t h e s o f t w a r e is in p r o c e s s .
3 .2 D is p la y o f P r e s e n t E r r o r
e rro r c o d e
1 0 -0 7 -0 1
- 5 +
A s s o o n a s a n e r r o r is d e t e c t e d , t h e d is p la y s h o w s th e c u r re n t e rro r c o d e . S e p a ra te d b y a
h y p h e n th e d is p la y s h o w s t h e e r r o r lo c a t io n , t h e e rro r ty p e a n d th e e r r o r p r io r it y . If m o r e
th a n o n e e rro r is d e te c te d a t th e s a m e t im e , t h e d is p la y s h o w s a ll m e s s a g e s a lt e r n a t in g
w it h 2 . 5 s e c o n d s d e la y . If t h e a ll e r r o r s s o lv e d , t h e d is p la y c h a n g e s b a c k to n o rm a l
o p e r a t io n m o d e (s e e c h a p te r 3 .1 ). T h e e r r o r c o d e s a re s h o w n o n p a g e 1 0 1 .
P a g e 6 5
3 .3 D is p la y o f In c o r r e c t P a r a m e t e r s
p a ra m e te r e rro r
n u m b e r: 1 2 6
- 5 +
F o r e a c h p a ra m e te r th e re is a lo w e r a n d u p p e r lim it . If t h e v a lu e s to r e d in t h e E E P R O M
( n o n v o la t ile m e m o ry ) is o u ts id e th e a llo w e d v a lu e r a n g e , t h e in d e x n u m b e r o f th e
in c o r r e c t p a r a m e t e r is d is p la y e d . T h e e rro r c a n o n ly b e c o r r e c t e d b y s e t t in g th e in d ic a t e d
p a ra m e te r to a c o rre c t v a lu e . In th e p a ra m e t e r lis t o f e a c h tru c k th e c o rre c t v a lu e fo r e a c h
p a r a m e t e r is lis t e d .
3 .4 P r o c e s s D a t a D is p la y
P ro c e s s d a ta d is p la y is s e le c te d b y p re s s in g t h e E N T E R k e y e it h e r in t h e n o rm a l m o d e
o r in th e e rro r d is p la y . A fte r p re s s in g t h e E N T E R k e y th e d is p la y s w a p s f r o m d is p la y in g
e rro r s to th e o p e r a t io n a l d a ta . P r e s s in g t h e E S C A P E k e y o r n o t p r e s s in g a n y k e y fo r
m o re th a n 5 m in u t e s it w ill a u to m a t ic a lly s w it c h b a c k to th e s t a t u s d is p la y .
n o e rro r P X : -1 3 7 6 1 .8 7
> P Y : 1 4 0 0 .0 0
- 5 + - 5 +
P a g e 6 6
In t h e o p e r a t io n a l d a t a m o d e , t h e r e a r e 1 3 m e n u s f o r t h e s t e e r in g s y s t e m a n d 8 m e n u s
f o r t h e w o r k in g h y d r a u lic . T h e m e n u s t o b e d is p la y e d c a n b e s e le c t e d b y p r e s s in g t h e
P L U S o r t h e M IN U S k e y .
P X : + IN F
P Y : 2 0 0 0 .0 0
- 5 +
P r e v io u s d is p la y N e x t d is p la y
3 .4 .1 D is p la y in g t h e S t e e r in g P o le
D is p la y o f t h e X - a n d Y - c o o r d in a t e s f r o m t h e s t e e r in g p o le s in [ m m ] . T h e s t e e r in g p o le is
c e n t r e o f t h e d r iv in g c u r v e . O n e v a lu e o f t h e s t e e r in g p o le g o e s in f in t e if t h e s t e e r in g is
s t r a ig h t a h e a d . In t h is c a s e t h e d is p la y s h o w s IN F .
P X : + IN F
P Y : 2 0 0 0 .0 0
- 5 +
3 .4 .2 D is p la y in g t h e S t e e r in g S e t p o in t
D is p la y o f t h e c u r r e n t s t e e r in g s e t p o in t in d e g re e s ( w it h s ig n e d ). T h e f ir s t lin e s h o w s t h e
s t e e r in g a n g le r e a d in f r o m t h e p ro g ra m m e d s te e r in g s e t p o in t g e n e r a t o r . In c a s e s o f a n
o r b it r o l s t e e r e d a x le t h e f ir s t lin e s h o w s th e a c tu a l v a lu e o f t h e le a d in g a x le .
T h e s e c o n d lin e s h o w s th e s te e r in g s e t p o in t a f t e r lo w - p a s s f ilt e r in g . T h is v a lu e is u s e d t o
c a lc u la t e t h e s e t p o in t f o r t h e a x le ( s ) .
s e tp : 4 3 .7 1
R a m p : 3 2 .0 8
- 5 +
P a g e 6 7
3 .4 .3 S e t p o in t a n d A c t u a l A n g le o f S in g le A x le
T h e d is p la y s h o w s t h e S e t p o in t a n d t h e a c t u a l a n g le f r o m a s t e e r in g a x le s 1 . . . 4 in f o u r
s e p a r a t e d is p la y s .
T h e v a lu e is s h o w n in d e g r e e ( ° ) . T h e f o llo w in g e x a m p le s h o w s v a lu e s o f a x le 1 :
s e tp 1 : 1 2 .0 0
a c t 1 : 1 1 .9 6
- 5 +
3 .4 .4 C o n t r o l o f P r o p o r t io n a l V a lv e s
T h e c o n t r o l o f t h e p r o p o r t io n a l v a lv e s is d e v id e d in t w o d is p la y s (o n e d is p la y f o r a x le 1 / 2
a n d o n e d is p la y f o r a x le 3 / 4 ). T h e d is p la y s h o w s t h e t h e a c t u a l s e t p o in t s o f t h e p o w e r
o u t p u t s in t h e r a n g e b e t w e e n 0 % a n d 1 0 0 % . 1 0 0 % is e q u iv a le n t t o a n o u t p u t v o lt a g e o f
+ 2 4 V .
P W M 1 : 7 3 % 0 %
P W M 2 : 0 % 2 2 %
- 5 +
O n e o f b o t h v a lu e s p e r lin e is 0 % b e c a u s e o n ly o n e s o le n o id o f t h e p r o p o r t io n a l v a lv e
( p e r a x le ) is p o w e r e d . If t h e le f t v a lu e is n o t 0 , t h e a x le h a s t o t u r n le f t . If t h e r ig h t v a lu e is
n o t 0 , t h e a x le h a s t o t u r n r ig h t .
T h e e x a m p le s h o w s : A x le 1 t u r n in g le f t
A x le 2 t u r n in g r ig h t
P a g e 6 8
C o d e fo r t h e s t e e r in g p r o g r a m s C o d e fo r t h e r e le a s e fla g s
0 1 C r o s s - r e a r a x le L e n g t h w a y s - f ix a x le 4 a x le 3 a x le 2 a x le 1
2 L e n g t h w a y s - a ll w h e e l
3 L e n g t h w a y s - d ia g o n a l 0 o u t o u t o u t o u t
4 L e n g t h w a y s - f r o n t s t e e r in g 1 o u t o u t o u t o n
5 L e n g t h w a y s - r e a r s t e e r in g 2 o u t o u t o n o u t
6 S id e w a y s - f ix 3 o u t o u t o n o n
7 S id e w a y s - a ll w h e e l 4 o u t o n o u t o u t
8 S id e w a y s - d ia g o n a l 5 o u t o n o u t o n
9 S id e w a y s - f r o n t s t e e r in g 6 o u t o n o n o u t
1 1 C ir c u la r d r iv in g 7 o u t o n o n o n
1 2 P a r k in g p r o g r a m 8 o n o u t o u t o u t
2 5 5 N o p r o g r a m s e le c t e d 9 o n o u t o u t o n
1 0 o n o u t o n o u t
1 1 o n o u t o n o n
1 2 o n o n o u t o u t
1 3 o n o n o u t o n
1 4 o n o n o n o u t
1 5 o n o n o n o n
3 .4 .7 H y d r a u lic A c c u m u la t o r L o a d in g S y s t e m (O p t io n )
W h e n w o r k in g w it h a h y d r a u lic a c c u m u la t o r p r e s s u r e s y s t e m t h e d is p la y s h o w s t h e
a c t u a l p r e s s u r e ( f ir s t lin e ) a n d t h e s w it c h o n v a lu e ( lo ) a n d t h e s w it c h o f f v a lu e (h i) o n t o
t h e s e c o n d lin e . A ll v a lu e s h o w s in [ m V ] .
p re s s u re : 1 3 0 0
lo :3 0 0 0 h i:4 0 0 0
- 5 +
3 .4 .8 E L S S e t p o in t V a lu e (O p t io n )
T h e d is p la y s h o w s th e a c tu a l c o n t r o l v a lu e ( in % o f + 2 4 V ) o f t h e p r o p o r t io n a l p r e s s u r e
r e lie f v a lv e (E L S ). T h e m a x im u m p r e s s u r e is c o n t r o lle d if t h e d is p la y s h o w s t h e v a lu e f o r
th e n o m in a l v o lt a g e o f th e p r o p o r t io n a l s o le n o id . F o r e x a m p le t h e m a x im u m v a lu e f o r a
1 0 V s o le n o id is 4 2 % (o f 2 4 V ).
E L S p re s s u re o u t
2 3 %
- 5 +
P a g e 6 9
3 .4 .9 Im p u ls e s o f S t e e r in g S e t p o in t G e n e r a t o r
T h e in t e r n a l c o u n t e r v a lu e s o f t h e s t e e r in g s e t p o in t g e n e r a t o r c a n b e d is p la y e d . W h e n
t u r n in g t h e s t e r in g w h e e l t h e c o u n t e r v a lu e o f t h e d e t e c t e d im p u ls e s is s h o w n o n t o t h e
d is p la y . T h e m a x . c o u n t e r r a n g e is f r o m 3 2 7 6 8 t o + 3 2 7 6 7 p u ls e s .
s te e r in g - w h e e l
c o u n te r: 2 3 6
- 5 +
3 . 4 . 1 0 W o r k in g H y d r a u lic F u n c t io n s ( O p t io n )
E a c h w o r k in g h y d ra u lic f u n c t io n ( m a x = f iv e f u n c t io n s ) is s h o w n o n a s e p a r a t e d is p la y . T h e
d is p la y e d v a lu e s a re in t e r n a lly s t a n d a r d iz e d f r o m 3 2 7 6 8 t o + 3 2 7 6 7 . T h e f ir s t lin e s h o w s
th e a c tu a l v a lu e o f th e jo y s t ic k a n d t h e s e c o n d lin e s h o w s t h e c a lc u la t e d v a lu e ( a f t e r r a m p
f u n c t io n a n d o th e r lim it a t io n s ).
jo y s t.1 : - 3 2 1 8 8
s e tp .1 : -3 2 0 6 5
- 5 +
3 . 4 . 1 1 C o n t r o l o f P r o p o r t io n a l V a lv e f o r L if t in g a n d L o w e r in g ( O p t io n )
T h e d is p la y s h o w s t h e s e t p o in t f o r t h e p r o p o r t io n a l s o le n o id in % . A t le a s t o n e v a lu e is
a lw a y s 0 % b e c a u s e o n ly o n e s o le n o id o f t h e v a lv e c a n b e o p e r a t e d a t t h e s a m e t im e .
liftin g : 4 3 %
lo w e r in g : 0 %
- 5 +
P a g e 7 0
3 . 4 . 1 2 P r o p o r t io n a l V a lv e f o r M a s t - R e a c h ( O p t io n )
T h e d is p la y s h o w s t h e s e t p o in t f o r t h e p r o p o r t io n a l s o le n o id in % . A t le a s t o n e v a lu e is a lw a y s 0 %
b e c a u s e o n ly o n e s o le n o id o f t h e v a lv e c a n b e o p e r a t e d a t t h e s a m e t im e .
m a s t o u t: 0 %
m a s t in : 3 3 %
- 5 +
3 . 4 . 1 3 R e v o lu t io n S e t p o in t f o r H y d r a u lic P u m p ( O p t io n )
T h e r e v o lu t io n o f t h e h y d r a u lic p u m p is c o n t r o lle d b y a s e r v o - a m p lif ie r . T h e s e t p o in t f o r

t h e s e r v o - a m p lif ie r is g e n e r a t e d b y t h e s t e e r in g c o m p u t e r . T h e d is p la y s h o w s t h e a c t u a l
a n a lo g v a lu e in V [ r a n g e : 0 V t o + 1 0 V ] .
p u m p s e t p o in t:
3 .7 5 V
- 5 +
P a g e 7 1
4 . M e n u f o r S e r v ic e F u n c t io n s
T h e s e r v ic e m e n u is a c t iv a t e d b y p r e s s in g t h e E N T E R - a n d t h e E S C A P E k e y a t t h e s a m e t im e f o r
m o r e t h a n 3 s e c . ( t h e s e r v ic e m e n u is a c t iv a t e d w h e n t h e d is p la y s h o w s i( o d a t a d is p la y ) .
n o e rro r
>
- 5 +
K e e p b o th b u tto n s p re s s e d fo r 3 s e c o n d s
P a g e 7 2
i/ o d a t a d is p la y
b a c k to E S C E S C
e x e c u te
t h e d is p la y
e rro r m e m o ry
b a c k to E S C E S C e x e c u te
t h e d is p la y
p a ra m e te r
t h e d is p la y
a x le a lig n m e n t
t h e d is p la y
a c c e s s c o d e
t h e d is p la y
P a g e 7 3
K e y f u n c t io n s :
E S C A P E - b a c k to s ta tu s m e n u
M IN U S - p r e v io u s s u b m e n u
P L U S - n e x t s u b m e n u
E N T E R - e n te r s u b m e n u .
4 .1 . I/ O - D a ta M e n u
T h e I/ O - d a t a m e n u g iv e s a c c e s s t o a ll t h e c u r r e n t I/ O - s t a t e s . T h is m e n u is u s e f u l b y
d o in g s t a r t u p a n d s e r v ic e o f t h e m a c h in e . W h ile a c t iv e s e r v ic e f u n c t io n s ( s e e c h a p t e r 4 )
t h e I/ O - D a t a s u b m e n u is e x e c u t e d b y p r e s s in g t h e e n t e r k e y ( s e e p ic t u r e b e lo w ) .
i/ o d a ta d is p la y
- 5 +
T h e f o llo w in g 1 9 s u b m e n u s c a n b e a c c e s s e d u s in g t h e P L U S o r M IN U S k e y s .
D I 1 ... 8 :
0 0 0 1 0 1 0 0
- 5 +
E x it d a ta d is p la y
P r e v io u s d a ta d is p la y
N e x t d a ta d is p la y
P a g e 7 4
4 .1 .1 D ig it a l In p u t s
T h e L P C 0 1 9 2 6 0 h a s g o t 2 4 d ig it a l in p u t s ( D I) . T h e lo g ic a l s t a t e ( o n o r o f f ) is s h o w n
s e p a r a t e ly f o r e a c h in p u t . A 1 in d ic a t e s a n a c t iv e d ig it a l in p u t .
D I 1 ... 8 :
0 0 0 1 0 1 0 0
- 5 +
D ig it a l in p u t 1 D ig it a l in p u t 8
E x a m p le : in p u t 1 = lo w , 2 = lo w , 3 = h ig h , 4 = h ig h , 5 = lo w , 6 = h ig h , 7 = lo w , 8 = lo w
D I 9 ... 1 6 :
1 1 0 0 0 0 0 1
- 5 +
D ig ita l in p u t 9 D ig ita l in p u t 1 6
E x a m p le : in p u t 9 = h ig h , 1 0 = h ig h , 1 1 = lo w ......
D I 1 7 ... 2 4 :
0 0 0 0 0 1 0 0
- 5 +
D ig ita l in p u t 1 7 D ig ita l in p u t 2 4
P a g e 7 5
4 .1 .2 A n a lo g In p u t s
T h e L P C 0 1 9 2 6 0 h a s g o t 8 a n a lo g in p u t s t h a t c a n b e u s e d f o r t h e a p p lic a t io n . In a d d it io n
t h e r e a r e s e v e r a l m o r e a n a lo g in p u t s w h it c h a r e u s e d f o r in t e r n a lly c o n t r o ll f u n c t io n s
( t e m p e r a t u r e c o n t r o l, s u p p ly v o lt a g e c o n t r o l, . . . ) .
A I1 : 2 7 9 8 m V
A I2 : 1 2 1 1 m V
- 5 +
T h e d is p la y s h o w s t h e v a lu e s o f t h e a n a lo g in p u t in m illiv o lt s (r a n g e : 0 m V . . . 5 0 0 0 m V ) .
4 .1 .3 P r o p o r t io n a l O u t p u t s
T h e L P C 0 1 9 2 6 0 h a s g o t 1 0 p ro p o r t io n a l o u tp u ts (P W M p o w e r o u tp u ts ). T h e ir v o lt a g e
o u tp u t le v e l is f r o m 0 ..1 0 0 % o f V C C (+ U B , t y p ic a lly + 2 4 V D C ). W h e n c o n n e c t in g a v a lv e
s o le n o id t h e t h e P W M o u tp u t, th e o u tp u t v o lt a g e is c o r r e c te d to a n o m in a l v a lu e o f + 2 4 V .
T h is f u n c t io n a lit y p r e v e n ts a c h a n g e o f th e o u tp u t v o lt a g e w h ile p o w e r s u p p ly v o lt a g e
( + U b a t) c h a n g e s .
T h e d is p la y e d v a lu e is in % o f + U b a t (2 1 % m e a n s : 5 , 0 4 V w h e n s u p p ly v o lt a g e is + 2 4 V )
P W M 1 : 2 1 %
P W M 2 : 0 %
- 5 +
P a g e 7 6
4 .1 .4 A n a lo g O u t p u t s
T h e L P C 0 1 9 2 6 0 h a s o n e a n a lo g o u t p u t w h ic h is p o t e n t ia l s e p a r a t e d . F o r t h is t h e o u t p u t
m u s t h a v e it s o w n (e x t e r n a l) p o w e r s u p p ly . If t h e r e s n o p o t e n t ia l s e p a r a t io n n e c c e s s a r y ,
t h e p o w e r s u p p ly c o u ld b e c o n n e c t e d t o t h e m a in p o w e r s u p p ly o f t h e e le c t r o n ic s .
T h e o u t p u t r a n g e is 0 V t o + 1 0 V w h e n t h e p o w e r s u p p ly is m o r e t h a n 1 2 V . W h e n t h e
p o w e r s u p p ly o f t h e a n a lo g o u t p u t is le s s t h a n 1 2 V , t h e d is p la y s h o w s a m a x im u m o u t p u t
o f + 1 0 V e v e n if t h e o u t p u t s ig n a l is r e d u c e d ( c a u s e d b y a r e d u c e d p o w e r s u p p ly )!
A A 1 : 5 .2 8 V
- 5 +
4 .1 .5 D ig it a l O u t p u t s
T h e L P C 0 1 9 2 6 0 h a s g o t 1 6 d ig it a l o u tp u ts :
D ig it a l o u t p u t 1 . . . 1 2 a r e h ig h a c t iv e : 1 m e a n s + U b a t,
0 m e a n s h ig h im p e d a n c e
D ig it a l o u t p u t 1 3 . . . 1 6 a r e lo w a c t iv e : 1 m e a n s o u t p u t s w it c h e s t o p o w e r g r o u n d (0 V ),
0 m e a n s h ig h im p e d a n c e .
D O 1 ... 8 :
1 0 0 0 0 1 0 0
- 5 +
D ig ita l o u tp u t 1 D ig itia l o u tp u t 8
D O 9 ... 1 6 :
0 1 1 1 0 1 0 0
- 5 +
D ig ita l o u tp u t 9 D ig ita l o u tp u t 1 6
P a g e 7 7
4 .1 .6 C o u n t e r In p u t s ( O p t io n )
T h e L P C 0 1 9 2 6 0 h a s g o t t w o c o u n t e r in p u t s . T h e d is p la y e d v a lu e s is t h e a c t u a l v a lu e
a n d c h a n g e s in p o s it iv e o r n e g a t iv e ( d e p e n d e n t o n t h e d e t e c t e d im p u ls e s ).
IN C 1 :-3 2 7 6 0
IN C 2 : 0 0 0 0 E 4 9 A
- 5 +
C y c le a n d tim e b a s e c o u n te r
In s id e s in f o :
B e s id e s th e s e c o n d c o u n t e r v a lu e , t h e r ig h t v a lu e o n t o th e s e c o n d lin e d is p la y s t h e c y c le
c o u n te r ( in t h e a b o v e e x a m p le E 4 ) a n d t h e t im e b a s e c o u n te r (in t h e a b o v e e x a m p le
9 A ). B o th th e c y c le c o u n te r a n d t h e t im e b a s e c o u n t e r m u s t c h a n g e fa s t w h e n th e
s y s te m w o rk s c o r r e c t ly . If t h e t im e b a s e c o u n te r c h a n g e s n o m o re , th e t im e b a s e o f th e
e le c t r o n ic s d id n o t w o rk . If t h e c y c le c o u n t e r c h a n g e s n o m o re , th e p ro g ra m m d id n o t
lo n g e r w o rk .
P a g e 7 8
4 .2 E rro r M e m o ry
U p t o 3 2 d e t e c t e d e r r o r s a r e s t o r e d p e r m a n e n t ly in t h e e r r o r m e m o r y o n t h e ir f ir s t
o c c u r r e n c e . T h e e r r o r is s t o r e d in t h e f o r m lo c a t io n / t y p e / p r io r it y a s t h r e e s e p a r a t e
n u m b e rs .
T o r e a d o u t o r e r a s e t h e e r r o r m e m o r y t h e m e n u it e m e r r o r m e m o r y h a s t o b e s e le c t e d .
e rro r m e m o ry
- 5 +
B y p r e s s in g t h e E N T E R k e y , t h e f ir s t p o s it io n o f t h e e r r o r m e m o r y is d is p la y e d . T h e n e x t
o r p r e v io u s p o s it io n s c a n b e a c c e s s e d b y p r e s s in g t h e P L U S - a n d M IN U S k e y s . T h e
s u b m e n u c a n b e le f t b y p r e s s in g t h e E S C A P E k e y .
T h e c o d e 2 5 5 , 2 5 5 , 2 5 5 in d ic a t e s t h a t n o m o r e e r r o r s a r e lo c a t e d in s id e t h e m e m o r y . If
t h e r e is n o e r r o r a t a ll, a ll n u m b e r s a r e 2 5 5 .
e rro r n u m b e r: 1
c o d e :0 0 1 0 0 1 0 0 3
- 5 +
P r e v io u s e r r o r N e x t e rro r
( S e e a ls o p a g e 1 0 0 )
P a g e 7 9
4 .2 .1 C le a r E r r o r M e m o r y
C le a r in g t h e e r r o r m e m o r y c a n b e d o n e a t a n y d is p la y e d e r r o r n u m b e r . It w ill a lw a y s c le a r
a ll e r r o r s in s id e t h e m e m o r y . Y o u c a n n o t c le a r a s in g le e r r o r .
c o d e :0 0 1 0 0 1 0 0 3
- 5 +
K e e p p re s s e d fo r 3 s e c o n d s
A f t e r t h e P L U S - k e y is p r e s s e d f o r 3 s e c o n d s t h e s y s t e m s a s k if t h e e r r o r m e m o r y s h o u ld
b e c le a r e d .
e rro r m e m o ry
C le a r ?
- 5 +
E x it w ith o u t c le a r in g C le a r
B y p r e s s in g t h e E S C A P E - k e y t h e e r r o r m e m o r y is n o t c le a r e d a n d t h e s y s t e m c h a n g e s
b a c k t o t h e e r r o r d is p la y . P r e s s in g t h e E N T E R - k e y s t a r t s t h e c le a r in g p r o c e d u r e .
T h e c le a r in g p r o g r e s s is d is p la y e d w it h a b a r o g r a p h in t h e s e c o n d lin e .
c le a r m e m o r y
----------
- 5 +
P a g e 8 0
A f t e r c le a r in g t h e m e m o r y a ll e r r o r c o d e s a r e s e t t o 2 5 5 (m e a n s n o e r r o r ). T h e d is p la y
a u t o m a t ic a lly c h a n g e s b a c k t o t h e f ir s t e r r o r n u m b e r .
c o d e :2 5 5 2 5 5 2 5 5
- 5 +
E x it t h e s u b m e n u ' e r r o r m e m o r y ' b y p r e s s in g t h e E S C A P E - k e y .
4 .3 . P r o g r a m m in g o f P a r a m e t e r s
T h e s t e e r in g s y s t e m a n d t h e w o r k in g h y d r a u lic f u n c t io n s o f t h e L P C 0 1 9 2 6 0 a r e d e f in e d
b y 2 5 6 p a r a m e t e r s . T h e s u b m e n u ' p a r a m e t e r ' is u s e d t o c h e c k o r m o d if y t h e s e
p a ra m e t e r s . T h e s u b m e n u ' p a r a m e t e r ' is a c t iv a t e d a s d e c r ib e d in c h a p t e r 4 o f t h is
m a n u a l.
p a ra m e te r
- 5 +
T h e p a r a m e t e r s u b m e n u is s t a r t e d w it h t h e E N T E R - k e y . T h e d is p la y c h a n g e s t o t h e
p a r a m e t e r n u m b e r in p u t . T h e in p u t c u r s o r is f la s h in g r ig h t o f t h e a c t u a l p a r a m e t e r
n u m b e r.
E x it t h e p a r a m e t e r s u b m e n u b y m o v in g t h e in p u t c u r s o r w it h t h e E S C A P E - k e y le f t u n t il
t h e m o s t le f t d ig it o f t h e p a r a m e t e r n u m b e r is r e a c h e d . P r e s s in g t h e E S C A P E - k e y o n c e
m o r e t h e p a r a m e t e r s u b m e n u is e x it e d .
p a ra m e te r
n u m b e r: 0 0 0
- 5 +
Is s u e 0 3 /2 0 0 6
P a g e 8 1
4 .3 .1 R e a d in g P a r a m e t e r s in S e q u e n z
B y u s in g t h e E N T E R - k e y t h e p a r a m e t e r v a lu e s c a n b e r e a d e a s ily w it h o u t c h a n g in g t h e
v a lu e s .
p a ra m e te r
n u m b e r: 0 0 0
- 5 +
O n t h e d is p la y o f t h e p a r a m e t e r n u m b e r p r e s s t h e E N T E R - k e y o n c e t o s h o w t h e v a lu e o f
t h e s e le c t e d p a r a m e t e r .
p a ra m e te r n o :0 0 0
v a lu e : 0 0 0 0
- 5 +
O n t h e d is p la y o f t h e p a r a m e t e r v a lu e p r e s s t h e E N T E R - k e y o n c e t o m o v e t o t h e n e x t
p a r a m e t e r n u m b e r . T h e p a r a m e t e r n u m b e r is a u t o m a t ic a lly in c r e m e n t e d b y o n e .
p a ra m e te r
n u m b e r: 0 0 1
- 5 +
T h e n e x t p r e s s o f t h e E N T E R - k e y c h a n g e s t o t h e v a lu e o f t h e p a r a m e t e r a g a in . E x it t h is
s u b m e n u a s d e s c r ib e d in c h a p t e r 4 . 3 .
Is s u e 0 3 /2 0 0 6
P a g e 8 2
4 .3 .2 D ir e c t E n t e r in g o f P a r a m e t e r N u m b e r s
T o r e a d o r t o m o d if y s in g le p a r a m e t e r s t h e p a r a m e t e r n u m b e r c a n b e e n t e r e d d ir e c t ly .
p a ra m e te r
n u m b e r: 0 0 0
- 5 +
T h e E S C A P E - k e y s h if t s t h e c u r s o r o n e d ig it t o t h e le f t s id e . T h e a c t u a l c u r s o r p o s it io n is
f la s h in g . If t h e E S C A P E - k e y is p r e s s e d w it h t h e c u r s o r a t t h e m o s t le f t d ig it t h e p a r a m e t e r
s u b m e n u is e x it e d .
p a ra m e te r
- 5 +
T h e E N T E R -k e y s h if t s t h e c u r s o r o n e d ig it t o t h e r ig h t s id e . If t h e E N T E R - k e y is p r e s s e d a t
a d ig it w it h o u t n u m b e r s o r a t t h e m o s t r ig h t d ig it t h e p a r a m e t e r n u m b e r in p u t is f in is h e d
a n d th e d is p la y c h a n g e s t o p a r a m e t e r v a lu e s . In t h is c a s e it d o e s n t m a t t e r if t h e p a r a m e t e r
n u m b e r is g iv e n a s 1 , 2 o r 3 d ig it s .
p a ra m e te r
n u m b e r: 0 0
- 5 +
T h e M IN U S - k e y is u s e d to re d u c e th e v a lu e o f t h e b lin k in g d ig it b y o n e . If t h e v a lu e is ' 0 '

th e M IN U S -k e y c h a n g e s it t o ' 9 ' . If t h e M IN U S - k e y is p r e s s e d a t t h e b e g in n in g o f t h e
p a ra m e te r n u m b e r in p u t (c u r s o r is r ig h t o f t h e p a r a m e t e r n u m b e r ) t h e c u r s o r ju m p s t o t h e
m o s t le f t d ig it w it h o u t c le a r in g t h e v a lu e .
P a g e 8 3
p a ra m e te r
n u m b e r:
- 5 +
T h e P L U S - k e y is u s e d t o in c r e m e n t t h e v a lu e o f th e b lin k in g d ig it b y o n e . If t h e v a lu e is ' 9 '

th e P L U S -k e y c h a n g e s it t o ' 0 ' . If t h e P L U S - k e y is p r e s s e d t o t h e b e g in n in g o f t h e
p a ra m e te r n u m b e r in p u t (c u r s o r is r ig h t o f t h e p a ra m e t e r n u m b e r ) t h e c u r s o r ju m p s t o t h e
m o s t le f t d ig it c le a r in g th e p a ra m e te r n u m b e r to '0 '.
4 .3 .3 P a r a m e t e r V a lu e In p u t
A f t e r t h e p a r a m e t e r n u m b e r in p u t (s e e c h a p t e r 4 . 3 . 2 ) t h e d is p la y s h o w s t h e a c t u a l
p a r a m e t e r v a lu e . T h e c u r s o r is o n t h e r ig h t s id e o f t h e p a r a m e t e r v a lu e .
v a lu e : 0 0 0 1
- 5 +
T h e E S C A P E - k e y s h if t s t h e c u r s o r o n e d ig it t o t h e le f t s id e . T h e a c t u a l c u r s o r p o s it io n
d ig it is b lin k in g . If t h e E S C A P E - k e y is p r e s s e d a t t h e m o s t le f t d ig it t h e d is p la y c h a n g e s
b a c k t o t h e p a r a m e t e r n u m b e r w it h o u t s a v in g t h e p a r a m e t e r v a lu e .
V a lu e : 0 0 1
- 5 +
T h e E N T E R -k e y s h if t s th e c u rs o r o n e d ig it to th e r ig h t s id e . If t h e E N T E R - k e y is p r e s s e d
a t a d ig it w it h o u t v a lu e o r a t th e m o s t r ig h t d ig it o f a 4 -d ig it d is p la y t h e p a r a m e t e r v a lu e is
s a v e d a n d th e d is p la y c h a n g e s to th e n e x t p a ra m e te r n u m b e r . It d o e s n o t m a t t e r if t h e
p a ra m e te r v a lu e s a re p ro g ra m m e d w it h 1 , 2 , 3 o r 4 d ig it s .
P a g e 8 4
B e f o r e s a v in g t h e f ir s t m o d if ie d p a r a m e t e r v a lu e a n a c c e s s c o d e h a s t o b e s e t ( s e e
c h a p t e r 4 . 3 . 4 ) . T h e v a lu e is o n ly s a v e d w it h c o r r e c t a c c e s s c o d e
m in : 0
m a x : 1
- 5 +
T h e p a r a m e t e r v a lu e is c h e c k e d t o b e w it h in t h e a llo w e d p a r a m e t e r r a n g e p r io r t o s a v in g .
If t h e v a lu e is o u t s id e t h e a llo w e d r a n g e t h e m in im u m a n d m a x im u m v a lu e is s h o w n o n
t h e d is p la y . P r e s s a n y k e y t o s w it c h b a c k t o t h e p a r a m e t e r v a lu e in p u t a g a in .
v a lu e : 0 0 9 1
- 5 +
T h e M IN U S -k e y is u s e d to d e c r e m e n t t h e b lin k in g d ig it b y o n e . If t h e v a lu e is ' 0 ' t h e

M IN U S - k e y c h a n g e s it t o '9 '. If t h e M IN U S - k e y is p r e s s e d a t t h e b e g in n in g o f t h e in p u t
s e q u e n c e (c u r s o r is lo c a t e d b e h in d t h e p a r a m e t e r v a lu e ), t h e c u r s o r ju m p s t o t h e f ir s t
in p u t d ig it w it h o u t c le a r in g th e p a r a m e t e r v a lu e .
v a lu e :
- 5 +
T h e P L U S - k e y is u s e d t o in c r e m e n t t h e v a lu e o f th e b lin k in g d ig it b y o n e . If t h e v a lu e is ' 9 '

th e P L U S -k e y c h a n g e s it t o ' 0 ' . If t h e P L U S - k e y is p re s s e d to th e b e g in n in g o f th e
p a ra m e te r n u m b e r in p u t (c u r s o r is r ig h t o f t h e p a ra m e te r n u m b e r) th e c u r s o r ju m p s to th e
m o s t le f t d ig it c le a r in g th e p a ra m e te r n u m b e r to '0 '. T h is c a n b e u s e d m a in ly t o s e t o n e
d ig it v a lu e s .
P a g e 8 5
4 .3 .4 A c c e s s C o d e In p u t
O n ly a u t h o r is e d p e r s o n s s h o u ld b e a b le t o c h a n g e t h e p a r a m e t e r a n d a lig n m e n t v a lu e s .
S o a n a c c e s s c o d e m u s t b e e n t e r e d b e f o r e p a r a m e t e r s c a n b e c h a n g e d o r a n a lig n m e n t
c a n b e m a d e .
D u r in g p a r a m e t e r p r o g r a m m in g t h e a c c e s s c o d e is r e q u e s t e d a t t h e f ir s t p a r a m e t e r v a lu e
c h a n g e . T h e n o t h e r p a r a m e t e r s c a n b e c h a n g e d w it h o u t s e t t in g t h e a c c e s s c o d e a g a in .
T h e a x le a lig n m e n t a c c e s s c o d e m u s t b e e n t e r e d o n c e a t t h e b e g in n in g o f t h e a lig n m e n t
m o d e .
s e t a c c e s s c o d e

- 5 +
T h e a c c e s s c o d e in p u t is m a d e t h e s a m e w a y a s p a r a m e t e r v a lu e in p u t ( s e e 4 . 3 . 3 ) . A f t e r
t h e c o r r e c t a c c e s s c o d e is e n t e r e d t h e d is p la y c o n t in u e s w it h t h e p a r a m e t e r p r o g r a m m in g
o r a lig n m e n t m o d e .
If t h e a c c e s s c o d e is in c o rre c t a n e rr o r m e s s a g e is d is p la y e d . T h is m e s s a g e c a n b e
c o n f ir m e d w it h a n y k e y . T h e n d u r in g p a ra m e te r p r o g r a m m in g t h e p a r a m e t e r n u m b e r is
d is p la y e d a g a in a n d d u r in g a lig n m e n t p ro c e d u re t h e a lig n m e n t m o d e is f in is h e d ( t h e
d is p la y c h a n g e s to ' i/ o d a t a d is p la y ' in m a in m e n u ).
a c c e s s c o d e
In c o rre c t !
- 5 +
C A U T IO N : T h e M a s t e r C o d e a p p r o v e s t h e c h a n g e s f o r a ll f u n c t io n s . In a d d it io n t h e
m a s t e r c o d e a llo w s t o c h a n g e t h e a c c e s s c o d e f o r p a r a m e t e r p r o g r a m m in g
a n d a lig n m e n t m o d e ( s e e 4 . 5 t o c h a n g e t h e a c c e s s c o d e s ) .
P a g e 8 6
4 .4 A lig n m e n t o f t h e A x le s
T o a lig n t h e a x le t h e a c t u a l v o lt a g e f e e d b a c k a t 0 ° s t e e r in g a n g le ( lo n g it u d in a l d r iv in g ) a n d
a t t h e 9 0 ° p o s it io n ( la t e r a l d r iv in g ) is s a v e d in t o t h e E E P R O M m e m o r y o f t h e s t e e r in g
c o m p u t e r . D u r in g n o r m a l s t e e r in g t h e s t e e r in g c o m p u t e r u s e s t h e s e v a lu e s t o k e e p b e s t
tra c k in g .
T h e m e n u ' a x le a lig n m e n t ' is a c t iv a t e d a s d e s c r ib e d in c h a p t e r 4 .
a x le a lig n m e n t
- 5 +
T h e E N T E R - k e y s t a r t s t h e a lig n m e n t m e n u . T h e d is p la y f ir s t c h a n g e s t o t h e a c c e s s c o d e
r e q u e s t (s e e 4 .3 .4 ).
W it h t h e c o r r e c t a c c e s s c o d e t h e b a s ic m e n u o f t h e a lig n m e n t m o d e is d is p la y e d . P r e s s in g
t h e E S C A P E - k e y in t h is m o d e q u it s t h e a lig n m e n t . m o d e a n d p r e s s in g t h e E N T E R - k e y
s e le c t t h e a lig n m e n t m o d e .
s e le c t a x le fo r
a lig n m e n t : 0
- 5 +
C A U T IO N :
D u r in g a lig n m e n t m o d e t h e s t e e r e d a x le c a n b e o p e r a t e d w it h o u t c o n s id e r a t io n t o
m a x im u m s t e e r in g a n g le s o r s e n s o r e r r o r s a n d w it h o u t e r r o r c o n t r o l. T h e e r r o r
m o n it o r in g is n o t a c t iv e ! S o t h e r e f o r e in c a s e o f a n e r r o r t h e a x le c a n u n c o n t r o lla b ly
s t r ik e o u t .
N o p e rs o n s a r e p e r m it t e d t o s t a y w it h in g t h e w o r k in g a r e a o f t h e a x le . T h is m o d e
m a y b e u s e fu l t o t u r n a n a x le b a c k t o s t r a ig h t p o s it io n s ( in c a s e s o f a n e r r o r ) .
P a g e 8 7
4 .4 .1 S e le c t t h e A x le f o r t h e A lig n m e n t
T o a lig n t h e a x le b y t h e in it ia l s t a r t - u p , t h e a lig n m e n t p r o c e d u r e is d o n e s t e p b y s t e p f o r
e a c h a x le s e p a r a t e ly . It is p o s s ib le t o a lig n o n ly o n ly o n e a x le s e p a r a t e ly t o o .
A a lig n m e n t is n o t p o s s ib le if 0 o r a w r o n g a x le is s e le c t e d .
s e le c t a x le fo r
a lig n m e n t: 0
- 5 +
B a c k to a lig n m o d e
A x le - 1
A x le + 1
S ta r t th e a lig n e m e n t
4 .4 .2 A lig n m e n t o f 0 ° a n d 9 0 °
A t f ir s t t h e s e le c t e d a x le h a s t o b e a lig n e d t o t h e 0 ° p o s it io n (in t h e f o llo w in g e x a m p le

a x le 2 is s e le c t e d ). If ju s t t h e 9 0 ° a lig n m e n t s h o u ld b e d o n e , t h e 0 ° a lig n m e n t c a n b e
s k ip e d b y p r e s s in g t h e E S C - k e y .
T u r n t h e a x le u s in g t h e M IN U S - k e y t o t h e le f t a n d t h e P L U S - k e y t o t h e r ig h t . If t h e k e y is
o n ly p r e s s e d s h o r t t im e t h e s t e e r in g a n g le is c h a n g e d b y 0 . 1 ° . T o t u r n t h e a x le 0 . 2 ° . . .
0 . 3 ° t h e k e y h a s t o b e p r e s s e d s e v e r a l t im e s .
If t h e k e y is h e ld p r e s s e d f o r m o r e t h a n 0 . 5 s t h e s t e e r in g s t a r t s t o t u r n c o n t in u o u s ly . T h e
s t e e r in g s p e e d is in c r e a s e d in t h r e e s t e p s u p t o a p p r o x im a t e ly 1 0 ° / s ( d e p e n d in g o n t h e
t im e t h e k e y is p r e s s e d ) .
N O T E : If t h e a x le d o e s n o t t u r n b y p r e s s in g t h e M IN U S - o r t h e P L U S - k e y , th e
f o llo w in g p o in t s h a v e t o b e c h e c k e d :
( 1 ) H y d r a u lic s u p p ly p r e s s u r e a v a ila b le ?
( 2 ) A x le m e c h a n ic a lly b lo c k e d ?
(3 ) S t e e r in g c o m p u t e r p o w e re ? a n d h y d r a u lic v a lv e a s w e ll a s a n g le
w h e e l p o ti c o n n e c te d a c c o r d in g t o t h e w ir in g d ia g r a m s ?
P a g e 8 8
C A U T IO N : If t h e a x le t u r n s a g a in s t t h e e n d s t o p w it h o u t p r e s s in g t h e M IN U S - o r
P L U S - k e y c h e c k t h e f o llo w in g d e f in it io n s :
( 1 ) W h e e l p o t i v o lt a g e m u s t in c r e a s e if t h e s t e e r in g is
s t e e r e d t o t h e r ig h t s id e ( if n o t , s w a p t h e s u p p ly v o lt a g e o f t h e w h e e l p o t i.
T h e v o lt a g e a t s t r a ig h t p o s it io n o f t h e a x le m u s t b e
a p p r o x im a t e ly + 2 , 5 0 V .
( 2 ) If t h e o ilf lo w t h r o u g h t h e p r o p o r t io n a l v a lv e is f r o m P t o A t h e s t e e r in g
h a s t o s t e e r t o t h e r ig h t s id e ( if n o t , s w a p t h e t w o s o le n o id p lu g s o f t h e
p r o p o r t io n a l v a lv e ).
( 3 ) T h e w h e e l p o t i m u s t b e m e c h a n ic a lly f ix e d t o t h e a x le .
T h e r e m u s t b e n o a n g u la r p la y b e t w e e n w h e e l a n d w h e e l p o t i.
( 4 ) C h e c k f o r t h e v a lv e n o t t o b e " s t ic k in g " o p e n .
s e t a x le to 0
a c tu a l: 2 4 5 3 m V
- 5 +
S k ip 0 ° a lig n e m e n t
S t e e r le ft
S te e r r ig h t
S a v e a lig n e m e n t v a lu e
T h e s e c o n d lin e o f t h e d is p la y s h o w s t h e w h e e l p o t i f e e d b a c k . S o d u r in g a lig n m e n t t h e
a c t u a l v a lu e s c a n b e c h e c k e d e a s ily . In a d d it io n t o t h e M IN U S - o r t h e P L U S - k e y s t h e a x le
c o u ld b e s t e e r e d b y a c t iv a t in g d ig it a l in p u t 1 0 ( t u r n s a x le r ig h t ) a n d d ig it a l in p u t 1 1 ( t u r n s
a x le le f t ).
If t h e a x le is p o s it io n e d t o t h e p r e c is e s t r a ig h t p o s it io n , s a v e t h e w h e e l p o t i v a lu e s b y
p r e s s in g t h e E N T E R - k e y . T h e a c t u a l v a lu e o f t h e a n g le t a n s d u c e r f e e d b a c k v o lt a g e s m u s t
b e in t h e r a n g e o f 2 4 0 0 m V . . . 2 6 0 0 m V . If t h e v o lt a g e is o u t s id e t h is r a n g e t h e v a lu e s a re
n o t s a v e d a n d t h e f o llo w in g e r r o r m e s s a g e a p p e a r s o n t h e d is p la y :
o u t o f to le r a n c e
2 4 0 0 m V .. 2 6 0 0 m V
- 5 +
C o n fir m
C o n f ir m t h e e r r o r m e s s a g e w it h t h e E N T E R - k e y . T h e n t h e s t e e r in g m o d e is a c t iv e a g a in
t o c o r r e c t t h e p o s it io n o r t h e m e c h a n ic a l in s t a lla t io n o f t h e w h e e l p o t i.
P a g e 8 9
N O T E : A t s t r a ig h t p o s it io n o f t h e a x le t h e f e e d b a c k v o lt a g e o f t h e w h e e l p o t i m u s t b e in
th e ra n g e o f 2 4 0 0 m V ... 2 6 0 0 m V .
If t h e w h e e l p o t i v o lt a g e is c o r r e c t , it w ill b e s a v e d in t o a n E E P R O M m e m o r y . T h e s a v e d v a lu e is
s h o w n o n t h e d is p la y .
s a v e d v a lu e is :
2 4 5 3 m V
- 5 +
C o n fir m
A f t e r c o n f ir m in g w it h t h e E N T E R - k e y t h e p r o g r a m c h a n g e d to th e 9 0 ° - a lig n m e n t m o d e .
s e t a x le 2 to 9 0
a c tu a l: 3 8 1 9 m V
- 5 +
S k ip 9 0 ° a lig n m e n t
, S te e r le ft
S te e r r ig h t
S a v e a lig n m e n t v a lu e s
S t e e r t h e a x le u s in g th e M IN U S -k e y a n d th e P L U S -k e y to th e 9 0 ° p o s it io n ( la t e r a l
d r iv in g ) . It d o e s n t m a t t e r if th e a x le is t u r n e d to + 9 0 ° o r 9 0 ° p o s it io n . T h e p o s it io n m o s t ly
d e p e n d s o n to th e m e c h a n ic a lly c o n s t r u c t io n o f th e m a c h in e . T h e t u r n in g d ir e c t io n f r o m
lo n g it u d in a l t o la t e r a l d r iv in g is s e t v ia p a r a m e te r fo r e a c h a x le s e p a r a t e ly .
P a g e 9 0
If t h e s t e e r in g is p o s it io n e d t o t h e p r e c is e 9 0 ° p o s it io n s a v e t h e w h e e l p o t i v a lu e s b y
p r e s s in g t h e E N T E R - k e y . Is t h e a c t u a l v a lu e s m a lle r t h a n 2 4 0 0 m V a n d h ig h e r a s
2 6 0 0 m V s h o w s t h e d is p la y a e r r o r m e s s a g e .
o u t o f to le r a n c e
> 2 6 0 0 m V < 2 4 0 0 m V
- 5 +
C o n fir m
C o n f ir m t h e e r r o r m e s s a g e w it h t h e E N T E R - k e y . T h e d is p la y c h a n g e b a c k t o t h e s t e e r in g
m o d e . T h e n t h e s t e e r in g m o d e is a c t iv e a g a in t o c o r r e c t t h e 9 0 ° p o s it io n o r t h e
m e c h a n ic a l in s t a lla t io n o f t h e w h e e l p o t i.
If t h e v o lt a g e is c o r r e c t , t h e v a lu e is s a v e d in t o a n E E P R O M m e m o r y . T h e s a v e d v a lu e is
s h o w n o n t h e d is p la y .
s a v e d v a lu e is :
3 8 1 9 m V
- 5 +
C o n fir m
A f t e r c o n f ir m in g w it h t h e E N T E R - k e y t h e p r o g r a m c a lle d t h e n e x t a x le a n d s t a r t e d t h e
n e x t a lig n m e n t .
P a g e 9 1
4 .5 P r o g r a m m in g A c c e s s c o d e s
T h e M a s t e r - c o d e is n e c c e s s a r y t o c h a n g e t h e a c c e s s c o d e s f o r p a r a m e t e r p r o g r a m m in g
a n d a lig n m e t p r o c e d u r e . T h is m e n u is o n ly a c t iv e a f t e r e n t e r t h e m a s t e r - c o d e s ( s e e
4 . 3 . 4 ) . T h e c o d e s f o r p a r a m e t e r p r o g r a m m in g a n d f o r a x le a lig n m e n t s is n o t a c c e p t e d
h e re .
s e t m a s te r c o d e
0 0 0
- 5 +
4 .5 .1 A c c e s s C o d e f o r t h e P a r a m e t e r P r o g r a m m in g
A f t e r e n t e r in g t h e c o r r e c t m a s t e r - c o d e t h e d is p la y c h a n g e s t o e n t e r t h e a c c e s s c o d e f o r
p a r a m e t e r p r o g r a m m in g .
p a ra m e te r c o d e
_ 2 3 4
- 5 +
S k ip o v e r th e c o d e in p u t
V a lu e - 1
V a lu e + 1
S a v e th e c o d e in p u t
P a g e 9 2
A f t e r s a v in g t h e a c c e s s c o d e f o r p a r a m e t e r p r o g r a m m in g ( o r s k ip t h e m e n u ) t h e d is p la y
s h o w s th e n e w c o d e .
p a ra m e te r c o d e
is 1 2 3 4
- 5 +
4 .5 .2 A c c e s s C o d e f o r t h e A lig n m e n t P r o c e d u r e
A f t e r e n t e r in g t h e a c c e s s c o d e f o r p a r a m e t e r p r o g r a m m in g t h e d is p la y c h a n g e s to e n te r
t h e a c c e s s c o d e f o r t h e a lig n m e n t p r o c e d u r e .
a lig n m e n t c o d e
_ 3 4 5
- 5 +
S k ip o v e r th e c o d e in p u t
V a lu e - 1
V a lu e + 1
S a v e th e c o d e in p u t
A f t e r s a v in g t h e a c c e s s c o d e f o r a lig n m e n t p r o c e d u r e ( o r s k ip t h e m e n u ) t h e d is p la y
s h o w s th e n e w c o d e .
a lig n m e n t c o d e
is 2 3 4 5
- 5 +
P a g e 9 3
5 . E rro r F o rm a t
A ll e r r o r s a r e s a v e d a n d d is p la y e d w it h 3 e r r o r c o d e s . T h e s e e r r o r c o d e s a llo w a d e t a ile d
d e t e r m in a t io n o f t h e e r r o r a n d it s c o n s e q u e n c e s .
1 . C o d e - e r r o r lo c a t io n a W h ic h c o m p o n e n t h a s c a u s e d th e e rro r?
2 . C o d e - e rro r ty p e a W h ic h e r r o r is a c t iv e ?
3 . C o d e - p r io r it y a H o w c r it ic a l is t h e a c tu a l e rro r?
0 = o p e r a t in g m e s s a g e
1 = w a r n in g / e rro r o f lo a d h a n d lin g
2 = e n a b le d r iv in g is s w it c h e d o f f , s t e e r in g is s t ill a c t iv e
3 = s t e e r in g o f f a u lt y a x le s is s w it c h e d o f f , e n a b le d r iv in g is o f f .
T h e e rro rs o f th e s te e r in g c o m p u te r L P C 0 1 9 2 6 0 c a n b e s e e n a t t h e f o llo w in g e r r o r t a b le .
T h e ro w s o f th e ta b le s h o w s a lis t o f p o s s ib le e r r o r lo c a t io n s . T h e c o lu m n s c o n t a in s t h e
p o s s ib le e r ro r ty p e s . E a c h c e ll o f t h is t a b le t h a t h a s a p r io r it y n u m b e r d e t e r m in e s a p o s s ib le
e rro r . C e lls w it h o u t a n u m b e r a re n o t m o n it o r e d .
P a g e 9 4
E r r o r L is t E le c t r o n ic S t e e r in g 0 1 9 2 6 1
P a g e 9 5
6 . P a r a m e t e r L is t L P C 0 1 9 2 6 1
s te p v a lu e u n it ra n g e d e s c r ip t io n
0 0 0 0 1 - 0 0 0 0 0 0 0 1 v e h ic le t y p e
0 0 0 0 = f u lly e le c t r o n ic s t e e r in g w it h s t e e r in g s e t p o in t g e n e r a t o r
(E M S )
0 0 0 1 = o r b it r o l s t e e r e d le a d in g a x le ( E V S , E V U , D A N C E R
1 0 0 0 3 S tü c k 0 0 0 1 0 0 0 4 n u m b e r o f s t e e r e s a x le s
N u m b e r o f a ll a x le s t h a t a r e s t e e r e d b y t h e s t e e r in g c o m p u t e r
in c lu d in g t h e o r b it r o l s t e e r e d le a d in g a x le .
2 0 0 0 0 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m lo n g it u d in a l f ix e d
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
3 0 0 0 1 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m lo n g it u d in a l n o r m a l
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
4 0 0 0 0 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m lo n g it u d in a l d ia g o n a l
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
5 0 0 0 0 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m lo n g it u d in a l f r o n t
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
6 0 0 0 0 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m lo n g it u d in a l r e a r
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
7 0 0 0 0 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m la t e r a l f ix e d
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
8 0 0 0 0 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m la t e r a l n o r m a l
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
9 0 0 0 0 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m la t e r a l d ia g o n a l
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
1 0 0 0 0 1 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m s id e w a y s f r o n t
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
1 1 0 0 0 0 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m s id e w a y s r e a r
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
1 2 0 0 0 1 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m c ir c u la r m o d e
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
1 3 0 0 0 1 - 0 0 0 0 0 0 0 1 e n a b le s t e e r in g p r o g r a m p a r k in g m o d e
0 0 0 0 = d is a b le d
0 0 0 1 = e n a b le d
1 4 m m 0 0 0 0 9 9 9 9 X c o - o r d in a t e a x le 1
1 5 m m 0 0 0 0 9 9 9 9 Y c o - o r d in a t e a x le 1
1 6 m m 0 0 0 0 9 9 9 9 X c o - o r d in a t e a x le 2
Electronic Steering
Electric Sideloader
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7. Parameter List 019 505
0 0001 - 0000 – 0001 vehicle type

0000 = Fully electro-hydraulic steering with steering set point
generator.
0001 = Orbitrol steered leading axle.
1 0004 axles 0001 – 0004 Number of steered axles

Number of all axles that are steered by the steering computer. This
number includes the orbitrol leading axle.
2 0000 - 0000 – 0001 Select steering program lengthways fixed.

0000 = Not avaiable
0001 = Available.
3 0001 - 0000 – 0001 Select steering program lengthways normal.

0000 = Not available
0001 = Available
4 0000 - 0000 – 0001 Select steering program lengthways crab.

0001 = Available
5 0000 - 0000 – 0001 Select steering program lengthways front.

0001 = Available
6 0000 - 0000 – 0001 Select steering program lengthways rear.

0001 = Available
7 0000 - 0000 – 0001 Select steering program sideways fixed.

0001 = Available
8 0000 - 0000 – 0001 Select steering program sideways normal.

0001 = Available
9 0000 - 0000 – 0001 Select steering program sideways crab.

0001 = Available
10 0001 - 0000 – 0001 Select steering program sideways front.

0001 = Available
11 0000 - 0000 – 0001 Select steering program sideways rear.

0001 = Available
12 0001 - 0000 – 0001 Select steering program circular drive.

0001 = Available
13 0001 - 0000 – 0001 Select steering program parking.

0001 = Available

Electronic Steering
Electric Sideloader
Page 126
17 mm 0000 – 9999 Y co-ordinate axle 2

19 mm 0000 – 9999 X co-ordinate axle 3
22 0001 mm 0000 – 9999 Steering line for lengthways normal.
Y co-ordinate of the steering line. The steering line of symmetrical
vehicles is positioned to half vehicle length. This causes the front and
rear steering angles to be the same (but with different sign).
23 0001 axle number 0001 – 0004 Right curve reference axle for lengthways normal.
Number of the inner curve steering axle at right curve driving This is
the axle that has the biggest steering angle at right hand curves. For
orbitrol steered vehicles the number of the orbitrol steered axle has to
be set here.
24 0180 ° 0000 – 0180 Right maximum steering angle for lengthways normal.
Maximum steering angle of the axle set at parameter 23. For
orbitrol steered vehicle this parameter is not evaluated. The maximum
angles are given by the mechanics of the orbitrol steered axle.
25 0001 axle number 0001 – 0004 Left curve reference axle for lengthways normal.
Number of the inner curve steering at left curve driving. This is the axle
that has the biggest steering angle at left hand curves. For orbitrol
steered vehicles the number of the orbitrol steered axle has to be set
here.
26 0180 ° 0000 – 0180 Left maximum steering angle for lengthways normal.
Maximum steering angle of the axle set at parameter 25. For
orbitrol steered vehicles this parameter is not evaluated. The
maxmimum angles are given by the mechanics of the orbitrol.
27 0001 axle number 0001 – 0004 Reference axle for lengthways crab.
As a reference axle only at orbitrol steering the orbitrol steered axle
must be indicated.
28 0000 ° 0000 – 0180 Right maximum steering angle for lengthways crab.
See parameter 24.
29 0000 ° 0000 – 0180 Left maximum steering angle for lengthways crab.
See parameter 26.
30 0000 mm 0000 – 9999 Steering lilne for lengthways front.

Y co-ordinate of the steering line. The steering line is frequently
exactly in the rear axles which are fixed on driving straight ahead.
31 0001 axle number 0001 – 0004 Right curve reference axle for lengthways front.
See parameter 23.
32 0000 ° 0000 – 0180 Right maximum steering angle for lengthways front.
See parameter 24.
33 0001 axle number 0001 – 0004 Left curve reference axle for lengthways front.
See parameter 25.
34 0000 ° 0000 – 0180 Left maximum steering angle for lengthways front.
See parameter 26.
35 0000 mm 0000 – 9999 Steering line for steering program lengthways rear.
Y co-ordinate of the steering line. The steering line is frequently
exactly in the front axles which are fixed on driving straigt ahead.
Electronic Steering
Electric Sideloader
Page 127
52 0018 ° 0000 – 01180 Left maximum steering angle for sideways front.
See parameter 43.
53 0000 mm 0000 – 9999 Steering line for sideways rear.

exactly in the ront axles which are fixed on driving straight ahead.
54 0003 axle number 0001 – 0004 Right curve reference angle for sideways rear.
See parameter 41.
55 0000 ° 0000 – 0180 Right maximum steering angle for sideways rear.
See parameter 42.
56 0003 axle number 0001 – 0004 Left curve reference axle for sideways rear.
See parameter 43.
57 0000 ° 0000 – 0180 Left maximum steering angle for sideways rear.
See parameter 44.
58 0001 - 0000 – 0001 Direction of rotation axle 1 sideways.

0000 = axle 1 turns to the right side from lengthways to sideways.
0001 = axle 1 turns to the left side from lengthways to sideways.



0001 = axel 4 turns to the left side from lengthways to sideways.
62 mm 0000 – 9999 X co-ordinate of rotatin point at circular drive.

In case of circular drive the vehicle turns around a fixed steering pole
which is determined with the parameters 62 and 63.
63 mm 0000 – 9999 Y co-ordinate of rotatin point at circular drive.

See parameter 62.
64 0000 - 0000 – 0001 Direction of rotation axle 1 at circular drive.

0000 = axle 1 turns the short way into circular drive. 0001
= axle 1 turns the long way into circular drive.



0000 = axle 4 turns the short way into circular drive.
0001 = axle 4 turns the long way into circular drive.
68 0020 ° 0000 – 0180 Parking angle axle 1.

In the parking program the steering axles are set to the programmed
fixed angles from parameter 68 to 71. So the vehicle is not able to
move even without parking brake.
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69 0020 ° 0000 – 0180 Parking Angle axle 2.

See parameter 68.
70 0020 ° 0000 – 0180 Parking angle axle 3.

See parameter 68.
71 0001 - 0000 - 0001 Parking angle axle 4.

See parameter 68.
72 0001 - 0000 – 0001 Sign of parking angle axle 1.

0000 = right
0001 = left
73 0000 - 0000 – 0001 Sign of parking angle axle 2.

0000 = right
0001 = left
74 00001 - 0000 - 0001 Sign of parking angle axle 3.

0000 = right
0001 = left
75 0000 - 0000 - 0001 Sign of parking angle axle 4.

0000 = right
0001 = left
76 0350 ° 0000 - 0360 Useable angle of the actual value potentiometers.

the actual angles of the steering axles are measured with a single
potentiometer. For the conversion of the potentiometer voltage into
angular degree the useable angle of the potentiometers must be
entered. The useable angle is the angle of rotation at wihich the actual
value of voltage increases linearly from 0 V to +5 V.
77 0050 % 0000 – 0100 Maximum output voltage for the steering valves.
The proportional solenoids of the steering valves are controlled from
proportional outputs of the steering computer directly. The maximum
output voltage is + 24 V. Also proportional solenoids with smaller
nominal voltage can be connected, however, when the output voltage
ist limited by this parameter.
Example: Nominal voltage = 10 V
Parameter value 10/24 * 100 % = 42 %.
78 0200 factor 0000 – 9999 Position control gain axle 1.

The deviation is multiplied in the digital position controller by the
control gain. The proportional valve is opened fully if the result of the
multiplication has a value larger than 4095.
Example: At a control gain of 4095 the proportional valve is
opened fully with a deviation of 1°.
In order to have opened the proportional valve fully at
10° deviation, the control gain must be programmed
to 410.

See parameter 78.
80 0020 factor 0000 - 9999 Position control gain axle 3.

See parameter 78.

See parameter 78.

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83 0020 % 0000 – 0100 Dead-band compensation prop valve 2.

See parameter 82.

See parameter 82.

See parameter 82.
86 0000 - 0000 – 0002 Operating terminal selection.

0000 = steering program set with DI1 … DI4 0001
= steering program set with Terminal EEA 092 131 0002 =
steering program set with EEA 092 431 (-1).
87 0000 - 0000 – 0001 Vehicle manufacturer selection.

With this parameter the display of the axle position is adapted to the
vehicle type. Ths is necessary since at Irion in comparison with
Baumann the steering axles 2 and 4 are exchanged.
0000 = Baumann
0001 = Irion
88 0002 - 0000 – 0012 Steering program set with DI1.

0000 = -
0001 = lengthways fixed
0002 = lengthways normal
0003 = lengthways grab
0004 = lengthways front
0005 = lengthways rear
0006 = sideways fixed
0007 = sideways normal
0008 = sideways grab
0009 = sideways front
0010 = sideways rear
0011 = circular drive
0012 = parking program

See parameter 88.

See parameter 88.
91 0012 - 0000 – 0012 Seering program set with DI4.

See parameter 88.
92 0000 - 0000 – 0003 Installation direction of EEA 092 131/431 connection 1

0000 = in direction lengthways forward looking 0001
= in direction lengthways backwards looking 0002 =
in direction sideways forward looking 0003 =
in direction sideways backwards looking
93 0000 - 0000 – 0003 Installation direction of EEA 092 131/431 connection 2

0000 = in direction lengthways forward looking 0001
= in direction lengthways backwards looking 0002 =
in direction sideways forward looking 0003 =
in direction sideways backwards looking
94 0000 - 0000 – 9999 -

95 0000 - 0000 – 9999 -
96 0000 - 0000 – 0111 Steering setpoint generator configuration.
xxx0 = single channel steering setpoint generator (LS 403 100)
xxx1 = double channel steering setpoint generator (SLS 403 610)
xx0x = clock and up/down signal
xx1x = A/B-track
x0xx = active clock-monitoring
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97 0000 - 0000 – 0001 Direction of rotation steering setpoint generator.

0000 = normal
0001 = inverse
98 0192 Impulses 0001 – 9999 Pulses per steering wheel turn of steering setpoint
generator.
Number pulses that an incremental steering setpoint generator
supplies per steering wheel turn.
99 0015 °/rotation 001 - 9999 Steering setpoint modification per steering wheel
rotation.
Transmission of the steering wheel turn to the steering. Each steering
wheel turn changes the steering-angle of the reference axle by the
parameter value.
100 0100 °/s 0001 – 9999 Maximum steering speed.

The steering-angle change per second is limited by this parameter in
order not to overdrive the prop valves. The value must be adapted to
the really attainable steering speed.
101 0000 0.1° 0000 – 0100 Steering angle threshold for steering straigt ahead.
The steering is straightened if the steering-angles of all steered axles
are smaller than the programmed steering-angle threshold. In case of
steering straight ahead the steering program change is ended and the
green LED in the EEA 092 131 is active. Below the programmed
threshold a steering programm change is possible during driving.
102 0000 0.1° 0000 – 1000 Steering angle threshold for DO ‘steering straight
ahead’.
The digital output “steering straight ahead” is active, if the steering
angles of all axles are smaller than the programmed steering-angle
threshold.
103 0000 - 0000 - 0003 Type of hydraulic supply.

0000 = Accumulator system with 2 pressure switches.
0001 = Accumulator system with analog pressure sensor. 0002
= Constant pump with ELS 0003 =
Independent hydraulic supply.
104 0000 mV or ° 0000 – 9999 Switch-on threshold hydraulic supply at standstill.

Accxumulator system with pressure sensor: The
accumulator is charged as soon as the voltage of the pressure sensor
(in mV) is lower than the programmed threshold.
Constant pumpe with ELS:
Steering-deviation (in °) at which the steerng pump is turned on.
105 0000 mV or ° 0000 – 9999 Switch-on threshold hydraulic supply during driving.
Accumulator system with pressure sensor:
The accumulator charging is finished as soon as the voltage of the
pressure sensor (in mV) is higher than the programmed threshold.
Switch off delay time (in s) of the steering pump after the steering-
deviation is steady-state.
106 0000 mV or ° 0000 – 9999 Switch-on threshold hydraulic supply during driving.
See parameter 104.
107 0000 mV or s 0000 – 9999 Switch-off threshold hydraulics supply during driving.
See parameter 105.
108 0000 mV or s 0000 – 9999 Switch-on threshold hydraulic supply during driving with
steering straight ahead.
See Parameter 104.
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109 0000 mV or s 0000 – 9999 Switch-off threshold hydraulic supply during driving with
steering straight ahead.
See parameter 105.
110 0000 % 0000 – 0100 Maximum output voltage for ELS-pressure relief valve.
The proportional solenoid of the pressure control valve for ELS is
controlled directly by one proportional output of the steering-
computer. The maximum output voltage is +24 V. Also a proportional
solenoid with smaller nominal voltage can be connected, however,
when the output voltage is limited.
Example: nominal solenoid voltage = 12 V
 parameter value = 12/24 * 100% = 50%
If the ELS-function is not used, the parameter mus be programmed to
0000.
111 0020 % 0000 – 0100 ELS minimum pressure.

The minimum pressure is set if the steering-deviation is smaller than
the dead zone of parameter 113. This function can also be used to
compensate a dead-band of the valve in the centre position.
112 0100 % 0000 – 0100 ELS maximum pressure.

The maximum pressure is reached, when the steering-deviation is
larger than dead zone (parameter 113) + slopw (parameter 114). With
the steering program change the maximum pressure is made
available automatically.
113 0000 0.1° 0000 – 0360 Dead zone for ELS increase of pressure.
As long as the steering-deviation is smaller than the dead zone the
minimum pressure of parameter 111 is made available.
114 0100 0.1° 0000 – 0360 Slope for ELS increase of pressure.
If the steering-deviation is larger than parameter 113, the system
pressure increases linear with increasing steering-deviation from the
minimum pressure on the maximum pressure. The slope defines the
zone of the steering-deviation in which this increase.
115 0050 0.01 s 0000 – 9999 Rise time of ELS pressure.

Ramp for the increase of pressure. The parameter defines the
minimum time for the increase of pressure from 0 to maximum
pressur.
116 0200 0.01 s 0000 – 9999 Release time of ELS pressure.

Ramp for the pressure reduction. The parameter defines the minimum
time for the pressure reduction from maximum pressure to 0.
117 0000 % 0000 – 0100 ELS constant pressure at axle alignment.

During the axle alignment a constant system pressure is made
available.
118 0080 % 0000 – 0100 ELS constant pressure while loading accumulator.
For the loading of the accumulator system a constant system
pressure is made available.
119 0050 % 0000 – 0100 Rotation speed set point for hydraulic pump
At order of steering (charging accumulator or hydraulic pump active) a
constant rotation speed set onto the pump control output. 100 %
corresponds + 10 V.
120 0020 ° 0000 – 0360 Deviation for warning

As soon as the steering-deviation is higher than the programmed
threshold, a warning becomes active The steering-speed is reduced
to 25 % of the maximum value of parameter 100, to allow the
deviating axle to catch up.

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121 0030 ° 0000 – 0360 Deviation for error.

As soon as the steering-deviation is higher than the programmed
threshold, an error becomes active. The steering-speed is reduced to
25 % of the maximum value of parameter 100, to allow the deviating
axle to catch up.
Since the track deviation of the single axles is too big, the enable
driving signal is switched off.
122 0001 - 0000 – 0001 Monitoring of the steering valves.

0000 = No monitoring
0001 = The steering-valves are checked on cable break, short
circuit and overload.
123 0001 - 0000 – 0001 Monitoring of the ELS pressure control valve.
0000 = No monitoring
0001 = The ELS pressure control valve is checked on cable break,
short circuit and overload.
124 0100 0.01 s 0000 – 9999 Delay after driving before program changes.
After the contact for driving is not active anymore first this delay runs,
until a program change is possible. So the vehicle can come to a
complete stop until the axles are steered according to the new
steering program.
125 0000 - 0000 - 9999 -

126 0000 - 0000 – 9999 -
127 0000 factor 0000 – 4095 Influence of the steering deviation on the pump rotation
speed during charging the hydraulic accumulator.
The programmed value is a factor by which the current steering
deviation is multiplied. The result is added to the constant pumpe set
point of parameter 119. So the pump can recharge the accumulator
for the hydraulic system also in case of high oil consumption of the
steering. With a factor of 4095 the maximum pumpe rotation speed is
reached already at 1° steering-deviation, at 409 for example at 10°.
128 0000 0,01° 0000 – 1500 Correction angle axle 1.

The steering-angles of the axles can be corrected in lengthways by
using these parameters. The parameter format contains a sign and a
correction angle which is limited to ± 5°. 0xxx
Correction to the right side. 1xxx
Correction to the left side.
x250 Correction in 0,01° steps (example 2,5°). The
maximum value is 500.

See parameter 128.

See parameter 128.

See parameter 128.
132 0000 - 0000 – 0005 Configuration digital output DO12

The digital output DA12 can be configured so that it is active at
specific steering program types.
0000 = Default = lengthways
0001 = DO12 active at lengthways
0002 = DO12 active at sideways
0003 = DO12 active at circular drive
0004 = DO12 active at parking program
0005 = DO12 is active at an invalid steering program.
Electronic Steering
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133 0000 - 0000 – 0001 Configuration login

In case of using the EEA 092 431 (-1) a login can be activated power
up of the electronics. If no login is carried out, the electronics starts
immediately after power up. With login all outputs of the electronics
stray inactive until the login is carried out correctly. 0000 = Login
requesdt active
0001 = No login
134 0000 mV 0000 – 5000 Voltage threshold for shock sensor.

Voltage threshold of the connected shock sensor at analog input 6
which the electronics uses to detect a crash. A status message (10-7-
2) is active and the driving is blocked until the service code will be
entered (at the EEA 092 431) (or the master code on the electronics).
The status message and disable driving are maintained even if the
electronics is switched off and on again. With parameter = 0000 the
function is deactivated.
135 0000 % 0000 – 0100 Threshold 1 battery capacity (warning).

Threshold of the battery capacity received by Sevcon, below that the
battery symbol in the EEA 092 431 begins to flash.
136 0000 % 0000 – 0100 Threshold 2 battery capacity (load handling speed
reduction).
Threshold of the battery capacity received by Sevcon, below that the
battery symbol in the EEA 092 431 begins to flash fast and the speed
of the load handling functions are reduced to the value programmed
in parameter 291. Is the
parameter = 0000, the battery capacity is not determined by Sevcon,
but from the digital input DI21.
137 0000 - 0000 – 0003 Configuration PWM9.

0 = PWM9 is used to drive the ELS pressure control valve.
1 = PWM9 becomes active (+Ub) if the mast is shifted in.
2 = PWM9 becomes active (+Ub) if the mast is shifted out.
3 = PWM9 becomes active (+Ub) if the mast is shfted in or out.
138 0020 - 0000 – 9999 -

139 0020 0,1° 0000 – 0100 Steering-angle threshold for steering program change
during driving.
If the steering-angles of all axles are smaller than the programmed
threshold, the steering program can be changed at lenthways
between all lengthways programs and at sideways between all
sideways programs.
The threshold determines the green LED of the steerng-position
indicator of the operating terminal EEA 092 131 to be on.
140 0020 0,1° 0000 – 0200 Swtich off threshold for steering controllers at standstill.
As soon as the steering-deviation at standstill is below the
programmed threshold, the controller of the appropriate steering-axle
is switched off. The proportional valve is not powered any longer.
141 0100 0,1° 0000 – 0200 Switch on threshold for steering controllers at standstill.
If the steering-deviation exceeds the programmed threshold at
standstill of the vehicle, the controller of the appropriate steering-axle
is activated again. The proportional valves are powered again.
Note:
In case of a steering program change, steering straightened or a turn
at the steering wheel the controllers are always activated.
142 0005 0,1° 0000 – 0200 Switch off threshold for steering controllers during
drivers.
Corresponds to parameter 140 is, however, effective during driving.

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143 0010 0.1° 0000 – 0200 Switch on threshold for steering controllers during
driving.
Corresponds to parameter 141 is, however, effective during driving.
144 0000 - 0000 – 9999 -

… 0000 - 0000 – 9999 -
239 0000 - 0000 – 9999 -
240 0000 - 0000 – 3333 Inversion digital inputs 1 … 8
xxx1 = Digital input 1 inverse 2 normal
xxx2 = Digital input 1 normal 2 inverse
xxx3 = Digital input 1 inverse 2 inverse
xx1x = Digital input 3 inverse 4 normal
xx2x = Digital input 3 normal 4 inverse
xx3x = Digital input 3 inverse 4 inverse
x1xx = Digital input 5 inverse 6 normal
x2xx = Digital input 5 normal 6 inverse
x3xx = Digital input 5 inverse 6 inverse
1xxx = Digital input 7 inverse 8 normal
2xxx = Digital input 7 normal 8 inverse
3xxx = Digital input 7 inverse 8 inverse



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243 0000 - 0000 - 3333 Inversion digital inputs 25 … 32

244 0000 - 0000 – 9999 -

245 0000 - 0000 – 9999 -
246 0000 - 0000 – 9999 -
247 0000 - 0000 – 9999 -
248 0000 - 0000 – 9999 -
249 0000 - 0000 - 9999 -
250 0000 - 0000 - 3333 Select analog input ?digital input
xxx0 = Analog input 1+2 Analog input
xxx1 = Analog input 1 Digital input
xxx2 = Analog input 2 Digital input
xxx3 = Analog input 1+2 Digital input
xx0x = Analog input 3+4 Analog input
xx1x = Analog input 3 Digital input
xx2x = Analog input 4 Digital input
xx3x = Analog input 3+4 Digital input
x0xx = Analog input 5+6 Analog input
x1xx = Analog input 5 Digital input
x2xx = Analog input 6 Digital input
x3xx = Analog input 5+6 Digital input
0xxx = Analog input 7+8 Analog input
1xxx = Analog input 7 Digital input
2xxx = Analog input 8 Digital input
3xxx = Analog input 7+8 Digital input
251 0000 - 0000 – 3333 Select digital input for high/low side signals
xxx0 = Digital input 17+18 high side
xxx1 = Digital input 17 low side
xxx2 = Digital input 8 low side
xxx3 = Digital input 17+18 low side
xx0x = Digital input 19+20 high side
xx1x = Digital input 19 low side
xx2x = Digital input 20 low side
xx3x = Digital input 19+20 low side
x0xx = Digital input 21+22 high side
x1xx = Digital input 21 low side
x2xx = Digital input 22 low side
x3xx = Digital input 21+22 low side
0xxx = Digital input 23+24 high side
1xxx = Digital input 23 low side
2xxx = Digital input 24 low side
3xxx = Digital input 23+24 low side
252 0000 - 0000 – 9999 -

253 0000 - 0000 – 9999 -
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255 0000 - 0000 – 9999 -

256 0000 - 0000 - 0001 Load handling
0000 = disabled
0001 = enabled
257 0000 - 0000 - 0001 Loading accumulator with active load handling.
0000 = no
0001 = yes
258 0001 - 0000 - 0001 Monitoring proportional valves for load handling
0000 = inactive
0001 = active
259 0100 - 0000 – 0001 Joystick configuration

It an be selected whether 1 or 2 joysticks are available.
0000 = 2 joysticks
0001 = 1 joystick
260 0100 % 0000 - 0200 Factor for load handling joysticks.

The setpoint of the joystick is wvaluated with the programmed factor.
With a value larger as 100 % the maximum control of the function is
achieved already with smaller setpoint voltages.
261 0100 mV 0000 - 1000 Starting threshold for joysticks

The load handling function is egarded as being activated, when the
joystick contact is closed and the analog voltage is larger than the
programmed threshold. The threshold is measured from the middle
voltage (2,5 V).
262 0050 % 0000 - 0100 Maximum output voltage for prop valves.
The proportional solenoids of the proportional valves for load handling
are driven directly by proportional outputs of the steering-computer.
The maximum output voltage is + 24 V, but also proportional
solenoids with smaller nominal voltage can be connected, if the
output voltage is limited.
Example: Nominal voltage = 12 V
?? Parameter value = 12/24 * 100 % = 50 %
263 - 0000 - 0333 Configuration pressure reduction

xxx0 = No pressure reduction after tilt up/down
xxx1 = Pressure reduction after tilt up
xxx2 = Pressure reduction after tilt down
xxx3 = Pressure reduction after tilt up and down
xx0x = No pressure reduction after fork left/right
xx1x = Pressure reduction after fork right
xx2x = Pressure reduction after fork left
xx3x = Pressure reduction after fork left and right
x0xx = No pressure reduction after HF6
x1xx = Pressure reduction after HF6 direction B
x2xx = Pressure reduction after HF6 direction A
x3xx Pressure reduction after HF6 direction A and B.
264 0000 0,01 s 0000 - 0100 Time of pressure reduction.

After every activity of the prop valve at PWM7 and PWM8 the
pressure inside the hydraulic lines is reduced by powering the
opposite side of the proportional valve for the programmed line.
265 0,01 s 0000 - 0100 Delay before pressure reduction.

The pressure reduction described in parameter 133 is delayed by the
programmed value. This avoids too fast reactions in case of short
interruptions of the function.
266 % 0000 – 0100 Value opening at pressure reduction in direction A.

During the pressure reduction the prop valve is opened at PWM7 with
constant control in order to reduce the pressure. The deadband of
the valve must be considered at that.
Electronic Steering
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Electric Sideloader
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267 % 0000 – 0100 Value opening at pressure reduction in direction B.

During the pressure reduction the prop valve is opened at PWM8 with
constant control in order to reduce the pressure. The deadband of
the valve must be considered at that.
268 0200 0,01 s 0000 – 9999 Delay seat-contact

If the seat-contact is not closed anymore the load handling is stopped
after the programmed delay.
269 0000 - 0000 - 9999 -

… 0000 - 0000 – 9999 -
279 0000 - 0000 – 9999 -
280 0000 - 0000 – 0001 Inversion lifting/lowering
0000 = No inversion
0001 = Function up/down inverted.
281 0000 % 0000 – 0100 Dead-band for lifting

As soon as lifting is activated, the pgrammed dead-band is output to
the proportional valve. A dead-band of the valve in centre position is
compensated.
282 0000 % 0000 – 0100 Dead-band for lowering

As soon as lowering is activated, the programmed dead-band is
output to the proportional valve. A dead-band of the valve in centre
position is compensated.
283 0100 % 0000 – 0100 Maximum valve opening for lifting

With maximum joystick excursion the programmed valve opening is
set in lifting direction. The proportional range of the joystick begins
with the dead-band (parameter 281) and ends with the maximum
valve opening.
285 0100 0,01 s 0000 - 1000 Acceleration-ramp for lifting.

if the joystick is excursed faster.
286 0050 0,01 s 0000 - 1000 Brake-ramp for lifting.

During lifting the the braking is limited to the programmed value even
if the joystick is taken back faster.
287 0100 0,01 s 0000 - 1000 Acceleration-ramp for lowering

During lowering the acceleration is limited to the programmed value
even if the joystick is excursed faster.
288 0050 0,01 s 0000 - 1000 Brake-ramp for lowering.

During lowering the braking is limited to the programmed value even if
the joystick is taken back faster.
289 0000 - 0000 – 0001 Hydraulic pump at lowering

0000 = off
0001 = on
290 0050 % 0000 – 0100 Factor lifting/lowering at DI “low speed lifting”.

With digital input DI06 and parameter 293 the speed can be reduced
during lifting/lowering. With a value of ‘0100’ no reduction occurs and
at ‘0000’ lifting/lowering is inhibited completely.
291 0050 % 0000 – 0100 Factor lifting at flat battery.

If the battery is flat (DI21 on 0 V) lifting is only possible with reduced
speed. With a value of ‘0100’ no reduction occurs and at ‘0000’ is
lifting inhibited completely.

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292 0000 - 0000 – 0003 Configration stop lifting/lowering with DI23.

If DI23 is activated a stop of the function lifting/lowering can be
programmed:
0000 = No stop active
0001 = Stop at lifting
0002 = Stop at lowering
0003 = Stop at lifting and lowering
293 0000 - 0000 - 0003 Configuration I06 “low speed” lifting/lowering.down.

If DI06 is activated the lifting/lowering speed is reduced, according to
the parameter setting:
0000 = No speed reduction
0001 = Low speed at lifting
0002 = Low speed at lowering
0003 = Low speed at lifting and lowering
294 0000 - 0000 – 9999 -

… 0000 - 0000 – 9999 -
299 0000 - 0000 – 9999 -
300 0000 - 0000 - 0001 Inversion extending/retracting mast.
0000 = No inversion
0001 = Function mast extend/retract inverted.
301 0000 % 0000 – 0100 Dead-band for extending mast.

As soon as extending mast is activated, the programmed dead-band
is output to the proportional valve. A dead-band of the valve in centre
302 0000 % 0000 – 0100 Dead-band for retracting mast.

As soon as retracting mast is activated, the programmed dead-band
is output to the proportional valve. A dead-band of the valve in centre
303 0100 % 0000 – 0100 Maximum valve opening for extending mast.
set in mast extension direction. The proportional range of the joystick
begins with the dead-band (parameter 301) and ends with the
maximum valve opening.
304 0100 % 0000 – 0100 Maximum valve opening for retracting mast.
set in tracting mast direction. The proportional range of the joystick
begins with the dead-band (parameter 302) and ends with the
305 0100 0,01 s 0000 - 1000 Acceleration-ramp for extending mast.

At extending mast the acceleration is limited on the programmed
value even if the joystick is excursed faster.
306 0050 0,01 s 0000 - 1000 Brake-ramp for extending mast.

At extending mast the braking is limited on the programmed value
even if the joystick is taken back faster.
307 0100 0,01 s 0000 – 1000 Acceleration-ramp for retracting mast.

At retracting mast the acceleration is limited on the programmed value
308 0050 0,01 s 0000 - 1000 Brake-ramp for retracting mast.

At retracting mast the braking is limited on the programmed value
309 0050 % 0000 – 0100 Maximum valve opening in outer end position.
In outer end positions (DI20 active) the maximm valve opening of

parameter 303 is reduced by the programmed factor. The
proportional control of the valve opening with the joystick is still active.
Electronic Steering
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Electric Sideloader
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310 0050 % 0000 – 0100 Maximum valve opening in inner end position.
In inner end positions (DI19 active) the maximum valve opening of
parameter 304 is reduced by the programmed factor. The
proportional control of the valve opening with the joystick is still active.
311 0100 0,01 s 0000 - 1000 Brake-ramp in end position outside.

At attaining of the mast outer end position a separate brake-ramp
becomes active (see parameter 306).
312 0100 0,01 s 0000 - 1000 Brake-ramp in end position inside.

At attaining of the mast inner end position a separate brake-ramp
becomes active (see parameter 308).
313 % 0000 – 0100 Mast shifting out limit at lifting.

If during the mast shifting out lifting is activated simultaneously, the
valve opening of the mast shifting out is reduced to the programmed
value. So a hydraulic influence of the two functions is prevented.
314 0000 - 0000 - 0003 Configuration stop mast retracting/extending with DI12
With active DI12 a stop can be programmed on the mast
retract/extend function:
0000 = No stop active
0001 = Stop at mast extending
0002= Stop at mast retracting
0003 = Stop at mast extending and rectracting.
315 0000 - 0000 – 9999 -

… 0000 - 0000 – 9999 -
319 0000 - 0000 – 9999 -
320 0000 - 0000 - 0001 Inversion platform tilting.
0000 = No inversion
0001 = Platform tilting up/down inverted
321 0000 % 0000 - 0100 Dead-band for platform tilting up

As soon as platform tilt up is activated, the programmed dead-band is
322 0000 % ^0000 – 0100 Dead-band for platform tilting down.

As soon as platform tilt down is activated, the programmed dead-
band is output to the proportional valve. A dead band of the valve in
centre position is compensated.
323 0100 % 0000 – 0100 Maximum valve opening for platform tilting up.
At maximum joystick excursion the programmed valve opening is
reached in direction platform tilting up. the proportional range of the
joystick begins with the dead band (parameter 321) and ends with the
324 0100 % 0000 - 0100 Maximum valve opening for platform tilting down.
reached in direction platform tilting down. The proportional range of
the joystick begins with the dead band (parameter 322) and ends with
the maximum valve opening.
325 0100 0,01 s 0000 – 1000 Acceleration-ramp for platform tilting up.
At tilting up platform the acceleration is limited on the programmed
326 0050 0,01 s 0000 – 1000 Brake-ramp for platform tilting up.
At tilting up platform is limited on the programmed value even if the
joystick is taken back faster.
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327 0100 0,01 s 0000 - 1000 Acceleration-ramp for platform tilting down.
At tilting down platform the acceleration is limited on the programmed
328 0050 0,01 s 0000 – 1000 Brake-ramp for platform tilting down.
At tilting down platform the braking is limited on the programmed
value even if the joystick is taken back faster.
329 0000 - 0000 – 0001 Hydraulic pump platform tilting down

0000 = out
0001 = on
330 0000 - 0000 – 0003 Configuration digital output DO4.

The activating of the digital output DO4 at active tilting platform
function can be programmed here:
0000 = Output never active
0001 = Output at lifting platform active
0002 = Output at lowering platform active
0003 = Output at lifting and lowering platform active.
331 0000 - 0000 – 9999 -

... 0000 - 0000 – 9999 -
339 0000 - 0000 – 9999 -
340 0000 - 0000 – 0001 Inversion forks tilting.
0000 = No inversion
0001 = Function fork tilting up/down inverted.
341 0000 % 0000 - 0100 Dead-band forks tilting up.

As soon as forks tilt up is activated, the programmed dead-band is
342 0000 % 0000 - 0100 Dead-band forks tilting down.

As soon as forks tilt up is activated, the programmed dead-band is
343 0100 % 0000 – 0100 Maximum valve opening forks tilting up.
reached in direction fork filting up. The proportional range of the
344 0100 % 0000 - 0100 Maximum valve opening forks tilting down.
reached in direction fork tilting down. The proportional range of the
345 0100 0,01 s 0000 – 1000 Acceleration-ramp forks tilting up.

At tilting up fork the acceleration is limited on the programmed value
346 0050 0,01 s 0000 – 1000 Brake-ramp forks tilting up.

At tilting up fork the braking is limited on the programmed value even
if the joystick is taken back faster.
347 0100 0,01 s 0000 – 1000 Acceleration-ramp forks tilting down.

At tilting down fork the acceleration is limited on the programmed

Electronic Steering
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349 0000 - 0000 – 9999 -

... 0000 - 0000 – 9999 -
359 0000 - 0000 – 9999 -
360 0000 - 0000 – 0001 Inversion fork adjusting
0000 = No inversion
0001 = Function adjusting fork right/left inverted.
361 0000 % 0000 – 0100 Dead-band fork adjusting to the right.

As soon as forks adjust right is activated, the programmed dead-band is
362 0000 % 0000 – 0100 Dead-band fork adjusting to the left.

As soon as forks adjust left is activated, the programmed dead-band is
363 0100 % 0000 – 0100 Maximum valve opening fork adjusting to the right.
At maximum joystick excursion the programmed valve opening is reached
in direction fork adjusting to the right. The proportional range of the joystick
begins with the dead band (parameter 361) and ends with the maximum
valve opening.
364 0100 % 0000 – 0100 Maximum valve opening fork adjusting to the left.
in direction fork adjusting to the left. The proportional range of the joystick
begins with the dead band (parameter 362) and ends with the maximum
valve opening.
365 0100 0,01 s 0000 – 1000 Acceleration-ramp fork adjusting to the right.
At adjusting fork to the right the acceleration is limited on the programmed
366 0050 0,01 s 0000 – 1000 Brake-ramp fork adjusting to the right.
At adjusting fork to the right the braking is limited on the programmed
367 0100 0,01 s 0000 – 0100 Acceleration-ramp fork adjusting to the left.
At adjusting fork to the left the acceleration is limited on the programmed
368 0050 0,01 S 0000 – 1000 Brake-ramp fork adjusting to the left.
At adjusting fork to the left the braking is limited on the programmed value
369 0000 - 0000 – 9999 -

... 0000 - 0000 – 9999 -
379 0000 - 0000 – 9999 -
380 000 - 0000 – 0001 Inversion hydro function 6 (HF6).
0000 = No inversion
0001 = hydro function 6 inverted.
381 0000 % 0000 – 0100 Dead-band HF6 direction B.

As soon as HF6 is activated in direction B, the programmed dead-band is
positions is compensated.
382 0000 % 0000 – 0100 Dead-band HF6 direction A.

As soon as HF6 is activated in direction A, the programmed dead-band is
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383 0100 % 0000 – 1000 Maximum valve opening HF6 direction B.

at adjusting hydro function in direction B. The proportional range of the
384 0100 % 0000 – 0100 Maximum valve opening HF6 direction A.

at adjusting hydro function in dreiction A. The proportional range of the
385 0100 0,01 s 0000 – 1000 Acceleration-ramp HF6 direction B.

At activating hydro function the acceleration is limited on the programmed
386 0050 0,01 s 0000 – 1000 Brake-ramp HF6 direction B.

At activating hydro function B the braking is limited on the programmed
387 0100 0,01 s 0000 - 1000 Acceleration-ramp HF6 direction A.

At activating hydro function A the acceleration is limited on the
programmed value even if the joystick is excursed faster.
388 0050 0,01 s 0000 - 1000 Brake-ramp HF6 direction A.

At activating hydro function A the braking is limited on the programmed
389 0000 - 0000 – 9999 -

... 0000 - 0000 – 9999 -
399 0000 - 0000 – 9999 -
400 0050 % 0010 - 0100 Maximum analog pump setpoint.
With this parameter the analogous setpoint of the pump rotation speed can
be limited. With a value of 100 + 10 V is output to the power amplifier of
the hydraulic pump maximally.
401 0050 0,01 s 0000 - 1000 Delay hydraulic function after pump
While deflecting the joystick the hydraulic pump is activated first. After the
programmedelay the function is started then.
402 0100 0,01 s 0000 - 1000 Delay pump after hydraulic function.
After the joystick is set to the neutral position, the hydraulic function is
stopped with the programmed ramp. The hydraulic pump continues
running until this delay is over.
403 0000 % 0000 - 0100 Minimum speed of hydraulic pump.

The programmed minimal rotation speed is output immediately, a soon as
the hydraulic pump is activated. This is necessary since many hydraulic
pumps wear at too small rotation speeds very fast.
404 0000 % 0000 – 0100 Offset pump speed at lifting.

The analogous pump set point is increased immediately by the offset value,
as soon as lifting is active.
405 0000 % 0000 – 0100 Offset pump speed at lowering.

See parameter 404.
406 0000 % 0000 – 0100 Offset pump speed at mast extending.

See parameter 404.
407 0000 % 0000 - 0100 Offset pump speed at mast retracting.

See parameter 404.
408
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Offset pump speed at platform tilting up.
See parameter 404.
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409 0000 % 0000 - 0100 Offset pump speed at platform tilting up.
See parameter 404.
410 0000 % 0000 – 0100 Offset pump speed at fork tilting up.
See parameter 404.
411 0000 % 0000 - 0100 Offset pump speed at fork tilting down.
See parameter 404.
412 0000 % 0000 - 0100 Offset pump speed at fork adjusting to the right.
See parameter 404.
413 0000 % 0000 - 0100 Offset pump speed at fork adjusting to the left.
See parameter 404.
414 0000 % 0000 - 0100 Offset pump speed at HF6 direction B.

See parameter 404.
415 0000 % 0000 - 0100 Offset pump speed at HF6 direction A.

See parameter 404.
416 0100 % 0000 – 0100 Maximum pump speed at lifting.

Maximum analogous pump set point with maximum excursion of the
joystick in lifting direction.
417 0100 % 0000 – 0100 Maximum pump speed at lowering.

See parameter 416.
418 0100 % 0000 - 0100 Maximum pump speed at mast extending.

See parameter 416.
419 0100 % 0000 - 0100 Maximum pump speed at mast retracting.

See parameter 416.
420 0100 % 0000 - 0100 Maximum pump speed at platform tilting up.
See parameter 416.
421 0100 % 0000 – 0100 Maximum pump speed at platform tilting down.
See parameter 416.
422 0100 % 0000 – 0100 Maximum pump speed at fork tilting up.
See parameter 416.
423 0100 % 0000 – 0100 Maximum pump speed at fork tilting down.
See parameter 416.
424 0100 % 0000 – 0100 Maximum pump speed at fork adjusting to the right.
See parameter 416.
425 0100 % 0000 - 0100 Maximum pump speed at fork adjusting to the left.
See parameter 416.
426 0100 % 0000 – 0100 Maximum pump speed at HF6 direction B.

See parameter 416.
427 0100 % 0000 - 0100 Maximum pump speed at HF6 direction A.

See parameter 416.
428 0000 - 0000 – 9999 -

429 0000 - 0000 – 9999 -

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430 0000 % 0000 -. 0100 Bending point of pump speed set point at lifting.
The analogous control of the hydraulic pump speed can be modified from
linear characteristic to bent characteristic. Always two parameters (e.g. 430
and 442 for lifting define the bending point in the range of 0…100 %.
So the pump speed slope can be low at fine movements of the hydraulic
function and high and high speed movements of the hydraulic function.
431 0000 % 0000 – 0100 Bending point of pump speed set point at lowering.
See parameter 430.
432 0000 % 0000 – 0100 Bending point of pump speed set point at mast extending.
See parameter 430.
433 0000 % 0000 - 0100 Bending point of pump speed set point at mast retracting.
See parameter 430.
434 0000 % 0000 - 0100 Bending point of pump speed set point at platform tilting
up.
See parameter 430.
435 0000 % 0000 - 0100 Bending point of pump speed set point at platform tilting
down.
See parameter 430.
436 0000 % 0000 - 0100 Bending point of pump speed set point at fork tilting up.
See parameter 430.
437 0000 % 0000 – 0100 Bending point of pump speed set point at fork tilting up.
See parameter 430.
438 0000 % 0000 – 0100 Bending point of pump speed set point at fork adjusting to
the right.
See parameter 430.
439 0000 % 0000 - 0100 Bending point of pump speed set point at fork adjusting to
the left.
See parameter 430.
440 0000 % 0000 - 0100 Bending point of pump speed set point at HF6 direction B.
See parameter 430.
441 0000 % 0000 - 0100 Bending point of pump speed set point at HF6 direction A.
See parameter 430.
442 0000 % 0001 – 0100 Bending point of joystick lifting.

See parameter 430.
443 0000 % 0001 – 0100 Bending point of joystick lowering.

See parameter 430.
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444 0000 % 0001- 0100 Bending point of joystick mast extending.

See parameter 430.
445 0000 % 0001 – 0100 Bending point of joystick mast retracting.

See parameter 430.
446 0000 % 0001 – 0100 Bending point of joystick platform tilting down.
See parameter 430.
448 0000 % 0001 - 0100 Bending point of joystick fork tilting up.
See parameter 430.
449 0000 % 0001 - 0100 Bending point of joystick fork tilting down.
See parameter 430.
450 0000 % 0001 - 0100 Bending point of joystick fork adjusting to the right.
See parameter 430.
451 0000 % 0001 - 0100 Bending point of joystick fork adjusting to the left.
See parameter 430.
452 0000 % 0001 - 0100 Bending point of joystick HF6 direction B.

See parameter 430.
453 0000 % 0001 - 0100 Bending point of joystick HF6 direction A.

See parameter 430.
454 0000 - 0000 – 9999 -

… 0000 - 0000 – 9999 -
511 0000 - 0000 – 9999 -

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C o n t r o lle r E H X / E G X
A C -3 / A C -4
W it h in th e Z A P IM O S fa m ily , th e A C 3 in v e r t e r is t h e m o d e l s u it a b le f o r c o n t r o l o f 7 + 1 2 k W m o t o r s ;
th e A C 4 in v e r t e r is t t h e m o d e l s u it a b le f o r c o n t r o l o f 1 2 k W t o 2 0 k W m o t o r s . T h e y h a v e b e e n
e x p re s s ly d e s ig n e d f o r b a tte ry e le c t r ic a l t r a c t io n .
T h e y a r e f it f o r e le c t r ic tru c k , e le c t r ic c a rs , tra c to rs a n d b u s e s .
2 . S p e c if ic a t io n
2 .1 A C - 3 T e c h n ic a l S p e c if ic a t io n s
In v e r t e r fo r A C a s y n c h ro n u s 3 - p h a s e m o to rs
R e g e n e r a t iv e b r a k in g f u n c t io n s
C A N - b u s in t e r f a c e
D ig it a l c o n t r o l b a s e d u p o n a m ic r o c o n t r o lle r
V o lt a g e : 3 6 - 4 8 - 7 2 - 8 0 V
M a x im u m c r r e n t (3 6 V , 4 8 V ) 6 0 0 A (R M S ) fo r 3 '
M a x im u m c u r r e n t (7 2 V , 8 0 V ) 4 5 0 A (R M S ) fo r 3 '
B o o s t e r (a ll v e r s io n ) 1 0 % o f m a x im u m c u rre n t fo r s o m e
s e c o n d s ;
O p e r a t in g f r e q u e n c y 8 k H z
E x te rn a l te m p e ra tu re ra n g e : - 3 0 ° C ÷ 4 0 ° C
M a x im u m in v e r t e r t e m p e r a t u r e ( a t f u ll p o w e r ) 7 5 ° C
2 .1 A C - 4 T e c h n ic a l S p e c it ic a t io n s
In v e r t e r fo r A C a s y n c h ro n u s 4 - p h a s e m o to rs
R e g e n e r a t iv e b r a k in g f u n c t io n s
C A N - b u s in t e r f a c e
D ig it a l c o n t r o l b a s e d u p o n a m ic r o c o n t r o lle r
V o lt a g e : 4 8 - 7 2 - 8 0 V
M a x im u m c u r r e n t (4 8 C ) V , 4 8 V ) 7 0 0 A (R M S ) fo r 3 '
M a x im u m c u r r e n t (7 2 V , 8 0 V ) 5 0 0 A (R M S ) fo r 3 '
B o o s t e r ( a ll v e r s io n ) 1 0 % o f m a x im u m c u r r e n t f o r s o m e
s e c o n d s ;
O p e r a t in g f r e q u e n c y 8 k H z
E x te rn a l te m p e ra tu re ra n g e : - 3 0 °C ÷ 4 0 ° C
M a x im u m in v e r t e r t e m p e r a t u r e (a t f u ll p o w e r ) 7 5 °C
Is s u e 0 2 /2 0 0 6
P a g e 2
2 .3 B lo c k D ia g r a m
2 .4 C o n t r o l U n it
2 .4 .a M ic r o s w it c h e s
- T h e m ic r o s w it c h e s m u s t h a v e a c o n t a c t r e s is t a n c e lo w e r t h a n 1 W a n d a le a k a g e c u r r e n t
lo w e r t h a n 1 0 0 µ A .
- W h e n f u ll lo a d c o n n e c t e d , t h e v o lt a g e b e t w e e n t h e k e y s w ic h c o n t a c t s m u s t b e lo w e r t h a n
0 .1 V .
- T h e m ic r o s w it c h e s s e n d a v o lt a g e s ig n a l t o t h e m ic r o p r o c e s s o r w h e n a f u n c t io n r e q u e s t ( f o r
e x . : r u n n in g r e q u e s t ) is m a d e .
2 .4 .b A c c e le r a t o r u n it
T h e a c c e le r a t o r u n it c a n c o n s is t o f a p o r t e n t io m e t e r o r a n H a ll e f f e c t d e v ic e . It s h o u ld b e in a
3 - w ir e c o n f ig u r a t io n .
C P O T (A 1 1 ) S a a b c o n n e c to r v e r s io n ; A 1 M o le x M in if it v e r s io n ) s ig n a l r a n g e s f r o m 0 t o 1 0 V .
P o t e n t io m e t e r v a lu e s h o u ld b e in t h e 0 . 5 - 1 0 K o h m r a n g e g e n e r a lly , t h e lo a d s h o u ld b e in t h e
1 . 5 m A t o 3 0 m A r a n g e . F a u lt s c a n o c c u r if it is o u t s id e t h is r a n g e .
Is s u e 0 2 /2 0 0 6
P a g e 3
T h e p ro c e d u re fo r a u t o m a t ic p o te n t io m e t e r s ig n a l a c q u is it io n is c a r r ie d o u t u s in g t h e
c o n s o le . T h is e n a b le s a d ju s t m e n t o f t h e m in im u m a n d m a x im u m u s e fu l s ig n a l le v e l
(P R O G R A M V A C C f u n c t io n ) , in e it h e r d ir e c t io n . T h is f u n c t io n is u n iq u e w h e n it is n e c e s s a r y
to c o m p e n s a te fo r a s y m m e try w it h t h e m e c h a n ic a l e le m e n t s a s s o c ia t e d w it h t h e
p o t e n t io m e t e r , e x p e c ia lly r e la t in g to t h e m in im u m le v e l.
T h e s e q u e n c e o f p r o c e d u r e is d e s c r ib e d in t h e p r o g r a m m in g c o n s o le m a n u a l.
M E C H A N IC A L A N G L E M E C H A N IC A L A N G L E
T h e tw o g ra p h s s h o w th e o u tp u t v o lt a g e f r o m a n o n -c a lib r a t e d p o t e n t io m e t e r w it h r e s p e c t
t o t h e m e c h a n ic a l " z e r o " o f t h e c o n t r o l le v e r . M I a n d M A in d ic a te th e p o in t w h e r e t h e
d ir e c t io n s s c h w it c h e s c lo s e . 0 re p re s e n ts th e m e c h a n ic a l z e ro o f r o t a t io n . T h e le f t h a n d
g r a p h s h o w s t h e r e la t io n s h ip o f th e m o to r v o lt a g e w it h o u t s ig n a l a c q u is it io n b e in g m a d e .
T h e r ig h t h a n d g r a p h s h o w s t h e s a m e r e la t io n s h ip a f t e r s ig n a l a c q u is it io n o f th e
p o t e n t io m e t e r .
2 .4 .c O t h e r A n a lo g C o n t r o l U n it
1 ) In p u t A 1 3 (S a a b c o n n e c to r v e r s io n ), A 8 ( M o le x M in if it v e r s io n ) is a n a n a lo g in p u t , w h o s e
t y p ic a l a p p lic a t io n is f o r p r o p o r t io n a l b r a k in g . It s h o u ld b e in a 3 w ir e c o n f ig u r a t io n .
P o te n t io m e t e r v a lu e h o u ld b e in t h e 0 . 5 - 1 0 k W r a n g e . G e n e r a lly , t h e lo a d s h o u ld b e in t h e
1 .5 m A to 3 0 m A ra n g e .
T h e C P O T B (A 1 3 , A 8 ) s ig n a l r a n g e is f r o m 0 to 1 0 V .
2 ) C o n n e c t io n s A 3 ( S a a b ), B 6 (M in if it ) ( P T H E R M ) a n d A 4 (S a a b ) , B 1 2 ( m in if it ) ( N T H E R M ) a r e
u s e d f o r a m o t o r t h e r m a l s e n s o r . It c a n b e d if it a l (o n / o f f s e n s o r , n o r m a lly c lo s e d ) o r
a n a lo g .
2 .4 .d S p e e d F e e d b a c k
T h e m o t o r c o n t r o l is b a s e d u p o n t h e m o t o r s p e e d f e e d b a c k . T h e s p e e d t r a n s d u c e r is a n
in c r e m e n t a l e n c o d e r , w it h t w o p h a s e s s h if t e d a t 9 0 ° . T h e e n c o d e r c a n b e o f d if f e r e n t t y p e s
- p o w e r s u p p ly + 5 V o r + 1 2 V
- e le c t r ic o u t p u t : o p e n c o lle c t o r ( N P N o r P N P ) , p u s h - p u ll, lin e d r iv e r
- s t a n d a r d ( A a n d B ) o r d if f e r e n t ia l ( A , A , B , B ) o u t p u t
F o r m o r e d e t a ils a b o u t e n c o d e r in s t a lla t io n s e e a ls o c h a p t e r 3 . 6
Is s u e 0 2 /2 0 0 6
P a g e 4
2 .5 P r o t e c t io n F e a t u r e s
- B a t t e r y p o la r it y in v e r s io n :
It is n e c e s s a r y t o f it a M A IN C O N T A C T O R t o p r o t e c t t h e in v e r t e r a g a in s t r e v e r s e b a t t e r y
p o la r it y a n d f o r s a f e t y r e a s o n s .
- C o n n e c t io n s E r r o r s :
A ll in p u t s a r e p r o t e c t e d a g a in s t c o n n e c t io n e r r o r s .
- T h e r m a l p r o t e c t io n
If t h e c h o p p e r t e m p e r a t u r e e x c e e d s 7 5 ° C , t h e m a x im u m c u r r e n t is r e d u c e d in p r o p o r t io n t o
t h e t h e r m a l in c r e a s e . T h e t e m p e r a t u r e c a n n e v e r e x c e e d s 1 0 0 ° C .
- E x te rn a l a g e n ts :
T h e in v e r t e r is p r o t e c t e d a g a in s t d u s t a n d t h e s p r a y o f liq u id t o a d e g r e e o f p r o t e c t io n
m e e t in g IP 5 4 .
- P ro t e c t io n a g a in s t u n c o n t r o lle d m o v e m e n t s :
T h e m a in c o n t a c t o r w ill n o t c lo s e if :
- T h e p o w e r u n it s is n o t f u n c t io n in g .
- T h e lo g ic is n o t f u n c t io n in g p e r f e c t ly .
- T h e o u t p u t v o lt a g e o f t h e a c c e le r a t o r d o e s n o t f a ll b e lo w t h e m in im u m v o lt a g e v a lu e
s t o r e d , w it h 1 V a d d e d .
- R u n n in g m ic r o s w it c h in c lo s e d p o s it io n .
- L o w b a tte ry c h a rg e :
W h e n t h e b a t t e r y c h a r g e is lo w , t h e m a x im u m c u r r e n t s is r e d u c e d t o t h e h a lf o f t h e
m a x im u m c u r r e n t p r o g r a m m e d .
- P ro te c t io n a g a in s t a c c id e n ta l s ta rt u p
A p re c is e s e q u e n c e o f o p e r a t io n s a r e n e c e s s a r y b e f o r e t h e m a c h in e w ill s t a r t . O p e r a t io n
c a n n o t b e g in if t h e s e o p e r a t io n s a r e n o t c a r r ie d o u t c o r r e c t ly . R e q u e s t s f o r d r iv e , m u s t b e
m a d e a fte r c lo s in g th e k e y s w it c h .
2 .6 O p e r a t io n a l F e a t u r e s
- S p e e d C o n tro l
- O p t im u m b e h a v io r a n a s lo p e d u e to th e s p e e d fe e d b a c k :
- T h e m o to r s p e e d f o llo w s th e a c c e le r a t o r , s t a r t in g a r e g e n e r a t iv e b r a k in g if t h e s p e e d
o v e rta k e s th e s p e e d s e t- p o in t .
- T h e s y s te m c a n p e rfo rm a n e le c t r ic a l s t o p o n a r a m p ( t h e m a c h in e is e le c t r ic a lly h o ld o n a
s lo p e ) fo r a p ro g ra m m a b le t im e (s e e a ls o c h a p t e r 4 . 4 ).
- S t a b le s p e e d in e v e r y p o s it io n o f t h e a c c e le r a t o r .
- R e g e n e r a t iv e r e le a s e b r a k in g b a s e d u p o n d e c e lr r a t io n r a m p s .
- R e g e n e r a t iv e b r a k in g w h e n t h e a c c e le r a t o r p e d a l is p a r t ia lly r e le a s e d ( d e c e le r a t io n ).
Is s u e 0 2 /2 0 0 6
P a g e 5
- D ir e c t io n in v e r s io n w it h r e g e n e r a t iv e b r a k in g b a s e d u p o n d e c e le r a t io n r a m p .
- R e g e n e r a t iv e b r a k in g a n d d ir e c t io n in v e r s io n w it h o u t c o n t a c t o r s : o n ly t h e m a in c o n t a c t o r is
p re s e n t.
- T h e r e le a s e b r a k in g r a m p c a n b e m o d u la t e d b y a n a n a lo g in p u t , s o t h a t a p r o p o r t io n a l
b r a k e f e a t u r e is o b t a in e d .
- O p t im u m s e n s it iv it y a t lo w s p e e d s .
- V o lt a g e b o o s t a t t h e s t a r t a n d w it h o v e r lo a d t o o b t a in m o r e t o r q u e ( w it h c u r r e n t c o n t r o l) .
- T h e in v e r t e r c a n d r iv e a n e le c t r o m e c h a n ic a l b r a k e
- H y d r a u lic s t e e r in g f u n c t io n :
1 ) t r a c t io n in v e r t e r
- t h e t r a c t io n in v e r t e r s e n d s a " h y d r a u lic s t e e r in g f u n c t io n " r e q u e s t t o t h e p u m p in v e r t e r o n
t h e c a n - b u s lin e ( s e e a ls o o p t io n c h a p t e r 4 . 4 ) .
- m o r e e v e r , if t h e p u m p in v e r t e r is n o t p r e s e n t ( f o r e x : t r a c t o r a p p lic a t io n ) , t h e t r a c t io n
in v e r t e r c a n m a n a g e a n " h y d r a u lic s t e e r in g f u n c t io n " b y d r iv in g a h y d r o c o n t a c t o r w h ic h a
h y d r a u lic s t e e r in g m o t o r ( o u t p u t A 7 ( S a a b ), B 9 ( M in if it ) , s e e a ls o o p t io n c h a p t e r .
2 ) p u m p in v e r t e r
- t h e p u m p in v e r t e r m a n a g e a n " h y d r a u lic s t e e r in g f u n c t io n " . T h a t is , it d r iv e s t h e p u m p
m o to r a t th e p ro g ra m m e d s p e e d fo r th e p ro g ra m m e d t im e .
- H ig h e f f ic ie n c y o f m o t o r a n d b a t t e r y d u e t o h ig h f r e q u e n c y c o m m u t a t io n s .
- S e lf d ia g n o s is w it h in d ic a t io n o f t h e f a u lt s h o w n b y a f la s h in g le d .
- M o d if ic a t io n o f p a r a m e t e r s t h r o u g h t h e p r o g r a m m in g c o n s o le .
- In t e r n a l h o u r - m e t e r w it h v a lu e s t h a t c a n b e d is p la y e d o n t h e c o n s o le
- M e m o r y o f t h e la s t f iv e a la r m s w it h r e la t iv e h o u r - m e t e r a n d t e m p e r a t u r e d is p la y e d o n t h e
c o n s o le .
- T e s t f u n c t io n w it h in c o n s o le f o r c h e c k in g m a in p a r a m e t e r s .
2 .7 D ia g n o s is
T h e m ic r o p r o c e s s o r c o n t in u a lly m o n it o r s t h e in v e r t e r a n d c a r r ie s o u t a d ia g n o s t ic p r o c e d u r e
o n t h e m a in f u n c t io n s . T h e d ia g n o s is is m a d e in 4 p o in t s
1 ) D ia g n o s is o n k e y s w it c h c lo s in g t h a t c h e c k s : w a t c h d o g c ir c u it , c u r r e n t s e n s o r , c a p a c it o r
c h a r g in g , p h a s e ' s v o lt a g e s , c o n t a c t o r d r iv e s , c a n - b u s in t e r f a c e , if t h e s w it c h s e q u e n c e f o r
o p e r a t io n is c o r r e c t a n d if t h e o u t p u t o f a c c e le r a t o r u n it is c o rre c t.
2 ) S t a n d b y d ia g n o s is a t r e s t t h a t c h e c k s : w a t c h d o g c ir c u it , p h a s e ' s v o lt a g e s , c o n t a c t o r
d r iv e r , c u r r e n t s e n s o r , c a n - b u s in t e r f a c e .
3 ) D ia g n o s is d u r in g o p e r a t io n t h a t c h e c k s : w a t c h d o g c ir c u it s , c o n t a c t o r d r iv e r , c u r r e n t
s e n s o r s , a n - b u s in t e r f a c e .
Is s u e 0 2 /2 0 0 6
P a g e 6
4 ) C o n t in u o s d ia g n o s is t h a t c h e c k : t e m p e r a t u r e o f t h e in v e r t e r , m o t o r t e m p e r a t u r e .
D ia g n o s is is p r o v id e d in t w o w a y s . T h e d ig it a l c o n s o le c a n b e u s e d , w h ic h g iv e s a d e t a ile d
in f o r m a t io n a b o u t t h e f a ilu r e ; t h e f a ilu r e c o d e is a ls o s e n t o n t h e C a n - B u s .
2 .8 T h e r m a l C o n s id e r a t io n
- T h e h e a t g e n e r a t e d b y t h p o w e r b lo c k m u s t b e d is s ip a t e d . F o r t h is t o b e p o s s ib le , t h e
c o m p a r t m e n t m u s t b e v e n t ila t e d a n d t h e h e a t s in k m a t e r ia ls a m p le .
- T h e h e a t s in k m a t e r ia l a n d s y s t e m s h o u ld b e s iz e d o n t h e p e r f o m a n c e r e q u ir e m e n t o f t h e
m a c h in e . A b n o r m a l a m b ie n t a ir t e m p e r a t u r e s s h o u ld b e c o n s id e r e d . I n s it u a t io n s w h e r e e it h e r
v e n t ila t io n is p o o r , o r h e a t e x c h a n g e is d if f ic u lt , f o r c e d a ir v e n t ila t io n s h o u ld b e u s e d .
T h e t h e r m a l e n e r g y d is s ip a t e d b y t h e p o w e r b lo c k m o d u le v a r ie s a n d is d e p e n d e n t o n t h e
c u r r e c t d r a w n a n d t h e d u t y c y c le .
2 .9 G e n e r a l In s t r u c t io n s a n d P r e c a u t io n s
- N e v e r c o n n e c t S C R lo w f r e q u e n c y c h o p p e r w it h A S Y N C H R O N O U S IN V E R T E R b e c a u s e t h e
A S Y N C H R O N O U S f ilt e r c a p a c it o r s a lt e r t h e S C R c h o p p e r s w o r k . If it is n e c e s s a r y t o u s e t w o o r
m o r e c o n t r o l u n it s ( t r a c t io n + lif t . f o r e x . ) , t h e y m u s t b e lo n g t o t h e Z A P IM O S f a m ily .
- D o n o t c o n n e c t t h e in v e r t e r t o a b a t t e r y w it h a n o m in a l v a lu e d if f e r e n t f r o m t h e v a lu e in d ic a t e d
o n t h e c h o p p e r p la t e . If t h e b a t t e r y v a lu e is g r e a t e r , t h e M O S m a y f a il; if it is lo w e r , t h e c o n t r o l
u n it d o e s n o t " p o w e r u p " .
- D u r in g b a t t e r y c h a n g e , d is c o n n e c t A S Y N C H R O N O U S f r o m th e b a tte ry .
- S u p p ly t h e A S Y N C H R O N O U S o n ly w it h b a t t e r y f o r t r a c t io n ; d o n o t u s e a p o w e r s u p p ly .
- W h e n t h e c h o p p e r is in s t a lle d , m a k e t e s t s w it h t h e w h e e ls r a is e d f r o m t h e g r o u n d , in o r d e r t o
a v o id d a n g e r o u s s it u a t io n s d u e t o c o n n e c t io n e r r o r s .
- A f t e r t h e c h o p p e r is s w it c h e d o f f (k e y o f f ), t h e f ilt e r c a p a c it o r r e m a in s c h a r g e d f o r s o m e
m in u t e s ; if y o u n e e d t o w o r k o n t h e in v e r t e r , d is c h a r g e t h e m u s in g a 1 0 W ÷ 1 0 0 W r e s is t a n c e
c o n n e c te d fro m th e + B a tt to th e - B a tt.
2 .1 0 S u s c e p t ib ilit y a n d E le c t r o m a g n e t ic E m is s io n
E le c tro m a g n e t ic s u s c e p t b ilit y a n d e m is s io n a re s tro n g ly in f lu e n c e d b y t h e in s t a lla t io n . S p e c ia l

a tte n t io n m u s t b e g iv e n to th e le n g t h s a n d th e p a th s o f th e e le c t r ic c o n n e c t io n s a n d t h e s h ie ld s .
T h is s it u a t io n is b e y o n d Z A P I's c o n tro l. T h e re fo re Z A P I d e c lin e s a n y r e s p o n s ib lit y f o r
n o n c o m p lia n c e if c o r r e c t t e s t in g is n o t m a d e (t h e ir r a d ia te d e m is s io n d ir e c t iv e is E N 5 0 0 8 1 - 2 ).
S te u e ru n g E H X / E G X
A u s g a b e 0 2 /2 0 0 6
S e it e 7
2 .1 1 M a in C o n t a c t o r a n d E m e r g e n c y S w it c h
- T h e c o n n e c t io n o f t h e b a t t e r y lin e s w it c h e s m u s t b e c a r r ie d o u t f o llo w in g Z A P I in s t r u c t io n s .
- If a m e c h a n ic a l b a t t e r y lin e s w it c h is in s t a lle d , it is n e c e s s a r y t h a t t h e k e y s u p p ly t o t h e
in v e r t e r is o p e n t o g e t h e r w it h p o w e r b a t t e r y lin e ; if n o t , t h e in v e r t e r m a y b e d a m a g e d if t h e
s w it c h is o p e n e d d u r in g a r e g e n e r a t iv e b r a k in g .
- A n in t r in s ic p r o t e c t io n is p r e s e n t in s id e t h e lo g ic w h e n t h e v o lt a g e o n t h e b a t t e r y p o w e r
c o n n e c t io n o v e r t a k e s 4 0 % m o r e t h a n t h e b a t t e r y n o m in a l v o lt a g e o r if t h e k e y is s w it c h e d
o f f b e f o r e t h e b a t t e r y p o w e r lin e is d is c o n n e c t e d .
A u s g a b e 0 2 /2 0 0 6
S e it e 8
3 . S a f e t y A n d P r o t e c t io n
Z A P I c o n tr o lle r s a re d e s ig n e d a c c o r d in g t o t h e p r E N 9 5 4 - 1 s p e c if ic a t io n s o r s a f e t y r e la t e d
p a rts o f c o n tro l s y s te m a n d to U N I E N 1 1 7 5 -2 n o rm .
T h e s a fe ty o f th e m a c h in e is s tro n g ly r e la t e d t o in s t a lla t io n ; le n g t h , la y o u t a n d s c r e e n in g o f
e le c t r ic a l c o n n e c t io n s h a v e to b e c a r e f u lly d e s ig n e d .
A C 3 / A C 4 in v e r t e r e le c t r o n ic im p le m e n t s a n h a r d w a r e s a f e t y c ir c u it , w h ic h is a b le t o o p e n t h e
L in e C o n t a c t o r (L C ) a n d t h e E le c t r ic B r a k e (E B ) - a n d t h e r e f o r e t o c u t t h e p o w e r lin e s t o p p in g
t h e m a c h in e v ia H A R D W A R E , t h a t is b y p a s s in g t h e s o f t w a r e c o n t r o l o f t h e L C a n d E B . T h is
s a f e t y c ir c u it is d r iv e n b y " S A F E T Y " in ( s e e n e x t c h a p t e r ) . If s a f e t y in p u t is c o n n e c t e d t o
- B A T T , t h e " S A F E T Y " c ir c u it is in a c t iv e ; if t h e in p u t is o p e n , t h e " S A F E T Y " c ir c u it b e c o m e s
a c t iv e a n d , w it h in a t im e o u t , it is a b le t o o p e n t h e d r iv e r s o f L C c o il a n d E B c o il. T h e s a f e t y
c ir c u it is a ls o p e r io d ic a lly c h e c k e d b y t h e A C 3 / A C 4 m ic r o c o n t r o lle r ; if t h e m ic r o c o n t r o lle r
d e t e c t s a f a ilu r e in t h e " S A F E T Y " c ir c u it , t h e m ic r o c o n t r o lle r it s e lf w ill b r in g t h e m a c h in e in a
s a fe s ta tu s .
S u g g e s t c o n n e c t io n o f " S A F E T Y " c ir c u it :
- S T A N D A L O N E C O N F IG U R A T IO N :
It is s u g g e s te d to c o n n e c t s a fe ty in p u t t o t h e " S E A T " m ic r o s w it c h o r t o t h e " D E A D M A N "
m ic r o s w it c h ( it d e p e n d s o n th e a p p lic a t io n ) ; in t h is w a y t h e m a c h in e w ill b e b r o u g h t t o a s a f e
s ta tu s a s s o o n a s th e o p e ra t o r le a v e s t h e m a c h in e .
- C O M B I C O N F IG U R A T IO N :
In t h is c a s e th e p u m p c o n t r o lle r a c ts a s s u p e r v is o r , c h e c k in g t h e t r a c t io n c o n tro lle r
f u n c t io n a lit y b y th e C A N B U S . S o it is s u g g e s te d to c o n n e c t th e " S A F E T Y " in p u t o f t r a c t io n
c o n tro lle r t o a d e d ic a t e d o u t p u t o f p u m p c o n t r o lle r , s o th a t th e p u m p c o n tro lle r c a n d r iv e
th e tra c t io n s a f e t y in p u t a n d o p e n th e p o w e r lin e in c a s e o f m a lf u n c t io n in g o f tra c t io n
c o n tro lle r .
Z A P I is a lw a y s a v a ila b le to c o o p e r a t e w it h th e c u s to m e r in o rd e r to e v a lu a t e in s t a llt io n a n d
c o n n e c t io n s o lu t io n s . F u rth e rm o r e , Z A P I is a v a ila b le to d e v e lo p n e w S W o r H W s o lu t io n s t o
im p r o v e t h e s a fe ty o f th e m a c h in e , a c c o r d in g t o c u s to m e r re q u ir e m e n ts .
M a c h in e m a n u fa c tu re r h o ld s th e r e s p o n s ib ilit y f o r th e tr u c k s a fe ty fe a t u r e s a n d r e la t e d
a p p r o v a l.
A u s g a b e 0 2 /2 0 0 6
S e it e 9
4 . In s t a lla t io n
In s t a ll t h e c h o p p e r w it h t h e b a s e - p la t e o n a f la t m e t a llic s u r f a c e t h a t is c le a n a n d u n p a in t e d .
A p p ly a lig h t la y e r o f t h e r m o - c o n d u c t iv e g r e a s e b e t w e e n t h e t w o s u r f a c e s t o p e r m it b e t t e r
h e a t d is s ip a t io n .
E n s u r e t h a t t h e w ir in g o f t h e c a b le t e r m in a ls a n d c o n n e c t o r s is c a r r ie d o u t c o r r e c t ly . F it
t r a n s ie n t s u p p r e s s io n d e v ic e s t o t h e h o r n , s o le n o id v a lv e s , a n d c o n t a c t o r s n o t c o n n e c t e d t o
t h e c h o p p e r s u c h a s t h o s e f o r a c t iv a t in g t h e p u m p m o t o r o r s t e e r in g m o t o r .
4 .1 C o n n e c t io n C a b le s
F o r t h e a u x ilia r y c ir c u it s , u s e c a b le s o f 0 , 5 m m ² s e c t io n .
F o r p o w e r c o n n e c t io n s t o t h e m o t o r a n d t o t h e b a t t e r y , u s e c a b le s h a v in g s e c t io n in t h e 3 5
÷ 5 0 m m ² ra n g e ( a s a m in im u m ).
F o r t h e o p t im u m in v e r t e r p e r f o r m a n c e , t h e c a b le s t o t h e b a t t e r y s h o u ld b e r u n s id e b y s id e
a n d b e a s s h o rt a s p o s s ib le .
4 .2 C o n ta c to rs
T h e m a in c o n t a c t o r m u s t b e in s t a lle d . D e p e n d in g o n t e p o s it io n o f a ju m p e r in s t a lle d in t h e
lo g ic b o a r d :
- T h e o u tp u t w h ic h d r iv e s t h e m a in c o n t a c t o r c o il is o n / o f f ( t h e c o il is d r iv e n w it h t h e f u ll
b a t t e r y v o lt a g e ).
- T h e o u tp u t w h ic h d r iv e s t h e m a in c o n t a c t o r c o il is s w it c h e d a t h ig h f r e q u e n c y ( 1 K H z ) w it h a
d u t y c ic le o f 7 0 % . t h is f e a t u r e is u s e f u l t o d e c r e a s e t h e p o w e r d is s ip a t io n o f t h e c o n t a c t o r
c o il.
4 .3 F u s e s
U s e a 6 . 3 A f u s e f o r p r o t e c t io n o f t h e a u x ilia ry c ir c u it s .
- F o r p r o t e c t io n o f t h e p o w e r u n it , r e fe r to d ia g r a m s . T h e f u s e v a lu e s h o w n is t h e m a x im u m
a llo w a b le . F o r s p e c ia l a p p lic a t io n s o r re q u ir e m e n t s t h e s e v a lu e s c a n b e r e d u c e d .
- F o r s a fe ty re a s o n s , w e re c o m m e n d e d th e u s e o f p r t e c t e d f u s e s in o r d e r t o p r e v e n t t h e s p r e a d
o f fu s e d p a r t ic le s s h o u ld b e t h e f u s e b lo w .
4 .4 D e s c r ip t io n O f C o n n e c t o r s - T r a c t io n C o n f ig u r a t io n
T h e A C 3 a n d A C 4 h a v e b e e n d e s ig n e d t o b e p r o d u c e d w it h t w o d if f e r e n t t y p e s o f I/ O c o n n e c to r:
O n e A M P S A A B 2 9 p o le s c o n n e c t o r o r s ix M o le x M in if it c o n n e c t o r s .
P a g e 1 0
4 .4 .a A m p S a a b C o n n e c to r
A 1 P P O T P o t e n t io m e t e r p o s it iv e : 1 0 V o u t p u t ; k e e p lo a d > 1 k W .
A 2 N P O T B - B a tt
A 3 P T H E R M In p u t fo r m o t o r t e m p e r a t u r e s e n s o r .
A 4 N T H E R M -B a tt.
A 5 -B A T T B a t t e r y n e g a t iv e .
A 6 N L C N e g a t iv e o f m a in c o n t a c t o r c o il.
A 7 N B R A K E O u t p u t f o r d r iv in g a b r a k e o r a n h y d r a u lic s t e e r in g c o n t a c t o r c o il; d r iv e s
t h e lo a d t o - B a t t m a x im u m c u r r e n t : 3 A .
A 8 P L C P o s it iv e o f m a in c o n t a c t o r c o il
A 9 C M C o m m o n o f F W / B W / S R / P B / S E A T / B A C K . F W / B A C K . B W /
E X C L U S IV E H Y D R O m ic r o s w it c h e s .
A 1 0 K E Y C o n n e c t e d t o t h e p o w e r s u p p ly t h r o u g h a m ic r o s w it c h ( C H ) w it h a 1 0 A
f u s e in s e r ie s .
A 1 1 C P O T A c c e le r a t o r p o t e n t io m e t e r w ip e r .
N 1 2 N P O T N e g a t iv e o f a c c e le r a t o r u n it , t e s t e d f o r w ir e d is c o n n e c t io n d ia g n o s is .
A 1 3 C P O T B B r a k e p o t e n t io m e t e r w ip e r .
A 1 4 C A N -H H ig h le v e l C A N - B U S v o lt a g e I/ O .
A 1 5 C A N -L L o w le v e l C A N - B U S v o lt a g e I/ O .
A 1 6 F O R W F o r w a r d d ir e c t io n r e q u e s t in p u t . M u s t b e c o n n e c t e d t o t h e f o r w a r d
d ir e c t io n m ic r o s w it c h , a c t iv e h ig h .
A 1 7 B W B a c k w a r d d ir e c t io n r e q u e s t in p u t . M u s t b e c o n n e c t e d t o t h e b a c k w a r d
A 1 8 B A C K .F O R W In c h in g f u n c t io n , f o r w a r d d ir e c t io n in p u t . M u s t b e c o n n e c t e d t o t h e
in c h in g f o r w a r d s w it c h . A c t iv e h ig h .
A 1 9 B A C K .F O R W In c h in g f u n c t io n , b a c k w a r d d ir e c t io n in p u t . M u s t b e c o n n e c t e d t o t h e
in c h in g b a c k w a r d s w it c h . A c t iv e h ig h .
A 2 0 E N C O D E R In c r e m e n t a l E N C O D E R c o n n e c t o r (s e e c h a p t e r 3 .6 )
A 2 2 E N C O D E R In c r e m e n t a l E N C O D E R c o n n e c t o r (s e e c h a p t e r 3 .6 ).
A 2 4 M O D E T h is in p u t a llo w s t h e c u s t o m e r t o s e le c t t h e s o f t w a r e f o r t r a c t io n o r
lif t in g a p p lic a t io n .
C o n f ig u r a t io n :
M O D E : O p e n (n o t c o n n e c t e d ) T r a c t io n in v e r t e r
M O D E : C lo s e (c o n n e c t e d w it h A 5 ) P u m p in v e r t e r
A 2 5 S A F E T Y If n o t c o n n e c t e d t o - B a t t t h e M C c o il p o w e r o u t p u t w ill b e d is a b le d .
C a n a ls o b e u s e a s a g e n e r a l p u r p o s e in p u t .
A 2 6 P B B r a k e r e q u e s t in p u t . M u s t b e c o n n e c t e d t o t h e b r a k e p e d a l s w it c h ,
a c t iv e h ig h .
P a g e 1 1
A 2 7 E X .H Y D R O E x c lu s iv e h y d r o f u n c t io n in p u t . M u s t b e c o n n e c t e d t o t h e e x c lu s iv e
h y d r o m ic r o s w it c h . A c t iv e h ig h (s e e a ls o O P T IO N c h a p t e r ).
A 2 8 S R /H B S p e e d re d u c t io n (h a n d b r a k e ) in p u t . A c t iv e lo w (s w it c h o p e n e d ). S e e
a ls o O P T IO N c h a p te r).
A 2 9 S E A T S e a t in p u t ; m u s t b e c o n n e c t e d t o t h e S E A T m ic r o s w it c h ; it is a c t iv e
h ig h .
4 .4 .b M o le x M in if it C o n n e c t o r s
A 1 C P O T A c c e le r a t o r p o t e n t io m e t e r w ip e r .
A 2 P P O T P o t e n t io m e t e r p o s it iv e : 1 0 V o u t p u t ; k e e p lo a d > 1 k W
A 3 N P O T N e g a t iv e o f a c c e le r a t o r u n it , t e s t e d f o r w ir e d is c o n n e c t io n d ia g n o s e s .
A 4 C M C o m m o n o f F W / B W / S R / P B / S E A T / B A C K .F W / B A C K .B W /
E X C L U S I V E H Y D R O m ic r o s w it c h e s .
A 5 F O R W F o r w a r d d ir e c t io n r e q u e s t in p u t . M u s t b e c o n n e c t e d t o t h e f o r w a r d
A 6 B W B a c k w a r d d ir e c t io n r e q u e s t in p u t . M u s t b e c o n n e c t e d t o t h e b a c k w a r d
A 7 P B B r a k e r e q u e s t in p u t . M u s t b e c o n n e c t e d t o t h e b r a k e p e d a l s w it c h ,
a c t iv e h ig h .
A 8 C P O T B B r a k e p o t e n t io m e t e r w ip e r .
A 9 P P O T B B r a k e p o t e n t io m e t e r p o s it iv e . 1 0 V o u t p u t ; k e e p lo a d > 1 k W .
A 1 0 N P O T B -B a tt.
A 1 1 -B A T T -B a tt.
A 1 2 B A C K .F O R W In c h in g f u n c t io n , f o r w a r d d ir e c t io n in p u t . M u s t b e c o n n e c t e d t o t h e
in c h in g f o r w a r d s w it c h . A c t iv e h ig h .
A 1 3 B A C K .B A C K In c h in g f u n c t io n , b a c k w a r d d ir e c t io n in p u t . M u s t b e c o n n e c t e d t o t h e
in c h in g b a c k w a r d s w it c h . A c t iv e h ig h .
A 1 4 E X .H Y D R O E x c lu s iv e h y d r o f u n c t io n in p u t . M u s t b e c o n n e c t e d t o t h e e x c lu s iv e
h y d r . m ic r o s w it c h . A c t iv e h ig h (s e e a ls o O P T IO N c h a p t e r )
B 1 K E Y C o n n e c t e d t o t h e p o w e r s u p p p ly t h r o u g h a m ic r o s w it c h (C H ) w it h a 1 0
A fu s e in s e r ie s .
B 2 P L C P o s it iv e o f m a in c o n t a c t o r c o il.
B 3 P B R A K E P o s it iv e o f t h e e le c t r o m e c h a n ic a l b r a k e c o il.
B 4 S E A T S E A T in p u t ; m u s t b e c o n n e c t e d t o t h e S E A T m ic r o s w it c h ; it is a c t iv e
h ig h .
B 5 S A F E T Y If n o t c o n n e c t e d t o - B a t t t h e M C c o il p o w e r o u t p u t w ill b e d is a b le d .
C a n a ls o b e u s e d a s a g e n e r a l p u r p o s e u n it .
B 6 P T H E R M In p u t m o o r te m p e ra tu re s e n s o r.
B 7 C M C o m m o n o f F W / B W / S R / P B / S E A T / IN C H IN G F W / IN C H IN G B W
/ E X C L U S IV E H Y D R O m ic r o s w it c h e s .
B 8 N L C N e g a t iv e o f m a in c o n t a c t o r c o il.
Is s u e 0 2 /2 0 0 6
P a g e 1 2
B 9 N B R A K E O u tp u t fo r d r iv in g a b r a k e o r a n h y d r a u lic s t e e r in g c o n t a c o r c o il; d r iv e s
th e lo a d to -B a tt m a x im u m c u r r e n t : 3 A
B 1 0 S R /H B S p e e d re d u c t io n (h a n d b r a k e ) in p u t . A c t iv e lo w (s w it c h o p e n e d ). S e e
a ls o O P T IO N c h a p te r.
B 1 1 G N D -B a tt.
B 1 2 N T H E R M -B a tt
C 1 C A N - L L o w le v e l C A N -B U S v o lt a g e I/ O .
C 2 C A N - L -O U T L o w le v e l C A N -B U S v o lt a g e I/ O .
C 3 C A N - H H ig h le v e l C A N -B U S v o lt a g e I/ O
C 4 C A N - H -O U T H ig h le v e l C A N -B U S v o lt a g e I/ O .
D 1 - B A T T -B a tt.
D 2 M O D E T h is in p u t a llo w s t h e c u s t o m e r t o s e le c t t h e s o f t w a r e f o r t r a c t io n o r
M O D E : O p e n ( n o t c o n n e c t e d ) T r a c t io n in v e r t e r
M O D E : C lo s e (c o n n e c t e d w it h A 5 ) P u m p in v e r t e r
E 1 + E 6 In c r e m e n t a l E N C O D E c o n n e c t o r (s e e c h a p t e r 3 .6 ).
F 1 P C L R X D P o s it iv e s e r ia l r e c e p t io n .
F 2 N C L R X D N e g a t iv e s e r ia l r e c e p t io n .
F 3 P C L T X D P o s it iv e s e r ia l t r a n s m is s io n
F 4 N C L T X D N e g a t iv e se r ia l t r a n s m is s io n
F 5 G N D N e g a t iv e c
o n s o le p o w e r s u p p ly .
F 6 + 1 2 P o s it iv e c o n s o le p o w e r s u p p ly .
F 7 F L A S H M u s t b e c o n n e c t e d t o F 8 f o r t h e F la s h m e m o r y p r o g r a m m in g (if u s e d ).
.
P a g e 1 3
4 .5 D e s c r ip t io n o f C o n n e c t o r s - P u m p C o n f ig u r a t io n
T h e A C 3 a n d A C 4 h a v e b e e n d e s ig n e d t o b e p r o d u c e d w it h t w o d if f e r e n t t y p e s o f I/ O
c o n n e c t o r : O n e A M P S A A B 2 9 p o le s c o n n e c t o r o r s ix M o le x M in if it c o n n e c t o r s .
4 .5 .a A m p S a a b C o n n e c to r
A 1 P P O T P o t e n t io m e t e r p o s it iv e : 1 0 V o u t p u t ; k e e p lo a d > 1 k W .
A 2 N P O T B -B a tt.
A 3 P T H E R M In p u t fo r m o t o r t e m p e r a t u r e s e n s o r .
A 4 N T H E R M -B a tt.
A 5 B A T T B a t t e r y n e g a t iv e .
N 6 N A U X T h is o u t p u t c a n b e u s e d f o r d r iv e t h e m a in c o n t a c t o r c o il ( s in g le p u m p
c o n f ig u r a t io n ) o r t o d r iv e a n a u x ilia r y lo a d ( c o m b i c o n f ig u r a t io n ) .
A 7 N B R A K E O u t p u t f o r d r iv in g a n h y d r a u lic s t e e r in g c o n t a c t o r c o il; d r iv e s t h e lo a d t o
- B a t t m a x im u m c u r r e n t : 3 A .
A 8 P A U X P o s it iv e o f t h e a u x ilia r y o u t p u t .
A 9 C M C o m m o n o f L IF T E N A B L E / 1 S P E E D / 2 n d S P E E D / 3 r d S P E E D / 4 t h
S P E E D / H Y D R O / S R m ic r o s w it c h e s .
A 1 0 K E Y C o n n e c t e d t o t h e p o w e r s u p p ly t h r o u g h a m ic r o s w it c h ( C H ) w it h a 1 0 A
A 1 1 C P O T P o t e n t io m e t e r w ip e in p u t .
A 1 2 N P O T N e g a t iv e o f lif t in g p o t e n t io m e t e r , t e s t e d f o r w ir e d is c o n n e c t io n
d ia g n o s is .
A 1 3 A N .IN F r e e a n a lo g in p u t .
A 1 4 C A N -H H ig h le v e l C A N - B U S v o lt a g e I/ O .
A 1 5 C A N -L L o w le v e l C A N - B U S v o lt a g e I/ O .
A 1 6 L IF T E N A B L E In p u t f o r p o t e n t io m e t e r lif t in g e n a b le in p u t ; it is a c t iv e H IG H .
A 1 7 1 s t S P E E D Im p u t f o r f ir s t s p e e d r e q u e s t ; it is a c t iv e H IG H .
A 1 8 H Y D R O R E Q . In p u t f o r h y d r a u lic s t e e r in g r e q u e s t . A c t iv e h ig h .
A 1 9 S R S p e e d r e d u c t io n in p u t . A c t iv e lo w ( s w it c h o p e n e d )
A 2 4 M O D E T h is in p u t a llo w s t h e c u s t o m e r t o s e le c t t h e s o f t w a r e f o r t r a c t io n o r lif t in g
a p p lic a t io n .
M O D E : O P E N (n o t c o n n e c te d ) T r a c t io n in v e r t e r
M O D E : C lo s e (c o n n e c t e d w it h A 5 ) P u m p in v e r t e r .
A 2 5 S A F E T Y If n o t c o n n e c t e d t o - B a t t t h e M C c o il p o w e r o u t p u t w ill b e d is a b le d .
C a n a ls o b e u s e d a s a g e n e r a l p u r p o s e u n it .
P a g e 1 4
A 2 6 3 rd S P E E D In p u t fo r t h ir d s p e e d re q u e s t ; it is a c t iv e H IG H .
A 2 7 D iG . IN . T h is is a d ig it a l in p u t , f r e e fo r c u s to m e r re q u e s t.
A 2 8 2 n d S P E E D In p u t fo r s e c o n d s p e e d re q u e s t; it is a c t iv e H IG H .
A 2 9 4 th S P E E D In p u t fo r fo u rth s p e e d re q u e s t ; it is a c t iv e H IG H ,
4 .5 .b M o le x M in if it C o n n e c t o r s
A 1 C P O T A c c e le r a t o r p o t e n t io m e t e r w ip e r .
A 2 P P O T P o t e n t io m e t e r p o s it iv e : 1 0 V o u t p u t ; k e e p lo a d < 1 k W
A 3 N P O T N e g a t iv e o f a c c e le r a t o r u n it , t e s t e d f o r w ir e d is c o n n e c t io n d ia g n o s e s .
A 4 C M C o m m o n o f L IF T E N A B L E / 1 s t S P E E D / 2 n d S P E E D / 3 rd S P E E D / 4 th
A 5 L IF T E N A B L E In p u t f o r p o t e n t io m e t e r lif t in g e n a b le in p u t ; it is a c t iv e H IG H .
A 6 1 s t S P E E D In p u t f o r f ir s t s p e e d r e q u e s t ; it is a c t iv e H IG H .
A 7 3 rd S P E E D In p u t f o r t h ir d s p e e d r e q u e s t ; it is a c t iv e H IG H .
A 8 A N .IN F r e e a n a lo g in p u t .
A 9 P P O T P o t e n t io m e t e r p o s it iv e : 1 0 o V o u t p u t ; k e e p lo a d > 1 k W .
A 1 0 - B A T T -B a tt.
A 1 1 - B A T T -B a tt.
A 1 2 H Y D R O R E Q . In p u t f o r h y d r a u lic s t e e r in g r e q u e s t . A c t iv e h ig h .
A 1 3 S R S p e e d r e d u c t io n in p u t . A c t iv e lo w ( s w it c h o p e n e d ) .
A 1 4 D ig . IN . T h is is a d ig it a l in p u t , f r e e f o r c u s t o m e r r e q u e s t .
B 1 K E Y C o n n e c t e d t o t h e p o w e r s u p p ly t h r o u g h a m ic r o s w it c h (C H ) w it h a 1 0 A
B 2 P A U X P o s it iv e o f t h e a u x ilia r y o u t p u t .
B 3 H Y D R O P o s it iv e f o r t h e h y d r a u lic s t e e r in g c o n t a c t o r .
B 4 4 th S P E E D In p u t f o r f o u r t h s p e e d r e q u e s t ; it is a c t iv e H IG H ,
B 5 S A F E T Y If n o t c o n n e c t e d t o - B a t t t h e M C c o il p o w e r o u t p u t w ill b e d is a b le d . C a n
a ls o b e u s e d a s a g e n e r a l p u r p o s e in p u t .
B 6 P T H E R M In p u t fo r m o t o r t e m p e r a t u r e s e n s o r .
B 7 C M C o m m o n o f L IF T E N A B L E / 1 s t S P E E D / 2 n d S P E E D / 3 rd S P E E D / 4 th
B 8 N A U X T h is o u t p u t c a n b e u s e d f r d r iv e t h e m a in c o n t a c t o r c o il ( s in g le p u m p
c o n f ig u r a t io n ) o r t o d r iv e a n a u x ilia r y lo a d ( c o m b i c o n f ig u r a t io n )
B 9 N H Y D R O O u t p u t f o r d r iv in g a n h y d r a u lic s t e e r in g c o n t a c t o r ; d r iv e s t h e lo a d t o - B a t t .
m a x im u m c u r r e n t : 3 A .
B 1 0 2 n d S P E E D In p u t f o r s e c o n d s p e e d r e q u e s t ; it is a c t iv e H IG H .
B 1 1 G N D -B a tt.
B 1 2 N T H E R M -B a tt.
C 1 C A N - L L o w le v e l C A N -B U S v o lt a g e I/ O .
C 2 C A N - L -O U T L o w le v e l C A N -B U S v o lt a g e I/ O .
C 3 C A N - H H ig h le v e l C A N -B U S v o lt a g e I/ O .
C 4 C A N - H -O U T H ig h le v e l C A N -B U S v o lt a g e I/ O .
Is s u e 0 2 /2 0 0 6
P a g e 1 5
D 1 -B A T T - B a tt.
D 2 M O D E T h is in p u t a llo w s t h e c u s t o m e r t o s e le c t t h e s o f t w a r e f o r t r a c t io n o r
M O D E : O p e n (n o t c o n n e c te d ) T r a c t io n In v e r t e r
M O D E : C lo s e ( c o n n e c t e d w it h A 5 ) P u m p in v e r t e r
E 1 ÷ E 6 In c r e m e n t a l E N C O D E R c o n n e c t o r (s e e c h a p t e r 3 .6 )
F 1 P C L R X D P o s it iv e s e r ia l r e c e p t io n
F 2 N C L R X D N e g a t iv e s e r ia l r e c e p t io n
F 3 P C L T X D P o s it iv e s e r ia l t r a n s m is s io n
F 4 N C L T X D N e g a t iv e s e r ia l t r a n s m is s io n
F 5 G N D N e g a t iv e c o n s o le p o w e r s u p p ly
F 6 G N D N e g a t iv e c o n s o le p o w e r s u p p ly
F 6 + 1 2 P o s it iv e c o n s o le p o w e r s u p p ly .
4 .6 E n c o d e r In s t a lla t io n
1 ) A C 4 c a r d is f it t e d f o r d if f e r e n t t y p e s o f e n c o d e r . T o c o n t r o l A C m o t o r w it h Z a p i in v e r t e r , it
is n e c e s s a r y t o in s t a ll a n in c r e m e n t a l e n c o d e r w it h 2 p h a s e s s h if t e d o f 9 0 ! . T h e e n c o d e r
p o w e r s u p p ly c a n b e + 5 o r + 1 2 V . It c a n h a v e d if f e r e n t e le c t r o n ic o u t p u t .
M in if it S a a b
E 1 A 2 0 + 5 V /+ 1 2 V p o s it iv e o f e n c o d e r p o w e r s u p p ly .
E 2 A 2 3 G n D n e g a t iv e o f e n c o d e r p o w e r s u p p ly
E 3 A 2 1 A p h a s e A o f e n c o d e r
E 4 -- A p h a s e A in v e r t e d ( e n c o d e r w it h d if f e r e n t ia l o u t p u t ) .
E 5 A 2 2 B p h a s e B o f e n c o d e r
E 6 -- B p h a s e B in v e r t e d (e n c o d e r w it h d if f e r e n t ia l o u t p u t ) .
2 ) C o n n e c t io n o f e n c o d e r w it h d if f e r e n t ia l o u t p u t s ; + 5 V p o w e r s u p p ly ( M in if it c o n n e c t o r s )
3 ) C o n n e c t io n o f e n c o d e r w it h o p e n c o lle c t o r o u t p u t ; + 5 V p o w e r s u p p ly ( M in if it c o n n e c t o r s ).
4 ) C o n n e c t io n o f e n c o d e r w it h o p e n c o lle c t o r o u t p u t : : + 1 2 V s u p p ly ( M in if it c o n n e c t o r s ).
V E R Y IM P O R T A N T
It is n e c e s s a ry t o s p e c if y in t h e o r d e r t h e t y p e o f e n c o d e r u s e d , in t e r m s o f p o w e r s u p p ly ,
e le c tro n ic o u t p u t a n d n ° o f p u ls e s f o r r e v o lu t io n , b e c a u s e t h e lo g ic u n it m u s t b e s e t in t h e
c o rr e c t w a y b y Z a p i.
3 .7 D e s c r ip t io n o f P o w e r C o n n e c t io n s
V ie w o f th e p o w e r b a rs :
-B A T T N e g a t iv e o f t h e b a tte ry .
+ B A T T P o s it iv e o f t h e b a tte ry .
U ; V ; W C o n n e c t io n b a r s o f t h e t h r e e m o t o r p h a s e s ; f o llo w t h is s e q u e n c e a n d t h e
in d ic a t io n o n t h e m o to r.
4 .8 A C 3 M e c h a n ic a l D r a w in g
Is s u e 0 2 /2 0 0 6
P a g e 1 8
4 .9 A C 4 M e c h a n ic a l D r a w in g
Is s u e 0 2 /2 0 0 6
P a g e 1 9
4 .1 0 C o n n e c t io n D r a w in g - T r a c t io n c o n f ig u r a t io n
4 .1 0 .a A m p S a a b C o n n e c to r
Is s u e 0 2 /2 0 0 6
P a g e 2 0
4 .1 1 C o n n e c t io n D r a w in g - P u m p C o n f ig u r a t io n
Is s u e 0 2 /2 0 0 6
P a g e 2 1
4 . 1 1 . b M o l e x M i n i f i t C o n n e c t o r s
Is s u e 0 2 /2 0 0 6
P a g e 2 2
4 .1 2 C o n n e c t io n D r a w in g - C o m b i C o n f ig u r a t io n
Is s u e 0 2 /2 0 0 6
P a g e 2 3
4 .1 2 .b M o le x M in if it C o n n e c t o r s
Is s u e 0 2 /2 0 0 6
P a g e 2 4
5 P r o g r a m m in g & A d ju s t m e n t s U s in g D ig it a l C o n s o le
5 .1 A d ju s t m e n t s v ia c o n s o le
A d ju s t m e n t o f p a r a m e t e r a n d c h a n g e s t o t h e in v e r t e r ' s c o n f ig u r a t io n a r e m a d e u s in g t h e
d ig it a l c o n s o le . T h e c o n s o le is c o n n e c t e d o f t h e " F " c o n n e c t o r o f t h e in v e r t e r ( M in if it
c o n n e c t o r s v e r s io n ).
5 .2 . D e s c r ip t io n o f C o n s o le & C o n n e c t io n
D ig it a l c o n s o le s u s e d t o c o m m u n ic a t e w it h A C in v e r t e r c o n t r o lle r s m u s t b e f it t e d w it h E P R O M C K
U L T R A , m in im u m " R e le a s e N u m b e r 3 . 0 2 " .
Is s u e 0 2 /2 0 0 6
P a g e 2 5
5 .3 D e s c r ip t io n o f S t a n d a r d C o n s o le M e n u
5 .3 .a T r a c t io n C o n f ig u r a t io n
Is s u e 0 2 /2 0 0 6
P a g e 2 6
5 .3 .b P u m p C o n f ig u r a t io n
5 .4 F u n c t io n C o n f ig u r a t io n
5 .4 .a T r a c t io n
U s in g t h e C O N F IG M E N U o f t h e p r o g r a m m in g c o n s o le , t h e u s e r c a n c o n f ig u r e t h e f o llo w in g
f u n c t io n s ( s e e " O P E R A T IO N A L F E A T U R E " c h a p t e r f o r a n e x p la n a t io n o f " h y d r a u lic s t e e r in g
f u n c t io n ):
s u b m e n u " S e t O p t io n s "
1 H O U R C O U N T E R
- R U N N IN G : t h e c o u n t e r r e g is t e r s t r a v e l t im e o n ly .
- K E Y O N : t h e c o u n t e r r e g is t e r s w h e n t h e " k e y " s w it c h is c lo s e d .
2 B A T T E R Y C H E C K
- O N : th e b a tte r y d is c h a rg e le v e l c h e c k is c a r r ie d o u t ; w h e n t h e b a t t e r y le v e l
re a c h e s 1 0 % , a n a la r m is s ig n a lle d a n d th e m a x im u m c u r r e n t is
re d u c e d to th e h a lf o f th e p ro g ra m m e d v a lu e .
- O F F : th e b a tte r y d is c h a rg e le v e l c h e c k is c a r r ie d o u t b u t n o a la r m is
s ig n a lle d .
3 C U T B A C K M O D E
- P re s e n t: in p u t B 1 0 ( M in if it ) , A 2 8 ( A m p S a a b ) is m a n a g e d a s a c u t b a c k s p e e d
in p u t .
- A b s e n t: in p u t B 1 0 ( M in if it ) , A 2 8 ( A m p S a a b ) is m a n a g e d a s a n h a n d b r a k e in p u t .
4 H Y D R O K E Y O N
- O N /O F F : if t h is o p t io n is p r o g r a m m e d O N t h e t r a c t io n in v e r t e r m a n a g e s a n
h y d r a u lilc s t e e r in g f u n c t io n w h e n t h e " k e y " is s w it c h e d O N (o n ly if t h e
"a u x o u tp u t # 1 " o p t io n is p r o g r a m m e d a s " h y d r o c o n t a c t o r " o r a s
"e x c lu s iv e h y d r o " ).
5 S T O P O N R A M P
- O N : th e s to p o n ra m p fe a tu re ( t r u c k e le c t r ic a lly h o ld o n a r a m p ) is m a n a g e d
fo r a t im e e s ta b lis h e d b y " a u x ilia r y t im e " p a r a m e t e r . A f t e r t h is t im e , t h e
b e h a v io r d e p e n d s o n th e " a u x o u t p u t # 1 o p t io n p r o g r a m m a t io n ( s e e
a ls o th e f o llw in g ta b le ).
- O F F : th e s to p o n ra m p fe a tu re is n o t p e r f o r m e d .
6 A U X O U T P U T # 1
- B ra k e : o u tp u t B 9 ( M in if it ) , A 7 (A m p S a a b ) d r iv e s a n e le c t r o m a g n e t ic b r a k e c o il
(s e e a ls o t h e t a b le b e lo w ).
- H Y D R O C O N T .: t h e in v e rte r m a n a g e s a n h y d r a u lic s t e e r in g f u n c t io n w h e n t h e d ir e c t io n
in p u t o r b ra k e p e d a l in p u t a r e a c t iv e o r a m o v e m e n t o f t h e t r u c k is
d e te c te d .
- E X . H Y D R O .: t h e in v e rte r m a n a g e s a n h y d r a u lic s t e e r in g f u n c t io n w h e n t h e e x c lu s iv e
h y d ro in p u t is a c t iv e .
P a g e 2 8
7 P E D A L B R A K IN G
- A n a lo g : t h e m e c h a n ic a l b r a k e p e d a l h a s a s w it c h a n d a p o t e n t io m e t e r in s t a lle d .
W h e n t h e a c c e le r a t o r is r e le a s e d a n d t h e p e d a l b r a k e is p u s h e d t h e
in v e r t e r p e r f o r m s a n e le c t r ic a l b r a k in g w h o s e in t e n s it y is p r o p o r t io n a l t o
t h e b r a k e p e d a l p o t e n t io m e t e r . T h e m in im u m in t e n s it y is e s t a b lis h e d b y
t h e " R e le a s e b r a k in g " p a r a m e t e r , w h e n t h e b r a k e p e d a l is s lig h t ly
p r e s s e d (b r a k e s w it c h c lo s e b u t b r a k e p o t e n t io m e t e r a t t h e m in im u m ).
T h e m a x im u m in t e n s it y is e s t a b lis h e d b y t h e " P e d a l b r a k in g " p a r a m e t e r
w h e n t h e b r a k e p e d a l is f u lly p r e s s e d (b r a k e p o t e n t io m e t e r a t t h e
m a x im u m ) . In t h e m id d le p o s it io n s , t h e e le c t r ic a l b r a k in g in t e n s it y is a
lin e a r f u n c t io n b e t w e e n m in im u m a n d m a x im u m in t e n s it y .
- D ig it a l: T h e t r u c k d o e s n o t h a v e a p o t e n t io m e t e r in s t a lle d o n t h e m e c h a n ic a l
b r a k e p e d a l, b u t o n ly a m ic r o s w it c h ; w h e n t h e a c c e le r a t o r p e d a l is
r e le a s e d a n d t h e b r a k e p e d a l is p u s h e d (b r a k e s w it c h c lo s e d ), t h e in v e r t e r
p e r f o r m s a n e le c t r ic a l b r a k in g f o llo w in g " P e d a l b r a k in g " p a r a m e t e r .
8 S E T T E M P E R A T U R E
- D ig it a l: a d ig it a l (O N /O F F ) m o t o r t h e r m a l s e n s o r is c o n n e c t e d t o B 6 (M in if it ), A 3
(A m p S a a b ) in p u t .
- A n a lo g : a n a n a lo g m o to r th e r m a l s e n s o r is c o n n e c t e d t o B 6 ( M in if it ) , A 3 ( A m p
S a a b ) (th e c u rv e c a n b e c u s t o m iz e d o n a c u s t o m e r r e q u e s t ).
- N O N E : n o m o to r th e rm a l s e n s o r s w it c h is c o n n e c t e d .
S U B M E N U "A D J U S T E M E N T "
1 S E T P O T B R K M IN : r e c o r d s t h e m in im u m v a lu e o f b r a k in g p e d a l p o t e n t io m e te r w h e n th e
b r a k in g p e d a l s w it c h is c lo s e d th e p ro c e d u r e is s im ila r to th e "P ro g ra m
V a c c " f u n c t io n (s e e c h a p te r 5 . 4 ). T h is p ro c e d u r e m u s t b e c a r r ie d o u t o n ly
if t h e " P e d a l b r a k in g " o p t io n is p r o g r a m m e d a s " A n a lo g ".
2 S E T P O T B R K M A X : re c o rd s th e m a x im u m v a lu e o f b ra k in g p e d a l p o te n t io m e t e r w h e n t h e
b ra k in g p e d a l is f u lly p re s s e d ; th e p ro c e d u r e is s im ila r t o t h e " P r o g r a m
V A C C " fu n c t io n (s e e c h a p te r 5 .4 ). T h is p r o c e d u re m u s t b e c a r r ie d o u t o n ly
if t h e "P e d a l b r a k in g " o p t io n is p ro g ra m m e d a s "A n a lo g " .
3 S E T B A T T E R Y T Y P E s e le c t s t h e n o m in a l b a t t e r y v o lt a g e .
4 A D J U S T B A T T E R Y : f in e a d ju s t m e n t o f t h e b a t t e r y v o lt a g e m e a s u r e d b y t h e c o n t r o lle r .
5 A D J U S T M E N T # 0 4 : th is p a r a m e te r d e te r m in e s th e m o to r te m p e ra tu re le v e l a t w h ic h t h e
"M o to r te m p e ra tu re " a la r m is s ig n a lle d . T h e r a n g e is f r o m 7 0 ° C to 1 6 0 ° C
w it h 1 0 ° C s te p s . T h is p a r a m e t e r m u s t b e a d ju s t e d o n ly if th e "S e t
te m p e ra tu re " (m e n u "S e t o p t io n " ) p a r a m e t e r is p r o g ra m m e d " A n a lo g " .
6 T H R O T T L E 0 Z O N E : e s t a b lis h e s a d e a d b a n d in t h e a c c e le r a t o r in p u t c u r v e (s e e a ls o c u r v e
b e lo w ).
7 T H R O T T L E X P O IN T : T h e s e p a r a m e t e r c h a n g e t h e c h a r a c t e r is t ic o f t h e a c c e le r a t o r in p u t c u r v e .
8 T H R O T T L E Y P O IN T : T h e s e p a r a m e t e r c h a n g e t h e c h a r a c t e r is t ic o f t h e a c c e le r a t o r in p u t c u r v e .
Is s u e 0 2 /2 0 0 6
P a g e 2 9
V A C C M IN a n d V A C C M A X a r e v a lu e s p r o g r a m m a b le b y t h e " P r o g r a m
V A C C " f u n c t io n .
9 A D J U S T M E N T # 0 1 : a d ju s t t h e u p p e r le v e l o f t h e b a t t e r y d is c h a r g e t a b le .
1 0 A D J U S T M E N T # 0 2 : a d ju s t t h e lo w e r le v e l o f t h e b a t t e r y d is c h a r g e t a b le .
1 1 L O A D G M F R O M M D I: f o r a n e x p la n a t io n o f t h is p o in t s e e t h e M D I in s t r u m e n t h a n d b o o k
1 2 C E C K U P D O N E : f o r a n e x p la n a t io n o f t h is p o in t s e e t h e M D I in s t r u m e n t h a n d b o o k
1 3 C H E C K U P T Y P E : f o r a n e x p la n a t io n o f t h is p o in t s e e t h e M D I in s t r u m e n t h a n d b o o k
P a g e 3 0
Is s u e 0 2 /2 0 0 6
P a g e 3 1
5 .4 .b P u m p
U s in g t h e c o n f ig m e n u o f t h e p r o g r a m m in g c o n s o le , t h e u s e r c a n c o n f ig u r e t h e f o llo w in g
f u n c t io n s .
S U B M E N U " S E T O P T IO N S "
1 H O U R C O U N T E R
- R U N N U IN G : t h e c o u n t e r r e g is t e r s t r a v e l t im e o n ly .
- K E Y O N : t h e c o u n t e r r e g is t e r s w h e n t h e " k e y " s w it c h is c lo s e d .
2 B A T T E R Y C H E C K
- O N : th e b a tte ry d is c h a rg e le v e l c h e c k is c a r r ie d o u t ; w h e n t h e b a t t e r y le v e l
re a c h e s 1 0 % , a n a la r m is s ig n a lle d a n d th e m a x im u m c u r r e n t is
re d u c e d to th e h a lf o f th e p ro g ra m m e d v a lu e .
- O ff: th e b a tte ry d is c h a rg e le v e l c h e c k is c a r r ie d o u t b u t n o a la r m is s ig n a lle d .
V E R Y IM P O R T A N T :
In th e c o m b i s y s te m (p u m p + t r a c t io n ) , th e b a tte ry d is c h a r g e c a lc u la t io n f o r t h e c o m p le t e
s y s te m is c a r r ie d o u t b y th e tr a c t io n in v e rte r ; t h e in fo rm a t io n a b o u t t h e p u m p in v e r t e r
c o n s u m p t io n s s e n t o n th e c a n - b u s lin e fro m th e p u m p in v e r t e r t o t h e t r a c t io n in v e r t e r . S o t h e
c o rre c t p ro g ra m m a t io n fo r th e "B a tte ry c h e c k "" o p t io n is :
- T r a c t io n in v e r t e r : O N
- P u m p in v e r t e r : O F F
3 S E T T E M P E R A T U R E
- D IG IT A L : a d ig it a l ( O N /O F F ) m o t o r t h e r m a l s e n s o r is c o n n e c t e d t o B 6 (M in if it ), A 3
(A m p S a a b ) in p u t .
- A N A L O G : a n a n a lo g m o to r th e r m a l s e n s o r is c o n n e c t e d t o B 6 ( M in if it ) , A 3 ( A m p
S a a b ) (th e c u rv e c a n b e c u s t o m iz e d o n a c u s t o m e r r e q u e s t .
- N O N E : n o m o to r th e rm a l s e n s o r s w it c h is c o n n e c t e d .
S U B M E N U "A D J U S T E M E N T "
1 S E T B A T T R Y T Y P E : s e le c t s t h e n o m in a l b a t t e r y v o lt a g e ;
2 A D J U S T B A T T E R Y : f in e a d ju s t e m e n t o f t h e b a t t e r y v o lt a g e m e a s u r e d b y t h e c o n t r o lle r .
3 A D J U S T M E N T # 0 4 : t h is p a ra m e te r d e te rm in e s th e m o to r te m p e ra tu re le v e l a t w h ic h th e
"M o to r te m p e ra tu re " a la rm is s ig n a lle d . T h e ra n g e is f r o m 7 0 ° C to
1 6 0 °C w it h 1 0 ° s te p s . T h is p a ra m e te r m u s t b e a d ju s t e d o n ly if th e "S e t
te m p e r a tu r e " (m e n u "S e t o p t io n " ) p a r a m e t e r is p r o g ra m m e d "A n a lo g " .
4 T H R O T T L E 0 Z O N E : e s t a b lis h e s a d e a d b a n d in t h e a c c e le r a t o r in p u t c u r v e (s e e a ls o c u r v e
b e lo w ) .
5 T R O T T L E X P O IN T : t h is p a r a m e t e r c h a n g e t h e c h a r a c t e r is t ic o f t h e a c c e le r a t o r in p u t c u r v e .
Is s u e 0 2 /2 0 0 6
P a g e 3 2
6 T H R O T T L E Y P O IN T : T h e s e p a r a m e t e r c h a n g e t h e c h a r a c t e r is t ic o f t h e a c c e le r a t o r in p u t
c u rv e .
V A C C M IN u n d V A C C M A X a r e v a lu e s p r o g r a m m a b le b y t h e " P r o g r a m V a c c " f u n c t io n .
7 A D J U S T M E N T # 0 2 : a d ju s t t h e u p p e r le v e l o f t h e b a t t e r y d is c h a r g e t a b le .
8 A D J U S T M E N T # 0 1 : a d ju s t t h e lo w e r le v e l o f t h e b a t t e r y d is c h a r g e t a b le .
F lo w c h a r t is s h o w in g h o w to m a k e c h a n g e s to
O P T IO N M E N U :
1 ) O p e n in g Z a p i M e n u
2 ) P r e s s T o L e f t & R ig h t B u t t o n s t o e n t e r S E T M e n u .
3 ) T h e d is p la y w ill s h o w : S E T M O D E L
4 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n it S E T
M O D E L M e n u a p p e a rs .
5 ) S E T O P T IO N S a p p e a r s o n t h e d is p la y .
6 ) P r e s s E N T E R t o g o in t o t h e S E T M O D E L M e n u .
7 ) T h e d is p la y w ill s h o w s t h e f ir s t O P T IO N .
8 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n t il d e s ir e d
O P T IO N a p p e a r s .
9 ) D e s ir e d O P T IO N a p p e a r s .
1 0 ) P r e s s S E T U P o r S E T D O W N b u t t o n in o r d e r t o m o d if y
th e c h a n g e s .
1 1 ) N e w O P T IO N a p p e a r s .
1 2 ) P r e s s O U T t o e x it t h e M e n u .
1 3 ) C o n f ir m a t io n r e q u e s t a p p e a r s .
1 4 ) P r e s s E N T E R t o a c c e p t t h e c h a n g e s , o r p r e s s O U T if
d o n o t a c c e p t th e c h a n g e s .
1 5 ) S E T O P T IO N S M e n u a p p e a r s .
1 6 ) P r e s s O U T a g a in . D is p la y n o w s h o w t h e O p e n in g Z a p i
M e n u .
F lo w c h a r t s h o w in g h o w to m a k e c h a n g e s to A D J U S T M E N T
M e n u
2 ) P r e s s T o p L e f t & R ig h t B u t t o n s t o e n t e r C o n f ig M e n u
3 ) T h e d is p la y w ill s h o w : S E T M O D E L .
4 ) P r e s s R o L L U P o r R o L L D O W N b u t t o n u n t il
A D J U S T M E N T is M e n u a p p e a r s .
5 ) A D J U S T M E N T S a p p e a r s o n t h e d is p la y .
6 ) P r e s s E N T E R t o g o in t o t h e A D J U S T M E N T S M e n u .
7 ) T h e d is p la y w ill s h o w s S E T B A T T E R Y T Y P E .
8 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n t il t h e
d e s ir e d p a r a m e t e r is r e a c h e d .
9 ) T h e d e s ir e d p a r a m e t e r is a p p e a r s .
1 0 ) P r e s s S E T U P o r S E T D O W N b u t t o n t o m o d if y t h e
a d ju s t m e n t .
1 1 ) P re s s O U T .
1 2 ) P r e s s E N T E R t o c o n f ir m .
1 3 ) R e p e a t th e s a m e fro m 5 t o 1 2 p o in t s f o r t h e o t h e r
a d ju s t m e n t
P a g e 3 5
F lo w c h a r t s h o w in g h o w to u s e th e S E T B A T T E R Y T Y P E
a d ju s t m e n t
2 ) P r e s s T o p L e f t & R ig h t B u t t o n s t o e n t e r C O N F IG M E N U .
3 ) T h e D is p la y w ill s h o w : S E T M O D E L .
4 ) P r e s s R O L L U P b u t t o n u n t il A D J U S T M E N T S . M e n u
a p p e a rs .
7 ) T h e d is p la y w ill s h o w : S E T B A T T E R Y T Y P E .
8 ) P r e s s S E T U P t o c h o o s e n o m in a l v a lu e o f t h e b a t t e r y
9 ) N e w b a t t e r y v a lu e a p p e a r s .
1 0 ) P re s s O U T .
y o u d o n o t a c c e p t th e c h a n g e s .
1 3 ) P r e s s O U T . D is p la y n o w s h o w s t h e O p e n in g Z a p i M e n u .
Is s u e 0 2 /2 0 0 6
P a g e 3 6
F lo w s h o w in g h o w t o c a r r y o u t A D J U S T M E N T B A T T E R Y
o p e r a t io n b y c o n s o le .
1 ) O p e n in g Z a p i M e n u .
2 ) P r e s s T o p L e f t & R ig h t B u t t o n s t o e n t e r C O N F IG M e n u .
3 ) T h e D is p la y w ill s h o w : S E T M O D E L .
4 ) P r e s s R O L L U P b u t t o n u n t il A D J U S T M E N T S M e n u
a p p e a rs .
7 ) T h e d is p la y w ill s h o w t h e f ir s t O P T IO N .
8 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n t il d e s ir e d
O P T IO N a p p e a r s .
9 ) A D J U S T B A T T E R Y a p p e a rs .
1 0 ) P r e s s S E T U P o r S E T D O W N b u t t o n in o r d e r t o in c r e a s e
o r d e c r e a s e r e s p e c t iv e ly . S e t t h e v a lu e r e a d b y a n
e x te rn a l m e te r.
1 1 ) B a t t e r y v a lu e a p p e a r s o n t h e d is p la y .
1 2 ) P r e s s O U T t o e x it t h e M e n u .
y o u d o n o t a c c e p t th e c h a n g e s .
1 5 ) A D J U S T M E N T S M e n u a p p e a rs .
1 6 ) P r e s s O U T . D is p la y n o w s h o w t h e O p e n in g Z a p i M e n u .
Is s u e 0 2 /2 0 0 6
P a g e 3 7
5 .5 P a r a m e t e r R e g u la t io n n : T r a c t io n C o n f ig u r a t io n
In a d d it io n t o t h e in p u t c o n f ig u r a t io n , p a r a m e t e r m o d if ic a t io n is m a d e d ir e c t ly b y Z A P I o n
c u s t o m e r s p e c if ic a t io n s , o r b y t h e c u s t o m e r , m a k in g t h e a d ju s t m e n t s u s in g t h e p r o g r a m m in g
c o n s o le . T h e f o llo w in g p a r a m e t e r s c a n b e m o d if ie d :
1 A C C D E L A Y : d e t e r m in e s t h e a c c e le r a t io n r a m p .
2 R E L E A S E B R A K IN G : c o n t r o ls t h e d e c e le r a t io n r a m p w h e n t h e t r a v e l r e q u e s t is
r e le a s e d .
3 IN V E R s io n b r a k in g : c o n t r o ls t h e d e c e le r a t io n r a m p w h e n t h e d ir e c t io n s w it c h is
in v e r t e d d u r in g t r a v e l.
4 P E D A L B R A K IN G : d e t e r m in e s t h e d e c e le r a t io n r a m p w h e n t h e t r a v e l r e q u e s t is
r e le a s e d a n d t h e b r a k e p e d a l s w it c h is c lo s e d .
5 S P E E D L IM IT B R A K IN G : d e c e le r a t io n r a m p w h e n t h e p e d a l p o s it io n is c h a n g e d b u t n o t
c o m p le t e ly r e le a s e d .
6 B R A K E C U T B A C K : d e t e r m in e s t h e d e c e le r a t io n r a m p w h e n t h e s p e e d r e d u c t io n
in p u t b e c o m e s a c t iv e a n d t h e m o t o r s lo w d o w n .
7 M A X S P E E D F O R W A R D : d e t e r m in e s t h e m a x im u m s p e e d in f o r w a r d d ir e c t io n .
8 M A X S P E E D B A C K W A R D : d e t e r m in e s t h e m a x im u m s p e e d in b a c k w a r d d ir e c t io n .
9 C U T B A C K S P E E D : s p e e d r e d u c t io n w h e n t h e c u t b a c k s w it c h is a c t iv e .
1 0 F R E Q U E N C Y C R E E P : m in im u m s p e e d w h e n t h e f o r w a r d o r r e v e r s e s w it c h is c lo s e d ,
b u t t h e a c c e le r a t o r is o n a m in im u m p o s it io n .
1 1 M A X IM U M C U R R E N T : t h is c h a n g e s t h e m a x im u m c u r r e n t o f t h e in v e r t e r .
1 2 B A C K IN G S P E E D : d e t e r m in e s t h e s p e e d in in c h in g f u n c t io n .
1 3 B A C K IN G T IM E : d e t e r m in e s t h e t im e o f t h e in c h in g f u n c t io n .
1 4 A U X IL IA R Y T IM E : d e t e r m in e s t h e t im e t h a t t h e t r u c k is h o ld o n t h e r a m p if t h e
" s t o p o n r a m p " o p t io n is o n .
T h e f o llo w in g t a b le s h o w s t h e d if f e r e n t v a lu e s a t w h ic h t h e p a r a m e t e r s c a n b e s e t .
A fte r c h a n g in g a p a ra m e te r, p re s s E N T E R to c o n f ir m d a t a w h e n r e q u e s t e d b y t h e m e s s a g e
o n th e c o n s o le . P a ra m e t e r s m o d if ie d a n d o p t im iz e d o n o n e u n it c a n b e s t o r e d b y t h e c o n s o le
(S A V E ) a n d th e n r e le a s e d (R E S T O R E ) o n a n o th e r c h o p p e r , t h u s a llo w in g f a s t a n d
s t a n d a r d iz e d s e t t in g s ( s e e c o n s o le m a n u a l fo r d e t a ils ).
(* ) T h e a c c e le r a t io n t im e s h o w n is t h e t im e f r o m 0 H z t o 1 0 0 H z . T h is is t h e id e a l r a m p
c a lc u la t e d b y t h e s o f t w a r e ; t h e r e a l r a m p c o u ld c h a n g e a s a f u n c t io n o f m o t o r c o n t r o l
p a r a m e t e r s e t t in g a n d , o b v io u s ly , a s a f u n c t io n o f t h e lo a d .
(* * ) T h e b r a k in g fe a tu r e is b a s e d u p o n d e c e le r a t io n ra m p s . T h e v a lu e s h o w n in t h e t a b le is
t h e t im e t o d e c re a s e th e s p e e d fro m 1 0 0 H z to 0 H z . T h is is t h e id e a l r a m p s
c a lc u la t e d b y th e s o ftw a re ; th e re a l ra m p c o u ld c h a n g e a s a f u n c t io n o f m o t o r c o n t r o l
p a ra m e te r s e t t in g a n d , o b v io u s ly , a s a fu n c t io n o f t h e lo a d .
Is s u e 0 2 /2 0 0 6
P a g e 3 9
5 .6 P a r a m e t e r R e g u la t io n : P u m p C o n f ig u r a t io n
T h e f o llo w in g p a r a m e t e r s c a n b e m o d if ie d :
1 P U . A C C E L E R D E L : a c c e le r a t io n r a m p
2 P U . D E C E L E R R A T IO N D E L d e c e le r a t io n r a m p
3 M A X S P E E D U P : d e t e r m in e s t h e m a x im u m lif t in g s p e e d w it h a
p o t e n t io m e t e r c o n t r o l
4 M IN S P E E D U P : d e t e r m in e s t h e m in im u m lif t in g s p e e d w it h a p o t e n t io m e t e r
c o n t r o l w h e n t h e lif t in g e n a b le s w it c h is c lo s e d .
5 1 S T S P E E D F IN E : f ir s t s p e e d , f in e r e g u la t io n
6 2 N D S P E E D F IN E : s e c o n d s p e e d , f in e r e g u la t io n
7 3 R D S P E E D F IN E : t h ir d s p e e d , f in e r e g u la t io n
8 4 T H S P E E D F IN E : f o u r t h s p e e d , f in e r e g u la t io n
9 H Y D S P E E D F IN E : h y d r o s p e e d , f in e r e g u la t io n
1 0 M A X IM U M C U R R E N T : t h e m a x im u m c u r r e n t o f t h e in v e r t e r
1 1 A U X IL IA R Y T IM E : t im e d e la y w h e n a n h y d r a u lic s t e e r in g f u n c t io n r e q u e s t is
s w it c h e d o f f .
T h e f o llo w in g t a b le s h o w s t h e d if f e r e n t v a lu e s a t w h ic h t h e p a r a m e t e r s c a n b e s e t .
(* ) T h e a c c e le r a t io n t im e s h o w n is t h e t im e f r o m 0 H z t o 1 0 0 H z ( m a x im u m s e le c t a b le
s p e e d ) . T h is is t h e id e a l r a m p c a lc u la t e d b y t h e s o f t w a r e ; t h e r e a l r a m p c o u ld c h a n g e
a s a f u n c t io n o f m o t o r c o n t r o l p a r a m e t e r s e t t in g a n d , o b v io u s ly , a s a f u n c t io n o f t h e
lo a d .
(* * ) T h e d e c e le r a t io n t im e s h o w n in t h e t a b le is t h e t im e f r o m 1 0 0 H z t o 0 H z . T h is is t h e
id e a l r a m p c a lc u la t e d b y t h e s o f t w a r e ; t h e r e a l r a m p c o u ld c h a n g e a s a f u n c t io n o f
m o t o r c o n t r o l p a r a m e t e r s e t t in g a n d , o b v io u s ly , a s a f u n c t io n o f t h e lo a d .
(* * * ) A d ju s t a b le w it h a 1 H z r e s o lu t io n in t h e 0 t o 2 0 0 H z r a n g e .
Is s u e 0 2 /2 0 0 6
P a g e 4 0
A fte r c h a n g in g a p a r a m e t e r p re s s E N T E R t o c o n f ir m d a t a w h e n re q u e s te d b y th e m e s s a g e o n
th e c o n s o le . P a r a m e t e r s m o d if ie d a n d o p t im iz e d o n o n e u n it c a n b e s t o r e d b y t h e c o n s o le
(S A V E ) a n d t h e n r e le a s e d ( R E S T O R E ) o n a n o th e r c h o p p e r, t h u s a llo w in g f a s t a n d
s ta n d a rd iz e d s e t t in g s ( s e e c o n s o le m a n u a l f o r d e t a ils ).
F lo w c h a r t s h o w in g h o w t o m a k e P r o g r a m c h a n g e s u s in g D ig it a l C o n s o le f it t e d w it h E p r o m
C K U L T R A .
1 ) O p e n in g Z a p i D is p la y .
2 ) P r e s s E N T E R t o g o in t o t h e G e n e r a l M e n u .
3 ) T h e D is p la y w ill s h o w :
4 ) P r e s s E N T E R t o g o in t o t h e P a r a m e t e r C h a n g e
f a c ilit y .
5 ) T h e D is p la y w ill s h o w t h e f ir s t p a r a m e t e r .
6 ) P r e s s e it h e r R O L L U P a n d R O L L D O W N t o d is p la y
th e n e x t p a ra m e te r.
7 ) T h e n a m e s o f t h e P a r a m e t e r s a p p e a r s o n t h e D is p la y .
8 ) W h e n th e d e s ir e d P a ra m e te r a p p e a r s , t h e D is p la y w ill
s h o w a L e v e l N u m b e r th a t w ill b e b e tw e e n 0 a n d 9 .
P re s s e it h e r P A R A M (T o p R ig h t ) o r S E T ( B o t t o m R ig h t )
b u tto n s to c h a n g e th e L e v e l v a lu e .
9 ) T h e d is p la y w ill s h o w th e N e w L e v e l.
1 0 ) W h e n y o u a r e s a t is f ie d w it h t h e r e s u lt s o f t h e c h a n g e s
y o u h a v e m a d e , P re s s O U T .
1 1 ) T h e d is p la y a s k s " A R E Y O U S U R E " ?
y o u d o n o t w is h t o a c c e p t t h e c h a n g e s a n d w is h t o
m a k e f u r t h e r m o d if ic a t io n s t o t h e p a r a m e t e r s .
1 3 ) T h e D is p la y w ill s h o w :
P a g e 4 1
5 .7 P r o g r a m m in g C o n s o le F u n c t io n s
- F u n c t io n a l c o n f ig u r a t io n ( s e e 4 . 1 , 4 . 2 , 4 . 3 , 4 . 4 )
- P a r a m e t e r p r o g r a m m in g (s e e 4 . 5 , 4 . 6 )
- T e s t e r : t h e u s e r c a n v e r if y t h e s t a t e o f t h e f o llo w in g p a r a m e t e r s :
T R A C T IO N P U M P
m o t o r v o lt a g e ( % ) m o t o r v o lt a g e (% )
fr e q u e n c y (H z ) fre q u e n c y (H z )
e n c o d e r (H z ) e n c o d e r (H z )
s lip v a lu e (H z ) s lip v a lu e ( H z )
c u rr e n t r m s (A ) c u rr e n t r m s (A )
te m p e ra tu r e (° C ) te m p e ra tu r e (° C )
m o to r te m p e r a tu r e (° C ) m o to r te m p e ra tu r e (° C )
a c c e le r a t o r (V ) a c c e le r a t o r (V )
f o r w . s w it c h ( O N / O F F ) lif t in g s w it c h ( O N / O F F )
b a c k . s w it c h (O N / O F F ) 1 s t s p e e d s w it c h (O N / O F F )
in c h in g f o r w . (O N / O F F ) 2 n d s p e e d s w it c h (O N / O F F )
in c h in g b a c k . (O N / O F F ) 3 r d s p e e d s w it c h ( O N / O F F )
c u t b a c k s w it c h (O N / O F F ) 4 t h s p e e d s w it c h (O O N / O F F )
b r a k e s w it c h (O N / O F F ) h y d r o s p e e d r e q . (O N / O F F )
s e a t s w it c h (O N / O F F ) v o lt a g e b o o s t e r (V )
e x c lu s iv e h y d r o (O N / O F F ) b a t t e r y v o lt a g e (V )
h a n d b r a k e (O N / O F F ) c o s fi
v o lt a g e b o o s t e r (% ) b a tte r y c u rr e n t (A )
b a t t e r y v o lt a g e (V ) b a tte r y c h a r g e (% )
c o s fi
b a tte ry c u rr e n t (A )
b a tte ry c h a r g e (% )
- S a v e f u n c t io n (f o r s t o r in g d a t a )
- R e s t o r e f u n c t io n (f o r lo a d in g p a r a m e t e r s o n a n o t h e r c h o p p e r )
- D is p la y o f t h e la s t 5 a la r m s in c lu d in g h o u r - m e t e r v a lu e a n d t e m p e r a t u r e a t t h e m o m e n t o f t h e
a la r m .
- A c c e le r a t o r r a n g e p r o g r a m m in g : r e c o r d s t h e m in im u m a n d m a x im u m u s e f u l a c c e le r a t o r s t r o k e
v a lu e f o r b o t h d ir e c t io n o f r u n n in g .
- S e e t h e c o n s o le m a n u a l f o r a d e t a ile d d e s c r ip t io n o f f u n c t io n a n d p a r a m e t e r s .
P a g e 4 2
5 .8 S e q u e n c e f o r A C In v e r t e r T r a c t io n S e t t in g
W h e n t h e " K e y S w it c h " is c lo s e d , if n o a la r m s o r e r r o r s a r e p r e s e n t , t h e C o n s o le D is p la y w ill

b e
s h o w in g th e S ta n d a rd Z a p i O p e n in g D is p la y .
If t h e c h o p p e r is n o t c o n f ig u re d to y o u r e q u ir e m e n t s , f o llo w t h e s e q u e n c e d e t a ile d o n C h a p t e r
5 .2 . R e m e m b e r to re -c y c le th e K e y S w it c h if y o u m a k e a n y c h a n g e s t o t h e c h o p p e r ' s
c o n f ig u r a t io n . O th e r w is e fo llo w th e s e q u e n c e d e t a ile d b e lo w :
1 ) S e le c t t h e O p t io n s r e q u ir e d . S e e C h a p t e r 4 . 1 + 4 . 4 .
2 ) S e le c t a n d s e t t h e B a t t e r y V o lt a g e . S e e c h a p t e r 4 . 4 .
3 ) C o n f ir m c o r r e c t in s t a lla t io n o f a ll w ir e s . U s e t h e C o n s o le ' s T E S T E R f u n c t io n t o a s s is t .
4 ) P e r f o r m t h e a c c e le r a t o r s ig n a l a c q u is it io n p r o c e d u r e u s in g t h e C o n s o le " P R O G R A M
V A C C " . P r o c e d u r e is d e t a ile d o n c h a p t e r 5 . 4
5 ) S e t t h e " M A X IM U M C U R R E N T " C u r r e n t , u s in g t h e t a b le o n C h a p t e r 4 . 5 , 4 . 6 .
6 ) S e t t h e A c c e le r a t io n D e la y r e q u ir e m e n t s f o r t h e m a c h in e . t e s t t h e p a r a m e t e r s in b o t h
d ir e c t io n s .
7 ) S e t t h e F R E Q U E N C Y C R E E P le v e l s t a r t in g f r o m le v e l 0 . 6 H z . T h e m a c h in e s h o u ld ju s t
m o v e w h e n t h e a c c e le r a t o r m ic r o s w it c h is c lo s e d . In c r e a s e t h e le v e l a c c o r d in g ly .
8 ) S e t t h e S p e e d R e d u c t io n s a s r e q u ir e d . M a k e a d ju s t m e n t s t o " C U T B A C K S P E E D " . C h e c k
t h e p e r f o r m a n c e w it h t h e a c c e le r a t o r p e d a l t o t a lly d e p r e s s e d . If t h e m a c h in e is a f o r k lif t ,
c h e c k t h e p e r f o r m a n c e w it h a n d w it h o u t lo a d .
9 ) R E L E A S E B R A K IN G . O p e r a t e t h e m a c h in e a t f u ll s p e e d . R e le a s e t h e a c c e le r a t o r p e d a l.
A d ju s t t h e le v e l t o y o u r e q u ir e m e n t s . If t h e m a c h in e is a f o r k lif t , c h e c k t h e p e r f o r m a n c e
w it h a n d w it h o u t lo a d .
1 0 ) IN V E R S IO N B R A K IN G . O p e r a te th e m a c h in e a t 2 5 % f u ll s p e e d . W h ils t tra v e lin g IN V E R T

th e D ir e c t io n S w it c h . S e t a s o ft L e v e l o f In v e r s io n B ra k in g . W h e n s a t is f a c to ry , o p e r a te th e
m a c h in e a t F U L L S P E E D a n d re p e a t . If t h e m a c h in e is a fo r k lif t , r e p e a t th e te s ts a n d m a k e
a d ju s t m e n t s w it h a n d w it h o u t lo a d . T h e u n la d e n f u ll s p e e d c o n d it io n s h o u ld b e th e m o s t
re p re s e n t a t iv e c o n d it io n .
1 1 ) P E D A L B R A K IN G (if u s e d ) . O p e r a t e t h e m a c h in e a t f u ll s p e e d . R e le a s e t h e a c c e le t o r p e d a l
a n d p r e s s t h e P e d a l B r a k e . S e t b r a k in g le v e l t o y o u r r e q u ir e m e n t s .
1 2 ) S e t " M A X S P E E D F O R W ."
1 3 ) S e t " M A X S P E E D B A C K " (r e v e rs e ).
1 4 ) M a k e t h e c h o ic e f o r t h e t r u c k b e h a v io r o n a s lo p e ( s e e c h a p t e r 4 . 4 ) . If t h e " S t o p o n r a m p "
o p t io n is O N , s e t t h e d e s ir e d v a lu e o f " a u x ilia r y t im e " p a r a m e t e r .
P a g e 4 3
5 .9 T e s t e r : D e s c r ip t io n o f t h e F u n c t io n ; T r a c t io n C o n f ig u r a t io n
T h e m o s t im p o r t a n t in p u t o r o u t p u t s ig n a ls c a n b e m e a s u r e d in r e a l t im e u s in g t h e T E S T E R
f u n c t io n o f t h e c o n s o le . T h e C o n s o le a c t s a s a m u lt im e t e r a b le t o r e a d v o lt a g e , c u r r e n t a n d
t e m p e r a t u r e . T h e f o llo w in g d e f in it io n lis t in g s h o w s t h e r e la t iv e m e a s u r e m e n t s :
1 ) M O T O R V O L T A G E : t h is is t h e v o lt a g e s u p p lie d t o t h e m o t o r b y t h e in v e r t e r ; it is
e x p r e s s e d a s a p e r c e n t a g e o f t h e f u ll v o lt a g e ( w h ic h d e p e n d s o f
t h e b a t t e r y v o lt a g e ).
2 ) F R E Q U E N C Y : t h is is t h e f r e q u e n c y o f t h e v o lt a g e a n d c u r r e n t s u p p lie d t o t h e
m o to r.
3 ) E N C O D E R : t h is is t h e s p e e d o f t h e m o t o r , e x p r e s s e d in t h e s a m e u n it o f t h e
f r e q u e n c y ; t h is in f o r m a t io n c o m e s f r o m t h e s p e e d s e n s o r .
4 ) S L IP V A L U E : t h is is t h e d if f e r e n c e o f s p e e d b e t w e e n t h e r o t a t in g f ie ld a n d t h e
s h a f t o f t h e m o t o r , e x p r e s s e d in t h e s a m e u n it o f t h e f r e q u e n c y .
5 ) C U R R E N T R M S : R o o t M e a n S q u a r e v a lu e o f t h e m o t o r c u r r e n t .
6 ) T E M P E R A T U R E : t h e t e m p e r a t u r e m e a s u r e d o n t h e a lu m in iu m h e a t s in k h o ld in g
t h e M O S F E T d e v ic e s .
7 ) M O T O R T E M P E R A T U R E : t h is is t h e t e m p e r a t u r e o f t h e m o t o r ; if t h e o p t io n is
p r o g r a m m e d " N O N E " ( s e e c h a p t e r 4 . 4 . a ) it s h o w s 0 ° .
8 ) A C C E L E R A T O R : t h e v o lt a g e o f t h e a c c e le r a t o r p o t e n t io m e t e r ' s w ip e r ( C P O T ) . T h e
v o lt a g e le v e l is s h o w n o n t h e L e f t H a n d S id e o f t h e C o n s o le
D is p la y a n d t h e v a lu e in p e r c e n t a g e is s h o w n o n t h e R ig h t H a n d
S id e .
9 ) F O R W A R D S W IT C H : t h e le v e l o f t h e F o r w a r d d ir e c t io n d ig it a l e n t r y F W .
O N / + V B = a c t iv e e n t r y o f c lo s e d s w it c h
O F F / G N D = n o n a c t iv e e n t r y o f o p e n s w it c h .
1 0 ) B A C K W A R D S W IT C H : t h e le v e l o f t h e R e v e r s e d ir e c t io n d ig it a l e n t r y B W .
O N / + V B = a c t iv e e n t r y o f c lo s e d s w it c h .
O F F / G N D = n o n a c t iv e e n t r y o f o p e n s w it c h
1 1 ) B A C K IN G F O R W : s t a t u s o f t h e in c h in g f u n c t io n ( f o r w a r d d ir e c t io n ) im p u t .
1 2 ) B A C K IN G B A C K : s t a t u s o f t h e in c h in g f u n c t io n (b a c k w a r d d ir e c t io n ) in p u t .
O F F / G N D = n o n a c t iv e e n t r y o f o p e n s w it c h
1 3 ) C U T B A C K S W IT C H : t h e le v e l o f t h e S p e e d R e d u c t io n M ic r o s w it c h
O N / G N D = a c t iv e e n t r y o f s p e e d r e d u c t io n m ic r o s w it c h
O F F / + V B = n o n a c t iv e e n t r y o f m ic r o s w it c h
Is s u e 0 2 /2 0 0 6
P a g e 4 4
1 4 ) B R A K E S W IT C H : t h e le v e l o f t h e P e d a l B r a k e M ic r o s w it c h .
O N / + V B = a c t iv e e n t r y o f B r a k e P e d a l M ic r o s w it c h
O F F / G N D = n o n a c t iv e e n t r y o f m ic r o s w it c h
1 5 ) S E A T S W IT C H : t h e le v e l o f t h e S e a t M ic r o s w it c h d ig it a l e n t r y .
O N / + V B = a c t iv e e n t r y o f c lo s e d s e a t s w it c h .
O F F / G N D = n o n a c t iv e o f o p e n s e a t s w it c h .
1 6 ) E X C L U S IV E H Y D R O : s t a t u s o f t h e e x c lu s iv e h y d r o s w it c h
O N / + V B = a c t iv e e n t r y o f c lo s e d s w it c h . .
1 7 ) H A N D B R A K E : t h e le v e l o f t h e H a n d b r a k e M ic r o s w it c h .
O N / G N D = a c t iv e e n t r y o f H a n d b r a k e S w it c h (o p e n s w it c h ).
O F F / + V B = n o n a c t iv e e n t r y o f m ic r o s w it c h ( c lo s e d s w it c h ) .
1 8 ) V O L T A G E B O O S T E R : t h is is t h e b o o s t e r o f t h e v o lt a g e s u p p lie d t o t h e m o t o r in lo a d
c o n d it io n ; it is e x p r e s s e d in a p e r c e n t a g e o f t h e f u ll v o lt a g e .
1 9 ) B A T T E R Y V O L T A G E : le v e l o f b a t t e r y v o lt a g e m e a s u r e d a t t h e in p u t t o t h e k e y s w it c h .
2 0 ) C O S F I: t h is is t h e c o s j (r e a l t im e c a lc u la t e d ) o f t h e m o t o r .
2 1 ) B A T T E R Y C U R R E N T : t h is is t h e b a t t e r y c u r r e n t (n o t m e a s u r e d b u t c a lc u la t e d ).
2 2 ) B A T T E R Y C H A R G E : t h e p e r c e n t a g e C h a r g e le v e l o f t h e b a t t e r y .
Is s u e 0 2 /2 0 0 6
P a g e 4 5
5 .1 0 T E S T E R : D e s c r it p t io n o f t h e F u n c t io n ; P u m p C o n f ig u r a t io n
T h e m o s t im p o r t a n t in p u t o r o u t p u t s ig n a ls c a n b e m e a s u r e d in r e a l t im e u s in g t h e T E S T E R
f u n c t io n o f t h e c o n s o le . T h e C o n s o le a c t s a s a m u lt im e t e r a b le t o r e a d v o lt a g e , c u r r e n t a n d
t e m p e r a t u r e . T h e f o llo w in g d e f in it io n lis t in g s h o w s t h e r e la t iv e m e a s u r e m e n t s :
1 ) M O T O R V O L T A G E : t h is is t h e v o lt a g e s u p p lie d t o t h e m o t o r b y t h e in v e r t e r ; it is
e x p r e s s e d a s a p e r c e n t a g e o f t h e f u ll v o lt a g e ( w h ic h d e p e n d s o f
t h e b a t t e r y v o lt a g e ).
2 ) F R E Q U E N C Y : t h is is t h e f r e q u e n c y o f t h e v o lt a g e a n d c u r r e n t s u p p lie d t o t h e
m o to r.
3 ) E N C O D E R : t h is is t h e s p e e d o f t h e m o t o r , e x p r e s s e d in t h e s a m e u n it o f t h e
f r e q u e n c y ; t h is in f o r m a t io n c o m e s f r o m t h e s p e e d s e n s o r .
4 ) S L IP V A L U E : t h is is t h e d if f e r e n c e o f s p e e d b e t w e e n t h e r o t a t in g f ie ld a n d t h e
s h a f t o f t h e m o t o r , e x p r e s s e d in t h e s a m e u n it o f t h e f r e q u e n c y .
5 ) C U R R E N T R M S : R o o t M e a n S q u a r e v a lu e o f t h e m o t o r c u r r e n t .
6 ) T E M P E R A T U R E : t h e t e m p e r a t u r e m e a s u r e d o n t h e a lu m in iu m h e a t s in k h o ld in g
t h e M O S F E T d e v ic e s .
7 ) M O T O R T E M P E R A T U R E : t h is is t h e t e m p e r a t u r e o f t h e m o t o r ; if t h e o p t io n is
p r o g r a m m e d " N o n e " ( s e e c h a p t e r 4 . 4 . b ) it s h o w s 0 ° .
8 ) A C C E L E R A T O R : t h e v o lt a g e o f t h e a c c e le r a t o r p o t e n t io m e t e r ' s w ip e r ( C P O T ) . T h e
v o lt a g e le v e l is s h o w n o n t h e L e f t H a n d S id e o f t h e C o n s o le
D is p la y a n d t h e v a lu e in p e r c e n t a g e is s h o w n o n t h e R ig h t H a n d
S id e .
9 ) L IF T IN G S W IT C H : s t a t u s o f t h e lif t in g s w it c h .
1 0 ) 1 S T S P E E D S W IT C H : s t a t u s o f t h e f ir s t s p e e d s w it c h o f t h e p u m p .
1 1 ) 2 N D S P E E D S W IT C H : s t a t u s o f t h e s e c o n d s p e e d s w it c h o f t h e p u m p .
1 2 ) 3 R D S P E E D S W IT C H : s t a t u s o f t h e t h ir d s p e e d s w it c h o f t h e p u m p e .
1 3 ) 4 T H S P E E D S W IT C H : s t a t u s o f t h e f o u r t h s p e e d s w it c h o f t h e p u m p .
Is s u e 0 2 /2 0 0 6
P a g e 4 6
1 4 ) H Y D R O S P P E D R E Q .: s ta tu s o f th e h y d ro s p e e d re q u e s t o f th e p u m p .
1 5 ) V O L T A G E B O O S T E R : t h is is t h e b o o s t e r o f t h e v o lt a g e s u p p lie d t o t h e m o t o r in lo a d
c o n d it io n ; it is e x p r e s s e d in a p e r c e n t a g e o f t h e f u ll v o lt a g e .
1 6 ) B A T T E R Y V O L T A G E : le v e l o f b a t t e r y v o lt a g e m e a s u r e d a t t h e in p u t t o t h e k e y s w it c h .
1 7 ) C O S F I: t h is is t h e c r o s j (r e a l t im e c a lc u la t e d ) o f t h e m o t o r .
1 8 ) B A T T E R Y C U R R E N T : t h is is t h e b a t t e r y c u r r e n t (n o t m e a s u r e d b u t c a lc u la t e d ).
1 9 ) B A T T E R Y C H A R G E : t h e p e r c e n t a g e c h a r g e le v e l o f t h e b a t t e r y .
F lo w C h a r t s h o w in g h o w t o u s e t h e T E S T E R f u n c t io n o f t h e D ig it a l C o n s o le .
1 ) O p e n in g Z a p i d is p la y .
2 ) P r e s s E N T E R t o g o in t o t h e g e n e r a l m e n u .
3 ) T h e d is p la y w ill s h o w :
4 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n t il T E S T E R
M E N U a p p e a r o n t h e d is p la y .
5 ) T h e d is p la y s h o w s :
6 ) P r e s s E N T E R t o g o in t o t h e T E S T E R f u n c t io n .
7 ) T h e f ir s t v a r ia b le t o b e t e s t e d is s h o w n o n t h e d is p la y .
8 ) P r e s s e it h e r R o L L U P o r R O L L D O W N b u t t o n s u n t il y o u r
d e s ir e d v a r ia b le f o r m e a s u r e m e n t a p p e a r s o n t h e d is p la y .
9 ) W h e n y o u f in is h e d , p r e s s O U T .
1 0 ) T h e d is p la y s h o w s :
1 1 ) P r e s s O U T a g a in a n d r e t u r n t o o p e n in g Z a p i d is p la y .
R e m e m b e r it is n o t p o s s ib le t o m a k e a n y c h a n g e s u s in g T E S T E R . A ll y o u c a n d o is m e a s u r e a s if
y o u w e r e u s in g a p r e - c o n n e c t e d m u lt im e t e r .
Is s u e 0 2 /2 0 0 6
P a g e 4 7
6 . O t h e r F u n c io n s
6 .1 D e s c r ip t io n o f t h e C o n s o le S a v e F u n c t io n
T h e S a v e f u n c t io n a llo w s t h e o p e r a t o r t o t r a n s m it t h e P a r a m e t e r v a lu e s a n d c o n f ig u r a t in d a t a
o f t h e c o p p e r in t o t h e C o n s o le m e m o r y . It is p o s s ib le t o lo a d 6 4 d if f f e r e n t p r o g r a m m e s .
T h e in f o r m a t io n s a v e d in t h e C o n s o le m e m o r y c a n t h e n b e r e lo a d e d in t o a n o t h e r c h o p p e r
u s in g t h e R E S T O R E f u n c t io n .
T h e d a t a t h a t is a v a ila b le v ia t h e S A V E f u n c t io n is a s f o llo w s :
- A ll P a r a m e t e r V a lu e s ( P A R A M E T E R C H A N G E ).
- O p t io n s (S E T O P T IO N S ).
- T h e L e v e l o f th e B a tte r y (A D J U S T B A T T E R Y ).
F lo w C h a r t s h o w in g h o w t o u s e t h e S A V E f u n c t io n o f t h e D ig it a l C o n s o le .
1 ) O p e n in g Z a p i D is p la y
2 ) P r e s s E N T E R t o g o in t o t h e G e n e r a l m e n u .
4 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n t il S A V E
P A R A M . a p p e a r s o n t h e d is p la y .
5 ) T h e d is p la y w ill s h o w :
6 ) P r e s s E N T E R t o g o in t o t h e S A V E f u n c t io n .
7 ) If t h is f a c ilit y h a s b e e n b e f o r e t h e t y p e o f c h o p p e r d a t a
s t o r e d a p p e a r s o n t h e t o p M a in w it h a 2 d ig it r e f e r e n c e .
8 ) K e e p p r e s s in g e it h e r R O L L U P o r D O L L D O W N k e y s u n t il
t h e s e c o n d M a in in d ic a t e s a F R E E s t o r a g e f a c ilit y .
9 ) P r e s s E N T E R t o c o m m e r c e D A V E r o u t in e .
1 0 ) Y o u c a n s e e t h e it e m s t h a t a r e b e in g s t o r e d w h ils t t h e
S A V E r o u t in e is h a p p e n in g .
1 1 ) W h e n f in is h e d , t h e c o n s o le s h o w s :
1 2 ) P r e s s O U T t o r e t u r n t o t h e O p e n in g Z a p i D is p la y .
Is s u e 0 2 /2 0 0 6
P a g e 4 8
6 .2 D e s c r ip t io n o f C o n s o le R e s t o r e F u n c t io n
T h e R E S T O R E P A R A M f u n c t io n a llo w s t r a n s f e r o f t h e C o n s o le ' s s t o r e d d a t a in t o t h e m e m o r y
o f t h e c h o p p e r . T h is s a c h ie v e d in a f a s t a n d e a s y w a y u s in g t h e m e t h o d p r e v io u s ly w it h t h e
S A V E P A R A M . f u n c t io n .
T h e d a t a t h a t is a v a ila b le v ia t h e R E S T O R E P A R A M . f u n c t io n is a s f o llo w s :
- A ll P a r a m e t e r V a lu e s (P A R A M E T E R C H A N G E ).
- O p t io n s (S E T O P T IO N S )
- T h e le v e l o f t h e B a tte ry (A D J U S T B A T T E R Y ).
A t t e n t io n :
W h e n t h e R E S T O R E o p e r a t io n is m a d e , a ll d a t a in t h e c h o p p e r m e m o r y w ill b e w r it t e n o v e r
a n d r e p la c e w it h d a t a b e in g r e s t o r e d .
F lo w C h a r t s h o w in g h o w t o u s e t h e R E S T O R E f u n c t io n o f t h e D ig it a l C o n s o le .
1 ) O p e n in g Z a p i D is p la y
4 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n t il R E S T O R E
P A R A M . a p p e a r s o n t h e d is p la y .
6 ) P r e s s E N T E R t o g o in t o t h e R E S T O R E P A R A M . f u n c t io n .
7 ) T h e D is p la y s h o w s t h e t y p e o f M o d e l s t o r e d , w it h a
C o d e N u m b e r.
8 ) K e e p p r e s s in g e it h e r R O L L U P a n d R O L L D O W N
b u t t o n s u n t il t h e d e s ir e d m o d e l a p p e a r s o n t h e d is p la y .
9 ) P r e s s E N T E R t o c o m m e n c e t h e R e s t o r e o p e r a t io n .
1 0 ) T h e D is p la y w ill a s k " A R E Y O U S U R E " . P r e s s E N T E R

fo r Y E S , o r O U T fo r N O .
1 1 ) Y o u c a n s e e t h e it e m s t h a t a r e b e in g s t o r e d in t h e
c h o p p e r m e m o r y w h ils t t h e R E S T O R E r o u t in e is
h a p p e n in g .
1 2 ) W h e n f in is h e d t h e C o n s o le d is p la y s :
Is s u e 0 2 /2 0 0 6
P a g e 4 9
6 .3 D e s c r ip t io n o f A la r m s M e n u
T h e m ic r o p ro c e s s o r in t h e c h o p p e r re m e m b e r s t h e la s t f iv e a la r m s th a t h a v e o c c u re d . It e m s
re m e m b e r e d r e la t iv e to e a c h A la r m a r e : t h e c o d e o f t h e a la r m , th e n u m b e r o f t im e s th e
p a r t ic u la r a la r m o c c u rre d , th e H o u r M e te r c o u n t, a n d th e c h o p p e r te m p e r a t u r e . T h is f u n c t io n
p e r m it s a d e e p te r d ia g n o s is o f p r o b le m s a s t h e r e c e n t h is t o ry c a n n o w b e a c c e s s e d .
F lo w C h a r t s h o w in g t o u s e t h e A L A R M S f u n c t io n v ia t h e D ig it a l C o n s o le .
4 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n t il
P A R A M E T E R C H A N G E a p p e a r s o n t h e d is p la y .
6 ) P r e s s E N T E R t o g o in t o t h e A L A R M S f u n c t io n .
7 ) T h e D is p la y w ill s h o w t h e m o s t r e c e n t A la r m .
8 ) E a c h p r e s s o f t h e R O L L U P b u t t o n b r in g s u p f o llo w in g
A la r m s . P r e s s in g R O L L D O W N r e t u r n s t o t h e m o s t r e c e n t .
9 ) If a n A la r m h a s n o t o c c u r e d , t h e D is p la y w ill s h o w :
A L A R M N U L L
1 0 ) W h e n y o u h a v e f in is h e d lo o k in g a t t h e A la r m s , p r e s s
O U T t o e x it t h e A L A R M S m e n u .
1 1 ) T h e D is p la y w ill a s k C L E A R L O G B O O K ?
1 2 ) P re s s E N T E R fo r Y E S , o r O U T fo r N O .
6 .4 D e s c r ip t io n o f C o n s o le P r o g r a m V a c c F u n c t io n
T h is fu n c t io n lo o k s fo r a n d re m e m b e rs th e m in im u m a n d m a x im u m p o t e n t io m e t e r w ip e r
v o lt a g e o v e r th e f u ll m e c h a n ic a l ra n g e o f th e p e d a l. It e n a b le s c o m p e n s a t io n f o r n o n s y m m e t r y
o f th e m e c h a n ic a l s y s te m b e tw e e n d ir e c t io n s .
T h e o p e r a t io n is p e rfo rm e d b y o p e ra t in g t h e p e d a l a f t e r e n t e r in g t h e P R O G R A M V A C C
fu n c t io n .
F lo w C h a r t s h o w in g h o w to u s e th e P R O G R A M V A C C f u n c t io n o f t h e D ig it a l C o n s o le .
2 ) P r e s s E n t e r t o g o in t o t h e G e n e r a l M e n u .
4 ) P r e s s R O L L U P o r R O L L D O W N b u t t o n u n t il
P R O G R A M V A C C a p p e a r s o n t h e d is p la y .
6 ) P r e s s E N T E R t o g o in t o t h e P R O G R A M V A C C r o u t in e .
7 ) T h e D is p la y w ill s h o w t h e m in im u m a n d m a x im u m v a lu e s
o f p o t e n t io m e t e r w ip e r o u t p u t .
B o t h d ir e c t io n s c a n b e s h o w n .
8 ) P r e s s E N T E R t o c le a r t h e s e v a lu e s .
D is p la y w ill s h o w 0 . 0 .
9 ) S e le c t F o r w a r d D ir e c t io n , c lo s e a n y in t e r lo c k s w it c h e s
t h a t m a y b e in t h e s y s t e m .
1 0 ) S lo w ly d e p re s s t h e a c c e le r a t o r p e d a l ( o r t ille r b u t t e r f ly )
t o it s m a x im u m v a lu e . T h e n e w m in im u m a n d m a x im u m
v o lt a g e s w ill b e d is p la y e d o n t h e C o n s o le p lu s a n a r r o w
in d ic a t in g th e d ir e c t io n .
1 1 ) S e le c t t h e R e v e r s e D ir e c t io n a n d r e p e a t It e m 1 0 .
1 2 ) W h e n f in is h e d , p r e s s O U T .
1 3 ) T h e D is p la y w ill a s k : A R E Y O U S U R E ?
1 4 ) P re s s E N T E R fo r Y E S , o r O U T fo r N O .
1 5 ) P r e s s O U T a g a in t o r e t u r n t o t h e O p e n in g Z a p i M e n u .
Is s u e 0 2 /2 0 0 6
P a g e 5 1
7 . A C In v e r t e r D ia g n o s t ic - T r a c t io n C o n f ig u r a t io n
T h e a la r m s a r e s ig n a lle d b y a d ia g n o s t ic L E D .
1 b lin k : lo g ic f a ilu r e (" W A T C H D O G " , " E E P R O M K O " , " L O G IC F A IL U R E # 1 " , " L O G IC

F A IL U R E # 2 " , " L O G IC F A IL U R E # 3 " , C H E C K U P N E E D E D " .
2 b lin k s : r u n n in g r e q u e s t o n s t a r t - u p o r e r r o r in s e a t s e q u e n c e o r d o u b le d ir e c t io n
r e q u e s t (" IN C O R R E C T S T A R T " ; " H A N D B R A K E " , " F O R W + B A C K " ).
3 b lin k s : p h a s e v o lt a g e o r c a p a c it o r c h a r g e f a ilu r e ( " C A P A C IT O R C H A R G E " , " V M N

L O W " , " V M N H IG H " ).
4 b lin k s : f a ilu r e in a c c e le r a t o r ( " V A C C N O T O K " , " P E D A L W IR E K O " ) .
5 b llin k s : f a ilu r e o f c u r r e n t s e n s o r ( " S T B Y I H IG H " ) .
6 b lin k s : f a ilu r e o f c o n t a c t o r d r iv e r ( " C O IL S H O R T E D " , " D R IV E R S H O R T E D " ,

" C O N T A C T O R D R IV E R " , " A U X O U T P U T K O " , " C O N T A C T O R O P E N " ).
7 b lin k s : e x c e s s iv e t e m p e r a t u r e (" H IG H T E M P E R A T U R E " , " M O T O R T E M P E R A T U R E " ,

" T H E R M IC S E N S O R K O " ).
8 b lin k s : f a ilu r e d e t e c t io n f r o m c a n - b u s (" W A IT IN G P U M P " , " C A N - B U S K O " ).
lo n g b lin k : d is c h a r g e b a t t e r y (" L O W B A T T E R Y " ).
7 .1 A n a ly s is o f A la r m s D is p la y e d o n C o n s o le
1 . W A T C H D O G :
T h e t e s t is m a d e in b o t h r u n n in g a n d s t a n d b y . It is a s e lf - d ia g n o s in g t e s t w it h in t h e lo g ic . If
a n a la r m s h o u ld o c c u r , r e p la c e t h e lo g ic .
2 . E E P R O M K O :
F a u lt in t h e a r e a o f m e m o r y in w h ic h t h e a d ju s t m e n t p a ra m e te rs a r e s t o r e d ; t h is a la r m
in h ib it s m a c h in e o p e r a t io n . If t h e d e f e c t p e r s is t s w h e n th e k e y is s w it c h e d O F F a n d o n
a g a in , r e p la c e t h e lo g ic . If t h e a la r m d is a p p e a r s , re m e m b e r th a t th e p a ra m e te rs s to re d
p r e v io u s ly h a v e b e e n c a n c e lle d a n d r e p la c e d b y th e d e fa u lt v a lu e s .
3 . L O G IC F A IL U R E # 1 :
T h is a la r m s ig n a ls t h a t a n u n d e r v o lt a g e / o v e r v o lt a g e p r o t e c t io n o p e r a t io n h a s o c c u r r e d .
T w o p o s s ib le re a s o n s :
a . A re a l u n d e r v o lt a g e / o v e r v o lt a g e s it u a t io n h a p p e n e d .
b . F a u lt in t h e h a r d w a r e s e c t io n o f t h e lo g ic b o a r d w h ic h m a n a g e s t h e o v e r v o lt a g e
p ro te c t io n . R e p la c e t h e lo g ic c a rd .
4 . L O G IC F A IL U R E # 2 :
F a u lt in t h e h a r d w a r e s e c t io n o f t h e lo g ic b o a r d w h ic h m a n a g e s t h e p h a s e ' s v o lt a g e
f e e d b a c k . R e p la c e t h e lo g ic b o a r d .
Is s u e 0 2 /2 0 0 6
P a g e 5 2
5 . L O G IC F A IL U R E # 3 :
F a u lt in t h e h a r d w a r e s e c t io n o f t h e lo g ic b o a r d w h ic h m a n a g e s t h e h a r d w a r e c u r r e n t
p r o t e c t io n . R e p la c e t h e lo g ic b o a r d .
6 . C H E C K U P N E E D E D
T h is is a w a r n in g . I t is a n in f o r m a t io n f o r t h e u s e r t h a t t h e p r o g r a m m e d t im e f o r m a in t e n a n c e
is
e la p s e d .
7 . IN C O R R E C T S T A R T
T h is a la r m s ig n a ls a n in c o r r e c t s t a r t in g s e q u e n c e . P o s s ib le c a u s e s :
a . r u n n in g m ic r o s w it c h f a ilu r e ;
b . e r r o r in s e q u e n c e m a d e b y th e o p e ra to r;
c . in c o r r e c t w ir in g ;
d . if t h e d e f a u lt p e r s is t s , r e p la c e t h e lo g ic .
8 . F O R W + B A C K
T h e t e s t is c a r r ie d o u t c o n t in o u s ly . A n a la r m is s ig n a lle d w h e n a d o u b le r u n n in g r e q u e s t is
m a d e s im u lt a n e o u s ly . P o s s ib le c a u s e s :
a . d e f e c t iv e w ir in g ;
b . r u n n in g m ic r o s w it c h f a ilu r e ;
c . in c o r r e c t o p e r a t io n ;
d . if t h e d e f e c t p e r s is t s , r e p la c e t h e lo g ic .
9 . H A N D B R A K E
T h e tru c k d o e s n o t s ta r t b e c a u s e t h e h a n d b r a k e s w it c h is o p e n e d . P o s s ib le c a u s e s :
a . d e f e c t iv e w ir in g ;
b . f a ilu r e o f t h e m ic r o s w it c h ;
c . in c o r r e c t o p e r a t io n o f th e o p e ra to r;
If t h e d e fe c t p e r s is t , r e p la c e t h e lo g ic .
1 0 . C A P A C IT O R C H A R G E
F o llo w s t h e c h a r g in g c a p a c it o r s y s t e m :
W h e n th e k e y is s w it c h e d O N , t h e in v e r t e r t r ie s t o c h a r g e t h e c a p a c it o r t h r o u g h a p o w e r
r e s is t a n c e , a n d c h e c k if t h e c a p a c it o r a r e c h a r g e d w it h in a t im e o u t . If h is is n o t t r u e : a n a la r m
is s ig n a lle d ; th e m a in c o n t a c t o r is n o t c lo s e d .
P o s s ib le r e a s o n s :
a ) T h e c h a rg in g r e s is t a n c e is o p e n e d ; if it is o p e n e d .
b ) T h e c h a rg in g c ir c u it h a s a f a ilu r e .
c ) T h e r e is a p ro b le m o n t h e p o w e r m o d u le s .
1 1 . V M N L O W , V M N H IG H
T h e t e s t is c a r r ie d o u t d u r in g in it ia l d ia g n o s is a n d in s t a n d b y .
P o s s ib le c a u s e s :
a . P r o b le m w it h t h e m o t o r c o n n e c t io n s o r t h e m o t o r p o w e r c ir c u it ; c h e c k if t h e 3 p h a s e s a r e
c o r r e c t ly c o n n e c t e d ; c h e c k if t h e r e ' s a d is p e r s io n o f t h e m o t o r t o w a r d s g r o u n d ;
b . In v e r t e r f a ilu r e , r e p la c e it .
Is s u e 0 2 /2 0 0 6
P a g e 5 3
1 2 . V A C C N O T O K
T h e te s t is m a d e in s t a n d b y . T h is a la r m in d ic a t e s t h a t t h e a c c e le r a t o r v o lt a g e is 1 V g r e a t e r
th a n th e m in im u m v a lu e p r o g r a m m e d b y t h e P R O G R A M V A C C f u n c t io n .
P o s s ib le c a u s e s :
a . T h e p o t e n t io m e t e r is n o t c o r r e c t ly c a lib r a t e d ;
b . T h e p o t e n t io m e t e r is d e f e c t iv e .
1 3 . P E D A L W IR E K O
T h is a la r m is s ig n a lle d if a f a u lt is d e t e c t e d in t h e a c c e le r a t o r u n it w ir in g ( N P O T o r P P O T
c a b le is in t e r r u p t e d ) .
1 4 . S T B Y I H IG H
T e s t c a r r ie d o u t in s t a n d b y . C h e c k if t h e c u r r e n t is 0 . If n o t v e r if ie d , a n a la r m is s ig n a lle d
w h ic h in h ib it s m a c h in e o p e r a t io n s . P o s s ib le c a u s e s :
a . C u r re n t s e n s o r fa ilu r e ;
b . L o g ic f a ilu r e : f ir s t r e p la c e t h e lo g ic ; if t h e d e f e c t p e r s is t s , r e p la c e t h e p o w e r u n it .
1 5 . M A IN C O N T A C T O R A L A R M S
C O IL S H O R T E D :
W h e n t h e k e y is s w it c h e d O N t h e µ P c h e c k s t h e M C d r iv e r F F S R . If it d o e s n o t r e a c t in a
c o r r e c t w a y t o t h e µ P s t im u lu s , t h e a la r m is s ig n a lle d . R e p la c e t h e lo g ic b o a rd . T h e F F S R
m a k e s a n h a r d w a r e c o n t r o l o f t h e c u r r e n t in t h e M C c o il. If t h is is t o o h ig h , it o p e n s t h e M C
a n d t h e a la r m is s ig n a lle d .
C h e c k if t h e r e a r e e x t e r n a l s h o r t c ir c u it a n d if t h e o h m ic v a lu e o f t h e M C is c o r r e c t ;
o t h e r w is e r e p la c e t h e lo g ic .
D R IV E R S H O R T E D :
W h e n t h e k e y is s w it c h e d O N , t h e µ P c h e c k s t h a t t h e M C c o il d r iv e r is n o t s h o r t e d ; if it is ,
t h is a la r m is s ig n a lle d ; r e p la c e t h e lo g ic b o a r d .
C O N T A C T O R D R IV E R :
W h e n t h e in it ia l d ia g n o s is is f in is h e d , t h e t r a c t io n lo g ic c lo s e s t h e M C a n d c h e c k s th e
v o lt a g e o n t h e D r a in o f t h e d r iv e r . If t h is is n o t lo w , a n a la r m is s ig n a lle d . R e p la c e t h e lo g ic .
C O N T A C T O R O P E N :
T h e m a in c o n t a c t o r c o il h a s b e e n d r iv e n b y t h e lo g ic b o a r d , b u t t h e c o n ta c to r d o e s n o t
c lo s e . T w o p o s s ib le r e a s o n s :
a )T h e w ir e s t o t h e c o il a r e in t e r r u p t e d o r n o t w e ll c o n n e c t e d .
b ) T h e c o n t a c t o f t h e c o n t a c t o r is n o t p r o p e r ly w o r k in g .
1 6 . A U X O U P U T K O
T h e µ P c h e c k s t h e d r iv e r o f t h e e le c t r o m e c h a n ic a l b r a k e . If t h e s t a t u s o f t h e d r iv e r o u t p u t
d o e s n o t c o r r e s p o n d t o t h e s ig n a l c o m in g f r o m t h e µ P , t h e a la r m is s ig n a lle d . R e p la c e t h e
lo g ic .
1 7 . H IG H T E M P E R A T U R E
C h o p p e r te m p e ra tu re is g r e a t e r t h a n 7 5 ° C . T h e m a x im u m c u r r e n t is r e d u c e d p r o p o r t io n a lly
to th e te m p e ra t u r e in c r e a s e . T h e c h o p p e r s t o p s a t 1 0 0 ° C . If t h e a la r m is s ig n a lle d w h e n
t h e c h o p p e r is c o ld :
a ) C h e c k th e w ir in g o f th e th e rm a l s e n s o r;
b ) T h e rm a l s e n s o r f a ilu re ;
c ) L o g ic f a ilu r e .
Is s u e 0 2 /2 0 0 6
P a g e 5 4
1 8 . M O T O R T E M P E R A T U R E
T h is w a r n in g is s ig n a lle d if t h e m o t o r t e m p e r a t u r e s w it c h o p e n s ( d ig it a l s e n s o r ) o r if t h e
a n a lo g s ig n a l o v e rta k e s t h e c u t o f f le v e l. If it h a p p e n s w h e n t h e m o t o r is c o ld , c h e c k t h e
w ir in g . If a ll is o k , re p la c e t h e lo g ic b o a r d .
1 9 . T H E R M IC S E N S O R K O
T h e r a n g e o f in v e r t e r t e m p e r a t u r e s e n s o r is a lw a y s c h e c k e d a n d a w a r n in g is s ig n a lle d if it
is o u t o f r a n g e . w h e n t h is a la r m is s ig n a lle d , c h e c k t h e c o n n e c t io n o f t h e s e n s o r .
2 0 . W A IT IN G P U M P
T h is a la r m is p r e s e n t in c o m b i s y s t e m s (t r a c t io n + p u m p ). T h e p u m p h a s d e t e c t e d a
f a ilu r e , t h e t r a c t io n c a n n o t c lo s e t h e m a in c o n t a c t o r b e c a u s e o f t h e a la r m s t a t u s o f t h e
p u m p (w h ic h t h e t r a c t io n k n o w s b y t h e C A N - B u s lin e ) . T h e f a ilu r e m u s t b e lo o k e d f o r in
th e p u m p in v e r t e r .
2 1 . C A N B U S K O
T h e d ia g n o s is o f th e C A N - B U S lin e is p r e s e n t o n ly if t h e in v e r t e r u s e s t h is lin k ( d e p e n d s
o n th e s o ftw a re v e rs io n ) . It is s ig n a lle d if t h e in v e r t e r d o e s n o t r e c e iv e a n y m e s s a g e f r o m
th e C A N -B U S lin e . F ir s t o f a ll, c h e c k t h e w ir in g . If it is o k , t h e p r o b le m is o n t h e lo g ic
b o a rd , w h ic h m u s t b e r e p la c e d .
2 2 . B A T T E R Y L O W
If t h e "b a tte r y c h e c k " o p t io n is O N , a b a t t e r y d is c h a r g e a lg o r it h m is c a r r ie d o u t . W h e n t h e
c h a rg e le v e l is 1 0 % , t h is a la r m is s ig n a lle d a n d t h e c u r r e n t is r e d u c e d t o t h e h a lf o f t h e
p ro g r a m m e d le v e l.
Is s u e 0 2 /2 0 0 6
P a g e 5 5
8 . A C In v e r t e r D ia g n o s t ic - P u m p C o n f ig u r a t io n
T h e a la r m s a r e s ig n a lle d b y a d ia g n o s t ic L E D .
1 b lin k : lo g ic f a ilu r e ( " W A T C H D O G " , " E E P R O M K O " , " L O G IC F A IL U R E # 1 " , " L O G IC

F A IL U R E # 2 " , " L O G IC F A IL U R E # 3 " ).
2 b lin k s : r u n n in g r e q u e s t o n s t a r t - u p o r e r r o r in s e a t s e q u e n c e (" IN C O R R E C T S T A R T " ).
3 b lin k s : p h a s e v o lt a g e o r c a p a c it o r c h a r g e f a ilu r e ( " C A P A C IT O R C H A R G E " , " V M N

L O W " , " V M N H IG H " ).
4 b lin k s : f a ilu r e in a c c e le r a t o r (" V A C C N O T O K " , " P E D A L W IR E K O " ).
5 b llin k s : f a ilu r e o f c u r r e n t s e n s o r (" S T B Y I H IG H " ).
6 b lin k s : f a ilu r e o f c o n t a c t o r d r iv e r (" D R IV E R S H O R T E D " , " C O N T A C T O R D R IV E R " ,

" C O N T A C T O R O P E N " ).
7 b lin k s : e x c e s s iv e t e m p e r a t u r e (" H IG H T E M P E R A T U R E " , " M O T O R T E M P E R A T U R E " ,

" T H E R M IC S E N S O R K O " ).
8 b lin k s : f a ilu r e d e t e c t io n f r o m c a n - b u s (" W A IT IN G T R A C T IO N " , " C A N - B U S K O " ).
lo n g b lin k : d is c h a r g e b a t t e r y ( " L O W B A T T E R Y " ).
1 . W A T C H D O G
T h e t e s t is m a d e in b o t h r u n n in g a n d s t a n d y . It is a s e lf - d ia g n o s in g t e s t w it h in t h e lo g ic . If a n
a la r m s h o u ld o c c u r , r e p la c e t h e lo g ic .
2 . E E P R O M K O
F a u lt in t h e a re a o f m e m o r y in w h ic h t h e a d ju s t m e n t p a r a m e t e r s a r e s t o r e d ; t h is a la r m in h ib it s
m a c h in e o p e ra t io n . If t h e d e fe c t p e r s is t s w h e n t h e k e y is s w it c h e d O F F a n d O N a g a in , r e p la c e
t h e lo g ic . If th e a la r m d is a p p e a rs , re m e m b e r t h a t t h e p a r a m e t e r s s t o r e d p r e v io u s ly h a v e b e e n
c a n c e lle d a n d r e p la c e d b y th e d e f a u lt v a lu e s .
3 . L O G IC F A IL U R E # 1
T h is a la r m s ig n a ls t h a t a n u n d e r v o lt a g e / o v e r v o lt a g e p r o t e c t io n o p e r a t io n h a s o c c u r r e d . T w o
p o s s ib le r e a s o n s :
a . A r e a l u n d e r v o lt a g e / o v e r v o lt a g e s it u a t io n h a p p e n e d .
b . F a u lt in t h e h a r d w a r e s e c t io n o f t h e lo g ic b o a r d w h ic h m a n a g e s t h e o v e r v o lt a g e p r o t e c t io n .
R e p la c e t h e lo g ic c a rd .
F a u lt in t h e h a r d w a r e s e c t io n o f t h e lo g ic b o a r d w h ic h m a n a g e s t h e p h a s e ' s v o lt a g e f e e d b a c k .
R e p la c e t h e lo g ic b o a r d .
F a u lt in t h e h a r d w a r e s e c t io n o f t h e lo g ic b o a r d w h ic h m a n a g e s t h e h a r d w a r e c u r r e n t
p r o t e c t io n . R e p la c e t h e lo g ic b o a r d .
Is s u e 0 2 /2 0 0 6
P a g e 5 6
6 . IN C O R R E C T S T A R T
T h is a la r m s ig n a ls a n in c o r r e c t s t a r t in g s e q u e n c e . P o s s ib le c a u s e s :
a . R u n n in g m ic r o s w it c h f a ilu r e ;
b . E r r o r in s e q u e n c e m a d e b y th e o p e ra to r;
c . In c o r r e c t w ir in g ;
d . If t h e d e f a u lt p e r s is t s , r e p la c e t h e lo g ic .
7 . C A P A C IT O R C H A R G E
F o llo w s t h e c h a r g in g c a p a c it o r s y s t e m :
W h e n t h e k e y is s w it c h e d O N , t h e in v e r t e r t r ie s t o c h a r g e t h e c a p a c it o r s t h r o u g h a p o w e r
r e s is t a n c e a n d c h e c k if t h e c a p a c it o r s a r e c h a r g e d w it h in a t im o u t . If t h is is n o t t r u e : a n
a la r m is s ig n a lle d ; t h e m a in c o n t a c t o r is n o t c lo s e d . P o s s ib le r e a s o n s :
a ) C h e c k if t h e c h a r g in g r e s is t a n c e is o p e n e d .
b ) T h e c h a r g in g c ir c u it h a s a f a ilu r e .
c ) T h e r e is a p r o b le m o n t h e p o w e r m o d u le s .
8 . V M N L O W , V M N H IG H
T h e t e s t is c a r r ie d o u t d u r in g in it ia l d ia g n o s is a n d in s t a n d b y . P o s s ib le c a u s e s :
a . P r o b le m w it h t h e m o to r c o n n e c t io n s o r t h e m o t o r p o w e r c ir c u it ; c h e c k if t h e 3 p h a s e s
a re c o rr e c t ly c o n n e c te d , c h e c k if t h e r e ' s a d is p e r s io n o f t h e m o t o r t o w a r d s g r o u n d ;
b . C h o p p e r f a ilu r e , r e p la c e it .
9 . P E D A L W IR E K O
T h is a la r m is s ig n a lle d if a f a u lt is d e t e c t e d in t h e a c c e le r a t o r w ir in g (N P O T o r P P O T c a b le
is u n t e r r u p t e d ) .
1 0 . V A C C N O T O K
T h e t e s t is m a d e in s ta n d b y . T h is a la r m in d ic a t e s t h a t t h e a c c e le r a t o r v o lt a g e is 1 V g r e a t e r
th a n t h e m in im u m v a lu e p ro g ra m m e d b y t h e P R O G R A M V A C C f u n c t io n . P o s s ib le c a u s e s :
a . th e p o te n t io m e te r is n o t c o rr e c t ly c a lib r a t e d ;
b . th e p o te n t io m e te r is d e f e c t iv e .
1 1 . S T B Y I H IG H
T e s t c a r r ie d o u t in s t a n d b y . C h e c k if t h e c u r r e n t is 0 . If n o t v e r if ie d , a n a la r m is s ig n a lle d
w h ic h in h ib it s m a c h in e o p e r a t io n s . P o s s ib le c a u s e s :
a . C u rre n t s e n s o r f a ilu r e ;
b . L o g ic f a ilu r e : f ir s t r e p la c e t h e lo g ic ; if t h e d e f e c t p e r s is t s , r e p la c e t h e p o w e r u n it .
Is s u e 0 2 /2 0 0 6
P a g e 5 7
1 2 . M IN C O N T A C T O R A L A R M S
In t h e c o m b i s y s t e m (p u m p + t r a c t io n ) t h e m a in c o n t a c t o r is d r iv e n b y t h e t r a c t io n in v e r t e r .
S o t h e f o llo w in g d e s c r ip t io n c o n c e r n s t h e p u m p in v e r t e r u s e d in d e p e n d e n t ly f r o m t h e
t r a c t io n in v e r t e r . In t h is c o n f ig u r a t io n t h e p u m p in v e r t e r m a n a g e s it s o w n m a in c o n t a c t o r .
C O IL S H O R T E D :
W h e n t h e k e y is s w it c h e d O N t h e µ P c h e c k s t h e M C d r iv e r F F S R . If it d o e s n o t r e a c t in a
c o r r e c t w a y t o t h e µ P s t im u lu s , t h e a la r m is s ig n a lle d . R e p la c e t h e lo g ic b o a r d . T h e F F S R
m a r k e s a n h a r d w a r e c o n t r o l o f t h e c u r r e n t in t h e M C c o il. If t h is is t o o h ig h , it o p e n s t h e M C
a n d t h e a la r m is s ig n a lle d . C h e c k if t h e r e a r e e x t e r n a l s h o r t c ir c u it a n d if t h e o h m ic v a lu e o f
t h e M C is c o r r e c t ; o t h e r w is e r e p la c e t h e lo g ic .
D R IV E R S H O R T E D :
W h e n t h e k e y is s w it c h e d O N , t h e µ P c h e c k s t h a t t h e M C c o il d r iv e r is n o t s h o r t e d ; if it is ,
t h is a la r m is s ig n a lle d ; r e p la c e t h e lo g ic b o a r d .
C O N T A C T O R D R IV E R :
W h e n t h e in it ia l d ia g n o s is is f in is h e d , t h e t r a c t io n lo g ic c lo s e s t h e M C a n d c h e c k s t h e v o lt a g e
o n t h e D r a in o f t h e d r iv e r . If t h is is n o t lo w , a n a la r m is s ig n a lle d . R e p la c e t h e lo g ic .
C O N T A C T O R O P E N :
T h e m a in c o n t a c t o r c o il h a s b e e n d r iv e n b y t h e lo g ic b o a r d , b u t t h e c o n t a c t o r d o e s n o t
c lo s e . T w o p o s s ib le r e a s o n s :
a ) T h e w ir e s t o t h e c o il a r e in t e r r u p t e d o r n o t w e ll c o n n e c t e d ;
b ) T h e c o n t a c t o f t h e c o n t a c t o r is n o t p r o p e r ly w o r k in g .
1 3 . H IG H T E M P E R A T U R E
C h o p p e r t e m p e r a t u r e is g r e a t h e r th a n 7 5 ° C . T h e m a x im u m c u r r e n t is r e d u c e d p r o p o r t io n a lly
t o t h e t e m p e r a t u r e in c r e a s e . T h e c h o p p e r s to p s a t 1 0 0 ° C .
If t h e a la r m is s ig n a lle d w h e n t h e c h o p p e r is c o ld :
a . c h e c k t h e w ir in g o t h e t h e r m a l s e n s o r
b . t h e r m a l s e n s o r f a ilu r e ;
c . lo g ic f a ilu r e .
1 4 . M O T O R T E M P E R A T U R E
T h is w a r n in g is s ig n a lle d if t h e m o t o r t e m p e r a t u r e s w it c h is o p e n s d ig it a l s e n s o r o r if t h e
a n a lo g s ig n a l o v e r t a k e s t h e c u t - o f f le v e l. If it h a p p e n s w h e n t h e m o t o r is c o ld , c h e c k t h e
w ir in g . If a ll is O K , r e p la c e t h e lo g ic b o a r d .
1 5 . T H E R M IC S E N S O R K O
T h e ra n g e o f in v e r t e r t e m p e r a t u r e s e n s o r is a lw a y s c h e c k e d a n d a w a r n in g is s ig n a lle d if it is
o u t o f ra n g e .
W h e n t h is a la r m is s ig n a lle d , c h e c k t h e c o n n e c t io n o f t h e s e n s o r s .
1 6 . W A IT IN G T R A C T IO N
T h is a la r m is p re s e n t in c o m b i s y s t e m s (t r a c t io n + p u m p ). T h e t r a c t io n h a s d e t e c t e d a f a ilu r e
h a s in f o rm e d th e p u m p in v e r t e r t h r o u g h t h e c a n - b u s lin e . t h e p u m p is w a it in g f o r t h e t r a c t io n
o k . T h e f a ilu r e m u s t b e lo o k e d f o r in t h e t r a c t io n in v e r t e r .
1 7 . C A N B U S K O
T h e d ia g n o s is o f th e C A N - B U S lin e is p r e s e n t o n ly if t h e in v e r t e r u s e s t h is lin k (d e p e n d s o n
th e s o ftw a re v e r s io n ). It is s ig n a lle d if t h e in v e r t e r d o e s n o t r e c e iv e a n y m e s s a g e f r o m t h e
C A N -B U S lin e . F ir s t o f a ll, c h e c k t h e w ir in g . If it is o k , t h e p r o b le m is o n t h e lo g ic b o a r d ,
w h ic h m u s t b e re p la c e d .
Is s u e 0 2 /2 0 0 6
P a g e 5 8
1 8 . B A T T E R Y L O W
If th e "b a tte r y c h e c k " o p t io n is O N , a b a t t e r y d is c h a r g e a lg o r it h m is c a r r ie d o u t . W h e n
th e c h a rg e le v e l is 1 0 % , t h is a la r m is s ig n a lle d a n d t h e c u r r e n t is r e d u c e d t o t h e h a lf o f
th e p ro g ra m m e d le v e l.
1 0 . P e r io d ic M a in t e n a n c e t o b e r e p e a t e d a t T im e s In d ic a t e d
C h e c k t h e w e a r a n d c o n d it io n o f t h e C o n t a c t o r ' s m o v in g a n d f ix e d c o n t a c t o r s . E le c t r ic a l
C o n t a c t s s h o u ld b e c h e c k e d e v e r y 3 m o n t h s .
C h e c k th e fo o t p e d a l o r t ille r m ic r o s w it c h . U s in g a s u it a b le t e s t m e t e r c o n f ir m t h a t t h e r e is
n o e le c t r ic a l r e s is t a n c e b e tw e e n th e c o n ta c ts b y m e a s u r in g t h e v o lt d r o p b e t w e e n t h e
t e r m in a ls . S w it c h e s s h o u ld o p e r a t e w it h a f ir m c lic k s o u n d .
M ic r o s w it c h e s s h o u ld b e c h e c k e d e v e ry 3 m o n th s .
C h e c k t h e b a t t e r y c a b le s , c a b le s t o t h e c h o p p e r , a n d c a b le s t o t h e m o t o r . E n s u r e t h e
in s u la t io n is s o u n d a n d t h e c o n n e c t io n s a r e t ig h t .
C a b le s s h o u ld b e c h e c k e d e v e r y 3 m o n t h s .
C h e c k t h e m e c h a n ic a l o p e r a t io n o f t h e p e d a l o r t ille r . A r e t h e r e t u r n s p r in g s o k . D o t h e
p o t e n t io m e t e r s w in d u p t o t h e ir f u ll o r g r o g r a m m e d le v e l.
C h e c k e v e ry 3 m o n th s .
C h e c k t h e m e c h a n ic a l o p e r a t io n o f t h e c o n t a c t o r ( s ) . M o v in g c o n t a c t s s h o u ld b e f r e e t o
m o v e w it h o u t r e s t r ic t io n .
C h e c k e v e ry 3 m o n th s .
C h e c k s s h o u ld b e c a r r ie d o u t b y q u a lif ie d p e s o n n e l a n d a n y r e p la c e m e n t p a r t s u s e d
s h o u ld b e o r ig n a l. B E W A R E O F N O N O R IG IN A L P A R T S .
T h e in s t a lla t io n o f t h is e le c t r o n ic c o n t r o lle r s h o u ld b e m a d e a c c o r d in g t o t h e d ia g r a m s
in c lu d e d h is m a n u a l. A n y v a r ia t io n s o r s p e c ia l r e q u ir e m e n ts s h o u ld b e m a d e a f t e r
c o n s u lt in g a Z a p i- A g e n t . T h e s u p p lie r is n o t r e s p o n s ib le fo r a n y p r o b le m t h a t a r is e s f r o m
w ir in g m e t h o d s t h a t d if f e r f r o m in f o r m a t io n in c lu d e d in t h is m a n u a l.
D u r in g p e r io d ic s c h e c k s , if a t e c h n ic ia n f in d s a n y s it u a t io n t h a t c o u ld c a u s e d a m a g e o r
c o m p r o m is e s a f e t y , t h e m a t t e r s h o u ld b e b o u g h t t o t h e a t t e n t io n o f a Z a p i A g e n t
im m e d ia t e ly . T h e A g e n t w ill t h e n t a k e t h e d e c is io n r e g a r d in g o p e r a t io n a l s a f e t y t o t h e
m a c h in e .
R e m e m b e r t h a t B a t t e r y P o w e r e d M a s c h in e s f e e l n o a g a in .
N E V E R U S E A V E H IC L E W IT H A F A U L T Y E L E C T R O N IC C O N R O L L E R .
T r a n s m is s io n
P a g e 1
G e n e ra l
F o r s a f e t y r e a s o n s , r e p la c e m e n t t r a n s m is s io n s a r e s u p p lie d w it h o u t o il.
W h e n f ir s t c o m m is s io n in g :
T h e t r a n s m is s io n s h o u ld b e f ille d w it h t r a n s m is s io n o il t o A P I G L 4 o r M IL L 2 1 0 5 .
V is c o s it y g r a d e s :
S t a n d a r d o il: A m b ie n t a ir t e m p e r a t u r e 0 t o + 4 0 ° C S A E 8 0 - 9 0
L o w - t e m p e r a t u r e o il: A m b ie n t a ir t e m p e r a t u r e 0 t o - 2 6 ° C S A E 8 0 W
A m b ie n t a ir t e m p e r a t u r e 0 t o - 4 0 ° C S A E 7 5 W
F o r s p e c ia l a p p lic a t io n s p le a s e c o n s u lt t h e m a n u f a c t u r e r .
O il q u a n t it y in lit r e s : a p p ro x . 0 .3
A t t e n t io n :
- T h e s t a t e d o il q u a n t it y is a g u id e o n ly . T h e e x a c t q u a n t it y is d e t e r m in e d b y t h e o v e r f lo w
s c re w .
- T o o m u c h o il c a n im p a ir le a k p r o t e c t io n a n d a d v e r s e ly a f f e c t t r a n s m is s io n o p e r a t in g
te m p e ra tu re s .
- O il s h o u ld o n ly b e f ille d in s t a lle d c o n d it io n .
S e e t h e s e c t io n o n " o il c h a n g e " in t h e c h a p t e r o n m a in t e n a n c e f o r g u id a n c e o n f illin g w it h

o il.
O p e r a t in g T e m p e ra tu re :
O v e r c o n t in u o u s p e r io d s t r a n s m is s io n o il t e m p e r a t u r e s h o u ld n o t e x c e e d
8 0 ° C . T h e m a x . a d m is s ib le o il t e m p e r a t u r e o f 1 0 0 ° C s h o u ld o n ly b e
re a c h e d fo r s h o rt p e r io d s .
D e c o m m is s io n in g o r lo n g - t e r m s to ra g e
If t h e t r a n s m is s io n is t o b e s t o r e d f o r m o r e t h a n o n e y e a r ( e g a s a s q u a r e ) it s h o u ld b e
w r a p p e d c a r e f u lly in p la s t ic f o il.
W e a ls o r e c o m m e n d p la c in g a d r y in g a g e n t in s id e t h e p a c k in g f o il ( e g 8 E H N o . 5 5 4 7 3
s u p p lie d b y H e r m a n n C h e m ie u n d P a c k m it t e l, C o lo g n e ) .
P a g e 2
M a in t e n a n c e
M a in t e n a n c e W o r k :
W e r e c o m m e n d t h e f o llo w in g m a in t e n a n c e o n t h e d r iv e u n it a f t e r 5 0 - 1 5 0 h o u r s ( f ir s t
v e h ic le in s p e c t io n ), t h e n e v e r y 1 0 0 0 h o u r s b u t a t le a s t e v e r y 2 y e a r s :
- O il c h a n g e
- R e t ig h t e n w h e e l s c r e w s (8 0 N m ).
- R e t ig h t e n f ix in g s c r e w s in t h e d r iv e u n it .
C h e c k in g o il le v e l ( s e e F ig . 3 6 ) .
T h e o il le v e l s h o u ld b e c h e c k e d a t le a s t e v e r y 3 m o n t h s . W h e n t o p p in g u p , u s e o n ly t h e
s a m e g r a d e a s t h e o r ig in a l ( s e e c h a p t e r " lu b r ic a t io n t a b le " ). W h e n c h e c k in g t h e o il le v e l,
t h e o il le v e l s c r e w s h o u ld b e p la c e d a t t h e lo w e s t p o in t .
T r a n s m is s io n o il s h o u ld r e a c h t h e lo w e r e d g e o f t h e o il in le t s c r e w th re a d . A fte r e v e ry
o il c h e c k r e p la c e a ll o - r in g s in t h e o il le v e l s c r e w s .
O il c h a n g e (s e e F ig . 3 6 ).
T r a n s m is s io n o il s h o u ld b e d r a in e d in w a r m c o n d it io n .
A t t e n t io n :
O il c h a n g e s a r e o n ly p o s s ib le o n in s t a lle d t r a n s m is s io n s .
a ) T u r n t h e t r a n s m is s io n u n t il t h e d r a in s c r e w is a t t h e lo w e s t p o in t .
b ) U n s c re w t h e d r a in s c r e w a n d d r a in t h e o il. M a k e s u r e t h e o il is p r o p e r ly d is p o s e d o f .
c ) S c re w b a c k t h e d r a in s c r e w a n d r e p la c e o - r in g .
d ) T u r n t h e t r a n s m is s io n u n t il t h e in le t s c r e w is a t t h e lo w e s t p o in t .
e ) U n s c r e w t h e in le t s c r e w a n d f ill w it h n e w o il a s f a r a s t h e lo w e r e d g e o f t h e o il in le t
S c re w th re a d .
f) S c re w b a c k t h e in le t s c r e w a n d r e p la c e o - r in g .
P a g e 3
B ild 3 6
O il in le t a n d c o n t r o l s c r e w
O il d r a in s c r e w
P a g e 4
R e p a ir M a n u a l
R e m o v in g A n d D is a s s e m b lin g D r iv e U n it ( S e e F ig . 3 7 )
a ) R e m o v in g d r iv e u n it :
- D r a in o f f o il ( s e e p a g e 6 5 ).
- D is c o n n e c t e le c t r ic m o t o r c a b le s .
- H y d r a u lic b r a k e c a b le s .
- G u id e c h a in c o n n e c t io n
C h a lk in t h e p o s it io n o f b o t h c h a in c o n n e c t o r s o n t h e t u r n t a b le b e a r in g .
L o o s e n c h a in t ig h t e n e r w it h t h e s t e e r in g c y lin d e r .
R a is e th e c h a in f r o m t u r n t a b le b e a r in g .
b ) R e m o v in g e le c t r ic m o t o r ( F ig . 3 8 )
R e m o v e 6 Z y lin d e r s c r e w s (1 3 ) a n d c a r e f u lly p u ll o u t t h e e le c t r ic m o t o r .
A t t e n t io n :
If t h e m o t o is n o t r e m o v e d c a r e f u lly , m o t o r s u r f a c e s a n d / o r m o t o r c o ils
m a y b e d a m a g e d .
N o te :
If o n ly t h e e le c t r ic m o t o r is r e m o v e d , s e a l o f f t h e o p e n in g t o t h e t r a n s m is s io n
t o p r e v e n t d ir t g e t t in g in t o t h e t r a n s m is s io n .
c ) R e m o v in g w h e e l
R e m o v e 1 2 c y lin d e r s c r e w s (2 ) a n d f o r c e t h e w h e e l o f f it s h u b w it h a p la s t ic h a m m e r ,
h it t in g a b o v e t h e c r o s s o n t h e s u r f a c e m a r k e d " A " ( F ig . 3 9 ) .
E le c t r ic S id e la a d e r
P a g e 5
F ig . 3 7
P a g e 6
F ig . 3 8
8 b o lts
c h a s s is
W h e e l b r a k e c y lin d e r
b r a k e c a lip e r
b r a k e d is c
1 2 b o lts
6 b o lts
ty re
P a g e 7
R e m o v in g A n d D is a s s e m b lin g T h e C o m p le t e E p ic y c lic U n it ( F ig . 3 9 )
a ) R e m o v e c y lin d r ic a l p in s ( 3 ) u s in g a n M 6 s c r e w d r iv e r .
b ) U n s c re w c y lin d e r s c r e w s ( 1 ) .
c ) L o o s e n t h e c o m p le t e e p ic y c lic u n it ( 2 ) f r o m t h e h u b u s in g a p la s t ic h a m m e r .
d ) R e m o v e t h e o - r in g ( 1 6 ) a n d s u n w h e e l s h a f t ( 4 ) .
e ) R e m o v e h e x a g o n a l n u t s (1 5 ) a n d f o r c e o u t r e a m e d b o lt s (4 ).
f ) T a k e o f f t h e q p ic y c lic u n it (1 3 ) a n d h o llo w w h e e l (7 ).
g ) F o r c e t h e n e e d le b u s h in g s ( 6 ) o u t o f t h e e p ic y c lic u n it .
A t t e n t io n :
T h e n e e d le b u s h in g s c a n n o t b e r e - u s e d .
h ) R e m o v e t h e n e e d le r im s (5 ) f r o m t h e p la n e t w h e e ls (8 ) .
i) T a k e o u t t h e p la n e t w h e e l s e t s (8 a n d 9 ) .
k ) T a k e o u t n e e d le r im s ( 1 1 ) .
l) R e m o v e n e e d le b u s h in g s (1 0 ) f r o m c o v e r (1 2 ) u s in g t o o l " B A " .
- S e t u p th e to o l a s s h o w n in F ig . 3 9 .
- U s in g h e x a g o n n u t (IV ) a n d w e d g e ( I), f o r c e o p e n s p lit b u s h in g ( II) u n t il t h e b u s h in g
ja w s a re re a d y fo r re m o v a l.
- R e m o v e n e e d le b u s h in g (1 0 ) b y t u r n in g h e x a g o n n u t (V ).
A t t e n t io n :
T h e n e e d le b u s h in g s c a n n o t b e r e - u s e d .
P a g e 8
F ig . 3 9
P a g e 9
R e m o v in g T h e C o m p le t e H u b f r o m t h e e p ic y c lic U n it ( F ig . 4 0 )
a ) R e m o v in g c y lin d r ic a l p in s ( 7 ) u s in g a n M 8 s c r e w d r iv e r .
N o te :
In t r a n s m is s io n s f e a t u r in g c y lin d r ic a l p in s w it h n o t h r e a d b o r e , t h e p in s
a r e r e m o v e d o n ly w h e n t h e c o m p le t e h u b is d is a s s e m b le d . W h e n
a s s e m b lin g , u n t h r e a d e d c y lin d r ic a l p in s s h o u ld b e r e p la c e d w it h t h r e a d e d
o n e s .
b ) U n s c re w c y lin d e r s c r e w s ( 8 ) .
c ) U s in g a s u it a b le t o o l s u c h a s a la r g e s c r e w d r iv e r p la c e d b e t w e e n t h e h u b ( 9 ) a n d
e p ic y c lic u n it ( 1 ) , le v e r t h e h u b a w a y f r o m t h e u n it a n d t a k e o f f t h e c o m p le t e h u b .
d ) R e m o v e n ilo s - R in g ( 5 ) a n d s h im s ( 4 ) f r o m t h e u n it a n d s e t t o o n e s id e .
e ) T a k e t h e c o n n e c t in g s le e v e ( 6 ), p la t e s p r in g s ( 3 ) a n d o - r in g ( 2 ) o f f t h e e p ic y c lic
u n it .
P a g e 1 0
F ig . 4 0
P a g e 1 1
D is a s s e m b lin g C o m p le t e H u b ( F ig . 4 1 )
R e m o v in g a n d d is a s s e m b lin g t h e b e a r in g f la n g e
N o te :
S t a g e c ) a p p lie s o n ly t o t r a n s m is s io n s f e a t u r in g c y lin d r ic a l p in s w it h o u t a n
in t e r n a l t h r e a d . C y lin d r ic a l p in s w it h n o in t e r n a l t h r e a d s h o u ld b e r e p la c e d
w it h p in s w it h a n in t e r n a l t h r e a d .
a ) R e m o v e b e a r in g f la n g e ( 2 ) u s in g t o o l " B B " .
b ) P la c e t a p e r e d r o lle r b e a r in g in s id e r in g ( 1 ) n e x t t o t h e n ilo s r in g .
c ) S e c u r e c y lin d r ic a l p in ( 3 ) b e t w e e n p r o t e c t iv e c la m p s in t h e v ic e a n d r e m o v e t h e
b e a r in g f la n g e b y t a p p in g p o in t " A " w it h a p la s t ic h a m m e r .
d ) U s in g a p u n c h , r e m o v e t a p e r e d r o lle r b e a r in g in s id e r in g ( 4 ) f r o m it s s e a t in g s u r f a c e
t h r o u g h b o r e " A " a n d p u ll d o w n u s in g a s u it a b le p u llin g t o o l; p la c e t h e t a p e r e d r o lle r
b e a r in g in s id e r in g c a r e f u lly t o o n e s id e .
e ) R e m o v e s h im (5 ) w it h a c o p p e r h a m m e r .
N o te :
T h e s h im is c a u lk e d a n d s h o u ld o n ly b e r e m o v e d w h e n t h e b e a r in g f la n g e
is d a m a g e d o r r e p la c e d .
R e m o v in g t h e r a d ia l s h a f t s e a l r in g a n d t h e t a p e r e d r o lle r b e a r in g o u t s id e r in g s f r o m th e
h u b .
a ) P r e s s r a d ia l s h a f t s e a l r in g ( 6 ) a n d t a p e r e d r o lle r b e a r in g o u t s id e r in g ( 7 ) d o w n u s in g
t o o l " A U " ; p la c e t h e o u t s id e r in g n e x t t o in s id e r in g ( 4 ) .
b ) R e m o v e t a p e r e d r o lle r b e a r in g o u t s id e r in g ( 8 ) u s in g a p u n c h ; p la c e t h e o u t s id e r in g
n e s t t o t h e in s id e r in g .
P a g e 1 2
F ig . 4 1
P a g e 1 3
A s s e m b ly
G e n e ra l N o te s
T h e f o llo w in g p o in t s s h o u ld b e n o t e d b e f o r e a s s e m b lin g t h e t r a n s m is s io n :
- C a r e f u lly c le a n a ll p a r t s ( w it h c le a n in g s p ir it ) a n d r e m o v e a ll t r a c e s o f L o c t it e ( u s in g
f o r e x a m p le , L o c t it e R e m o v e r 8 0 6 4 6 ; f o llo w m a n u f a c t u r e r ' s in s t r u c t io n s c a r e f u lly ).
- C h e c k a ll p a r t s f o r w e a r o r d a m a g e a n d r e p la c e if n e c e s s a r y .
- W h e e l s e t p a r t s s h o u ld b e r e p la c e d a s c o m p le t e s e t s o n ly .
- C le a n s e a lin g a r e a s u s in g a n o ils t o n e o r a f in e s m o o t h in g f ile .
- A f t e r c le a n in g , o il r o lle r b e a r in g s b e f o r e r e f it t in g t h e m .
- A lw a y s r e p la c e s e a ls .
P a g e 1 4
A s s e m b lin g C o m p le t e H u b ( F ig . 4 2 )
P r e a s s e m b ly o f b e a r in g f la n g e
a ) P r e s s s h im ( 1 ) d o w n u n t il it s it s f ir m ly , u s in g t o o l " B B " , a n d s e c u r e it w it h t h r e e p u n c h
m a rk s .
A t t e n t io n :
T a k e c a r e t o p o s it io n s lo t c o r r e c t ly : A p p r o x . in t h e c e n t r e b e t w e e n b o r e
" B " a n d t h e p in b o r e .
b ) P r e s s t a p e r e d r o lle r b e a r in g in s id e r in g ( 2 ) d o w n u n t il it s it s f ir m ly , u s in g t o o l " A V " .
c ) P la c e p r e a s s e m b le d b e a r in g f la n g e ( 8 ) o n t h e b a s e p la t e u s in g t o o l " Y " .
d ) P la c e t o o l " A X " o n t h e b e a r in g f la n g e t o p r o t e c t t h e r a d ia l s h a f t s e a l r in g .
P r e a s s e m b ly o f h u b
a ) P r e s s r a d ia l s h a f t s e a l r in g ( 4 ) in t o t h e c o r r e c t p o s it io n u s in g t o o l " A W " , ie t h e o p e n
s id e s h o u ld p o in t t o w a r d s t h e t r a n s m is s io n in t e r io r .
b ) P r e s s t a p e r e d r o lle r b e a r in g o u t s id e r in g s ( 3 a n d 5 ) d o w n u n t il t h e y s it f ir m ly u s in g
to o l "A W ".
M o u n t in g t h e b e a r in g f la n g e in t h e h u b
a ) A p p ly t h in c o a t o f g r e a s e t o r a d ia l s e a l r in g ( 7 ) .
b ) P u s h t h e p r e a s s e m b le d h u b ( 9 ) d o w n w a r d s .
c ) G r e a s e t h e s p a c e s n t h e t a p e r e d r o lle r b e a r in g in s id e r in g ( 6 ) b e t w e e n t h e r o lle r s a n d
t h e c a g e u s in g S h e ll A lv a n ia R 3 g r e a s e .
d ) P r e s s t h e t a p e r e d r o lle r b e a r in g in s id e r in g d o w n u n t il it s it s f ir m ly .
e ) R e m o v e t o ll " A X " .
P a g e 1 5
F ig . 4 2
P a g e 1 6
M o u n t in g t h e c o m p le t e h u b in t h e e p ic y c lic u n it
S p e c ia l c a r e is n e e d e d w h e n m e a s u r in g o r c a lc u la t in g t h e b e a r in g s e t t in g
b e c a u s e it is n o t p o s s ib le t o c h e c k th e b e a r in g p r e s t r e s s le v e l o n c e t h e
h u b h a s b e e n m o u n te d . O n n o a c c o u n t s h o u ld t h e r e b e a n y b e a r in g
c le a ra n c e a fte r th e m o u n t in g o p e ra t io n is c o m p le t e d .
S e t t in g t h e b e a r in g p r e s t r e s s le v e l ( F ig . 4 3 )
a ) P la c e t h e m e a s u r in g p la t e o f t o o l " Y " o n t h e e p ic y lc ic u n it ( 1 ) a n d s e t t h e g a u g e o f
to o l "L " a t 0 .
b ) P la c e t h e m e a s u r in g p la t e o n t h e c o m p le t e h u b a n d c o n n e c t t o t h e b a s e p la t e o f t h e
t o o l u s in g t h e c e n t r a l s c r e w .
c ) S e t b e a r in g p r e s t r e s s le v e l N
- S e t b e a r in g f la n g e ( 3 ) a n d t a p e r e d r o lle r b e a r in g in n e r r in g ( 2 ) a t t h e p r e s t r e s s le v e l
u s in g t h e t o o l. T ig h t e n in g t o r q u e N m + / - 1 0 % .
- T u r n h u b ( 4 ) a t le a s t 1 0 t im e s in b o t h d ir e c t io n s t o a llo w t h e r o lle r s in t h e t a p e r e d
r o lle r b e a r in g s t o a lig n t h e m s e lv e s .
- C h e c k N m + /- 1 0 % t ig h t e n in g t o r q u e , t u r n h u b o n c e m o r e .
d ) D e t e r m in e s h im m a s s " X "
- P la c e t h e g a u g e o f t o o l " L " o n t h e m e a s u r in g p la t e a n d m e a s u r e t h e d is t a n c e f r o m th e
p la n e s u r f a c e o f b e a r in g f la n g e ( 3 ) a t t h r e e p o in t s ( s e e F ig . 4 3 ) .
- A d d u p t h e 3 m e a s u r e d m a s s v a lu e s X 1 , X 2 a n d X 3 a n d d iv id e b y 3 .
N o t e : R e m e m b e r t o t a k e a c c o u n t o f t h e t h ic k n e s s o f t h e n ilo s r in g w h e n c a lc u la t in g " X " .

P a g e 1 7
F ig . 4 3
P a g e 1 8
M o u n t in g t h e c o m p le t e h u b ( F ig . 4 4 )
T o e n s u r e m a x im u m s a f e t y in t h e s c r e w c o n n e c t io n b e t w e e n w h e e l h u b
g e a r a n d e p ic y c lic u n it , L o c t it e 2 7 5 s h o u ld b e u s e d in t h e jo in t .
H o w e v e r, a s m o o th u n io n c a n o n ly b e e n s u re d b y re m o v in g a ll t r a c e s
o f o ld L o c t it e , o il a n d g re a s e fro m th e c o n ta c t fa c e s . O n ly u s e o il a n d
g r e a s e s o lv e n t c le a n in g a g e n ts w h ic h le a v e d o n o t f r o m a f ilm (e g
L o c t it e 8 0 6 4 6 t o r e m o v e o ld tra c e s o f L o c t it e a n d t h e L o c t it e 7 0 6 a s
a q u ic k c le a n in g a g e n t).
a ) M o u n t t h e m e a s u r e d s h im s " X " ( 4 ) o n t h e c e n t r e s e c t io n o f t h e e p ic y c lic u n it ( 1 ) .
b ) G r e a s e t h e s e a lin g e d g e o f n ilo s r in g ( 5 ) w it h S h e ll A lv a n ia R 3 g r e a s e a n d m o u n t
t h e n ilo s r in g o n t h e u n it ' s c e n t r e s e c t io n .
c ) P la c e o - r in g ( 2 ) a n d s p r in g p la t e s ( 3 ) in t h e u n it .
d ) C o a t t h e u n it c o n t a c t f a c e s lig h t ly w it h L o c t it e 2 7 5 .
e ) P u s h c o n n e c t in g s le e v e ( 6 ) in t o t h e b e a r in g f la n g e .
f ) M o u n t t h e c o m p le t e h u b o n t h e e p ic y c lic u n it .
E p ic y c lic u n it w it h s a m e b e a r in g f la n g e
- P la c e c y lin d r ic a l p in ( 7 ) in t h e u n it s o t h a t it p r o je c t s a b o u t 2 m m fro m t h e p la n e s u r f a c e s .
- P la c e c o m p le t e h u b ( 9 ) o n t h e u n it .
- C o a t c y lin d e r s c r e w s ( 8 ) w it h L o c t it e 2 7 5 , s c r e w in p la c e a n d t ig h t e n b y h a n d .
- P r e s s d o w n t h e c y lin d r ic a l p in .
- T ig h t e n c y lin d e r s c r e w s . T ig h t e n in g t o r q u e M A = 1 0 8 N m .
E p ic y c lic u n it w it h n e w b e a r in g f la n g e
N o t e : T h e c y lin d r ic a l p in b o r e in t h e b e a r in g f la n g e h a s a p r e d r ille d d ia m . o f 1 3 . 5 .
- M o u n t c o m p le t e h u b ( 9 ) a n d p la c e in c o r r e c t p o s it io n u s in g t o o l " A Y " .
- C o a t c y lin d e r s c r e w s ( 8 ) w it h L o c t it e 2 7 5 , s c r e w in p la c e a n d t ig h t e n b y h a n d . T ig h t e n in g
to rq u e M A = 1 0 8 N m .
- R e m o v e to o l "A Y ".
P a g e 1 9
A t t e n t io n :
M a k e s u r e y o u c o v e r t r a n s m is s io n o p e n in g s b e f o r e d r illin g t o p r e v e n t c h ip s
f r o m g e t t in g in t o t h e g e a r s .
- D r ill o u t t h e p r e d r ille d b o r e ( 1 3 . 5 ) in t h e b e a r in g f la n g e t o a d ia m . o f 1 5 . 8 , t h e n r e a m t h is
t o 1 6 H 7 w it h a r e a m in g b it .
- P u t c y lin d r ic a l p in ( 7 ) in p la c e .
P a g e 2 0
F ig . 4 4
P a g e 2 1
P r e a s s e m b ly O f C o m p le t e E p ic y c lic U n it ( S e e F ig . 4 5 )
E p ic y c lic u n it ( 3 ) a n d c o v e r ( 5 ) a r e d r ille d t o g e t h e r a n d m u s t b e r e p la c e d
jo in t ly w h e n d a m a g e d .
D u r in g a s s e m b ly , t a k e c a r e t h a t t h e s e t n u m b e r s o n t h e e p ic y c lic u n it a n d
th e c o v e r c o rre s p o n d .
a ) P r e s s n e w n e e d le s le e v e s ( 7 ) in t o t h e c o v e r b o r e (5 ) a s f a r a s t h e y w ill g o m a r k in g
s u r e t h a t t h e o p e n s id e is f a c in g u p w a r d s .
b ) P la c e n e e d le r im s ( 6 ) in p o s it io n .
c ) P la c e p la n e t w h e e ls ( 8 ) o n t h e c o v e r .
T h e p la n e t w h e e ls a r e n o t h o u s e d s y m m e t r ic a lly . O n e a c h p la n e t w h e e l
o n e o f th e o u te r te e th h a s a p u n c h m a rk . T h e s e p u n c h m a rk s m u s t b e
v is ib le .
d ) P la c e p la n e t w h e e ls ( 9 ) in p o s it io n in f it n e e d le s h im s (1 2 ) .
e ) P r e s s in n e w n e e d le s le e v e s ( 1 1 ) f lu s h in t o t h e e p ic y c lic u n it (3 ) ; t h e o p e n s id e s h o u ld
p o in t t o w a r d s t h e c o v e r .
f ) P la c e t o o l " A Z " o n t h e c o v e r a s s h o w n in F ig . 4 5 a n d r o t a t e t h e p la n e t w h e e ls u n it t h e
p u n c h m a r k s c o r r e s p o n d t o t h e t e m p la t e m a r k in g s .
g ) P la c e s u n w h e e l ( 4 ) in p o s it io n .
h ) R e m o v e t e m p la t e a n d p la c e h o llo w w h e e l ( 1 0 ) in p o s it io n .
i) P la c e e p ic y c lic u n it c o r r e c t ly o n t h e c o v e r .
k ) A p p ly a t h in c o a t o f o il t o r e a m e d b o lt s ( 2 ) a n d c o r r e s p o n d in g b o r e s .
l) P r e s s in r e a m e d b o lt s a s f a r a s t h e y w ill g o a n d t ig h t e n h e x a g o n n u t s ( 1 ). T ig h t e n in g
to rq u e M A = 4 3 M n .
P a g e 2 2
F ig . 4 5
P a g e 2 3
A s s e m b lin g C o m p le t e E p ic y c lic U n it ( F ig . 4 6 )
a ) F it o - r in g ( 2 ) in t h e c o v e r g r o o v e .
b ) A p p ly a t h in f ilm o f L o c t it e 5 7 4 t o t h e c o n t a c t f a c e o f h u b (8 ).
c ) G u id e c o m p le t e e p ic y c lic u n it ( 3 ) h o r iz o n t a lly in t o t h e h u b . A t t h e s a m e t im e , t u r n
t h e u n it u n t il t h e t e e t h o f s u n w h e e l a n d c o n n e c t in g s le e v e (4 ) a n d h o llo w w h e e l ( 6 )
a n d b e a r in g f la n g e ( 5 ) m e s h .
d ) C o a t c y lin d e r s c r e w s ( 1 ) w it h L o c t it e 2 4 2 a n d s c r e w in p la c e .
e ) P la c e c y lin d r ic a l p in s ( 7 ) in p o s it io n .
f ) T ig h t e n c y lin d e r s c r e w s . T ig h t e n in g t o r q u e M A = ) 4 3 N m .
P a g e 2 4
F ig . 4 6
P a g e 2 5
A s s e m b lin g A n d F it t in g T h e D r iv e U n it
A s s e m b lin g t h e e le c t r ic m o t o r :
B e f o r e a s s e m b lin g , c h e c k t h e m o t o r a n d r e p la c e a n y d a m a g e d p a r t s . C h e c k t h a t c a r b o n
b r u s h e s a r e n o t b u r n t o u t a n d a ls o c h e c k t h e c o m m u t a t io n .
a ) G u id e t h e m o t o r e c a r e f u lly in t o t h e t r a n s m is s io n w h ile t u r n in g t h e h u b .
A tte n t io n :
A v o id a p p ly in g a n y f o r c e w h e n g u id in g it s in c e t h is c o u ld r e s u lt in
d a m a g e t o t h e g e a r t e e t h o n t h e m o t o r s h a f t a n d c o n n e c t in g s le e v e
a n d a ls o t o t h e w in d in g a n d b e a r in g in t h e e le c t r ic m o t o r .
b ) S e c u r e t h e m o t o r in p la c e w it h 6 c y lin d e r s c r e w s f it t e d w it h s p r in g w a s h e r s , t h e n
t ig h t e n t h e s c r e w s . T ig h t e n in g t o r q u e M A = 8 0 N m .
A s s e m b lin g t h e r o t o r w h e e l:
C h e c k t h e c o n t a c t s u r f a c e a n d r e p la c e if t h e r e a n y s ig n s o f e x c e s s iv e a b r a s io n o r
d a m a g e . C h e c k f o r f la t t e n in g o r z o n a l a b r a s io n .
S c r e w t h e r o t o r w h e e l in t h e t r a n s m is s io n u s in g 1 2 h e x a g o n b o lt s , t h e n t ig h t e n b o lt s .
T ig h t e n in g t o r q u e M A = 8 0 N m .
P a g e 2 6
G e n e r a l N o t e s F o llo w in g A s s e m b ly
In c a s e s w h e r e t h e t r a n s m is s io n is t o b e k e p t in s t o r a g e a f t e r a s s e m b ly (e g a s a s p a r e ) ,
p le a s e n o t e f o llo w in g :
- In t r a n s m is s io n s s t o r e d w it h o u t a n e le c t r ic m o t o r , s e a l o f f t h e o p e n in g f o r t h e m o t o r .
- P r e v e r s in g t h e t r a n s m is s io n :
Y o u c a n p r e s e r v e t h e t r a n s m is s io n , f o r e x a m p le , b y f illin g it w it h o il. T u r n t h e p o w e r
t a k e - o f f s h a f t s e v e r a l t im e s a n d d r a in o f f o il.
- P a c k in g t h e t r a n s m is s io n :
S e a le d p la s t ic s h e e t in g w ill s u f f ic e f o r p a c k in g p u r p o s e s , w it h a d r y in g a g e n t p la c e d
in s id e ( e g E H N o . 5 5 4 7 3 m a d e b y H e r r m a n n C h e m ie u n d P a c k m it t e l) .
P a g e 2 7
T ig h t e n in g V a lu e s
It e m D e s ig n a t io n Q u a n t it y T ig h t e n in g T o r q u e
A s s e m b lin g e le c t r ic m o t o r
1 5 C y lin d e r s c r e w s 6 9 ,5 N m
1 4 S p r in g w a s h e r s 6
A s s e m b lin g r o t o r w h e e l
1 2 C y lin d e r s c r e w s 1 2 8 0 N m
1 3 S p r in g w a s h e r s 1 2
A s s e m b lin g d r iv e u n it
2 0 H e x a g o n s c re w s 8 4 6 N m
2 1 S p r in g w a s h e r s 8
F ig . 4 7
P a g e 2 8
S e r v ic e
R e g u la r a n d c a r e f u l c h e c k s , lu b r ic a t io n a n d c le a n in g a r e v it a l t o e n s u r e t h a t
t h e lo a d e r is a lw a y s r e a d y f o r s e r v ic e , r u n s e f f ic ie n t ly a n d h a s a lo n g s e r v ic e
lif e .
A n y c la im s a r is in g f r o m t h e w a r r a n t y w ill b e a c c e p t e d o n ly if r e g u la r s e r v ic e
h a s b e e n c a r r ie d o u t b y t r a in e d p e r s o n n e l a n d o n ly if t h e lu b r ic a n t s a n d
O R IG IN A L B A U M A N N s p a r e p a r t s a u t h o r is e d b y u s h a v e b e e n u s e d .
T h e d e f in it io n s , d e s c r ip t io n s , d ia g r a m s a n d n o t e s lis t e d h e r e c o r r e s p o n d
to th e la t e s t in f o r m a t io n a v a ila b le a t t h e t im e o f g o in g p r in t . M o d if ic a t io n s
m a y a f f e c t s e r v ic e o f y o u r v e h ic le w it h o u t t h is r e s u lt in g in a n y o b lig a t io n s
o n o u r p a rt.
N o t e o n s e r v ic e g iv e n h e r e a r e m e r e ly r e c o m m e n d a t io n s f o r w h ic h w e
a c c e p t n o lia b ilit y . D u r in g a n y w o r k c a r r ie d o u t o n t h is v e h ic le c a r e s h o u ld
b e t a k e n t o e n s u r e t h e p r o t e c t io n o f p e r s o n n e l a n d e q u ip m e n t .
N . B . : In f o r m a t io n o f p a r t ic u la r im p o r t a n c e is s h o w n a s f o llo w s :
P a g e 1
G e n e ra l
T h e B A U M A N N f o r - w a y e le c t r ic s id e lo a d e r is a v e r y r o b u s t m a c h in e . E v e n s o , if
y o u a r e t o g a in g r e a t e s t b e n e f it f r o m it , t h e o ld m a x im u m a p p lie s : " P re v e n t io n is
b e tte r t h a n c u r e . " R e g u la r , e x p e r t m a in t e n a n c e is t h e b e s t re m e d y o f a ll. B y
im m e d ia t e ly t r a c in g t h e c a u s e o f a n y ir r e g u la r it y n o t e d b y t h e d r iv e r , m o s t r e p a ir
w o rk c a n b e a v o id e d .
M a in t e n a n c e S c h e d u le
In a c c o r d a n c e w it h t h e " c u s t o m e r s e r v ic e b o o k le t " d u r in g t h e w a r r a n t y p e r io d , t h e r e a f t e r e v e r
5 0 0 h o u rs .
M a in t e n a n c e W o r k
B y t h is w e m e a n a ll r e c u r r in g m a in t e n a n c e w o r k t h e r e q u ir e d f r e q u e n c y o f w h ic h is
s t a t e d in t e r m s o f o p e r a t in g h o u r s .
1 . O il a n d lu b r ic a n t s u p p ly :
a ) L u b r ic a t io n c h a rt
T h is s h o w s t h e v a r io u s lu b r ic a t io n p o in t s g r o u p e d t o g e t h e r u n d e r o p e r a t in g h o u r s .
T h e n u m b e r g iv e n f o r t h e t y p e o f lu b r ic a n t r e f e r s t o t h e r e le v a n t n u m b e r in t h e
lu b r ic a t io n c h a rt.
b ) L u b r ic a t io n t a b le
T h is t a b le lis t s lu b r ic a n t t y p e s g r o u p e d a c c o r d in g t o a p p lic a t io n a n d t h e p r o d u c t s
r e c o m m e n d e d b y v a r io u s o il c o m p a n ie s .
2 . B a tte ry
P le a s e r e f e r t o t h e s e p a r a t e s e c t io n c o n t a in in g d e t a ile d in s t r u c t io n s .
3 . H y d r a u lic t a n k
O il c a p a c it y a p p r o x . c a . 6 0 L it r e s
a ) O il c h e c k : S e e a f t e r c u s t o m e r s e r v ic e b o o k le t
b ) 1 s t o il c h a n g e : A f t e r 1 0 0 O p e r a t in g h o u r s
c ) S u b s e q u e n t c h a n g e s : A fte r e v e ry 1 0 0 0 h o u rs .
R e a ) a n d c ) : D u r in g o il c h a n g e s t h e f ilt e r in s e r t in t h e r e t u r n f ilt e r m u s t a ls o b e c h a n g e d .
P a g e 2
4 . L u b r ic a t io n ( lu b r ic a t in g p o in t s a s p e r lu b r ic a t io n c h a r t )
A s in d ic a t e d in c u s t o m e r s e r v ic e b o o k le t , m o r e f r e q u e n t ly if n e c e s s a r y .
a ) L u b r ic a t e a ll c o n ic a l g r e a s e n ip p le s u s in g a g r e a s e g u n . C h a n g e a n y d a m a g e d
o r c lo g g e d n ip p le s w it h o u t d e la y .
b ) L u b r ic a t e a ll o t h e r m o v in g p a r t s s u c h a s p a w ls , b a ll a n d s o c k e t jo in t s , f o r k jo in t s
f o r c o n t r o ls , e t c . a s o f t e n a s p o s s ib le w it h t w o d r o p s o f o il.
5 . L o a d c h a in s (a s in d ic a t e d in a f t e r c u s t o m e r s e r v ic e b o o k le t )
R e m o v e a ll d ir t y a n d u s e d g r e a s e a f t e r e v e r y 1 0 0 0 o p e r a t in g h o u r s . In a d d it io n ,
r e m o v e c h a in s , c le a n in D ie s e l f u e l a n d r e g r e a s e a c c o r d in g t o t h e lu b r ic a t io n
c h a rt.
6 . H y d r a u lic s y s t e m
N o m a in t e n a n c e n e e d e d ! E v e n s o , c h e c k e a c h d a y f o r le a k s a n d g o o d p e rfo rm a n c e .
T h e s e a le d p r e s s u r e - r e lie f v a lv e in t h e c o n t r o l u n it m u s t n o t b e a d ju s t e d . T h is is a
t e r m o f t h e w a r r a n t y ! A n y ir r e g u la r it ie s c a n u s u a lly b e tra c e d to n o rm a l w e a r a n d
t e a r in t h e s e a ls . A n y n e c e s s a r y m o d if ic a t io n s ( e g n e w s e a ls ) s h o u ld b e e n tru s te d
t o t r a in e d p e r s o n n e l o n ly . C a r e s h o u ld b e g iv e n t o p r o p e r v e n t in g . F o r t h is , e a c h
h y d r a u lic c y lin d e r s h o u ld b e f u lly e x t e n d e d in a n d o u t . S p e c ia l c a r e o f t h e s te e r
h y d r a u lic s m u s t b e t a k e n . It is r e c o m m e n d e d t o c h a n g e h y d r a u lic h o s e s a f t e r s ix
y e a r s o f o p e r a t io n (s e e d a t e o n h o s e s ).
7 . S t e e r in g (s t a n d a r d ) E 4 S
O il s u p p ly v ia t h e c e n t r a l h y d r a u lic t a n k .
M e c h a n ic a l p a r t s s h o u ld b e c h e c k e d in a c c o r d a n c e w it h t h e a f t e r - s a le s m a n u a l.
O p t io n :
If r e q u ir e d , a n e le c t r o n ic s t e e r in g s y s t e m c a n b e u s e d . S e e t h e s e c t io n e n t it le d :
" E le c t r o n ic S t e e r in g " .
S t e e r in g is b y m e a n s o f a s te e r in g o r b it r o l c o n t r o lle d b y th e s te e r in g w h e e l. A s t e e r in g
c y lin d e r lo c a t e d in th e c e n tre o f th e v e h ic le s te e rs th e tw o d r iv e w h e e ls d u r in g s t r a ig h t
d r iv e . S t e e r in g d u r in g tra n s v e r s e d r iv e is b y m e a n s o f a h y d r a u lic m o t o r in w h e e l 2
u n d e r t h e p la t f o rm . In t h is m o d e th e d r iv e m o to rs c a n b e s w it c h e d o ff to a s s is t s t e e r in g
if r e q u ir e d .
P a g e 3
8 . E le c t r ic a l s y s t e m
N o n e e d f o r m a in t e n a n c e ! E v e n s o , c h e c k f o r c o r r e c t f u n c t io n e a c h d a y . It is n o t
e n o u g h to s e e w h e th e r a ll la m p s o n th e d a s b o a rd c o m e o n u s in g a t o u c h in g k e y ,
th e y m u s t c o m o n v ia t h e ir a s s o c ia te d w a r n in g s w it c h e s a n d c o n ta c t o r s . It is
e s p e c ia lly im p o r t a n t th a t a ll w a r n in g a n d s a fe ty fe a tu re s a re c h e c k e d r e g u la r ly .
9 . B re a k s y s te m
B r a k e lin in g s w e a r o u t ! Y o u t h e r e f o r e n e e d t o c h e c k t h e lin in g s in t h e d r iv e w h e e l
b r a k e c la m p s r e g u la r ly a n d r e p la c e w h e r e n e c e s s a r y . T h e o t h e r w h e e ls a r e n o t
f it t e d w it h b r a k e s .
P r e p a r a t io n s p r io r t o h a n d in g o v e r a v e h ic le .
T h e a c c e p t a n c e c e r t if ic a t e a t t a c h e d t o t h e c u s t o m e r s e r v ic e b o o k le t c o n t a in s t h e f o llo w in g
jo b s t h a t h a v e t o b e c a r r ie d o u t b y t h e a u t h o r is e d d e a le r :
P o in t 2 : C h e c k h y d r a u lic s c r e w c o n n e c t io n s f o r le a k s a n d r e t ig h t e n if n e c e s s a r y .
P o in t 7 : C h e c k t h a t m a s t , lo a d c h a in s , e x t e n s io n c h a in s a n d r o lle r s a r e in g o o d
w o r k in g o r d e r , c h e c k m a s t s e t t in g .
P o in t 8 : R e t ig h t e n a ll s c r e w c o n n e c t io n s in t h e h y d r a u lic c y lin d e r s .
P o in t 1 1 : C a r r y o u t a t e s t r u n w it h lo a d in t h e p r e s e n c e o f t h e o p e r a t o r a n d h a n d
o v e r t h e lo a d e r .
A d a p t t h e b a t t e r y c h a r g e r t o t h e lo c a l p o w e r s u p p ly . C h e c k t h e p a r a m e t e r s e t t in g s o f t h e
c o n t r o lle r a n d s t e e r c o m p u t e r .
C o n f ir m t h e c h e c k r id e , in s t r u c t io n o f o p e r a t o r s w it h t h e a t t a c h e d " c u s t o m e r s e r v ic e b o o k le t "
fo rm . F o rm to b e s e n t b a c k to B a u m a n n .
P a g e 4
S e r v ic e A n d R e p a ir S a f e t y M e a s u r e s
1 . T h e o p e r a t in g a n d m a in t e n a n c e in s t r u c t io n s s u p p lie d w it h t h e lo a d e r m u s t b e a d h e r e d
t o . P le a s e m a k e s u r e t h a t y o u h a v e t a k e n c a r e f u l n o t e o f a ll r e f e r e n c e s t o h a z a r d s .
2 . B e f o r e c a r r y in g o u t a n y w o r k , u n p lu g t h e m a in b a t t e r y p lu g .
3 . O n ly u s e t o o ls t h a t a r e in g o o d w o r k in g o r d e r a n d h a v e b e e n p r o p e r ly in s u la t e d .
K e e p b o t h t h e c o m p o n e n t a n d y o u r w o r k s p la c e in g o o d o r d e r .
4 . A lw a y s p la c e a n " o u t o f o r d e r " s ig n o n t h e d a s h b o a r d w h e n e v e r s u c h w o r k is
b e in g c a r r ie d o u t .
5 . A lw a y s u s e w e d g e s o r a p p r o p r ia t e s u p p o r t s t o p r o t e c t t h e lo a d e r o r p a r t s o f it f r o m
r o llin g o r f a llin g .
6 . D o n o t a t t e m p t t o m o v e h e a v y o b je c t s b y h a n d . A lw a y s u s e s u it a b le h o is t s a n d
s e c u r e a n y r a is e d lo a d s a g a in s t f a llin g .
7 . M a k e s u r e t h a t a ll n u t s , b o lt s , c ir c lip s a n d o t h e r f ix in g p a r t s a r e u n t ig h t e n e d o r
r e m o v e d b e f o r e a p p ly in g a n y f o r c e .
8 . If y o u n e e d t o lif t in d iv id u a l p a r t s o r s u b a s s e m b lie s , m a k e s u r e t h a t a ll b e lt s , c h a in s
o r p u lle y s a r e p r o p e r ly s e c u r e d a b o v e t h e c e n t r e o f g r a f it y . C h e c k t h a t y o u r lif t in g
g e a r h a s t h e r e q u ir e d lif t in g c a p a c it y .
9 . D u r in g t h e c h a r g e p r o c e s s b a t t e r ie s p r o d u c e a n e x p lo s iv e g a s . K e e p a w a y f r o m
n a k e d f la m e s a n d s p a r k s . M a k e s u r e t h e w o r k p la c e is w e ll v e n t ila t e d .
1 0 . W e ld in g w o r k s h o u ld o n ly b e c a r r ie d o u t b y t r a in e d w e ld e r s . S a f e t y g o g g le s m u s t
b e w o r n . D is c o n n e c t a n y e le c t r o n ic p a r t s p r io r t o e le c t r ic w e ld in g .
1 1 . B e f o r e s t a r t in g a n y w o r k , r e m o v e a ll m e t a llic o b je c t s f r o m c lo t h in g s u c h a s r in g s ,
w r is t w a t c h e s a n d c h a in s .
1 2 . W h e n c a r r y in g o u t w o r k o n t h e p u ls e c o n t r o l s y s t e m p le a s e r e m e m b e r t h a t t h e
c o n d e n s e r s c a n c o n d u c t h ig h v o lt a g e s e v e n a f t e r t h e t r u c k h a s b e e n s w it c h e d o f f .
1 3 . O n ly u s e o r ig in a l B A U M A N N s p a r e p a r t s .
P a g e 5
I. D a ily C h e c k s
- T a k e a r a n d o m o f 5 b a t t e r y c e lls f o r t e s t in g . T e s t d if f e r e n t c e lls e a c h d a y . T h e c e lls s h o u ld
d is p la y t h e s a m e c h a r g e a n d t h e c o r r e c t a c id le v e l.
- C h e c k t h e S id e lo a d e r f o r a n y le a k s ( e g p a t c h e s o f o il) .
- C h e c k h y d r a u lic f lu id le v e l
- D u r in g t h e t im e o f r u n n in g in t h e t r u c k , g r e a s e r e a c h r a ils o n t h e v e r t ic a l s id e b e h in d t h e
s lid in g p a d s .
II. R e g u la r M a in t e n a n c e A c c o r d in g T o C u s t o m e r S e r v ic e B o o k le t
G e n e ra l
T h e f o llo w in g s ig n s m u s t b e c le a r ly v is ib le o n t h e t r u c k :
- T y p e p la t e f o r S id e lo a d e r s .
- L o a d d ia g r a m , f o r m o r e t h a n 3 . 3 0 0 m m lif t w it h lo a d r e d u c t io n .
- 2 s ig n s t h a t r e a d : " D o n o t w a lk u n d e r lo a d s / d o n o t c a r r y p a s s e n g e r s " .
- S a f e t y r e g u la t io n s .
- 1 f u n c t io n s y m b o l f o r e a c h c o n t r o l le v e r .
A u x illa r y e q u ip m e n t m a y r e q u ir e s p e c ia l w a r n in g s ig n s . If t h is is t h e c a s e ,
m a k e s u r e t h a t t h e s e t o o a r e d is p la y e d . O b s e r v c e r e g u la t io n s c o v e r in g
t h e d is p o s a l o f w a s t e m a t e r ia l.
P a g e 6
P o in t 1 : C h e c k in g a n d c h a n g in g o ils ; c le a n in g a n d r e p la c in g f ilt e r s .
A ll o ils a n d f ilt e r s s h o u ld b e c h a n g e d a f t e r 1 0 0 o p e r a t in g h o u r s . A f t e r 5 0 0
h o u r s f ilt e r s a r e c h a n g e d a s r e q u ir e d . A f t e r 1 0 0 0 h o u r s c h a n g e a ll o ils a n d
f ilt e r s a g a in .
O b s e r v e r e le v a n t r e g u la t io n s c o v e r in g t h e d is p o s a l o f lu b e o ils
a n d o p e r a t in g m e d ia .
a ) H y d r a u lic o il a n d h y d r a u lic o il f ilt e r s ( s u c t io n f ilt e r s ) :

- C h a n g e t h e h y d r a u lic a t o p e r a t in g t e m p e r a t u r e s (a p p r o x . 4 0 ° C ).
- R u n o u t t h e e x t e n s io n g e a r , d ip t h e p la t f o r m d o w n w a rd s .
- D r a in t h e o il ( if n e e d b e , p u m p a w a y u n d e r p r e s s u r e ).
- L o o s e n t h e s c r e w s in t h e o il s u m p ( F ig . 1 ) , d r a in t h e o il.
- U n s c r e w t h e f o u r s c r e w s in t h e o il in le t s o c k e t . A fte r re m o v in g t h e c o v e r
(F ig . 2 ) a lo n g w it h t h e in le t s o c k e t a n d s ie v e , y o u w ill s e e t w o h y d r a u lic
f ilt e r s in t h e s u m p . C h e c k t h e c o v e r g a s k e t a n d r e p la c e if n e c e s s a ry .
- U n s c r e w f ilt e r s b y t u r n in g t o t h e le f t .
- C le a n t h e h y d r a u lic t a n k .
- F it n e w f ilt e r s .
In t h e m u lt i- d ir e c t io n a l v e r s io n ( E M S , E V S ), y o u a ls o n e e d t o r e p la c e
t h e h ig h p re s s u r e f ilt e r ( c a r d t r id g e ) s h o w n in th e h y d r a u lic s d ia g r a m
a fte r th e s te e r in g p u m p . T h e f ilt e r is lo c a t e d in th e fra m e n e x t to
th e tw o h y d r a u lic p u m p u n it s . R e p la c e f ilt e r h o u s in g f ille d w it h o il
t o a v o id a ir in t h e s t e e r in g s y s t e m .
- W it h lif t in g c y lin d e r s o f s iz e s 1 a n d 2 t h e c y lin d e r a ls o s e r v e s a s a t a n k . Y o u

t h e r e f o r e n e e d t o d r a in o il a s f o llo w s :
* R u n o u t th e e x te n s io n g e a r , d ip t h e p la t f o r m d o w n w a rd s .
* R a is e t h e m a s t f o f u ll lif t .
* D r a in t h e o il.
* L o w e r th e fo rk s to g r o u n d le v e l (t h is d r a in s t h e lif t c y lin d e r c o m p le t e ly ) .
* C o n t in u e b y c h a n g in g f ilt e r s a s a b o v e .
- R e p la c e t h e c o v e r p lu s in le t s o c k e t a n d s ie v e a n d t ig h t e n .
- F ill w it h h y d r a u lic o il o f c o r r e c t s p e c if ic a t io n t h r o u g h t h e s ie v e in t h e in le t
s o c k e t.
- W it h lif t in g c y lin d e r s o f s iz e s 1 a n d 2 t h e c y lin d e r n e e d s t o b e e x t e n d e d t o it s
f u ll lif t s e v e r a l t im e s t o f ill it .
- C h e c k th e o il le v e l in t h e s p y g la s s a n d t o p u p if n e e d b e . T h e a m o u n t r e q u ir e d
ra n g e s fro m 5 0 to 8 0 lit r e s d e p e n d in g o n f r a m e d e s ig n a n d c y lin d e r t y p e .
P a g e 7
F ig . 1
F ig . 2
P a g e 8
F ig . 3
P a g e 9
b ) T r a n s m is s io n o il f o r t h e t w o d r iv e w h e e ls ( f ig . 4 )
- W a r m u p t h e t r a n s m is s io n o il.
- T u r n t h e d r iv e w h e e l s o t h a t t h e n a m e " H U R T H " is h o r iz o n t a l.
- U n s c r e w t h e o il le v e l s c r e w a n d o il d r a in s c r e w .
- A f t e r d r a in in g o f f t h e o il, s c r e w t h e d r a in s c r e w b a c k in .
- F ill w it h n e w o il. T h e a m o u n t r e q u ir e d is a p p r o x . 0 , 4 l, h o w e v e r n o lo w e r t h a n t h e
le v e l m a r k e d " in le t s o c k e t lo w e r le v e l" ( S A E 8 0 W 9 0 ).
- R e t ig h t e n t h e o il le v e l s c r e w .
N e w t r a n s m is s io n s a r e n o r m a lly s u p p lie d w it h o u t o il. O b s e r v e

r e g u la t io n s c o v e r in g t h e d is p o s a l o f w a s t e o il.
P o in t 2 : C h e c k in g h y d r a u lic s c r e w c o n n e c t io n s f o r le a k s / t ig h t e n in g
a ) In a d d it io n t o th e " d a ily c h e c k s " , t h e f o llo w in g s c r e w c o n n e c t io n s s h o u ld b e

c h e c k e d a n d t ig h t e n e d w h e r e n e c e s s a r y . T h e c o n n e c t io n is c o n s id e r e d
a d e q u a t e if it c lo s e s t ig h t ly . S c r e w c o n n e c t io n s t h a t c a n n o t b e r e t ig h t e n e d
m u s t b e r e p la c e d .
A ll s c r e w c o n n e c t io n s :
1 . U n d e r t h e c a b in e (t ilt t h e c a b ) .
2 . O n t h e c o n t r o l s lid e v a lv e .
3 . In t h e s t e e r in g c y lin d e r ( r e m o v e b a t t e r ie s ) .
4 . In t h e h y d r o m o t o r o n a x le 2 .
5 . In E M S lo a d e r s , in h y d r o m o t o r s o n a x le s 1 t o 4 ( e le c t r o n ic s t e e r in g ) .
6 . O n t h e h y d r a u lic t a n k .
7 . O n t h e s t e e r in g / m a in p u m p .
8 . O n p r o p o r t io n a l v a lv e s o n a x le s 1 a n d 2 (e le c t r o n ic s t e e r in g ) .
9 . O n p r o p o r t io n a l v a lv e s o n a x le s 3 a n d 4 (e le c t r o n ic s t e e r in g ) .
1 0 . In E M S lo a d e r s , in t h e h ig h - p r e s s u r e f ilt e r in t h e s t e e r in g c ir c u it .
1 1 . O n b o t h h y d r o m o t o r s in t h e e x t e n s io n g e a r .
1 2 . O n t h e lif t f r a m e .
1 3 . A ll h o s e c o n n e c t io n s .
P a g e 1 0
P o in t 3 : C h e c k in g t e n s io n in g u id e c h a in a n d o t h e r c h a in s , lu b r ic a t in g a n d r e t ig h t e n in g .
a ) G u id e c h a in (lin k e d c h a in )
- C h e c k t e n s io n : T h e g u id e c h a in s h o u ld b e t a u g h t a n d s h o u ld g iv e
o n ly s lig h t ly w h e n p r e s s e d .
- C h e c k a lig n m e n t : In e a c h t u r n t a b le a 1 3 m m d ia . b o r e h a s b e e n c u t
in t o t h e f ix e d a n d m o v e a b le s e c t io n s . If t h e s e
b o r e s a r e a lig n e d o n e c o v e r t h e o t h e r , t h e w h e e l
is in e x a c t t r a n s v e r s e p o s it io n ( b r a k e d is c s o n t h e
o u t s id e ) .
- T ig h t e n in g s t e e r c h a in : T ig h t e n o r s la c k e n t h e s c r e w s h a c k le a n d c h a in
s u p p o r t in t h e s t e e r in g c y lin d e r u n t il t h e c o r r e c t
c h a in t e n s io n a n d w h e e l a lig n m e n t a r e a c h ie v e d .
- O ilin g g u id e c h a in : T o p re s e r v e c h a in lif e , o il t h e s e c t io n r u n n in g
a b o v e t h e t a il p u lle y s . A s p r a y - o n c h a in o il s h o u ld
b e u s e d . O il b e f o r e t ig h t e n in g .
- T a il p u lle y s : T h e p u lle y s h o u ld t u r n e a s ily . L u b r ic a t e b e a r in g s
if n e e d b e .
- M e t ic u lo u s c a r e s h o u ld b e t a k e n t o e n s u r e t h a t t h e g u id e c h a in r u n s in
p r e c is e a lig n m e n t in t o t h e t u r n t a b le f r o m t h e t a il p u lle y .
- C h e c k t h e t u r n t a b le a n d t a il p u lle y lip s d a m a g e .
- In t h e c a s e o f lin k e d g u id e c h a in s a ll s h o e s s h o u ld b e c h e c k e d , if n e e d b e
r e p la c e d .
b ) E x te n s io n g e a r c h a in s ( F ig . 5 )
- R e m o v e a n d c le a n c h a in s ( u s in g D ie s e l o il) e v e ry 1 0 0 0 h o u rs .
- U s e s p r a y - o n o il f o r lu b r ic a t io n . w h e n c h a in is n o t t ig h t u p .
- R e f it c h a in s a n d t ig h t e n . W h e n t e n s io n e d c o r r e c t ly , t h e c h a in c a n b e p re s s e d
d o w n a t th e c e n tre u p t o 5 m m d e p e n d in g o n p la t f o r m w id t h . T o o h ig h a
te n s io n w ill d a m a g e t h e b e a r in g s . C h a in t e n s io n m u s t b e a b s o lu t e ly e q u a l
o n b o t h c h a in s .
c ) S te e r in g m o to r c h a in ( s ) F ig . 6
- R e m o v e a n d c le a n c h a in ( u s in g D ie s e l o il) e v e r y 1 0 0 0 h o u r s .
- U s e s p ra y -o n o il f o r lu b r ic a t io n , b e f o r e t ig h t e n in g .
- R e f it c h a in s a n d t ig h t e n .
d ) L if t c h a in s
- R e m o v e a n d c le a n c h a in s (u s in g D ie s e l o il) e v e ry 1 0 0 0 h o u rs .
- U s e s p r a y - o n o il f o r lu b r ic a t io n , w h e n c h a in is n o t t ig h t u p .
- R e f it c h a in s a n d t ig h te n , th e c o rr e c t c h a in le n g t h is s e t w h e n th e fo rk s a re
a p p ro x . 5 m m fro m th e g ro u n d w it h f o r k s a n d p la t f o r m h o r iz o n t a l a n d t h e
lif t c y lin d e r r e t r a c t e d . (C h e c k c h a i fo r w e a r a n d te a r b e f o r e r e f it . R e f . 7 b ).
P a g e 1 1
F ig . 4
F ig . 5
P a g e 1 2
P o in t 4 : L u b r ic a t in g w h e e l b e a r in g s , t u r n t a b le s , f o r k c a r r ia g e s , c a s t o r s a n d r o lle r a s w e ll
a s lin k a g e in t h e m a s t ( s e e lu b r ic a t io n c h a r t ) .
G r e a s e N ip p le s : K e e p t h e g r e a s e g u n p r e s s e d u n t il n e w g r e a s e is f o r c e d
f r o m t h e b e a r in g . W ip e a w a y e x c e s s g r e a s e .
a ) W h e e l b e a r in g s , a x le s 2 a n d 3 ( f ig . 7 ) o n e g r e a s e n ip p le p e r a x le .
b ) T u r n t a b le s ( o n s t a n d a r d s te e re d tru c k s o n ly ) , a x le s 1 t o 4 ( F ig . 8 )
- A x le 1 : T ip d r iv e r's c a b , tw o g r e a s e n ip p le s .
- A x le 2 + 3 : R e m o v e p la s t ic p lu g a b o v e th e a x le o n t h e p la t f o r m a n d
tu rn th e w h e e l u n t il t h e g re a s e n ip p le a p p e a rs .
- A x le 4 : T w o g re a s e n ip p le s a c c e s s ib le fro m o u t s id e ( in la t e r v e r s io n s ) .
O ld v e r s io n : L if t t h e s m a ll b a t t e ry tra y .
c ) F o r k c a r r ia g e s :
- 4 c a r r ia g e r o lle r s : G r e a s e N ip p le
- 2 t ilt c y lin d e r s : 1 d ro p o f o il o n e a c h t u r n in g a x le ( F ig . 9 ); 1 d r o p o f o il
o n th e s u p p o r t b a r h o u s e in g ( F ig . 1 0 ) . G r e a s e t h e b a ll-
a n d -s o c k e t jo in t b e t w e e n t ilt c y lin d e r a n d f o r k c a r r ia g e .
d ) C a s to rs : S e e a ) a n d b )
e ) M a s t r o lle r s : O n e g r e a s e n ip p le e a c h ( F ig . 1 1 )
- t w o f o ld lif t f r a m e : 4 m a s t r o lle r s
- T h r e e f o ld lif t f r a m e : 8 m a s t r o lle r s
f) L in k a g e : A p p lic a b le o n ly t o a d d e d a x u llia r ie s .
g ) C ro s s h e a d : 2 g r e a s e n ip p le s ( F ig . 1 2 ) .
h ) C r o s s h e a d g u id e (F ig . 1 2 ): G r e a s e s q u a r e d e d g e o n a ll f o u r s id e s .
j) L if t f r a m e c o n t a c t s u r f a c e s :
T h e s e s h o u ld b e c le a n e d , n o t o ile d o r g r e a s e d . M a s t r o lle r s s h o u ld r o ll b u t
n o t s lid e .
k ) F o r k c a r r ia g e s lid in g s u r f a c e s ( F ig . 1 3 ):
T h e e n d f a c e s m u s t n o t b e o ile d o r g r e a s e d . T h e s u r f a c e s o n w h ic h t h e f o r k
h o o k s s lid e u p a n d d o w n m u s t b e g r e a s e d .
l) E x t e n s io n t r a c k s lid in g s u r f a c e s ( F ig . 1 4 ) :
G r e a s e t o t w o f a c e s o n w h ic h t h e p la s t ic e le m e n t s o f t h e e x t e n s io n g e a r s lid e .
W h e r e n e c e s s a r y , s lid in g c o n t a c t s s h o u ld b e f it t e d w it h s p a c e r s .
m ) E x t e n s io n t r a c k c o n t a c t s u r f a c e s ( F ig . 1 4 ) :
A s w it h j) , t h e s e s h o u ld b e c le a n e d b u t n e v e r g r e a s e d .
n ) R e a c h c a h in s p r o c k e t w it h g r e a s e n ip p le s :
G r e a s e t h r o u g h t h e o p e n in g o f t h e c h a s s is .
M a in te n a n c e
E le c tr ic S id e lo a d e r
P a g e 13
F ig . 6
F ig . 7
P a g e 1 4
F ig . 8
F ig . 9
P a g e 1 5
F ig . 1 0
F ig . 1 1
Is s u e 0 3 /2 0 0 6
P a g e 1 6
F ig . 1 2
F ig . 1 3
P a g e 1 7
F ig . 1 4
D o n o t g re a s e h e re !
P a g e 1 8
P o in t 5 : C h e c k in g , if n e c e s s a r y r e s e t t in g , s e r v ic e b r a k e a n d p a r k in g b r a k e .
A p r o p e r ly f u n c t io n in g b r a k e s y s t e m is d e p e n d e n t o n t h e c o r r e c t le v e l o f b r a k e
f lu id in t h e s e t t lin g t a n k ( F ig . 1 5 ) . T h e t a n k is lo c a t e d d ir e c t ly o n t h e m a in b r a k e
c y lin d e r o r , w it h c e r t a in o n e - o f f v e r s io n s , in t h e d r iv e r ' s c a b .
a ) C h e c k t h e s e r v ic e b r a k e f o r le a k s a n d d a m a g e :
W h e n t h e b r a k e p e d a l is p r e s s e d t h e r e s h o u ld b e a f r e e p la y o f a p p r o x . 5 m m
b e f o r e t h e b r a k e b e c o m e s e f f e c t iv e .
S e t t in g : O n ly p o s s ib le o n t h e w h e e l b r a k e c y lin d e r . L o o s e n t h e
c o u n t e r n u t o n t h e b r a k e c o n e , t u r n t h e c o n e u n t il c o r r e c t
c le a r a n c e is a c h ie v e d . R e t ig h t e n c o u n t e r n u t .
b ) P a rk in g b r a k e :
T h e p a r k in g b r a k e a c t s o n t h e s a m e m a in b r a k e c y lin d e r a s t h e s e r v ic e
b ra k e . th e re fo r e a lw a y s c h e c k a n d s e t t h e s e r v ic e b r a k e f ir s t , f o llo w e d b y t h e
p a rk in g b r a k e . T h e h a n d b r a k e le v e r is a d e a d p o in t le v e r , t h e t r a n s m is s io n
r a t io b e in g a p p ro x . 1 :6 0 .
- S e t t in g a n d t e s t in g ( F ig . 1 6 )
P r e s s t h e s e r v ic e b r a k e p e d a l t o t h e m a x im u m e x t e n t , n o r m a lly r e q u ir e d
d u r in g t r a v e l. T u r n t h e h a n d b r a k e le v e r k n o b in t h e ( - ) d ir e c t io n u n t il t h e t e n s io n
h a s re d u c e d to th e p o in t w h e r e t h e le v e r c a n b e b r o u g h t e a s ily in t o it s e n d
p o s it io n .
W it h t h e f o o t b r a k e o n , tu rn th e h a n d b r a k e le v e r k n o b in t h e ( + ) d ir e c t io n u n t il
y o u f e e l a s lig h t s la k e n in g (a p p r o x . 1 m m ) . T h e c lo s in g f o r c e r e q u ir e d f o r
th e le v e r is t a k e n a s a c o n tr o l. B e c a u s e o f t h e h ig h t r a n s m is s io n r a t io , it
s h o u ld b e n o m o re th a n 3 0 N (3 k g ).
c ) C h e c k in g b r a k e lin in g s
B r a k e lin in g s s h o u ld b e c h a n g e d o n c e t h e s e m i- r o u n d n o t c h is n o lo n g e r
v is ib le o r if t h e m in im u m t h ic k n e s s o f 3 m m is n o lo n g e r g u a r a n t e e d (F ig . 1 7 ) .
d ) C h e c k in g b r a k e d is c s
A b r a k e d is c s h o u ld b e r e p la c e d if it s t h ic k n e s s is le s s t h a n 8 m m .
B e f o r e t a k in g m e a s u r e m e n t s , r e m o v e a n y b u r r s . N e w b r a k e lin in g s
s h o u ld b e f it t e d w h e n e v e r a b r a k e d is k is r e p la c e d .
P a g e 1 9
F ig . 1 5
F ig . 1 6
P a g e 2 0
P o in t 6 : H y d r a u lic p r e s s u r e in t h e s t e e r in g h y d r a u lic s a n d m a in h y d r a u lic s s y s t e m s
a ) S t e e r in g h y d r a u lic s
T h e p re s s u re s e t b y th e m a n u fa c tu r e r is g iv e n in th e d a t a s h e e t a n d s h o u ld
n o t b e e x c e e d e d . In g e n e r a l, th e p re s s u r e is s e t to a p p ro x . 1 0 0 to 1 2 0 b a r
(d e p e n d in g o n m o d e l). P re s s u re is c h e c k e d u s in g th e m in i m e a s u r in g s o c k e t
lo c a t e d u n d e r t h e d a s h b o a rd o n th e o rb it r o l (F ig . 1 8 ).
b ) M a in h y d r a u lic s
T h e m a n u f a c t u r e r lim it s t h e m a x im u m p re s s u r e t o a llo w t h e r a t e d lif t in g lo a d
p lu s a p p r o x . 5 % t o b e h o is t e d . T h e p re s s u re - r e lie f v a lv e is s e a le d f o r s a f e t y
r e a s o n s a n d m u s t n o t b e a d ju s te d . P re s s u re s e t t in g is e f f e c t e d f o r e a c h lo a d e r
in d iv id u a lly d e p e n d in g o n r a t e d lo a d , f o r k d im e n s io n s , s p e c ia l a t t a c h m e n t s
a n d o v e r a ll e f f ic ie n c y . P r e s s u r e c a n b e c h e c k e d u s in g t h e m in i m e a s u r in g
s o c k e t in t h e m a in h y d r a u lic s p u m p ( F ig . 1 9 ). T h e p r e s s u r e g a u g e s h o u ld
h a v e a ra n g e u p to 2 5 0 b a r. T h e m a in h y d r a u lic s y s t e m s p r e s s u r e s e t b y t h e
m a n u f a c t u r e r is g iv e n in t h e d a ta s h e e t a n d s h o u ld n e v e r b e e x c e e d e d .
P a g e 2 1
F ig . 1 7
F ig . 1 8
P a g e 2 2
P o in t 7 : C h e c k in g t h a t m a s t , lo a d c h a in s , e x t e n s io n c h a in s a n d r o lle r s a r e in g o o d
c o n d it io n , c h e c k in g m a s t s e t t in g
a ) M a s t
- A re th e re a n y s ig n s if o m p a c t d a m a g e o r e x c e s s iv e lo a d in g ?
- A n y c ra c k s v is ib le ?
- A n y c ra c k s in t h e w e ld s e a m s , in p a r t ic u la r b e t w e e n t h e m a s t p r o f ile a n d
e x te n s io n g e a r?
W h e n c h e c k in g t h e m a s t , c h e c k a ls o t h e f r a m e s e c t io n s o f t h e lo a d e r f o r a n y
c r a c k s . T h is is p a r t ic u la r ly im p o r t a n t a t t h e t r a n s it io n p o in t s b e t w e e n p la t f o r m
a n d t h e lo n g it u d in a l s e c t io n o f t h e f r a m e .
L e a k a g e : A t t h e r a t e d lo a d (f o r m a x . lif t in g lo a d s e e t h e lo a d d ia g r a m ) t h e
g o o d s - c a r r y in g s e c t io n s h o u ld f a ll b y n o m o r e t h a n 4 0 m m in
5 m in u t e s a n d t h e lif t f r a m e s h o u ld n o t t ilt u n in t e n t io n a lly .
b ) C h e c k in g lo a d c h a in s
E lo n g a t io n o f t h e lo a d c h a in s s h o u ld b e c h e c k e d . T o d o th is , h o is t a lo a d o f a t
le a s t 1 t a n d m e s u re th e s p a c e b e tw e e n c h a in b o lt s . M e a s u r e m e n t is b a s e d o n
th e o r ig in a l c h a in s iz e . T h e s p a c e is m e a s u re d a c ro s s 1 7 d o u b le lin k s . F o r
e x a m p le t h e s iz e o f a d o u b le lin k in a 1 " c h a in is 5 0 . 8 m m . M a x . a d m is s ib le
e lo n g a t io n is 0 . 5 d o u b le lin k s = 2 5 .4 m m .
(1 8 x 5 0 ,8 ) + 2 5 = 8 8 9 ,0
Ie , 8 8 9 . 0 is t h e m a x . a d m is s ib le e lo n g a t io n o f a 1 " c h a in a c r o s s 1 7 d o u b le
lin k s . If a g r e a t e r e lo n g a t io n is m e a s u r e d , t h e c h a in m u s t b e r e p la c e d .
c ) E x te n s io n c h a in s
It is im p o r ta n t to a c h ie v e u n if o r m t e n s io n in b o t h e x t e n s io n c h a in s . E x c e s s iv e
t e n t io n in g c a n d a m a g e b e a r in g s , u n e v e n t e n s io n d is t o r t s t h e m a s t a n d lo o s e
c h a in s p la c e e x c e s s s t r a in o n t h e c h a in ' s f lig h t a t t a c h m e n t c a u s in g c o n n e c t in g
m e m b e rs to fra c tu re .
T h e c h a in s h o u ld t h e r e f o r e a lw a y s b e t e n s io n e d s o t h a t t h e r e is a p p r o x . 5 m m
s la c k a t n o r m a l p la t f o r m w id t h . E x t e n s io n c h a in s c a n b e t ig h t e n e d o r lo o s e n e d
b y a d ju s t in g t h e e x t e n s io n h y d r a u lic m o t o r v ia a s o c k e t s c r e w ( F ig . 2 0 ) .
d ) R o lle r s
A lw a y s m a k e s u r e t h a t r o lle r c o n t a c t s u r f a c e s a r e c le a n a n d f r e e f o r m g re a s e .
R e p la c e d a m a g e d r o lle r s .
e ) M a s t s e t t in g s :
C h e c k th e s id e c le a r a n c e o f t h e lif t c a r r ia g e , in s id e m a s t a n d e x t e n s io n g e a r .
R e p la c e a n y d a m a g e d s h o e s in t h e e x t e n s io n g e a r o r f it w it h s h im p la t e s
( F ig . 2 1 ) . If n e c e s s a r y , a d ju s t m a s t a n d lif t c a r r ia g e r o lle r s u s in g s h im s (F ig . 2 2 ) .
P a g e 2 3
F ig . 1 9
F ig . 2 0
P a g e 2 4
F ig . 2 1
F ig . 2 2
P a g e 2 5
F o r lif t h e ig h ts a b o v e 4 .5 m , e x t e n s io n g e a r s a r e f it t e d a d d it io n a lly
w it h e x c e n t r ic r o lle rs (F ig . 2 3 ) . T h e s e h e lp s t o p t h e m a s t s w a y in g .
A d ju s t m e n t m ig h t b e n e c e s s a ry .
T ig h t e n c o u n te r e x c e n t ic r o lle r s a lw a y s c lo c k w is e !
f) F o rk s
C a rry o u t a v is u a l c h e c k . In p a r t ic u la r, c h e c k fo r a n y d a m a g e c a u s e d b y
o v e r lo a d in g . If t h e fo rk s s h o w u n e v e n b e n d , t e s t f o r c r a c k s u s in g D if u d o r
d y e s . C h e c k w e ld s e a m s fo r c ra c k s a t th e s u s p e n s io n p o in t s . K e e p t h e f o r k
e n d fa c e fre e fro m g re a s e . C h e c k lo c k in g m e c h a n is m .
g ) D r iv e r ' s c a b ro o f
S in c e t h e d r iv e r ' s c a b r o o f is in c lu d e d f o r s a f e t y r e a s o n s , it t o o s h o u ld b e
c h e c k e d . C h e c k t h a t t h e p r o t e c t iv e g r id is in t a c t a n d t h e c a b is s e c u r e
f ix e d t o th e c h a s s is v ia s t o p n u t .
P o in t 8 : R e t ig h t e n in g a ll s c r e w c o n n e c t io n s in t h e h y d r a u lic c y lin d e r s
S c r e w c o n n e c t io n s in t h e c y lin d e r s lis t e d b e lo w s h o u ld b e c h e c k e d a n d
r e t ig h t e n e d ( b o t h c o n n e c t io n s in d o u b le a c t in g c y lin d e r s ) .
L if t c y lin d e r , s t e e r in g c y lin d e r , f o r k t ilt c y lin d e r , p e n d u lu m c y lin d e r , c y lin d e r s

f it t e d in a t t a c h m e n t s .
P o in t 9 : C h e c k in g a ll c o n t r o l le v e r s a n d c o n t r o ls ( p u lle y , e t c . ) f o r s m o o t h o p e r a t io n
a n d c o r r e c t s e t t in g .
a ) C o r r e c t s e t t in g m e a n s :
- W h e n a c t iv a t e d , t h e m ic r o s w it c h in t h e c o n t r o l s lid e v a lv e f o r t h e s e r v ic e
p u m p s h o u ld b e t r ig g e r e d f ir s t b e f o r e a n y o il b e g in s t o f lo w .
- W h e n t h e c o n t r o l le v e r is in it s e n d s t o p p o s it io n t h e c o n t r o l s lid e v a lv e
s h o u ld h a v e f u lly o p e n e d .
- L e v e r s s h o u ld r e t u r n t o s t a r t p o s it io n a u t o m a t ic a lly .
b ) J o in t s in t h e c o n t r o l lin k a g e s h o u ld b e lu b r ic a t e d w it h o n e d r o p o f o il d u r in g
e v e r y in s p e c t io n a n d s h o u ld d is p la y n o la t e r a l c le a r a n c e .
c ) C h e c k t h e p r o p e r f u n c t io n o f t h e p o t e n t io m e t e r f it t e d t o t h e lif t le v e r .
P a g e 2 6
P o in t 1 0 : C h e c k in g t h e e le c t r ic a l s y s t e m (E 4 S )
a ) C h e c k t o m a k e s u r e t h a t t h e r e le v a n t la m p s lig h t u p w h e n a s s o c ia t e d f u n c t io n s
a r e a c t iv a t e d . C h e c k t h a t w h a t is lit c o r r e s p o n d s t o t h e f u n c t io n s e le c t e d .
E x a m p le :
T h e g r e e n c o n t r o l la m p lig h t s u p w h e n s w it c h in g f r o m s t r a ig h t t o t r a n s v e r s e
d r iv e . M a k e s u r e t h a t t h e la m p o n ly lig h t s u p a f t e r t h e d r iv e w h e e ls h a v e
a c tu a lly m o v e d in t o t r a n s v e r s e p o s it io n ( s e e o p e r a t in g m a n u a l) .
b ) C h e c k e le c t r ic c a b le s f o r d a m a g e a n d r e p la c e w h e r e n e c e s s a r y .
c ) P u ls e c o n tr o ls a r e in g o o d o r d e r if fu n c t io n s a r e c a r r ie d o u t c o r r e c t ly . T h e
s e t t in g s m a d e b y th e m a n u fa c tu re r s h o u ld n o t b e a lt e r e d . If, h o w e v e r,
d if f e r e n t o p t io n s a r e re q u ir e d , t h e f o llo w in g c a n b e m o d if ie d b y r e m o v in g
th e ro u n d p la s t ic s e a l in t h e b la c k lo g ic b o x o f th e p o t e n t io m e te r:
P 1 f o r s e le c t io n
P 2 f o r b r a k in g T y p e M C G
(P 3 m a x im u m c u r r e n t )
P 1 a n d P 2 c a n b e s e t t o s u it o p e r a t io n a l r e q u ir e m e n t s . P 2 s h o u ld o n n o
a c c o u n t e x c e e d t h e m a x im u m c u r r e n t o f 4 0 0 A f o r b o t h m o t o r s .
d ) C h e c k a ls o e le c t r ic a l e le m e n t s f it t e d t o a t t a c h m e n t s o r a u x illia r y e q u ip m e n t .
e ) C h e c k t h a t t h e o p e r a t in g h o u r s c o u n t e r is in g o o d w o r k in g o r d e r .
f) C h e c k e a c h b a t t e r y c e ll s e p a r a t e ly u s in g a n a c id s ip h o n . T h e c o r r e c t a c id
s tre n g th ( F ig . 2 4 ) lie s b e tw e e n 1 .1 3 k g / l (e m p ty ) a n d 1 .2 7 k g / l (c h a r g e d ). T o o
lo w a n a c id le v e l m u s t b e c o r r e c t e d u s in g d is t ille d w a t e r in lin e w it h V D E 0 5 1 0
f o llo w in g th e c h a rg e p ro c e s s .
g ) B a t t e r y c a b le s s h o u ld n o t b e s h o r n a t a n y p o in t a n d t h e r e s h o u ld b e n o s ig n s
o f d a m a g e in t h e m a in p lu g .
h ) F u s e s s h o u ld h a v e t h e c o r r e c t a m p e r e n u m b e r . F u s e e le m e n t s s h o u ld n o t b e
b r id g e d u s in g o t h e r m a t e r ia ls .
i) C h e c k t h a t a ll s a f e t y f e a t u r e s s u c h a s t h e " e m e r g e n c y s t o p " s w it c h a n d o t h e r
o p t io n s a r e in g o o d w o r k in g o r d e r .
j) F o r te s tin g th e M C G o r M C M C o n tr o lle r m a k e u s e o f th e B a u m a n n S .A .P .

T e s te r P /N 2 4 0 1 2 1 .
k ) C h e c k a ll m o to r b r u s h e s fo r w e a r ( d r iv e m o to r s , lift a n d s te e r p u m p m o to r ) .
R e p la c e w h e n n e c c e s s a r y o n tim e .
P a g e 2 7
F ig . 2 3
F ig . 2 4 F ig . 2 5
E M P T Y
F U L L
C u s to m e r
E le c tr ic S id e lo a d e r S e r v ic e B o o k le t
P a g e 2 8
P o in t 1 1 : S t a g in g a t e s t r u n u n d e r lo a d in t h e p r e s e n c e o f t h e o p e r a t o r a n d h a n d in g o v e r
t h e lo a d e r in g o o d w o r k in g o r d e r
a ) T e s t r u n (E 4 S ):
P la c e t h e m a x . a d m is s ib le lo a d o n t h e p la t f o r m a n d r u n t h r o u g h f o llo w in g
s te p s :
- In d ic a t e p la t f o r m t ilt s e t t in g s b y t ilt in g u p a n d d o w n . B r in g b a c k to c e n tre

p o s it io n ( n o r m a l w o r k in g c o n d it io n ) .
- T r a v e l in a s t r a ig h t lin e f o r w a r d s a n d b a c k w a r d s .
- T r a v e l in a c ir c le w it h m in im u m r a d iu s , c lo c k w is e a n d a n t ic lo c k w is e .
- S w it c h t o t r a n s v e r s e d r iv e , t r a v e l f o r w a r d s a n d b a c k w a r d s w it h m a x .
a d m is s ib le s t e e r in g lo c k .
- D e m o n s t r a t e s p e e d r e d u c t io n in t r a n s v e r s e d r iv e .
- S w it c h t o s t r a ig h t d r iv e .
- T r a v e l f o r w a r d s , b lo c k c a s t o r in a x le 2 u s in g r e le v a n t b u t t o n , tra v e l b a c k w a rd s
th e n fo rw a rd s .
- T u r n c a s t o r in a lx e 2 t h r o u g h 9 0 ° .
- W h e n s e t t in g d o w n t h e lo a d , d e m o n s t r a t e t h e f o r k t ilt f u n c t io n .
b ) F u n c t io n t e s t :
T h e v a r io u s f u n c t io n s h o u ld b e d e m o n s t r a t e d u s in g t h e m a x . a d m is s ib le lo a d
fo r t h e m a x . lif t h e ig h t ( s e e t h e lo a d d ia g r a m , m a x . lif t h e ig h t a n d s m a lle s t L S P ) .
T h e f o llo w in g f u n c t io n s s h o u ld b e d e m o n s t r a t e d t o t h e c u s t o m e r :
- T a k e u p lo a d , re tra c t m a s t.
- R a is e lo a d t o m a x . lif t h e ig h t .
- L o w e r lo a d .
- D e m o n s tra te v a r io u s o p t io n a l f u n c t io n s w it h a n d w it h o u t lo a d a s a p p r o p r ia t e .
F o r e x a m p le , a d ju s t in g f o r k s w it h o u t lo a d , lim it in g lif t h e ig h t u n d e r lo a d .
c ) T h e a f t e r - s a le s m a n u a l (F ig . 2 5 ) c a n t h e n b e f ille d in , a lo n g w it h t h e t e s t
b o o k ( W e s t G e r m a n y o n ly ) , a n d t h e lo a d e r is r e a d y t o b e h a n d e d o v e r t o t h e
c u s t o m e r in g o o d w o r k in g o r d e r .
Im p o r t a n t :
' W h e n e v e r m o v in g t h e t r u c k , t h e p la t f o r m m u s t b e k e p t in n e u t r a l h e ig h t p o s it io n
( h a lf w a y u p - o r - h a lf w a y d o w n ) t o a llo w w h e e ls c o m p e n s a t in g u n e v e n f lo o r s .
L u b r ic a t io n C h a r t
In t e r v a ls a s in a f t e r - s a le s m a n u a l, t h e n e v e r y 5 0 0 o p e r a t in g h o u r s
S e e M o d e o f L u b r ic a n t
P a g e P a rt T re a tm e n t lu b r ic a t io n t a b le
1 0 4 d r iv e p e d a l m e c h a n is m o il o il c a n 4
2 3 b ra k e p e d a l g re a s e 1 n ip p le 5
1 7 e x t e n s io n g e a r t r a c k s g re a s e 4 c o a t 5
1 0 4 d r iv e p e d a l r e t u r n s p r in g s s p ra y 2 s p ra y 6
1 0 c a s t o r , s w in g le v e r g re a s e 4 n ip p le 5
1 2 c a s t o r , a x le g re a s e 4 n ip p le 5
1 2 c a s t o r , t u r n t a b le g re a s e 2 n ip p le 5
1 2 d r iv e w h e e l, t u r n t a b le g re a s e 4 n ip p le 5
1 0 g u id e c h a in / lin k e d c h a in s p ra y 2 s p ra y 6
1 0 e x t e n s io n c h a in s s p ra y 2 s p ra y 6
1 0 s t e e r in g m o t o r c h a in s s p ra y 3 /4 s p ra y 6
1 0 lif t c h a in s / f o r k c h a in s s p ra y 2 /2 s p ra y 6
2 6 c a b c o n t r o l le v e r lin k a g e o il o il c a n 4
1 2 f o r k c a r r ia g e , c a r r ia g e r o lle r s g re a s e 4 n ip p le 5
1 2 f o r k t ilt c y lin d e r o il/ g r e a s e o il c a n / c o a t 4 /5
1 2 m a s t r o lle r s g re a s e n ip p le 5
1 2 c r o s s h e a d r o lle r s g re a s e 2 n ip p le 5
1 2 c r o s s h e a d g u id e s g re a s e c o a t 5
1 2 lif t f r a m e c o n t a c t s u r f a c e s c le a n g re a s e - fre e
1 2 f o r k c a r r ie r e n d f a c e s c le a n g re a s e - fre e
1 2 f o r k c a r r ie r u p p e r + lo w e r e d g e s g re a s e 2 c o a t 5
1 3 e x t e n s io n t r a c k c o n t a c t s u r f a c e s c le a n 4 g re a s e - fre e
1 9 b r a k e f lu id c h e c k 1 to p u p
6 h y d r a u lic o il c h a n g e 1 0 0 /1 0 0 0 h rs . 6 0 l 8
9 w h e e l t r a n s m is s io n o il 1 0 0 /1 0 0 0 h rs . 0 ,4 l 9
1 3 r e a c h c h a in s p r o c k e t g re a s e 2 n ip p le 5
L u b r ic a n t T a b le " E 4 S "
N r. L u b r ic a n t T y p e S ta n d a rd V is k o s iy A R A L B P E S S O T E X A C O
4 L u b e o il A P I- S E / C D 1 5 W -4 0 M u lit T u r b o r a l V a n d lu s E s s o lu b X D - 3 U rs a S u p e r
M IL - L - 2 1 0 4 M o to re n ö l M u lt ig r a d M u lt ig r a d e L A
5 g re a s e D IN 5 1 8 2 5 T y p K -2 K H L 2 L S -E P 2 B e a to n 2 M a rfa k
6 c h a in s p r a y
7 b r a k e f lu id S A E IJ 1 7 0 3 6
8 h y d r a u lic o il D IN 5 1 5 2 5 H L P 4 6 V IT A M C F 4 6 E n e rg o l N u to n H 4 6 R a n d o H D B
H L P 4 6
9 t r a n s m is s io n o il S A E 8 0 -9 0
P a g e 3 0
Is s u e 0 3 /2 0 0 6
P a g e 3 1
M a in t e n a n c e P la n F o r B A U M A N N E le c t r ic S id e lo a d e r s
1 0 0 0 h w o r k in g h o u r s
1 0 0 h w o r k in g h o u r s
o r a fte r 1 2 m o n th s
o r a fte r 2 m o n th s
p a rt d a m a g e d
d a ily c h e c k u p
p a rt c h a n g e d
o k a y
U p r ig h t
C h e c k u p m a s t if t h e r e a r e a n y k in d s o f d a m a g in g s , c r a c k s in
w e ld in g s , o v e r s t r e s s in g s X X X
C h e c k u p m a s t le a k a g e : A f t e r 5 m in u t e s lif t in g m a x im u m
a llo w e d c a p a c it y , d if f e r e n c e s h o u ld n o t b e la r g e r t h a n 4 0 m m .
M a s t s h o u ld n o t in c lin e b y it s e lf . X X X
C h a in s d is m o u n t in g a n d c le a n in g X
C h a in s h a v e t o b e lu b r ic a t e d X X X
C h e c k u p t e n s ib le f o r c e a n d le n g t h o f c h a in s X X X
M a s t r o lle r s h a v e t o b e lu b r ic a t e d .
R u n n in g o f r o lle r s s u r f a c e h a v e t o b e c le a n a n d f r e e o f g r e a s e ! X X X
C r o s s c la m p h a s t o b e lu b r ic a t e d X X X
C r o s s c la m p g u id a n c e h a s t o b e lu b r ic a t e d X X X
U p r ig h t t r e a d s :
H a s t o b e c le a n d e d !
D o n o t lu b r ic a t e o r o il it ! X X X
F o r k C a r r ie r
C a r r ia g e r o lle r s h a v e t o b e lu b r ic a t e d X X X
C a r r ie r s lid e :
D o n o t lu b r ic a t e o r o il f a c e s u r f a c e !
L u b r ic a t e c a r r ie r s lid e o f f o r k s h o u s a t t h e t o p a n d b e lo w X X X
V is u a l e x a m in a t io n o f t h e f o r k s X X X X
V is u a l e x a m in a t io n o f d r iv e r p r o t e c t io n X X X X
T ra v e rs e m o v e m e n t
C h a in s h a v e to b e lu b r ic a t e d X X X
C h e c k u p te n s ib le f o r c e a n d le n g t h o f c h a in s X X X
M o v e m e n t tra c k a g e
S lid e s : L u b r ic a t e f a c e s w h e r e s lid in g b lo c k s a r e m o v in g X X X
T r e a d s : H a s t o b e c le a n e d ! X X X
D o n o t lu b r ic a t e o r o il it !
P a g e 3 2
o k a y
H y d r a u lic ( g e n e r e ll)
C h e c k u p f it t in g s u n d e r c a b in X X X
C h e c k u p f it t in g s o f c o n t r o l c y lin d e r X X X
C h e c k u p f it t in g s o f s t e e r in g c y lin d e r ( d is m o u n t b a t t e r y ) X X X
C h e c k u p f it t in g s o f h y d r o m o t o r a x le 2 X X X
C h e c k u p f it t in g s o f h y d r o m o t o r a x le 1 t ill 4 ( E M S ) X X X
C h e c k u p f it t in g s o f h y d r a u lic t a n k X X X
C h e c k u p f it t in g s o f s t e e r in g a n d m a in h y d r a u lic p u m p X X X
C h e c k u p f it t in g s o f a ll p r o p o r t io n a l v a lv e s X X X
C h e c k u p f it t in g s o f h ig h p r e s s u r e f ilt e r ( E M S ) X X X
C h e c k u p f it t in g s o f m o v e m e n t h y d r o m o t o r X X X
C h e c k u p f it t in g s u p r ig h t X X X
C h e c k u p f it t in g s o f lif t in g c y lin d e r s X X X
C h e c k u p f it t in g s o f ( f r a m e ) t ilt in g c y lin d e r s X X X
C h e c k u p f it t in g s o f a c c e s s o r y e q u ip m e n t X X X
C h e c k u p a ll h o s e c o n n e c t io n s X X X X
S t e e r in g H y d r a u lic
C h e c k u p p r e s s u r e a c c o r d in g t o d a t a s h e e t ( 1 0 0 - 1 2 0 b a r )
W o r k in g h y d r a u lic
C h e c k u p p r e s s u r e a c c o r d in g t o d a t a s h e e t ( - 2 5 0 b a r )
H y d r a u lic T a n k
L e a k in e s s X X X X
F u n c t io n a lit y X X X X
C h e c k u p le v e l o f h y d r a u lic o il X X X X
O il c h a n g e ( c a . 6 0 l) X X
C h a n g in g o f h ig h p r e s s u r e f ilt e r ( E M S X X
S t e e r in g M o t o r
C h a in s h a v e t o b e lu b r ic a t e d X X X
C h e c k u p t e n s ib le f o r c e , le n g t h o f c h a in s a n d f a s t e n in g X X X
S e r v ic e a n d R e p a ir M a n u a l Is s u e 3 /2 0 0 6
P a g e 3 3
o k a y
S t e e r in g
C h e c k u p s t e e r in g c h a in / s t e e r in g w ir e a n d lu b r ic a t e it .
M a y b e it s h o u ld b e n e w a d ju s t e d X X X
C h e c k u p t e n s ib le f o r c e , le n g t h o f c h a in s a n d f a s t e n in g s X X X
C h e c k u p d e f le c t io n r o lle r s ( d a m a g in g ) X X
C h e c k u p s lid in g b lo c k s o f s t e e r in g c h a in X X
C h e c k u p 0 ° / 9 0 ° a d ju s t m e n t o f t h e w h e e ls X X
C h e c k u p m in im u m - / m a x im u m p r e s s u r e o f t h e a c c u m u la t o r X X
A x le 1 t ill 4
L u b r ic a t e w h e e l b e a r in g (a x le 2 a n d 3 ) X X X
L u b r ic a t e r o t a t in g a s s e m b ly X X X
L u b r ic a t e a n d c h e c k u p c a s t e r X X X
C h e c k u p w h e e ls o n c o n d it io n a n d w e a r in g d o w n X X X X
T r a c t io n w h e e l
C h a n g in g g e a r o il X X
B re a k
C h e c k u p b r e a k p a d (> = 3 m m ) X X X
C h e c k u p b r e a k d is k (> = 8 m m ) X X X
S e r v ic e b r e a k in g d e v ic e
C h e c k u p o f le a k in e s s X X X
C h e c k u p o f d a m a g in g X X X
E m p ty ru n < = 5 m m X X X
F ix in g b r a k e ( O p t io n )
C h e c k u p f u n c t io n a lit y X X X X
E le c t r ic
C h e c k u p a ll o p e r a t in g e le m e n t s f o r s m o o t h r u n n in g a n d c o r r e c t
a d ju s t m e n t X X X X
C h e c k u p f u n c t io n a lit y X X X X
C h e c k u p e x h a u s te r X X X X
C h e c k u p a ll w a r n in g a n d s e c u r it y e le m e n t s X X X X
B lo w o f f e le c t r ic a l c o m p o n e n t s in t h e c a b in e t X X X
C h e c k u p a ll c a b le s f o r a n y k in d o f d a m a g in g X X X X
C h e c k u p f u n c t io n a lit y o f o p t io n s X X X X
P a g e 3 4
o k a y
C h e c k u p f u n c t io n o f o p e r a t in g h o u r m e t e r X X X X
C h e c k u p b a t t e r y c a b le s a n d c o n n e c t o r s X X X X
C h e c k u p fu s e s X X X
C h e c k u p a ll c a r b o n b r u s h e s o f e le c t r ic m o t o r s X X X
C e c h k u p a ll e r r o r m e m o r ie s a n d e r a s e t h e m X X X
C a b in
C h e c k u p f a s t e n in g o f c a b in X X X
C h e c k u p f a s t e n in g o f s e a t X X X
F u n c t io n a l t e s t a n d t e s t r u n w it h m a x im u m lo a d in t h e p r e s e n c e o f
th e o p e ra to r X X X
P le a s e t a k e c a r e t h a t d u r in g w o r k in g a ll s a f e t y m e a s u r e s f o r m a in t e n a n c e a n d r e p a ir in g w ill b e n o t e d .
G lo s s a r y
1 . G e n e ra l
- A rra y o f p ro d u c ts
- S H S - O r g a n is a t io n
- C o n ta c t P e rs o n
2 . B a s ic s 4 8 / 8 0 V - F a m ily
- E M S - S c h e m a t ic
- A p p lic a t io n A re a s
- E V S - S c h e m a t ic
- A p p lic a t io n A re a s
3 . C o n tro l S y s te m
- O v e r v ie w
- E V L 0 1 2 5 0 0
- L P C 0 1 9 2 6 1
- L P C 0 1 9 5 0 0
4 . E le c t r o n ic S t e e r in g
- O v e r v ie w
- S C 2 0 0 0
- P o w e r P a k
5 . E H X / E G X
- E le c t r o n ic S t e e r in g
- W ir in g d ia g r a m
6 . M a in t e n a n c e
7 . T r a n s m is s io n
8 . B a tte ry
9 . D o c u m e n t s E le c t r ic / H y d r a u lic . . .
1 0 . S e r v ic e - In f o r m a t io n

Baumann Side Loader Service and Repair Manual

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B a tte ry

T h e v e h ic le ' s t r a c t io n b a tte r y is it s e n e r g y s o u r c e a n d t h e r e f o r e it s m o s t im p o rta n t p a rt.

5 . If a b a t t e r y " b o ils o v e r " , c le a n t h e b a t t e r y s u m p ( w a s h s e v e r a l t im e s a n d r e m o v e

Speed Controller MC400G, P/N: 46369 no longer available

Speed Controller MCM400M, P/N: 241838 only as replacement part available

Speed- and Pump Controller SC2000, P/N: 245727 actual standard

T h e c o n tro lle r s s a fe ty s y s te m h a s b o th h a rd w a re w a tc h d o g a n d s o f t w a r e f a il- s a f e s y s t e m s

T h e m a x im u m c u r r e n t o f e a c h c o n t r o lle r w ill b e lim it e d a t h ig h a n d lo w d u t y c y c le s

If t h e a v e r g e b a tte ry v o lt a g e f a lls b e lo w a p r e - s e t v o lt a g e , t h e c o n t r o lle r w ill s t o p

T h is u s e r m a n u a l d e t a ils t h e f e a t u r e s o f t h e f o llo w in g P o w e r p a K S e r ie s c o n t r o lle r s a n d v a r ia n t s .

T o f u r t h e r in c r e a s e f le x ib ilit y a n d t r a ilo r t h e c o n t r o lle r t o s p e c if ic a p p lic a t io n s , t h e r e a r e 3

L in e ( O p tio n ) A lb r ig h t S W 8 0 C o n tin u o u s R a tin g

C a n is e x tre m e ly f le x ib le a n d v e r s a t ile , a llo w in g m u lt i- m a s te r o p e r a t io n in a s e r ia l

7 . 1 . 1 T r a c t io n C o n t r o lle r P e r s o n a lit ie s ( C o n t r o lle r A d ju s t m e n t s )

7 . 2 . 1 P u m p C o n t r o lle r P e r s o n a lit ie s ( C o n t r o lle r A d ju s t m e n t s )

A m a x im u m s p e e d a d ju s t m e n t is a ls o a v a ila b le t o lim it t h e m a x im u m a p p lie d 0 % o n . (If

ii) C lo s u r e o f th e fo o t-b ra k e s w it c h in n e u t r a l, w ill in it ia t e r e g e n b r a k in g a t t h e f o o t b r a k e

Steering Position Computer

Steering Position Computer

4-Axle Steering System with propotional working hydraulic

2. Display of Software Version

LPC 019 261 'A'

3. Error and Status Display

3.1 Display in Normal Operation (no error)

3.2 Display of Present Error

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3.3 Display of Incorrect Parameters

3.4 Process Data Display

no error PX: -13761.87

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Previous display Next display

3.4.1 Displaying the Steering Pole

3.4.2 Displaying the Steering Setpoint

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3.4.3 Setpoint and Actual Angle of Single Axle

3.4.4 Control of Proportional Valves

The example shows: Axle 1 turning left

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01 Cross-rear axleLengthways-fix axle 4 axle 3 axle 2 axle 1

3.4.7 Hydraulic Accumulator Loading System (Option)

3.4.8 ELS Setpoint Value (Option)

ELS pressure out

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3.4.9 Impulses of Steering Setpoint Generator

3.4.10 Working Hydraulic Functions (Option)

3.4.11 Control of Proportional Valve for Lifting and Lowering (Option)

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3.4.12 Proportional Valve for Mast-Reach (Option)

3.4.13 Revolution Setpoint for Hydraulic Pump (Option)

pump set point:

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4. Menu for Service Functions

Keep both buttons pressed for 3 seconds

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i/o data display

back to ESC ESC

back to ESC ESC execute

back to ESC ESC execute

back to ESC ESC execute

back to ESC ESC execute

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4.1. I/O-Data Menu

i/o data display